Active airflow through gel grid mattress with individual pocket coils

Abstract

An active airflow system includes a cushion assembly and an air circulation device. The cushion assembly includes a base layer, a coil layer, an upper layer, an elastomeric cushioning element, and an outer cover. The coil layer includes a plurality of coils arranged in an array and spaced apart. The elastomeric cushioning element includes a plurality of interconnected buckling walls that define a plurality of hollow columns. The air circulation device directs air to flow through the array of the plurality of pocketed coils of the cushion assembly. Additionally, the coil layer includes a plurality of internal barriers that forms a plurality of regions in the coil layer. The upper layer comprises a foam with a plurality of perforations. The perforations have a diameter greater than the thickness of the upper layer.

Description

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 730,792, filed Dec. 11, 2024, which is incorporated herein by reference in its entirety and for all purposes.TECHNICAL FIELD

[0002] Embodiments and aspects of this disclosure relate generally to cushion assemblies such as mattresses and mattress covers and an active airflow system for use with cushion assemblies.BACKGROUND

[0003] Cushion assemblies include mattresses, cushions, shoe inserts, padding, packaging, etc. Cushion assemblies may include a cushion member (e.g., a mattress) that includes multiple layers of cushioning elements. Cushioning elements may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications. For example, mattresses may include pocketed coils in combination with layers of foam, elastomer gels, etc., in order to achieve desired results in the cushioning materials. While different cushioning elements can be used to tune temperature regulation, climate control systems can be installed to provide additional air flow, humidity control, or cooling effect. Climate control systems require modifying the cushion assemblies or circumventing the layers of cushioning elements. It would be advantageous to have an airflow system that require minimal to no modification to the existing cushioning elements.SUMMARY

[0004] One embodiment relates to an active airflow system including a cushion assembly. The cushion assembly including a base layer, a coil layer disposed over the base layer and comprised a plurality of pocketed coils arranged in an array and spaced apart, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer and comprised a plurality of interconnected buckling walls that define a plurality of hollow columns, and an outer covering disposed over the elastomeric cushioning element. The cushion assembly further includes an air circulation device that can direct air to flow through the coil layer.

[0005] Another embodiment relates to an active airflow system including a cushion assembly. The cushion assembly includes a base layer, a coil layer disposed over the base layer and comprised a plurality of pocketed coils arranged in an array and spaced apart, an upper layer disposed over the coil layer, and a plurality of side panels extending along outer perimeters of the base layer and the upper layer. Each side panel is disposed between the upper layer and the base layer. The cushion assembly further includes an air circulation device that directs an airflow through at least a part of the coil layer.

[0006] Still another embodiment relates to an active airflow system including a cushion assembly. The cushion assembly includes a base layer, a coil layer disposed over the base layer and comprised a plurality of pocketed coils arranged in an array and spaced apart, an upper layer disposed over the coil layer, the upper layer comprising a foam with a plurality of perforations, an elastomeric cushioning element disposed over the upper layer and comprised a plurality of interconnected buckling walls that define a plurality of hollow columns; and an outer covering disposed over the elastomeric cushioning element.

[0007] Numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. The described features of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of an aspect of the invention may be combined with one or more features of a different aspect of the invention. Moreover, additional features may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a top perspective view of a cushion assembly, according to an exemplary embodiment.

[0009] FIG. 2 is a perspective view of the elastomeric cushioning element configured for use with the cushion assembly of FIG. 1, according to an exemplary embodiment.

[0010] FIG. 3 is a side view of an active airflow system with a cushion assembly of FIG. 1, according to an exemplary embodiment.

[0011] FIG. 4 is a cross-sectional view of a cushion assembly configured for use with the active airflow system of FIG. 3 is shown, according to another exemplary embodiment.DETAILED DESCRIPTION

[0012] Referring now to FIG. 1, a top perspective view of a cushion assembly 100 is shown, according to an exemplary embodiment. The cushion assembly 100 may include a base layer 102, a coil layer 104, an elastomeric cushioning element 108, an edge portion 109, and the outer covering 112. In some embodiments, the cushion assembly 100 may include an upper layer 106. In some embodiments, the cushion assembly 100 may include one or more side panels 114.

