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, 35, 1st Floor, Vijay Transtech, Chandivali Village Off SakiVihar Rd Sakinaka Andheri E, Mumbai City, Maharashtra 400072
NATIONALITY: Indian.
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
Present disclosure in general relates to cushioning. Particularly, but not exclusively, the present disclosure relates to a resilient cushioning member. Further, embodiments of the present disclosure disclose a grid structured cushioning layer for the resilient cushioning member used in mattress, pillows, chairs, sofa furniture and the like.
BACKGROUND OF THE DISCLOSURE
Typically, cushioning components have wide range of applications such as mattresses, cushions, pillows, seating furniture and many more. These cushion components are designed to deflect or deform under load, thereby absorbing an impact and providing comfort to a user. Usually, the cushioning component includes a plurality of layers of different types of materials such as polyethylene or polyurethane foams, vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible sheets, etc. However, these constructions and structure of the cushioning components tend to have surfaces and wear after continuous usage over a period of time, thus causing discomfort and disruption to the user. Conventional cushioning components comprises 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 reduce life span of the cushioning components as well.
Additionally, surfaces of these conventional cushioning component like foam, memory foam, or coirs have a uniform block structure, which fail to distribute load/weight thereby generating pressure points. Thus, usage of these conventional cushioning component causes discomfort to user and adversely affecting on various body regions of the user. Also, cushioning component having the block structure 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.
The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the 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 discloses a cushioning component comprising a plurality of first ribs extending in a first direction and a plurality of second ribs intersecting the plurality of first ribs and extending in a second direction perpendicular to the first direction. The plurality of first ribs and the second ribs form a grid structure having a top portion and a bottom portion. The grid structure is defined with an array of openings with interconnected buckling walls. The array of openings with interconnected buckling walls is configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component and return to an original state upon removal of the load.
In an embodiment, a plurality of reinforcing ribs intersect the plurality of first ribs and the second ribs and extending in a third direction forming a predetermined angle to the first and second direction.
In an embodiment, the plurality of first ribs and the second ribs are defined with a predetermined height ranging between 7 mm to 100mm.
In an embodiment, the plurality of first ribs and the second ribs is defined with a predetermined wall thickness ranging between 0.5mm to 6 mm.
In an embodiment, the cushioning component comprises a frame surrounding and laterally supporting at least one side of the grid structure.
In an embodiment, at least one of the plurality of first ribs and the plurality of second ribs is defined with a draft angle with respect to a vertical axis of the cushioning component.
In an embodiment, the draft angle is -5 degree to +5 degree with respect to the vertical axis of the cushioning component.
In an embodiment, the grid structure is coated with a powdered material.

In an embodiment, the cushioning component is manufactured by a material including one of an elastomeric material, a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, silica gel, polymer, liquid silicon and any suitable material. In an 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 present disclosure further discloses a mattress comprising 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.. At least one cushioning component is positioned above the layer of the spring coils. The cushioning component comprises a plurality of first ribs extending in a first direction and a plurality of second ribs intersecting the plurality of first ribs and extending in a second direction perpendicular to the first direction. The plurality of first ribs and the second ribs forms a grid structure having a top portion and a bottom portion. The grid structure is defined with an array of openings with interconnected buckling walls. The array of openings with interconnected buckling walls is configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component and return to an original state upon removal of the load.
In an embodiment, comprises a second felt layer on top of the layer of spring coils.
In an embodiment, a side encasing foam layer extends between the first and the second felt layers and laterally surrounds at least one side of the layer of the spring coils.
In an embodiment, a support foam layer is positioned between the transition foam layer and the upper foam layer and laterally surrounds the cushioning component.
In an embodiment, the mattress comprises a fabric layer secured to at least one of the top portion and the bottom portion of the cushioning component.
In an embodiment, the mattress comprises an upper foam layer being secured above the at least one cushioning component.

