Cushioning structure

Abstract

To provide a cushioning structure making it possible to prevent or at least reduce entrapment of moisture between a person positioned on the cushioning structure and the cushioning structure itself, and / or a cushioning structure which provides comfort and resilience.SOLUTION: A cushioning structure includes: a first layer of a three-dimensional structured mat of extruded entangled filaments; a second layer of a three-dimensional structured mat of extruded entangled filaments; and an intermediate layer between the first layer and the second layer.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a cushion structure.

Background Art

[0002] For example, cushion structures for high-performance applications such as medical mattresses or luxury mattresses generally consist of multiple layers of (different) materials, with a flexible foam, in particular one or more layers of polyurethane foam and / or foam rubber, provided on top of a layer of springs for providing elasticity. The foam layer redistributes pressure, in particular the pressure component perpendicular to the main plane of the cushion structure (also known as the Z-component), when a person is positioned on the mattress, so that the person on the mattress no longer feels the individual springs arranged under the flexible foam layer. Around this structure, a liquid-impermeable cover is generally provided for hygienic reasons.

[0003] However, foams and especially polyurethane foams have the drawback that moisture, such as sweat or spilled liquid, can be trapped between the person located on the cushion structure and the cushion structure itself. Generally, closed-cell foams are used within the cushion structure.

[0004] Therefore, there is a need for a cushion structure that prevents or at least reduces the trapping of moisture between the person located on the cushion structure and the cushion structure itself. However, such a cushion structure should still provide sufficient elasticity and support to the person located on the cushion structure.

[0005] Furthermore, there is a need for a cushion structure that is more sustainable compared to foams that are difficult to recycle, especially polyurethane foams.

Summary of the Invention

Problems to be Solved by the Invention

[0006] The object of the present invention is to provide a cushion structure that can prevent or at least reduce the capture of moisture between a person located on the cushion structure and the cushion structure itself, and / or a cushion structure that provides comfort and elasticity.

Means for Solving the Problems

[0007] This object is achieved by the cushion structure according to claim 1.

[0008] The cushion structure is a structure that provides comfort and elasticity to one or more body parts of a person in a lying or sitting position, particularly in a direction perpendicular to the main plane of the cushion structure (also known as the Z direction). Elasticity is the ability of a material or structure to absorb energy when elastically deformed (mainly in the Z direction, but not exclusively) and release that energy when the load is removed. Comfort in this regard is called spatially resolved (i.e., in the X and Y directions) elasticity, where the local pressure (the onset of elastic deformation) in the Z direction is redistributed in the X and Y directions, thereby reducing the local pressure in the region of maximum deformation and transferring it to adjacent regions through the deformed medium. The energy release upon load removal is time-dependent, and a slower release tends to be experienced as an improvement in comfort. The cushion effect is usually measured by compressing a specific region of the material to a specific indentation level (expressed as a percentage of the original thickness) in the Z direction and then measuring the amount by which the compressed region returns to its original thickness. The durability of the cushion effect is measured by repeatedly performing this indentation periodically and measuring the reduction in recovery over time with respect to the number of cycles. The first layer, the second layer, and the intermediate layer provide sufficient elasticity to the cushion structure, and the breathability of the first layer, the second layer, and the intermediate layer acts as a guiding and mixing medium for moist and warm air, which is conveyed to reduce the capture of local (body) heat and moisture.

[0009] Preferably, the intermediate layer between the first layer and the second device is present throughout the first layer and / or the second layer.

[0010] In one embodiment, the cushion structure has a first layer and a second layer, and the first layer and / or the second layer has a residual thickness of at least 70%, preferably at least 80%, more preferably at least 90% of the initial thickness after 1000, preferably 5000, more preferably 10000, even more preferably 50000, and most preferably 80000 repeated compression cycles, and a residual indentation hardness at 25% compression of at least 70%, preferably at least 80%, more preferably at least 90% of the initial indentation hardness at 25% compression after 1000, preferably 5000, more preferably 10000, even more preferably 50000, and most preferably 80000 repeated compression cycles, and a breathability of at least 10 l / (m 2 ·s) at 200 Pa, and an air pressure gradient of 0.5, and has one or more zones in the X direction.

[0011] One or more first zones included in the first layer and / or the second layer of the cushion structure extend in the plane of the first layer and / or the second layer of the cushion structure (also known as the X-Y plane). The X-direction dimension of the cushion material is understood to mean the principal dimension of the cushion structure, which is usually the largest dimension of the cushion structure and is also known as the length of the cushion structure. Generally, the X direction of the cushion structure is the direction in which the first layer and / or the second layer is manufactured, which is also known as the manufacturing direction or the longitudinal direction, or the direction in which the body lying on the cushion structure extends in its length. The Y-direction dimension of the cushion structure is understood to mean the dimension in the plane of the cushion structure perpendicular to the X-direction dimension of the cushion structure, which is also known as the width of the cushion structure and is usually the second largest dimension of the cushion structure. The Y direction of the cushion structure is a plane inner direction perpendicular to the direction in which the first layer and / or the second layer is manufactured and is also known as the width direction.

[0012] Preferably, one or more first zones included in the first layer and / or the second layer of the cushion structure extend along the entire width of the cushion structure (zoning in the X direction), and one or more first zones included in the first layer and / or the second layer of the cushion structure enable support of body parts of a human body that are prone to pressure ulcers, such as the sacrum, coccyx, heel or buttocks, elbows, knees, ankles, the back of the shoulders or the back of the head.

[0013] One or more first zones included in the first layer and / or the second layer of the cushion structure may extend along a certain length of the cushion structure (zoning in the Y direction). Preferably, one or more first zones included in the first layer and / or the second layer of the cushion structure are arranged such that one or more first zones in the Y direction included in the first layer and / or the second layer of the cushion structure support body parts of a human body that are prone to pressure ulcers.

[0014] In an alternative embodiment, one or more first zones included in the first layer and / or the second layer of the cushion structure extend along the entire length (Y direction dimension) at the outer ends of the entire width (X direction dimension), and one or more first zones of the first layer and / or the second layer of the cushion structure ensure support of a human body sitting on one end of the cushion structure before lying on the cushion structure or before rising from the cushion structure.

