Orthogonally alternating structure of foam cushion

Abstract

Foam cushions having an orthogonal alternating structure and cushioning products formed from or including such foam cushions are provided. The orthogonal alternating structure can be formed by assembling layers of foam and bonding all or a portion of the interface where the layers are formed from at least two types or hardnesses of foam. The layered arrangement of foam can be cut as needed to create foam cushions where the layers extend along the length or width of the foam cushion or in a direction orthogonal to the direction of the force the foam cushion is intended to support. The foam cushion can be formed using a foam cushion component having a base and a layer emanating from the base.

Description

[Technical field]

[0001] The present invention extends to foam cushions having an orthogonal alternating structure, and cushioning articles formed from or including such foam cushions. [Background technology]

[0002] Foams are commonly used as cushioning materials in a variety of applications. For example, mattresses are commonly formed with memory foam due to its ability to mold to the body and provide uniform support. However, memory foam also has a variety of undesirable properties. Many individuals complain that memory foam feels dead, meaning it tends to absorb forces as opposed to traditional spring mattresses and traditional polyurethane non-memory foams. Also, it can be difficult to roll on a memory foam mattress due to the depressions that form around the body. Additionally, memory foam has minimal breathability and therefore becomes too hot for many individuals. Summary of the Invention [Problem to be solved by the invention]

[0003] To address such shortcomings of foams, particularly memory foams, other materials have been used in mattresses and other cushioning articles. For example, mattresses such as those sold under the Purple trademark are formed of a gelatinous material having adjacent hollow column shapes. Mattresses made of this gelatinous material provide localized instability and general stability due to the ability of the columns to flex where needed, such as under an individual's hips. However, such mattresses are very heavy and require specialized manufacture. [Means for solving the problem]

[0004] The present invention extends to foam cushions having an orthogonal alternating structure, and cushioning articles formed from or including such foam cushions. The orthogonal alternating structure can be formed by joining together layers of foam, where the layers are formed of alternating foam types or hardnesses. If desired, the layered arrangement of foam can be cut to create foam cushions where the layers extend orthogonally along the length or width of the foam cushion, or in the direction of forces that the foam cushion is intended to support. The foam cushion can be formed using a foam cushion component having a base and layers emanating from the base.

[0005] In some embodiments, the present invention may be implemented as a foam cushion that includes a layer of foam disposed along the length of the foam cushion. In some embodiments, the present invention may be implemented as a cushioning article that includes a first foam cushion. The first foam cushion may include a layer of foam disposed along a length of the foam cushion.

[0006] In some embodiments, the invention may be implemented as a method for manufacturing a mattress. Sheets of foam may be stacked along an axis to form a layered foam block. The layered foam block may be cut along an axis to form a foam cushion including a layer of foam. The foam cushion may be oriented within a mattress to position the layer of foam along the length of the mattress.

[0007] In some embodiments, the present invention may be implemented as a method for manufacturing a foam cushion. A first portion of foam and a second portion of foam may be created in a desired shape. The first portion of foam and the second portion of foam may be cut into corresponding layers. Alternating layers of the first portion of foam and the second portion of foam may be bonded together to form the desired shape.

[0008] In some embodiments, the present invention can be implemented as a method for assembling a foam cushion. A first foam cushion component can be obtained, the first foam cushion component including a base and a layer resulting from the base. A second foam cushion component can be obtained, the second foam cushion component including a base and a layer resulting from the base. The layer of the first foam cushion component can be inserted between the layer of the second foam cushion component to form a foam cushion.

[0009] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter. [Brief description of the drawings]