In an embodiment, the mattress comprises a transition foam layer positioned over the second felt layer and below the cushioning component.
In an embodiment, comprises a support foam layer positioned between the transition foam layer and the upper foam layer and laterally surrounding the cushioning component.
The present disclosure further discloses a mattress comprising a bottom foam layer, at least one cushioning component positioned above the bottom foam layer. The cushioning component comprises a plurality of first ribs extending in a first direction and a plurality of second ribs intersecting the plurality of first ribs and extending in a second direction perpendicular to the first direction. The plurality of first ribs and the second ribs forms a grid structure having a top portion and a bottom portion. The grid structure is defined with an array of openings with interconnected buckling walls. The array of openings with interconnected buckling walls is configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component and return to an original state upon removal of the load. Further, an upper foam layer is secured above the cushioning component.
In an embodiment, the mattress comprises an upper foam layer secured above the at least one cushioning component.
In an embodiment, the mattress comprises a support foam layer laterally surrounding the cushioning component.
In an embodiment, the mattress comprises a fabric layer secured to at least one of the top portion and the bottom portion of the cushioning component.
In an embodiment, 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 any combination with each other. Several of the aspects and embodiments may be combined together 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 characteristic 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 perspective top view of a cushioning component, in accordance with an embodiment of the present disclosure;
Figure 1b illustrates a schematic sectional view of a portion of ribs of cushioning component of Figure 1a;
Figure 2 illustrates a perspective bottom view of the cushioning component of Figure. 1a;
Figures 3a and 3b illustrates an exemplary schematic view of a portion of the cushioning component, in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a schematic view of another embodiment the cushioning component;
Figure 5 illustrates a schematic view of another embodiment the cushioning component;
Figure 6a to Figure 6n illustrates a top and perspective views of another embodiment of the cushioning component;
Figure 7 illustrates a schematic view of a mattress comprising the cushioning component;
Figure 8 illustrates a schematic view of another embodiment of a mattress comprising the cushioning component;

Figure 9a to Figure 6j illustrates a schematic views cushioning component arranged within a mattress;
Figure 10a to Figure 10b illustrates a schematic view of another embodiment the cushioning component as seat cushion;
Figure 11 illustrates a schematic view of test results upon contact of the user with the mattress; and
Figure 12 illustrates a schematic view of test results upon of the user with the mattress.
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 mechanism 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 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 variations thereof, are intended to cover a non¬exclusive inclusions, such that a setup, device, 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 a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Cushioning component includes a plurality of layers of different types of materials 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. Moreover, these conventional cushioning components fail to distribute load/weight thereby generating pressure points. Further, these cushioning components having a block structure 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 to overcome the problems associated with the conventional cushioning components. The cushioning component of the present disclosure comprises a plurality of first ribs extending in first direction and a plurality of second ribs intersecting plurality of first ribs and extending in second direction form a grid structure. The grid structure defines an array of openings with interconnected buckling walls. Further, the grid structure is configured to buckle when a load applied on same 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 peak points as per the user requirement.
Referring to Figures 1 to 10b which are exemplary embodiments of the present disclosure illustrating a cushioning component is illustrated and identified with reference numeral 100.
The cushioning member (100) includes a plurality of first ribs (12) extending in a first direction (A), and a plurality of second ribs (14) intersecting the plurality of first ribs (12) and extend in a second direction (B) perpendicular to the first direction (A). The plurality of first ribs (12) and plurality of second ribs (14) are integrally arranged in an array to form a grid structure. The grid structure is defined with a top portion and a bottom portion. Further, the grid structure is defined with an array of openings (20) such that each opening (20) is surrounded by two or more buckling walls of the plurality of first and second ribs (12, 14). The array of openings (20) with interconnected buckling walls are configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component (100), and return to an original state upon removal of the load. In an embodiment, the plurality of fist ribs (12) and the second ribs (14) may extend are defined with a predetermined height (H1, H2) and wall thickness. The predetermined height (H1, H2) of the plurality of first ribs (12) and the second ribs (14) may range about 7 mm to 100mm. Further, a wall thickness of the plurality of first ribs (12) and the second ribs (14) may range about 0.5mm to 6 mm.
In an embodiment, the cushioning component (100) further comprises, a plurality reinforcing ribs (16) intersects the plurality of first ribs (12) and the second ribs (14) and extends in a third direction (C) as seen in Figures 1b and 3a forming a predetermined angle with respect to the first and second direction (A, B). The plurality reinforcing ribs (16) are integrally formed with respect to the plurality of first ribs (12) and the second ribs (14) to define another type of grid structure formed in an array. Each of the reinforcing ribs (16) along with the plurality first and second of ribs (12 and 14) are in a spaced apart configuration with each other to form the grid structure as shown in Figure 1b to 3b defining plurality of openings (20). Each of the plurality of reinforcing ribs (16) includes a predetermined height (H3). In an embodiment, the predetermined height (H3) of the plurality of reinforcing ribs (16) is less than the predetermined height (H1) of the first plurality of

