FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10 and Rule 13]
TITLE: “A CUSHIONING COMPONENT”
NAME AND ADDRESS OF THE APPLICANT:
COMFORT GRID TECHNOLOGIES PRIVATE LIMITED, 7th Floor, Unit 7A, Techweb
Centre, New Link Road, Near Raigad Military School, Jogeshwari West, Mumbai, Mumbai
Suburban, Maharashtra, 400102, India
NATIONALITY: Indian.
The following specification particularly describes the invention and the manner in which it is to
be performed.
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TECHNICAL FIELD
Present disclosure in general relates to cushioning. Particularly, but not exclusively, the present
disclosure relatesto an elastic cushioning member. Further, embodiments of the present disclosure
disclose a grid structured cushioning component with stabilizing fabric for use in mattress,
pillows, chairs, sofa furniture and the like.
BACKGROUND OF THE DISCLOSURE
Typically, cushioning components have a wide range of applications such as mattresses,
cushions, pillows, seating furniture and many more. These cushioning components are designed
to deflect or deform under the application of load, thereby absorbing an impact and providing
comfort to a user. Usually, the cushioning component is made of different materials such as
polyethylene or polyurethane foams, vinyl, rubber, springs, natural or synthetic fibers, fluid-filled
flexible sheets, etc. Such constructions and structure of the cushioning components tend to have
surfaces and wear after continuous usage over a period, thus causing discomfort and disruption
to the user. Conventional cushioning components include springs and foam to impart feel and
compression. Further, flexible sheets are provided that may be filled with fluid, which when
depressed, in the vicinity of the loading also increases pressure in the remaining volume of the
sheets. The response is resistive and bouncy, which is undesirable characteristics for the comfort
of the user, thereby leading to reduced life span of the cushioning components as well.
Additionally, surfaces of these conventional cushioning components like foam, memory foam,
or coir have a uniform block structure, which fail to distribute load/weight thereby generating
pressure points. Thus, usage of conventional cushioning component causes discomfort to user
and adversely affects various body regions of the user. Also, cushioning components having the
block structure have minimum space or air pockets to allow circulation of the air, which tends to
retain the body heat of the user causing heating and soreness to the user.
Some of the conventional arts, such as US patent publication no. US20170254379A1 disclose
elastomeric cushion members including perforated skins and related methods. Elastomeric
cushion members of US20170254379A1 patent publication include a plurality of interconnected
buckling walls including an elastomeric material. The interconnected buckling walls may
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together define a plurality of columns. A perforated skin may extend between at least some of
the plurality of interconnected buckling walls of at least some of the plurality of columns.
Methods of making elastomeric cushion members may involve interconnecting a plurality of
buckling walls including an elastomeric material. The interconnected buckling walls may
together define a plurality of columns. A perforated skin may be positioned to extend between at
least some of the plurality of interconnected buckling walls of at least some of the plurality of
columns.
Such elastomeric cushion members offer felxiblity under loading by uniform distribution of the
load. However, such elastomeric cushion members may have a poor bonding strength with other
materials used in mattresses like foam, felt etc., and therefore, would have limited product life.
Also, grids / holes causes discomfort while sleeping. In addition, the buckling walls of the
elastomeric cushioning members lack support, resulting in tearing/breakage over time and hence
reduces the usage life.
The present disclosure is directed to overcome one or more limitations stated above or any other
limitation associated with conventional arts.
SUMMARY OF THE DISCLOSURE
The shortcomings of the prior art are overcome, and additional advantages are provided through
the provision of cushioning component of the present disclosure. Additional features and
advantages are realized through the techniques of the present disclosure. Other embodiments and
aspects of the disclosure are described in detail herein.
In one non-limiting embodiment of the present disclosure a cushioning component is disclosed.
The cushioning component includes an elastomeric cushioning member defined with a top
cushioning surface and a bottom base surface. The elastomeric cushioning member includes a
plurality of buckling walls defining a grid structure having an array of openings. The plurality of
buckling walls are structured to buckle on application of load, for uniformly distributing the load
across the cushioning component and return to an original state upon removal of the load. The
cushioning component also includes a stabilizing fabric secured to at least the top cushioning
surface and the bottom base surface of the elastomeric cushioning member.
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In an embodiment, the grid structure is defined by a first plurality of buckling walls extending in
a fist direction and a second plurality buckling walls intersecting the first plurality of buckling
walls and extending in a second direction.
In an embodiment, the grid structure is defined by the plurality of buckling walls arranged in a
non-intersecting orientation.
In an embodiment, the plurality buckling walls are defined with a height ranging between 5mm
to 100mm, and a wall thickness ranging between 0.5mm to 6mm.
In an embodiment, the cushioning component includes a frame surrounding and laterally
supporting at least one side of the grid structure.