[0010] The present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, with the understanding that these drawings depict only typical embodiments of the present invention and therefore should not be considered limiting of its scope, and in which: [Figure 1A] 1A-1D are side perspective and side views of a foam cushion having orthogonal alternating structures according to one or more embodiments of the present invention. [Figure 1B] 1A-1D are side perspective and side views of a foam cushion having orthogonal alternating structures according to one or more embodiments of the present invention. [Figure 2A] FIG. 13 is a side perspective view of another foam cushion having an orthogonal alternating structure according to one or more embodiments of the present invention. [Figure 2B] FIG. 13 is a side perspective view of another foam cushion having an orthogonal alternating structure according to one or more embodiments of the present invention. [Figure 3A] 1A-1C are side perspective and side views of another foam cushion having an orthogonal alternating structure according to one or more embodiments of the present invention. [Figure 3B]1A-1C are side perspective and side views of another foam cushion having an orthogonal alternating structure according to one or more embodiments of the present invention. [Figure 4] 1 provides an example of how a foam cushion having an orthogonal alternating structure may be formed in accordance with one or more embodiments of the present invention. [Figure 5A] 5A-5D are cross-sectional side views of a mattress including a foam cushion having an orthogonal alternating structure in accordance with one or more embodiments of the present invention. [Figure 5B] 5A and 5B are cross-sectional side views of a mattress including a foam cushion having an orthogonal alternating structure in accordance with one or more embodiments of the present invention. [Figure 5C] 5A-5C are cross-sectional side views of a mattress including a foam cushion having an orthogonal alternating structure in accordance with one or more embodiments of the present invention. [Figure 5D] 5A-5D are cross-sectional side views of a mattress including a foam cushion having an orthogonal alternating structure in accordance with one or more embodiments of the present invention. [Figure 6] FIG. 6 is a cross-sectional perspective top view of a mattress including a foam cushion having an orthogonal alternating structure in accordance with one or more embodiments of the present invention. [Figure 7] 1 provides an example of how a non-rectangular foam cushion having orthogonal alternating structures may be formed in accordance with one or more embodiments of the present invention. [Figure 7A] 1 provides an example of how a non-rectangular foam cushion having orthogonal alternating structures may be formed in accordance with one or more embodiments of the present invention. [Figure 7B] 1 provides an example of how a non-rectangular foam cushion having orthogonal alternating structures may be formed in accordance with one or more embodiments of the present invention. [Figure 7C] 1 provides an example of how a non-rectangular foam cushion having orthogonal alternating structures may be formed in accordance with one or more embodiments of the present invention. [Figure 8]FIG. 8 provides an example of a mattress including a foam cushion formed with opposing foam cushion components according to one or more embodiments of the present invention. [Figure 9] FIG. 9 provides another example of a mattress including a foam cushion formed with opposing foam cushion components according to one or more embodiments of the present invention. [Figure 10A] FIG. 10A provides an example of a foam cushion formed from opposing foam cushion components that also include a gap. [Figure 10B] FIG. 10B provides an example of a foam cushion formed from opposing foam cushion components that also include a gap. [Figure 10C] FIG. 10C provides an example of a foam cushion formed from opposing foam cushion components that also include a gap. [Figure 11] FIG. 11 provides an example of a foam cushion formed from opposing foam cushion components where the layers have rounded edges, according to one or more embodiments of the present invention. [Figure 12A] FIG. 12A provides an example of a mattress including a unitary foam cushion formed from opposing foam cushion components, according to one or more embodiments of the present invention. [Figure 12B] FIG. 12B provides an example of a mattress including a unitary foam cushion formed from opposing foam cushion components according to one or more embodiments of the present invention. [Figure 12C] FIG. 12C provides an example of a mattress including a unitary foam cushion formed from opposing foam cushion components according to one or more embodiments of the present invention. [Figure 13A] FIG. 13A provides an example of a mattress including two foam cushions, each formed from opposing foam cushion components, according to one or more embodiments of the present invention. [Figure 13B]FIG. 13B provides an example of a mattress including two foam cushions, each formed from opposing foam cushion components, according to one or more embodiments of the present invention. [Figure 13C] FIG. 13C provides an example of a mattress including two foam cushions, each formed from opposing foam cushion components, according to one or more embodiments of the present invention. [Figure 13D] FIG. 13D provides an example of a mattress including two foam cushions, each formed from opposing foam cushion components, according to one or more embodiments of the present invention. [Figure 13E] FIG. 13E provides an example of a mattress including two foam cushions, each formed from opposing foam cushion components, according to one or more embodiments of the present invention. [Figure 14] FIG. 14 provides an example of a pillow formed with opposing foam cushioning components, according to one or more embodiments of the present invention. [Figure 15A] FIG. 15A provides an example of how a foam cushion may be formed from opposing foam cushion components. [Figure 15B] FIG. 15B provides an example of how a foam cushion may be formed from opposing foam cushion components. [Figure 16A] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 16B] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 17A] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 17B] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 18A] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 18B]1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 19A] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. [Figure 19B] 1 is a table summarizing the results of experiments performed to test embodiments of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In this specification and claims, the term "cushioning article" is intended to encompass mattresses, pillows, sofas, car seats, aircraft seats, aftermarket seat cushions, and other furniture or articles that provide cushioning to an individual. A cushioning article may include one or more foam cushions configured according to one or more embodiments of the present invention. Foam cushions configured according to embodiments of the present invention may also be separate and / or freestanding from the cushioning article and may be covered with a fabric or plastic film or other flexible covering. The term "about" means within 10% of the stated value.

[0012] According to an embodiment of the present invention, the foam cushion may be formed from layers of foam having an orthogonal alternating structure. In this context, the term "orthogonal" is intended to indicate that the layers are arranged along an axis that is orthogonal to the forces that the foam cushion is intended to support. The term "alternating" is intended to indicate that the layers are formed with alternating foam types or hardnesses.

[0013] 1A and 1B provide an example of a foam cushion 100 having an orthogonal alternating structure. The foam cushion 100 has a rectangular shape labeled with a length, width, and height. The height can be considered the vertical dimension when the foam cushion 100 is lying flat, and the length and width can be considered the horizontal dimensions. The foam cushion 100 is formed of two types of foam arranged in layers 101 and 102 alternating along the length of the foam cushion (the length does not have to be longer than the width). Thus, the combined thickness of all layers 101 and 102 defines the overall length of the foam cushion 100. In this embodiment, the width of each layer 101 and 102 defines a consistent width of the foam cushion 100, although in some embodiments the layers may have different widths (e.g., to create a non-rectangular foam cushion). In this embodiment, the height (LH) of each layer 101 and 102 defines a consistent height of the foam cushion 100, although the layers may have different heights or be positioned at different vertical positions relative to each other, as described below.

