Seat cushion for pressure relieving support

Abstract

Disclosed is a cushioning structure that utilizes multiple layers of differing materials, each providing an aspect of comfort, cooling, and support for users in a sitting position. In one aspect, a first layer comprises an elastomeric gel supported on an intermediary transition layer followed by an intermediary gel memory foam layer and a fourth underlying foam layer. In another aspect, an additional layer circumscribes the four inner layers and comprises a thin fiber fill. In a further aspect, the cushioning structure may offer improved durability and use for several years without breakdown from use.

Description

PATENT APPLICATION Inventors: Wendell Alan Martens Docket No.: 58683-00005 TITLE SEAT CUSHION FOR PRESSURE RELIEVING SUPPORT CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The application claims priority to U.S. Patent Application No. 63 / 661,147, filed onJune 18, 2024, entitled “SEAT CUSHION FOR PRESSURE RELIEVING SUPPORT,” which is incorporated herein by reference in its entirety. FIELD OF THE INVENTION

[0002] The present disclosure relates generally to the field of chair cushions, seatingcushions, and other cushioning structures that provide both cushioning and support to users in a sitting position and that are resistant to breakdown over time. BACKGROUND

[0003] Sitting for prolonged periods of time without adequate support can have numeroushealth implications. For example, sitting can affect spinal alignment and posture as well as pressure and weight distribution of one’s body. Sitting without adequate support can cause pain in the hips and legs due to increased pressure against these areas, straining muscle groups, and can restrict circulation in the body which in turn can constrict and contort the lumbar curve, pinch the sciatica nerve, and result in pain or tingling sensations down the legs. Prolonged pressure on certain areas can also lead to the development of pressure points or sores, particularly in individuals who are disabled, immobile, or have limited ability to shift positions. Over time, these issues may contribute to chronic discomfort and even long-term musculoskeletal problems. Additionally, poor sitting habits can negatively impact overall mobility and quality of life. 1 36363701.4

[0004] Conventional chair cushions are inadequate to provide long term and consistentsupport for sitting. Initially, conventional cushions used latex with clay binder to provide their shape and support, but overtime, use of these cushions would breakdown the clay binder in the latex creating dust around the cushion. The cushion industry switched to polyurethane foam components, but virtually all sofas, pit groups, and chair cushions using polyurethane foam components breakdown beginning within 6 months to full breakdown between 2½ to 4 years. Moreover, layers of these cushions can be formulated in different densities and ILD ranges and, as a result, the overall durability and performance of the cushions remain inconsistent. Indentation Load Deflection—which is measured based on a load factor to compress the surface 25% of the thickness of the layer with measurements ranging from a super soft 10 to a semi-rigid 80—is one such variable indicator. Although most seat cushions have an estimated ILD range from 15 to 28 and foam density range from 1.8 to 2.2 lbs. per cubic foot, this can be variable and deteriorate over time.

[0005] Since most manufacturers purchase from multiple foam sources, even from the onset,the resulting cushions often suffer from differences in foam consistencies and wider specification deviation guidelines. This results in significant consistency differences in the comfort, support, and durability in the same SKU models. Such inconsistency and breakdown of the conventional cushions over time can cause increased counter pressure diminishing comfort and support which can cause pain of its users and result in poor customer satisfaction. As a result, consumers often experience premature sagging, loss of support, and discomfort, leading to frequent replacement or, at worst, physical pain and health issues with prolonged use of inadequate cushioning support.

[0006] There is thus a need for durable chair cushions, seating cushions, or other cushioningstructures that provide both cushioning and support to users in a sitting position and that are resistant to breakdown over time or sustainable for longer term durability. 2 36363701.4SUMMARY

[0007] The following presents a summary of this disclosure to provide a basic understandingof some aspects. This summary is intended to neither identify key or critical elements nor define any limitations of embodiments or claims. Furthermore, this summary may provide a simplified overview of some aspects that may be described in greater detail in other portions of this disclosure. Any of the described aspects may be isolated or combined with other described aspects without limitation to the same effect as if they had been described separately and in every possible combination explicitly.

[0008] Disclosed are embodiments of durable chair, lounge chair, recliner, and sofa cushions,seating cushions, sectional cushions, or other cushioning structures that provide both cushioning and support to users in a sitting position and that are resistant to breakdown over time. The disclosed cushioning structures can maintain their shape and performance, even after extended periods of regular use.

[0009] Disclosed is a cushioning structure that utilizes multiple layers of differing materials,each providing an aspect of comfort, cooling, and support for users in a sitting position. In one aspect, a first layer comprises an elastomeric gel supported on an intermediary transition layer followed by an intermediary gel memory foam layer and a fourth underlying foam layer. In another aspect, an additional layer circumscribes the four inner layers and comprises a thin fiber fill. In a further aspect, the cushioning structure may offer improved durability and use for several years without breakdown from use. In an embodiment, the disclosed cushioning structures may last an estimated 6 to 10 years with regular use.

[0010] Disclosed is a multi-layer seat cushion for pressure relieving support. In anembodiment, the cushion comprises a first layer comprising an elastomeric gel. In an embodiment, the cushion comprises a transition layer under the first layer, the transition layer comprising a latex material. In an embodiment, the cushion comprises a gel memory foam 3 36363701.4layer under the transition layer. In an embodiment, the cushion comprises a support layer under the gel memory foam layer, the support layer comprising a foam material. In an embodiment, the cushion comprises an outer fill layer circumscribing the first, transition, gel memory foam, and support layers, the outer fill layer comprising a fiber fill material. In an embodiment, the cushion comprises an outer fabric layer circumscribing the outer fill layer. In an embodiment, the cushion is configured to provide cushioning, cooling, and support to a user in a sitting position, and is resistant to breakdown over an extended period of use.

[0011] In an embodiment, either or both the first layer and the gel memory foam layer furthercomprises one or more additives selected from the group consisting of graphite, copper, and oxygel. In an embodiment, the first layer includes surface features comprising protrusions or depressions to enhance air flow and pressure support.

[0012] In an embodiment, the first layer comprises elastomeric gel supported in a foam layer.In an embodiment, the foam layer comprises patterning having valleys configured to receive the elastomeric gel and ridges configured to support the elastomeric gel. In an embodiment, the patterning of the foam layer is selected from the group consisting of hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, and “egg carton” shapes.

[0013] In an embodiment, the ridges of the foam layer and the elastomeric gel in the valleysof the foam layer are approximately the same height to provide a generally planar top surface of the first layer comprising foam and elastomeric gel. In an embodiment, the ridges of the foam layer extend slightly above the elastomeric gel in the valleys of the foam layer to provide protruding foam surface features on a top surface of the first layer. In an embodiment, the elastomeric gel in the valleys of the foam layer extend slightly above the ridges of the foam layer to provide protruding gel surface features on a top surface of the first layer. In an embodiment, the elastomeric gel is configured to fill the valleys of the foam layer and cover the ridges of the foam layer to provide a solid gel layer as a top surface of the first 4 36363701.4layer.

[0014] In an embodiment, the valleys of the foam layer extend partially through the foamlayer and do not extend fully through the foam layer. In an embodiment, the elastomeric gel is curable after 24 hours from application to the foam layer and becomes inseparable from the foam layer.

