Collapsible cushion with a buffer grid

Abstract

The cushion includes a core and at least one cushioning mesh stacked on the outer surface of the core. The core includes an outer surface and opposing side edges. At least one cushioning element includes: opposing side edges positioned adjacent to opposing side edges of the core, the opposing side edges of the at least one cushioning mesh defining a width; a central axis extending along the width; and a plurality of interconnected walls defining a plurality of voids and oriented on the outer surface, the plurality of interconnected walls being configured to collapse within the plurality of voids when the opposing side edges of the at least one cushioning mesh are pressed against each other in a direction substantially parallel to the central axis to cause the cushion to collapse.

Description

[0001] Cross-referencing of related patent applications This application claims the benefit and priority of U.S. Provisional Application No. 63 / 548,213, filed November 12, 2024, the entire contents of which are incorporated herein by reference and used for all purposes.

[0002] background This disclosure generally relates to cushions. More specifically, this disclosure relates to collapsible cushions. Even more specifically, this disclosure relates to collapsible cushions with a cushioning mesh. This disclosure also relates to methods for designing, manufacturing, and using collapsible cushions.

[0003] In recent years, cushioned pillows have become increasingly popular. These include the Purple Pillow, available from Purple Innovation LLC (purple.com / pillows / purple-pillow / 2) and described in U.S. Patents 10,772,445, 10,863,837, and 11,812,880; the Purple Harmony Pillow, available from Purple Innovation, LLC (purple.com / pillows / harmonise / 2) and described in U.S. Patent Application Publication US 2020 / 0390247 A1; and a cylindrical pillow disclosed in U.S. Design Patent Application No. 29 / 779,639, the entire disclosure of which is incorporated herein by reference.

[0004] While the cushioning mesh of these pads provides unique cushioning and cooling effects, it also prevents the pads from optimally collapsing across their width. Specifically, the cushioning mesh comprises interconnected walls defining a hexagonal and / or triangular grid, many of which are aligned along (or parallel to) a central axis extending across the width of the pads. When the pads collapse along their longest dimension (their width), these walls cause the cushioning mesh to buckle (e.g., its outer surface includes undulations, etc.). This buckling effectively increases the thickness of the cushioning mesh, introducing the amount of force required to cause the pads to collapse and potentially damaging the mesh.

[0005] Overview One embodiment relates to a cushion including a core and at least one cushioning mesh. The core includes an outer surface and opposing side edges. The at least one cushioning mesh is stacked on the outer surface of the core and includes: opposing side edges positioned adjacent to opposing side edges of the core, the opposing side edges of the at least one cushioning mesh defining a width; a central axis extending along the width; and a plurality of interconnected walls defining a plurality of voids and oriented on the outer surface. The plurality of interconnected walls are configured to collapse within the plurality of voids when the opposing side edges of the at least one cushioning mesh are pressed against each other in a direction substantially parallel to the central axis to cause the cushion to collapse.

[0006] Another embodiment relates to a method for manufacturing a collapsible pillow, the method comprising: providing a core pad that is collapsible when a relative contractile force is applied along a central axis spanning the width of the core pad; and positioning a buffer grid comprising interconnected walls on an outer surface of the core pad, wherein substantially none of the interconnected walls is oriented parallel to the central axis of the core pad.

[0007] Another embodiment relates to a cushion comprising: a cushioning mesh including opposing side edges and a plurality of interconnected walls, wherein the plurality of interconnected walls are oriented such that when at least one of the opposing side edges of the cushioning mesh is pressed against another of the opposing side edges to cause the cushion to collapse, the plurality of interconnected walls collapse without substantially increasing the thickness.

[0008] This overview is illustrative only and is not intended to be limiting in any way. Other aspects, inventive features, and advantages of the apparatus or process described herein will become apparent from the detailed description set forth herein in conjunction with the accompanying drawings, wherein similar reference numerals refer to similar elements. Numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of this disclosure. The described features of the subject matter of this disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this respect, one or more features of one aspect of the invention may be combined with one or more features of different aspects of the invention. Furthermore, additional features that may not be present in all embodiments or implementations may be recognized in some embodiments and / or implementations. Brief description of the attached diagram This disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, wherein similar reference numerals denote similar elements, wherein: Figure 1 This is a top perspective view of an embodiment of the pillow cushion of this disclosure; Figure 2 It is inside the cover Figure 1 A top-down perspective view of the pillowcase; Figure 3 It is inside the cover Figure 1 A perspective view of the pillowcase from below; Figure 4 yes Figure 1 A top view of the pillowcase; Figure 5 yes Figure 1 Side view of the pillow; Figure 6 yes Figure 1 A side view of an embodiment of the pillow cushion; Figure 7 yes Figure 1 A top plan view of an embodiment of the pillow cushion; Figure 8 yes Figure 1 A top plan view of an embodiment of the pillow cushion; Figure 9 yes Figure 1 A top plan view of an embodiment of the pillow cushion; and Figure 10 yes Figure 1 A top plan view of an embodiment of the pillow cushion.

