Chipped foam support cushion

Abstract

A support cushion, such as a mattress, is provided that comprises an upper layer and a base layer. The upper layer has a top surface, a bottom surface, and sidewalls defining a cavity, with an amount of chipped foam positioned within the cavity, while the base layer is positioned below the bottom surface of the upper layer. The cavity of the support cushion can include one or more partitions to subdivide the cavity into two or more compartments. Mattresses are also provided and comprise an upper layer and a base layer. Methods of producing a support cushion are also provided and include steps of: providing an upper layer having a top surface, a bottom surface, and sidewalls defining a cavity; inserting an amount of chipped foam into the cavity; and attaching the upper layer to a base layer to thereby form the support cushion.

Description

CHIPPED FOAM SUPPORT CUSHIONRELATED APPLICATIONS

[0001] This application claims priority from U.S. Provisional Application Serial No. 63 / 727,452, filed December, 3, 2024, the entire disclosure of which is incorporated herein by this reference.TECHNICAL FIELD

[0002] The present invention relates to a support cushion. In particular, the present invention relates to a support cushion that includes a base layer and an upper layer, where the upper layer includes a cavity that is filled with an amount of chipped foam.BACKGROUND

[0003] An aspect of successful and restful sleep is individual sleep comfort and the support provided by a mattress, or other support cushion, is an important component of such sleep comfort. Medical research suggests that sleep deprivation (“sleep debt”) can have significant negative impacts on longevity, productivity, and overall mental, emotional, and physical health. Chronic sleep debt has been linked to weight gain and, more specifically, has been observed to not only affect the way the body processes and stores carbohydrates, but has also been observed to alter hormone levels that affect appetite. Moreover, sleep debt may result in irritability, impatience, inability to concentrate, and moodiness, which has led some researchers to suggest a link between sleep debt and worksite accidents, traffic incidents, and general afternoon inattentiveness. Furthermore, sleep disorders have been linked to hypertension, increased stress hormone levels, and irregular heartbeats, and additional research has recently suggested that a lack of sleep can affect immune function, resulting in increased susceptibility to illness and110613170:v3disease, e.g., cancer. In all, researchers have now suggested that sleep debt costs the United States billions of dollars annually in lost productivity due to these various effects.

[0004] With that in mind, a support cushion’s ability to provide the comfort and performance demanded by users necessarily relies on the underlying support structure of the cushion, including the support material used in the cushion. Commonly, layers of flexible foam, coil springs, or a hybrid of the two are used in support cushions to provide the requisite comfort and performance characteristics needed in the support cushion. To date, however, chipped foam has not been effectively and / or extensively utilized in these support cushions. Despite the ability of chipped foam to conform to the profile of the user’s body to a degree not achieved with other foam and / or spring embodiments, the use of chipped foam is often regarded as inferior to other type of support materials due to the fact that chipped foam may shift around during use, causing potential discomfort for the user and potentially creating an inconsistent thermal performance.

[0005] Accordingly, a support cushion that makes use of an amount of chipped foam in a manner that provides a consistent feel to a user without any loss in performance during use would be both highly desirable and beneficial.SUMMARY

[0006] The present invention includes support cushions with chipped foam provided as the support material to accommodate user comfort and performance preferences. In particular, certain embodiments of the present invention relate to support cushions that include an upper layer and a base layer, where the upper layer includes a cavity that is filled with an amount of chipped foam.210613170:v3

[0007] In one exemplary embodiment of the present invention, a support cushion is provided with an upper layer having a top surface, a bottom surface, and sidewalls to define a cavity. The upper layer includes an amount of chipped foam positioned within the cavity, and a base layer is then positioned below the bottom surface of the upper layer. In some embodiments, the support cushion is a mattress topper.

[0008] In some exemplary embodiments, the upper layer includes one or more partitions, wherein the one or more partitions subdivide the cavity into two or more compartments. In some other embodiments, the partitions are provided in a manner to define a desired shape. For instance, in some embodiments, the partitions are provided so that each compartment has a substantially square shape, or in some other embodiments, the partitions are provided so that the length and width of each compartment are different. Additionally, some embodiments include partitions such that an exemplary support cushion has three compartments extending along the width of the support cushion and four compartments extending along the length of the support cushion.

