TECHNICAL FIELD
Present disclosure in general relates to cushioning components. Particularly, but not exclusively,
the present disclosure relates to an elastomeric cushioning member. Further, embodiments of the
5 present disclosure disclose a non-intersecting grid-structured cushioning component for use in
mattress, pillows, chairs, sofa furniture and the like.
BACKGROUND OF THE DISCLOSURE
10 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
15 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
20 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
25 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.
30 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
3
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
5 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 flexibility under loading by uniform distribution of the
10 load. However, such elastomeric cushion members fail under constant loading and tangential
pressure, particularly in the intersection of the buckling walls due to stress concentration. More
particularly, the buckling walls tend to break at intersection due to tangential loading. Also,
rejection percentage of cushioning component while molding is higher as the sharp ends will
tend to cause breakage while ejection.
15
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
20
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.
25
In one non-limiting embodiment of the present disclosure a cushioning component is disclosed.
The cushioning component includes an elastomeric cushioning member. The elastomeric
cushioning member includes a top cushioning surface and a bottom base surface. The elastomeric
cushioning member includes a plurality of buckling walls arranged in a non-intersecting
30 configuration defining a grid structure having an array of openings, the plurality of buckling
walls are being 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.
4
In an embodiment, the plurality of buckling walls adjacent to each other forms an angle, to define
the non-intersecting configuration.
In an embodiment, the angle is at least one of an obtuse angle and an acute angle.
5
In an embodiment, the plurality buckling walls are defined with a height ranging between 2
mm to 75 mm.
In an embodiment, the plurality buckling walls are defined with a wall thickness ranging between
10 0.3 mm to 6mm
In an embodiment, the cushioning component includes a frame surrounding and laterally
supporting at least one side of the grid structure.
15 In an embodiment, the cushioning component is manufactured from a material including one of
an elastomeric material, a thermoplastic elastomer, polypropylene material, silicon, a natural
rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, silica gel, polymer,
and liquid silicon.
20 In an embodiment, the height of the plurality buckling walls gradually decreases from an
imaginary central axis of the cushioning component towards lateral ends of the cushioning
component.
In an embodiment, the non-intersecting configuration is at least one of pentagon, rhombus,
25 hexagon, heptagon, nonagon, decagon and octagon.
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
30 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. Further, the elastomeric
cushioning member includes a plurality of buckling walls arranged in a non-intersecting
configuration defining a grid structure having an array of openings, the plurality of buckling
walls is being structured to buckle on application of load, for uniformly distributing the load
5
across the cushioning component and return to an original state upon removal of the load.
In an embodiment, the mattress includes a second felt layer on top of the layer of spring coils, a
side encasing foam layer and laterally surrounding at least one side of the layer of spring coils, a
5 fabric layer secured to at least one of the top portion and the bottom portion of the at least one
cushioning component, 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 laterally surrounding the at least one
cushioning component.
10
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
15 includes a plurality of buckling walls arranged in a non-intersecting configuration defining a grid
structure having an array of openings, the plurality of buckling walls are being 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.
20 In an embodiment, the mattress includes an upper foam layer secured above the at least one
cushioning component, a support foam layer laterally surrounding the at least one cushioning
component, a fabric layer secured to at least one of the top portion and the bottom portion of the
at least one cushioning component.
25 In an embodiment, the mattress includes a transition foam layer positioned above the bottom
foam layer.
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
30 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,
6
embodiments, and features will become apparent by reference to the drawings and the following
detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
5
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
10 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 1 illustrates a schematic perspective top view of a cushioning component, in accordance
with an embodiment of the present disclosure;
15
Figure 2 illustrates a schematic top view of the cushioning component of Figure 1;
Figure 3 illustrates a sectional view of the cushioning component along the X-X axis of Figure
2;
20
Figure 4a illustrates a schematic top view of the cushioning component, in accordance with
another embodiment of the present disclosure;
Figure 4b illustrates a schematic top view of the cushioning component, in accordance with yet
25 another embodiment of the present disclosure;
Figure 5 illustrates an exemplary schematic view of the cushioning component without a frame,
in accordance with yet another embodiment of the present disclosure;
30 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
35
7
Figure 8a to Figure 8j illustrates a schematic view 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
5 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
10
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
15 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,
20 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.