[0015] One or more first zones included in the first layer and / or the second layer of the cushion structure may extend across the entire thickness of the first layer or the second layer of the cushion structure (zoning in the Z direction).

[0016] In an alternative embodiment, one or more first zones included in the first layer and / or the second layer of the cushion structure may extend partially through the first layer and / or the second layer of the cushion structure (Z-direction dimension). For example, one or more first zones included in the first layer and / or the second layer of the cushion structure may extend partially through the first layer and / or the second layer of the cushion structure by about 75%, about 50% or about 25% of the thickness of the first layer and / or the second layer of the cushion structure in order to optimize the performance of the cushion structure, such as comfort.

[0017] In a preferred embodiment, one or more first zones included in the first layer and / or the second layer of the cushion structure extend through the first layer and / or the second layer of the cushion structure by about 50% of the thickness of the first layer or the second layer of the cushion structure.

[0018] In one embodiment, the cushion structure has a first layer and / or a second layer, and the first layer and / or the second layer have a residual thickness of at least 70%, preferably at least 80%, more preferably at least 90% of the initial thickness after 1000, preferably 5000, more preferably 10000, even more preferably 50000, most preferably 80000 repeated compression cycles, and a residual indentation hardness at 40% compression of at least 70%, preferably at least 80%, more preferably at least 90% of the initial indentation hardness at 40% compression after 1000, preferably 5000, more preferably 10000, even more preferably 50000, most preferably 80000 repeated compression cycles, and have one or more first zones.

[0019] In one embodiment, the cushion structure has a first layer and a second layer, and the first layer and / or the second layer have one or more first zones having a residual thickness of at least 70%, preferably at least 80%, more preferably at least 90% of the initial thickness after 1000, or even 5000, 10000, 50000, 80000 repeated compression cycles, and a residual indentation hardness at 65% compression of at least 70%, preferably at least 80%, more preferably at least 90% of the initial indentation hardness at 65% compression after 1000, preferably 5000, more preferably 10000, even more preferably 50000, most preferably 80000 repeated compression cycles.

[0020] The indentation hardness at 25%, 40% or 65% compression is determined according to Method B of ISO 2439:2008. The initial indentation hardness at 25%, 40% or 65% compression is determined in the cushion structure or in the individual layers (e.g., the first layer, the second layer, the intermediate layer) included in the cushion structure.

[0021] Thereafter, the cushion structure or the individual layers included in the cushion structure are subjected to 1000, or even 5000, 10000, 50000, 80000 repeated compressions according to Method E of ISO 2439:2008. In this case, a sample of the cushion structure or the individual layers included in the cushion structure is compressed at a rate of 100 mm / min to an indentation of 75% of its thickness, i.e., to a thickness of 25% of the initial thickness. The thickness of the cushion structure or the individual layers included in the cushion structure is determined according to ISO 9864:2014.

[0022] After reaching this compression level, the load is released at a rate of 100 mm / min. Between each compression cycle, the cushion structure or the individual layers included in the cushion structure are rested for 4 minutes before the next compression cycle is started. The residual thickness and residual indentation hardness after 1000 repeated compression cycles are determined again according to Method B of ISO 2439:2008.

[0023] In one embodiment, the first layer has a breathability perpendicular to the plane of the first layer (in the Z direction) of at least 10 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, preferably a breathability of at least 100 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, more preferably a breathability of at least 500 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, and most preferably a breathability of at least 1000 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5.

[0024] The first layer preferably also exhibits breathability in the directions (X and / or Y directions) within the plane of the first layer. Preferably, the first layer has a breathability of at least 10 l(m 2 ·s) in the directions (X and / or Y directions) within the plane of the first layer at 200 Pa and a pressure gradient of 0.5, preferably a breathability of at least 100 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, more preferably a breathability of at least 500 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, and most preferably a breathability of at least 1000 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5.

[0025] Preferably, the first layer and / or the second layer and / or the intermediate layer of the cushion structure is liquid permeable.

[0026] In one embodiment, one or more first zones of the first layer and / or the second layer of the cushion structure are configured such that one or more first zones of the first layer and / or the second layer of the cushion structure match or approach the initial coefficient of subcutaneous fat in the human body, and thus have an initial coefficient in the range of less than 50 kPa, preferably less than 30 kPa, more preferably 5 to 20 kPa. The initial coefficient is determined as the compression stress at 2% compression, which is determined during the compression of the cushion structure according to Method B of ISO 2439:2008.

[0027] In one embodiment, the second layer has a breathability perpendicular to the plane of the second layer (Z direction) of at least 10 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5, preferably a breathability of at least 100 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5, more preferably a breathability of at least 500 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5, and most preferably a breathability of at least 1000 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5.

[0028] The second layer preferably also exhibits breathability in the directions (X and / or Y directions) within the plane of the second layer. Preferably, the second layer has a breathability of at least 10 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5 in the directions (X and / or Y directions) within the plane of the second layer, preferably a breathability of at least 100 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5, more preferably a breathability of at least 500 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5, and most preferably a breathability of at least 1000 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5.

[0029] The intermediate layer of the cushion structure has a breathability of at least 10 l / (m 2·s) in the Z direction perpendicular to the plane of the intermediate layer and an air pressure gradient of 0.5, preferably at least 100 l / (m 2 ·s) air permeability and an air pressure gradient of 0.5, more preferably at least 500 l / (m 2 ·s) air permeability and an air pressure gradient of 0.5, most preferably at least 1000 l / (m 2 ·s) air permeability and an air pressure gradient of 0.5.

[0030] The air permeability of the first layer, the second layer and the intermediate layer of the cushion structure is determined according to DIN 53887 dated August 1986 using a measurement area of 20 cm 2 It should be noted that for clarity, the air permeability of the first layer, the second layer and the intermediate layer of the cushion structure is usually determined in an uncompressed state. To determine the air permeability in the in-plane directions (X and / or Y directions) of the first layer and the second layer included in the cushion structure, one section of the first layer or the second layer having a length of 50 mm is used.

[0031] However, even in the compressed state, the cushion structure makes it possible to prevent or at least reduce the capture of moisture between the person located on the cushion structure and the cushion structure itself.