[0014] The thickness (LT) of each layer 101, 102 (i.e., the dimension of the layer along the length of the foam cushion 100) can be less than the height of each layer, thereby creating localized instability. In other words, this smaller thickness allows each layer 101, 102 to collapse more easily under a downward force, such as from an individual's hips or shoulders, when lying on the foam cushion 100. However, the combination of layers 101 and 102 can still provide general stability across the foam cushion 100. For example, if the foam cushion 100 is a mattress, the individual layers 101 and 102 may collapse under localized pressure from an individual's hips and shoulders, while a combination of layers 101 and 102 that extends across a wider portion of the body, such as the torso, can exhibit general stability to provide back support.

[0015] Layer 101 can be formed from a different type of foam than layer 102, such that foam cushion 100 can exhibit synergistic advantages compared to the use of a single type of foam or a different structural arrangement of foam. Stated another way, the type of foam in layer 101 can have a first set of properties, and the type of foam in layer 102 can have a second set of properties, and the orthogonal alternating structure of these layers can provide synergistic advantages to the first set of properties and the second set of properties. For example, layer 101 can be formed from a relatively hard foam, and layer 102 can be formed from a relatively soft foam, such that each layer collapses / compresses differently than the adjacent layer. As another example, layers 101 and 102 can have different breathability, bounce, and / or softness.

[0016] The ratio of the height (LH) of each layer to the thickness (LT) of each layer can be selected to achieve a desired instability of the layers under significant pressure (e.g., due to the hips or shoulders when an individual lies on the mattress). In some embodiments, the ratio may be at least 2.5, at least 3.0, at least 3.5, at least 4.0, at least 4.5, or more. With a higher ratio, the layers may exhibit greater instability, or in other words, collapse under pressure to better shape to the individual's body.

[0017] The IFD of the foam used for each layer may also be selected to achieve the desired instability. For example, alternating layers of higher IFD foam with layers of lower IFD foam may facilitate the higher IFD foam layers to buckle (i.e., the lower IFD foam layers may compress to accommodate buckling of the higher IFD foam layers) because the lower IFD foam layers do not offer significant resistance to such buckling.

[0018] The layered structure of the foam cushion constructed in accordance with embodiments of the present invention allows this instability to occur only in response to sufficient load / pressure, and thus a mattress constructed in accordance with embodiments of the present invention may only provide support under the hips or shoulders while remaining firm under other parts of the body.

[0019] As one particular example, the foam cushion 100 can represent a mattress or a portion of a mattress, where the layer 101 can be formed of latex foam (or latex foam rubber) and the layer 102 can be formed of memory foam. In such a case, the latex foam can impart some desirable properties to the mattress, such as breathability, bounce when moving from place to place on the mattress, and softness. Memory foam lacks these properties. It is known for making you feel "dead" when lying on the mattress or doing other activities. It is also known for making it difficult to roll on the mattress, as it creates a body-shaped indentation that takes time to return to its original shape. It is also known for not being very breathable, such that a person lying on the mattress becomes hot with body heat and steam that cannot escape. It does not have the amazing softness of latex foam (e.g., Talalay latex foam rubber). Memory foam can also lack back support, as it softens as the body heats up the memory foam, and the heavy torso of the body can sag in its softness. However, memory foam has positive properties that latex foam lacks, the most important of which is that memory foam is known to mold itself to the shape of the body over time, giving the body more uniform support (relief from pressure points). Thus alternating layers of memory foam with layers of latex foam can be synergistic. Latex foam tends to shape instantly, promotes memory foam's return to shape after deformation, and will feel much more lively (as opposed to memory foam's inelasticity). Latex foam is more breathable, allowing body heat and vapor to escape through the intermittent latex foam layers. The softness of the latex foam gives the mattress a much softer "hand" and overcomes the initial stiff feel of memory foam that is present while the memory foam is heating up to body temperature and slowly forming to the body. The elasticity of the latex foam helps offset the loss of support as the memory foam heats up and softens. Alternating layers of memory foam enhance the synergistic effect by enhancing the form-conforming properties that reduce pressure points.These synergistic advantages, combined with the benefits of localized instability and general stability, can result in a highly desirable mattress or other foam cushion.

[0020] In some embodiments, the foam cushion can have two or more types of foam arranged in layers. Using the example above, a layer of reticulated foam can be used with a layer of memory foam and a layer of latex foam to provide greater breathability. As another example, if more robustness is desired or the adjacent memory foam needs to spring back to its shape more quickly, the soft Talalay latex of the example above can be replaced with a harder latex, typically made by the Dunlop process rather than the Talalay process. Although each layer 101 and 102 is represented as being formed from a single piece of foam, in some embodiments, layer 101 or layer 102 can be formed from multiple pieces of the same foam.