[0015] In an embodiment, the transition layer comprises a foamed latex selected from thegroup consisting of natural latex, synthetic latex, or a combination thereof. In an embodiment, the gel memory foam layer comprises a high-density, viscoelastic polyurethane foam infused with liquid polymer gel. In an embodiment, the support layer comprises polyurethane foam having a thickness selected based on the intended user’s body mass.

[0016] In an embodiment, the outer fill layer has a thickness of approximately 5 / 8 inches tominimize compression and surface breakdown. In an embodiment, the first layer is configured to absorb up to 17° F more body heat than foam, providing a cooling effect to the user. In an embodiment, the cushion has a total thickness in the range of about 4 to 12 inches. In an embodiment, the cushion is configured for use in transportation seating, home or office seating, outdoor seating, or as a supplemental cushion for wheelchairs and mobility devices. In an embodiment, the layers are adhered together by an adhesive, welding process, interlocking shapes, or are stacked and held together by the surrounding layers.

[0017] Disclosed is a multi-layer seat cushion for pressure relieving support. In anembodiment, the cushion comprises a first layer comprising an elastomeric gel supported in a foam layer. In an embodiment, the cushion comprises a transition layer under the first layer, the transition layer comprising a latex material. In an embodiment, the cushion comprises a gel memory foam layer under the transition layer. In an embodiment, the cushion comprises a foam support layer under the gel memory foam layer. In an embodiment, the foam layer comprises patterning having valleys configured to receive the elastomeric gel and ridges 5 36363701.4configured to support the elastomeric gel. In an embodiment, the cushion is configured to provide cushioning, cooling, and support to a user in a sitting position, and is resistant to breakdown over an extended period of use.

[0018] Disclosed is a multi-layer seat cushion for pressure relieving support. In anembodiment, the cushion comprises a first layer comprising an elastomeric gel supported in a foam layer. In an embodiment, the cushion comprises a transition layer under the first layer, the transition layer comprising a latex material. In an embodiment, the cushion comprises a gel memory foam layer under the transition layer. In an embodiment, the cushion comprises a foam support layer under the gel memory foam layer. In an embodiment, the foam layer comprises patterning having valleys configured to receive the elastomeric gel and ridges configured to support the elastomeric gel. In an embodiment, the patterning of the foam layer is selected from the group consisting of hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, and “egg carton” shapes. In an embodiment, the cushion is configured to provide cushioning, cooling, and support to a user in a sitting position, and is resistant to breakdown over an extended period of use.

[0019] In an embodiment, the ridges of the foam layer and the elastomeric gel in the valleysof the foam layer are approximately the same height to provide a generally planar top surface of the first layer comprising foam and elastomeric gel. In an embodiment, the ridges of the foam layer extend slightly above the elastomeric gel in the valleys of the foam layer to provide protruding foam surface features on a top surface of the first layer.

[0020] In an embodiment, the elastomeric gel in the valleys of the foam layer extend slightlyabove the ridges of the foam layer to provide protruding gel surface features on a top surface of the first layer. In an embodiment, the elastomeric gel is configured to fill the valleys of the foam layer and cover the ridges of the foam layer to provide a solid gel layer as a top surface of the first layer. In an embodiment, the valleys of the foam layer extend partially through the 6 36363701.4foam layer and do not extend fully through the foam layer. In an embodiment, the elastomeric gel is curable after 24 hours from application to the foam layer and becomes inseparable from the foam layer.

[0021] In an embodiment, the transition layer comprises a foamed latex selected from thegroup consisting of natural latex, synthetic latex, or a combination thereof. In an embodiment, the gel memory foam layer comprises a high-density, viscoelastic polyurethane foam infused with liquid polymer gel.

[0022] The following description and the drawings disclose various illustrative aspects. Someimprovements and novel aspects may be expressly identified, while others may be apparent from the description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present teachings may be better understood by reference to the following detaileddescription taken in connection with the following illustrations, in which like reference characters refer to like parts throughout, wherein:

[0024] FIG. 1 is a perspective view of an embodiment of a cushion system comprisingmultiple layers in accordance with aspects disclosed herein;

[0025] FIGs. 2A-B are cross sectional views of an embodiment of a cushion systemcomprising multiple layers in accordance with aspects disclosed herein;

[0026] FIGs. 3A-B are perspective views of an embodiment of a cushion system comprisingmultiple layers in accordance with aspects disclosed herein;

[0027] FIG. 4 is a perspective view of an embodiment of a cushion system comprisingmultiple layers in accordance with aspects disclosed herein;

[0028] FIGs. 5A-B are flow charts showing an embodiment of formation and arrangement ofa cushion system comprising multiple layers in accordance with aspects disclosed herein; and 7 36363701.4

[0029] FIGs. 6A-C show various seat and cushion applications that may be used with thedisclosed cushion system in accordance with aspects disclosed herein.

[0030] The invention may be embodied in several forms without departing from its spirit oressential characteristics. The scope of the invention is defined in the appended claims, rather than in the specific description preceding them. All embodiments that fall within the meaning and range of equivalency of the claims are therefore intended to be embraced by the claims. DETAILED DESCRIPTION

[0031] Reference will now be made in detail to exemplary embodiments of the presentteachings, examples of which are illustrated in the accompanying drawings, wherein like numbered aspects refer to a common feature throughout. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the present teachings. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the present teachings. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the present teachings.

[0032] In this disclosure, numerous specific details provide a thorough understanding of thesubject disclosure. It should be understood that aspects of this disclosure may be practiced with other embodiments not necessarily including all aspects described herein, etc.

[0033] As used herein, the words “example” and “exemplary” means an instance, orillustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather than exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another 8 36363701.4matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0034] Various aspects of the sitting cushion or other cushioning structure may be illustratedby describing components that are coupled, attached, and / or joined together. As used herein, the terms “coupled”, “attached”, and / or “joined” are interchangeably used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly attached”, and / or “directly joined” to another component, there are no intervening elements shown in said examples.

[0035] Various aspects of the sitting cushion or other cushioning structure may be describedand illustrated with reference to one or more exemplary implementations. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other variations of the devices, systems, or methods disclosed herein. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. In addition, the word “comprising” as used herein means “including, but not limited to”.

[0036] Relative terms such as “lower” or “bottom” and “upper” or “top” may be used hereinto describe one element's relationship to another element illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of aspects of the sitting cushion or other cushioning structure in addition to the orientation depicted in the drawings. By way of example, if aspects of the sitting cushion or other cushioning structure in the drawings are turned over, elements described as being on the “bottom” side of the other elements would then be oriented on the “top” side of the other elements as shown in the relevant drawing. The term “bottom” can therefore encompass both an orientation of 9 36363701.4“bottom” and “top” depending on the particular orientation of the drawing and unless context or this disclosure suggests otherwise. It is noted that the sitting cushion or other cushioning structure may have a preferred orientation or top and bottom use depending on the layer material and surface features.

[0037] It must also be noted that as used herein and in the appended claims, the singularforms “a”, “an”, and “the” include the plural reference unless the context clearly dictates otherwise. For example, although reference is made to “a” phase change material, “a” support material, “an” upper layer, “a” top layer, and “the” base layer, one or more of any of these components and / or any other components described herein can be used. For example, a particular “layer” may actually comprise one or more, or a plurality of, smaller layers to combine and form a larger layer. It is noted that the smaller layers may be oriented on the same axis as the larger layer or may be oriented in any other manner, such as perpendicularly. It is further noted that the smaller layers may comprise the same or different materials as one another, forming a larger layer comprised of one or more materials, e.g. uniformly or variedly.