[0010] Detailed description Before turning to the accompanying drawings, which illustrate exemplary embodiments in detail, it should be understood that this application is not limited to the details or methods set forth in the description or shown in the drawings. It should also be understood that terminology is used for descriptive purposes only and should not be considered limiting.

[0011] Referring generally to the accompanying drawings, various aspects of a collapsible mattress, as well as its design, manufacture, and use, are disclosed. While the following disclosure relates primarily to mattresses, and more specifically, to mattresses with a cushioning mesh, this disclosure is also applicable to other types of mattresses with configurations that enable them to collapse.

[0012] Collapsible pillows or pads (e.g., travel pillows, easy-to-store pillows, etc.), which may also be more simply referred to herein as “pillows”, can have a configuration that allows them to collapse from their normal or relaxed size to a significantly smaller size (e.g., half or less of their relaxed volume, one-third or less of their relaxed volume, one-quarter or less of their relaxed volume, one-fifth or less of their relaxed volume, etc.). The reduced size of collapsible pillows in a compressed configuration reduces the packaging volume required for transporting or shipping the pillows, which can advantageously reduce costs for manufacturers due to the reduced volume required during transportation and increase the convenience for users in shipping the pillows.

[0013] The cushions according to this disclosure may include a cushioning mesh. The cushioning mesh may be oriented in such a way that the cushioning mesh, and thus the cushions in which the cushioning mesh is a part, can collapse when their side edges or ends are pressed together (e.g., pushed together, etc.).

[0014] In some embodiments, the cushioning mesh may include the main cushioning element of the cushion. The main cushioning element may include the cushioning mesh. Alternatively, the main cushioning element of the cushion may consist essentially of the cushioning mesh; for example, the main cushioning element may include non-essential elements such as a cover, one or more inflators, etc. As another option, the main cushioning element of the cushion may consist of the cushioning mesh.

[0015] Alternatively, this pillow may include a cover.

[0016] The cushioning mesh of this type of pillow can be slightly flat. It may include opposing side edges or ends, with the width of the cushioning mesh, and therefore the width of the pillow, extending between the opposing side edges. The width of the cushioning mesh can be its longest dimension, and therefore a dimension that may be shortened when the cushioning mesh, and the pillow as a part of the cushioning mesh, collapses. The central axis of the cushioning mesh, and therefore the central axis of the pillow, can extend from one side edge through the center of the cushioning mesh to the opposing side edge. When one of the side edges is parallel or substantially parallel (e.g., at about 15° or less, about 10°...), the width of the cushioning mesh extends from one side edge through the center of the cushioning mesh to the opposite side edge. 0 Or lower, about 5 0 When the buffer mesh is pushed toward the opposite edge in the direction of the central axis (or lower, etc.), the mesh can collapse.

[0017] The buffer grid comprises interconnected walls defining an array of geometric prisms or prisms. The interconnected walls can define an array of regular hexagons (i.e., a hexagonal array), an array of rhomboid or oblique square prisms (e.g., squares, diamonds, etc.) (i.e., an oblique square array), an array of triangles (i.e., a triangular array), and so on. The array can be oriented in such a way that when one of its side edges is pushed against another or its opposite side edges are pushed together, the array can collapse with substantially no buckling relative to its collapsing plane, or substantially no increase in its thickness. For example, the buffer grid can be oriented such that none or substantially none (e.g., no more than 10%, 5%, 2%, 1%, etc. of the wall) of the buffer grid is oriented substantially parallel to the central axis of the buffer grid, or substantially parallel to the direction in which the cushion may or tends to collapse.

[0018] The walls of the buffer mesh can be formed of any suitable cushioning material. In some embodiments, the walls of the buffer mesh can be formed of an elastomeric polymer or a gel. Examples of such gels include plasticizer-extended block copolymers (e.g., triblock copolymers, ABA triblock copolymers, etc.), such as those 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. As used herein, the term “elastomeric polymer” means and includes polymers that are capable of recovering their original size and shape after deformation. In other words, an elastomeric polymer is a polymer that is elastic or viscoelastic. Elastomers are also referred to in the art as “elastomers.” Elastomer polymers include, but are not limited to, homopolymers (polymers having repeating single chemical units) and copolymers (polymers having two or more chemical units).

[0019] In other embodiments, the pillow may include a core pad and at least one cushioning mesh assembled with the core pad. Optionally, such a pillow may include a cover.

[0020] The core pad may include an outer surface. In embodiments where the core pad has a pillow shape, the outer surface may include an opposing main surface. In other embodiments, the core pad may be substantially cylindrical in shape, with its outer surface corresponding to the circumferential surface of the cylinder. Other shapes of core pads and their outer surfaces are also within the scope of this disclosure.