In an embodiment, the elastomeric cushioning member is manufactured from a material
including one of an elastomeric material, a thermoplastic elastomer, a natural rubber, a synthetic
elastomer, polypropylene, silicon, a blend of natural and synthetic elastomers, silica gel,
polymer, and liquid silicon.
In an embodiment, the stabilizing fabric is heat fused to the top cushioning surface and the bottom
base surface of the elastomeric cushioning member, wherein the heat fusing of the stabilizing
fabric to the top cushioning surface and the bottom base surface is carried out during molding
process or post molding process of the elastomeric cushioning member.
In an embodiment, the stabilizing fabric is bonded to the top cushioning surface and the bottom
base surface of the elastomeric cushioning member.
In another non-limiting embodiment of the disclosure, a mattress is disclosed. The mattress
includes a bottom foam layer, a first felt layer on top of the bottom foam layer, a layer of spring
coils positioned above the first felt layer and at least one cushioning component positioned above
the layer of spring coils. At least one cushioning component includes an elastomeric cushioning
member defined with a top cushioning surface and a bottom base surface. The elastomeric
cushioning member includes a plurality of buckling walls defining a grid structure having an
array of openings. The plurality of buckling walls are structured to buckle on application of load,
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for uniformly distributing the load across the cushioning component and return to an original
state upon removal of the load. The cushioning component also includes a stabilizing fabric
secured to at least the top cushioning surface and the bottom base surface of the elastomeric
cushioning member.
In an embodiment, the mattress includes a second felt layer on top of the layer of spring coils, a
side encasing foam layer extending between the first and the second felt layers and laterally
surrounding at least one side of the layer of spring coils, an upper foam layer secured above the
at least one cushioning component, a transition foam layer positioned over the second felt layer
and below the at least one cushioning component, and a support foam layer positioned between
the transition foam layer and the upper foam layer and laterally surrounding the at least one
cushioning component.
In yet another non-limiting embodiment of the disclosure a mattress is disclosed. The mattress
bottom foam layer and at least one cushioning component positioned above the bottom foam
layer. At least one cushioning component includes an elastomeric cushioning member defined
with a top cushioning surface and a bottom base surface. The elastomeric cushioning member
includes a plurality of buckling walls defining a grid structure having an array of openings. The
plurality of buckling walls are structured to buckle on application of load, for uniformly
distributing the load across the cushioning component and return to an original state upon
removal of the load. The cushioning component also includes a stabilizing fabric secured to at
least the top cushioning surface and the bottom base surface of the elastomeric cushioning
member.
In an embodiment, the mattress includes an upper foam layer secured above the at least one
cushioning component, and a support foam layer laterally surrounding the at least one cushioning
component.
In an embodiment, the mattress includes a transition foam layer positioned above the bottom
foam layer.
In an embodiment, the mattress includes a cover layer in the form of a zipper or tape edged cover,
covering the mattress.
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It is to be understood that the aspects and embodiments of the disclosure described above may
be used in combination with each other. Several of the aspects and embodiments may be
combined to form a further embodiment of the disclosure.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In
addition to the illustrative aspects, embodiments, and features described above, further aspects,
embodiments, and features will become apparent by reference to the drawings and the following
detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristics of the disclosure are set forth in the appended claims. The
disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages
thereof, will best be understood by reference to the following detailed description of an illustrative
embodiment when read in conjunction with the accompanying figures. One or more embodiments
are now described, by way of example only, with reference to the accompanying figures wherein
like reference numerals represent like elements and in which:
Figure 1a illustrates a schematic top perspective view of a cushioning component, in
accordance with an embodiment of the present disclosure;
Figure 2 illustrates an exploded view of the cushioning component of Figure. 1;
Figure 3 illustrates a schematic top view of the cushioning component of Figure 1;
Figure 4 illustrates a sectional side view of the cushioning component along section s-s of
Figure 3;
Figure 5a illustrates a schematic top perspective view of a cushioning component, in
accordance with another embodiment of the present disclosure;
Figure 5b illustrates a schematic top perspective view of a cushioning component with
stabilizing fabric in only one side, in accordance with yet another embodiment of the present
disclosure;
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Figure 6 illustrates a schematic view of a mattress comprising the cushioning component, in
accordance with an embodiment of the present disclosure;
Figure 7 illustrates a schematic view of a mattress comprising the cushioning component,
in accordance with another embodiment of the present disclosure; and
Figure 8a to Figure 8j illustrates schematic views of the cushioning component arranged
within mattress, in accordance with various embodiments of the present disclosure.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled
in the art will readily recognize from the following description that alternative embodiments of
the structures and methods illustrated herein may be employed without departing from the
principles of the disclosure described herein.
DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure
in order that the detailed description of the disclosure that follows may be better understood.
