Cushioning elements with pressurizable cells

Abstract

A cushioning element includes pressurizable cells. The pressurizable cells of the cushioning elements are grouped into a plurality of sets, with each set of pressurizable cells being independently pressurizable from every other set of pressurizable cells of the cushioning element. The pressurizable cells may extend across a widths of the cushioning element and be arranged in series along the length of the cushioning element. Such a cushioning element may be part of a cushion, such as a mattress, a mattress topper, or the like. Methods for manufacturing the cushioning elements are also disclosed.

Claims

1. A cushioning element, comprising: a planar intermediate element having a first surface, a second surface opposite from the first surface, a length, and a width; a series of first bladders arranged over the first surface of the planar intermediate element, along the length of the planar intermediate element, each first bladder of the series of first bladders extending substantially across the width of the planar intermediate element; a series of second bladders arranged over the second surface of the planar intermediate element, along the length of the planar intermediate element, each second bladder of the series of second bladders extending substantially across the width of the planar intermediate element and completely superimposed with a corresponding first bladder of the series of first bladders to define a pressurizable cell, the series of first bladders, the series of second bladders, and the planar intermediate element defining a series of pressurizable cells; and a plurality of apertures defined through the planar intermediate element, at least one aperture of the plurality of apertures establishing communication between each second bladder and its corresponding first bladder, the series of pressurizable cells being grouped into a plurality of sets of adjacent pressurizable cells, each set of the plurality of sets being independently pressurizable from every other set of the plurality of sets, where no first pressurizable cell of a first set of the plurality of sets is in communication with any second pressurizable cell of a second set of the plurality of sets.

2. The cushioning element of claim 1, wherein an entirety of the series of first bladders is defined from a first sheet of material and an entirety of the series of second bladders is defined from a second sheet of material.

3. The cushioning element of claim 1, wherein each first bladder and each second bladder comprises a pliable material.

4. The cushioning element of claim 3, wherein a rigidity of the planar intermediate element exceeds a rigidity of each first bladder and each second bladder.

5. The cushioning element of claim 1, wherein each first bladder includes a top edge and a bottom edge sealed against the planar intermediate element to define a first chamber.

6. The cushioning element of claim 5, wherein each second bladder includes a top edge and bottom edge sealed against the planar intermediate element to define a second chamber in communication with the first chamber by way of the at least one aperture therebetween.

7. The cushioning element of claim 1, wherein each first bladder has a semi-cylindrical shape.

8. The cushioning element of claim 7, wherein each second bladder has a semi-cylindrical shape, the series of pressurizable cells defined by the first bladder and the second bladder being cylindrical in shape.

9. The cushioning element of claim 1, wherein the series of pressurizable cells includes a first set adjacent to a first end of the planar intermediate element and a second set adjacent to a second end of the planar intermediate element.

10. The cushioning element of claim 9, wherein the first set and the second set are pressurizable independently from one another.

11. The cushioning element of claim 9, wherein the series of pressurizable cells further includes a third set between the first set and the second set.

12. The cushioning element of claim 11, wherein the first set, the second set, and the third set are pressurizable independently from one another.

13. The cushioning element of claim 1, comprising conduits between at least some adjacent pairs of pressurizable cells of the series of pressurizable cells.

14. The cushioning element of claim 1, comprising a mattress.

15. A method for fabricating a cushioning element, comprising: providing a planar intermediate element having a first side, a second side opposite from the first side, a length, and a width, the planar intermediate element including a plurality of apertures defined through the planar intermediate element; positioning at least one first sheet of material over the first side of the planar intermediate element, substantially across the width of the planar intermediate element, the at least one first sheet of material comprising a pliable material; securing spaced-apart, parallel locations of the at least one first sheet of material to corresponding spaced-apart, parallel locations extending substantially across the width of the planar intermediate element on the first side of the planar intermediate element to define a series of first bladders over a first surface, each first bladder of the series of first bladders extending over at least one aperture of the plurality of apertures through the planar intermediate element; positioning at least one second sheet of material over the second side of the planar intermediate element, substantially across the width of the planar intermediate element, the at least one second sheet of material comprising a pliable material; and securing spaced-apart, parallel locations of the at least one second sheet of material to corresponding spaced-apart, parallel locations extending substantially across the width of the planar intermediate element on the second side of the planar intermediate element to define a series of second bladders over a second surface, each second bladder of the series of second bladders extending over at least one aperture of the plurality of apertures through the planar intermediate element, the series of first bladders, the series of second bladders, and the planar intermediate element defining a series of pressurizable cells, the series of pressurizable cells being grouped into a plurality of sets of adjacent pressurizable cells, each set of the plurality of sets being independently pressurizable from every other set of the plurality of sets, where no first pressurizable cell of a first set of the plurality of sets is in communication with any second pressurizable cell of a second set of the plurality of sets.