[0009] In other embodiments, the support cushion includes regions of compartments, including, in certain embodiments, a foot region, a torso region, and a head region, where the chipped foam of each region has a density and / or hardness tailored specific regions of the body. In such an embodiment, the chipped foam of the torso region has a greater density and / or hardness than the chipped foam of the foot region and the head region. In another embodiment, the support cushion includes additional regions, including a foot region, a thigh region, a torso region, a shoulder region, and a head region. In such embodiments, the amount of chipped foam of the foot region and the head region has a density and / or hardness less than that of the amount of chipped foam in the torso region. The amount of chipped foam in the thigh region and the310613170:v3shoulder region then has a density and / or hardness less than that of the amount of chipped foam in the torso region and greater than that of the amount of chipped foam in the head region.

[0010] In some embodiments of the support cushions of the present invention, the amount of chipped foam is compressed and / or compacted within the cavity. Additionally, in some other embodiments, the density and / or hardness of the chipped foam in each compartment of the two or more compartments in the same. In certain embodiments, the chipped foam is a polyurethane foam, and the chipped foam is, more specifically, viscoelastic foam in some exemplary embodiments. In further embodiments, the chipped foam material includes an additive selected from the group consisting of a moisture reducing material, a phase change material, and a fire retardant material.

[0011] With regard to additional layers that can added to the support cushion, in some embodiments, the support cushion further comprises a cover surrounding the support cushion. Additionally, a foam plate is positioned on top of the upper layer in some other embodiments.

[0012] To ensure the comfort and performance of the support cushion, a suitable base layer is provided. In some exemplary embodiments, the base layer comprises one or more layers of flexible foam. In other embodiments, the base layer comprises a plurality of coil springs. Meanwhile, some other embodiments comprise a base layer comprised of one or more layers of foam in combination with a plurality of coil springs.

[0013] Further provided, in some particular embodiments of the support cushions described herein, is a mattress including an upper layer having a top surface, a bottom surface, and sidewalls to define a cavity, where the upper layer has an amount of chipped foam positioned within the cavity. The mattress then further includes a base layer positioned below the bottom surface of the upper layer in some embodiments. In some embodiments, the base layer includes410613170:v3one or more layers of foam, a plurality of coil springs, or a combination thereof In further embodiments, the upper layer of the mattress includes one or more partitions, wherein the one or more partitions subdivide the cavity into two or more compartments.

[0014] The present invention further includes, in some implementations, methods of making a support cushion. In some implementations, a methods of making a support cushion comprises an initial step of providing an upper layer having a top surface, a bottom surface, and sidewalls defining a cavity. An amount of chipped foam is then inserted in the cavity and, subsequently, the upper layer is attached to a base layer to thereby form the support cushion. In some exemplary implementations of the methods, the upper layer includes one or more partitions, where the one or more partitions subdivide the cavity into two or more compartments, and where inserting the amount of chipped foam into the cavity comprises inserting an amount of chipped foam into each compartment of the two or more compartments. Further, in some exemplary methods, inserting the amount of chipped foam includes compressing or compacting the chipped foam within each compartment, and closing each compartment subsequent to compressing or compacting the chipped foam. In some other methods, inserting the amount of chipped foam includes providing an excess amount of chipped foam within each compartment of the two or more compartments so as to overfill each compartment.

[0015] Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a perspective view of an exemplary support cushion made in accordance with the present invention;510613170:v3

[0017] FTG. 2 is a partial cutaway view of the support cushion of FIG. 1 , where the base layer comprises a layer of flexible foam;

[0018] FIG. 3 is a partial cutaway view of another support cushion made in accordance with the present invention and similar to the support cushion of FIG. 1, but where the base layer comprises a plurality of coil springs;

[0019] FIG. 4 is a perspective view of an another support cushion made in accordance with the present invention and similar to the support cushion of FIG. 1, but where the upper layer comprises an alternative configuration of compartments;

[0020] FIG. 5 is a flow chart showing an exemplary method of making a support cushion in accordance with one implementation of the method;

[0021] FIG. 6 is a graph showing the results of experiments performed to compare heat index increases observed with a support cushion made in accordance with the present invention and comprising an amount of chipped foam versus those observed with a traditional flexible foam mattress over a five minute time period;