Additional features and advantages of the disclosure will be described hereinafter which forms
the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that
the conception and specific embodiment disclosed may be readily utilized as a basis for
modifying or designing other alternatives for carrying out the same purposes of the present
disclosure. It should also be realized by those skilled in the art that such equivalent constructions
do not depart from the scope of the disclosure as set forth in the appended claims. The novel
features which are believed to be characteristic of the disclosure, both as to its organization and
method of operation, together with further objects and advantages will be better understood from
the following description when considered in connection with the accompanying figures. It is to
be expressly understood, however, that each of the figures is provided for the purpose of
illustration and description only and is not intended as a definition of the limits of the present
disclosure.
In the present disclosure, the word "exemplary" is used herein to mean "serving as an example,
instance, or illustration." Any embodiment or implementation of the present subject matter
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described herein as "exemplary" is not necessarily to be construed as preferred or advantageous
over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific
embodiments thereof have been shown by way of example in the drawings and will be described
in detail below. It should be understood, however that it is not intended to limit the disclosure to
the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents,
and alternative falling within the spirit and the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variationsthereof, are intended to cover a nonexclusive inclusion, such that an arrangement, or process that comprises a list of components or
steps does not include only those components or steps but may include other components or steps
not expressly listed or inherent to such setup or device or process. In other words, one or more
elements in an arrangement proceeded by “comprises… a” does not, without more constraints,
preclude the existence of other elements or additional elements in the arrangement.
Embodiments of the present disclosure disclose a cushioning component for use in applications
including but not limiting to bedding [mattress and/or pillows], seating, and other cushions.
Generally, the cushioning component includes a plurality of layers of different types of materials
deflect or deform under load. Usually, these cushioning components wear after continuous usage
over a period of time, thus causing discomfort and disruption to the user. Moreover, conventional
cushioning components fail to distribute load/weight thereby generating pressure points. Further,
the cushioning components having a block structure will have minimum space or air pockets to
allow circulation of air, which tends to retain a body heat of the user causing heating and soreness
to the user. Also, cushioning components with buckling walls are known in the art and such
configurations overcome the problems associated with the conventional cushioning components.
However, the cushioning component with buckling walls will have a poor bonding strength with
other materials used in mattresses like foam, felt etc., and therefore, would have limited product
life. Also, grids / holes causes discomfort to the user while sleeping. In addition, the buckling
walls of the elastomeric cushioning members lack support, resulting in tearing/breakage over
time and hence reduces the usage life.. Hence, there is a need a to improve overall stability of the
cushioning component having buckling wall structure.
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The cushioning component of the present disclosure includes an elastomeric cushioning member
defined with a top cushioning surface and a bottom base surface. The elastomeric cushioning
member includes a plurality of buckling walls defining a grid structure having an array of
openings. The plurality of buckling walls are structured to buckle on application of load, for
uniformly distributing the load across the cushioning component and return to an original state
upon removal of the load. The cushioning component also includes a stabilizing fabric secured
to at least the top cushioning surface and the bottom base surface of the elastomeric cushioning
member. The provision of stabilizing fabric improves stability of cushioning component and
increases longevity, thereby improving the usage life of the cushioning component. Further,
addition of the stabilizing fabric increases bonding strength of cushioning component to other
materials used in mattresses like foam, felt etc. The stabilizing fabric also improves the comfort
to the user, as the user doesn’t feel the grids/holes while sleeping. Furthermore, the stabilizing
fabric increases the support provided to the cushioning member and avoids/ reduces tearing/
breakage over time and hence increase usage life.
Referring to Figures 1 to 4, which are exemplary embodiments of the present disclosure
illustrating a cushioning component identified with reference numeral 100.
The cushioning component (100) includes an elastomeric cushioning member (101). The
elastomeric cushioning member (101) as the name indicates is a flexible member of generally a
polygonal or circular configuration having a top surface and a bottom surface. In an embodiment,
the top surface is defined as a top cushioning surface (101a) and the bottom surface is defined as
a bottom base surface (101b). The elastomeric cushioning member (101) includes a plurality of
buckling walls (BW) defining a grid structure having an array of openings (20). The plurality of
buckling walls (BW) are structured to buckle on application of load, for uniformly distributing
the load across the cushioning component (100) and return to an original state upon removal of
the load. As shown in Figure. 1, the cushioning component (100) includes a stabilizing fabric
(102) [also referred as a layer of fabric] secured to the top cushioning surface (101a) and the
bottom base surface (101b) of the elastomeric cushioning member (101). In an embodiment, the
stabilizing fabric (102) may be a cotton, a cotton jersey, jersey fabric, spun, polyester, felt fabric
,cotton/polyester blend, lycra, wool, a cloth or any suitable fabric material. The stabilizing fabric
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(102) is secured to the top cushioning surface (101a) and the bottom base surface (101b) of the
elastomeric cushioning member (101) through fusing or bonding process. The stabilizing fabric
(102) supports buckling walls (BW) of the elastomeric cushioning member (101) and thereby
increases strength of the elastomeric cushioning member (101). This configuration increases the
longevity of the cushioning component (100). Further, addition of the stabilizing fabric (102)
increases bonding strength of cushioning component (100) to other materials used in mattresses
like foam, felt etc. The stabilizing fabric (102) also improves the comfort to the user, as the user
doesn’t feel the grids/holes while sleeping. Furthermore, the stabilizing fabric (102) increases
the support provided to the cushioning member (100) and avoids/ reduces tearing/ breakage over
time and hence increase usage life.
