IMPROVED CUSHIONING MATERIAL

Abstract

Cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric being joined together to form discrete spring-containing pockets; wherein the cover material is fastened to the microcoil sheet by one or more seams. Also provided is a cushioned or upholstered article (such as a mattress, mattress topper, seat, chair or loose cushion) comprising cushioning material according to any preceding claim. Also provided is a method of manufacturing cushioning material) comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric having been joined together to form discrete spring-containing pockets; the method comprising fastening the cover material to the microcoil sheet by one or more seams.

Claims

1. Cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric being joined together to form discrete spring-containing pockets; wherein the cover material is fastened to the microcoil sheet by one or more seams.

2. The cushioning material according to claim 1, wherein the seams run continuously across the cushioning material.

3. The cushioning material according to claim 1, wherein the seams are discontinuous across the cushioning material.

4. The cushioning material according to claim 1, wherein the seams coincide with inherent weld lines of the microcoil sheet, the weld lines joining said layers of fabric together.

5. The cushioning material according to claim 4, wherein the seams are discontinuous across the cushioning material and in the form of cross stiches coinciding with intersections of the weld lines of the microcoil sheet.

6. The cushioning material according to claim 1, wherein the cover material is directly in contact with the microcoil sheet.

7. The cushioning material according to claim 1, further comprising an interlayer material between the cover material and the microcoil sheet; optionally wherein the interlayer material is arranged in discrete regions between the seams.

8. The cushioning material according to claim 1, wherein the seams are formed by machine needle-and-thread stitching, the stitching passing through the cover material and the microcoil sheet.

9. The cushioning material according to claim 8, further comprising an interlayer material between the cover material and the microcoil sheet, wherein the stitching also passes through the interlayer material.

10. (canceled)

11. (canceled)

12. The cushioning material according to claim 1, wherein the seams are formed by welding.

13. The cushioning material according to claim 1, wherein the seams define, in the cover material, pockets that separate individual springs or groups of springs; or wherein the seams define, in the cover material, elongate flutes that separate groups of springs.

14. (canceled)

15. The cushioning material according to claim 1, being a first piece of cushioning material, attached by means of a further seam to a second piece of such cushioning material to form a cushioning structure.

16. (canceled)

17. (canceled)

18. (canceled)

19. The cushioning material according to claim 15, wherein the further seam is along at least two edges of the first and second pieces of cushioning material, the first and second pieces of cushioning material overlaying one another; optionally wherein the microcoil sheet of the first piece of cushioning material faces towards the microcoil sheet of the second piece of cushioning material; and optionally further comprising an insert between the microcoil sheet of the first piece of cushioning material and the microcoil sheet of the second piece of cushioning material, the insert comprising one or more of: sheet foam or moulded foam; a rigid or semi-rigid former; one or more structural members that form part of the structure of an item of furniture; heating elements, or vibration or massage elements; one or more fixing structures or mounts; or another microcoil sheet.

20. (canceled)

21. (canceled)

22. A cushioned or upholstered article comprising cushioning material according to claim 1; for example being a mattress, wherein the cushioning material or cushioning structure is attached to a mattress support core; or being, for example, a mattress topper, a weighted blanket, a cushion, a seat or a chair.

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. A method of manufacturing cushioning material comprising a microcoil sheet and a surface cover material, the microcoil sheet comprising an array of wire springs held between two layers of fabric, the layers of fabric having been joined together to form discrete spring-containing pockets; the method comprising fastening the cover material to the microcoil sheet by one or more seams.

29. (canceled)

30. (canceled)

31. The method according to claim 28, wherein the seams coincide with inherent weld lines of the microcoil sheet, the weld lines joining said layers of fabric together.

32. (canceled)

33. (canceled)

34. (canceled)

35. The method according to claim 28, wherein the seams are formed by machine needle-and-thread stitching, the stitching passing through the cover material and the microcoil sheet.

36. The method according to claim 35, further comprising providing an interlayer material between the cover material and the microcoil sheet, wherein the stitching also passes through the interlayer material.

37. (canceled)

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. The method according to claim 41, wherein the seams define, in the cover material, elongate flutes that separate groups of springs, and wherein, when forming each seam, the cover material is first folded shortly after the intended position of the seam to form a double-layer of the cover material, then said double-layer of the cover material is fastened to the microcoil sheet to form the seam, and then the cover material is unfolded and pulled over a group of springs before the next seam is formed.