[0022] FIG. 7 is a graph showing the results of experiments performed to compare heat index increases observed with a support cushion made in accordance with the present invention and comprising an amount of chipped foam versus those observed with a traditional flexible foam mattress over a twenty minute time period; and

[0023] FIG. 8 is a graph showing the results of experiments performed to compare heat index increases observed with a support cushion made in accordance with the present invention and comprising an amount of chipped foam versus those observed with a traditional flexible foam mattress over an eight hour time period.610613170:v3DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0024] The present invention includes a support cushion, such as a mattress, with chipped foam serving as a support material. In particular, the present invention includes a support cushion having a base layer and an upper layer, where the upper layer includes a cavity that is filled with an amount of chipped foam. In some embodiments of the present invention, the inclusion of the chipped foam provides a better ability for the support cushion to conform to the profile of the user’s body and to do so to a degree not achieved by support cushions comprised of only layers of flexible foam and / or coil springs. Additionally, as opposed to support cushions formed solely from coil springs and / or layers of flexible foam, the use of chipped foam is believed to provide greater contact area and, in turn, provide a unique and customizable feel without also providing undesirable thermal performance characteristics.

[0025] Referring first to FIGS. 1-2, in one exemplary embodiment of the present invention, a an exemplary support cushion in the form of a mattress 10 is provided. The mattress 10 comprises an upper layer 20 and a base layer 30. The upper layer 20 is positioned above the base layer 30 and includes a top surface 21, a bottom surface 22, and sidewalls 23 which are joined together to collectively define a cavity 25. Partitions 40 are further included in the upper layer 20 and subdivide the cavity 25 into multiple separate compartments 50. In particular, in the mattress 10, the upper layer is subdivided into twelve individual compartments 50 with four of the compartments 50 extending along the length of the mattress 10, and with three of the compartments 50 extending along the width of the mattress 10.

[0026] As shown in FIGS. 1-2, each of the compartments 50 included in the upper layer 20 of the mattress 10 are substantially the same size and include a generally square shape with the length and width of each of the compartments 50 being substantially the same. Specifically, in710613170:v3the mattress 10, the compartments are typically constructed with the length and width of each of the compartments 50 being the same and in a range of between approximately 20 cm and 30 cm, while the height of each of the compartments 50 (i.e.,. the thickness of the upper layer 20) is also the same and is typically in the range of between approximately 10 cm and 30 cm. As such, in some embodiments, the compartments are described as having a substantially square shape. As used herein, a compartment is “substantially square” if the length and width dimensions of the compartment are within approximately ±10% of each other. In this regard, it is appreciated that that compartments in a mattress that are “substantially” the same can, in some embodiments, have variations of up to ±10% to account for variations in manufacturing mattresses, in mattress materials, in using rounded edges, as well as other commonly observed variations or practices that prevent construction of a mattress in a perfect geometric configuration. It is of course contemplated, however, that the compartments themselves need not necessarily have the same dimensions, but can also be provided in a number of sizes and configurations, including of different sizes and lengths, without departing from the spirit and scope of the present invention, and as may be necessary for a particular use or application.

[0027] Regardless of the particular dimensions of each of the compartments 50 included in the upper layer, to effectively form the partitions 40 and, in turn, each of the compartments 50, the upper layer 20 is typically constructed of single knit polyester jersey or light weight polypropylene non-woven (e.g., stitch bond, needle punch non-woven, or spun bond non-woven) that is sufficiently durable and capable of being joined together, such as by electronic heat sealing, ultrasonic welding, sewing, or other similar techniques known to those skilled in the art. For instance, in some embodiments that make use of a single knit polyester jersey to form the upper layer 20, the density of the single knit polyester jersey is in the range of about 100 g / m2to810613170:v3about 200 g / m2. Similarly, in some embodiments that make use of a light weight polypropylene non-woven material, the light weight polypropylene non-woven material has a density in the range of about 50 g / m2to about 100 g / m2.