In an embodiment, the stabilizing fabric (102) may be heat fused to the elastomeric component
during the molding process of the elastomeric component or post molding process. In another
embodiment, the stabilizing fabric (102) is bonded to the top cushioning surface (101a) and the
bottom base surface (101b) of the elastomeric cushioning member (101) through an adhesive or
heat bonding.
In an embodiment, the plurality of buckling walls (BW) may be defined with a height (H) and
wall thickness (t). The height (H) of the plurality of buckling walls (BW) may range from about
5 mm to 100mm and the wall thickness (t) may range from about 0.5mm to 6 mm.
Referring to Figures. 2-4, the elastomeric cushioning member (101) is formed by interconnected
buckling walls (BW). As seen in Figure. 2, the array of openings (20) is formed by intersection of a
plurality of first buckling walls (BW1) and a plurality of second buckling walls (BW2) extending
in different orientations i.e., first and the second directions (A and B). The intersection of the
plurality of first buckling walls (BW1) and the plurality of second buckling walls (BW2) defines an
intersection of the interconnected buckling walls of the grid structure. In an exemplary embodiment,
as shown in Figure. 2, the interconnected buckling walls (BW) are defined by the first buckling
walls (BW1) and the plurality of second buckling walls (BW2) extending in the first and second
directions (A and B), in which the second direction (B) is perpendicular to the first direction (A).
Such configuration of the interconnected buckling walls defines an intersection point (I).
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In an embodiment, the elastomeric cushioning member (101) may include a plurality of buckling
walls (BW) of non-intersecting configuration [shown in Figure. 5a] defining a grid structure having
an array of openings (20). The plurality of buckling walls (BW) adjacent to each other forms an
angle, to define the non-intersecting configuration. The angle may be an obtuse and/or an acute
angle, and non-intersecting configuration can be pentagon, rhombus, hexagon and/or octagon. In an
embodiment, the non-intersecting configuration may be honeycomb configuration as shown in
Figure. 5. As shown in Figure. 5a, the cushioning component (100) includes a stabilizing fabric
(102) [also referred as a layer of fabric] secured to the top cushioning surface (101a) and the
bottom base surface (101b) of the elastomeric cushioning member (101).
In an embodiment, the cushioning component (100) may have a stabilizing fabric (102) in only
on the sides. For example, the cushioning component (100) may have a stabilizing fabric (102)
heat fused to the top cushioning surface (102a) of the elastomeric cushioning member (101)
[shown in Figure. 5b]. In other examples, the stabilizing fabric (102) may be heat fused to the
bottom base surface (102b) of the elastomeric cushioning member (101)
Referring again to Figure. 1 and Figure. 5a, the elastomeric cushioning member (101) includes a
frame (10) surrounding and laterally supporting at least one side of the grid structure. The frame
(10) aids in defining an outer skeleton of the grid structure. The frame (10) is composed of strip
extending along a periphery of the elastomeric cushioning member (101). In an exemplary
configuration, the frame (10) includes a first side, a second side, a third side and a fourth side.
The frame (10) may also be defined with a top surface and a bottom surface. The second side is
configured opposite the first side and the third side is opposite the fourth side. In an embodiment,
the plurality of buckling walls (BW) are longitudinal members integrally arranged in an array to
form grid structure within the frame (10) defined with the plurality of the openings (20). In an
embodiment, the elastomeric cushioning member (101) may be manufactured without the frame
(10) as per the application requirement.
Further, the elastomeric cushioning member (101) is manufactured using an elastomeric material
which may include an elastomeric polymer. The elastomeric material may be a gelatinous
elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic
elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers,
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Silica gel, polymer, liquid silicon, polypropylene and silicon and any suitable material that
provides durability and elasticity the elastomeric cushioning member (101). In another
embodiment, the material comprises a hardness on a Shore A scale of less than 10. In an
embodiment, the cushioning component is manufactured by a Thermoplastic ABA co-polymer
with shore A hardness of less than 1.The hardness indicated here is example and should not be
considered as limiting to the present disclosure.