[0032] In a preferred embodiment, the first layer compressed to 50% of its initial thickness has at least 10 l / (m 2 ·s) air permeability in the Z direction perpendicular to the plane of the first layer and an air pressure gradient of 0.5, preferably at least 100 l / (m 2 ·s) air permeability and an air pressure gradient of 0.5, more preferably at least 500 l / (m 2 ·s) air permeability and an air pressure gradient of 0.5, most preferably at least 1000 l / (m 2 ·s) air permeability and an air pressure gradient of 0.5.

[0033] In a preferred embodiment, the first layer compressed to 50% of its initial thickness has a gas permeability in the in-plane direction (X and / or Y direction) of the first layer of at least 10 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, preferably a gas permeability of at least 100 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, more preferably a gas permeability of at least 500 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, and most preferably a gas permeability of at least 1000 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5.

[0034] In a preferred embodiment, the second layer compressed to 50% of its initial thickness has a gas permeability perpendicular to the plane of the second layer (Z direction) of at least 10 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, preferably a gas permeability of at least 100 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, more preferably a gas permeability of at least 500 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, and most preferably a gas permeability of at least 1000 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5.

[0035] In a preferred embodiment, the second layer compressed to 50% of its initial thickness has a gas permeability in the in-plane direction (X and / or Y direction) of the second layer of at least 10 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, preferably a gas permeability of at least 100 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, more preferably a gas permeability of at least 500 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5, and most preferably a gas permeability of at least 1000 l / (m 2 ·s) at 200 Pa and a pressure gradient of 0.5.

[0036] The second layer of the cushion structure may have a pressure redistribution ability, particularly a (Z-direction) pressure component perpendicular to the plane of the cushion structure.

[0037] The pressure redistribution ability of the second layer is determined by placing the first layer together with the intermediate layer on top of the first layer on a mat having a plurality of pressure sensors, the pressure sensors being distributed across the surface of the mat and recording the pressure distribution when a human body or a body simulating a human body is located above the intermediate layer. The human body or the body simulating a human body is removed from the intermediate layer, the second layer is placed above the intermediate layer, and the pressure distribution when the human body or the body simulating a human body is located above the second layer is recorded. By comparing the two recorded pressure distributions, the pressure redistribution ability of the second layer can be obtained. Preferably, the plurality of pressure sensors are arranged in parallel, and the rows of sensors are preferably arranged at a distance of 5 cm. Preferably, the distance between the pressure sensors in a row of pressure sensors is equal to the distance between the rows of pressure sensors.

[0038] Preferably, the pressure redistribution ability of the second layer reduces the recorded maximum pressure by at least 25%, more preferably by at least 40%, even more preferably by at least 50%, and most preferably by at least 60%.

[0039] Preferably, the second layer of the cushion structure is arranged closer to the human body located on the cushion structure than the first layer and the intermediate layer during use. The pressure redistribution ability of the second layer provides comfort to the person located on the cushion structure. This is because the person located on the cushion structure is less aware of the presence of the first layer.

[0040] The intermediate layer of the cushion structure may have a pressure redistribution ability, particularly a (Z-direction) pressure component perpendicular to the plane of the cushion structure.

[0041] The pressure redistribution ability of the intermediate layer is determined by placing a first layer on a mat having a plurality of pressure sensors, the pressure sensors being distributed across the surface of the mat and recording the pressure distribution when a human body or a body simulating a human body is located above the first layer. The human body or the body simulating a human body is removed from the first layer, the intermediate layer is placed above the first layer, and the pressure distribution when the human body or the body simulating a human body is located above the intermediate layer is recorded. By comparing both recorded pressure distributions, the pressure redistribution ability of the intermediate layer can be obtained. Preferably, the plurality of pressure sensors are arranged in parallel, and the rows of sensors are preferably arranged at a distance of 5 cm. Preferably, the distance between the pressure sensors in a row of pressure sensors is equal to the distance between the rows of pressure sensors.

[0042] Preferably, the pressure redistribution ability of the intermediate layer reduces the recorded maximum pressure by at least 25%, more preferably by at least 40%, even more preferably by at least 50%, and most preferably by at least 60%.

[0043] Preferably, the intermediate layer of the cushion structure is, in use, arranged closer to the human body located on the cushion structure than the first layer. The pressure redistribution ability of the intermediate layer provides comfort to a person located on the cushion structure. This is because a person located on the cushion structure is less aware of the presence of the first layer.

[0044] The first layer of the cushion structure may have a pressure component perpendicular (in the Z direction) to the plane of the cushion structure, especially when at least one other layer is included in the cushion structure. The at least one other layer is preferably arranged below the first layer of the cushion structure in use.

[0045] The pressure redistribution ability of the first layer is determined by placing at least one additional layer on a mat having a plurality of pressure sensors, the pressure sensors being distributed across the surface of the mat and recording the pressure distribution when a human body or a body simulating a human body is positioned above the at least one additional layer. The human body or the body simulating a human body is removed from the at least one additional layer, the first layer is placed above the at least one additional layer, and the pressure distribution is recorded when the human body or the body simulating a human body is positioned above the first layer. By comparing the two recorded pressure distributions, the pressure redistribution ability of the first layer can be obtained. Preferably, the plurality of pressure sensors are arranged in parallel, and the rows of sensors are preferably arranged at a distance of 5 cm. Preferably, the distance between the pressure sensors in a row of pressure sensors is equal to the distance between the rows of pressure sensors.

[0046] Preferably, the pressure redistribution ability of the first layer reduces the recorded maximum pressure by at least 25%, more preferably by at least 40%, even more preferably by at least 50%, and most preferably by at least 60%.

[0047] In a preferred embodiment, the first layer and / or the second layer of the cushion structure is a three-dimensional structured mat of extruded intertwined filaments.

[0048] In another preferred embodiment, the cushion structure includes an intermediate layer selected from the group including woven fabric, spunbonded or spunlaced nonwoven fabric, meltblown nonwoven fabric, carded nonwoven fabric, airlaid nonwoven fabric, wetlaid nonwoven fabric, knitted fabric, net, scrim, and a two-dimensional mat of extruded intertwined filaments.

