Cushions including buckling columns with a plurality of buckling points

Abstract

A cushion includes interconnected walls that define an array of buckling columns. Each buckling column of the array of buckling columns includes a plurality of buckling points at different elevations along a height of the buckling column. The buckling points buckle under different loads. Methods of designing cushions with a plurality of buckling points are also disclosed.

Description

CUSHIONS INCLUDING BUCKLING COLUMNS WITH A PLURALITY OFBUCKLING POINTSCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Patent Application No. 18 / 769,123, filed July 10, 2024, the entire disclosure of which is incorporated by reference herein.TECHNICAL FIELD

[0002] This disclosure relates generally to cushions and, more specifically, to cushions that include interconnected walls that define arrays of buckling columns. Even more specifically, this disclosure relates to cushions with interconnected walls that impart the buckling columns with a plurality of buckling points that buckle under a corresponding plurality of different loads. Methods of designing cushions that included buckling columns with a plurality of buckling points are also disclosed.RELATED ART

[0003] Cushions with interconnected walls that define arrays of buckling columns are typically made from gel elastomers. Examples of such cushions are disclosed by U.S. Patents 5,749,111, 6,026,527, and 7,060,213, the entire disclosures of which are hereby incorporated herein. Examples of the materials from which such cushions may be made are disclosed by the same patents, as well as by U.S. Patents 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein. Buckling reduces interface pressures between a subject and the cushion. Conventionally, however, the buckling columns of such cushions buckle at a single location, or elevation, across the heights of the walls. Buckling typically occurs when a buckling column is subjected to a set amount of force, or weight. When the force, or weight, applied to a buckling column exceeds the force, or weight, required to buckle that column, that buckling column continues to apply pressure to a portion of the subject supported by the buckling column. That pressure may be uncomfortable to the subject and potentially cause pressure damage to the subj ect.SUMMARY

[0004] A cushion of this disclosure includes a plurality of interconnected walls defining an array of buckling column. Each wall of the plurality of walls may buckle at a plurality of defined locations, or elevations or “buckling points.” Each buckling point may be located at a defined elevation along the height of the wall. In some embodiments, the walls of the cushion may impart each buckling column of the cushion and, thus, the cushion, with at least two buckling points; for example, a base buckling point and a top buckling point. In other embodiments, the walls of the cushion may impart the cushion and its buckling columns with three buckling points; for example, a base buckling point, a middle buckling point, and a top buckling point. Each buckling point of a cushion and its buckling columns may be located at an intermediate location, or elevation, within a corresponding region of the wall.

[0005] In some embodiments, each wall of the plurality of interconnected walls of a cushion of this disclosure may have a plurality of different thicknesses. More specifically, in reference to the height of each wall, a base of each wall may have a base thickness, a top of each wall may have a top thickness, and, in embodiments where the wall includes a middle, the middle of the wall may have a middle thickness. Each wall may include one or more ledges. For example, a wall with a base and a top may include a ledge between the base and the top. A wall with a base, a middle, and a top may include a base ledge between the base and the middle and a top ledge between the middle and the top. One or more of the base thickness, the optional middle thickness, and the top thickness may be uniform. A buckling point may be located at an intermediate location, or elevation, of each portion of each wall. For example, a base buckling point may be located along an intermediate location, or elevation of the base of the wall, an optional middle buckling point may be located along an intermediate location, or elevation, of the optional middle of the wall, and a top buckling point may be located along an intermediate location, or elevation, of the top of the wall.

[0006] A method for designing a cushion with buckling columns that buckle at a plurality of locations, or buckling points, includes determining a thickness of the cushion and, thus, a height of each buckling column of the cushion, determining a number of buckling points to be provided along the height of each buckling column and a location of eachbuckling point along the height of each buckling column, and determining a threshold load required to cause each buckling point of the buckling column to buckle. The location of each buckling point and the load under which it buckles may be defined by one or more of a material from which the walls of the buckling column are formed, a thickness of the portion of the wall in which the buckling point is located (i.e., a base, a middle, or a top), a height of the portion of the wall in which the buckling point is located, and a cross- sectional shape and dimensions of the buckling column. Thus, one or more of these factors may be adjusted to adjust the location of each buckling point and / or a load under which each buckling point buckles.