43. (canceled)

44. (canceled)

45. (canceled)

46. (canceled)

47. The method according to claim 28, further comprising attaching first and second pieces of the cushioning material together by means of a further seam, wherein the further seam is along at least two edges of the first and second pieces of cushioning material, the first and second pieces of cushioning material overlaying one another; optionally wherein: an opening is provided in the further seam; the first and second pieces of cushioning material are initially attached by the further seam such that the microcoil sheets of the first and second pieces of cushioning material face away from one another, thereby forming an intermediate product; and the method further comprises turning the intermediate product inside-out, through said opening, to result in the microcoil sheets of the first and second pieces of cushioning material facing towards one another; and wherein the method optionally further comprises inserting an insert between the microcoil sheet of the first piece of cushioning material and the microcoil sheet of the second piece of cushioning material, the insert comprising one or more of: sheet foam or moulded foam; a rigid or semi-rigid former; one or more structural members that form part of the structure of an item of furniture; heating elements, or vibration or massage elements; one or more fixing structures or mounts; or another microcoil sheet.

48. (canceled)

49. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Embodiments of the invention will now be described, by way of example only, and with reference to the drawings in which:

[0045] FIG. 1 illustrates a cross-sectional side view of a typical microcoil mattress construction;

[0046] FIG. 2 illustrates a cross-sectional side view of a typical microcoil array;

[0047] FIG. 3 illustrates typical degrees of movement of an independent microcoil spring;

[0048] FIG. 4a is a pressure map of an individual's buttocks sitting directly on a foam cushion;

[0049] FIG. 4b is a pressure map under the same conditions as for FIG. 4a but with a microcoil sheet added at the interface between the individual and the foam cushion;

[0050] FIG. 5 illustrates a cross-sectional side view of an embodiment of a microcoil-based cushioning material comprising a microcoil sheet to which a surface cover material is attached;

[0051] FIG. 6 illustrates, in cross-section, a sewing method for attaching a surface cover material to a microcoil sheet using vertical stitching;

[0052] FIG. 7 illustrates, in cross-section, an alternative sewing method for attaching a surface cover material to a microcoil sheet using vertical stitching;

[0053] FIG. 8 illustrates, in cross-section, a sewing method for attaching a surface cover material to a microcoil sheet using horizontal stitching;

[0054] FIG. 9 illustrates a cross-sectional side view of a configuration of a microcoil mattress incorporating a microcoil-based cushioning material as in FIG. 5;

[0055] FIG. 10 illustrates a surface design of a microcoil-based cushioning material as in FIG. 5, where cross stitches (that attach the cover material to the microcoil sheet) are placed at the intersections of inherent weld lines in the microcoil sheet to create pockets;

[0056] FIG. 11 illustrates a surface design of a microcoil-based cushioning material as in FIG. 5, where parallel seams (that attach the cover material to the microcoil sheet) are stitched along the inherent weld lines in the microcoil sheet to create flutes, and also showing that tension may be applied in the direction of the seams, e.g. if fitting to a support, to enhance the fluting;

[0057] FIG. 12a illustrates a plan view of a fluted microcoil-based cushioning material substantially as in FIG. 11;

[0058] FIG. 12b illustrates a cross-sectional side view of the microcoil-based cushioning material of FIG. 12a stretched around a foam pad and fastened to a wooden base;

[0059] FIGS. 13a and 13b illustrate plan and cross-sectional views respectively of first and second pieces of fluted microcoil-based cushioning material joined together by means of a further seam, and FIG. 13c illustrates the joined-together pieces of microcoil-based cushioning material of FIG. 13b having been opened-up to lay flat;

[0060] FIG. 14 illustrates plan views of conjoined first and second pieces of fluted microcoil-based cushioning material, with the flutes of the first and second pieces (a) oriented parallel to one another, and (b) oriented perpendicularly to one another;

[0061] FIGS. 15a and 15b illustrate cross-sectional and plan views respectively of first and second pieces of fluted microcoil-based cushioning material joined together in an overlaying manner by means of a perimeter seam having an opening on one side, with the microcoil sheets on the outside, to form an intermediate product; and FIG. 15c illustrates a cross-sectional view of the intermediate product of FIGS. 15a and 15b having been turned inside-out, to result in the microcoil sheets of the first and second pieces of cushioning material being on the inside, facing towards one another.

