COMPOSITE CUSHIONS

Abstract

A composite cushion includes a first cushioning element and a second cushioning element. The second cushioning element is formed in a manner that engages a peripheral engagement are of the first cushioning element to interlock the second cushioning element onto the first cushioning element. The second cushioning element may surround an outer periphery of the first cushioning element. In addition, a portion of the second cushioning element may be superimposed over a central cushioning area of the first cushioning element. Superimposed portions of the first and second cushioning elements may have an unsecured relationship (i.e., they are not directly secured to each other).

Claims

1. A composite cushioning element, comprising: a first cushioning element comprising a first cushioning structure, the first cushioning element including: a central cushioning area having a central cushion thickness, a first cushioning material of the central cushioning area forming the first cushioning structure, including walls defining an outer periphery of the central cushioning area and columnar cushioning cells within the outer periphery, the first cushioning material enabling the walls and the columnar cells to buckle, a first surface of the central cushioning area defined by first ends of the walls and coincident with first ends of the columnar cushioning cells, a second surface of the central cushioning area opposite from the first surface, defined by second ends of the walls opposite from the first ends of the walls, and coincident with second ends of the columnar cushioning cells opposite from the first ends of the columnar cushioning cells; a peripheral engagement area located outside of and adjacent to at least a portion of the outer periphery of the central cushioning area, the peripheral engagement area having an engagement thickness, the peripheral engagement area defined by the first cushioning material, a first surface of the peripheral engagement area corresponding to the first surface of the central cushioning area, a second surface of the peripheral engagement area opposite from the first surface and corresponding to the second surface of the central cushioning area; a second cushioning element comprising a second cushioning structure adjacent to at least a portion of the outer periphery of the central cushioning area of the first cushioning element, a second cushioning material including features formed complementarily to the peripheral engagement area to mechanically secure the second cushioning element to the first cushioning element.

2. The composite cushioning element of claim 1, wherein the second cushioning element laterally surrounds an entirety of the outer periphery of the central cushioning area of the first cushioning element.

3. The composite cushioning element of claim 1, wherein the second cushioning structure comprises a foamed cushioning structure.

4. The composite cushioning element of claim 1, wherein the first cushioning material of the peripheral engagement area defines engagement cells adjacent to the outer periphery of the central cushioning area, the first surface of the peripheral engagement area being coincident with first ends of the engagement cells, the second surface of the peripheral engagement area being coincident with second ends of the engagement cells, the second ends of the engagement cells opposite from the first ends of the engagement cells.

5. The composite cushioning element of claim 4, wherein the second cushioning material extends into and through the engagement cells of the peripheral engagement area of the first cushioning element to mechanically secure the second cushioning element to the first cushioning element.

6. The composite cushioning element of claim 4, wherein the engagement thickness of the peripheral engagement area of the first cushioning element is the same as the central cushion thickness of the central cushioning area of the first cushioning element.

7. The composite cushioning element of claim 4, wherein the second cushioning element covers the first surface of the peripheral engagement area of the first cushioning element.

8. The composite cushioning element of claim 7, wherein the second cushioning element covers the second surface of the peripheral engagement area of the first cushioning element.

9. The composite cushioning element of claim 7, wherein the second cushioning element covers at least a portion of the first surface of the central cushioning area of the first cushioning element.

10. The composite cushioning element of claim 9, further comprising: a relief layer between superimposed portions of the second cushioning element and the central cushioning area of the first cushioning element, the relief layer not being adhered to or directly secured to a majority of the first surface of the central cushioning area of the first cushioning element.

11. The composite cushioning element of claim 4, wherein at least one of the first surface of the peripheral engagement area of the first cushioning element and the second surface of the peripheral engagement area of the first cushioning element is oriented at an angle relative to a corresponding surface of the central cushioning area of the first cushioning element to impart the peripheral engagement area with a narrowing taper from the outer periphery of the central cushioning area to an outer peripheral edge of the peripheral engagement area.

12. The composite cushioning element of claim 4, wherein at least one of the first surface of the peripheral engagement area of the first cushioning element and the second surface of the peripheral engagement area of the first cushioning element is stepped to impart the peripheral engagement area with an outer peripheral edge that is shorter than a thickness of the central cushioning area at the outer periphery of the central cushioning area.

13. The composite cushioning element of claim 1, further comprising: a third cushioning element positioned over the first cushioning element and the second cushioning element.

14. A method for fabricating a cushion, comprising: forming a first cushioning element from a first cushioning material, the first cushioning element comprising walls defining columnar cushioning cells in a central cushioning area of the first cushioning element and engagement features in a peripheral engagement area adjacent to an outer periphery of the central cushioning area, major surfaces of the central cushioning area of the first cushioning element being defined by exposed edges of the walls and coincident with ends of the columnar cushioning cells; and forming a second cushioning element, including: forming a second cushioning material to a shape complementary to shapes of the engagement features in the peripheral engagement area of the first cushioning element to define engagement elements of the second cushioning element; and defining a remainder of the second cushioning element from the second cushioning material.