[0007] Other features of the disclosed subject matter, as well as features and advantages of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the drawings:

[0009] FIG. l is a first perspective view of a portion of an embodiment of a cushion with interconnected walls that define buckling columns with two buckling points, depicting different portions of the interconnected walls with different thicknesses;

[0010] FIG. 2 is a top view of the portion of the embodiment of the cushion shown in FIG. 1;

[0011] FIG. 3 is a cutaway perspective view of the portion of the embodiment of the cushion shown in FIG. 1, showing interior surfaces of the buckling columns;

[0012] FIG. 4 is a second perspective view of the portion of the embodiment of the cushion shown in FIG. 1, showing only external surfaces of the buckling columns of the cushion;

[0013] FIGs. 5 and 6 are cross-sectional representations of a buckling column of the portion of the embodiment of the cushion shown in FIG. 1, depicting how the buckling column may buckle under different loads;

[0014] FIG. 7 is a first perspective view of a portion of an embodiment of a cushion with interconnected walls that define buckling columns with three buckling points, depicting different portions of the interconnected walls with different thicknesses;

[0015] FIG. 8 is a top view of the portion of the embodiment of the cushion shown in FIG. 7;

[0016] FIG. 9 is a cutaway perspective view of the portion of the embodiment of the cushion shown in FIG. 7, showing interior surfaces of the buckling columns;

[0017] FIG. 10 is a second perspective view of the portion of the embodiment of the cushion shown in FIG. 7, showing only external surfaces of the buckling columns of the cushion;

[0018] FIGs. 11-13 are cross-sectional representations of a buckling column of the portion of the embodiment of the cushion shown in FIG. 7, depicting how the buckling column may buckle under different loads;

[0019] FIG. 14 is a schematic representation of an embodiment of a mattress that includes a cushion of this disclosure;

[0020] FIG. 15 is a schematic representation of an embodiment of a pillow that includes a cushion of this disclosure; and

[0021] FIG. 16 is a schematic representation of an embodiment of a seat cushion that includes a cushion of this disclosure.DETAILED DESCRIPTION

[0022] FIGs. 1-4 show a portion of an embodiment of a cushion 10 that includes a plurality of interconnected walls 20 that define an array of buckling columns 40. Each wall 20 has two buckling points 32, 36 (and may include additional buckling points) along its height, including a base buckling point 32 at a lower elevation and a top buckling point 36 at a higher elevation. As depicted by FIGs. 1-4, the cushion 10 may be configured similarly to the cushions of U.S. Patent Application No. 18 / 528,273, filed on December 4, 2023 and titled ELASTOMERIC CUSHIONING ELEMENTS WITHSUBSTANTIALLY CYLINDRICAL COLUMNS (“the ’273 Application”), the entire disclosure of which is hereby incorporated herein. Alternatively, the cushion 10 may be configured similar to any of the cushions of U.S. Patents 5,749,111, 6,026,527, and 7,060,213.

[0023] The interconnected walls 20 may be formed from any suitable material. The material from which the interconnected walls 20 are made may comprise a compressible, resilient material. Some non-limiting examples of compressible, resilient materials that are suitable for forming the wall are disclosed by U.S. Patents 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein by reference. The compressible, resilient material used to form the interconnected walls may comprise a thermoplastic elastomer (TPE). The thermoplastic elastomer may comprise a block copolymer (e.g., a triblock copolymer, such as an A-B-A triblock copolymer, etc.). The thermoplastic elastomer may be part of an elastomeric gel. The elastomeric gel may comprise a plasticizer-extended block copolymer. These plasticizer-extended block copolymers include plasticizer-extended A-B-A block copolymers, such as oil-extended styrene-[ethylene-(ethylene-propylene)]-styrene (SEEPS) block copolymers, oil-extended styrene-(ethylene-butylene)-styrene (SEBS) block copolymers, and other oil extended A- B-A block copolymers. Other copolymers are also considered, including A-B-C copolymers. Alternatively, the interconnected walls 20 may be formed from other materials, such as rubber (e.g., natural latex, polyurethane, butyl rubber, etc.), foam rubber (e.g., natural latex, polyurethane, viscoelastic foams, etc.), silicones, silicone copolymers, hydrogels, or any other suitable material.

