Supportive cushioning including foam arches

Abstract

The support cushion includes a tub defining a well and a plurality of foam arches disposed within the well. Each foam arch includes an upper curved portion, and each foam arch is disposed in the well such that each upper curved portion faces away from a bottom panel of the tub. A body support layer having a first surface and a second surface opposite the first surface is disposed above the well and atop the plurality of flexible foam arches.

Description

[Technical field]

[0001] [Related Applications] This application claims priority to U.S. Provisional Application Serial No. 63 / 229,756, filed August 5, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a support cushion including a plurality of flexible foam arches. In particular, certain embodiments of the present invention relate to a support cushion, such as a mattress assembly, that includes a plurality of flexible foam arches disposed within the support cushion and is configured to provide sustained energy and continuous support to an individual resting on the support cushion. [Background technology]

[0003] One aspect of successful, restful sleep is the comfort of an individual's sleep, and the support provided by a mattress or other support cushion is a key component of such sleep comfort. Medical research has shown that insufficient sleep ("sleep deprivation") can have a significant negative impact on lifespan, productivity, and overall mental, emotional, and physical health. Chronic sleep deprivation has been associated with weight gain, specifically affecting how the body processes and stores carbohydrates, as well as altering hormone levels that affect appetite. In addition, sleep deprivation can result in irritability, impatience, lack of concentration, and moodiness, leading some researchers to suggest a link between sleep deprivation and workplace accidents, traffic accidents, and general afternoon inattention. Additionally, sleep disorders have been associated with high blood pressure, increased stress hormones, and cardiac arrhythmias, and recent studies suggest that sleep deprivation affects immune function, resulting in increased susceptibility to illness and disease, such as cancer. Due to these various effects, researchers have suggested that sleep deprivation costs the United States billions of dollars in lost productivity annually. Therefore, a support cushion that improves the sleeping comfort and improves the support provided by the support cushion, thereby reducing an individual's sleep deprivation, would be highly desirable and beneficial. Summary of the Invention

[0004] The present invention includes a support cushion having a plurality of foam arches disposed within the support cushion and configured to provide sustained energy and continuous support to an individual resting on the support cushion.

[0005] In some exemplary embodiments of the invention, the support cushion includes a tub with a bottom panel and sidewalls that together define a well. The support cushion further includes a plurality of foam arches disposed within the well. Each foam arch includes an upper curved portion, and each foam arch is disposed within the well such that each upper curved portion faces the bottom panel of the tub. The support cushion further includes a body support layer having a first side and a second side opposite the first side, the second side of the support cushion disposed across the well and atop the plurality of flexible foam arches.

[0006] In some exemplary embodiments, the well of the tub has a width, and each foam arch has a length that spans the width of the well. Further, in some exemplary embodiments, the tub has a longitudinal axis, and the upper curved portion of each foam arch extends in the same direction as the longitudinal axis of the tub. In some exemplary embodiments, each foam arch is independent of each other foam arch. In certain embodiments, each foam arch is encased in fabric. In other exemplary embodiments, each foam arch is affixed to adjacent foam arches. For example, in some exemplary embodiments, a fabric band extends along the longitudinal axis of the tub, and a fabric band is affixed to an end face of each foam arch to connect the foam arches. In some exemplary embodiments, each foam arch is in the form of a circular arch.

[0007] In some exemplary embodiments, the body support layer and the plurality of foam arches comprise flexible foam. In some exemplary embodiments, the body support layer comprises viscoelastic foam. In some exemplary embodiments, the tub comprises flexible foam, and the flexible foam comprising the body support layer has a density less than the density of the flexible foam comprising the tub. In some exemplary embodiments, the sidewalls of the tub include an inner support encased in flexible foam.

[0008] Further features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the description, figures, and non-limiting examples herein. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view of a mattress assembly made in accordance with the present invention, with a portion of the body support layer of the mattress assembly removed to reveal the underlying foam arch.

[0010] [Diagram 2] 2 is a cross-sectional view of the mattress assembly of FIG. 1 taken along line 2-2 shown in FIG.

[0011] [Figure 3A] FIG. 3A is a partial perspective view of the flexible foam used to form the exemplary foam arch shown in FIG.