25 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
described herein as "exemplary" is not necessarily to be construed as preferred or advantageous
over other embodiments.
30 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,
8
and alternative falling within the spirit and the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a nonexclusive inclusion, such that an arrangement, or process that comprises a list of components or
5 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.
10 Embodiments of the present disclosure discloses a cushioning component for use in applications
including but not limiting to bedding [mattress and/or pillows], seating, and other cushions. The
cushioning component includes a plurality of layers of different types of materials that deflect or
deform under load. Usually, these cushioning components have uneven surfaces and wear after
continuous usage over a period of time, thus causing discomfort and disruption to the user.
15 Moreover, conventional cushioning components fail to distribute load/weight thereby generating
pressure points between the user and the cushioning components. 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.
Accordingly, cushioning component with buckling walls of the present disclosure is configured
20 to overcome the problems associated with the conventional cushioning components.
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 arranged in a non-intersecting configuration,
25 defining a grid structure having an array of openings. The plurality of buckling walls may be
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. Therefore, the
cushioning component of the present disclosure is suitable to achieve required comfort and
eliminate pressure points as per the user requirement. Also, provision of the non-intersecting
30 configuration of the elastomeric cushioning components reduces stress concentration at the
intersection points, thereby improving the usage life of the cushioning component.
9
Referring to Figures 1 to 3 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 having a top surface and a bottom surface. The top surface
5 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 opening (20). The 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
10 in Figure. 2, the cushioning component (100) includes the plurality of buckling walls (BW) that
are kept adjacent to each other to define the non-intersecting configuration. One of a buckling
wall of the plurality of buckling walls (BW) form an angle (α) with an adjacent buckling wall of
the plurality of buckling walls (BW) to form the non-intersecting configuration. Further, the angle
(α) may be at least one of an obtuse angle or an acute angle i.e. the angle may be be greater than
15 90° and less than 180° or the angle may be less than 90°.
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
2 mm to 75 mm and the wall thickness (t) may range from about 0.3 mm to 6 mm.
20
In an embodiment, the non-intersection is defined with a radius or radius of curvature to strengthen
the point of non-intersection and to avoid stress concentration at the non-intersection. The
provision of radius uniformly distributes the load and adds additional strength to the nonintersection, thereby enhancing the usage life of the cushioning component (100). The provision
25 of radius will also prevent the breaking of buckling walls during tangential loading and even
prevents breakage during molding process, particularly during ejection of the cushioning
component (100) from the mold.
Referring to Figure 3, it illustrates a sectional view of the cushioning component along the X-X
30 axis of figure 2. As can be seen in Figure 3, the height (H) of the plurality buckling walls (BW)
gradually decreases from an imaginary central axis (Y-Y) of the cushioning component (100)
towards lateral ends of the cushioning component (100).
10
In an embodiment, as can be seen in Fig 4a and 4b, the non-intersecting configuration of the
cushioning component (100) may include shapes such as but not limiting to at least one of a pentagon,
rhombus, hexagon, heptagon, nonagon, decagon and octagon. Although, multiple non-intersecting
5 configurations of the cushioning component is illustrated, the same should not be construed as a
limitation of the present disclosure asthe cushioning component (100) may have any non-intersecting
geometric shapes/configurations.
In an embodiment, the cushioning component may include a frameless configuration as shown in
10 Figure 5. In another embodiment the cushioning component may have a configuration with a
frame as shown in Figures. 1 to 3. The cushioning component (100) having the frame
configuration 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
15 (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 to the first side and the third side is opposite to the fourth
side. In an embodiment, the plurality of buckling walls (BW) is arranged in a non-intersecting
array to form grid structure within the frame (10) defined with the plurality of the openings (20).
20
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,
25 Silica gel, polymer, liquid silicon, polypropylene, silicon, and any suitable material that provides
durability and elasticity the 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
30 present disclosure.
In an embodiment, the grid structure formed is coated with a powdered material. The powdered
11
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.