[0021] The core pad includes opposing side edges. These opposing side edges are located at opposite ends of the width of the core pad. The width of the core pad can be its longest dimension, and therefore is a dimension that can be shortened when the core pad and any other pad, to which the core pad is part, collapse. The central axis of the core pad (or pad) (along which the core pad (and pad) can collapse) extends from one end of the core pad to the other end, or across or through its width.

[0022] The core pad can have any suitable configuration. As some examples, it can include a single piece of cushioning material, or it can include an assembly of cushioning elements (e.g., sheets, granules, etc.) held together in a flexible container.

[0023] The core pad can be formed from any suitable material or combination of materials. Without limitation, a one-piece core pad can be formed from foam, such as latex foam (e.g., Talalay latex, Dunlop latex, etc.), polyurethane foam, etc. The core pad can also be formed from a fabric cover filled with a soft cushioning material (e.g., filled with synthetic or natural fiber fillings, down, elastomeric polymers or gels, or other fillings used for pillows).

[0024] At least one buffer mesh may be slightly flat. The at least one buffer mesh may include opposing side edges or ends. Opposing side edges may be located at opposite ends of the width of the buffer mesh, which may correspond to the width of the core pad to be used with the buffer mesh. Each side edge may be positioned close to or adjacent to the corresponding side edge of the core pad.

[0025] The number of cushioning meshes included in such a pillow can correspond to the shape of the core pad. For example, a pillow comprising a core pad with opposing main surfaces (e.g., a core pad with a bed pillow shape, etc.) may include a cushioning mesh superimposed on one of the main surfaces (e.g., a single cushioning mesh) or a cushioning mesh superimposed on each main surface (e.g., two cushioning meshes). As another example, a pillow with a core pad having a generally cylindrical shape may include a cushioning mesh that can substantially surround the outer surface of the core pad.

[0026] Each cushioning grid comprises interconnected walls defining an array of geometric prisms or prisms. The interconnected walls may define an array of regular hexagons (i.e., a hexagonal array), an array of rhombuses (e.g., squares, diamonds, etc.) (i.e., an array of elongated oblique squares), an array of triangles (i.e., a triangular array), etc. The array may be oriented in such a way that it can collapse without buckling, or collapse with substantially no impact on its thickness, when at least one of its opposing side edges is pushed towards the other opposing side edge (e.g., if a core pad is included, when the opposing side edges of the core pad are pushed together, etc.). For example, the cushioning grid may be oriented on the outer surface of the core pad such that the cushioning grid is substantially without walls or without walls oriented substantially parallel to the central axis of the core pad (and the central axis of the pillow), or substantially parallel to the direction in which the pillow is to collapse. The compression position facilitates packaging the pillow for transport by reducing its overall volume.

[0027] The buffer mesh can have a substantially uniform thickness. Alternatively, the thickness of the buffer mesh can gradually decrease from the center portion of the buffer mesh toward at least one edge of the buffer mesh (e.g., toward opposite side edges, toward each edge, etc.).

[0028] The walls of the buffer mesh can be formed of any suitable cushioning material. In some embodiments, the walls of the buffer mesh can be formed of an elastomeric gel. Examples of such gels include plasticizer-extended block copolymers (e.g., triblock copolymers, ABA triblock copolymers, etc.), as disclosed in U.S. Patents 6,413,458; 6,797,765; and 7,964,664.

[0029] In some embodiments, the following are included: embodiments in which the cushioning mesh includes a main pad or a main pad of a pillow; and embodiments in which the cushioning mesh is stacked on the outer surface of the core pad, and the pillow may include an optional cover.

[0030] In embodiments where the pillow includes a core pad and at least one cushioning mesh, a cover may be positioned on the core pad. The cover may accommodate at least one cushioning mesh. An example of how the cover may accommodate the cushioning mesh is disclosed in U.S. Patent Application Publication US2020 / 0390247A1. As an example, the cushioning mesh can be located inside the pocket of the hood. As another example, the cushioning mesh can be attached to (e.g., formed thereon and partially immersed in, adhered to, etc.) the panel of the hood.

[0031] A method for designing a cushion (e.g., a collapsible cushion, such as a travel cushion, an easy-to-store cushion, etc.) includes determining the direction in which the cushion is likely to collapse or tends to collapse (e.g., across its width, etc.). Additionally, characteristics of at least one cushioning grid can be determined (e.g., the shape of prisms within the grid, etc.). The orientation of each cushioning grid is also determined such that, when the cushion collapses in a predetermined direction, each cushioning grid will collapse optimally (e.g., without buckling or significantly increasing its thickness, etc.).