[0038] Further, unless context suggest otherwise, descriptions of shapes (e.g., planar,circular, rectangular, triangular, etc.) refer to shapes meeting the definition of such shapes and general representation of such shapes. For instance, a triangular shape or generally triangular shape may include a shape that has three sides and three vertices or a shape that generally represents a triangle, such as a shape having three major sides that may or may not have straight edges, triangular like shapes with rounded vertices, etc.

[0039] Moreover, other than in any operating examples, or where otherwise indicated, allnumbers used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations 10 36363701.4that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0040] Notwithstanding that the numerical ranges and parameters setting forth the broadscope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art.

[0041] Further, as herein disclosed, the terms “substantially,” “about,” and variations thereofdescribe features that are equal or approximately equal to a value or characteristic, as desired, reflecting tolerances, conversion factors, rounding off, measurement error, acceptable variation thresholds, and the like. For example, unless context or this disclosure suggests otherwise, the term “substantially” includes values or characteristics that are exact or within 15% of exact (or what is stated), for example within 10% of exact, or within 5% of exact. In another example, unless context or this disclosure suggests otherwise, the term “about” includes values within .5 of a degree to 1 degree of exact (or what is stated).

[0042] Disclosed is a cushioning structure that utilizes multiple layers of differing materials,each providing an aspect of comfort, cooling, and support for users in a sitting position. In one aspect, a first layer comprises an elastomeric gel supported on an intermediary transition layer followed by an intermediary gel memory foam layer and a fourth underlying foam layer. In another aspect, an additional layer circumscribes the four inner layers and comprises a thin fiber fill. In a further aspect, the cushioning structure may offer improved durability 11 36363701.4and use for several years without breakdown from use. In an embodiment, the disclosed cushioning structures may last an estimated 6 to 10 years with regular use.

[0043] It is noted that the disclosed cushioning structures may be used for a chair, sittingdevice, or cushion, see FIGs. 6A-C showing several non-limiting example. For example, the disclosed cushioning structures can be used in transportation seating, such as automotive seating, car seating, truck seating, airplane seating, bus seating, and the like, see FIG. 6A, as well as home or office seating such as an office chair, couch, sectional pit group, sofa chair, armchair, lounge chair, dining chair, and the like, see FIG. 6B. The disclosed cushioning structures can also be used for outdoor seating, such as outdoor lounge chairs, couches, dining chairs, and the like. The disclosed cushioning structures can be used with wheelchairs and other mobility devices, to support users with diverse seating needs such as those who require long-term sitting or have limited movement.

[0044] It is further noted that the disclosed cushioning structures can be integrated into any ofthe foregoing or any other chair, seat, or cushion, or the disclosed cushioning structures can be provided as a separate cushion that may be placed and used on any of the foregoing or any other chair, seat, or cushion, see FIG. 6C, for example, showing several different types of supplemental seat cushions that may be adapted to the disclosed cushioning structures. It is noted that the separate or supplemental seat cushions may be any general shape or size, such as those shown in FIG. 6C as well as any other shapes or sizes that may be desired. It is also noted that the disclosed cushioning structures can be used to replace other cushions including broken down cushions, for example, including those that have zipper or removeable covers.

[0045] Turning to FIGs. 1-4, shown is an embodiment of a cushion 100. In an embodiment,cushion 100 may comprise four inner layers 110, 120, 130, 140. In an embodiment, the four inner layers 110, 120, 130, 140 may be oriented one on top of the other sequentially and in the same direction, e.g., parallel to one another. In an embodiment, the four inner layers 110, 12 36363701.4120, 130, 140 may each include top and bottom surfaces as well as four side surfaces, wherein the side surfaces are smaller in dimension or area than the top or bottom surfaces. It is noted that for each described layer, the top and bottom surfaces of that layer may directly contact or abut the top and bottom surfaces of the layers oriented above and below the described layer respectively. For example, a bottom surface of the first layer 110 may directly contact or abut a top surface of the transition layer 120 and vice versa. For example, a bottom surface of the transition layer 120 may directly contact or abut a top surface of the gel memory foam layer 130 and vice versa. For example, a bottom surface of the gel memory foam layer 130 may directly contact or abut a top surface of the support layer 140 and vice versa.

[0046] In an embodiment, cushion 100 may comprise a surrounding or outer fill layer 150that circumscribes the four inner layers 110, 120, 130, 140. In an embodiment, cushion 100 may comprise five layers including four inner layers 110, 120, 130, 140 and one surrounding or outer fill layer 150 that circumscribes the four inner layers 110, 120, 130, 140. In an embodiment, cushion 100 may comprise a surrounding or outer fabric layer 160 that circumscribes the surrounding or outer fill layer, which may act to hold the four inner layers 110, 120, 130, 140 together and to otherwise protect the four inner layers 110, 120, 130, 140 against the environment and from contact my a person sitting on the cushion 100. The outer fabric layer 160 may comprise a waterproof or water resistant fabric that may be particularly useful in an outdoor environment or on a boat. In an embodiment, cushion 100 may comprise six layers including four inner layers 110, 120, 130, 140, one surrounding or outer fill layer 150 that circumscribes the four inner layers 110, 120, 130, 140, and one surrounding or outer fabric layer 160 that circumscribes the surrounding or outer fill layer 150.

[0047] In an embodiment, cushion 100 may have a thickness range from about 4 to 12inches. In an embodiment, cushion 100 may be approximately 7.5 inches thick. In an 13 36363701.4embodiment, cushion 100 may have a width range from about 10 to 50 inches. In an embodiment, cushion 100 may be approximately 25 inches wide. In an embodiment, cushion 100 may have a length range from about 10 to 72 inches. In an embodiment, cushion 100 may be approximately 26 inches long. It is noted that other ranges and sizes are also herein contemplated and form a part of the disclosure. It is noted that the thickness of each layer may be generally adjusted as may be suitable or desired for a particular purpose. For example, the thicknesses of each layer may be approximately 0.5 inches to 3 inches. In an embodiment the gel layer 114 and / or first layer 110 may be approximately 0.5 inches thick. In an embodiment the transition layer 120 may be approximately 0.5 inches thick. In an embodiment, the gel memory foam layer 130 may be approximately 1 inch thick. In an embodiment, the gel memory foam layer 130 may be thicker than the gel layer 114 and / or first layer 110. In an embodiment, the gel memory foam layer 130 may be thicker than the transition layer 120. In an embodiment, the gel memory foam layer 130 may be approximately the same thickness as the combined thickness of the gel layer 114 and / or first layer 110 and the transition layer 120. In an embodiment, the support layer 140 may be approximately 2 inches to 10 inches thick.

[0048] Each of the multiple layers will have its own specifications, or ranges ofspecifications. Such specifications can include density, Indentation Load / Force Deflection (ILD or IFD), compression, elongation, tensile strength, tear strength, air flow and recovery time, all as measured by standards known in the art unless context or this disclosure suggests otherwise.