In an embodiment, the grid structure formed is coated with a powdered material. The powdered
material may include materials like silica, calcium carbonate, Talc, and other powders. In an
embodiment, the coating may be at least one of lubricant, and glidant. In another embodiment,
the glidant may be selected from the group comprising Starch, Talc, Colloidal Silica.
In an exemplary embodiment, the elastomeric cushioning member (101) is manufactured by a
thermoplastic molding process.
Further, as illustrated in Figure 6, the present disclosure discloses a mattress (200) comprising a
bottom foam layer (210) forming a base of the mattress (200). The mattress (200) includes a first
felt layer (230a) positioned on top of the bottom foam layer (210). Further, a layer of spring coils
(220) is positioned above the first felt layer (230a). In an embodiment, a second felt layer (230b)
is provided on top of the layer of spring coils (220). More specifically, the layer of spring coils
(220) may be disposed between the first and second felt layers (230a, 230b) to securely hold and
protect the layer of spring coils (220). In an embodiment, height of the first and second felt layer
(230a, 230b) may range between 2 mm to 30 mm. Further, the first and the second felt layers
(230a, 230b) include at least one of thick cloth, polyester wadding, polyester blend fabric, spun
fabric cotton, non-woven fabric, felt fabric layers and any combination thereof. In an embodiment,
a side encasing foam layer (260) is provided such that it extends between the first and the second
felt layers (230a, 230b) and laterally surrounds at least one side of the layer of the spring coils
(220). The side encasing foam layer (260) may be provided to laterally surround all sides of the
layer ofspring coils(220). Thisside encasing foam layer (260)laterally secureslayer of the spring
coils (220) and prevents misalignment of the layer of the spring coils (220) with respect to
adjacent layers of the mattress (200) and also helps to ensure there is support on the edges of the
cushioning material (100). A predetermined height of the side encasing foam layer (260) may be
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similar to a predetermined height of the layer of the spring coils(220). The layer of the spring coils
(220) is a layer of wire pocket spring coils arranged in an array.
In an embodiment, the mattress (200) may include a transition foam layer (240) positioned over
the second felt layer (230b) and below the cushioning component (100). Further, at least one
cushioning component (100) is positioned above the transition foam layer (240). The transition
foam layer (240) provides a stabilizing base to the at least one cushioning component (100) and
aids in better bonding and strength of the mattress (200). The height of the transition foam layer
(240) may range between 5 mm to 50mm. The at least one cushioning component (100) of the
mattress (200) includes an elastomeric cushioning member (101) having a top cushioning surface
(101a) and a bottom base surface (101b). The elastomeric cushioning member (101) includes a
plurality of buckling walls (BW) defining a grid structure having an array of openings (20). The
plurality of buckling walls (BW) are structured to buckle on application of load, for uniformly
distributing the load across the cushioning component (100) and return to an original state upon
removal of the load. As shown in Figure. 6, the cushioning component (100) includes a
stabilizing fabric (102) [also referred as a layer of fabric] secured to the top cushioning surface
(101a) and the bottom base surface (101b) of the elastomeric cushioning member (101). In an
embodiment, the stabilizing fabric (102) may be a cloth or any suitable material and is secured
to the to the top cushioning surface (101a) and the bottom base surface (101b) of the elastomeric
cushioning member (101) through fusing or bonding process. The stabilizing fabric (102)
supports buckling walls (BW) of the elastomeric cushioning member (101) and thereby increases
strength of the elastomeric cushioning member (101). This configuration increases the longevity
of the cushioning component (100). The stabilizing fabric (102) is also configured to provide
grip for attaching other components of the mattress (200) to the cushioning component (100).
The mattress (200) further includes a support foam layer (255) that is positioned between the
transition foam layer (240) and the upper foam layer (250) and laterally surrounds the at least one
cushioning component (100) as shown in Figure 6. This support foam layer (255) is provided
to support the at least one cushioning component (100) at the edges to maintain the positioning
and alignment of the cushioning component (100) and any damage to the grid structure is averted.
In an embodiment, an upper foam layer (250) is secured above the at least one cushioning
component (100) and holds the below layers as a single component. In an embodiment, the upper
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foam layer (250), the transition foam layer (240) and the bottom foam layer (210) is at least one
of polyurethane foam, memory foam, coir, latex, rebonded foam. In an embodiment, the upper
foam layer (240) be between 7 mm to 50 mm. The objective is to ensure user will not feel
structure of the grid structure while sleeping and still have the benefit of weight distribution and
pressure relief.
Further, the mattress (200) is surrounded and enclosed by a cover (272) to hold on all the layers
of the mattress (200). The cover may be made of tricot jersey cover or any suitable material. In
an embodiment, the mattress is covered with a packaging cover (274) such as zipper to store and
allow access to the mattress (200). This packaging cover (274) allows ease of transportation
without causing any damage to the mattress (200).