[0013] The base layer 102 may have generally planar top and bottom surfaces. The coil layer 104 may be disposed on the top surface of the base layer 102 and between the base layer 102 and the elastomeric cushioning element 108. The elastomeric cushioning element 108 may be disposed over an upper surface of coil layer 104 and may extend over at least a portion of the coil layer 104. The edge portion 109 may extend around an outer peripheral edge of the elastomeric cushioning element 108. The outer covering 112 may extend from the base layer 102 and may at least substantially encase the coil layer 104, the elastomeric cushioning element 108, and the edge portion 109. In some embodiments, the cushion assembly 100 may include one or more side panels 114. The one or more side panels 114 may extend along outer perimeters of the base layer 102 and within a place perpendicular to a plane defined by the top surface of the base layer. In some embodiments, the outer covering 112 may at least substantially encase the one or more side panels 114.

[0014] The cushion assembly 100 may include a stabilization material 116 between the elastomeric cushioning element 108 and the coil layer 104. In some instances, the stabilization material 116 may include a relatively thin material (e.g., cotton spandex blend “scrim”) and may be used to provide a surface for adhering (e.g., gluing) the elastomeric cushioning element 108 to surrounding materials, such as another elastomeric cushioning element 108, the coil layer 104, and / or an upper surface of the upper layer 106. In some embodiments, the stabilization material 116 may comprise a scrim fabric (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushioning element 108 may seep through (e.g., be melt fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric of the stabilization material 116. For example, when the elastomeric cushioning element 108 includes a gel material, portions of the gel material may be heat fused through the stabilization material 116. The portions of the elastomeric cushioning element 108 that extend through the scrim fabric of the stabilization material 116 may create a non-slip surface or reduced slip surface on a lower surface of the stabilization material 116 (e.g., surface that would contact an upper surface of the coil layer 104). The nonslip surface or reduced slip surface created by the elastomeric cushioning element 108 may help the cushioning materials stay in place relative to one another.

[0015] Furthermore, an adhesive may be disposed between the stabilization material 116 and the coil layer 104. An adhesive may be disposed between the base layer 102 and the coil layer 104. In some embodiments, an adhesive may be disposed between the one or more side panels 114 and the coil layer 104.

[0016] In some embodiments, the outer covering 112 may comprise a stretchable material that may be secured to or be integral with the elastomeric cushioning element 108. The base layer 102 may include a polyurethane foam, a latex foam rubber, or any other suitable foam. In some embodiments, the base layer 102 may include a polyurethane foam having a nominal density of about 2.0 lb / ft3 and an indention load deflection (ILD) of 55 (i.e., “55 ILD”). The base layer 102 may, alternatively, be a single or multiple layers of fabric that is either stiff or stretchable. A base layer 102 of stiffer fabric may include a polypropylene fabric, a continuous filament, polyster or any other stiffening fabrics. The one or more side panels 114 may also include a polyurethane foam or any other spacer fabric. In the alternative, the side panels 114 may be integrated into the outer covering 112 and may solely be fabric similar to the rest of the cover or may include additional fabric or quilted fabrics for a more robust side panel. In some embodiments, the upper layer 106 may comprise a polyurethane foam, a latex foam rubber, or any other suitable foam.

[0017] The coil layer 104 may include a plurality of coils 118 (e.g., steel coils), and each coil 118 of the plurality of coils 118 may be encased in at least one respective casing 120 (e.g., polypropylene socks or bags). Each casing 120 of each coil 118 of the plurality of coils 118 may be individual and discrete. For example, each casing 120 may form a pocket for a respective coil 118. In some embodiments, each coil 118 may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. Furthermore, in one or more embodiments, each coil 118 may be encased in multiple casings 120. For instance, each coil 118 may be double bagged or triple bagged. In some embodiments, the casings 120 may include a polypropylene material. The casings 120 may include a two-ply polypropylene non-woven material. In some embodiments, each ply of the casings 120 may have a thickness within a range of about 0.10 mm and about 0.40 mm. As an example, each ply of the casings 120 may have a thickness within a range of about 0.15 mm and about 0.30 mm. However, any suitable material may be used. Additionally, each coil 118 of the plurality of coils 118 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer 102. Furthermore, the plurality of coils 118 may be spaced next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer 104.