[0049] Generally, the disclosed cushion 100 may combine separate gel and foam layers (andlatex layers) which work together to provide superior envelopment, lower back support, adoptive comfort for the hips and thighs, does not restrict circulation, absorbs excess body heat, and do not collapse when two people are sitting side by side. Moreover, the disclosed 14 36363701.4cushion 100 can provide sustained support and structure over time, for example, having an expected useable life of 6 to 10 years or potentially even longer. In an embodiment, the gel and foam layers (e.g., gel 114 and foam 115 of first layer 110 and gel memory foam layer 130) may be separated by a latex layer (e.g., transition layer 120) and may further include a top surface layer of gel (e.g., gel 114) which may be provided as a separate planar layer or a layer of gel patterned and integrated into one of the foam layers (e.g., forming first layer 110). In an embodiment, the gel and foam layers (e.g., gel 114 and foam 115 of first layer 110 and gel memory foam layer 130) may provide cushioning and the latex layer (e.g., transition layer 120) may provide support separately or in addition to support layer (e.g., support layer 140). It is noted that layers of cushion 100 may be interchangeable or provided in a different order wherein the gel 114 is always on top or more specifically comprises the top layer.

[0050] In an embodiment, cushion 100 may include minimal fiber fill, for example, only anouter layer of fiber fill (e.g., outer fill layer 150) no more than approximately 1.5 inches that compresses to 5 / 8 inch, in an embodiment, so that the cushion 100 is not susceptible to the quick degradation that can occur with cushions having a greater amount of fiber fill material.

[0051] As described herein, most conventional retail cushions use thick layers of fiberfillpadding to soften a cheaper harder support foam layer. The padding of the fiberfill can be up to 4 or more inches thick. To further soften a cushion a "crown" design may be used in conventional cushions to create a raised bump on the surface covering most of the top surface. Within a very short time span, both examples of conventional cushions including thick fiberfill layers flatten out dramatically which creates increased painful counter pressure caused by the core against the legs and hips of the body. This also in turn can create pressure against the lumbar curve of the spine affecting the lower spine posture.

[0052] Cushion 100 may comprise a first layer 110. It is noted that first layer 110 may also15 36363701.4be referred to interchangeably as a top or upper layer unless context or this disclosure suggests otherwise. First layer 110 may comprise part of an inner core of layers (e.g., with transition layer 120, gel memory foam layer 130, and support layer 140). First layer 110 may be covered by a surrounding layer (e.g., outer fill layer 150). In an embodiment, first layer 110 may be a gel layer or may otherwise be formed, in whole or in part, of a gel material (e.g., polymer gel or polymer gel pattern). In an embodiment, first layer 110 may be a gel foam layer or may otherwise be formed, in whole or in part, of a gel (e.g., polymer gel, polymer gel pattern, elastomeric gel, and / or elastomeric gel pattern) and foam material (e.g., foam urethane and / or foam polyurethane and / or polyurethane foam with the properties of a latex or latex blend).

[0053] In an embodiment, first layer 110 may have a smooth, continuous, or planar exposedsurface. In an embodiment, first layer 110 may comprise one or more surface features 112, see, for example, FIG. 1. Surface features 112 may include protrusions and / or depressions (e.g., where the top surface is not smooth or continuous). Surface features 112 may provide air flow and / or additional pressure support to its users, e.g., the protrusions and / or depressions may be a shape and size that air may flow therebetween, which may provide a cooling effect. Surface features 112 may be uniform or may include any shapes, pattern, and size, as may be as may be suitable or desired for a particular purpose, e.g., for a cooling effect or for support. Surface features 112 may be formed from the gel, gel foam, foam, or other component of the first layer 110 as described herein. It is noted that surface features 112 may also be applied or formed separately onto the surface of the first layer 110.

[0054] In an embodiment, first layer 110 comprises an elastomeric gel. In an embodiment,first layer 110 comprises an elastomeric gel supported in a foam structure. In an embodiment, the first layer 110 may be or comprise a solid gel layer (e.g., gel 114). In an embodiment, the first layer 110 may be or comprise a solid gel layer (e.g., gel 114) alone or in combination 16 36363701.4with foam layer 115. In an embodiment, the solid gel layer 114 may have varying thicknesses and compositions as may be suitable or desired for a particular purpose. In an embodiment, the first layer 110 may comprise a gel layer (e.g., gel 114) poured onto or into a foam base (e.g., foam layer 115). In an embodiment, the foam base 115 may be patterned, including, for example, soccer ball or egg crate configurations comprising valleys and depths. It is noted the foam base 115 may be patterned with different configurations and depths.

[0055] In an embodiment, first layer 110 may comprise gel 114 and foam material 115. In anembodiment, first layer 110 may comprise patterning of the foam layer 115. Patterning may include, for example, hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, “egg carton,” or any other shape as may be suitable or desired for a particular purpose. Generally, in an embodiment, the foam layer 115 may include patterning that provides ridges and valleys wherein the valleys of the foam layer 115 are configured to receive and hold gel 114.

[0056] It is noted that the valleys and ridges may both have the same shape, e.g., hexagonal,“soccer ball,” circular, ovular, triangular, square, rectangular, etc. or that either the valleys for the gel 114 or the ridges of the foam 115 may have the described shape while the other comprises the negative or in-between space, e.g., “egg carton” shapes where, for example, one of gel 114 or foam 115 occupies the egg space (e.g., valleys) while the other occupies the carton space (e.g., ridges). In an embodiment, once applied, the gel 114 may enter into the valleys of the foam layer 115 and may abut the ridges of the foam layer 115.

[0057] In an embodiment, when the gel 114 is applied to the foam layer 115 the gel 114 andfoam 115 may provide a generally planar top surface of the first layer 110 having both gel 114 and foam 115 in a pattern. In an embodiment, when the gel 114 is applied to the foam layer 115, the ridges of the foam layer 115 may extend slightly above the gel 114 in the valleys of the foam layer 115, providing surface features, such as surface features 112. In an 17 36363701.4embodiment, when the gel 114 is applied to the foam layer 115, the gel in the valleys of the foam layer 115 may extend slightly above the ridges of the foam layer 115, providing surface features, such as surface features 112. As described, the gel 114 in the valleys of the foam layer 115 and the ridges of the foam layer 115 may also be approximately the same height, in an embodiment, such that the top surface includes both gel 114 and foam 115 in a pattern.

[0058] It is also noted that gel 114 may be applied into the valleys of the foam layer 115 aswell as extend on top of the ridges of the foam layer 115 so that the first layer 110 includes an inner patterning of gel 114 and foam 115, but the top surface of the first layer 110 is gel 114 (e.g., in different depths due to the patterning). It is noted that the bottom surface of the first layer 110 may be foam 115. It is also noted that the bottom surface of the first layer 110 may be gel 114 and foam 115 in a pattern, e.g., where the valleys of the foam 115, and therefore the gel 114 when thereto applied, extend through the bottom surface of the foam 115.

[0059] It is noted that the gel 114 may be cured after application to the patterned foam layer115. For example, the gel 114 may cure after approximately 24 hours. It is noted that the gel 114 may also cure in different time frames after application to the foam layer 115. After curing, the gel 114 may be considered integrated into the patterned foam layer 115 and inseparable from the patterned foam layer 115 (e.g., forming first layer 110). After curing, the gel 114 may not move from its position within the patterned foam layer 115 and may only selectively compressed under weight of a user, for example. Once the gel 114 is applied to the foam 115 and either before or after curing of the gel 114, a fabric layer may be applied to the surface of the first layer 110 and may stick or adhere to the exposed gel 114 surface of the first layer 110. In an embodiment, the gel 114 may be a soy based gel or petroleum that hardens into a polymer over time, exposure to the air, or the like. In an embodiment, the gel 114 may be self-extinguishing in case of fire.