[0028] Referring now more specifically to FIG. 2, to provide a support cushion capable of supporting a user in a desirable manner, each of the compartments 50 included in the upper layer 20 include an amount of chipped foam 24 that is used to fill each of the compartments 50 of the upper layer 20 of the mattress 10. Each piece of chipped foam 24 is generally comprised of a flexible foam suitable for providing a requisite amount of comfort and support to a user resting upon the upper layer 20 of the mattress 10. Such flexible foams capable of use in accordance with the present invention include, but are not limited to, latex foam, reticulated or nonreticulated viscoelastic foam (sometimes referred to as memory foam or low-resilience foam), reticulated or non-reticulated non-viscoelastic foam, polyurethane high-resilience foam, expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. In the embodiment shown in FIGS. 1-2, the chipped foam 24 is comprised of a viscoelastic foam that has a low resilience as well as a sufficient density, hardness, and compression characteristics that allows pressure to be absorbed uniformly and distributed among the pieces of chipped foam 24 included in the compartments 50 of the upper layer 20. Generally, such viscoelastic foams have a hardness of at least about 10 N to no greater than about 80 N, as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the material at approximately room temperature (i.e., 21°C to 23°C), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard. In some embodiments, the viscoelastic foams used in the chipped foam 24 have a910613170:v3hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70N, or about 80 N to provide a desired degree of comfort and body-conforming qualities.

[0029] The viscoelastic foam described herein for use with the chipped foam 24 of the mattress 10 can also have a density that assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability. In some embodiments, the viscoelastic foams used for the chipped foam 24 has a density of no less than about 30 kg / m3to no greater than about 150 kg / m3. In some embodiments, the density of the viscoelastic foams used with the chipped foam 24 is about 30 kg / m3, about 40 kg / m3, about 50 kg / m3, about 60 kg / m3, about 70 kg / m3, about 80 kg / m3, about 90 kg / m3, about 100 kg / m3, about 110 kg / m3, about 120 kg / m3, about 130 kg / m3, about 140 kg / m3, or about 150 kg / m3. Of course, the selection of a foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it is appreciated that a foam having a desired density and hardness, as well as a particular size, weight, and shape, can readily be selected for a particular application or support cushion as desired and in order to provide a support cushion, or mattress, having varying degrees of support and comfort to a user of such a support cushion made in accordance with the present invention. In this regard, in some embodiments, the foam used in accordance with the present invention can be further characterized or described using Indentation Force Deflection (“IFD”) testing methodologies, such as those found in ASTM D3574, which measures the firmness of a foam by compressing the foam sample to a specific percentage of its original height. In some embodiments, the flexible foam used with the support cushions of the present invention have an IFD of between 3 to 80 lbs. and a density of 1 to 7 lbs. per cubic foot. For example, in some1010613170:v3embodiments, the flexible foam used with the support cushions of the present invention have an IFD of 12 lbs. and a density of 4 lbs. per cubic foot.

[0030] With further regard to the chipped foam 24 included in each compartment 50 of the mattress 10, the chipped foam 24 can be produced in any manner desired, including without limitation by shredding, cutting, grinding, chopping, tearing, or ripping virgin, recycled, or scrap viscoelastic material, by molding or casting individual pieces, or in any other suitable manner. For instance, to produce the chipped foam 24 included in the mattress 10, an amount of flexible foam can be processed with a shredding or chipping machine having a 3 mm aperture to produce individual chipped foam pieces having dimensions ranging from about 0.3 cm to as long as about 4 cm in length. In some embodiments, by making use of such an automated process to produce the chipped foam 24, the chipped foam 24 can be produced to be a consistent dimensions (e.g., length) or can be made to have varying dimensions within the desired range of dimensions.

[0031] By making use of such dimensions for the chipped foam 24, the chipped foam 24 is configured such that upon insertion into each of the compartments 50 of the mattress 10, the chipped foam 24 can be inserted until it becomes compressed or compacted within the cavity or within each compartment to create a support cushion that meets an end user’s desired specifications. For instance, in some embodiments, the chipped foam 24 can be inserted in each compartment 50 and then compressed or compacted until the compartment is filled to a desired height using a high and low (go / no-go) measurement of the filled compartment. Such compartment height is of course typically dependent on the size of the compartment 50 and, in certain embodiments, can include a height of between 1 / 2” to 4”. Upon compression or compaction to a desired level, each compartment 50 can subsequently be closed (e.g., by1110613170:v3electronically heat sealing or sewn closed) to form the upper layer 20 and to thereby maintain the compression characteristics of the upper layer 20.