15. The method of claim 14, further comprising: positioning the first cushioning element into a mold.

16. The method of claim 15, wherein forming the second cushioning element comprises introducing the second cushioning material into the mold after positioning the first cushioning element into the mold.

17. The method of claim 14, wherein forming the second cushioning element includes applying the second cushioning material over at least a portion of the central cushioning area of the first cushioning element.

18. The method of claim 17, further comprising: positioning a relief layer over at least a portion of the central cushioning area of the first cushioning element before forming the second cushioning element without adhering the relief layer to a majority of an upper surface of the central cushioning area.

19. The method of claim 14, wherein forming the first cushioning element comprises forming the first cushioning element with the engagement features of the peripheral engagement area comprising engagement cells.

20. The method of claim 19, wherein forming the second material to the shape complementary to shapes of the engagement features in the peripheral area of the first cushioning element comprises introducing the second cushioning material into and through the engagement cells of the peripheral engagement area of the first cushioning element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In the drawings:

[0024] FIG. 1 is a cross-sectional representation of an embodiment of a composite cushion according to this disclosure, showing embodiments of a first cushioning element that of the composite cushion and a second cushioning element that at least partially surrounds a periphery of the first cushioning element and that at least partially covers a top surface of the first cushioning element;

[0025] FIG. 2 is a partial perspective view of the first cushioning element of the composition cushion shown in FIG. 1, in which a peripheral engagement area of the first cushioning element has a stepped configuration relative to an outer periphery of a central cushioning area of the first cushioning element;

[0026] FIG. 3 is a cross-sectional representation of another embodiment of composite cushion that includes the first cushioning element of FIG. 1, with a second cushioning element that at least partially surrounds a periphery of the first cushioning element;

[0027] FIG. 4 is a top view of the composite cushion of FIG. 3;

[0028] FIG. 5 is a partial perspective view of another embodiment of first cushioning element, in which a peripheral engagement area of the first cushioning element tapers downward from an outer periphery of a central cushioning area of the first cushioning element;

[0029] FIG. 6 is a cross-sectional representation of the embodiment of the first cushioning element shown in FIG. 5;

[0030] FIG. 7 is a cross-sectional representation of yet another embodiment of composite cushion, including yet another embodiment of first cushioning element, in which a peripheral engagement area of the first cushioning element comprises flanges that protrude from an outer periphery of a central cushioning area of the first cushioning element;

[0031] FIG. 8 is a cross-sectional representation of a cushioning system that includes still another embodiment of a composite cushion according to this disclosure, as well as a third cushioning element that has been assembled with the composite cushion;

[0032] FIG. 9 is a partial perspective view of another embodiment of first cushioning element, in which ends of cells of a central cushioning area are at least partially closed; and

[0033] FIG. 10 is a cross-sectional representation of an embodiment of composite cushion that includes an embodiment of first cushioning element that includes a central cushioning area with cells that have ends that are at least partially closed.

DETAILED DESCRIPTION

[0034] With reference to FIG. 1, an embodiment of a composite cushion 1 according to this disclosure is depicted. The composite cushion 1 includes a first cushioning element 10 and a second cushioning element 20.

[0035] As FIG. 1 and FIG. 2 depict, the first cushioning element 10 includes a central cushioning area 12 and a peripheral engagement area 17. The central cushioning area 12 includes a top surface 12t and a bottom surface 12b. A plurality of cells 13 may extend substantially through the central cushioning area, between the top surface 12t and the bottom surface 12b. The cells 13, which may be arranged in an array, are defined by side walls 14, which may be formed from a compressible, resilient material. Together, the configurations of the cells 13 and the side walls 14 that define the cells 13, the arrangement of the cells 13, and the material from which the side walls 14 are formed may provide a plurality of so-called buckling columns in the central cushioning area 12. In some embodiments, the side walls 14 that define a cell 13 may buckle independently from the side walls 14 that define non-adjacent, or distant, cells 13.

[0036] The peripheral engagement area 16 is located adjacent to, and protrudes from, at least a portion of an outer periphery 15 of the central cushioning area 12. In some embodiments, the peripheral engagement area 16 may surround a portion of the central cushioning area 12. In other embodiments, the peripheral engagement area 16 may completely surround the central cushioning area 12.

[0037] Like the central cushioning area 12, the peripheral engagement area 16 of the first cushioning element 10 may include a plurality of cells 17 that are defined by side walls 18 and that extend between a top surface 16t and a bottom surface 16b of the peripheral engagement area 16. A top end 17t of each cell 17 may be open.

[0038] FIGS. 1 and 2 depict an embodiment of first cushioning element 10 in which the peripheral engagement area 16 is shorter or thinner than the central cushioning area 12.