[0032] A method for manufacturing a cushion (e.g., a collapsible cushion, such as a travel cushion, an easy-to-store cushion, etc.) includes defining a cushioning grid formed of a suitable cushioning material. The cushioning grid is defined by defining interconnected walls oriented such that the cushioning grid can collapse along its width without buckling or unintentionally increasing its thickness. More specifically, the cushioning grid can be defined such that there are no walls or substantially no walls oriented parallel to or substantially parallel to the central axis of the cushion, or parallel to or substantially parallel to the direction in which the cushion may or tends to collapse. The interconnected walls of the cushioning grid can define an array of polygonal prisms (e.g., hexagonal prisms, rhomboid prisms, triangular prisms, etc.).

[0033] Another method for manufacturing a cushion (e.g., a collapsible cushion, such as a travel cushion, an easy-to-store cushion, etc.) involves providing a core pad and positioning at least one cushioning grid on the outer surface of the core pad. The core pad can be collapsible when a force is applied along or substantially parallel to a central axis spanning the width of the core pad. Each cushioning grid includes interconnected walls oriented such that no wall or substantially no wall among the interconnected walls is oriented parallel to the central axis of the core pad, or substantially parallel to the direction in which the core pad may or tends to collapse. The interconnected walls of the cushioning grid may define an array of polygonal prisms (e.g., hexagonal prisms, rhomboid prisms, triangular prisms, etc.) on the outer surface of the core pad. The cushioning grid can be positioned on the core pad by covering it with a cover containing the cushioning grid.

[0034] A method for storing and / or transporting a cushion includes collapsing the cushion. The cushion can be collapsed by pressing (e.g., pushing, etc.) the ends of the cushion together along a central axis that runs through the width of the cushion. Each cushioning grid of the cushion (e.g., the cushion's buffer grid, the cushion's core pad, etc.) can collapse when its ends are pressed together. If the buffer grid is properly oriented (e.g., substantially any wall of the buffer grid is not substantially parallel or substantially non-parallel to the central axis of the cushion, the direction in which the cushion may or tends to collapse, etc.), the buffer grid can collapse without buckling, or thus collapse without affecting its thickness. When at least one buffer grid collapses, the wall of at least one buffer grid can move into the space or cell defined between the walls, thereby reducing the volume of the space or cell. This collapse can continue until the walls of at least one buffer grid contact each other.

[0035] When the collapse force is removed, the cushion (e.g., the core pad, each cushioning grid, etc.) may expand substantially to its relaxed width, or substantially to its original size and volume. This expansion may occur due to the elasticity of one or more parts of the cushion (e.g., its core pad, its cushioning grid, etc.).

[0036] Other aspects of this disclosure, as well as the features and advantages of each aspect of the disclosure, will be apparent to those skilled in the art upon consideration of the preceding disclosure, the accompanying drawings, and the appended claims.

[0037] Figure 1 An embodiment of the pillow pad 102 of the pillow 100 of this disclosure is shown. Figure 4A top plan view of a pillow 102 is shown. The pillow 102 includes a cushioning mesh 120 having a plurality of interconnected walls 122. The pillow 102 includes opposing side edges, including opposing first side edges 106 and second side edges 108, and opposing front edges 110 and rear edges 112. The first side edges 106 and second side edges 108 are located at opposite ends of a width 114 of the pillow 102, which extends between the first side edges 106 and the second side edges 108. A first central axis 118 of the pillow 102 extends from the first side edge 106 through the center of the cushioning mesh 120 to the second side edge 108. A second central axis 119 extends from the front edge 110 through the center of the cushioning mesh 120 to the rear edge 112, thereby defining a depth 116 of the pillow 102.

[0038] Figure 2 and Figure 3 A perspective view of a pillowcase 102 within a pillowcase cover 140 is shown. The pillowcase cover 140 includes an upper side 152 and an opposite lower side 154. In some embodiments, a cushioning mesh 120 is housed in a pocket of the pillowcase cover 140, such that the pillowcase cover 140, which provides cushioning around the core pad 150, also simultaneously provides cushioning mesh 120 around the core pad 150. The pocket can be defined as a gap between two layers of fabric elements. In some embodiments, the core pad 150 is not included. In such embodiments, the primary structure of the pillowcase 102 may be the cushioning mesh 120.

[0039] Multiple interconnected walls 122 define multiple voids 124, such as an array of geometric prisms or pillars. Figure 1 and Figures 4-6 As shown, interconnected walls 122 define a plurality of gaps 124, which define an array of regular hexagons (i.e., a hexagonal array). Figure 7 As shown, interconnected walls 122 define a plurality of gaps 124 that define an array of rhombuses (e.g., squares, diamonds, etc.) (i.e., an array of elongated oblique squares). However, in other embodiments, different shapes and / or sizes may be defined. Figure 8 As shown, interconnected walls 122 define a plurality of gaps 124 that define an array of triangles (i.e., a triangular array). In some embodiments, interconnected walls 122 may define a plurality of gaps 124 that define an array of other geometries.