[0049] In another embodiment, one or more first zones of the first layer and / or the second layer of the cushion structure comprise a three-dimensional structured mat of extruded intertwined filaments. Preferably, the filaments of the three-dimensional structured mat of extruded intertwined filaments are extruded polymer filaments. The three-dimensional structured mat of extruded intertwined filaments may be provided by any suitable process. Preferably, the three-dimensional structured mat of extruded intertwined filaments is provided by extruding polymer filaments, bending the filaments while still in a molten state, intertwining and bringing them into contact with each other, and collecting the extruded filaments into a three-dimensional structure. The bending and intertwining of the extruded filaments is preferably initiated by collecting the filaments onto a contoured surface that defines the structure of the three-dimensional structured mat of extruded intertwined filaments. Preferably, the surface onto which the filaments are collected is contoured such that the three-dimensional structured mat of filaments is shaped into a three-dimensional shape that includes a cylinder capped by hills and valleys, hemispheres, positive and / or negative cusps, cups and / or waffles, pyramids, U-shaped grooves, V-shaped grooves, cones and / or hemispheres.

[0050] In another embodiment, one or more first zones of the first layer and / or the second layer have different three-dimensional shapes in different zones. As an example, a first zone of the one or more first zones has hills and valleys, and a second zone of the one or more first zones has positive and / or negative cusps.

[0051] In another embodiment, one or more first zones of the first layer and / or the second layer have three-dimensional shapes (extensions in the Z-direction dimension) of different sizes in different zones perpendicular to the plane. As an example, the first zone of the one or more first zones has 75% of the total thickness of the first layer and / or the second layer, and the second zone of the one or more first zones has 50% of the thickness of the first layer and / or the second layer.

[0052] In another embodiment, one or more first zones of the first layer and / or the second layer have different sizes in different zones within the plane of the first layer (in the X and / or Y directions). As an example, the first zone of the one or more first zones has 1.5 times the length (in the X direction) of the second zone of the one or more first zones. Another example is that the first zone of the one or more first zones has 0.8 times the width (in the Y direction) of the second zone of the one or more first zones. Combinations of different lengths (in the X direction) and different widths (in the Y direction) between different zones of the one or more first zones are also possible.

[0053] The three-dimensional structured mat of the extruded intertwined filaments may be shaped into any desired three-dimensional shape, for example, in a series of hills and valleys spaced apart by a specific distance or in contact with each other and arranged in parallel or staggered, or a series of hemispheres spaced apart by a specific distance or in contact with each other and arranged in parallel or staggered. The three-dimensional structured mat of the extruded intertwined filaments may have positive and / or negative cusps, cups or waffles spaced apart by a specific distance or in contact with each other and arranged in parallel or staggered. Alternatively, the three-dimensional structured mat of the extruded intertwined filaments may have a series of pyramids spaced apart by a specific distance or in contact with each other and arranged in parallel or staggered. The three-dimensional structured mat of the extruded intertwined filaments may preferably have U-shaped and / or V-shaped grooves extending in the longitudinal and / or width directions. The three-dimensional structured mat of the extruded intertwined filaments may have a series of cylinders capped by hemispheres spaced apart by a specific distance or in contact with each other and arranged in parallel or staggered. The three-dimensional structured mat of the extruded intertwined filaments may have any combination of hills and valleys, hemispheres, positive and / or negative cusps, cups or waffles, pyramids, cones, cylinders capped by hemispheres, U-shaped grooves and / or V-shaped grooves.

[0054] Preferably, the three-dimensional structured mat of extruded intertwined filaments is configured such that the three-dimensional structured mat of extruded intertwined filaments has two main surfaces defined by the length and width of the cushion structure, and the two main surfaces are oriented parallel to each other in a plane. When the three-dimensional structured mat of extruded intertwined filaments has a series of hills and valleys, the peaks of the hills are arranged in the plane of the first main surface, and the bottoms of the valleys are arranged in the plane of the second main surface. When the three-dimensional structured mat of extruded intertwined filaments has a series of hemispheres, the vertices of the hemispheres are arranged in the plane of the first main surface, and the bottoms of the hemispheres are arranged in the plane of the second main surface. When the three-dimensional structured mat of extruded intertwined filaments has a series of pyramids, the vertices of the pyramids are arranged in the plane of the first main surface, and the bottoms of the pyramids are arranged in the plane of the second main surface. When the three-dimensional structured mat of extruded intertwined filaments has U-shaped grooves and / or V-shaped grooves, the vertices of the U-shaped grooves and / or V-shaped grooves are arranged in the plane of the first main surface, and the bottoms of the U-shaped grooves and / or V-shaped grooves are arranged in the plane of the second main surface. When the three-dimensional structured mat of extruded intertwined filaments has cusps, cups and / or waffles, the vertices of the cusps, cups or waffles are arranged in the plane of the first main surface, and the bottoms of the cusps, cups or waffles are arranged in the plane of the second main surface. When the three-dimensional structured mat of extruded intertwined filaments has a cylinder capped by a hemisphere, the vertex of the hemisphere is arranged in the plane of the first main surface, and the bottom of the cylinder is arranged in the plane of the second main surface.

[0055] Preferably, one or more first zones of the first layer and / or the second layer of the cushion structure comprise a three-dimensional structured mat of extruded intertwined filaments.

[0056] The diameter of the extruded intertwined filaments in the three-dimensional structured mat of extruded intertwined filaments may vary widely. Preferably, the extruded intertwined filaments in the three-dimensional structured mat of extruded intertwined filaments have an average diameter in the range of 100 μm to 2000 μm, more preferably in the range of 200 μm to 1500 μm, even more preferably in the range of 300 μm to 1100 μm, and most preferably in the range of 500 μm to 900 μm.

[0057] Preferably, the filaments of the three-dimensional structured mat of extruded intertwined filaments are joined by heat at the crossing points, thereby forming an intertwined structure of the extruded filaments formed in three dimensions. Most preferably, the filaments of the three-dimensional structured mat of extruded intertwined filaments are still in a molten state when collected on the contoured surface in order to form a molten bond that partially penetrates each other in their intertwining. Further solidification of the intertwined filaments on the contoured surface forms a three-dimensional network structure of the extruded intertwined filaments that has solidified in the X, Y, and Z directions.

[0058] The extruded intertwined filaments of the three-dimensional structured mat of the first layer, second layer, and / or intermediate layer may consist of any suitable polymer or blend of polymers.