[0024] Each wall 20 may include a base 22 and a top 26. Optionally, a ledge 23 may delineate the base 22 from the top 26. As FIG. 4 illustrates, an outer surface 42 of each buckling column 40 may be substantially smooth. Thus, the optional ledge(s) 23 of each buckling column 40 may be confined to an interior surface 46 of the buckling column 40, within a void 45 of the buckling column 40, as depicted by FIGs. 2 and 3. While FIGs. 2 and 3 illustrate each optional ledge 23 as being located on an interior surface 46 of a buckling column 40, within a void 45 of the buckling column 40, embodiments in which the optional ledges 23 are additionally or alternatively located on an outer surface 42 of each column 40 are also within the scope of this disclosure. The ledge 23 may be abrupt(e.g., perpendicular, substantially perpendicular, etc., to the orientation of the interior surface 46) or it may comprise a taper.

[0025] The base 22 of each wall 20 may have a base thickness 22t. The top 26 of each wall 20 may have a top thickness 26t. The base thickness 22t may be greater than the top thickness 26t. One or both of the base thickness 22t and the top thickness 26t may be substantially uniform. As depicted, both the base thickness 22t and top thickness 26t are substantially uniform.

[0026] Each buckling point 32 and 36 of a wall 20 may extend laterally across the wall 20 and, thus, laterally across a portion of the cushion 10. The base buckling point 32 of each wall 20 may extend laterally across an intermediate elevation of the base 22 of the wall 20. The top buckling point 36 of each wall 20 may extend laterally across an intermediate elevation of the top 26 of the wall 20.

[0027] FIGs. 5 and 6 depict how a buckling column 40 of the cushion of FIGs. 1-4 may buckle. In particular, FIG. 5 depicts the manner in which the buckling column 40 may respond to a load L (e.g., force or weight) applied to a top 41 of the buckling column 40. As the load L is equal to or greater than a threshold buckling load of a top buckling point 36 of the wall(s) 20 that define the buckling column 40, the top buckling point 36 buckles under the load L. If the load L on the top 41 of the buckling column 40 does not equal or exceed a threshold buckling load of the base buckling point 32 of the wall(s) 20 that define(s) the buckling column 40 (which is greater than the threshold buckling load of the top buckling point 36), no further buckling may occur. If, however, the load equals or is greater than the threshold buckling load of the base buckling point 32, the buckling column 40 will then start to buckle along the base buckling point 32, as depicted by FIG. 6. Such compound buckling of the buckling column 40 may reduce the amount of interface pressure applied to the portion of the subject that rests against the top 41 of the buckling column 40.

[0028] Turning now to FIGs. 7-10, another embodiment of a cushion 10' is depicted. The cushion 10' includes a plurality of interconnected walls 20' that define an array of buckling columns 40'. Each wall 20' has three buckling points 32', 34', 36' along its height, including a base buckling point 32' at a lower elevation, a middle buckling point34' at a central elevation, and a top buckling point 36' at a higher elevation. As depicted by FIGs. 7-10, the cushion 10' may be configured similarly to the cushions of the ’273 Application. Alternatively, the cushion 10' may be configured similar to any of the cushions of U.S. Patents 5,749,111, 6,026,527, and 7,060,213.