[0012] [Figure 3B] FIG. 3B is a partial perspective view of the flexible foam of FIG. 3A after it has been folded to form a foam arch.

[0013] [Figure 4] FIG. 4 is a perspective view of a mattress assembly made in accordance with the present invention, with a portion of the body support layer and sidewall of the mattress assembly removed to show the underlying foam arches connected by a nonwoven material.

[0014] [Diagram 5] FIG. 5 is a perspective view of another mattress assembly made in accordance with the present invention, including a portion of the body support layer and sidewall of the mattress assembly removed to show an underlying foam arch encased in a nonwoven material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The present invention includes a support cushion having a plurality of foam arches disposed within the support cushion and configured to provide sustained energy and continuous support to an individual resting on the support cushion.

[0016] 1, in one exemplary embodiment of the present invention, a support cushion is provided in the form of a mattress assembly 10 including a tub 20 having a bottom panel 22 and side walls 24 that together define an interior cavity or well 50 of the tub 20. A plurality of foam arches 30 are further included in the mattress assembly 10 and are disposed within the well 50 of the tub 20. More specifically, each foam arch 30 is disposed within the well 50 such that the length of each foam arch 30 spans the width of the well 50 and the curved portion 32 of each foam arch 30 extends in the same direction as the longitudinal axis of the tub 20. A body support layer 40 having a first side 42 and a second side 44 opposite the first side 42 is also included in the mattress assembly 10. The second side 44 of the body support layer 40 is disposed above and covers the well 50 and the associated tub 20, but is also disposed atop and covering the plurality of foam arches 30. In this manner, each of the foam arches 30 contacts the second surface 44 of the body support layer 40 and is configured to provide support to the body support layer 40 and, therefore, to a user resting on the mattress assembly 10, as described further below. The exemplary mattress assembly 10 further includes a base layer 70 disposed below and supporting the bottom panel 22 of the tub 20, as described further below.

[0017] 2, 3A and 3B, each of the exemplary foam arches 30 comprises a piece of flexible foam that is bent into the shape of a circular arch such that each of the foam arches 30 includes an upper curved portion 32 and a flat end 34 opposite the upper curved portion 32. More specifically, as shown in FIG. 3A, the flexible foam prior to bending is a substantially rectangular foam slab that can be characterized as having a first side 36, a second side 37 opposite the first side 36, two end faces 35 extending between the first side 36 and the second side 37 along a major axis of the foam slab, and two edge faces 38 (only one shown) extending between the first side 36 and the second side 37 along a minor axis of the foam slab. 3B, in folding the flexible foam, the two end faces 35 approach one another as they fold inwardly on themselves, such that the second face 37 becomes the inner face 37 of the foam arch 30, and the first face 36 becomes the outer face 36 of the foam arch 30. As mentioned above, the resulting foam arch 30 can also be characterized as having a curved portion 32 where the foam piece is bent, with an end 34 opposite the curved portion 32 where the two end faces 35 approach one another.

[0018] In the exemplary embodiment shown in Figures 1, 2, and 3B, the foam arch 30 is held together with an adhesive, such as a water-based adhesive or a hot melt adhesive, that is applied to the inner surface 37 of the flexible foam prior to folding. In some particular embodiments, the adhesive is applied to only a portion of the inner surface 37, such as a 2 inch portion of the end 34 immediately adjacent the end face 35. Of course, other means of maintaining the shape of the foam arch are possible without departing from the spirit and scope of the present invention, including but not limited to sewing, tufting, heat welding, and sonic welding. As described further below, in some other embodiments, additional components are used to form and / or maintain the shape of the foam arch.