[0060] In an embodiment, the first layer 110 may include one or more additives of graphite,18 36363701.4copper and / or oxygel. In an embodiment, the first layer 110 may include one or more coatings of coolluminate, thermic, graphite, and / or copper. In embodiments, the additives may be presented uniformly throughout the first layer 110, may be presented in different concentrations in different parts of the first layer 110, e.g., higher concentrations towards the top or bottom surfaces, or provided as part of a core of the first layer 110, and the like. In embodiments, the coatings may be provided around all surfaces of the first layer 110, exposed surfaces of the first layer 110, e.g., top and side surfaces, or just on the top surface, on the gel surface, and the like, for example.

[0061] In an embodiment, the first layer 110 may have one or more (or all) of the followingproperties: odorless; having a smooth or silky surface rather than porous; maintaining consistent levels of support, cushioning, envelopment, and recovery time over a range of ambient temperatures, for example, from approximately 50° to 96° F.

[0062] In an embodiment, first layer 110 may be approximately 0.5 to 3 inches thick. In anembodiment, first layer 110 may be approximately 1 inch thick. In an embodiment, first layer 110 may be approximately 0.5 inches thick. In an embodiment, the first layer 110 may have a foam thickness of approximately ½ of an inch to 4 inches with a gel depth in the pattern of approximately ¼ of an inch to 2 inches. In an embodiment, the first layer 110 may have a homogenous or patterned layer comprising foam, gel, both foam and gel, or either or both with any additional materials as may be desired. In an embodiment, the first layer 110 may have separate layers of foam and gel. For example, the first layer 110 may have a bottom layer of foam and a top layer of gel, or vice versa. In an embodiment, the first layer 110 may have separate layers of one or more of foam, gel, and any additional materials as may be suitable or desired for a particular purpose.

[0063] In an embodiment, first layer 110 may absorb up to 17° F more body heat than foam.In an embodiment, the gel material may serve as a heat sink to remove heat generated by a 19 36363701.4user's body that comes in contact with cushion 100 including such gel and thus provide a cooler surface temperate experience by the user by absorbing excess body heat. In combination with the foam in first layer 110 and other layers of cushion 100, cushion 100 may provide a cooling effect and cushion to its users. The cooling aspects of the first layer 110 (and gel material thereof) may help minimize discomfort and overheating of its user during prolonged use, e.g., it may prevent a user from sweating while sitting on the cushion 110 for a prolonged period of time.

[0064] In an embodiment, first layer 110 may serve as or comprise a pressure relievingmaterial and / or patterning surface features that support the hips, thighs, and body for its user. In an embodiment, first layer 110, and surface thereof, does not restrict circulation of its user and can prevent pressure points from occurring during use. In an embodiment, first layer 110, and surface thereof, may provide breathability and air flow between the cushion 100 and its user during use. In an embodiment, the gel or polymer gel used in the foam layer configuration of first layer 110 may not lose any of its pressure relieving properties for up to 15 years and may still provide adequate and consistent support to its users during this time.

[0065] Cushion 100 may comprise a transition layer 120. It is noted that transition layer 120may also be referred to interchangeably as a middle or intermediary unless context or this disclosure suggests otherwise. It is noted that transition layer 120 may also be referred to as a lower or upper layer in relation to first layer 110 or gel memory foam layer 130 and support layer 140, respectively. Transition layer 120 may comprise part of an inner core of layers (e.g., with first layer 110, gel memory foam layer 130, and support layer 140). Transition layer 120 may be covered by a surrounding layer (e.g., outer fill layer 150), or may have its edges or perimeter surrounded by first layer 110, support layer 140, or both. In an embodiment, transition layer 120 may be a latex layer or may otherwise be formed, in whole or in part, of a latex material (e.g., synthetic latex and / or natural latex). 20 36363701.4

[0066] In an embodiment, the transition layer 120 may have the following specifications:may also be used. For example,transition layer 120 may have an IFD 25% that goes up to 65 lbf. In embodiments, these specifications can change as the thickness of the transition layer 120 changes.

[0068] In an embodiment, transition layer 120 is a foamed latex layer, comprised of eithernatural, synthetic, or combined natural and synthetic latex. In an embodiment, transition layer 120 may comprise natural rubber latex or from one or more of such synthetic latexes as polybutadiene / styrene latex, polybutadiene / acrylonitrile latex, polychloroprene latex and the like or from a mixture of natural rubber latex and one or more such synthetic latexes. The latex foam includes conventional latex foam as well as viscoelastic latex foam. In an embodiment, the transition layer 120 is latex or a mixture of latex and foam. For example, transition layer 120 may comprise 50% natural latex and 50% synthetic latex. The distribution of materials within the transition layer 120 may be uniform or may be provided as smaller layers within the larger transition layer 120. An example of a latex foam product and processes for making such that can be used as the latex layer 102, in an exemplary embodiment, is disclosed in U.S. Pat. No. 10,842,290, which is incorporated herein by reference in its entirety.

[0069] In an embodiment, the latex blend may be microwaved in order to cure the latex in thetransition layer 120. In an embodiment, the transition layer 120 may comprise stable weight and firmness consistently across numerous cushions 100 and batches.

[0070] In an embodiment, transition layer 120 is a homogenous foam structure. Transition21 36363701.4layer 120 may possess an excellent hysteresis and has a high tensile strength. Transition layer 120 may exhibit humidity control and limits the amount of moisture absorbed. Transition layer 120 may have optimal ventilation properties throughout the foam structure to allow for temperature and humidity control throughout the layer and the assembled cushion 100. Transition layer 120 may provide support and pressure relief in a user’s hips and legs when sitting. In an embodiment, transition layer 120 may be approximately 0.5 to 3 inches thick. In an embodiment, transition layer 120 may be approximately 1 inch thick. In an embodiment, transition layer 120 may be approximately 0.5 inches thick.

[0071] In an embodiment, transition layer 120 may complement the first layer’s 110 ability toreduce counter pressure while the combination of layers may promote lower spinal support. Laboratory testing was performed to assess the durability of the transition layer 120 by rolling a roller 30,000 times across the surface which compares to 10 years of use. The test results found the surface of transition layer 120 broke down approximately 2%.

[0072] Cushion 100 may comprise a gel memory foam layer 130. It is noted that gel memoryfoam layer 130 may also be referred to interchangeably as a middle or intermediary unless context or this disclosure suggests otherwise. It is noted that gel memory foam layer 130 may also be referred to as a lower or upper layer in relation to first layer 110 and transition layer 120 or support layer 140, respectively. Gel memory foam layer 130 may comprise part of an inner core of layers (e.g., with first layer 110, transition layer 120, and support layer 140). Gel memory foam layer 130 may be covered by a surrounding layer (e.g., outer fill layer 150), or may have its edges or perimeter surrounded by first layer 110, support layer 140, or both. In an embodiment, gel memory foam layer 130 may be a gel memory foam layer or may otherwise be formed, in whole or in part, of a gel memory foam material.

[0073] In an embodiment, the gel memory foam layer 130 may have the followingspecifications: 22 36363701.4[ ple,gel memory foam layer 130 may have a density range from 2.5 lb / ft3up to 5.2 lb / ft3, to as high as 6 or 7 lb / ft3. In embodiments, these specifications can change as the thickness of the gel memory foam layer 130 changes.