[0059] In one embodiment, the first layer and / or the second layer and / or the intermediate layer of the cushion structure comprises a thermoplastic elastomeric polymer or a low density polyethylene (LDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE) and metallocene polymer plastomer. The thermoplastic elastomeric polymer is preferably selected from thermoplastic polyolefin elastomeric polymers (TPO) such as, for example, thermoplastic polypropylene elastomeric polymers, thermoplastic vulcanizates (TPV), thermoplastic polyester elastomeric polymers (TPE-E or CoPET), thermoplastic styrene elastomeric polymers (TPS, including styrene-butadiene copolymers (SBC)), thermoplastic polyamides (TPA) or thermoplastic elastomeric polyurethane polymers (TPU).

[0060] The first layer, the second layer and / or the intermediate layer of the cushion structure preferably consists of at least 50% by mass, preferably at least 75% by mass, more preferably at least 90% by mass, and most preferably at least 95% by mass of the polymer.

[0061] The filaments of the intermediate layer may be single-component filaments and bicomponent filaments, and the bicomponent filaments may be in a side-by-side model, a concentric or eccentric core / sheath model or a sea-island model.

[0062] In a preferred embodiment, the filaments of the intermediate layer are core / sheath model bicomponent filaments, and the sheath and the core may consist of two polymers having the same chemical structure, or the sheath and the core may consist of different polymers having different chemical structures.

[0063] As long as the sheath polymer has a melting temperature lower than the melting temperature of the core polymer, any suitable polymer can be used for the core and the sheath.

[0064] In a preferred embodiment, the intermediate layer is a nonwoven fabric containing bicomponent filaments, and the filaments of the nonwoven fabric may be bonded by heat. Preferably, the melting temperature of the sheath polymer is lower than or at least equal to the melting temperature of any other polymer used in the cushion structure.

[0065] In another preferred embodiment, the intermediate layer is a two-dimensional mat of extruded intertwined filaments, and the filaments are preferably extruded single-component filaments. The two-dimensional mat of extruded intertwined filaments may be provided by any suitable process. Preferably, the two-dimensional structured mat of extruded intertwined filaments is provided by extruding polymer filaments, bending the filaments preferably while still in a molten state, intertwining and bringing them into contact with each other, and collecting the extruded filaments on a two-dimensional flat surface. The bending and intertwining of the extruded filaments is preferably initiated by collecting the filaments on a flat surface that defines the flat structure of the two-dimensional mat of extruded intertwined filaments.

[0066] The filaments of the two-dimensional mat of extruded intertwined filaments may include a thermoplastic elastomeric polymer or low density polyethylene (LDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE), and metallocene polymer plastomers. The thermoplastic elastomeric polymer is preferably selected from thermoplastic polyolefin elastomeric polymers (TPO) such as, for example, thermoplastic polypropylene elastomeric polymers, thermoplastic vulcanizates (TPV), thermoplastic polyester elastomeric polymers (TPE-E or CoPET), thermoplastic styrene elastomeric polymers (TPS, including styrene-butadiene copolymers (SBC)), thermoplastic polyamides (TPA), or thermoplastic elastomeric polyurethane polymers (TPU).

[0067] In another embodiment, the first layer and / or the second layer and / or the intermediate layer preferably comprises a polymer selected from the group comprising thermoplastic polypropylene elastomeric polymers, thermoplastic vulcanizates (TPV), thermoplastic polyester elastomeric polymers (TPE-E or CoPET), thermoplastic styrene elastomeric polymers (TPS, including styrene-butadiene copolymers (SBC)), thermoplastic polyamides (TPA) or thermoplastic elastomeric polyurethane polymers (TPU) and low density polyethylene (LDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE) and metallocene polymerized plastomers, for example.

[0068] In a preferred embodiment, the first layer and / or the second layer and / or the intermediate layer comprises the same polymer for easier and more economical manufacture of the cushion structure and for easier recycling of the cushion structure.

[0069] In one embodiment, the first layer and / or the second layer of the cushion structure has one or more first zones having an initial modulus in the range of less than 50 kPa, preferably less than 30 kPa, more preferably 5 - 20 kPa, and one or more second zones having an initial modulus higher than the initial modulus of the one or more first zones, preferably at least 20 kPa, more preferably at least 30 kPa, even more preferably at least 50 kPa, in order to enable the cushion structure to help prevent the occurrence of pressure ulcers in the human body.

[0070] In one embodiment, the first layer and / or the second layer of the cushion structure has one or more first zones having a first indentation hardness at 25% compression, and one or more second zones having a second indentation hardness at 25% compression that is higher than the indentation hardness of the one or more first zones at 25% compression. Preferably, the ratio of the second indentation hardness at 25% compression of the one or more second zones to the first indentation hardness at 25% compression of the one or more first zones of the first layer and / or the second layer of the cushion structure is in the range of 1.5 to 5, more preferably in the range of 1.6 to 4, and most preferably in the range of 1.75 to 3.

[0071] Preferably, the cushion structure is configured such that one or more first zones included in the first layer and / or the second layer of the cushion structure support a part of the human body where pressure ulcers are likely to occur, such as the sacrum, coccyx, heel or buttocks, elbow, knee, ankle, the back of the shoulder or the back of the head.

[0072] In one embodiment, the first layer and / or the second layer of the cushion structure has one or more first zones having a first indentation hardness at 40% compression, and one or more second zones having a second indentation hardness at 40% compression that is higher than the indentation hardness of the one or more first zones at 40% compression. Preferably, the ratio of the second indentation hardness at 40% compression of the one or more second zones to the first indentation hardness at 40% compression of the one or more first zones of the first layer and / or the second layer of the cushion structure is in the range of 1.5 to 5, more preferably in the range of 1.6 to 4, and most preferably in the range of 1.75 to 3.

[0073] In one embodiment, the first layer and / or the second layer of the cushion structure has one or more first zones having a first indentation hardness at 65% compression, and one or more second zones having a second indentation hardness at 65% compression that is higher than the indentation hardness of the one or more first zones at 65% compression. Preferably, the ratio of the second indentation hardness at 65% compression of the one or more second zones of the first layer and / or the second layer of the cushion structure to the first indentation hardness at 65% compression of the one or more first zones is in the range of 1.5 to 5, more preferably in the range of 1.6 to 4, and most preferably in the range of 1.75 to 3.