[0018] Still referring to FIG. 1, in some embodiments, a pocketed coil 121 includes a casing 120 encasing a coil 118 and a coil topper 119 positioned over a coil 118. In some embodiments, the coil topper 119 comprises a compressible, resilient material (e.g., polyurethane foam, a memory foam, a latex rubber foam, or any other suitable foam). In some embodiments, the coil topper 119 comprises an elastomeric material (e.g., a gelatinous elastomer, plasticized block copolymers, etc.). In some embodiments, a casing 120 encases a coil 118 and a plurality of coil toppers 119. Each coil topper 119 may have any suitable shape (e.g., cylinder, puck, rectangular, etc.). In some embodiments, a pocket coil is configured according to the teachings of U.S. Pat. No. 10,098,474, the entire disclosures of which are incorporated by reference herein. In such embodiments, the elastomeric cushioning element 108 is disposed on the top surface of the coil layer 104, and a stabilization material 116 is positioned to adhere the elastomeric cushioning element 108 to the coil layer 104. In some embodiments, a plurality of foam coil toppers 119 form an upper layer 106 positioned over the top surfaces of a plurality of coils 118.

[0019] In an alternative embodiment, the cushion assembly 100 may include an upper layer 106 disposed on the top surface of the coil layer 104 and between the coil layer 104 and the elastomeric cushioning element 108. In such embodiment, the cushion assembly 100 includes a stabilization material 116 between the coil layer 104 and the upper layer 106. In some embodiments, an adhesive may be disposed between the stabilization material 116 and the upper surface of the upper layer 106. The upper layer 106 may comprise perforations to form a continuous internal space from the elastomeric cushioning element 108 to the coil layer 104. The perforations may vary in size across the entire length and width of the base layer or in the alternative the perforations may be uniform.

[0020] Referring now to FIG. 2, a perspective view of the elastomeric cushioning element 108 configured for use with the cushion assembly 100 of FIG. 1, in an exemplary embodiment. The elastomeric cushioning element 108 may include a singly molded elastomeric cushioning element 108. For example, the entirety of the elastomeric cushioning element 108 may be formed via a single molding process. In some embodiments, the elastomeric cushioning element 108 may include buckling walls 122. The buckling walls 122 of the elastomeric cushioning element 108 may be interconnected to one another and may define hollow columns 124 or voids in an expanded form. As used herein, the term “expanded form” means and includes a state in which an elastomeric cushioning element 108 has its original size and shape and wherein the buckling walls 122 are separated and define hollow columns 124. The buckling walls 122 may extend in two directions, intersecting at right angles, and defining square voids 126. However, in some embodiments, the buckling walls 122 may intersect at other angles and define voids 126 of other shapes, such as triangles, parallelograms, hexagons, etc.

[0021] The buckling walls 122 may be formed of an elastomeric material. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc. The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene / propylene or ethylene / butylene or ethylene / ethylene / propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi component thermoset elastomers.

[0022] The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.

[0023] Referring still to FIG. 2, a configuration of having the elastomeric cushioning element 108 disposed directly to the top of the coil layer 104 provide advantages. In such configurations, the coil layer 104 includes a plurality of pocketed coils 121 spaced apart in an array, and the elastomeric cushioning element 108 includes hollow columns 124.

[0024] Furthermore, the configuration does not include an upper layer 106 between the coil layer 104 and the elastomeric cushioning element 108, forming a continuous internal space composed of the space between the plurality of pocketed coils 121 and the hollow columns 124 of the elastomeric cushioning element 108. In some embodiments of the configuration, each pocketed coil 121 includes a coil topper 119 made of materials similar to an upper layer 106 such as foam. The foregoing configuration may make methods of manufacturing the cushion assembly 100 easier in comparison to conventional methods of manufacturing mattresses because it removes a need for an upper layer 106.

[0025] Referring still to FIG. 2, a configuration of having the coil layer 104 with the upper layer 106 on top of the coil layer 104 and the elastomeric cushioning element 108 on top of the upper layer 106 may provide advantages. Having the upper layer 106 between the coil layer 104 and the elastomeric cushioning element 108 provides a porous surface to adhere to both of the coil layer 104 and the elastomeric cushioning element 108. In such a configuration, the upper layer 106 may comprise perforations to form a continuous internal space from the elastomeric cushioning element 108 to the coil layer 104. The perforations may vary in size across the entire length and width of the base layer or in the alternative the perforations may be uniform.