[0029] The interconnected walls 20' may be formed from any suitable material. The material from which the interconnected walls 20' are made may comprise a compressible, resilient material. Some non-limiting examples of compressible, resilient materials that are suitable for forming the wall are disclosed by U.S. Patents 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein by reference. The compressible, resilient material used to form the interconnected walls may comprise a thermoplastic elastomer (TPE). The thermoplastic elastomer may comprise a block copolymer (e.g., a triblock copolymer, such as an A-B-A triblock copolymer, etc.). The thermoplastic elastomer may be part of an elastomeric gel. The elastomeric gel may comprise a plasticizer-extended block copolymer. These plasticizer-extended block copolymers include plasticizer-extended A-B-A block copolymers, such as oil-extended styrene-[ethylene-(ethylene-propylene)]-styrene (SEEPS) block copolymers, oil-extended styrene-(ethylene-butylene)-styrene (SEBS) block copolymers, and other oil extended A- B-A block copolymers. Alternatively, the interconnected walls 20' may be formed from other materials, such as rubber (e.g., natural latex, polyurethane, silicone, butyl rubber, etc.), foam rubber (e.g., natural latex, polyurethane, viscoelastic foams, etc.), or any other suitable material.

[0030] Each wall 20' may include a base 22', a middle 24', and a top 26'. Optionally, a base ledge 23' may delineate the base 22' from the middle 24' and / or a top ledge 25' may delinate the middle 24' from the top 26'. As FIG. 7 illustrates, an outer surface 42' of each buckling column 40' may be substantially smooth. Thus, the optional base ledge(s) 23' and / or top ledge(s) 25' of each buckling column 40' may be confined to an interior surface 46' of the buckling column 40', within a void 45' of the buckling column 40', as depicted by FIGs. 8 and 9. While FIGs. 8 and 9 illustrate each optional base ledge 23' and top ledge 25' as being located on an interior surface 46' of a buckling column 40', within a void 45' of the buckling column 40', embodiments in which the optional base ledges 23'and / or top ledges 25' are additionally or alternatively located on an outer surface 42' of each column 40' are also within the scope of this disclosure.

[0031] The base 22' of each wall 20' may have a base thickness 22t'. The middle 24' of each wall 20' may have a middle thickness 24t'. The top 26' of each wall 20' may have a top thickness 26t '. The base thickness 22t' may be greater than the middle thickness 24t' and the top thickness 26t'. The middle thickness 24t' may be greater than the top thickness 26t'. One, two, or all of the base thickness 22t', the middle thickness 24t', and the top thickness 26 / may be substantially uniform. As depicted, all of the base thickness 22 / , the middle thickness 24 / , and the top thickness 26 / are substantially uniform.

[0032] Each buckling point 32', 34', and 36' of a wall 20' may extend laterally across the wall 20' and, thus, laterally across a portion of the cushion 10'. The base buckling point 32' of each wall 20' may extend laterally across an intermediate elevation of the base 22' of the wall 20'. The middle buckling point 34' of each wall 20' may extend laterally across an intermediate elevation of the middle 24' of the wall 20'. The top buckling point 36' of each wall 20' may extend laterally across an intermediate elevation of the top 26' of the wall 20'.

[0033] FIGs. 11-13 depict how a buckling column 40' of the cushion of FIGs. 7-10 may buckle. In particular, FIG. 11 depicts the manner in which the buckling column 40' may respond to a load L' (e.g., force or weight) applied to a top 41' of the buckling column 40'. As the load L' is equal to or greater than a threshold buckling load of a top buckling point 36' of the wall(s) 20' that define the buckling column 40', the top buckling point 36' buckles under the load L'. If the load L' on the top 41' of the buckling column 40' does not equal or exceed a threshold buckling load of the middle buckling point 34' of the wall(s) 20' that define(s) the buckling column 40' (which is greater than the threshold buckling load of the top buckling point 36'), no further buckling may occur. If, however, the load equals or is greater than the threshold buckling load of the middle buckling point 34', the buckling column 40' will then start to buckle along the middle buckling point 34, as depicted by FIG. 12. If the load L' on the top 41' of the buckling column 40' does not equal or exceed a threshold buckling load of the base buckling point 32' of the wall(s) 20' that define(s) the buckling column 40' (which is greater than the threshold buckling load of the middle buckling point 34'), no further buckling may occur. If, however, the loadequals or is greater than the threshold buckling load of the base buckling point 32', the buckling column 40' will then start to buckle along the base buckling point 32', as depicted by FIG. 13. Such compound buckling of the buckling column 40 may reduce the amount of interface pressure applied to the portion of the subject that rests against the top 41 of the buckling column 40.