[0019] 2, each of the foam arches 30 are independent of one another and are positioned adjacent to one another in the well 50 of the tub 20 with the end 34 of each foam arch 30 in the well 50 and the two end faces 35 positioned against the bottom panel 22 of the tub 20. The upper curved portion 32 of each foam arch 30 is thus positioned opposite the bottom panel 22 of the tub 20 with the foam arch 30 extending flush with or slightly above the sidewall 24 of the tub 20. The foam arches 30 are thus positioned and configured to provide sustained energy and continuous support to the body support layer 40 of the mattress assembly 10 when the body support layer 40 is positioned over and in contact with the upper curved portion 32 of each foam arch 30. Specifically, by configuring the foam arches 30 in this manner, the foam arches 30 are able to provide sustained energy and continuous support not only through the natural pushback and bounce present in the arch itself, but also by each side and end of the foam arches 30 pushing against the sides and ends of adjacent foam arches 30 and / or tubs 20 to create pushback energy upon compression. Additionally, the placement of the foam arches 30 provides a mechanism for adding natural bounce to an all-foam mattress and improving air flow and compression recovery.

[0020] As mentioned above, the plurality of foam arches 30 of the mattress assembly 10 generally comprise flexible foam. In particular, the flexible foam used for the foam arches 30 is suitable for providing the necessary amount of support to the body support layer 40 as well as the necessary resistance to compression and sustained energy, i.e., "push-back". Such flexible foams that may be used in accordance with the present invention include, but are not limited to, latex foam, reticulated or non-reticulated viscoelastic foam (sometimes referred to as memory foam or memory foam), reticulated or non-reticulated non-viscoelastic foam, polyurethane high resilience foam, expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene). In the embodiment shown in Figures 1-2, each of the foam arches 30 comprises a flexible foam having sufficient resilience, density, and hardness to enable the foam arches 30 to provide sufficient resistance to compression and thus push-back against the body support layer 40 and adjacent foam arches 30 upon compression. Typically, such flexible foams have a hardness of at least about 10N to no more than about 80N, measured at about room temperature (i.e., 21° C.-23° C.), by compressing a sample of the material from a plate to at least 40% of its original thickness and holding the 40% compression for a period of time as specified by Hardness Measurement Standard, International Organization for Standardization (ISO) 2439. In some embodiments, the flexible foam with foam arches 30 has a hardness of about 10N, about 20N, about 30N, about 40N, about 50N, about 60N, about 70N, or about 80N to provide the body support layer 40 with the desired degree of compression resistance and support.

[0021] The flexible foams described herein for use in the foam arch 30 may also have a density that helps provide a desired degree of compression resistance and other qualities, as well as enhancing a degree of durability of the material. In some embodiments, the flexible foams used in the foam arch 30 have a density of about 30 kg / m 3 More than about 150kg / m 3In some embodiments, the density of the viscoelastic foam used in the foam arch 30 of the mattress assembly 10 is about 30 kg / m 3 , about 40kg / m 3 , about 50kg / m 3 , about 60kg / m 3 , about 70kg / m 3 , about 80kg / m 3 , about 90kg / m 3 , about 100kg / m 3 , about 110kg / m 3 , about 120kg / m 3 , about 130kg / m 3 , about 140kg / m 3 , or about 150 kg / m 3 Of course, the selection of a flexible foam having a particular density will affect other properties of the foam, including the firmness of the foam, the way the foam responds to pressure, and the overall feel of the foam, but it is understood that flexible foams having desired densities and firmnesses, as well as particular sizes, weights, and shapes, can be readily selected for a particular application or mattress assembly, as desired and to provide foam arches with varying degrees of support and comfort to a user lying on an exemplary mattress assembly of the present invention. In some embodiments, the flexible foams used in accordance with the present invention may be characterized or described as having an indentation force deflection ("IFD") of between 20-40 pounds and a density of 1-2 pounds per cubic foot.

[0022] In addition to the foam arches 30 comprising flexible foam, the tub 20 of the mattress assembly 10 also generally comprises flexible foam. As shown in FIG. 2, the exemplary sidewall 24 includes an inner support 26 and a foam envelope 28. The inner support 26 and bottom panel 22 comprise flexible foam having sufficient density and hardness to secure the plurality of flexible foam arches 30 within the tub 20 and to support the body support layer 40 of the mattress assembly 10. Meanwhile, the flexible foam comprising the foam envelope 28 typically has a density less than that of the inner support 26 to provide a soft edge to the mattress assembly 10. Such viscoelastic foams similarly have hardness values ​​ranging from about 10 N to no more than about 80 N and density values ​​of about 30 kg / m 3 to about 150 kg / m 3 , but of course it is contemplated that flexible foams, including other flexible foams such as latex or soft conventional foams having the desired density, hardness, or other properties, can be readily selected for the particular application or mattress assembly desired. In some embodiments, there is no inner support at all, and the sidewalls are made of a single piece of foam having suitable support properties. In other embodiments, the inner support, the bottom panel, or both the inner support and the bottom panel may not be made of foam, but instead may be made of a rigid or semi-rigid material, such as plastic or wood.