[0039] The peripheral engagement area 16 of that embodiment is stepped, or recessed, relative to the outer periphery 15 of the central cushioning area 12. More specifically, the top surface 16t of the peripheral engagement area 16 is at a different elevation than the top surface 12t of the central cushioning area 12 and the bottom surface 16b of the peripheral engagement area 16 is stepped up relative to the bottom surface 12b of the central cushioning area 12. Such a configuration results in a peripheral engagement area 16 with outer edges that are shorter than a thickness of an outer periphery 15 of the central cushioning area 12, enabling the second cushioning element 20 to lock onto the first cushioning element 10 without being thicker than the first cushioning element 10. Alternatively, the top surface 16t of the peripheral engagement area 16 may be stepped down relative to the top surface 12t of the central cushioning area 12 while the bottom surfaces 16b and 12b of the peripheral engagement area 16 and the central cushioning area 12, respectively, are coplanar, or the bottom surface 16b of the peripheral engagement area 16 may be stepped up relative to the bottom surface 12b of the central cushioning area 12 while the top surfaces 16t and 12t of the peripheral engagement area 16 and the central cushioning area 12, respectively, are coplanar.

[0040] With continued reference to FIG. 1, in addition to the first cushioning element 10 and the second cushioning element 20, the composite cushion 1 includes a relief layer 30. The relief layer 30 is positioned on at least a portion of the top surface 12t of the central cushioning area 12 of the first cushioning element 10. The relief layer 30 may be positioned on the top surface 12t of the central cushioning area 12 without being secured to the top surface 12t. Alternatively, the relief layer 30 (e.g., one or more peripheral portions thereof, one or more central portions thereof, etc.) may be secured to the top surface 12t of the central cushioning area 12 while a remainder of the relief layer 30 (e.g., a majority of the portions of the relief layer 30 that contact the top surface 12t, etc.) may remain unsecured to the top surface 12t.

[0041] Peripheral portions 26 of the second cushioning element 20 at least partially surround the first cushioning element 10. In addition, the peripheral portions 26 of the second cushioning element 20 engage the peripheral engagement area 16 of the first cushioning element 10. More specifically, a material of the peripheral portions 26 of the second cushioning element 20 extends through cells 17 in the peripheral engagement area 16 of the first cushioning element 10 to interlock the peripheral portion 26 of the second cushioning element 20 to the peripheral engagement area 16 of the first cushioning element 10.

[0042] A central portion 22 of the second cushioning element 20 covers the relief layer 30 on the top surface 12t of the central cushioning area 12 of the first cushioning element 10. Such an arrangement may enable central superimposed portions of the first cushioning element 10 and the second cushioning element 20 to function somewhat independently from one another and without significant interference from one another. As an example, while the second cushioning element 20 located over the central cushioning area 12 of the first cushioning element 10 provides substantially constant cushioning and resistance without interfering with the ability of the central cushioning area 12 of the first cushioning element 10 to collapse under focused forces, while providing support to distributed forces.

[0043] FIGS. 3 and 4 illustrate an embodiment of a composite cushion 1 that includes a first cushioning element 10 and a second cushioning element 20 with substantially the same thickness, or height. Thus, neither the top surface 12t nor the bottom surface 12b of the central cushioning area 12 of the first cushioning element 10 is covered any portion of the second cushioning element 20; both of these major surfaces remain exposed. The second cushioning element 20 extends around an entire outer periphery 15 of the central cushioning area 12 of the first cushioning element 10, which may define a structure such as that shown in FIG. 3 or a laterally thinner racetrack structure around the first cushioning element 10.

[0044] Turning now to FIGS. 5 and 6, another embodiment of first cushioning element 10 is illustrated. The first cushioning element 10 includes a central cushioning area 12 and a peripheral engagement area 16. In some embodiments, the central cushioning area 12 may include the same features as the central cushioning area 12 of the embodiment of first cushioning element 10 depicted by FIGS. 1 and 2.

[0045] The peripheral engagement area 16 is located adjacent to at least a portion of an outer periphery 15 of the central cushioning area 12. Rather than have a stepped, or recessed, configuration like the peripheral engagement area 16 of the embodiment of first cushioning element 10 depicted by FIGS. 1 and 2, the peripheral engagement area 16 of the first cushioning element 10 illustrated by FIGS. 5 and 6 may include top and bottom surfaces 16t and 16b, respectively, that are tapered in such a way that outer edges 19 of the peripheral engagement area 16 are shorter than a thickness of the central cushioning area 12 at an outer periphery 15 thereof.