[0026] Referring now to FIG. 3, a side view of an active airflow system 200 with a cushion assembly 100 of FIG. 1 is shown, according to an exemplary embodiment. The airflow system includes a cushion assembly 100 from FIG. 1. The cushion assembly 100 may include a base layer 102, a coil layer 104, an elastomeric cushioning element 108, an edge portion 109, one or more side panels 114, and the outer covering 112. The base layer 102 may have generally planar top and bottom surfaces. The coil layer 104 may be disposed on the top surface of the base layer 102. The elastomeric cushioning element 108 may be disposed over the coil layer 104. The edge portion 109 may extend around an outer peripheral edge of the elastomeric cushioning element 108. The one or more side panels 114 may extend along outer perimeters of the base layer 102. Furthermore, the one or more side panels 114 may extend within a plane perpendicular to a plane defined by the top surface of the base layer 102. The outer covering 112 may extend from the base layer 102 and may at least substantially encase the coil layer 104 and the elastomeric cushioning element 108. The side panels 114 may be impermeable or substantially impermeable to air. The outer covering 112 is configured to be permeable or substantially permeable to air. In some embodiments, the side panels 114 may be integrated into the outer covering 112 and may solely be fabric similar to the rest of the cover or may include additional fabric or quilted fabrics for a more robust side panel. In some embodiments, the upper layer 106 may comprise a polyurethane foam, a latex foam rubber, or any other suitable foam.

[0027] The coil layer 104 may include a plurality of coils 118 (e.g., steel coils), and each coil 118 of the plurality of coils 118 may be encased in at least one respective casing 120 (e.g., polypropylene socks or bags). Each casing 120 of each coil 118 of the plurality of coils 118 may be individual and discrete. In some embodiments, a pocketed coil 121 includes a casing 120 encasing a coil topper 119 positioned over a coil 118. A coil topper 119 comprises a compressible, resilient material or an elastomeric material. Each coil 118 of the plurality of coils 118 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer 102. Furthermore, the plurality of coils 118 may be spaced next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer 104. In some embodiments, a plurality of pocketed coils 121 with foam coil toppers 119 forms the coil layer 104 and the upper layer 106 as a unitary or substantially unitary layer.

[0028] The elastomeric cushioning element 108 include buckling walls 122. The buckling walls 122 of the elastomeric cushioning element 108 may be interconnected to one another and may define hollow columns 124 or voids in an expanded form. As used herein, the term “expanded form” means and includes a state in which an elastomeric cushioning element 108 has its original size and shape and wherein the buckling walls 122 are separated and define hollow columns 124. The buckling walls 122 may extend in two directions, intersecting at right angles, and defining square voids 126. However, in some embodiments, the buckling walls 122 may intersect at other angles and define voids 126 of other shapes, such as triangles, parallelograms, hexagons, etc.

[0029] Still referring to FIG. 3, the active airflow system 200 includes an air circulation device 220. The air circulation device 220 is an electromechanical device that can direct or ventilate air. As illustrated, the air circulation device 220 may be a fan. In some embodiments, the air circulation device 220 is capable of cooling, heating, or conditioning air. Additionally, the air circulation may be able to condition the air, altering the humidity of air. The air circulation device 220 is powered by a power source (e.g. battery, outlet, etc.). In the illustrated example, the air circulation device 220 is located at a proximal distance from the cushion assembly 100. In such embodiment, an air hose 225 is mechanically attached to the air circulation device 220 and directs airflow from the air circulation device 220. An air inlet 230 is an opening in a bottom surface of the base layer 102 of the cushion assembly 100 or a side panel 114 of the cushion assembly 100. The air inlet 230 provides access to a space within the coil layer 104. The air hose 225 is configured with the air inlet 230 to direct airflow from the air circulation device 220 to the space within the coil layer 104.

[0030] In some embodiments, the air circulation device 220 is physical attached to the bottom surface of the base layer 102 of the cushion assembly 100 or the side panel 114 of the cushion assembly 100 at the air inlet 230. Such embodiment does not use an air hose 225. In another embodiment, the air circulation device 220 is physically located in the space within the coil layer 104. Such embodiment does not use the air hose 225 or the air inlet 230. In some embodiments, the air circulation device 220 is located underneath the cushion assembly 100 and the bottom surface of the base layer 102 is permeable or substantially permeable to air. Such embodiment does not require an air hose 225 or air inlet 230. The air circulation device 220 directs airflow through the bottom surface of the base layer 102 and into the space within the coil layer 104.