ribs (12). In another embodiment, the predetermined height (H3) of the plurality of reinforcing ribs (16) is less than the predetermined height (H2) of the plurality of second ribs (14). Further, the predetermined height (H3) of the plurality of reinforcing ribs (16) may be less than a mean of the predetermined height (H1, H2) of the first plurality of ribs (12) and the plurality of second ribs (14). This configuration of the plurality of reinforcing ribs (16) provides structural rigidity to the plurality of first and second ribs (12, 14). More specifically, the grid structure formed in combination of the plurality of first and second ribs (12, 14) and with plurality of reinforcing ribs (16) provides denser grid structure at the bottom portion of the cushioning component (100) as shown in Figure 2. Accordingly, the grid structure formed by the plurality of first and second ribs (12, 14) defined with height greater than the plurality of reinforcing ribs (16) forms less dense grid at the top portion of the cushioning component (100), as seen from in Figure 1a. In an embodiment, the predetermined height (H1, H2, H3,) of the plurality of first and second ribs (12, 14) and the reinforcing ribs (16) can be same. The density of the grid structure can be varied based on an application of usage of the cushioning component (100). This is possible by providing the grid structure of cushioning component (100) which is integrally formed by at least one of plurality of first and second ribs (12,14) and the plurality of reinforcing ribs (16). A predetermined height (H3) of the reinforcing ribs (16) may range between 7 mm to 100mm. Further, a thickness (T3) of the each of the plurality of reinforcing ribs (16) range between 0.5mm to 6 mm. The plurality of first and second ribs (12,14) and the plurality of reinforcing ribs (16) is defined with a draft angle with respect to a vertical axis (A-A) of the cushioning component (100). In an embodiment, the draft angle is -5 degree to +5 degree with respect to the vertical axis (A-A) of the cushioning component (100). More particularly as seen in Figure 2, the plurality of reinforcing ribs (16) may have a second end having a thickness larger than a thickness of the rib at the top end. This facilitates ease of the removal of the grid from a mold post manufacturing, thereby reducing cycle time and thus aids in reducing cost of material and manufacturing as an overall thickness of buckling walls is reduced.
Referring to Figures 1 to Figure 5, the cushioning component (100) comprise 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 by strip extending along a periphery of the cushioning component (100). In an exemplary configuration, the frame

(10) includes a first side (10a), a second side (10b), a third side (10c) and a fourth side (10d). The frame (10) may also be defined with a top surface and a bottom surface. The second side (10b) is configured opposite to the first side (10a) and the third side (10c) is opposite to the fourth side (10d). In an embodiment, the frame (10) comprises a predetermined height which may range between 7 mm to 100mm. The plurality of first and second ribs (12,14) and the plurality of reinforcing ribs (16) are longitudinal members integrally arranged in an array to form grid structure within the frame (10) defined with the plurality of the openings (20). The plurality of openings (20) of may have a shape of square, rectangle, rhombus, triangular, hexagonal or any polygonal shape obtained based on the arrangement of at least one of the plurality of first and second ribs (12, 14), respectively. In an embodiment, the cushioning component (100) may be manufactured without the frame (10) as per the application requirement.
Referring to Figure 5, the cushioning component (100) is defined with grid structure having a rectangular or square openings (20). In another embodiment, the frame (10) is configured with edges having a fillet radius of 10 mm to 40 mm to provide smooth edges of the cushioning component (100). In another embodiment, the cushioning component (100) includes the plurality of buckling walls arranged to have a honeycomb structure. Further, this honeycomb structure is enclosed by the frame (10) along a periphery as shown in Figure 4, but it must not be limited to this structure. In another embodiment, the cushioning component (100) includes the plurality of first and second ribs (12,14) arranged to have array of openings (20) forming a triangular structure. Further, this triangular structure is enclosed by the frame (10) along a periphery as shown in Figure 6a and 6b.
Further, the cushioning component (100) 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, Silica gel, polymer, liquid silicon and any suitable material that provides durability and elasticity the cushioning component. 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.