16. The method of claim 15, wherein: the spaced-apart, parallel locations extending substantially across the width of the planar intermediate element on the first side of the planar intermediate element and the spaced-apart, parallel locations extending substantially across the width of the planar intermediate element on the second side of the planar intermediate element are completely superimposed; and each first bladder of the series of first bladders is completely superimposed with a corresponding second bladder of the series of second bladders, with each bladder and the corresponding second bladder defining a cell of the cushioning element, with a series of cells arranged along a length of the cushioning element.

17. The method of claim 16, further comprising: sealing ends of each cell of the series of cells.

18. The method of claim 15, further comprising: sealing ends of each first bladder of the series of first bladders; and sealing ends of each second bladder of the series of second bladders.

19. The method of claim 15, wherein: positioning the at least one first sheet comprises positioning a single first sheet that substantially covers the first side of the planar intermediate element over the first side of the planar intermediate element; and positioning the at least one second sheet comprises positioning a single second sheet that substantially covers the second side of the planar intermediate element over the second side of the planar intermediate element.

20. The method of claim 15, wherein positioning the at least one first sheet and positioning the at least one second sheet comprise positioning pliable sheets.

21. The method of claim 20, wherein positioning pliable sheets comprises positioning the pliable sheets over the first side and second side of the planar intermediate element, with the planar intermediate element being substantially rigid.

22. The method of claim 15, wherein securing spaced-apart, parallel locations of the at least one first sheet of material to corresponding spaced-apart, parallel locations extending substantially across the width of the planar intermediate element on the first side of the planar intermediate element to define the series of first bladders over the first surface includes defining conduits between at least some adjacent pairs of first bladders of the series of first bladders.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings:

(2) FIG. 1 is a perspective view of an embodiment of a cushioning element with pressurizable cells that may grouped into separately inflatable sets;

(3) FIG. 2 is a top view of the embodiment of the cushioning element shown in FIG. 1;

(4) FIG. 3 is a side view of the embodiment of the cushioning element shown in FIG. 1;

(5) FIG. 4 is an end view of the embodiment of the cushioning element shown in FIG. 1;

(6) FIG. 5 is a cross-sectional view of the embodiment of the cushioning element shown in FIG. 1, taken midway between major surfaces of the cushioning element along a length of the cushioning element and across a width of the cushioning element;

(7) FIG. 6 is a perspective cross-sectional view of the embodiment of the cushioning element shown in FIG. 1, taken partially between major surfaces of the cushioning element along the length of the cushioning element and across the width of the cushioning element to show a planar intermediate element of the cushioning element;

(8) FIG. 7 is another perspective cross-sectional view of the embodiment of the cushioning element shown in FIG. 1, taken transverse to a thickness of the cushioning element and along the length of the cushioning element.

(9) FIG. 8 is another cross-sectional view of the embodiment of the cushioning element shown in FIG. 1, taken transverse to a thickness of the cushioning element and along the length of the cushioning element;

(10) FIG. 9 is yet another cross-sectional view of the embodiment of the cushioning element shown in FIG. 1, taken transverse to the thickness of the cushioning element and at a first location across the width of the cushioning element;

(11) FIG. 10 is still another cross-sectional view of the embodiment of the cushioning element shown in FIG. 1, taken transverse to the thickness of the cushioning element and at a second location across the width of the cushioning element; and

(12) FIG. 11 is a schematic representation of an embodiment of a mattress that includes a cushioning element such as that depicted by FIGS. 1-10.