In a non-limiting embodiment, themattress(200) may include one ormore layers ofthe cushioning
component (100), upper, lower and transition foam layers (210, 240, 250), layer of spring coils
(220), the first and second felt layers (230a, 230b) and may be arranged in an any combination
thereof as per user’s comfort and application requirement.
Referring to Figure. 7 the present disclosure discloses another embodiment of a mattress
(300) comprising a bottom foam layer (310) forming a base of the mattress (300). In an
embodiment, the bottom foam layer (310) may have a height ranging between 1 inch to 8 inches.
Further, the material of the bottom foam layer (310) is at least one of the Polyurethane foam,
memory foam, rebonded foam, COIR, natural or synthetic latex, profile cut foam. The mattress
(300) includes at least one cushioning component (100) positioned above the bottom foam layer
(310). The cushioning component (100) of the mattress (300) includes an elastomeric cushioning
member (101) having a top cushioning surface (101a) and a bottom base surface (101b). The
elastomeric cushioning member (101) includes a plurality of buckling walls (BW) defining a grid
structure having an array of openings (20). The plurality of buckling walls (BW) are structured
to buckle on application of load, for uniformly distributing the load across the cushioning
component (100) and return to an original state upon removal of the load. As shown in Figure.
7, the cushioning component (100) includes a stabilizing fabric (102) [also referred as a layer of
fabric] secured to the top cushioning surface (101a) and the bottom base surface (101b) of the
elastomeric cushioning member (101). In an embodiment, the stabilizing fabric (102) may be a
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cloth or any suitable material and is secured to the to the top cushioning surface (101a) and the
bottom base surface (101b) of the elastomeric cushioning member (101) through fusing or
bonding process. The stabilizing fabric (102) supports buckling walls (BW) of the elastomeric
cushioning member (101) and thereby increases strength of the elastomeric cushioning member
(101). This configuration increases the longevity of the cushioning component (100). The
stabilizing fabric (102) is also configured to provide grip for attaching other components of the
mattress (300) to the cushioning component (100).
In an embodiment, a transition foam layer (320) is positioned above the bottom foam layer (310)
and below the cushioning component (100). The transition foam layer (320) provides a stabilizing
base to the cushioning component (100) and aids in better bonding and strength of the mattress
(300). The height of the transition foam layer (320) may range between 5 mm to 50mm.In an
embodiment, one or more cushioning components(100) may be configured adjacent to each other
depending on length and width of the mattress (300). The mattress (300) comprises a support
foam layer (355) that is positioned between the transition foam layer (320) and an upper foam
layer (330) and laterally surroundsthe at least one cushioning component (100) asshown in Figure
5. This support foam layer (355) is provided to support the at least one cushioning component
(100) at the edges to maintain the positioning and alignment of the cushioning component (100)
and any damage to the grid structure is averted. Also, the side encasing helps provide an edge
support to the mattress which prevents damage and better comfort while sitting on the edges of
the mattress. The mattress (300) also includes an upper foam layer (330) which is secured above
the at least one cushioning component (100) and holds the below layers as a single component.
In an embodiment, the upper foam layer (330) may have a height between 7 mm to 50 mm. The
objective is to ensure user will not feel structure of the grid structure while sleeping and still
have the benefit of weight distribution and pressure relief. In an embodiment, the upper foam
layer (330), the transition foam layer (320) and the bottom foam layer (310) is at least one of
memory foam, coir, latex. Further, the mattress(300) is surrounded and enclosed by a cover (340)
to hold on all the layers of the mattress (300). The cover may be made of tricot jersey cover or
any suitable material. In an embodiment, the mattress is covered with a packaging cover (350)
such as zipper or tape edge cover to store and allow access of the mattress (300). This packaging
cover (345) allows ease of transportation without causing any damage to the mattress (300).
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Further, other embodiments of the mattress are disclosed from Figures 8a to 8j illustrates various
configuration of the cushioning component (100) within a mattress (200, 300). As shown in
Figure 8a and Figure 8b, the bottom layer is a foam layer (25), above which a layer of spring coils
(26) is provided which is disposed between two felt layers (27). Further, an additional foam layer
(25) is provided and at the top the cushioning component (100) is provided. In figure 8c and
8d, the bottom layer includes the foam layer (25), above which the layer of spring coils (26) is
provided. Later, cushioning component (100) is provided, above which an additional foam layer
(25) is provided. The mattress (200, 300) may include a combination of cushioning component
(100) disposed between two or more foam layers (25) as seen in Figures 8e to 8g. Further, the
cushioning component (100) may be provided as top layer for one or more foam layers (25)
as shown in Figures 8h to Figure 8j. The predetermined height of the foam layer (25), the layer
of spring coils (26) and the felt layers (27) and the cushioning component (100) may vary as
per application requirements of the mattress (200, 300). Further, each layer of the mattress (200,
300) can be positioned to joined to other layers by any adhesive material, mechanical fastening
means, stitching means, resin bonding and the like. The cushioning components (100) may be
used in any applications including mattresses (200, 300), cushions, pillows, seating furniture.