[0075] In an embodiment, the gel memory foam layer 130 may be a gel-infused foam layer.In an embodiment, the gel memory foam layer 130 comprises a high-density, viscoelastic polyurethane foam infused with liquid polymer gel. It is understood that viscoelastic foam comprises mainly polyurethane mixed with other chemicals to increase its viscosity and elasticity and is commonly referred to as “memory foam.” In an embodiment, the gel memory foam layer 130 and foam or viscoelastic polyurethane foam thereof is reticulated to increase porousness and reduce density. In an embodiment, the gel memory foam layer 130 can envelop and reduce counter pressure on bodily protrusions. In an embodiment, the gel memory foam layer 130 provides a comfort layer and has fast recovery times after compression. In an embodiment, the gel memory foam layer 130 has a homogeneous consistency.

[0076] In an embodiment, the gel memory foam layer 130 and foam or viscoelasticpolyurethane foam thereof can be infused with gel polymers. In an embodiment, the gel infusion can reduce heat sensitivity and retention and decrease the “spring back” or “recovery” time of the foam within the gel memory foam layer 130. In an embodiment, the 23 36363701.4gel memory foam layer 130 may comprise beads containing the gel which is a phase change material and creates temperature stabilization or a cooling effect by changing from a solid to liquid state within in the capsule. In an embodiment, the gel memory foam layer 130 may comprise infused gel by swirling in liquid form. In both cases, this changing of the physical state alters the heat absorption properties of the memory foam to which the gel is infused.

[0077] In an embodiment, the gel memory foam layer 130 may include one or more additivesof graphite, copper and / or oxygel. In an embodiment, the gel memory foam layer 130 may include one or more coatings of coolluminate, thermic, graphite, and / or copper. In embodiments, the additives may be presented uniformly throughout the gel memory foam layer 130, may be presented in different concentrations in different parts of the gel memory foam layer 130, e.g., higher concentrations towards the top or bottom surfaces, or provided as part of a core of the gel memory foam layer 130, and the like. In embodiments, the coatings may be provided around all surfaces of the gel memory foam layer 130, exposed surfaces of the gel memory foam layer 130, e.g., top and side surfaces, or just on the top surface, and the like, for example.

[0078] In an embodiment, the gel memory foam layer 130 may have one or more (or all) ofthe following properties: odorless; having a smooth or silky surface rather than porous; maintaining consistent levels of support, cushioning, envelopment, and recovery time over a range of ambient temperatures, for example, from approximately 50° to 96° F.

[0079] In an embodiment, gel memory foam layer 130 may be approximately 0.5 to 3 inchesthick. In an embodiment, gel memory foam layer 130 may be approximately 2 inches thick. In an embodiment, gel memory foam layer 130 may be approximately 1 inch thick. In an embodiment, gel memory foam layer 130 is a homogenous foam structure. In an embodiment, gel memory foam layer 130 may complement the first layer’s 110 ability to provide cushioning support to a user. 24 36363701.4

[0080] Cushion 100 may comprise a support layer 140. It is noted that support layer 140 mayalso be referred to interchangeably as a bottom or lower layer unless context or this disclosure suggests otherwise. Support layer 140 may comprise part of an inner core of layers (e.g., with first layer 110, transition layer 120, and gel memory foam layer 130). Support layer 140 may be covered by a surrounding layer (e.g., outer fill layer 150). In an embodiment, support layer 140 may be a foam layer or may otherwise be formed, in whole or in part, of a foam material (e.g., polyurethane).

[0081] In an embodiment, the support layer 140 may have the following specifications:

[0082] It is noted that specifications outside of these ranges may also be used. Inembodiments, these specifications can change as the thickness of the support layer 140 changes. 25 36363701.4

[0083] In an embodiment, support layer 140 can be 1) made according to the HD23specifications above and be 3 inches thick for a cushion designed for a child or petite body mass adult, 2) made according to the HD36 specification and be 5 inches thick for a cushion designed for a normal-sized adult, e.g., up to and including 240 lbs., and 3) made according to the LUX specifications and be 5 inches thick for a cushion designed for a heavy adult, e.g., over 240 lbs. In an embodiment, the support layer 140 may be approximately 2 inches to 10 inches thick. In an embodiment, support layer 140 may be approximately 5 inches thick.

[0084] It is noted that for any layer comprising polyurethane foams (e.g., first layer 110, gelmemory foam layer 130, and / or support layer 140), various polyurethane foam blends or compositions may be utilized. For example, these layers may include viscoelastic and gel infused viscoelastic. For example, the polyurethane foam may be high-density polyurethane foam. Additional foams or elastics may be used which include copper, graphite and other infusion variations or latex and synthetic latex blends. Such combinations may also be used for transition layer 120.

[0085] It is noted that any layer may be generally homogenous or uniform, or may compriseone or more materials in layers, sections, or the like. It is also noted that any layer may be patterned including surface patterning or patterning that extends partially or completely through a layer. Patterning in the layers may include foam patterns, gel patterns, or patterns of any combination of components. For example, foam patterns may be combined with valleys of gel, in an example. It is noted that any layer may include a solid gel layer or a solid foam layer. For example, first layer 110 may include a solid gel layer on its surface (which can be patterned) where first layer 110 may comprise a gel and foam combination.

[0086] Cushion 100 may comprise an outer fill layer 150. It is noted that outer fill layer 150may also be referred to interchangeably as an outer, exterior, or surrounding layer unless context or this disclosure suggests otherwise. Outer fill layer 150 may cover or surround an 26 36363701.4inner core of layers (e.g., of first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140). Outer fill layer 150 may cover or surround an inner core of layers (e.g., of first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140) on all exposed surfaces (e.g., top, sides, and bottom of the inner core of layers). When arranged together, the exposed top, sides, and bottom of the inner core of layers may include top of first layer 110, e.g., also including gel surface thereof, sides of all first 110, transition 120, gel memory foam 130, and support 140 layers, and bottom of support layer 140. In an embodiment, outer fill layer 150 may be a fill layer or may otherwise be formed, in whole or in part, of a fill material (e.g., fiber fill padding).

[0087] In an embodiment, outer fill layer 150 may be approximately 5 / 8 inches thick. Thismay be thinner than layers in conventional cushions. Outer fill layer 150 may minimize the compression and surface breakdown of the padding to an estimated ¼ inch. This in turn may not show significant surface breakdown compared to conventional cushions which can use up to 2 inches or more of fiber fill. In conventional cushions, as the thicker fiber fill comfort layers breakdown, this can create increased counter pressure against the hips, thighs, and lower back of its users over time. In addition, unsightly depressions begin to form on the surface of the conventional cushion, which can impact its support of its users.

[0088] Cushion 100 may comprise an outer fabric layer 160. It is noted that outer fabric layer160 may also be referred to interchangeably as an outer, exterior or surrounding layer unless context or this disclosure suggests otherwise. Outer fabric layer 160 may cover or surround an inner core of layers (e.g., of first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140) and outer fill layer 150. Outer fabric layer 160 may cover or surround outer fill layer 150 on all exposed sides, which in turn covers or surrounds an inner core of layers (e.g., of first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140). In an embodiment, outer fabric layer 160 may be a fabric layer or may 27 36363701.4otherwise be formed, in whole or in part, of a fabric material.

[0089] As non-limiting embodiments, it is noted that any of the layers in cushion 100 may beadhered through one or more of an adhesive, a welding process, interlocking shapes, or may be stacked and held together by surrounding layers, for example.