[0062] In the figures, like elements are indicated by like reference signs throughout.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0063] The present embodiments represent the best ways known to the Applicant of putting the invention into practice. However, they are not the only ways in which this can be achieved.

[0064] As illustrated in FIG. 5, embodiments of the present invention provide a microcoil-based cushioning material 20 (e.g. for upholstery or a mattress) wherein a surface cover material 22 (that may be outwardly visible to a user and contacted by a user in use) is attached to a microcoil sheet 14, e.g. by sewing or welding, such that the cover material 22 and the microcoil sheet 14 are fastened to one another by seams (i.e. join lines) 24.

[0065] The seams 24 may run continuously across the cushioning material 20, or may be discontinuous (e.g. in discrete places only).

[0066] The cover material 22 may be directly in contact with the microcoil sheet 14 (i.e. with no interlayer material between them). Alternatively, in some variants, one or more interlayer materials may be provided between the microcoil sheet 14 and the cover material 22 to provide, for example, additional cushioning or fire retardancy. However, even when one or more interlayer materials are provided between the microcoil sheet 14 and the cover material 22, the microcoil sheet 14 and the cover material 22 are nevertheless still fastened to one another by the seams 24e.g. by stitching that passes through the microcoil sheet 14, through the interlayer material(s), and through the cover material 22; or by the interlayer material(s) being arranged in discrete regions between the seams 24, such that the seams 24 pass around the interlayer material(s).

[0067] In more detail, the present embodiments provide a new configuration of cushioning material 20 that interfaces microcoil pocket springs 14 with the cushion surface cover material 22, wherein the microcoil sheet 14 is fastened directly to the cover material 22 along seams 24 (e.g. by sewing or welding), and wherein zones are defined between the seams 24 that allow for independent movement of the constituent springs (of the microcoil sheet 14) within said zones.

[0068] The seams 24, along which the microcoil sheet 14 and the cover material 22 are fastened together, create either corresponding pockets or elongate flutes that separate individual springs or groups of springs. Merely by way of example, such a pocket may contain a single spring, or a 1?2, 2?2, 1?3, 2?3 or 3?3 group of springs. Naturally other numbers of springs are also possible within such a pocket. On the other hand, in a fluted arrangement (obtained using continuous seams), the flutes may separate continuous lines of springs that are a single spring wide, or two, three, four or more springs wide.

[0069] A typical commercially-available microcoil pocketed spring sheet 14 comprises two synthetic fabrics (of either the same or differing types) welded together by the manufacturer along seams, to create discrete spring-containing pockets. The present inventor has found that the size of such pockets (which is typically of the order of 2-4 cm?2-5 cm) is suitable to fit through a needle-and-thread sewing machine or a weld-seam sewing machine. Accordingly, this enables the cover material 22 to be stitched to the microcoil pocketed spring sheet 14 in parallel lines along the inherent pre-existing weld seams of the microcoil sheet 14. Alternatively, the cover material 22 may be stitched to the microcoil pocketed spring sheet 14 at the intersections of the inherent weld seams.

[0070] In presently-preferred embodiments the seams 24 are formed by a needle-and-thread sewing machine, by passing the microcoil sheet 14 and the cover material 22 together through the sewing machine, to form the seams 24 along the inherent pre-existing weld seams of the microcoil sheet 14, between adjacent rows of springs. That it is possible to pass a microcoil sheet, with its inherent metallic wire components, through such a sewing machine, was a surprising and counterintuitive finding on the part of the inventor, as such sewing machines are generally understood as being designed for sewing fabrics only, and the natural assumption would have been that the springs of the microcoil sheet 14 would risk catching, bending or breaking a sewing machine needle, or other delicate parts around the presser foot of the sewing machine.

[0071] FIG. 6 shows an example of the position and direction of the stitches with respect to the microcoil sheet 14, to attach the cover material 22 and form a seam 24 (the join line between the cover material 22 and the microcoil sheet 14). Here, the stitches are vertical, inserted using a needle 30 (e.g. of an industrial sewing machine) in parallel lines along the pre-existing weld seams of the microcoil sheet 14, between adjacent spring-containing pockets of the microcoil sheet 14.