[0021] A wide variety of foams may be used in embodiments of the present invention, including, but not limited to, fast rebound polyurethane foams (selected from the group including conventional polyurethane foams, high resilience polyurethane foams, and reticulated polyurethane foams), low rebound polyurethane foams (selected from the group including low rebound memory foams, fast rebound memory foams, and gel memory foams), latex foams (selected from the group including natural latex foams, organic natural latex foams, synthetic latex foams, and partial natural and partial synthetic latex foams), expanded polyolefin foams, EVA foams, silicone foams, melamine foams, PVDF foams, polyethylene foams, shredded and recombined foams (including any shredded flexible foam type), Energex® foams (a proprietary foam made by Elite Comfort Solutions that is highly breathable and somewhat viscous foam that changes from its original viscosity to body heat), and the like. Foams with different stiffnesses are intended to include, but are not limited to, using conventional polyurethane open cell cushion foams with stiffnesses of IFD (Indentation Force Deflections) 8, IFD13, IFD18, IFD24, IFD32, IFD36, IFD44, IFD55, and IFD60 or equivalent. In embodiments of the present invention, the type of foam may be different in one layer adjacent to the next layer, or the foam stiffness may be different in one layer adjacent to the next layer, or both. Two or more types of foam may be selected for a synergistic effect of properties with adjacent layers, and two or more stiffnesses of foam may be selected to create stability under wide areas of the body or other cushioning object and to create instability under sharp areas of the body or other cushioning object. When adjacent foams differ in both type and stiffness, the results may be more pronounced.

[0022] 2A and 2B provide another example of a foam cushion 200 having an orthogonal alternating structure. In the foam cushion 200, layers 101 are vertically offset relative to layers 102, thereby forming gaps 103 at the top and bottom of the foam cushion 200. In the depicted embodiment, gaps 103 are formed at the top of the foam cushion 200 between pairs of adjacent layers 102, and gaps 103 are formed at the bottom of the foam cushion 200 between pairs of adjacent layers 101.

[0023] 3A and 3B provide another example of a foam cushion 300 having an orthogonal alternating structure. In the foam cushion 300, the layers 102 have a different height than the layers 101 (i.e., are taller than the layers 101), thereby forming gaps 103 at the top of the foam cushion 300 (or at the bottom if the foam cushion 300 is inverted) between pairs of adjacent layers 102.

[0024] In both foam cushion 200 and foam cushion 300, gaps 103 form air pockets that can provide greater breathability, less overall stiffness, less initial stiffness during the initial descent of a body or other cushioning object into the foam cushion, and reduced foam costs. FIG. 4 provides examples of how foam cushions 100, 200, and 300 can be cut from a layered foam block 400. For example, sheets of different types and / or stiffness of foam can be alternately stacked and bonded together to create layered foam block 400. Layered foam block 400 can then be cut (e.g., using a CNC band saw) in the desired pattern to produce foam cushions 100, 200, and / or 300. By cutting foam cushions 100, 200, and / or 300 from layered foam block 400, foam waste, labor, and time can be minimized. In some embodiments, the foam can be glued together using a flexible or stretchy adhesive with a precisely controlled thickness to prevent the adhesive from creating too much localized stiffness. It should be noted that in one embodiment, when the foam cushion 300 is cut in the pattern shown in FIG. 4, one half of the resulting cushion 300 will have a first type of higher portion or foam stiffness, and the other half of the resulting cushion 300 will have a second type of higher portion or foam stiffness. It is also possible to shift the cuts by a half layer so that the top and bottom portions have 50% of the first type of foam or stiffness, and 50% of the second type of foam or stiffness, respectively. This shift cut will allow all of the foam cushions 300 to be essentially identical, whereas a non-shift cut would result in two different foam cushions 300 that can then be put into separate cushion designs. For example, a non-shift cut where the higher portion is latex foam and the lower portion is memory foam may exhibit more latex foam properties than memory foam properties. As another example, a non-shift cut where the top portion is memory foam and the bottom portion is latex foam may exhibit more memory foam properties than latex foam properties.

[0025] The cross-sectional views of Figures 5A-5D provide examples of how the foam cushions 100, 200, and 300 can be integrated into a mattress 500. In each example, the foam cushion 100, 200, or 300 is supported on top of a base layer 501 and surrounded by a side layer 502. A top layer 503 can be placed on top of the side layer 502 and the foam cushion 100, 200, or 300. In Figure 5A, the mattress 500 includes a foam cushion 100 that has the same height as the side layer 502 so that no air pockets are formed. In Figure 5B, the mattress 500 includes a foam cushion 200 that has the same height as the side layer 502 so that a gap 103 is formed toward the base layer 501 and toward the top layer 503. In Figure 5C, the mattress 500 includes a foam cushion 300 that has the same height as the side layer 502 and the gap 103 is oriented toward the top layer 503. In Figure 5D, mattress 500 includes foam cushion 300, but gap 103 is oriented toward base layer 501. Notably, the mattress may be formed with foam cushion 100, 200, or 300, but does not include any or all of base layer 501, side layer 502, and top layer 503. Figure 6 is a cross-sectional perspective view of mattress 500 configured in Figure 5A or 5D.

[0026] Figures 7 and 7A-7C illustrate another technique that may be used to manufacture foam cushions constructed in accordance with embodiments of the present invention. This technique is particularly suited to manufacturing foam cushions that do not have a rectangular cross-sectional shape, such as pillows or car seats. Figure 7 illustrates a portion of foam 700 shaped like a pillow. In particular, at least two foams 700 having different properties should be used (i.e., two different types and / or stiffnesses of foam as described above) that can be molded into the desired shape of the foam cushion.

[0027] FIG. 7A is a side view of two pieces of foam 700 and illustrates how these pieces of foam 700 can be cut to produce layers 701 and 702 shown in FIG. 7B. Each piece of foam 700 can be cut in a similar manner such that the set of layers 701 has the same shape and size as layer 702. Layers 701 and 702 can then be joined together to form the orthogonal alternating structure described above, as shown in FIG. 7C, thereby resulting in two foam cushions 750. Foam cushion 750 has the same general shape as the piece of foam 700, although this need not be the case, such as when less than all of layers 701 or 702 are used.