[0031] Referring to the illustrated example in FIG. 3, in use, the air circulation device 220 conditions the temperature or humidity of air and directs the conditioned air through the air hose 225. The air hose 225 directs the conditioned air to the space within the coil layer 104. The conditioned air flows through the space in between the plurality of coils 118 in the coil layer 104. The conditioned air flows through the hollow columns or voids of the elastomeric cushioning element 108. The conditioned air flows through the outer covering 112.

[0032] In some embodiments, the temperature conditioning, humidity conditioning, or airflow by the air circulation device 220 can be manually set by a user. In another embodiment, the temperature conditioning, humidity conditioning, or airflow is automatically controlled by a control system that includes a sensor to detect the temperature or humidity of the environment, cushion assembly 100, or user.

[0033] In some embodiments, the outer covering 112 comprises multiple materials with different air permeability to create different zones of airflow through the cushion assembly 100. For example, a right side of the outer covering 112 may be made of a first permeability and the left side of the outer covering 112 may be made of a second permeability that is greater than the first permeability. This results in greater airflow to the left side of the cushion assembly 100 than the right side of the cushion assembly 100.

[0034] In another embodiment, an upper layer 106 is positioned in between the elastomeric cushioning element 108 and the coil layer 104. The upper layer 106 is made of a foam with a plurality of perforations. Each perforation has a diameter or width greater than a thickness of the upper layer 106. In such embodiment, conditioned air flows through the perforations.

[0035] In another embodiment, the air circulation device 220 may create a suctioning or vacuuming effect that pulls air. In use, the suctioning or vacuuming pulls air from the outer covering 112 to the elastomeric cushioning element 108. The suctioned air pulls through the elastomeric cushioning element 108 to the coil layer 104. The suctioned air pulls through the coil layer 104 and outside the cushion assembly 100.

[0036] Referring now to FIG. 4, a cross-sectional view of a cushion assembly 100 configured to be used with the active airflow system 200 of FIG. 3 is shown, according to an exemplary embodiment. The cushion assembly 100 may include a base layer 102, a coil layer 104, and an elastomeric cushioning element 108. The coil layer 104 may be disposed on a top surface of a base layer 102 and between the base layer 102 and an elastomeric cushioning element 108. In particular, the elastomeric cushioning element 108 may be disposed over and may at least substantially extend over the coil layer 104. One or more side panels 114 may extend along outer perimeters of the base layer 102 and may be disposed between the elastomeric cushioning element 108 and the base layer 102. Furthermore, the one or more side panels 114 may extend within a plane perpendicular to a plane defined by the top surface of the base layer 102.

[0037] In the exemplary embodiment, the coil layer 104 may include a plurality of pocketed coils 121. Each pocketed coil 121 of the plurality of pocketed coils 121 includes a coil 118, a coil topper 119, and a casing 120. Each casing 120 of each pocketed coil 121 may be individual and discrete. For example, each casing 120 may form a pocket for a respective coil 118 and a respective coil topper 119. In some embodiments, each coil 118 may include a relatively thin-gauge, barrel-shaped, knotless coil. In some embodiments, the casings 120 may include a polypropylene material. The casings 120 may include a two-ply polypropylene non-woven material. In some embodiments, each ply of the casings 120 may have a thickness within a range of about 0.10 mm and about 0.40 mm. As an example, each ply of the casings 120 may have a thickness within a range of about 0.15 mm and about 0.30 mm. However, any suitable material may be used. Additionally, each coil 118 of the plurality of pocketed coils 121 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer 102. Furthermore, the plurality of pocketed coils 121 may be spaced next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer 104.

[0038] Still referring to the exemplary embodiment of FIG. 4, a pocketed coil 121 includes a casing 120 encasing a coil 118 and a coil topper 119 positioned over a coil 118. In some embodiments, the coil topper 119 comprises a compressible, resilient material (e.g., polyurethane foam, a memory foam, a latex rubber foam, or any other suitable foam). In some embodiments, the coil topper 119 comprises an elastomeric material (e.g., a gelatinous elastomer, plasticized block copolymers, etc.). Each coil topper 119 may have any suitable shape (e.g., cylinder, puck, rectangular, etc.).

[0039] In the exemplary embodiment, the elastomeric cushioning element 108 is disposed on the top surface of the coil layer 104, and a stabilization material 116 is positioned to adhere the elastomeric cushioning element 108 to the coil layer 104. The elastomeric cushioning element 108 may include buckling walls 122. The buckling walls 122 of the elastomeric cushioning element 108 may be interconnected to one another and may define hollow columns 124 or voids in an expanded form. The buckling walls 122 may intersect at various angles and define voids 126 of many shapes, such as triangles, parallelograms, hexagons, etc. The elastomeric cushioning element 108 and the coil layer 104 are configured and oriented such that the hollow columns 124 form at least one continuous internal space with the space between the plurality of pocketed coils 121. A continuous internal space includes an uninterrupted void from the base layer 102 to a top surface of the elastomeric cushioning element 108.