[0072] FIG. 7 illustrates an alternative sewing method to that of FIG. 6, for attaching the surface cover material 22 to the microcoil sheet 14, again using vertical stitching. In this case, though, before each seam 24 is stitched using the needle 30, the cover material 22 is folded back on itself as shown, shortly after the intended position of the seam 24, to form a local double-layer of the cover material 22. The stitching is then made through that local double-layer of the cover material 22 and the microcoil sheet 14 to form the seam 24. The cover material 22 is then unfolded and pulled over the next row (or multiple rows) of spring-containing pockets, and then folded back on itself ready to form the next seam 24. The stitching process is then repeated for that next seam 24, and so on. The advantage of this technique, compared to that of FIG. 6, is that in this case the seams 24 are hidden from view in the final product.

[0073] Alternatively, as shown in FIG. 8, the microcoil sheet 14 may be produced with rows of empty pockets to provide space for folding the microcoil sheet 14, to enable the stitches to be performed horizontally to form a seam 24. This technique also results in the seams 24 being hidden from view in the final product.

[0074] With the techniques of FIGS. 6, 7 and 8, the stitches may be created with a needle-and-thread sewing machine which allows for non-weldable cover materials, or alternatively the stitches may be welded if the cover material 22 is weldable to the microcoil sheet 14. Additional interlayer materials may be stitched between the microcoil sheet 14 and the cover material 22 to provide, for example, additional cushioning or fire retardancy. In such a case, the microcoil sheet 14 and the cover material 22 are nevertheless still fastened to one another, by the seam stitching that passes through the microcoil sheet 14, through the interlayer material(s), and through the cover material 22. Alternatively the interlayer material(s) may be arranged in discrete regions between the seams 24, such that the seams 24 pass around the interlayer material(s).

[0075] Sewn seams 24, passing through the microcoil sheet 14, have been found to significantly increase the strength and durability of the overall assembly (including the strength and durability of the microcoil sheet itself). This can be of particular importance if the assembly is to be at the extremity of a cushion or mattress, and not protected by a layer of foam or the like (which is the convention). This can be of even greater importance in a seat application where ingress and egress can add extra wear and tear. A car seat cushion, for example, needs to be significantly more durable than a bed mattress.

[0076] The above techniques may be used to manufacture cushioning material 20 for a range of purposes, wherein the surface cover material 22 and the microcoil sheet 14 are fastened to one another by seams 24. With reference to FIG. 9, in the case of the cushioning material 20 being for a mattress, the present cushioning material 20 may be fitted to a mattress support core 16 (optionally with a transitional layer 15 of cushioning material therebetween) in a conventional manner to create a new type of microcoil mattress 40. The support core 16 may, for example, be made from larger springs, memory foam, high resilience polyurethane foam, latex foam, natural fibres, or a combination thereof.

[0077] Exemplary Surface Designs

[0078] FIG. 10 shows a surface design of an embodiment of the cushioning material 20 in (a) plan view, and (b)/(c) cross-sectional side views, where the seams 24 are discontinuous, in the form of cross stitches 50 that are applied only at the intersection of the welds in the microcoil sheet 14 to create corresponding pockets.

[0079] It will be appreciated that, in this example, the cross stitches 50 are at every intersection of the welds in the microcoil sheet 14, such that each pocket created contains a single microcoil spring. However, in variants of this design, the cross stiches may be less frequente.g. at every other intersection of the welds in the microcoil sheet 14, such that each pocket created contains four microcoil springs (in a 2?2 group).

[0080] FIG. 11 shows another surface design of an embodiment of the cushioning material 20 in (a) plan view, and (b)/(c) cross-sectional side views, in this case where parallel seams 24 are stitched along the weld seams in the microcoil sheet to create flutes 52. Such flutes may contain single rows of springs, or multiple rows of springs. In the example illustrated, the flutes contain two rows of springs, although other numbers are of course possible. Applying tension in the direction of the seams 24, as illustrated, may enhance the fluting effecte.g. if the cushioning material 20 is to be fitted to a support.

[0081] Exemplary Applications

[0082] Embodiments of the invention are particularly applicable, but by no means limited, for use in mattresses and mattress toppers, and seat/chair cushions (which may be fixed to a seat or chair, or loose). Applications in other types of upholstery and cushioning are also possible. For instance, it is envisaged that embodiments may be used to form consumer mattresses, consumer mattress toppers, medical mattresses, medical mattress toppers, fixed seat/chair upholstery, loose seat/chair cushions, seat cushion toppers, weighted blankets, medical fixed seat/chair upholstery, medical loose seat/chair cushions, and medical seat cushions. Embodiments may also be used to provide cushioning in non-furniture items such as backpacks and infant carriers.