[0028] Non-rectangular foam cushions can also be made using the technique depicted in FIG. 4 by performing one or more cuts to create the desired shape (e.g., rounded edges, tapered edges, buckets, or other indentations, etc.). This can be done, for example, by band sawing block / stack 400 from two sides. In one embodiment, a bed pillow that tapers from its center in all four directions (standard pillow shape) may be created by band sawing a tapered shape through one side of block / stack 400 to achieve tapering of the two sides of the pillow, and then band sawing a tapered shape through a second side of block / stack 400 to achieve tapering of the other two sides of the pillow. Non-rectangular foam cushions can also be made using the technique depicted in FIG. 4 by first cutting a rectangular block as shown in FIG. 4, and then milling the cushion to its final shape, for example, with a CNC mill.

[0029] FIG. 8 provides an example of a mattress 800 constructed in accordance with one or more embodiments of the present invention. Mattress 800 includes a base layer 801 and a foam cushion 802 that includes alternating layers 101 and 102, similar to foam cushions 100, 200, and 300. However, unlike foam cushions 100, 200, and 300, layers 101 and 102 of foam cushion 802 originate from bases 101a and 102a, respectively. In some embodiments, base 101a and each layer 101 may be a single foam (or "foam cushion component"), and base 102a and each layer 102 may be separate foam cushion components. In foam cushion 802, base 101a and base 102a have the same height (or vertical thickness) (labeled BH in FIG. 12C), and all layers 101 and 102 have the same height (labeled LH in FIG. 12C). However, in other embodiments, base 101a and base 102a may have different heights and / or layer 101 and layer 102 may have different heights.

[0030] 9 provides an example of a mattress 900 constructed in accordance with one or more embodiments of the present invention. Mattress 900 includes only a foam cushion 901. Foam cushion 901 is the same as foam cushion 802, except that in foam cushion 901, base 101a has a substantially higher height than base 102a. For example, the height of base 101a can be increased so that base 101a can function as a base layer for mattress 900.

[0031] 10A-10C provide additional examples of foam cushions 1001-1003, respectively, which are similar to foam cushion 802, but include gaps 103. In foam cushion 1001, gaps 103 are formed between layer 101 and base 102a, and between layer 102 and base 101a. This may be accomplished by gluing or otherwise adhering layer 101 to layer 102 without fully inserting the layer between the layers.

[0032] In the foam cushion 1002, the gap 103 is only formed between layer 101 and base 102a. This may be accomplished by configuring layer 102 to have a greater height than layer 101, such that even when layer 101 is fully inserted between layer 102, the gap 103 is still formed.

[0033] Foam cushion 1003 is similar to foam cushion 1002, except that a gap 103 is formed between layer 102 and base 101a. This may be accomplished by configuring layer 101 to have a greater height than layer 102, such that even when layer 102 is fully inserted between layer 101, gap 103 is still formed.

[0034] 11 provides an example of a foam cushion 1100 including layers 101 and 102 arising from bases 101a and 102a, respectively, as described above (i.e., foam cushion 1100 is formed of opposing foam cushion components). Unlike the previous example, the ends of layers 101 and 102 are rounded, and the portions of bases 101a and 102a between layers 101 and 102, respectively, are correspondingly rounded. In some embodiments, layers 101 and 102 may be bonded together by gluing only the rounded ends, while in other embodiments, adhesive may be applied along the entire interface between the layers.

[0035] 12A-12C provide an example of a mattress 1200 formed from a single foam cushion 1201. The foam cushion 1201 is the same as the foam cushion 1100, except that the base 102a has a greater height than the base 101a. FIG. 12C provides an example of suitable dimensions that the foam cushion 1201 may have. However, any other reasonable dimensions may be used. In this example, the layers 101 and 102 have a thickness (LT) of about 1.4815 inches, and the rounded ends have a radius (R) of about 0.7407 inches. The layers 101 and 102 may have a height (LH) of about 7.000 inches, while the bases 101a and 102a may have heights of about 0.500 inches and 2.500 inches, respectively. Thus, the height of the foam cushion 1201 / mattress 1200 is about 10.000 inches.

[0036] 13A-13E provide an example of a mattress 1300 formed from a foam cushion 1301 positioned on top of a foam cushion 1302. Foam cushions 1301 and 1302 each include opposing foam cushion components.

[0037] 13B and 13C show the foam cushion 1301 alone and provide suitable dimensions. However, any other reasonable dimensions can be used. In this example, layers 101 and 102 have a width of about 1.000 inches and the rounded ends have a radius of about 0.500 inches. Layers 101 and 102 have a height of about 3,000 or 4,000 inches and bases 101a and 102a have a height (BH) of about 0.500 inches. Thus, the height of foam cushion 1301 can be about 4.000 inches or 5.000 inches.

[0038] 13D and 13E show the foam cushion 1302 alone and provide suitable dimensions. However, any other reasonable dimensions can be used. In this example, the layers 101 and 102 have a width of about 1.4815 inches and the rounded ends have a radius of about 0.7407 inches. The layers 101 and 102 have a height of about 7.000 inches and the bases 101a and 102a have a height of about 0.500 inches. Thus, the height of the foam cushion 1302 can be about 8.000 inches and the height of the mattress 1300 can be about 12.000 inches or 13.000 inches.