DETAILED DESCRIPTION

(13) FIGS. 1-4 depict an embodiment of a cushioning element 10. The cushioning element 10 includes a series 30 of elongated cells 20 (or, more simply, cells 20), with each cell 20 extending across a width W of the cushioning element 10 and the series 30 arranged along a length L of the cushioning element 10. The cells 20 are defined by a series of first bladders 21 on a first side 24 of a planar intermediate element 23 and a series of second bladders 22 on a second side 25 of the planar intermediate element 23. Each first bladder 21 is completely superimposed with a corresponding second bladder 22.

(14) As depicted by FIGS. 5 and 6, the planar intermediate element 23 may include apertures 26 extending through its thickness, from the first side 24 to the second side 25 of the planar intermediate element 23. The apertures 26 may be arranged in one or more columns 26c along a length of the planar intermediate element 23. The apertures 26 may also be arranged in rows 26r across a width of the planar intermediate element 23. The apertures 26 in each column 26c may be spaced equidistantly apart from each other, which spaces the rows 26r equidistantly along the length of the planar intermediate element 23. In some embodiments, such as that depicted by FIGS. 5 and 6, an array of apertures 26 may be defined through the planar intermediate element. Alternatively, the apertures 26 may be randomly positioned rather than equidistantly positioned across the planar intermediate element 23.

(15) As shown in FIG. 7, each cell 20 may be defined by a first bladder 21 and a corresponding second bladder 22 on opposite sides of the planar intermediate element 23. The first bladder 21 may be secured to and sealed against the first side 24 of the planar intermediate element 23. The first bladder 21 and second bladder 22 may be positioned over a row 26r of apertures 26 through the planar intermediate element 23. The corresponding first bladder 21 and second bladder 22 may be superimposed with each other.

(16) The planar intermediate element 23 may be formed from any suitable material. In some embodiments, the planar intermediate element 23 may be made from the same material used to form the first bladder 21 and the second bladder 22. The planar intermediate element 23 may be formed from a sheet of a polymeric material (e.g., a plastic). The planar intermediate element 23 may be flexible. Alternatively, the planar intermediate element 23 may be somewhat rigid. A rigidity of the planar intermediate element 23 may be due the material from which it is formed, a thickness of the sheet that defines it, or a combination of material and sheet thickness.

(17) The first bladders 21 and second bladders 22 may be formed from a pliable material, such as a polymeric film, that is impermeable or substantially impermeable (e.g., accounting for tolerable rates of decreased pressure (e.g., 1 psi per 24 hours, 1 psi per 48 hours, 1 psi per 72 hours, 1 psi per week, etc.) to one or more suitable gases (e.g., nitrogen, air, etc.) under ambient conditions (e.g., pressure, room temperature, etc.). A pliability of the first bladders 21 and the second bladders 22 may be attributed to the material used to form the first bladders 21 and the second bladders 22, a film thickness of the material, or a combination thereof.

(18) In some embodiments, a single sheet of pliable material may be used to form a plurality of adjacent first bladders 21 or second bladders 22, with various spaced-apart portions that extend at least partially across a width of the sheet material and are secured to and sealed against the planar intermediate element 23 defining the edges of the adjacent first bladders 21 or second bladders 22. In some embodiments, a single sheet of pliable material may be used to form all of the first bladders 21 on the first side 24 of the planar intermediate element 23. Similarly, a single sheet of pliable material may be used to form all of the second bladders 22 on the second side 25 of the planar intermediate element 23. The material from which the first bladders 21 and second bladders 22 are made may be less rigid than a material from which the planar intermediate element 23 is made.

(19) In other embodiments, a single sheet of material may be used to form the planar intermediate element 23, the first bladders 21, and the second bladders 22.

(20) As illustrated by FIGS. 2 and 3, the ends 28, 29 of each cell 20 may be sealed. More specifically, edges of the ends 28, 29 of the corresponding first bladder 21 and second bladder 22 that define each cell 20 may be sealed against the corresponding first side 24 and second side 25 of the planar intermediate element 23. Alternatively, caps (not shown) may be assembled with, secured to, and sealed to each end 28, 29 of each cell 20.