[0040] Return to reference Figure 1The array of interconnected walls 122 can be oriented in such a way that when one of the first side edges 106 or the second side edge 108 is pushed against the other, the first side edge 106 and the second side edge 108 are pushed together, and the array of interconnected walls 122 can collapse with substantially no buckling relative to the plane of its collapse, or increase its thickness substantially unaffected. All the walls 122 of the cushioning mesh 120 can be positioned relative to the second central axis 119 of the cushion 102 (i.e., relative to the depth 116 between the front edge 110 and the rear edge 112 of the cushion 102) at approximately 0°. 0 Up to 60 0 Oriented at an angle θ1. Therefore, all walls 122 of the multiple interconnected walls can be oriented at a 30° angle relative to axis 121 (which is parallel to the first central axis 118 spanning or through the width of the pillow 102 (i.e., between or between the first side edge 106 and the second side edge 108 of the pillow 102) or relative to the direction in which the pillow or pad will be compressed or collapsed). 0 Up to 90 0 Oriented at an angle θ2 (or approximately at these angles). θ2 can be the smaller of a pair of adjacent complementary angles sharing a common side parallel to wall 122, where the other angle is θ1 + 90°. 0 These adjacent complementary angles together form a straight line parallel to the first central axis 118. θ1 and θ2 can therefore be complementary angles. Therefore, each of the plurality of interconnected walls 122 can be oriented along an axis that intersects the first central axis 118 at some point (i.e., not parallel to the central axis 118). Thus, the plurality of interconnected walls 122 of the cushioning grid 120 may have no walls parallel to the first central axis 118 and parallel to the axis 121 that spans the width 114 of the pillow pad 102. For example, the cushioning grid 120 may be oriented on the outer surface of the core pad 150 such that there are substantially no walls in the cushioning grid 120 (e.g., no more than 10% of the walls, no more than 5% of the walls, no more than 2% of the walls, no more than 1% of the walls, etc.) or no walls are oriented substantially parallel to the first central axis 118 of the core pad 150 (and the central axis of the pillow pad 102 or the cushioning grid 120), or no walls are oriented substantially parallel to the direction in which the pillow pad 102 is to collapse. The wall is oriented at a 30° angle to axis 121 and therefore to the first central axis 118. 0 Up to 90 0The angle θ2, the orientation of the interconnected walls along an axis intersecting axis 121 and / or the first central axis 118, and / or the absence of walls parallel to the first central axis 118, allow the pillow 102 to collapse substantially without buckling or substantially without significantly increasing the thickness of the pillow 102 (i.e., an increase in dimension in a direction perpendicular to the plane defined by the width 114 and depth 116) relative to the plane on which the pillow 102 collapses. Upon collapse, the interconnected walls 122 extend into a plurality of gaps 124, thereby allowing the pillow 102 to collapse along the first central axis 118 without significantly increasing its thickness. In some embodiments, the cushioning mesh 120 has a substantially uniform thickness. In some embodiments, the thickness of the cushioning mesh 120 gradually decreases from the central portion of the cushioning mesh 120 toward at least one edge of the cushioning mesh 120 (e.g., the first side edge 106, the second side edge 108).

[0041] A cushioning mesh 120 is positioned on the outer surface of the core pad 150 of the pillow pad 102. The core pad 150 may be shaped similarly to a pillow. In some embodiments, the core pad 150 has a cylindrical or substantially cylindrical shape. The core pad 150 may be formed from any suitable material or combination of materials. Non-limitingly, the one-piece core pad 150 may be formed from foam, such as latex foam (e.g., Talalay latex, Dunlop latex, etc.), polyurethane foam, etc. The core pad 150 may also be formed from a fabric cover filled with a soft cushioning material (e.g., filled with synthetic or natural fiber filling, down, elastomeric polymers or gels, or other fillings used for pillows). Alternatively, the cushioning mesh may comprise the main pad of the pillow or mattress. In some embodiments, the pillow pad 102 does not include the core pad 150.

[0042] Figure 4 and Figures 7-8 A buffer grid 120 is depicted with an acceptable pattern of multiple interconnected walls 122 and multiple voids 124 satisfying θ1 and θ2 as described above. Figure 4 and Figures 7-8 In each of the two types of cushioning grids, none of the walls 122 of the cushioning grid 120 extend parallel to or substantially parallel to the second central axis 119 through or across the width 114 of the pillow pad 102, the cushioning grid 120, or the core pad 150 (if present), or extend parallel to or substantially parallel to the direction in which the pillow pad 102 is intended to be compressed (i.e., from the first side edge 106 to the second side edge 108 of each figure). Figure 4 and Figures 7-8In each of these angles, θ1 refers to the maximum angle of any wall 122 of the cushioning grid relative to the second central axis 119 and / or depth 116 of the cushion 102. The angle θ2 can be the smaller of a pair of adjacent complementary angles sharing a common side parallel to the wall 122, which together form a straight line on axis 121 parallel to the second central axis 119. θ1 and θ2 can be complementary angles such that the walls 122 of the illustrated cushioning grid 120 relative to the respective central axes 118 and 119 of the cushion 102, or relative to the direction along which the cushion 102 may be compressed or is intended (i.e., designed) to be compressed or collapsed. Figure 4 and Figures 7-8 60 0 45 0 and 30 0 The maximum angle θ2 corresponds to 30°. 0 45 0 and 60 0 The smallest angle θ1.