[0039] When each of the foam cushions is formed with opposing foam cushion components, the type of foam for the upper and lower foam cushion components can be selected to provide one or more desired benefits. For example, the upper foam cushion component can be formed from a more breathable foam than the lower foam cushion component to enhance breathability. In contrast, the upper foam cushion component can be formed from a less breathable memory foam, while the lower foam cushion component can be formed from a more breathable foam. In such a case, the more breathable foam of the bottom foam cushion component can enhance the breathability of the less breathable foam of the upper foam cushion component. This may be because the layer of the bottom foam cushion component extends upward and is located close to the base of the upper foam cushion component, so that heat does not have to convect very far through the less breathable foam to reach the more breathable foam.

[0040] 14 provides an example of a pillow-shaped foam cushion 1400. Foam cushion 1400 is formed by opposing foam cushion components constructed in a similar manner as described above. Additionally, bases 101a and 102a each include tapered extensions 101b and 102b that extend parallel to layers 101 and 102 to form a pillow shape.

[0041] 15A and 15B provide an example of how a foam cushion may be manufactured in accordance with one or more embodiments of the present invention. FIG. 15A shows a first portion of foam 1510 and a second portion of foam 1520. Foam 1510 and foam 1520 may be different types of foam and may be sized and shaped to allow multiple foam cushion components 1511 and 1521, respectively, to be cut therefrom. For example, foams 1510 and 1520 may have rectangular dimensions that are a multiple of the desired dimensions of the mattress to be manufactured. In FIG. 15A, the length of foams 1510 and 1520 is twice the desired length of the mattress, the width is perhaps the same as the desired width of the mattress, and the height is six times the desired height of the mattress (which is the case in this example because foam cushion components 1511 and 1521 have the same height). 15A also shows how foam cushioning components 1511 and 1521 can be cut from foam 1510 and 1520, respectively. In some embodiments, foam cushioning component 1511 can be cut from foam 1510 and foam cushioning component 1521 can be cut from foam 1520 using a single CNC saw cutting program.

[0042] FIG. 15B shows how a pair of opposing foam cushion components 1511 and a pair of opposing foam cushion components 1521 can be removed from the foam 1510 and 1520, respectively, and then separated from each other. One of the foam cushion components 1511 and one of the foam cushion components 1521 can be inverted, and then the foam cushion components 1511 and the foam cushion components 1521 can be bonded together. In some embodiments, this bonding can be performed in a fastener manner. In particular, the layers 101 and 102 at one end of the foam cushion components 1521 and 1511 can be inserted together first, followed by the next layers 101 and 102, until all layers 101 and 102 are combined. In some embodiments, an adhesive or another adhesive can be placed on at least the ends of the layers 101 and 102 before fastening the layers together in this manner.

[0043] Although Figures 15A and 15B depict the manufacture of a foam cushion having a rectangular shape (e.g., for a mattress), the same manufacturing techniques can be used to manufacture foam cushions having other shapes (e.g., foam cushion 1400).

[0044] In some embodiments, a lubricant may be used during the process of assembling the foam cushioning components. For example, the ends of layers 101 and 102 (whether rounded or not) may be coated with a lubricant to facilitate insertion of the layers between one another. In embodiments where an adhesive is used, the lubricant may be added to the adhesive and then the mixture of adhesive and lubricant may be applied to the ends of layers 101 and 102. In some embodiments, the adhesive may be water-based (e.g., Simalfa 350) and the lubricant may also be water-based (e.g., KY Jelly). In some embodiments, the mixture adhesive and lubricant may include 10% lubricant by volume, 20% lubricant by volume, or 50% lubricant by volume. In some embodiments, the lubricant may reduce the evaporation rate of the adhesive and therefore extend the working time of the adhesive (i.e., the lubricant may slow the drying of the adhesive). This may be particularly beneficial for assembling foam cushioning components, such as foam cushioning components 1511 and 1521, which may require significant time to fasten.

[0045] In embodiments where an adhesive (or other adhesive) is used to bond the layers together, the instability of the layers may be controlled by applying the adhesive only on and / or near the top and / or bottom of the layers, rather than along the complete interface between the layers. In this way, layers that are intended to be unstable (e.g., layers with higher IFDs) may collapse more easily due to the reduced length at which they are bonded to adjacent layers. As noted above, this engineered instability allows the mattress (or other cushioning article) to deform in response to substantial pressure (e.g., hips or shoulders) while the rest of the mattress provides firm support.

[0046] Experiments and Results Various experiments were conducted with the different types of foam cushions described herein and with different configurations of such foam cushions, and the results of these experiments are summarized below.

[0047] Various foam cushions conforming to the configurations shown in Figures 1A and 1B (e.g., layers 101 and 102 were made with foams A and B, respectively) were tested as foam cushions for mattresses. In each test, the foam cushion was placed on a base consisting of 1" 32 ILD conventional polyurethane foam on top of an 8" pocketed coil spring. Figure 16 is a table summarizing the results of these tests. The results indicate that different synergistic effects can be obtained from using different foam layered arrangements.