(21) With returned reference to FIGS. 2 and 3, as well as with reference to FIG. 8, the series 30 of cells 20 of the cushioning element may include a plurality of sets 31, 32, 33, etc., of cells 20. For example a first set 31 of cells 20 may be located adjacent to a first end 11 (e.g., a head, a foot, etc.) of the cushioning element 10. In the illustrated embodiment, the first set 31 of cells 20 includes the first through eighth cells 20 (from left to right) of the series 30. The series 30 of cells 20 may also include a second set 32 of cells 20 adjacent to a second end 12 (e.g., a foot, a head, etc.) of the cushioning element 10. In the illustrated embodiment, the second set 32 of cells 20 includes the eleventh through fifteenth cells 20 (from left to right) of the series 30. Optionally, the series 30 of cells 20 may also include a third set 33 of cells 20 at an intermediate location 13 (e.g., a thigh location, a lumbar location, etc.) along the length L of the cushioning element 10. In the illustrated embodiment, the third set 33 of cells 20 includes the ninth and tenth cells 20 (from left to right) of the series 30. As an alternative to a single cushioning element 10 with physically connected sets 31, 32, 33, etc., of cells 20, a series of cushioning elements may be positioned adjacent to one another, or end-to-end. An orientation of the cushioning element 10 within a mattress may determine which end 11, 12 thereof is located adjacent to the head of the mattress and which end 11, 12 of the cushioning element 10 is located adjacent to the foot of the mattress.

(22) The cells 20 of each set 31, 32, 33, etc., may communicate with one another by way of one or more conduits 40 between adjacent cells 20, as illustrated by FIGS. 2, 3, 8, and 9. Thus, as pressure within one cell 20 of a set 31, 32, 33, etc., is adjusted, the adjustment in pressure may be communicated to an adjacent cell 20 of the same set 31, 32, 33, etc., which may also cause pressure within the adjacent cell 20 to be adjusted. The conduits 40 may comprise unsealed locations between adjacent cells 20 of the same set 31, 32, 33, etc. Alternatively, the conduits 40 may comprise tubular elements that establish communication between adjacent cells 20.

(23) The conduits 40 may be positioned relatively centrally, or away from the ends 28 and 29 of the cells 20 they establish communication between. Alternatively, as depicted, the conduits 40 may be spaced evenly, or equidistantly, between the ends 28 and 29 of the cells 20 they extend between. As another option, the conduits 40 may be positioned adjacent to, along, or near the ends 28 and 29 of the cells 20 they establish communication between. As yet another option, the conduits 40 may establish communication between adjacent cells through adjacent ends 28 or 29 of the adjacent cells 20; such a conduit 40 may be located beyond, or outside, of the ends 28 or 29 of the cells 20. It should be appreciated that the conduits 40 may be positioned at any of a variety of locations relative to the widths W of the cells 20 they connect. In some embodiments, conduits 40 may connect cells 20 that are not adjacent to each other.

(24) Notably, conduits 40 do not extend between adjacent cells 20 of different sets 31, 32, 33, etc., which enables each set 31, 32, 33, etc., to be pressurized independently of other sets 31, 32, 33, etc. FIG. 10 illustrates a side of a cell 20 that lacks conduits 40, such as the adjacent sides of the eighth and ninth cells 20 of FIG. 2 and the tenth and eleventh cells 20 of FIG. 2. Notably, there are no conduits on side of a cell 20 that defines a boundary between two adjacent sets 31 and 32, 32 and 33, etc., of cells 20 or between adjacent cushioning elements. However, in some embodiments, a cushioning element may include a single set of cells 20, with conduits 40 connecting each adjacent pair of cells 20 of the series 30, thereby fluidly connecting each cell 20 to every other cell 20 of the series 30.