[0032] In some embodiments and to further provide a support cushion having a unique feel or characteristic, each of the compartments 50 is overfilled prior to compressing or compacting the chipped foam 24 to reduce the possibility of shifting of the chipped foam within the cavity or compartment. Moreover, and without wishing to be bound by any particular theory or mechanism, it is believed that the use of the chipped foam 24 with the characteristics described herein allows a support cushion to be produced having an increased contact surface area, which results in better pressure relief to users, and which provides better comfort and support when compared to other support cushions using foam plates or layers, coils springs, or some combination thereof. In particular, the characteristics described herein, including the increased contact surface area achieved through the use of the chipped foam are believed allow an exemplary support cushion of the present invention to conform more to the portion of the user’s body that comes into contact with the support cushion and thereby makes such an exemplary support cushion desirable for use over extended periods of time.

[0033] Referring still to FIGS. 1-2, as indicated above, the mattress 10 further includes a base layer 30 that is positioned below and provides support to the upper layer 20 of the support cushion 10. In the exemplary embodiment shown in FIGS. 1-2, the base layer 30 is comprised of a flexible foam having a sufficient density and hardness for supporting the upper layer 20 of the mattress 10, and will thus typically have a density and / or hardness greater than that of the flexible foam used with the chipped foam 24. In this regard, in the mattress 10, the base layer 30 is comprised of a single layer of flexible foam. However, in other embodiments, it is of course contemplated that an exemplary based layer for use with the support cushions of the present1210613170:v3invention can alternatively be comprised of one or more layers of foam connected together and as would be appreciated by those skilled in the art.

[0034] As a refinement to the support cushions of the present invention and although the support cushions are configured such that a user can rest his or her body or a portion thereof directly on the upper layer, it is additionally contemplated that a cover (not shown in the drawings) can be added on top of or surrounding the mattress 10. Such a cover can be in the form of a topper including an additional foam plate on top of the upper layer 20 of the mattress 10 or can be in the form of a quilted package manufactured using a knit or woven fabric and with additional quilted layers including various materials, e.g., foam or fiber, to provide an additional level of comfort to the user.

[0035] In addition to the use of a foam plate in a cover, it is further contemplated that, in some embodiments, a foam plate (not shown) alone is added on top of the mattress 10. Such a foam plate is provided on top of the upper layer 20 of the mattress 10 to provide additional support for the chipped foam and can further be refined to provide unique and customizable feel for the user. Additionally, multiple layers of foam plates are added on top of the upper layer 20 of the mattress 10 in some embodiments, however, it is still recognized that the support cushions of the present invention are configured such that a user can rest his or her body or a portion thereof directly on the upper layer.

[0036] As a further refinement to the present invention, and referring now to FIG. 3, another support cushion in the form a mattress 1 10 is provided. The mattress 1 10, similar to the mattress 10 shown in FIGS. 1-2, also includes an upper layer 120 and a base layer 130. The upper layer 120 is again positioned above the base layer 130 and likewise includes a top surface 121, a bottom surface 122, and sidewalls 123 which are joined together to collectively define a cavity1310613170:v3125. Partitions 140 are also further included in the upper layer 120 and subdivide the cavity 125 into multiple separate compartments 150. Unlike the mattress 10 shown in FIGS. 1-2, however, the upper layer 120 of the mattress 110 is subdivided into twenty individual compartments 150 with five of the compartments 150 extending along the length of the mattress 110, and with four of the compartments 150 extending along the width of the mattress 110. Also unlike the mattress 10 shown in FIGS. 1-2 and rather than including flexible foam in the base layer 130 of the mattress 110, the base layer 130 of the mattress 110 includes a plurality of coil springs 171 configured to provide the requisite support to the upper layer 120. Of course, it is further contemplated that base layers having various combinations of flexible foam, coil springs, and the like can also be utilized without departing from the spirit and scope of the subject matter described herein.