[0048] Various foam cushions generally corresponding to the configuration shown in Figure 11 were tested as foam cushions for mattresses. In tests 14 and 15, no base was used. In test 16, the foam cushion was tested as a mattress base. Figure 17 is a table summarizing the results of these tests. The results show that different synergistic effects can be obtained from using different foam layering arrangements.

[0049] Various mattresses generally corresponding to the configurations shown in Figures 12A-13E were also tested. In each test, the foam cushion of Test 16 or a variation was used as the base foam cushion. Figure 18 is a table summarizing the results of these tests. The results show that different synergistic effects can be obtained by using different foam layering arrangements in both the upper and lower foam cushions.

[0050] Various pillows were also tested, generally corresponding to the configuration shown in Figure 14. Figure 19 is a table summarizing the results of these tests. The results show that different synergistic effects can be obtained from using different foam layering arrangements.

[0051] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing specification.

Claims

1. A foam cushion comprising a layer of foam disposed along a length of the foam cushion.

2. 10. The foam cushion of claim 1, wherein the layer of foam is formed from at least two types of foam.

3. 3. The foam cushion of claim 2, wherein the at least two types of foam are arranged in alternating layers.

4. 4. The foam cushion of claim 3, wherein the at least two foams have indentation force deflections (IFD) that differ by at least 15%.

5. 4. The foam cushion of claim 3, wherein the at least two foams have indentation force deflections (IFD) that differ by at least 20%.

6. 4. The foam cushion of claim 3, wherein the at least two foams have indentation force deflections (IFD) that differ by at least 25%.

7. The at least two types of foams are Fast-rebound polyurethane foam, Low-resilience polyurethane foam, Latex foam, Expanded polyolefin foam, EVA foam, Silicone foam, Melamine foam, PVDF foam, Polyethylene foam, Shredded and rebonded foam, Energex foam, 4. The foam cushion of claim 3, selected from:

8. 10. The foam cushion of claim 1, wherein each layer has a thickness and a height, said thickness being less than said height.

9. 9. The foam cushion of claim 8, wherein the ratio of the height to the thickness is at least 2.

5.

10. 9. The foam cushion of claim 8, wherein the ratio of the height to the thickness is at least 3.

11. 9. The foam cushion of claim 8, wherein the ratio of the height to the thickness is at least 3.

5.

12. 9. The foam cushion of claim 8, wherein the ratio of the height to the thickness is at least four.

13. The foam cushion of claim 1 , wherein the layer is formed from opposing first and second foam cushion components.

14. 14. The foam cushion of claim 13, wherein each of the first and second foam cushion components includes a layer originating from a base, and layers of the first foam cushion component alternate with layers of the second foam cushion component.

15. 15. The foam cushion of claim 14, wherein the base of the first foam cushion component has a greater height than the base of the second foam cushion component.

16. 15. The foam cushion of claim 14, wherein a layer height of the first foam cushion component is greater than a layer height of the second foam cushion component.

17. 17. The foam cushion of claim 16, wherein a gap is formed between the layer of the second foam cushion component and the base of the first foam cushion component.

18. The foam cushion of claim 14 , wherein a gap is formed between the layer of the second foam cushion component and the base of the first foam cushion component.

19. 20. The foam cushion of claim 18, wherein a gap is formed between the layer of the first foam cushion component and the base of the second foam cushion component.

20. 15. The foam cushion of claim 14, wherein an end of the layer of the first foam cushioning component and an end of the layer of the second foam cushioning component are rounded.

21. 21. The foam cushion of claim 20, wherein the layer of the first foam cushioning component and the layer of the second foam cushioning component are secured together by applying adhesive only to the rounded ends.

22. 15. The foam cushion of claim 14, wherein each layer has a thickness and a height, said thickness being less than said height.

23. 23. The foam cushion of claim 22, wherein the ratio of the height to the thickness is at least 2.

5.

24. 23. The foam cushion of claim 22, wherein the ratio of the height to the thickness is at least 3.

25. 23. The foam cushion of claim 22, wherein the ratio of the height to the thickness is at least 3.

5.

26. 23. The foam cushion of claim 22, wherein the ratio of the height to the thickness is at least four.

27. 15. The foam cushion of claim 14, wherein the layer of the first foam cushioning component is formed from a first type of foam and the layer of the second foam cushioning component is formed from a second type of foam.

28. 30. The foam cushion of claim 27, wherein the first type of foam and the second type of foam have IFDs that differ by at least 15%.

29. 30. The foam cushion of claim 27, wherein the first type of foam and the second type of foam have IFDs that differ by at least 20%.

30. 30. The foam cushion of claim 27, wherein the first type of foam and the second type of foam have IFDs that differ by at least 25%.

31. 10. The foam cushion of claim 1, wherein the layers of foam are vertically offset to form gaps between the layers.

32. 10. The foam cushion of claim 1, wherein the layers of foam have different heights that define gaps between the layers.

33. The foam cushion of claim 1 , wherein the foam cushion has a rectangular cross-sectional shape.

34. The foam cushion of claim 1 , wherein the foam cushion has a non-rectangular cross-sectional shape.

35. A cushioning material, a first foam cushion comprising a layer of foam disposed along a length of the foam cushion; The cushioning material includes:

36. 36. The cushioning material of claim 35, further comprising a second foam cushion comprising a layer of foam disposed along a length of the foam cushion, the first foam cushion being disposed over the second foam cushion.