[0090] Turning to FIGs. 5A-B, shown is an embodiment of a method 200 of forming cushion100, for example. Method 200 may comprise, in an embodiment, step 210 for forming a support layer (e.g., support layer 140). Method 200 may comprise, in an embodiment, step 220 for applying a gel memory foam layer onto the support layer (e.g., gel memory foam layer 130 and support layer 140). Method 200 may comprise, in an embodiment, step 230 for applying a transition layer onto the combined gel memory foam layer and support layer (e.g., transition layer 120, gel memory foam layer 130, and support layer 140). Method 200 may comprise, in an embodiment, step 240 for applying a gel layer onto the combined transition layer, gel memory foam layer, and support layer (e.g., first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140).

[0091] As non-limiting embodiments, it is noted that any of the layers in cushion 100 may beadhered through one or more of an adhesive, a welding process, interlocking shapes, or may be stacked and held together by surrounding layers, for example.

[0092] In an embodiment, the cushion 100 may be flappable and include the first layer 110,transition layer 120, and gel memory foam layer 130 also on the underside or opposite side of the support layer 140 (e.g., the same or opposite sequence as the layers on the top side of the support layer 140). In an embodiment, the support layer 140 may have the same layers (e.g., the first layer 110, transition layer 120, and gel memory foam layer 130) mirrored on each the top and the bottom side of the support layer 140.

[0093] It is noted that these steps 210, 220, 230, 240 may be reversed and begin with formingthe gel layer, applying the transition layer to the gel layer, applying the gel memory foam 28 36363701.4layer to the transition layer, and applying the support layer to the combined gel memory foam layer, transition layer, and gel layer. In an embodiment, method 200 may comprise applying each the gel layer and support layer to the transition layer or the gel memory foam layer in any order, sequentially, or simultaneously. The preceding steps 210, 220, 230, 240 may be used to form an inner core of layers. In an embodiment, each of these layers may be approximately the same length and width. In an embodiment, each of these layers may vary in thickness or may have approximately the same thickness as described herein.

[0094] Method 200 may comprise, in an embodiment, step 250 for applying an outer filllayer (e.g., outer fill layer 150) onto the combined layers forming the inner core of layers (e.g., first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140). In an embodiment, outer fill layer may fully surround the exposed top, bottom, and edges of the inner core of layers. Method 200 may comprise, in an embodiment, step 250 for applying an outer fabric layer (e.g., outer fabric layer 160) onto the fill layer (e.g., outer fill layer 150) and the combined layers forming the inner core of layers (e.g., first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140). In an embodiment, outer fabric layer may fully surround the top, bottom, and edges of the outer fill layer and the inner core of layers. It is noted that both or either the outer fill layer and / or the outer fabric layer may alternatively be planar layers similar to the layers of the inner core of layers.

[0095] As shown in FIG. 5B, step 240 for applying a gel layer onto the combined transitionlayer, gel memory foam layer, and support layer (e.g., first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140), may comprise multiple steps. Step 240 may comprise, in an embodiment, step 242, for applying a patterned foam layer onto the transition layer (e.g., patterned foam layer 115 and transition layer 120). Step 240 may comprise, in an embodiment, step 244, for applying a gel to the patterned foam layer (e.g., gel 114 and patterned foam layer 115). For example, a patterned foam layer (e.g., patterned foam layer 29 36363701.4115) may be applied onto the combined transition layer, gel memory foam layer, and support layer (e.g., transition layer 120, gel memory foam layer 130, and support layer 140) or may be applied to the transition layer (e.g., transition layer 120) separately form the other layers. For example, and gel (e.g., gel 114) may be applied to the patterned foam layer (e.g., patterned foam layer 115).

[0096] It is noted that patterning of the patterned foam layer (e.g., patterned foam layer 115)may occur prior to application of the patterned foam layer (e.g., patterned foam layer 115) to the transition layer (e.g., transition layer 120) or after. It is noted that application of the gel (e.g., gel 114) to the patterned foam layer (e.g., patterned foam layer 115) may occur prior to application of the patterned foam layer (e.g., patterned foam layer 115) to the transition layer (e.g., transition layer 120) or after.

[0097] For example, the patterning of foam layer (e.g., patterned foam layer 115) and / orapplication of gel (e.g., gel 114) may occur while already coupled with one or more of the other layers, such as one or more of the transition layer, gel memory foam layer, and support layer (e.g., transition layer 120, gel memory foam layer 130, and support layer 140). For example, the patterning of foam layer (e.g., patterned foam layer 115) and / or application of gel (e.g., gel 114) may occur separately from the other layers and may be applied to the transition layer (e.g., transition layer 120) as a single, formed layer (e.g., first layer 110), noting that transition layer may be alone or already coupled to one or more of the other layers, such as one or more of the gel memory foam layer, and support layer (e.g., transition layer 120, gel memory foam layer 130, and support layer 140).

[0098] As described herein, patterning of foam layer (e.g., patterned foam layer 115) maycomprise, hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, “egg carton,” or any other shape as may be suitable or desired for a particular purpose. As described herein, patterning of foam layer (e.g., patterned foam layer 115) may comprise 30 36363701.4ridges and valleys wherein the valleys are configured to receive and hold gel (e.g., gel 114).

[0099] As described herein, it is noted that the valleys and ridges may both have the sameshape, e.g., hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, etc. or that either the valleys for the gel (e.g., gel 114) or the ridges of the foam (e.g., foam 115) may have the described shape while the other comprises the negative or in-between space, e.g., “egg carton” shapes where, for example, one of gel (e.g., gel 114) or foam (e.g., foam 115) occupies the egg space (e.g., valleys) while the other occupies the carton space (e.g., ridges). In an embodiment, once applied, the gel (e.g., gel 114) may enter into the valleys of the foam layer (e.g., foam 115) and may abut the ridges of the foam layer (e.g., foam 115).

[0100] It is noted that the gel (e.g., gel 114) may be cured after application to thepatterned foam layer (e.g., patterned foam layer 115). For example, the gel (e.g., gel 114) may cure after approximately 24 hours. After curing, the gel (e.g., gel 114) may be considered integrated into the patterned foam layer (e.g., patterned foam layer 115) and inseparable from the patterned foam layer (e.g., patterned foam layer 115). After curing, the gel (e.g., gel 114) may not move from its position within the patterned foam layer (e.g., patterned foam layer 115) and may only selectively compressed under weight of a user, for example.

[0101] In an embodiment, before the outer fill layer (e.g., outer fill layer 150) isadded onto the combined layers forming the inner core of layers (e.g., first layer 110, transition layer 120, gel memory foam layer 130, and support layer 140), the assembly may be cut to size such that the resultant size fits on a chair or other sitting device. This may allow the combined layers forming the inner core to be larger in size and then cut down to the appropriate size before the outer fill layer is added. In an embodiment, after the outer fill layer (e.g., outer fill layer 150) is added onto the combined layers forming the inner core of layers (e.g., first layer 110, transition layer 120, gel memory foam layer 130, and support 31 36363701.4layer 140), the assembly may be cut to size such that the resultant size fits on a chair or other sitting device.