[0074] The higher indentation hardness at 25%, 40% and / or 65% compression of the one or more second zones of the first layer and / or the second layer of the cushion structure may be obtained by increasing the number of filaments per unit volume in the one or more second zones of the first layer and / or the second layer as compared to the number of filaments per unit volume in the one or more first zones of the first layer and / or the second layer of the cushion structure. Preferably, the number of filaments per unit volume in the one or more second zones of the first layer and / or the second layer is at least 10% more, more preferably at least 20% more, more preferably at least 30% more, and most preferably at least 40% more than the number of filaments per unit volume in the one or more first zones of the first layer and / or the second layer.

[0075] The higher indentation hardness at 25%, 40% and / or 65% compression of one or more second zones of the first layer and / or the second layer of the cushion structure may be obtained by increasing the diameter of the filaments in one or more second zones of the first layer and / or the second layer of the cushion structure as compared to the diameter of the filaments in one or more first zones of the first layer and / or the second layer of the cushion structure. Preferably, the diameter of the filaments in one or more second zones of the first layer and / or the second layer is at least 10% greater than the diameter of the filaments in one or more first zones of the first layer and / or the second layer, more preferably at least 20% greater, more preferably at least 30% greater, and most preferably at least 40% greater.

[0076] The higher indentation hardness at 25%, 40% and / or 65% compression of one or more second zones of the first layer and / or the second layer of the cushion structure may be obtained by changing the polymer type included in the filaments in one or more second zones of the first layer and / or the second layer as compared to the polymer type included in the filaments in one or more first zones of the first layer and / or the second layer of the cushion structure.

[0077] In a preferred embodiment, one or more first zones of the first layer and / or the second layer and one or more second zones of the first layer and / or the second layer comprise a three-dimensional structured mat of extruded intertwined filaments. The higher initial modulus of one or more second zones of the first layer and / or the second layer of the cushion structure may be obtained by selecting a different three-dimensional shape for the three-dimensional structured mat of extruded intertwined filaments included in one or more second zones of the first layer and / or the second layer of the cushion structure as compared to the three-dimensional shape for the three-dimensional structured mat of extruded intertwined filaments included in one or more first zones of the first layer and / or the second layer of the cushion structure.

[0078] The three-dimensional structured mat of the extruded intertwined filaments may be formed independently in any desired three-dimensional shape for one or more second zones of the first layer and / or the second layer and one or more first zones of the first layer and / or the second layer, for example, in a series of hills and valleys spaced apart by a specific distance or in contact with each other and arranged parallel or staggered, or in a series of hemispheres spaced apart by a specific distance or in contact with each other and arranged parallel or staggered. The three-dimensional structured mat of the extruded intertwined filaments may have positive and / or negative cusps, cups or waffles spaced apart by a specific distance or in contact with each other and arranged parallel or staggered. Alternatively, the three-dimensional structured mat of the extruded intertwined filaments may have a series of pyramids spaced apart by a specific distance or in contact with each other and arranged parallel or staggered. The three-dimensional structured mat of the extruded intertwined filaments preferably has U-shaped grooves and / or V-shaped grooves extending in the longitudinal and / or width directions. The three-dimensional structured mat of the extruded intertwined filaments may have a series of cylinders capped by hemispheres spaced apart by a specific distance or in contact with each other and arranged parallel or staggered. The three-dimensional structured mat of the extruded intertwined filaments may have any combination of hills and valleys, hemispheres, positive and / or negative cusps, cups or waffles, pyramids, hemispheres, cylinders capped by cones, U-shaped grooves and / or V-shaped grooves.

[0079] Preferably, the first layer and / or the second layer included in the cushion structure has a three-dimensional structured mat of extruded intertwined filaments having a thickness in the range of 5 to 100 mm, preferably 5 to 50 mm, determined in accordance with ISO9864:2014.

[0080] Preferably, the first layer and / or the second layer included in the cushion structure is 100 cm 2 in weight, determined in accordance with EN965-1995 as the average of 10 samples of 100 to 1500 g / m 2 , preferably 250 to 1000 g / m 2 , more preferably 400 to 800 g / m 2 and has a three-dimensionally structured mat of extruded intertwined filaments having a thickness in the range of.

[0081] In one embodiment, the three-dimensionally structured mat of extruded intertwined filaments has an open area of at least 75% by volume (i.e., at most 25% by volume is occupied by the extruded intertwined filaments) in order to obtain a lightweight cushion structure with high breathability, preferably at least 90% by volume, more preferably at least 95% by volume.

[0082] In one embodiment, the first layer and / or the second layer of the cushion structure has a three-dimensional (3D) printed structure. The 3D printing process enables the 3D printed structure to be provided in a specific pattern in one or more first zones of the product, by different internal geometries for at least two first zones of the product and / or by applying two different materials. The filling pattern is an "internal geometry" formed within the 3D printed structure by "filling in" (printing) an area inside the outer edge of the 2D layer slice. The properties of one material can be varied by introducing changes in the pattern of the deposition path of the extrusion head when forming a layer of the material on the working surface. Other techniques can also be used, such as using overlapping loop deposition paths (instead of straight lines) by varying both the tool head path and its deposition settings so as to be able to be induced by phenomena such as viscous thread instability. These techniques enable the deposition of various coil-shaped paths of various coil shapes, sizes and lateral and vertical overlaps, which produce various desired mechanical properties by a combination of multiple factors including the density and number of nodular connections between the loops. Techniques using non-loop strands or strands of various shapes, thicknesses and patterns can also be used. Similarly, various known 3D printing techniques can be used to form honeycomb-like or similar grid-like patterns using one or more materials.

[0083] In one embodiment, the intermediate layer prevents a specific shape formed by a three-dimensional structured mat of extruded intertwined filaments or a three-dimensional printed material included in the first layer from overlapping a specific shape formed by a three-dimensional structured mat of extruded intertwined filaments or a three-dimensional printed material included in the second layer.

[0084] Preferably, the intermediate layer prevents or at least reduces the deformation of the first layer and / or the second layer in the X and Y directions.