[0040] In some embodiments, the coil layer 104 or more generally the cushion assembly 100 additionally includes at least one internal barrier. The internal barrier can divide the continuous internal space of the cushion assembly 100, particularly the coil layer 104 into a plurality of regions. In some embodiments, each internal barrier may extend along outer perimeters of the base layer 102 and may be disposed between the elastomeric cushioning element 108 and the base layer 102. Each internal barrier is impermeable or substantially impermeable, forming a plurality of regions. One or more of the internal barriers may extend across the coil layer 104, including longitudinally, laterally, and / or diagonally. In some embodiments, one or more of the internal barriers follows a straight path. In some embodiments, one or more of the internal barriers follows a path with one or more turns. In some embodiments, one or more of the internal barriers follows a curved path. One or more regions of the plurality of regions may be isolated from one or more other regions of the plurality of regions, such that an airflow in one region may be different than an airflow in another region. In the exemplary example, the coil layer 104 has a first internal barrier 300 and a second internal barrier 305. The first internal barrier 300 and a side panel 114 forms a first region 310. The first internal barrier 300 and the second internal barrier 305 forms a second region 320. The second internal barrier 305 and a side panel 114 forms a third region 330. The first internal barrier 300 and the second internal barrier 305 are substantially impermeable to form one or more isolated airflow regions. In use, each region facilitates airflow separately from airflow in another region (i.e., are isolated). For example, the first region 310 of the coil layer 104 facilitates a first airflow from the base layer 102 to a top surface of the elastomeric cushioning element 108. The second region 320 facilitates a second airflow from the base layer 102 to a top surface of the elastomeric cushioning element 108. In the exemplary embodiment, the second airflow is greater in airflow speed as denoted by the longer arrows in FIG. 4. The third region 330 facilitates a third airflow from a top surface of the elastomeric cushioning element 108 to the base layer 102. In the exemplary embodiment, the third airflow is in a different direction than the first and second airflow.

[0041] In some embodiments, a plurality of air circulation devices 220 generates a plurality of airflows that flows through the plurality of regions in the coil layer 104. For example, a first air circulation device generates the first airflow, a second air circulation device generates the second airflow, and a third air circulation device generates the third airflow.

[0042] In some embodiments, the cushion assembly 100 is comprised of one or more heat-activated materials. One or more portions of the cushion assembly 100 may include a heat-activated material as part of the threads or stitching securing the one or more portions together or to other components of the cushion assembly 100. In some embodiments, based on the temperature of the air circulation device 220, a stich density of a seam sewn with a heat-activated fabric can be adjusted if the temperature is at or above a heat-set temperature of the heat-activated material (e.g., the stiches can be tightened). Additional details regarding a heat-activated material for use in the cushion assembly 100 can be found in U.S. Provisional Application No. 63 / 691,833, filed Sep. 6, 2024, the entire disclosure of which are incorporated by reference herein.

[0043] In some embodiments, the cushion assembly 100 further includes an outer covering 112. The outer covering may comprise a stretchable material that is air permeable, such that airflow directed into or out of the hollow columns 124 is not completely obstructed and passes at least partially or substantially through the outer covering 112. The outer covering 112 may comprise different zones of air permeability. For example, one or more zones may be substantially impermeable to air, and / or one or more zones may be substantially permeable to air. In such embodiments, the zones on the outer covering 112 can correspond in amount, shape, and orientation of the plurality of regions.

[0044] As utilized herein, the terms “approximately,”“about,”“substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims. With respect to numerical values or ranges, the terms “approximately,”“about,”“substantially,” and similar terms generally mean±10% of the stated value.

[0045] The terms “coupled” as used herein means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0046] References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. References to at least one of a conjunctive list of terms may be construed as an inclusive OR to indicate any of a single, more than one, and all of the described terms. For example, a reference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only ‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunction with “comprising” or other open terminology can include additional items.

[0047] References herein to the positions of elements (e.g., “top,”“bottom,”“above,”“below,” etc.) are merely used to describe the orientation of various elements in the FIGURES It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0048] The construction and arrangement of the elements of the assembly as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied.