[0034] With returned reference to FIGs. 1-4 and 7-10, a method for designing a cushion 10, 10' includes determining a thickness of the cushion 10, 10' and, thus, a height of each buckling column 40, 40' of the cushion 10, 10', determining a number of buckling points 32, 36; 32', 34', 36' to be provided along the height of each buckling column 40, 40' and a location of each buckling point 32, 36; 32', 34', 36' along the height of each buckling column 40, 40', and determining a threshold load required to cause each buckling point 32, 36; 32', 34', 36' of the buckling column 40, 40' to buckle. The location of each buckling point 32, 36; 32', 34', 36' and the load under which it buckles may be defined by one or more of a material from which the walls 20, 20' of the buckling column 40, 40' are formed, a thickness of the portion of the wall 20, 20' in which the buckling point 32, 36; 32', 34', 36' is located (i.e., a base 32, 32', a middle 34', or a top 36, 36'), a height of the portion of the wall 20, 20' in which the buckling point 32, 36; 32', 34', 36' is located, and a cross-sectional shape and dimensions of the buckling column 40, 40'. Thus, one or more of these factors may be adjusted to adjust the location of each buckling point 32, 36; 32', 34', 36' and / or a load under which each buckling point 32, 36; 32', 34', 36' buckles.

[0035] Turning now to FIG. 14, an embodiment of a mattress 100 is shown. The mattress 100 includes a primary cushion 110, a base cushion 120 beneath the primary cushion 110, and a cover 130 that partially holds the primary cushion 110 and the base cushion 120 in an assembled relationship. The primary cushion 110 may comprise a cushion (e.g., cushion 10, cushion 10', etc.) of this disclosure. The base cushion 120 may comprise a suitable base for a mattress, including without limitation, a block of foam, coil springs, one or more pressurizable chambers, or the like. The cover 130 may be pliable and comprise any fabrics or other materials that are suitable for holding the internal elements of the mattress 100 in place and for defining an exterior of the mattress 100.

[0036] FIG. 15 is a schematic representation of an embodiment of a pillow 200. The pillow 200 includes a cushion 210. Optionally, the pillow 200 may include a cover 230over the cushion 210. The cushion 210 may comprise a cushion (e.g., cushion 10, cushion 10', etc.) of this disclosure. The cover 230 may comprise a fabric or any other suitable cover for a pillow. The cover 230 may limit exposure of the cushion 210 to body oils, hair, dander, and other contaminants. In some embodiments, the cover 230 may enhance the performance of the pillow 200.

[0037] FIG. 16 shows an embodiment of a seat cushion 300. The seat cushion 300 includes a cushion 310 , which may comprise a cushion (e.g., cushion 10, cushion 10', etc.) of this disclosure. Optionally, the cushion 310 may be assembled with other components of the seat cushion 300, such as other cushioning layers, a cover, or the like.

[0038] While buckling columns with a plurality of buckling points may be showcased with a substantially circular cross-sectional design, it will be appreciated that buckling columns of any geometric cross-sectional shape, including any other circular or polygonal cross-sectional design, with a plurality of buckling points are contemplated herein.

[0039] Although the disclosure provides many specifics, the specifics should not be construed as limiting the scope of any of the claims, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter that fall within the scopes of the claims. Other embodiments of the disclosed subject matter may be devised that are also within the scopes of the claims. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.