[0085] The intermediate layer may provide increased shear resistance to a three-dimensionally structured mat of extruded intertwined filaments included in the first layer and / or the second layer of the cushion structure.

[0086] In a preferred embodiment, the first layer, the second layer and the intermediate layer are joined to each other at their major surfaces by any suitable process. Typically, mechanical joining by needling and / or stitching, chemical bonding by additional adhesives, or thermal bonding by heat provision, for example by hot air or ultrasound, is possible. Preferably, the bond between the first layer, the second layer and the intermediate layer is provided by thermal bonding. Preferably, the bond between the first layer, the second layer and the intermediate layer is provided by thermal bonding of the sheath polymer of the bicomponent filaments of the nonwoven fabric of the intermediate layer.

[0087] The occurrence of pressure ulcers is an increasing problem in hospitals and even more so in facilities for long-term care, elderly care, etc. Therefore, there is a need to provide materials and / or structures that can help prevent the occurrence of pressure ulcers in patients who have to lie or sit on a cushion structure, for example a wheelchair, for extended periods of time.

[0088] The market for pressure ulcer prevention devices presents various product solutions aimed at reducing the chances of pressure ulcers forming. For the vast majority of these devices, pressure redistribution (or erroneously called pressure reduction) is the central design principle. However, in recent years, it has been shown that in addition to absolute local pressure, the generation of shear forces and microclimate conditions are also important.

[0089] Pressure ulcers, also known as bedsores or decubitus ulcers, are local injuries to the skin and / or underlying tissue that typically occur over bony prominences due to pressure, or pressure in combination with shear and / or friction. The most common locations on the human body where pressure ulcers form are the skin over the sacrum, coccyx, heels or buttocks, although other locations on the human body such as the elbows, knees, ankles, the back of the shoulders or the back of the head may be affected. The commonality here is that pressure ulcers mainly occur over bony prominences, which basically means parts of the human body where there is no subcutaneous fat or limited subcutaneous fat.

[0090] Pressure ulcers are caused by pressure being applied to the soft tissues of the human body, as a result of which blood flow to the soft tissues is completely or partially obstructed. Shearing forces are also a cause, because shearing forces stress the blood vessels that supply blood to the skin. Pressure ulcers most commonly form in immobile individuals such as, for example, bedridden or wheelchair-bound people. Other factors can potentially affect the skin's tolerance to pressure and shearing forces, and it is widely believed that this increases the risk of pressure ulcer formation in the human body. These factors include protein-calorie malnutrition, for example, a lack of protein or a lack of / abundance of calories, an unfavourable microclimate in human skin, for example skin wetness caused by sweating or incontinence, diseases that reduce blood flow to the skin, such as arteriosclerosis, or diseases that reduce the sensation of the skin, such as paralysis or neuropathy.

[0091] The importance of the microclimate in human skin is twofold. When the temperature of human skin increases, the occurrence of pressure ulcers is promoted. Basically, the increase in temperature increases the metabolism within the cells of human skin, and thus the need for nutrients within the cells. In particular, when the elevated temperature of human skin occurs in combination with elevated pressure and the associated obstructed blood flow to human skin, the cells of human skin starve.

[0092] In addition to the temperature in human skin becoming higher, humans sweat, and the local humidity in human skin increases. The high humidity has a strong effect on the coefficient of friction of human skin, thereby increasing the chance of local frictional injury in the upper layer of human skin, and then this injury acts as the onset of a pressure ulcer.

[0093] A cushion structure including a breathable first layer, a breathable second layer, and a breathable intermediate layer enables preventing or at least reducing the capture of moisture between a person located on the cushion structure and the cushion structure itself. When the surface that contacts a person located on the cushion structure during use is breathable, moisture can be removed by discharge and / or ventilation through the breathable first layer, second layer, and / or breathable intermediate layer of the cushion structure. When the cushion structure is enclosed in a liquid-impermeable cover, the breathable first layer, second layer, and / or breathable intermediate layer of the cushion structure still improves the cooling of the human body located on the liquid-impermeable cover of the cushion structure, which reduces the amount of sweating from the human body.

[0094] U.S. Patent No. 6,272,707 discloses a support pad having one layer of an air- and liquid-permeable three-dimensional matrix of nylon material or polyester material. The support pad of U.S. Patent No. 6,272,707 may be used as a cushion structure, but this support pad does not always provide sufficient comfort to a person located on the cushion structure.

[0095] U.S. Patent Application Publication No. 2016 / 0174725 discloses a hygienic cushion having a core with a three-dimensional network structure. A three-dimensional random mat of intertwined filaments is provided by providing the filaments and collecting the filaments into a three-dimensional structure by bending the filaments, preferably in a molten state, and bringing them into contact with each other. The bending of the filaments can be initiated, for example, by collecting the filaments in an aqueous tank. U.S. Patent No. 5639543 discloses an example of such a three-dimensional random mat of intertwined filaments. The bending of the filaments is random and does not result in an arrangement of a specific three-dimensional shape.

[0096] In one embodiment, a cushion structure having one or more additional layers may be provided by any suitable material as long as one or more additional layers of the cushion structure have a breathability of at least 10 l / (m 2 ·s) at 200 Pa and an air pressure gradient of 0.5.

[0097] One or more additional layers of the cushion structure may include a V-wrap nonwoven fabric, an airlaid nonwoven fabric, a spunbonded or spunlaced nonwoven fabric, a meltblown nonwoven fabric, a carded nonwoven fabric, a three-dimensional woven fabric, a three-dimensional knitted fabric, a three-dimensional random mat of intertwined filaments, a three-dimensional structured mat of extruded intertwined filaments, a 3D printed material, a honeycomb structure and / or a relaxed honeycomb structure.

[0098] In a preferred embodiment, the cushion structure does not include a foam.

[0099] One or more additional layers preferably have a breathability equal to or higher than that of the first layer and / or the second layer and / or the intermediate layer of the cushion structure.

[0100] The cushion structure is any surface based on a compressible material that comes into contact with the human body for longer periods of time while standing, sitting, lying down, or during physical activity.

[0101] In one embodiment, one or more additional layers of the cushion structure include a three-dimensional fabric. Three-dimensional fabrics are known to those skilled in the art.