[0102] Although the embodiments of the present teachings have been illustrated inthe accompanying drawings and described in the foregoing detailed description, it is to be understood that the present teachings are not to be limited to just the embodiments disclosed, but that the present teachings described herein are capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof. 32 36363701.4

Claims

CLAIMS What is claimed is:

1. A multi-layer seat cushion for pressure relieving support, comprising:a first layer comprising an elastomeric gel; a transition layer under the first layer, the transition layer comprising a latex material; a gel memory foam layer under the transition layer; a support layer under the gel memory foam layer, the support layer comprising a foam material; an outer fill layer circumscribing the first, transition, gel memory foam, and support layers, the outer fill layer comprising a fiber fill material; and an outer fabric layer circumscribing the outer fill layer.

2. The seat cushion of claim 1, wherein either or both the first layer and gel memoryfoam layer further comprises one or more additives selected from the group consisting of graphite, copper, and oxygel.

3. The seat cushion of claim 1, wherein the first layer includes surface featurescomprising protrusions or depressions to enhance air flow and pressure support.

4. The seat cushion of claim 1, wherein the first layer comprises elastomeric gelsupported in a foam layer.

5. The seat cushion of claim 4, wherein the foam layer comprises patterning havingvalleys configured to receive the elastomeric gel and ridges configured to support the elastomeric gel.

6. The seat cushion of claim 5, wherein the patterning of the foam layer is selected fromthe group consisting of hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, and “egg carton” shapes.

7. The seat cushion of claim 5, wherein the ridges of the foam layer and the elastomeric33 36363701.4gel in the valleys of the foam layer are approximately the same height to provide a generally planar top surface of the first layer comprising foam and elastomeric gel.

8. The seat cushion of claim 5, wherein the ridges of the foam layer extend slightlyabove the elastomeric gel in the valleys of the foam layer to provide protruding foam surface features on a top surface of the first layer.

9. The seat cushion of claim 5, wherein the elastomeric gel in the valleys of the foamlayer extend slightly above the ridges of the foam layer to provide protruding gel surface features on a top surface of the first layer.

10. The seat cushion of claim 5, wherein the elastomeric gel is configured to fill thevalleys of the foam layer and cover the ridges of the foam layer to provide a solid gel layer as a top surface of the first layer.

11. The seat cushion of claim 5, wherein the valleys of the foam layer extend partiallythrough the foam layer and do not extend fully through the foam layer.

12. The seat cushion of claim 4, wherein the elastomeric gel is curable after 24 hoursfrom application to the foam layer and becomes inseparable from the foam layer.

13. The seat cushion of claim 1, wherein the transition layer comprises a foamed latexselected from the group consisting of natural latex, synthetic latex, or a combination thereof.

14. The seat cushion of claim 1, wherein the gel memory foam layer comprises a high-density, viscoelastic polyurethane foam infused with liquid polymer gel.

15. The seat cushion of claim 1, wherein the support layer comprises polyurethane foamhaving a thickness selected based on an intended user’s body mass.

16. The seat cushion of claim 1, wherein the outer fill layer has a thickness ofapproximately 5 / 8 inches to minimize compression and surface breakdown.

17. The seat cushion of claim 1, wherein the first layer is configured to absorb up to 17°F more body heat than foam, providing a cooling effect to the user. 34 36363701.

418. The seat cushion of claim 1, wherein the cushion has a total thickness in a range ofabout 4 to 12 inches.

19. The seat cushion of claim 1, wherein the cushion is configured for use intransportation seating, home or office seating, outdoor seating, or as a supplemental cushion for wheelchairs and mobility devices.

20. The seat cushion of claim 1, wherein the layers are adhered together by an adhesive,welding process, interlocking shapes, or are stacked and held together by surrounding layers.

21. A multi-layer seat cushion for pressure relieving support, comprising:a first layer comprising an elastomeric gel supported in a foam layer; a transition layer under the first layer, the transition layer comprising a latex material; a gel memory foam layer under the transition layer; a foam support layer under the gel memory foam layer; wherein the foam layer comprises patterning having valleys configured to receive the elastomeric gel and ridges configured to support the elastomeric gel.

22. The seat cushion of claim 21, wherein the patterning of the foam layer is selectedfrom the group consisting of hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, and “egg carton” shapes.

23. The seat cushion of claim 21, wherein the ridges of the foam layer and theelastomeric gel in the valleys of the foam layer are approximately the same height to provide a generally planar top surface of the first layer comprising foam and elastomeric gel.

24. The seat cushion of claim 21, wherein the ridges of the foam layer extend slightlyabove the elastomeric gel in the valleys of the foam layer to provide protruding foam surface features on a top surface of the first layer.

25. The seat cushion of claim 21, wherein the elastomeric gel in the valleys of the foamlayer extend slightly above the ridges of the foam layer to provide protruding gel surface 35 36363701.4features on a top surface of the first layer.

26. The seat cushion of claim 21, wherein the elastomeric gel is configured to fill thevalleys of the foam layer and cover the ridges of the foam layer to provide a solid gel layer as a top surface of the first layer.

27. The seat cushion of claim 21, wherein the valleys of the foam layer extend partiallythrough the foam layer and do not extend fully through the foam layer.

28. The seat cushion of claim 21, wherein the elastomeric gel is curable after 24 hoursfrom application to the foam layer and becomes inseparable from the foam layer.

29. The seat cushion of claim 21, wherein the transition layer comprises a foamed latexselected from the group consisting of natural latex, synthetic latex, or a combination thereof.

30. The seat cushion of claim 21, wherein the gel memory foam layer comprises a high-density, viscoelastic polyurethane foam infused with liquid polymer gel.

31. A multi-layer seat cushion for pressure relieving support, comprising:a first layer comprising an elastomeric gel supported in a foam layer; a transition layer under the first layer, the transition layer comprising a latex material; a gel memory foam layer under the transition layer; a foam support layer under the gel memory foam layer; wherein the foam layer comprises patterning having valleys configured to receive the elastomeric gel and ridges configured to support the elastomeric gel and wherein the patterning of the foam layer is selected from the group consisting of hexagonal, “soccer ball,” circular, ovular, triangular, square, rectangular, and “egg carton” shapes.

32. The seat cushion of claim 31, wherein the ridges of the foam layer and theelastomeric gel in the valleys of the foam layer are approximately the same height to provide a generally planar top surface of the first layer comprising foam and elastomeric gel.

33. The seat cushion of claim 31, wherein the ridges of the foam layer extend slightly36 36363701.4above the elastomeric gel in the valleys of the foam layer to provide protruding foam surface features on a top surface of the first layer.

34. The seat cushion of claim 31, wherein the elastomeric gel in the valleys of the foamlayer extend slightly above the ridges of the foam layer to provide protruding gel surface features on a top surface of the first layer.

35. The seat cushion of claim 31, wherein the elastomeric gel is configured to fill thevalleys of the foam layer and cover the ridges of the foam layer to provide a solid gel layer as a top surface of the first layer.

36. The seat cushion of claim 31, wherein the valleys of the foam layer extend partiallythrough the foam layer and do not extend fully through the foam layer.

37. The seat cushion of claim 31, wherein the elastomeric gel is curable after 24 hoursfrom application to the foam layer and becomes inseparable from the foam layer.

38. The seat cushion of claim 31, wherein the transition layer comprises a foamed latexselected from the group consisting of natural latex, synthetic latex, or a combination thereof.

39. The seat cushion of claim 31, wherein the gel memory foam layer comprises a high-density, viscoelastic polyurethane foam infused with liquid polymer gel. 37 36363701.4

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