The cushioning component (100) having elastomeric cushioning member and a stabilizing fabric
(102) allows object/ user to sink deeply because of the buckling of the grids structure when
subjected to the load. Further, the dense grid structure provides a surface area to expand and
resist higher load/weights.
In an embodiment, the present disclosure provides the cushioning component (100) and the
mattress (200, 300) that is simple, robust, and aids in reusability.
In an embodiment, the cushioning component (100) and the mattress (200, 300) of the present
disclosure provides comfort to the user for longer durations.
In an embodiment, the stabilizing fabric (102) in the cushioning component (100) increases
strength of the buckling walls and hence the usage life of the cushioning component (100) and
longevity can be increased. Further, addition of the stabilizing fabric increases bonding strength
of cushioning component to other materials used in mattresses like foam, felt etc. The stabilizing
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fabric also improves the comfort to the user, as the user doesn’t feel the grids/holes while
sleeping. Furthermore, the stabilizing fabric increases the support provided to the cushioning
member and avoids/ reduces tearing/ breakage over time and hence increase usage life.
Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill
in the art can translate from the plural to the singular and/or from the singular to the plural as is
appropriate to the context and/or application. The various singular/plural permutations may be
expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in
the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms
(e.g., the term “including” should be interpreted as “including but not limited to,” the term
“having” should be interpreted as “having at least,” the term “includes” should be interpreted as
“includes but is not limited to,” etc.). It will be further understood by those within the art that if
a specific number of an introduced claim recitation is intended, such an intent will be explicitly
recited in the claim, and in the absence of such recitation no such intent is present. For example,
as an aid to understanding, the following appended claims may contain usage of the introductory
phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such
phrasesshould not be construed to imply that the introduction of a claim recitation by the indefinite
articles “a” or “an” limits any particular claim containing such introduced claim recitation to
inventions containing only one such recitation, even when the same claim includes the
introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an”
(e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”);
the same holds true for the use of definite articles used to introduce claim recitations.
In addition, even if a specific number of an introduced claim recitation is explicitly recited, those
skilled in the art will recognize that such recitation should typically be interpreted to mean at least
the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically
means at least two recitations, or two or more recitations). Furthermore, in those instances where
a convention analogousto “at least one of A, B, and C, etc.” is used, in generalsuch a construction
isintended in the sense one having skill in the art would understand the convention (e.g., “a system
18
having at least one of A, B, and C” would include but not be limited to systems that have A alone,
B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C
together, etc.). In those instances where a convention analogousto “at least one of A, B, or C, etc.”
is used, in general such a construction is intended in the sense one having skill in the art would
understand the convention (e.g., “a system having at least one of A, B, or C” would include but
not be limited to systemsthat have A alone, B alone, C alone, A and B together, A and C together,
B and C together, and/or A, B, and C together, etc.). It will be further understood by those within
the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms,
whether in the description, claims, or drawings, should be understood to contemplate the
possibilities of including one of the terms, either of the terms, or both terms. For example, the
phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
While various aspects and embodiments have been disclosed herein, other aspects and
embodiments will be apparent to those skilled in the art. The various aspects and embodiments
disclosed herein are for purposes of illustration and are not intended to be limiting, with the true
scope and spirit being indicated by the following claims.
Referral Numeral:
Referral numerals Description
100 Cushioning component
10 Frame
101 Elastomeric cushioning member
101a Top cushioning surface
101b Bottom base surface
102 Stabilizing fabric
BW Buckling walls
BW1 First plurality of buckling walls
BW2 Second plurality of buckling walls
20 Openings
25 Foam layer
26 Spring coils layer
19
27 Fabric layers
200, 300 Mattress
210 Bottom foam layer
220 Layer of spring coils
230a, 230b First and a second felt layer
240 Transition foam layer
250 Upper foam layer
255 Support foam layer
260 Side encasing foam layer
272 Cover
274 Packaging cover
310 Bottom foam layer
320 Transition foam layer
330 Upper foam layer
340 Cover
345 Packaging cover
355 Support foam layer
370 Fabric layer
A First direction
B Second direction
20
We claim:
1. A cushioning component (100), comprising:
an elastomeric cushioning member (101), defined with:
a top cushioning surface (101a); and
a bottom base surface (101b);
wherein, the elastomeric cushioning member (101) comprises a plurality of buckling
walls (BW) defining a grid structure having an array of openings (20), the plurality
of buckling walls (BW) are being structured to buckle on application of load, for
uniformly distributing the load across the cushioning component (100) and return to
an original state upon removal of the load; and
a stabilizing fabric (102) secured to at least the top cushioning surface (101a) and the
bottom base surface (101b) of the elastomeric cushioning member (101).