(25) Referring again to FIG. 7, an embodiment of a method for manufacturing a cushioning element 10 is described. In such a method, a planar intermediate element 23 is provided. At least one first sheet 21′ of material is positioned over the first side 24 of the planar intermediate element 23. Portions (e.g., linear portions, etc.) of the at least one first sheet 21′ are secured to the first side 24 of the planar intermediate element 23 (e.g., by way of thermal bonding, welding (e.g., ultrasonic, RF, etc.), use of an adhesive, etc.). Such a portion may extend continuously across a width of the at least one second sheet 22′ or it may include one or more gaps that may define one or more conduits 40. Selective securing may include securing spaced-apart, parallel locations of the at least one first sheet 21′ to corresponding spaced-apart, parallel locations extending substantially across the width of the planar intermediate element 23 on the first side 24 of the planar intermediate element 23. The spaced-apart, parallel locations may be on opposite sides of a row 26r of apertures 26 and between adjacent rows 26r of apertures 26. The result of such selective securing may include the definition of a series of first bladders 21 over the first surface 24. The locations at which the at least one first sheet 21′ is secured to the first side 24 may result in the definition of a first bladder 21 that extends over a row 26r or apertures 26 through the planar intermediate element 23.

(26) In addition to securing the at least one first sheet 21′ to the first side 24 of the planar intermediate element 23, at least one second sheet 22′ of material may be positioned over the second side 25 of the planar intermediate element 23. Portions (e.g., linear portions, etc.) of the at least one second sheet 22′ may be secured to the second side 25 of the planar intermediate element 23 (e.g., by way of thermal bonding, welding, use of an adhesive, etc.). Such a portion may extend continuously across a width of the at least one second sheet 22′ or it may include one or more gaps that may define one or more conduits 40. Spaced-apart, parallel locations of the at least one second sheet 22′ may be secured to corresponding spaced-apart, parallel locations extending substantially across the width of the planar intermediate element 23 on the second side 24 of the planar intermediate element 23. The spaced-apart, parallel locations may be on opposite sides of a row 26r of apertures 26 and between adjacent rows 26r of apertures 26. The result of such selective securing may include the definition of a series of second bladders 22 over the second surface 25. The locations at which the at least one second sheet 22′ is secured to the second side 24 may result in the definition of a second bladder 22 that extends over a row 26r of apertures 26 through the planar intermediate element 23. In embodiments where the second bladders 22 are completely superimposed with the first bladders 21, the result of such selective securing may also the definition of a series 30 of cells 22 arranged along the length L of the cushioning element 10.

(27) In some embodiments, locations adjacent to edges of the at least one first sheet 21′ and the at least one second sheet 22′ may be secured to the first side 24 and second side 25, respectively, of the planar intermediate sheet 23 to define ends of the first bladders 21 and the second bladders 22 and, thus, ends of the cells 20. Alternatively, a cap (not shown) may be assembled with and sealed to an end of each cell 20.

(28) Turning now to FIG. 11, the cushioning element 10 and, more specifically, the interiors of the sets 31, 32, 33, etc., of cells 20 of the cushioning element 10, may communicate with a pressure source 50 (e.g., an air compressor, etc.), which may operate under control of a processing element 60 to enable adjustment and maintenance of a desired pressure within each cell 20 or set 31, 32, 33, etc., of cells 20 of the cushioning element 10.

(29) Furthermore, it should be appreciated that the cushioning element 10 may include a single pressure source 50 connected to a plurality of sets 31, 32, 33, etc., or to each set 31, 32, 33, etc., of cells 20, with a valve determining the set 31, 32, 33, etc., to which the pressure source 50 will communicate, or cause, a pressure change (e.g., inflation, deflation, etc.). Alternatively, a plurality of pressure sources 50 may be fluidly connected to the cushioning element 10, with each pressure source 50 dedicated and fluidly connected to a specific set 31, 32, 33, etc., of cells 20 to allow for appropriate pressurization of that set 31, 32, 33, etc. Access to each set 31, 32, 33, etc., may be from either of the ends 28 and 29 of a cell 20 or from any number of locations of each set 31, 32, 33, etc., or each cell 20 or the cushioning element 10.

(30) The cushioning element 10 may be combined with one or more other elements of a cushion 100, such as a cover 70, one or more cushioning layers 80, 82, 84, etc. (e.g., foam 82, 84, memory foam 84, elastomeric grid 80, coils 86, etc.), and support 90 and foundational elements 92 to define a mattress, a mattress topper, or any of a variety of other embodiments of cushions 100. Without limitation, such a cushion 100 may comprise mattress such as that described by U.S. Pat. No. 11,213,139, the entire disclosure of which is hereby incorporated herein.

(31) Although the preceding disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.