[0037] Referring now to FIG. 4, in another exemplary embodiment, a further support cushion in the form of a mattress 210 is provided. Similar to the mattress 10 shown in FIGS. 1-2, the mattress 210 also includes an upper layer 220 and a base layer 230. The upper layer 220 is also positioned above the base layer 230 and likewise includes a top surface 221, a bottom surface 222, and sidewalls 223 which are joined together to collectively define a cavity (not shown) including chipped foam and similar to that shown in FIGS. 1-3. Partitions 240 are also further included in the upper layer 220 and subdivide the cavity 225 into multiple separate compartments 250. In this exemplary embodiment, however, the upper layer 220 of the mattress is subdivided into three individual compartments 250 with the three compartments 250 collectively extending along the length of the mattress 210 and with each of the compartments 250 extending along the full width of the mattress 210.1410613170:v3

[0038] Referring still to FIG. 4, the compartments 250 included in the upper layer 220 of the mattress 210 are substantially the same size and include a generally rectangular shape, such that the length and width of each compartment are different from one another. More specifically, in the mattress 210, the compartments are constructed with the length of each compartment 250 being the same as the length of the other compartments 250 and in a range of between approximately 25 cm to 40 cm, while the width of each compartment 250 is also typically the same as the width of the other compartments 250 and is typically in the range of between approximately 60 cm and 90 cm. Also, the height of each of the compartments 250 (i.e., the thickness of the upper layer 220) is substantially the same and is typically in the range of approximately 10 cm to 30 cm.

[0039] In some embodiments, to further provide a unique and / or customizable feel to the exemplary support cushions of the present invention, the exemplary support cushions and, more specifically, the compartments formed in the upper layer of the exemplary support cushion can be further divided into regions of compartments where the density, hardness, or other (e.g., compression) characteristics of each region varies to provide a particular feel to the support cushions. For example, and with reference to FIGS. 1-2, the compartments 50 included in the mattress 10 are subdivided to include a foot region 60, a torso region 61, and a head region 62, where the density and / or hardness of the chipped foam 24 in the compartments 50 included in the torso region 61 is greater than the density and / or hardness of the chipped foam 24 included in the compartments 50 of the foot region 60 and in the head region 62. This, in turn, allows the chipped foam 24 in the head region 62 and the foot region 60 to have a soft or medium feel, while the chipped foam 24 in the torso region 61 has a medium or firm feel, and thereby also offers greater support in the torso region 61.1510613170:v3

[0040] Of course, additional or alternative compartments and regions having varying density and hardness characteristics can also be included in an exemplary support cushion as desired to provide different support profiles in an exemplary support cushion. As one example of such support cushions having additional regions, and referring now to FIG. 3, the mattress 110 is divided into five regions including a foot region 160, a thigh region 161, a torso region 162, a shoulder region 163, and a head region 164. In this configuration, the amount of chipped foam 124 in the foot region 160 and the head region 164 has a density and / or hardness less than that of the amount of chipped foam in the torso region 162. Meanwhile, the chipped foam 24 in the thigh region 161 and the shoulder region 163 are the same, and have a density and / or hardness less than that of the amount of chipped foam 124 in the torso region 162 but greater than that of the amount of chipped foam 124 in the head region 164 and the foot region 160. In other words, softer chipped foam 124 is provided in the foot region 160 and the head region 164, firmer chipped foam 124 is provided in the torso region 162, and chipped foam 124 having a moderate firmness is included in the thigh region 161 and the shoulder region 163 of the mattress 110.

[0041] As another nonlimiting example of such support cushions having regions of compartments, and referring now to FIG. 4, the mattress 210 is divided into three regions including include a foot region 260, a torso region 261, and a head region 262, where the density and / or hardness of the chipped foam (not shown) in the compartments 250 included in the torso region 261 is greater than the density and / or hardness of the chipped foam included in the compartments 250 of the foot region 260 and in the head region 262. These characteristics allow the chipped foam in the head region 262 and the foot region 260 to have a soft or medium feel, while the chipped foam in the torso region 261 has a medium or firm feel, and thereby also offers greater support in the torso region 261.1610613170:v3