[0083] To provide additional explanation in respect of weighted blankets, in beds an objective of the present invention is to reduce interface pressure acting on the user's body from the mattress. Low pressure distribution is associated with improved sleep quality. Weighted blankets exist that claim to help with sleep disorders such as insomnia, and act by increasing pressure from the cover, thereby reducing the pressure differential on the whole of the user's body. Accordingly, a weighted blanket that embodies the present invention, that interfaces with the user using the same pressure redistributing technology as the mattress, would reduce the pressure differential on the user's body, homogenise the pressure distribution by using springs on all contact areas, and reduce any peak pressures that may otherwise exist in other weighted blankets.

[0084] Another exemplary application in relation to upholstered furniture will now be described with reference to FIGS. 12a and 12b. FIG. 12a illustrates a plan view of a piece of fluted microcoil-based cushioning material 20, substantially as in FIG. 11. However, as shown in the cross-sectional view in FIG. 12b, in this case the surface cover material 22 extends beyond the region occupied by the microcoil sheet 14. Such an arrangement of the surface cover material 22 relative to the microcoil sheet 14 provides a way of fastening the cushioning material 20 around an underlying structurein this case, a foam pad 60 and a wooden (e.g. plywood) base 62. More particularly, the surface cover material 22 is stretched around the foam pad 60 and attached to the underside of the wooden base 62 by means of staples 64a, 64b or tacks.

[0085] Cushioning Structures Comprising Conjoined Pieces of Microcoil-Based Cushioning Material

[0086] As illustrated for example in FIGS. 13a-c, 14 and 15a-c, cushioning structures may be fabricated comprising a plurality of pieces of microcoil-based cushioning material joined together by means of one or more further seams.

[0087] FIGS. 13a and 13b illustrate plan and cross-sectional views respectively of a first piece of fluted microcoil-based cushioning material 20 joined to a second piece of fluted microcoil-based cushioning material 20 by means of a further seam 70, to form a combined cushioning structure 80 as shown in cross-section in FIG. 13c.

[0088] In more detail, and with particular reference to FIG. 13b, the first and second pieces of microcoil-based cushioning material 20, 20 are initially placed back to back, i.e. with the respective pieces of cover material 22, 22 touching each other and the respective microcoil sheets 14, 14 facing outwards. A seam 70 is then sewn (or welded) to join the two pieces of cover material 22, 22 together, beyond one edge of the microcoil sheets 14, 14 (i.e. along one edge of the first and second pieces of cushioning material 20, 20).

[0089] The conjoined pieces of microcoil-based cushioning material 20, 20 of FIG. 13b are then opened-up (as indicated by the curved arrows) to lay substantially flat, resulting in the combined cushioning structure 80 shown in FIG. 13c. It will be appreciated that the seam 70 is hidden from view when the opened-up cushioning structure 80 is viewed from the side of the cover material 22, 22.

[0090] Such a combined cushioning structure 80 enables the constituent pieces of microcoil-based cushioning material to be selectively configured to suit the desired end product. For instance, as shown in FIG. 14, the flutes of the first and second pieces 20, 20 may be oriented (a) parallel to one another, or (b) perpendicularly to one another, to suit the design and load-supporting/pressure-relieving requirements of the end product. It will of course be appreciated that one or both of the first and second pieces 20, 20 need not be fluted, and could have a different surface design (e.g. that as shown in FIG. 10).

[0091] Moreover, the surface cover material 22 and/or microcoil sheet 14 of the first piece of cushioning material 20 may be different from the surface cover material 22 and/or microcoil sheet 14 of the second piece of cushioning material 20, again to suit the design and load-supporting/pressure-relieving requirements of the end product. For example, the surface cover materials 22, 22 could be different fabrics. Alternatively, or in addition, the microcoil sheets 14, 14 could have different properties, e.g. in terms of the stiffness of the springs, the height of the springs, the density of the springs (number of springs per unit area), etc.

[0092] FIGS. 15a-c illustrate a further example of a combined cushioning structure comprising first and second pieces of microcoil-based cushioning material 20, 20 joined together in an overlaying manner by means of one or more further seams 72. The resulting cushioning structure 90 is shown in cross-section in FIG. 15c, in which the microcoil sheets 14, 14 of the first and second pieces of microcoil-based cushioning material 20, 20 are on the inside of the structure, facing towards one another. Such a cushioning structure 90 may be formed by starting from the configuration shown in FIGS. 15a and 15b.