[0023] The exemplary body support layer 40 of the mattress assembly 10 also comprises a flexible foam, however the flexible foam of the body support layer 40 typically has a density less than that contained in the sidewall 24 of the tub 20 and is generally adapted to distribute pressure from the user's body or portions thereof across the body support layer 40. For example, in some embodiments, the flexible foam comprising the sidewall 24 of the tub 20 has a density and / or hardness similar to that observed in the foam arch 30 (discussed above), but the body support layer 40 has a lower density or behavior than that present in the foam arch 30. In this regard, the body support layer 40 can comprise a viscoelastic foam that is memory resilient and has sufficient density and hardness such that pressure is evenly absorbed and distributed evenly across the body support layer 40 of the mattress assembly 10. Again, such viscoelastic foam can similarly have hardness values ​​ranging from about 10 N to no more than about 80 N and density values ​​of about 30 kg / m 3 ~Approx. 150kg / m 3 Although the range may be from 0.01 to 0.01 mm, it is of course contemplated that flexible foams, including other flexible foams such as latex or soft conventional foams having the desired density, hardness, or other properties, may be readily selected for a particular application or body support layer of a mattress assembly, as desired. In some embodiments, such properties may also be provided by a fiber-based body support layer.

[0024] The exemplary base layer 70 of the mattress assembly 10 also comprises a flexible foam, but the flexible foam of the base layer 70 typically has a density equal to or greater than the density of the bottom panel 22 and sidewalls 24 of the tub 20 to provide additional support to the tub 20. In certain embodiments, the base layer 70 and bottom panel 22 are made of the same flexible foam and can be combined into a single layer. In other embodiments, the base layer is made of or includes a rigid or semi-rigid material, such as plastic or wood, to provide additional support. Thus, in some embodiments, the base layer can be considered a foundation or base, such as a box spring, that is typically used in conjunction with mattresses.

[0025] In some further embodiments of the present invention, although not shown in the figures, the body support layer of the exemplary mattress assembly may be further covered by a comfort portion or layer disposed on the body support layer and providing a level of comfort to a user's body or a portion thereof resting on such exemplary mattress assembly. The comfort layer may also comprise a viscoelastic foam. However, the comfort layer is typically less dense, stiff, or both than the body support layer of the mattress assembly, so that the comfort layer provides a softer surface for the user's body or a portion thereof to rest on, while also providing a sufficiently soft barrier between the user's body and the foam arch of the mattress assembly, the hardness or density of which is increased to provide a desired level of compression resistance. For example, in certain embodiments, the exemplary mattress assembly may comprise a viscoelastic foam having a density of about 80 kg / m 3 and a body support layer having a viscoelastic foam with a hardness of about 13 N and a density of about 35 kg / m 3 and may include a comfort layer having a viscoelastic foam with a hardness of about 10 N.

[0026] Further to the body support layer and comfort layer of the mattress assembly of the present invention, as indicated above, the body support layer and comfort layer generally each have a layer of viscoelastic foam having a density and hardness suitable for dispersing pressure from the user's body or a portion thereof. However, it is further contemplated that the exemplary body support section can have different or additional layers having various densities and hardnesses. For example, a layer of high resilience polyurethane foam can be used alone or can be secured to a second surface of a layer of low resilience viscoelastic foam used in the body support section. Such multi-layer body support sections are described, for example, in U.S. Patent Nos. 7,469,437, 7,507,468, 8,025,964, and 8,034,445, each of which is incorporated herein by reference.

[0027] As a further refinement of the mattress assembly of the present invention, one or more outer covers may be included and used to cover various portions of the mattress assembly. For example, in one embodiment, a fire sock may first be used to enclose the body support layer and the tub of the exemplary mattress assembly. An outer fabric cover, such as a fabric cover made of a durable, washable fabric material (e.g., a cotton / polyester blend), may then be used to cover the fire sock that encloses the body support layer and the tub.