[0043] See details Figures 4-6 Interconnected walls 122 define a plurality of gaps 124, which define an array of regular hexagons (i.e., a hexagonal array). The maximum angle of any wall 122 of the buffer grid 120 relative to axis 121 (which is parallel to the first central axis 118 and / or width 114 of the cushion 102) is 60° relative to the second central axis 119. 0 And the complementary angle θ2 is 30 degrees relative to 118. 0 .like Figure 5 As shown, the core pad 150 may have cushioning meshes 120 on its top and bottom sides. The top cushioning mesh 120 includes a plurality of walls 122 of thickness T1, which define a plurality of gaps 124 of diameter D1. The bottom cushioning mesh 120 includes a plurality of walls 122 of thickness T2, which define a plurality of gaps of diameter D2. In some embodiments, T1 is equal to T2, while in other embodiments, T1 and T2 are different. Similarly, in some embodiments, D1 is equal to D2, while in other embodiments, D1 and D2 are different. Figure 6As shown, pillow 102 may not include core pad 150, and cushioning mesh 120 extends from the top to the bottom of pillow 102. Also as shown, the diameter D1 of the gaps 124 and the thickness T1 of the interconnected walls 122 of the cushioning mesh 120 are consistent throughout pillow 102. Still in other embodiments, the diameter D1 of the gaps 124 and the thickness T1 of the interconnected walls 122 may differ from one side of pillow 102 to the other. In some embodiments, pillow 102 is divided into one or more regions (e.g., corners, center, sides, top, bottom, etc.), and the diameter D1 of the gaps 124 and the thickness T1 of the interconnected walls 122 in one or more regions may differ from the diameter D1 of the gaps 124 and the thickness T1 of the interconnected walls 122 in another region.

[0044] Now for reference Figure 7 Another embodiment of the cushioning grid 120 is shown, wherein interconnected walls 122 define a plurality of gaps 124 that define a regular array of rhombuses (e.g., squares, diamonds, etc.). The maximum angle of any wall 122 of the cushioning grid, denoted by θ1, relative to axis 121 (which is parallel to the first central axis 118 and / or width 114 of the cushion 102) is 45 degrees relative to the second central axis 119. 0 And the complementary angle θ2 is 45 degrees relative to 118. 0 Now for reference. Figure 7 Interconnected walls 122 define a plurality of gaps 124, which define a regular array of triangles (i.e., a triangular array). The maximum angle of any wall 122 of the buffer grid, denoted by θ1, relative to axis 121 (which is parallel to the first central axis 118 and / or width 114 of the cushion 102) is 30° relative to the second central axis 119. 0 And the complementary angle θ2 is 60 degrees relative to 118. 0 .

[0045] Figure 9 and Figure 10 A buffer grid 120 is depicted, which has a subset of interconnected walls 122 extending parallel to the first central axis 118, and therefore does not conform to the references above. Figures 1-8 The standards for θ1 and θ2 discussed. Therefore, Figure 9 and Figure 10This represents a less-than-ideal arrangement where, when a force is applied substantially parallel to 118 to one or both of the first side edge 106 and the second side edge 108, the arrangement will not compress as much along 118. This is because each of these cushioning grids 120 includes a wall 122 that extends parallel or substantially parallel to the width 114 or central axis 118 of the pillow 102, the cushioning grids 120, and the core pad 150 (if present), or parallel or substantially parallel to the opposite direction in which the pillow 102 is expected to be compressed (i.e., from top to bottom in each illustration). The angle θ1 in each illustration refers to the maximum angle between any wall 122 of the cushioning grid 120 and the depth 116 of the pillow 102 (which is the dimension between the front edge 110 and the rear edge 112). Figure 9 and Figure 10 In this case, angle θ1 is 90°. Figure 9 and Figure 10 The maximum angle in 90 degrees 0 The minimum angle of 0° corresponds to the direction opposite to the central axis 118 of the pillow 102 or the direction along which the pillow 102 is designed to be compressed or collapsed. This means Figure 9 and Figure 10 The buffer grid 120 shown includes walls oriented in the opposite direction to the first central axis 118 and the second central axis 119 parallel to the pillow 102 and parallel to the direction in which the pillow 102 may or is intended (i.e., designed) to be compressed or collapsed.