Claims

What is claimed:

1. A cushion, comprising: a plurality of interconnected walls defining an array of buckling columns, each wall of the plurality of interconnected walls having a height and including a base buckling point extending laterally across the wall at a lower elevation along the height of the wall and a top buckling point extending laterally across the wall at a higher elevation along the height of the wall to enable each buckling column of the array of buckling columns to buckle at at least two elevations.

2. The cushion of claim 1, wherein the base buckling point is located at an intermediate elevation within a base of the wall and the top buckling point is located at an intermediate elevation within a top of the wall.

3. The cushion of claim 2, wherein the base of the wall has a base thickness and the top of wall has a top thickness.

4. The cushion of claim 3, wherein the base thickness is greater than the top thickness.

5. The cushion of claim 1, wherein the base buckling point has a base buckling threshold and the top buckling point has a top buckling threshold.

6. The cushion of claim 5, wherein the base buckling threshold is greater than the top buckling threshold.

7. The cushion of claim 1, wherein each wall of the plurality of interconnected walls further includes a middle buckling point extending laterally across the wall to enable each buckling column to buckle at a third elevation.

8. The cushion of claim 7, wherein the base buckling point is located at an intermediate elevation within a base of the wall, the middle buckling point is located at an intermediate elevation within a middle of the wall, and the to buckling point is located at an intermediate elevation within a top of the wall.

9. The cushion of claim 8, wherein the base of the wall has a base thickness, the middle of the wall has a middle thickness, and the top of the wall has a top thickness.

10. The cushion of claim 9, wherein the base thickness is greater than the middle thickness and the middle thickness is greater than the top thickness.

11. The cushion of claim 8, wherein the base buckling point has a base buckling threshold, the middle buckling point has a middle buckling threshold, and the top buckling point has a top buckling threshold.

12. The cushion of claim 11, wherein the top buckling threshold is less than the middle buckling threshold and the middle buckling threshold is less than the base buckling threshold.

13. A cushion, comprising: a plurality of interconnected walls defining an array of buckling columns, each wall of the plurality of interconnected walls having a height and including a base with a base thickness at a lower portion of the height of the wall and a top with a top thickness at a higher portion of the height of the wall, each buckling column including an interior surface defining a void extending along a height of the buckling column.

14. The cushion of claim 13, wherein each wall of the plurality of walls further includes a ledge between the base and the top.

15. The cushion of claim 14, wherein the ledge is part of the interior surface of the void of the at least one buckling column.

16. The cushion of claim 15, wherein at least one of the base thickness and the top thickness is substantially uniform.

17. The cushion of claim 16, wherein the base thickness and the top thickness are both substantially uniform.

18. The cushion of claim 13, wherein each wall of the plurality of interconnected walls further includes a middle with a middle thickness at an intermediate portion of the height of the wall.

19. The cushion of claim 18, wherein each wall of the plurality of interconnected walls further includes a base ledge between the base and the middle and a top ledge between the middle and the top.

20. The cushion of claim 19, wherein at least one of the base thickness, the middle thickness, and the top thickness is substantially uniform.

21. The cushion of claim 20, wherein at least two of the base thickness, the middle thickness, and the top thickness are substantially uniform.

22. The cushion of claim 21, wherein the base thickness, the middle thickness, and the top thickness are all substantially uniform.

23. The cushion of claim 13, wherein the base thickness and the top thickness enable each buckling column of the plurality of buckling columns to buckle at a plurality of elevations.

24. A method for designing a cushion, comprising: determining a thickness of the cushion and a height of interconnected walls and buckling columns of the cushion; determining a number of buckling points to be provided along the height of each buckling column of the buckling columns of the cushion; and determining a threshold load required to cause each buckling point of the plurality of buckling points to buckle.

25. The method of claim 24, wherein determining the number of buckling points comprises determining a number of lateral regions of each wall of the plurality of interconnected walls, from a base of the wall to a top of the wall.

26. The method of claim 25, wherein determining the number of lateral regions comprises determining a height and a thickness of each lateral region of the plurality of lateral regions.

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