[0028] As a further refinement of the present invention, although the support cushion shown in Figures 1-2 is in the form of a mattress assembly and is dimensioned to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to head pillows, seat cushions, seat backs, neck pillows, leg spacer pillows, mattress toppers, overlays, etc. Thus, phrases such as "support cushion" are used herein to refer to any and all such objects of any size or shape capable of or generally used to support the body or a portion thereof of a user.

[0029] As another refinement, as mentioned above, in some exemplary embodiments, the foam arches 30 are formed with adhesive applied to the inner surface 37 of the foam arches 30 and are positioned within the tub 20 independently of each other. However, in other embodiments, each of the foam arches is connected to each adjacent foam arch. In some embodiments, for example, additional adhesive is applied to the outer surface of the foam arch to connect adjacent foam arches. However, as another example, and referring now to FIG. 4, in another exemplary mattress assembly 110, in addition to or instead of adhesive, the foam arches 130 are held together with a fabric band 160 that is applied to the edge surface 138 after folding. More specifically, the fabric band 160 extends along the longitudinal axis of the tub 120 along the end of the foam arch 130 adjacent the side wall 124 and closest to the bottom panel 122. Although not explicitly shown, another fabric band is applied to the other end of the foam arch 130 in a similar manner. In this manner, the foam arches 130 connected by the fabric bands 160 can be collectively characterized as an insert 180 disposed within the well 150 of the tub 120. The exemplary fabric bands 160 are made of a non-woven material and can be glued (e.g., with a water-based or hot melt adhesive) or welded (e.g., with heat or sonic welding) to the edge surface 138. However, other materials known in the art can be used to hold the foam arches. The height of the fabric bands 160 is also not limited and can extend only partially up the edge surface 138 of the foam arches 130 or can extend substantially the entire edge surface 138 of the foam arches 130. In some embodiments, a similar fabric band can be similarly affixed to the bottom (e.g., end surface) of the arch in addition to or instead of the edge surface 138 as shown. The exemplary mattress assembly 110 also includes a body support layer 140 and a base layer 170 that are substantially similar to the body support layer 40 and base layer 70 described above with respect to Figures 1-2.

[0030] 5, in another exemplary mattress assembly 210, foam arches 230 are disposed independently of one another within wells 250 of tubs 220, similar to arches 30 described above with respect to FIGS. 1-2. However, unlike arches 30 shown in FIGS. 1-2, the exemplary foam arch 230 shown in FIG. 5 includes a fabric 260 that substantially surrounds or encases the folded flexible foam. While in some embodiments, fabric 260 may loosely surround the folded flexible foam, in exemplary embodiments, fabric 260 is affixed to at least a portion of the underlying folded flexible foam. More specifically, with reference to the exemplary foam arch 30 shown in FIG. 3B, fabric 260 may be affixed to end faces 35, edge faces 38, flat portions of exterior surface 36, and / or the entire exterior surface 36. Nevertheless, fabric 260 may be affixed to the folded flexible foam via adhesive (e.g., water-based or hot melt adhesive) or welding (e.g., heat or sonic welding). In some embodiments, fabric 260 maintains the shape of the foam arches in addition to or in place of other means described above. Additionally, the inclusion of fabric 260 prevents foam-to-foam friction during compression and, more importantly, decompression, improving the handling of the mattress. To this end, the exemplary fabric 260 is generally made of a nonwoven material, although other materials known in the art may be used to hold the foam arches together and provide a lower level of friction against the underlying flexible foam.

[0031] Additionally, while the exemplary fabric 260 shown in FIG. 5 completely surrounds and wraps the foam arch 230, in other embodiments, a similar fabric may cover only a portion of the fabric arch. For example, the fabric may surround the bottom and sides and not cover the top, the fabric may not cover some or all of the top curve, the fabric may only extend to a portion of the sides of the foam arch, and / or may cover or not cover the bottom of the foam arch. The exemplary mattress assembly 210 also includes a body support layer 240 and a base layer 270 that are substantially similar to the body support layer 40 and base layer 70 described above with respect to FIGS. 1-2.