[0049] Additionally, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Rather, use of the word “exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

[0050] Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. For example, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein.

[0051] Also, for example, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

Claims

1. An active airflow system, comprising:a cushion assembly comprising:a base layer;a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils arranged in an array and spaced apart, each pocketed coil of the plurality of pocketed coils comprises of a coil topper disposed over a coil;an elastomeric cushioning element disposed over the coil layer, the elastomeric cushioning element comprising a plurality of interconnected buckling walls that define a plurality of hollow columns; andan outer covering disposed over the elastomeric cushioning element; andan air circulation device that can direct air to flow through the coil layer.

2. The active airflow system of claim 1, wherein the cushion assembly further comprises:an edge portion extending around an outer peripheral edge of the elastomeric cushioning element; anda plurality of side panels extending along outer perimeters of the base layer and an upper layer, each side panel disposed between the upper layer and the base layer.

3. The active airflow system of claim 2, wherein each side panel of the cushion assembly comprises a substantially impermeable material.

4. The active airflow system of claim 2, wherein the upper layer of the cushion assembly comprises a substantially permeable material.

5. The active airflow system of claim 1, wherein the active airflow system further comprises an air inlet that forms an opening in the base layer of the cushion assembly and is configured to facilitate the directed air flowing between the air circulation device and the coil layer of the cushion assembly.

6. The active airflow system of claim 5, wherein the active airflow system further comprises an air hose mechanically coupled to the air circulation device and configured to facilitate the directed air flowing between the air circulation device and the air inlet.

7. The active airflow system of claim 1, wherein the coil layer of the cushion assembly further comprises at least one internal barrier, at least one of the at least one internal barrier disposed between the elastomeric cushioning element and the base layer.

8. The active airflow system of claim 7, wherein the at least one internal barrier comprises a first internal barrier and a second internal barrier, wherein each of the first and second internal barriers is substantially impermeable to form an isolated airflow region.

9. The active airflow system of claim 8, wherein a first airflow in a first isolated airflow region is different from a second airflow in a second isolated airflow region.

10. The active airflow system of claim 1, wherein the outer covering is substantially permeable.

11. An active airflow system, comprising:a cushion assembly comprising:a base layer;a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils arranged in an array and spaced apart, each pocketed coil of the plurality of pocketed coils comprise of a coil topper disposed over a coil;a plurality of side panels integrated with a cushion cover extending along outer perimeters of the base layer and an upper layer, each side panel disposed between the upper layer and the base layer; anda single elastomeric cushioning element disposed over the upper layer; andan air circulation device that directs an airflow through at least a part of the coil layer.

12. The active airflow system of claim 11, wherein the coil layer of the cushion assembly further comprises a plurality of internal barriers extending along outer perimeters of the base layer and the upper layer, each internal barrier disposed between the upper layer and the base layer.

13. The active airflow system of claim 12, wherein a first internal barrier of the plurality of internal barriers and a first side panel of the plurality of side panels form a first region of the coil layer.

14. The active airflow system of claim 13, wherein the air circulation device directs the airflow through the first region of the coil layer.

15. The active airflow system of claim 14, wherein a second internal barrier of the plurality of internal barriers and a third internal barrier of the plurality of internal barriers form a second region of the coil layer.

16. The active airflow system of claim 15, wherein the active airflow system further comprises a second air circulation device that directs a second airflow through the second region of the coil layer.

17. The active airflow system of claim 16, wherein the first region comprises at least one heat-activated material, and wherein heating the first region at or above a heat-set temperature changes a first stitch density of the first region.

18. An active airflow system, comprising:a cushion assembly comprising:a base layer;a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils arranged in an array and spaced apart;an upper layer disposed over the coil layer, the upper layer comprising a foam with a plurality of perforations;an elastomeric cushioning element disposed over the upper layer, the elastomeric cushioning element comprising a plurality of interconnected buckling walls that define a plurality of hollow columns; andan outer covering disposed over the elastomeric cushioning element.

19. The active airflow system of claim 18, wherein the upper layer has a thickness and each perforation of the plurality of perforations has a diameter greater than the thickness of the upper layer.

20. The active airflow system of claim 19, wherein the active airflow system further comprises an air circulation device that is configured to direct air to flow through the array of the plurality of pocketed coils of the cushion assembly.

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