[0046] A method for designing a cushion 100 (e.g., a collapsible cushion, such as a travel cushion, an easy-to-store cushion, etc.) includes determining the direction in which the cushion 100 is likely to collapse or tends to collapse (e.g., across its width, etc.). Additionally, characteristics of at least one cushioning grid 120 (e.g., the shape of voids 124 or prisms in the grid 120, etc.) may be determined. The orientation of each cushioning grid 120 is also determined such that, when the cushion 100 collapses in a predetermined direction, each cushioning grid will collapse optimally (e.g., without buckling or significantly increasing thickness, etc.).

[0047] A method for manufacturing a cushion 100 (e.g., a collapsible cushion, such as a travel cushion, an easy-to-store cushion, etc.) includes defining a cushioning mesh 120 by a suitable cushioning material (e.g., a flexible material, a deformable material, an elastomeric gel, etc.). The cushioning mesh 120 is defined by defining interconnected walls 122 that define a plurality of voids 124 oriented such that the cushioning mesh 120 can collapse along its width 114 without buckling or unintentionally increasing its thickness. More specifically, the cushioning mesh 120 may be defined in such a way that there are no walls 122 or substantially no walls 122 parallel to or substantially parallel to the central axis 118 of the cushion 100, or parallel to or substantially parallel to the direction in which the cushion 100 may or tends to collapse. The interconnected walls 122 of the cushioning mesh 120 may define a plurality of voids 124 that may define an array of polygonal prisms (e.g., hexagonal prisms, rhomboid prisms, triangular prisms, etc.).

[0048] Another method for manufacturing a cushion 100 (e.g., a collapsible cushion, such as a travel cushion, an easy-to-store cushion, etc.) involves providing a core 150 and positioning at least one cushioning grid 120 on the outer surface of the core 150. The core 150 is collapsible when a force is applied along or substantially parallel to the central axis 118 across the width 114 of the core 150. Each cushioning grid 120 includes interconnected walls 122 oriented such that no wall 122 or substantially none of the interconnected walls 122 is oriented parallel to the central axis 118 of the core 150, or substantially parallel to the direction in which the core 150 may collapse or tends to collapse. The interconnected walls 122 of the cushioning grid 120 may define an array of polygonal prisms (e.g., hexagonal prisms, rhomboid prisms, triangular prisms, etc.) on the outer surface of the core 150. The cushioning mesh 120 can be positioned on the core pad 150 by placing the cover 140 containing the cushioning mesh 120 on the core pad 150.

[0049] A method for storing and / or transporting a pillow 100 includes collapsing the pillow 100. The pillow 100 can be collapsed by pressing (e.g., pushing, etc.) the ends of the pillow 100 together along a central axis 118 extending through a width 114 of the pillow 100. Each cushioning grid 120 of the pillow 100 can collapse when the edges 106, 108 of the pillow 100 (e.g., the cushioning grid 120 of the pillow 100, the core pad 150 of the pillow 100, etc.) are pressed together. If the cushioning grid 120 is properly oriented (e.g., where substantially none of the walls 122 of the cushioning grid 120 are substantially parallel or substantially parallel to the central axis 118 of the pillow 100, the direction in which the pillow 100 may or tends to collapse, etc.), the cushioning grid 120 can collapse without buckling, or thus collapse without affecting its thickness. When at least one buffer grid 120 collapses, the walls 122 of at least one buffer grid 120 can move into the space, cell, or void 124 defined between the walls 122, thereby reducing the volume of the space, cell, or void 124. This collapse can continue until the walls 122 of at least one buffer grid 120 come into contact with each other.

[0050] When the collapse force is removed, the cushion 100 (e.g., the core pad 150, each cushioning grid 120, etc.) may substantially expand to its relaxed width 114, or substantially expand to its original size and volume. This expansion may occur due to the elasticity of one or more portions of the cushion 100 (e.g., its core pad 150, its cushioning grid 120, etc.).

[0051] While this disclosure provides numerous details, these should not be construed as limiting the scope of any of the appended claims, but rather as illustrations of some embodiments of the elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter and its elements and features may be designed without departing from the spirit or scope of any claim. Features from different embodiments may be combined. Therefore, the scope of each claim is limited only by its concise language and its legal equivalents.

[0052] As used herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning consistent with common and acceptable use by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art upon reviewing this disclosure will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the scope of those features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating non-substantial or irrelevant modifications or variations to the described subject matter and are considered to be within the scope of this disclosure.

[0053] It should be noted that the term “exemplary” used herein to describe various embodiments is intended to indicate possible examples, representations and / or illustrations of possible embodiments (and such term is not intended to imply that such embodiments must be unusual or the best examples).

[0054] For the purposes of this disclosure, the term "connection" means that two components are directly or indirectly connected to each other. Such connection may be static or movable in nature. Such connection may be achieved by the two components, or two components and any additional intermediate components, being integrally formed into a single whole, or by the two components, or two components and any additional intermediate components, being attached to each other. Such connection may be permanent in nature, or it may be removable or detachable in nature.