[0102] In another embodiment, one or more additional layers of the cushion structure include a three-dimensional knitted fabric. Three-dimensional knitted fabrics are known to those skilled in the art.

[0103] In another embodiment, one or more additional layers of the cushion structure include a V-wrap nonwoven fabric. V-wrap nonwoven fabrics are known to those skilled in the art.

[0104] In another embodiment, one or more additional layers of the cushion structure include a honeycomb structure. The honeycomb structure may be provided by any suitable process.

[0105] The cushion structure may advantageously be a mattress, a topper or overlay for a mattress, an individual body part, in particular a cushion for supporting the heels, elbows, shoulders or head in a lying and sitting position, for example a seat cushion such as in automotive applications, in aircraft applications, in wheelchair seats, in office chairs or in furniture seats, a protective body cushion such as a thigh pad, a knee pad or a helmet, or a shock pad in a sports field, in particular an artificial turf sports field.

[0106] The following drawings and the description of the drawings are exemplary examples and should not be understood as limiting features of the present invention.

Brief Description of the Drawings

[0107]

Figure 1

Figure 2

Figure 3

DETAILED DESCRIPTION OF THE INVENTION

[0108] FIG. 1 shows a cross-sectional view of a cushion structure 100 including a first layer 110, a second layer 120, and an intermediate layer 130.

[0109] FIG. 2 shows a perspective view of one layer of a cushion structure 10 including one or more zones 11 in the X direction (arrow X).

[0110] FIG. 3 shows a perspective view of one layer of a cushion structure 20 including one or more zones 21 in the Y direction (arrow Y).

Claims

1. A cushion structure comprising a first layer of a three-dimensionally structured mat of extruded intertwined filaments, a second layer of a three-dimensionally structured mat of extruded intertwined filaments, and an intermediate layer between the first layer and the second layer.

2. The cushion structure according to claim 1, wherein the first layer and / or the second layer has one or more first zones in the X direction.

3. The cushion structure according to claim 1 or 2, wherein the first layer and / or the second layer has one or more first zones in the Y direction and / or the Z direction. One or more first zones of the first layer and / or the second layer have a residual thickness of at least 70% of the initial thickness after 1000 repeated compression cycles, a residual indentation hardness at 25% compression of at least 70% of the initial indentation hardness after 1000 repeated compression cycles, a breathability of at least 10 l / (m 2 ·s) at 200 Pa, and an air pressure gradient of 0.

5. The cushion structure according to any one of claims 1 to 3.

4. The intermediate layer has a breathability of at least 10 l / (m 2 ·s) at 200 Pa and a pneumatic gradient of 0.

5. The cushion structure according to any one of claims 1 to 4.

5.

6. The cushion structure according to any one of claims 1 to 5, wherein the first layer, the second layer and the intermediate layer have a pressure redistribution ability.

7. One or more first zones of the first layer and / or the second layer have an initial modulus in the range of less than 50 kPa, preferably less than 30 kPa, more preferably 5 to 20 kPa, and one or more second zones have an initial modulus higher than the initial modulus of the one or more first zones, preferably at least 20 kPa, more preferably at least 30 kPa, even more preferably at least 50 kPa. The cushion structure according to any one of claims 1 to 6.

8. The cushion structure according to any one of claims 1 to 7, wherein one or more first zones of the first layer and / or the second layer comprise a three-dimensionally structured mat of extruded filaments, the extruded filaments being shaped into a three-dimensional shape including mountains and valleys, hemispheres, positive and / or negative cusps, cups and / or waffles, pyramids, U-shaped grooves, V-shaped grooves, cylinders capped by cones and / or hemispheres.

9. The cushion structure according to claim 8, wherein the one or more first zones comprise extruded filaments shaped into different three-dimensional shapes, and the three-dimensional shapes can have different heights.

10. The filaments of the three-dimensional structured mat of the extruded intertwined filaments are thermally bonded or penetrate and melt-bond at their intersection points, the cushion structure according to any one of claims 1 to 9.

11. The first layer and / or the second layer and / or the intermediate layer is selected from the group comprising polymers such as, for example, thermoplastic polypropylene elastomeric polymers, thermoplastic vulcanizates (TPV), thermoplastic polyester elastomeric polymers (TPE-E or CoPET), thermoplastic styrene elastomeric polymers (TPS, including styrene-butadiene copolymers (SBC)), thermoplastic polyamides (TPA) or thermoplastic elastic polyurethane polymers (TPU) and low density polyethylene (LDPE), linear low density polyethylene (LLDPE), ultra low density polyethylene (VLDPE) and metallocene polymer plastomers, the cushion structure according to any one of claims 1 to 10.

12. The first layer and / or the second layer and / or the intermediate layer consists of at least 50% by mass, preferably at least 75% by mass, more preferably at least 90% by mass, most preferably at least 95% by mass of the polymer, the cushion structure according to claim 11.

13. The cushion structure comprises one or more additional layers selected from the group consisting of V-wrap nonwoven layers, three-dimensional woven fabrics, three-dimensional knitted fabrics, three-dimensional random mats of intertwined filaments, three-dimensional structured mats of extruded filaments, 3D printed materials and / or honeycomb structures, the cushion structure according to any one of claims 1 to 12.

14. The first layer and / or the second layer and / or the intermediate layer are thermally, chemically or mechanically bonded, the cushion structure according to any one of claims 1 to 13.

15. The cushion structure comprises an intermediate layer selected from the group comprising woven fabrics, meltblown nonwovens, carded nonwovens, airlaid nonwovens, wetlaid nonwovens, knitted fabrics, nets, scrims and two-dimensional mats of extruded intertwined filaments, the cushion structure according to any one of claims 1 to 14.

16. The cushion structure according to any one of claims 1 to 15, wherein the cushion structure is a mattress, a topper or overlay for a mattress, an individual body part, in particular a cushion for supporting the heels, elbows, shoulders or head in a lying or sitting position, such as a seat cushion in automotive applications, a seat in aircraft applications, a seat in a wheelchair, a seat in an office chair or a seat in furniture, a protective body cushion such as a thigh rest, a knee rest or a helmet, or a shock pad in a sports field, in particular an artificial turf sports field.

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