[0032] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of the present invention or the scope of the following claims. This detailed description, and in particular the specific details of the exemplary embodiments disclosed herein, are given primarily for clarity of understanding, without unnecessary limitations to be understood therefrom, as modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

Claims

1. a tab including a bottom panel and a sidewall that together define a well; a plurality of foam arches disposed in the well, each foam arch including an upper curved portion, the plurality of foam arches disposed in the well such that each upper curved portion faces away from the bottom panel of the tub; a body support layer having a first surface and a second surface opposite the first surface, the second surface being disposed above the well and atop the plurality of flexible foam arches; The support cushion has

2. the well in the tab has a width, and each of the foam arches has a length spanning the width of the well. The support cushion of claim 1.

3. the tabs have a longitudinal axis, and the upper curved portion of each foam arch extends in the same direction as the longitudinal axis of the tab. The support cushion of claim 2.

4. each foam arch is independent of each other foam arch; The support cushion of claim 1.

5. Each of the foam arches is encased in fabric. The support cushion of claim 1.

6. Each foam arch is attached to an adjacent foam arch. The support cushion of claim 1.

7. The method further includes a fabric band extending along a longitudinal axis of the tab, the fabric band being attached to an edge surface of each foam arch to connect the plurality of foam arches. The support cushion of claim 1.

8. Each foam arch is in the shape of a circular arch. The support cushion of claim 1.

9. the body support layer and the plurality of foam arches comprise flexible foam. The support cushion of claim 1.

10. The body support layer comprises a viscoelastic foam.

10. The support cushion of claim 9.

11. The tab comprises a flexible foam; the flexible foam constituting the body support layer has a density less than the density of the flexible foam constituting the tub; 10. The support cushion of claim 9.

12. The side walls of the tub include an inner support encased in flexible foam.

10. The support cushion of claim 9.

13. a tab including a bottom panel and sidewalls that together define a well, said well having a width; a plurality of foam arches disposed in the well, each foam arch having a length spanning the width of the well and having an upper curved portion, each foam arch being disposed in the well such that each upper curved portion is opposite the bottom panel of the tub and extends in the same direction as a longitudinal axis of the tub; a body support layer having a first surface and a second surface opposite the first surface, the second surface being disposed above the well and atop the plurality of foam arches; The mattress assembly comprises:

14. each foam arch being independent of each other foam arch; 14. The support cushion of claim 13.

15. Each of the foam arches is encased in fabric.

14. The support cushion of claim 13.

16. Each foam arch is attached to an adjacent foam arch.

14. The support cushion of claim 13.

17. The method further includes a fabric band extending along a longitudinal axis of the tab, the fabric band being attached to an edge surface of each foam arch to connect the plurality of foam arches.

14. The support cushion of claim 13.

18. Each foam arch is in the shape of a circular arch.

14. The support cushion of claim 13.

19. the body support layer and the plurality of foam arches comprise flexible foam.

14. The support cushion of claim 13.

20. The body support layer comprises a viscoelastic foam.

20. The support cushion of claim 19.

21. the tab comprises a flexible foam; the flexible foam constituting the body support layer has a density less than the density of the flexible foam constituting the tub; 20. The support cushion of claim 19.

22. The side walls of the tub include an inner support encased in flexible foam.

20. The support cushion of claim 19.

23. 1. A foam insert for use in a mattress assembly, comprising: a plurality of foam arches, each foam arch having a length and including edge surfaces at opposite ends of the length of the foam arch, an upper curved portion extending perpendicular to the direction of the length of the foam arch, and a flat end opposite the upper curved portion; a cloth band attached to each edge surface of the plurality of foam arches; A foam insert.

24. each of the foam arches has a first side, a second side opposite the first side, and two end sides extending along a longitudinal axis of the slab of foam between the first side and the second side, the slab of foam being created by bending the two end sides toward each other to form the flat ends of the foam arches; 24. The foam insert of claim 23.

25. and further comprising an adhesive applied to the second surface of the foam slab that is folded onto itself to become the inner surface of the foam arch.

24. The foam insert of claim 23.

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