2. The cushioning component (100) as claimed in claim 1, wherein the grid structure is defined
by:
a first plurality of buckling walls (BW1) extending in a fist direction (A); and
a second plurality buckling walls (BW2) intersecting the first plurality of buckling
walls (BW1) and extending in a second direction (B).
3. The cushioning component (100) as claimed in claim 1, wherein the grid structure is defined
by the plurality of buckling walls (BW) arranged in a non-intersecting orientation.
4. The cushioning component (100) as claimed in claim 1, wherein the plurality buckling walls
(BW) are defined with a height (H) ranging between 5mm to 100mm.
5. The cushioning component (100) as claimed in claim 1, wherein the plurality buckling walls
(BW) are defined with a wall thickness (t) ranging between 0.5mm to 6mm.
6. The cushioning component (100) as claimed in claim 1, comprises a frame (10) surrounding
and laterally supporting at least one side of the grid structure.
7. The cushioning component (100) as claimed in claim 1, wherein the elastomeric cushioning
member (101) is manufactured from a material including one of an elastomeric material, a
thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and
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synthetic elastomers, silica gel, silicon, polypropylene, polymer, and liquid silicon.
8. The cushioning component (100) as claimed in claim 1, wherein the stabilizing fabric (102)
is heat fused to the top cushioning surface and the bottom base surface of the elastomeric
cushioning member (101).
9. The cushioning component (100) as claimed in claim 1, wherein the heat fusing of the
stabilizing fabric (102) to the top cushioning surface (101a) and the bottom base surface
(101b) is carried out during molding process or post molding process of the elastomeric
cushioning member (101).
10. The cushioning component (100) as claimed in claim 1, wherein the stabilizing fabric (102)
is bonded to the top cushioning surface and the bottom base surface of the elastomeric
cushioning member (101).
11. A mattress (200), comprising:
a bottom foam layer (210);
a first felt layer (230a) on top of the bottom foam layer (210);
a layer of spring coils (220) positioned above the first felt layer (230a);
at least one cushioning component (100) positioned above the layer of spring coils
(220), the at least one cushioning component (100) comprising:
an elastomeric cushioning member (101), defined with:
a top cushioning surface (101a); and
a bottom base surface (101b);
wherein, the elastomeric cushioning member (101) comprises a plurality of
buckling walls (BW) defining a grid structure having an array of openings
(20), the plurality of buckling walls (BW) are being structured to buckle on
application of load, for uniformly distributing the load across the cushioning
component (100) and return to an original state upon removal of the loa; and
a stabilizing fabric (102) secured to at least the top cushioning surface (101a)
and the bottom base surface (101b) of the elastomeric cushioning member (101).
12. The mattress (200) as claimed in claim 11, comprises a second felt layer (230b) on top of the
layer of spring coils (220).
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13. The mattress (200) as claimed in claims 11 and 12, comprises a side encasing foam layer
(260) laterally surrounding at least one side of the layer of spring coils (220).
14. The mattress (200) as claimed in claim 11, comprises an upper foam layer (250) secured
above the at least one cushioning component (100).
15. The mattress (200) as claimed in claim 11, comprises a transition foam layer (240) positioned
over the second felt layer (230b) and below the at least one cushioning component (100).
16. The mattress (200) as claimed in claim 15, comprises a support foam layer (255) laterally
surrounding the at least one cushioning component (100).
17. A mattress (300), comprising:
a bottom foam layer (310);
at least one cushioning component (100) positioned above the bottom foam layer
(310), the at least one cushioning component (100) comprising:
an elastomeric cushioning member (101), defined with:
a top cushioning surface (101a); and
a bottom base surface (101b);
wherein, the elastomeric cushioning member (101) comprises a plurality of
buckling walls (BW) defining a grid structure having an array of openings
(20), the plurality of buckling walls (BW) are being structured to buckle on
application of load, for uniformly distributing the load across the cushioning
component (100) and return to an original state upon removal of the load; and
a stabilizing fabric (102) secured to at least the top cushioning surface (101a)
and the bottom base surface (101b) of the elastomeric cushioning member (101).
18. The mattress (300) as claimed in claim 17, comprises an upper foam layer (330) secured
above the at least one cushioning component (100).
19. The mattress (300) as claimed in claim 17, comprises a support foam layer (355) laterally
surrounding the at least one cushioning component (100).
20. The mattress (300) as claimed in claims 17 and 18, comprises a transition foam layer (320)
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positioned above the bottom foam layer (310).
21. The mattress (300) as claimed in claim 17, comprises a zipper or tape edged cover, covering
the mattress (300).