[0042] In some embodiments, to further manipulate the hardness or density of the compartments included in an exemplary matter, additional material can also be added to the chipped foam, and can also be mixed in with the chipped foam to reduce humidity at the surface of the support cushion and create a comfortable microclimate for user. In some further embodiments, additives such as copper can also be utilized in the chipped foam material to improve the characteristics of the support cushion relative to moisture content and inhibition of mold growth. Other additives can also be included in the chipped foam material to improve the fire retardant characteristics of the foam and / or to improve the smell of the foam (e.g., carbon or charcoal additives). Still further, the chipped foam may be coated with, impregnated with, or otherwise include nanobionic materials or phase change materials (PCM). Additionally, the chipped foam may further include biocides, preservatives, odor blocking agents, scents, pigments, dyes, stain guards, antistatic agents, anti -soiling agents, water-proofing agents, moisture wicking agents, and the like, as are known in the art.

[0043] Referring now to FIG. 5, FIG. 5 includes a flow chart depicting an exemplary method of manufacturing a support cushion in accordance with one implementation of the present invention. In this implementation, to produce a support cushion such as a mattress, and as indicated by step 1000 in FIG. 5, a support cushion, such as one including an upper layer that has a top surface, a bottom surface, and sidewalls defining a cavity, is first provided and is subdivided into two or more compartments. An amount of chipped foam is then inserted into each compartment, as indicated by step 1100. Then, as indicated by step 1200, the chipped foam is compressed or compacted within each compartment. Following this, each compartment can be closed, as indicated by step 1300, and finally, the upper layer can be attached to a base layer to produce the support cushion, as indicated by step 1400. In some implementations, the upper1710613170:v3layer can be provided with one or more partitions that subdivide the cavity into the two or more compartments before the chipped foam is added to the compartments.

[0044] With respect to the exemplary support cushions described herein, while the support cushions are described with reference to a mattress that is typically dimensionally-sized to support a user lying in a supine or prone position, a support cushion made in accordance with the present invention may be embodied in a number of different structures to provide support to one or more portions of a user’s body. Accordingly, the phrase “support cushion” includes, but is not limited to, various types of support cushions including bedding and / or cushions for chairs and furniture, mattresses, pillows, padding for medical devices and equipment (e.g., wheelchair seat pads, wheelchair padding, medical pads, hospital gurney pads, operating table pads, positioning pads), padding for furniture (e.g., upholstery padding, furniture cushions, furniture pads), padding for athletic equipment and devices (e.g., athletic cushions, sports and athletic padding, gymnastic mats), padding for recreational equipment and devices (e.g., camping and sleeping mats), padding for household goods (e.g., anti-fatigue mats, mattress pads, mattress covers, mattress toppers, the pillow-top portion of pillow-top mattresses, pillows, and the like); padding accessories (e.g., briefcase shoulder straps, computer carrying cases, purses, gloves, and the like), pet beds, and the like. Thus any of these types of such structures, and others, may fall within the scope of the term “support cushion” and can be used interchangeably.

[0045] One of ordinary skill in the art will recognize that additional embodiments and methods are also possible without departing from the teachings of the present invention or the scope of the claims which follow the Example. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications1810613170:v3will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

[0046] The presently-disclosed subject matter is further illustrated by the following specific but non-limiting examples. The following examples are prophetic, notwithstanding the numerical values, results and / or data referred to and contained in the examples.EXAMPLES

[0047] The unique use of chipped foam material in place of traditional foam sheets was believed to result in a construction that did not result in negative impacts on thermal performance such that the use of chipped foam in a support cushion allowed for a unique feel while the thermal performance remained consistent with traditional foam support cushions. Tests were thus conducted to compare the heat index increase observed between support cushions comprised of chipped foam versus those comprised of foam layers. The heat index increase of chipped foam over the course of 5 minutes and 20 minutes was consistent with traditional foam constructions. In fact, chipped foam began to show a lower heat index increase than foam towards the end of each test. In the 5 minute test, chipped foam was just above a heat index increase of 35°F, while foam had a heat index increase of approximately 38°F (see FIG. 6). In the 20 minute test, chipped foam and foam had a heat index increase of approximately 24°F, with chipped foam having a heat index increase slightly lower than foam (see FIG. 7). The calculated heat index increase of chipped foam and foam over 8 hours was substantially similar, with both having a heat index increase around 52°F (see FIG. 8).1910613170:v3

Claims

CLAIMSWhat is claimed is:

1. A support cushion, comprising: an upper layer having a top surface, a bottom surface, and sidewalls defining a cavity, the upper layer including an amount of chipped foam positioned within the cavity; and a base layer positioned below the bottom surface of the upper layer.