37. 37. The cushioning material of claim 36, wherein the layer of the first foam cushion is formed from opposing first and second foam cushion components and the layer of the second foam cushion is formed from opposing third and fourth foam cushion components.

38. 38. The cushioning material of claim 37, wherein each of the first and second foam cushion components includes a layer originating from a base, the layers of the first foam cushion component alternating with layers of the second foam cushion component, and each of the third and fourth foam cushion components includes a layer originating from a base, the layers of the third foam cushion component alternating with layers of the fourth foam cushion component.

39. 40. The cushioning material of claim 38, wherein the layers of the first and second foam cushioning components have a shorter height than the layers of the third and fourth foam cushioning components.

40. 40. The cushioning material of claim 38, wherein the first foam cushioning component layer, the second foam cushioning component layer, the third foam cushioning component layer, and the fourth foam cushioning component layer are each formed from a different type of foam.

41. 40. The cushioning material of claim 38, wherein the first foam cushioning component layer, the second foam cushioning component layer, the third foam cushioning component layer, and the fourth foam cushioning component layer each have a thickness and a height, and a ratio of the height to the thickness is at least 2.

5.

42. 36. The cushioning material of claim 35, further comprising a second foam cushion, the first foam cushion being disposed above the second foam cushion.

43. 36. The cushioning of claim 35, wherein the layers are composed of alternating different types of foam.

44. 44. The cushioning material of claim 43, wherein the alternating types of foam have different IFDs.

45. 36. The cushioning material of claim 35, wherein the layers each have a height and a thickness, and the ratio of the height to the thickness is at least 2.

5.

46. 1. A method of manufacturing a mattress, comprising the steps of: axially stacking the sheets of foam to form a layered foam block; cutting the layered foam block along the axis to form a foam cushion including a layer of foam; orienting the foam cushion within the mattress and disposing a layer of foam along the length of the mattress; A method for providing the above.

47. 47. The method of claim 46, wherein a thickness of each of the one or more layers of foam is less than a height of each of the one or more layers of foam.

48. 47. The method of claim 46, wherein the foam cushion is oriented on top of a base layer of the mattress.

49. 47. The method of claim 46, wherein the foam cushion is surrounded by side layers of the mattress.

50. 47. The method of claim 46, wherein cutting the layered foam block along the axis comprises making a linear cut.

51. 47. The method of claim 46, wherein cutting the layered foam block along the axis comprises non-linearly cutting to form gaps between the layers of foam.

52. 47. The method of claim 46, further comprising bonding overlapping sheets of foam together prior to cutting the layered foam block.

53. 47. The method of claim 46, further comprising bonding the layers of foam together after cutting the layered foam block.

54. 47. The method of claim 46, further comprising bonding the foam cushion to another cushioning layer comprising one or more of a spring, a foam, a quilted panel, a gelatinous elastomer, or an air bladder.

55. 55. The method of claim 54, further comprising attaching a fabric cover over the foam cushion.

56. 47. The method of claim 46, wherein the layers of foam are arranged in alternating fashion and comprise foam types with different IFDs.

57. 47. The method of claim 46, wherein the layers each have a height and a thickness, and the ratio of the height to the thickness is at least 2.

5.

58. 1. A method of making a foam cushion, comprising: creating a first foam piece and a second foam piece of a desired shape; cutting the first foam piece and the second foam piece into corresponding layers; bonding alternating layers of the first and second foam pieces to form a desired shape; The method includes:

59. 59. The method of claim 58, wherein the desired shape is a pillow shape, an aftermarket seat cushion, a furniture cushion insert, or a bucket seat insert.

60. 60. The method of claim 58, wherein the first foam piece and the second foam piece are extruded or cut into a desired shape.

61. 60. The method of claim 58, wherein at least some of the layers have a thickness that is less than their height.

62. 1. A method of assembling a foam cushion, comprising: Obtaining a first foam cushion component including a base and a layer arising from the base; Obtaining a second foam cushion component including a base and a layer arising from the base; inserting a layer of the first foam cushion component between layers of the second foam cushion component to form a foam cushion; A method for providing the above.

63. 63. The method of claim 62, wherein the layer of the first foam cushioning component is inserted between the layers of the second foam cushioning component in a fastener manner.

64. 63. The method of claim 62, further comprising the step of applying adhesive to edges of the first foam cushioning component layer and the second foam cushioning component layer before inserting the first foam cushioning component layer between the second foam cushioning component layer.

65. 65. The method of claim 64, wherein the ends are rounded.

66. 63. The method of claim 62, further comprising the step of applying a lubricant to an edge of the first foam cushioning component layer and an edge of the second foam cushioning component layer prior to inserting the first foam cushioning component layer into the second foam cushioning component layer.

67. 67. The method of claim 66, wherein the lubricant is mixed with an adhesive.

68. 63. The method of claim 62, wherein the layer of the first foam cushioning component is formed from a first type of foam and the layer of the second foam cushioning component is formed from a second type of foam.

69. 69. The method of claim 68, wherein the first type of foam and the second type of foam have different IFDs.

70. 63. The method of claim 62, wherein the layers each have a height and a thickness, and the ratio of the height to the thickness is at least 2.5.

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