[0046] FIG. 7 provides a cross-sectional representation of another embodiment of first cushioning element 10and of a composite cushion 1 of which the first cushioning element 10 is a part. The embodiment of first cushioning element shown in FIG. 7 includes a peripheral engagement area 16 with one or more flanges 18 that protrude from an outer periphery 15 of central cushioning area 12of the first cushioning element 10. Each flange 18 defines recesses, including a top recess 18t that faces upwardly and a bottom recess 18b that faces downwardly. The top recess 18t and the bottom recess 18bmay receive the material of a second cushioning element 20, as shown, thus enabling the second cushioning element 20 to engage, or lock onto, the first cushioning element 10. In some embodiments, the peripheral engagement area 16 of the cushioning element 10 may comprise a single flange 18 that extends along a portion of the outer periphery 15 of the central cushioning area 12of the first cushioning element 10 that is to receive a second cushioning element 12 (e.g., along a portion of the outer periphery 15, around an entirety of the outer periphery 15, etc.). In other embodiments, the peripheral engagement area 16 may comprise a plurality of discrete flanges 18 positioned along at least a portion of the outer periphery 15. Discrete flanges 18may be short and/or elongated. In some embodiments, discrete flanges 18 may extend around corners of the outer periphery 15 of the central cushioning area 12 of the first cushioning element 10

[0047] FIG. 8 depicts, in cross-section, another embodiment of composite cushion 1 in which the peripheral engagement area 16 has a same thickness as the central cushioning area 12. A thickness of the second cushioning element 20 exceeds a thickness of the first cushioning element 10, with the top surface 21t of the second cushioning element 20 being located at a higher elevation than the top surface 11t of the first cushioning element 10 and the bottom surface and 21b of the second cushioning element 20 being located at a lower elevation than the bottom surface 11b of the first cushioning element 10.

[0048] In addition, the composite cushion 1 shown in FIG. 8 includes a third cushioning element 40, which is positioned on at least the first cushioning element 10 and, optionally, on the second cushioning element 20.

[0049] In the embodiments of first cushioning elements 10, 10, 10, and 10 depicted by FIGS. 1-8, their central cushioning areas 12, 12, 12, and 12 include open-ended cells (e.g., cells 13 shown in FIGS. 1 and 2). As an alternative, as shown in FIGS. 9 and 10, the central cushioning area 112 of a first cushioning element 110 may include a top surface 112t that comprises a membrane that extends at least partially over at least some cells 113. In the depicted embodiment, the membrane that defines the top surface 112t of the central cushioning area 112 may completely cover the top ends 113t of some cells 113 and partially cover the top ends 113t of other cells 113. Thus, openings 112o may extend through some locations of the membrane that defines the top surface 112t.

[0050] As FIG. 10 shows, during formation of a second cushioning element 120 with a central portion 122 that at least partially overlaps, or that is at least partially superimposed over, the central cushioning area 112 of the first cushioning element 110, material from which the second cushioning element 120 is formed may be introduced into through openings 112o in the top surface 112t and into their respective cells 113. That material may be subsequently removed from the cells 113.

[0051] Any embodiment of first cushioning element 10, 10, 10, 10, 110 (FIGS. 1-10) may be formed by any of a variety of suitable processes, including, but not limited to, the use of molds (e.g., by injecting the first cushioning material (e.g., a gel, etc.) into a mold, etc.). Once a first cushioning element 10, 10, 10, 10, 110 has been formed, it may be placed into another mold. In some embodiments, a relief layer 30 (FIG. 1) may be applied to at least a portion of the top surface 12t (FIG. 1) of the central cushioning area 12, 12, 12, 12 of the first cushioning element 10, 10, 10, 10 (FIGS. 1-8). The relief layer 30 may be placed on the central cushioning area 12, 12, 12, 12 of the first cushioning element 10, 10, 10, 10 without adhering to or otherwise being secured to the top surface 12t.

[0052] With the first cushioning element 10, 10, 10, 10, 110 (FIGS. 1-10) and any relief layer 30 (FIG. 1) in the mold, a second cushioning material (e.g., a rise in place foam, etc.) may be introduced into (e.g., injected, etc.) the mold to form the second cushioning element 20, 20, 20, 20, 120 (FIGS. 3, 4, 7, 8 and 10), including any engagement features thereof, laterally adjacent to at least a portion of the first cushioning element 10, 10, 10, 10, 110. In embodiments such as that depicted by FIGS. 9 and 10 where the second cushioning material is applied directly to the top surface 112t of the central cushioning area 112 of the first cushioning element 110 and the second cushioning material enters into cells 113 of the central cushioning area 112, the second cushioning material may be removed from those cells 113 after the second cushioning element 120 has been formed.

[0053] Although the preceding disclosure provides many specifics, these should not be construed as limiting the scope of any of the ensuing claims. Other embodiments may be devised which do not depart from the scopes of the claims. Features from different embodiments may be employed in combination. The scope of each claim is, therefore, indicated and limited only by its plain language and the full scope of available legal equivalents to its elements.