2. The support cushion of claim 1 , wherein the upper layer includes one or more partitions, and wherein the one or more partitions subdivide the cavity into two or more compartments.

3. The support cushion of claim 2, wherein each compartment of the two or more compartments has a substantially square shape.

4. The support cushion of claim 2, wherein each compartment of the two or more compartments has a length and a width, and wherein the length and width of each compartment of each of the two or more compartments are different.

5. The support cushion of claim 2, wherein the support cushion comprises three compartments extending along a width of the support cushion and four compartments extending along a length of the support cushion.

6. The support cushion of claim 2, wherein the support cushion includes a foot region, a torso region, and a head region, and wherein the density and / or hardness of the chipped foam in2010613170:v3the torso region is greater than the density and / or hardness of the chipped foam in the foot region and the head region.

7. The support cushion of claim 2, wherein the support cushion includes a foot region, a thigh region, a torso region, a shoulder region, and head region, wherein the amount of chipped foam in the foot region and the head region has a density and / or hardness less than that of the amount of chipped foam in the torso region, and wherein the amount of chipped foam in the thigh region and the shoulder region has a density and / or hardness less than that of the amount of chipped foam in the torso region and greater than that of the amount of the chipped foam in the head region.

8. The support cushion of 2, wherein the density and / or hardness of the amount of thechipped foam in each compartment of the two or more compartments is the same.

9. The support cushion of claim 1, wherein the amount of chipped foam is compressed and / or compacted within the cavity.

10. The support cushion of claim 1, wherein the support cushion further comprises a cover surrounding the support cushion.

11. The support cushion of claim 1 , wherein the support cushion further comprises a foam plate positioned on top of the upper layer.

12. The support cushion of claim 1 , wherein the support cushion is a mattress topper.2110613170:v313. The support cushion of claim 1, wherein the chipped foam is a polyurethane foam.

14. The support cushion of 13, wherein the chipped foam is a viscoelastic foam.

15. The support cushion of claim 1, further comprising an additive selected from the group consisting of a moisture reducing material, a phase change material, and a fire retardant material; and wherein the additive is added to the chipped foam.

16. The support cushion of claim 1, wherein the base layer comprises one or more layers of a flexible foam.

17. The support cushion of claim 1 , wherein the base layer comprises a plurality of coil springs.

18. The support cushion of claim 1 , wherein the base layer comprises one or more layers of foam in combination with a plurality of coil springs.

19. A mattress, comprising: an upper layer having a top surface, a bottom surface, and sidewalls defining a cavity, the upper layer including an amount of chipped foam positioned within the cavity; and a base layer positioned below the bottom surface of the upper layer, the base layer including one or more layers of foam, a plurality of coil springs, or a combination thereof.2210613170:v320. The mattress of cl im 19, wherein the upper layer includes one or more partitions, and wherein the one or more partitions subdivide the cavity into two or more compartments, each of the two or more compartments including an amount of the chipped foam.

21. A method of producing a support cushion, comprising the steps of: providing an upper layer having a top surface, a bottom surface, and sidewalls defining a cavity; inserting an amount of chipped foam into the cavity; and attaching the upper layer to a base layer to thereby form the support cushion.

22. The method of claim 21, wherein the upper layer includes one or more partitions, the one or more partitions subdividing the cavity into two or more compartments, and wherein inserting the amount of chipped foam into the cavity comprises inserting an amount of chipped foam into each compartment of the two or more compartments.

23. The method of claim 22, wherein inserting the amount of chipped foam includes compressing or compacting the chipped foam within each compartment, and closing each compartment subsequent to compressing or compacting the chipped foam.

24. The method of ciaim 22, wherein inserting the amount of chipped foam includes providing an excess amount of chipped foam within each compartment of the two or more compartments so as to overfill each compartment.2310613170:v3

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