[0093] More particularly, FIGS. 15a and 15b illustrate cross-sectional and plan views respectively of a first piece of fluted microcoil-based cushioning material 20 joined to a second piece of fluted microcoil-based cushioning material 20 in a mutually overlaying manner by means of a perimeter seam 72 extending along at least two edges of the first and second pieces of cushioning material 20, 20, beyond the edges of the microcoil sheets 14, 14. Preferably the perimeter seam 72 is along at least three edges of the overlaying pieces of cushioning material 20, 20, and moreover may be along part (but not all) of a fourth edge, as illustrated. An opening 74 is provided in one edge of the perimeter seam 72, sufficiently large for the turning inside-out purpose described below. In the illustrated example the opening 74 in the perimeter seam 72 is approximately one third of the length of the edge of the microcoil sheet 14 therein. Initially, as shown in FIG. 15a, when the first and second pieces of cushioning material 20, 20 are joined together by means of the perimeter seam 72, the microcoil sheets 14, 14 are on the outside of the structure, facing away from one another. The structure of FIG. 15a may be considered to be an intermediate product.

[0094] With reference to FIGS. 15b and 15c, the above intermediate product is then turned inside-out, through the opening 74 in the perimeter seam 72, to result in the structure 90 of FIG. 15c in which the microcoil sheets 14, 14 of the first and second pieces of cushioning material 20, 20 face towards one another. By virtue of this method of manufacture, the microcoil sheets 14, 14 and the perimeter seam 72 are hidden from view once the cushioning structure 90 has been formed.

[0095] The structure 90 encapsulates the microcoil sheets 14, 14 and can be used as a standalone pillow or cushion, or may be attached to a frame or other structure. Moreover, by virtue of the microcoil sheets 14, 14 acting against each other whilst not being particularly constrained laterally (thus allowing the springs a high degree of mobility), the resulting cushioning structure 90 is able to provide a high level of pressure relief.

[0096] The cushioning structure 90 of FIG. 15c represents an improvement in spring mobility compared to fixed upholstery of the kind illustrated in FIG. 12b, where the surface cover material 22 of the cushioning material 20 is stapled or tacked down onto a wooden base 62. A problem with such fixed upholstery is that the cushioning unit has less mobility, which is key to the pressure-relieving performance of the product. For instance, with reference to FIG. 12b, the fabric of the cover material 22 may be pulled tight to reduce gathered fabric and pleats, and for general quality, but this tension reduces movement of the springs of the microcoil sheet 14, even if a knitted fabric with two-way stretch is used. The foam pad 60 may also grip the springs of the microcoil sheet 14, reducing movement further. The cushioning structure 90 of FIG. 15c solves these problems, by embodying the present invention in effectively a loose cushion. This greatly improves the freedom of movement of the springs of the microcoil sheets 14, 14, allowing them to fully conform to the user's body rather than be constrained by the wooden base 62. Far greater immersion of the user into the product is therefore possible. The combination of greater immersion and greater contact area, together with the ability of the microcoil sheets 14, 14 and constituent springs to move and conform to the user's body, results in significantly lower peak pressures.

[0097] The enclosed cushioning structure 90 as a standalone product may be used as for pressure-relieving cushions for seats (e.g. wheelchairs, vehicles seats, office chairs, etc.), bed mattresses, mattress toppers or weighted blankets.

[0098] If desired, the cushioning structure 90 may be modified by providing an insert between the microcoil sheet 14 of the first piece of cushioning material 20 and the microcoil sheet 14 of the second piece of cushioning material 20. The insert may comprise one or more of: [0099] sheet foam or moulded foam (to alter the thicknesses of the structure 90 and create profiling); [0100] a rigid or semi-rigid former (to provide focused support, e.g. to the user's lower spine in seatingthe position of such a former may be adjustable); [0101] one or more structural members that form part of the structure of an item of furniture (e.g. a tubular backrest frame); [0102] heating elements, or vibration or massage elements; [0103] one or more fixing structures or mounts (by which the cushioning structure 90 may be attached to an item of furniture); or [0104] another (i.e. third) microcoil sheet.

[0105] When introducing the third microcoil sheet between the existing microcoil sheets 14, 14, the third sheet may for example be stitched onto either of the existing microcoil sheets 14, 14 along its edges. This would give the user greater immersion in regions of a backrest, for example. If a third microcoil sheet with stronger (i.e. stiffer) springs were to be used, this would give more support to those regions of the backrest too.