5 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
10 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
15 (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
20 (220). The side encasing foam layer (260) may be provided to laterally surround all sides of the
layer of spring coils (220). Thisside encasing foam layer (260) laterally secures layer 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 similar to a
25 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
30 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
12
(240) may range between 5 mm to 50 mm. 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 non-intersecting grid structure having an array of
5 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.
The mattress (200) further includes a support foam layer (255) that is positioned between the
10 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
15 (100) and holds the below layers as a single component. In an embodiment, the upper 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
20 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
25 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, the mattress (200) may include one or more layers of the cushioning
component (100), upper, lower and transition foam layers (210, 240, 250), layer of spring coils
30 (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.
13
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,
5 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 non10 intersecting 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.
In an embodiment, a transition foam layer (320) is positioned above the bottom foam layer (310)
15 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
20 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) as shown in Figure
7. 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
25 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
30 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
14
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)
5 allows ease of transportation without causing any damage to the mattress (300).
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
10 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)
15 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
20 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 allows object/ user to
25 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.
30
In an embodiment, the cushioning component (100) and the mattress (200, 300) of the present
disclosure provides comfort to the user for longer durations.
15
In an embodiment, the cushioning component (100) with the gradual decrease in height (H) of the
buckling walls leads to less usage of material for manufacturing and also leads to light weight of
the cushioning component, thereby decreasing the manufacturing cost and transportation cost.
5 In an embodiment, the cushioning component (100) with the angle between the buckling walls
(BW) to be at least of an obtuse and an acute angle prevents breaking of the buckling walls during
loading, thereby improves usage life of the cushioning component (100).
Equivalents:
10 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.
15 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
20 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
25 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 includesthe 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.
30
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
16
means at least two recitations, or two or more recitations). Furthermore, in those instances where
a convention analogous to “at least one of A, B, and 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, and C” would include but not be limited to systems that have A alone,
5 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 analogous to “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 systems that have A alone, B alone, C alone, A and B together, A and C together,
10 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.”
15
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.
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Referral Numeral:
Referral numerals Description
100 Cushioning component
10 Frame
101 Elastomeric Cushioning member
101a Top cushioning surface
101b Bottom cushioning surface
BW Buckling walls
α angle
20 Openings
25 Foam layer
17
26 Spring coils layer
27 Fabric layers
200, 300 Mattress
210 Bottom foam layer
220 Layer of spring coils
230a, 230b First and 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
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Claims:
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) arranged in a non-intersecting configuration 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.
2. The cushioning component (100) as claimed in claim 1, wherein the plurality of buckling
walls (BW) adjacent to each other forms an angle (α), to define the non-intersecting
configuration.
3. The cushioning component (100) as claimed in claim 1, wherein the angle (α) is at least one
of an obtuse and an acute angle.
4. The cushioning component (100) as claimed in claim 1, wherein the plurality buckling walls
(BW) are defined with a height (H) ranging between 2mm to 75mm.
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 0.3 mm 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 polypropylene, a silicon, a synthetic elastomer, a
blend of natural and synthetic elastomers, silica gel, polymer, and liquid silicon.
8. The cushioning component (100) as claimed in claim 1, wherein the height (H) of the plurality
buckling walls (BW) gradually decreases from an imaginary central axis (Y-Y) of the
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cushioning component (100) towards lateral ends of the cushioning component (100).
9. The cushioning component (100) as claimed in claim 1, wherein the non-intersecting
configuration is at least one of pentagon, rhombus, hexagon, heptagon,nonagon,decagon and
octagon.
10. The cushioning component (100) as claimed in claim 1, wherein the non-intersecting
configuration is defined with a radius.
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) arranged in a non-intersecting configuration 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.
12. The mattress (200) as claimed in claim 11, comprises a second felt layer (230b) on top of the
layer of spring coils (220).
13. The mattress (200) as claimed in claim 11, 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
20
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) positioned
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 upper foam layer 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) arranged in a non-intersecting configuration 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.
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 claim 17, comprises a transition foam layer (320) positioned
above the bottom foam layer (310).
21. The mattress (300) as claimed in claim 17, comprises a zipper or tape edged cover (345),
covering the mattress (300).