[0055] It should be noted that, according to other exemplary embodiments, the orientation of different elements may be different, and such variations are intended to be covered by this disclosure.

[0056] It is important to note that the construction and arrangement of the non-powered treadmills shown in the various exemplary embodiments are merely illustrative. While only a few embodiments are described in detail in this disclosure, those skilled in the art who review this disclosure will readily recognize that many modifications (e.g., variations in the size, dimensions, structure, shape and proportion of various elements, values ​​of parameters, installation arrangements, use of materials, color, orientation, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter described in the claims. For example, an element shown as integrally formed may be composed of multiple parts or elements, the positions of elements may be reversed or otherwise changed, and the nature or number or position of discrete elements may be altered or varied. According to alternative embodiments, the order or sequence of any process or method steps may be changed or rearranged. Other substitutions, modifications, variations, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of this disclosure.

Claims

1. A cushion, comprising: - A core pad, the core pad including an outer surface and opposing side edges; and - At least one buffer mesh, said at least one buffer mesh being stacked with the outer surface of the core pad, and said at least one buffer mesh comprising: -- Opposite side edges, which are positioned adjacent to the opposite side edges of the core pad, and the opposite side edges of the at least one buffer mesh define the width; -- A central axis that extends along the width; and -- A plurality of interconnected walls defining a plurality of voids and oriented on the outer surface, the plurality of interconnected walls being configured to collapse within the plurality of voids when the opposing side edges of the at least one buffer grid are pressed against each other in a direction substantially parallel to the central axis to cause the cushion to collapse.

2. The pillow according to claim 1, wherein, The core pad includes foam.

3. The pillow according to claim 1, wherein, The plurality of interconnected walls of the at least one buffer mesh comprise an elastomeric gel.

4. The pillow according to claim 1, wherein, The at least one buffer grid has essentially no walls parallel to the central axis spanning the width of the at least one buffer grid.

5. The pillow according to claim 4, wherein, The plurality of interconnected walls of the at least one buffer grid are arranged to form the plurality of gaps as at least one of the following: An array of hexagonal prisms; An array of rhombic prisms; or An array of triangular prisms.

6. The pillow according to claim 1, wherein, Each of the plurality of interconnected walls is oriented along an axis that intersects the central axis.

7. The pillow according to claim 1, wherein, The plurality of interconnected walls are oriented at an angle of less than 90 degrees relative to the central axis.

8. The pillow according to claim 1, wherein, The outer surface of the core pad includes opposing main surfaces.

9. The pillow according to claim 8, wherein, The at least one buffer grid includes: A first buffer grid is superimposed on a first main surface in the oppositely facing main surface.

10. The pillow according to claim 9, wherein, The at least one buffer grid also includes: A second buffer grid is superimposed on the second main surface of the oppositely facing main surface.

11. The pillow according to claim 1, wherein, The at least one buffer grid substantially surrounds the outer surface of the core pad.

12. The pillow according to claim 1, further comprising: A cover, which is located on the core pad and contains the at least one buffer mesh.

13. A method for manufacturing a collapsible pillow, the method comprising: A core pad is provided that is capable of collapsing when a relative contractile force is applied along a central axis spanning the width of the core pad; and A buffer grid comprising interconnected walls is positioned on the outer surface of the core pad, wherein substantially none of the interconnected walls are oriented parallel to the central axis of the core pad.

14. The method according to claim 13, wherein, Positioning the buffer grids includes positioning a plurality of buffer grids on a portion of the outer surface of the core pad.

15. The method according to claim 13, wherein, Positioning the buffer grid includes positioning the interconnected walls to define a buffer grid that includes at least one of the following: An array of hexagonal prisms, the array of hexagonal prisms being located on the outer surface of the core pad; An array of rhomboid prisms, the array of rhomboid prisms being said on the outer surface of the core pad; or An array of triangular prisms on the outer surface of the core pad.

16. The method according to claim 13, wherein, Positioning the buffer mesh involves covering the core pad with a cover including the buffer mesh.

17. A cushion, comprising: A buffer grid comprising opposing side edges and a plurality of interconnected walls, wherein the plurality of interconnected walls are oriented such that when at least one of the opposing side edges of the buffer grid is pushed toward the other of the opposing side edges to cause the cushion to collapse, the plurality of interconnected walls collapse without substantially increasing in thickness.

18. The pillow according to claim 17, wherein, The multiple interconnected walls comprise an elastomeric gel.

19. The pillow according to claim 17, wherein, None of the multiple interconnected walls are substantially parallel to the central axis spanning the width of the buffer grid.

20. The pillow according to claim 17, wherein, The plurality of interconnected walls are arranged to form at least one of the following: An array of hexagonal prisms; An array of rhombic prisms; or An array of triangular prisms.

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