In an embodiment, the grid structure formed is coated with a powdered material. The powdered material may include material like silica, calcium carbonate, Talc 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.
Further, as illustrated in Figure 7, the present disclosure includes 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, a 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) comprises 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 of spring coils (220). This side encasing foam layer (260) laterally secures layer of the spring coils (220) and prevents mis-alignment 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 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 cushioning component (100) and aids in better bonding and strength of the mattress (200). A height of the transition foam layer (240) may range between 5 mm to 50mm. The cushioning component (100) includes a plurality of first ribs (12) extending in a first direction (A) and a plurality of second ribs (14) intersecting the plurality of

first ribs (12) and extending in a second direction (B) perpendicular to the first direction (A). The plurality of first ribs (12) and the second ribs (14) forms a grid structure having a top portion and a bottom portion. The grid structure defines an array of openings (20) with interconnected buckling walls. The array of openings (20) with interconnected buckling walls are configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component (100) and the mattress (200), and return to an original state upon removal of the load. In an embodiment, one or more cushioning components (100) may be configured adjacent to each other depending on a length and width of the mattress (100). In an exemplary embodiment, the cushioning component (100) further comprises, a plurality reinforcing ribs (16) intersects the plurality of first ribs (12) and the second ribs (14) and extends in a third direction (C) as seen in Figures 1b and 3a forming a predetermined angle with respect to the first and second direction (A, B). The plurality reinforcing ribs (16) are integrally formed with respect to the plurality of first ribs (12) and the second ribs (14) to define another type of grid structure formed in an array. Each of the reinforcing ribs (16) along with the plurality first and second of ribs (12 and 14) are in a spaced apart configuration with each other to form the grid structure as shown in Figure 1b to 3b defining plurality of openings (20). This configuration of the plurality of reinforcing ribs (16) provides structural rigidity to the plurality of first and second ribs (12, 14). More specifically, the grid structure formed in combination of the plurality of first and second ribs (12, 14) and with plurality of reinforcing ribs (16) provides denser grid structure at the bottom portion of the cushioning component (100) as shown in Figure 2.
The mattress (200) comprises 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 7. 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. The mattress (200) comprises a fabric layer (270) secured to at least one of the top portion and the bottom portion of the cushioning component (100) to act protective layer of the grid structure. Moreover, the fabric layer (270) allows adhesion of the layers arranged below and top of the cushioning component (100). 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 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 (100) 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) to store and allow accessing of 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 (220), the first and second felt layers (230a, 230b) and can be arranged in an any combination thereof as per user’s comfort and application requirement.
Referring to Figure 8 the present disclosure discloses another embodiment of a mattress (300) comprising a bottom foam layer (310) forming a base of the mattress (200). 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) comprises a plurality of first ribs (12) extending in a first direction (A), and a plurality of second ribs (14) intersecting the plurality of first ribs (12) and extending in a second direction (B) perpendicular to the first direction (A), the plurality of first ribs (12) and the second ribs (14) forming a grid structure having a top portion and a bottom portion, wherein the grid structure defining an array of openings (20) with interconnected buckling walls. The array of openings (20) with interconnected buckling walls are configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component (100), and return to an original state upon removal of the load. In an exemplary embodiment, the cushioning component (100) further comprises, a plurality reinforcing

ribs (16) intersects the plurality of first ribs (12) and the second ribs (14) and extends in a third direction (C) as seen in Figures 1b and 3a forming a predetermined angle with respect to the first and second direction (A, B). The plurality reinforcing ribs (16) are integrally formed with respect to the plurality of first ribs (12) and the second ribs (14) to define another type of grid structure formed in an array. Each of the reinforcing ribs (16) along with the plurality first and second of ribs (12 and 14) are in a spaced apart configuration with each other to form the grid structure as shown in Figure 1b to 3b defining plurality of openings (20). This configuration of the plurality of reinforcing ribs (16) provides structural rigidity to the plurality of first and second ribs (12, 14). More specifically, the grid structure formed in combination of the plurality of first and second ribs (12, 14) and with plurality of reinforcing ribs (16) provides denser grid structure at the bottom portion of the cushioning component (100) as shown in Figure 2.
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). A 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 a length and width of the mattress (100). 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 surrounds the at least one cushioning component (100) as shown in Figure 8. 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 damages and better comfort while sitting on the edges of the mattress. Similar, to mattress (200) as described above, the mattress (300) comprises a fabric layer (370) secured to at least one of the top portion and the bottom portion of the cushioning component (100) to act protective layer of the grid structure. Moreover, the fabric layer (370) allows adhesion of the layers arranged below and top of the cushioning component (100). In an embodiment, the upper foam layer (330) 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 (100) 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) to store and allow accessing of the mattress (300). This packaging cover (345) allows ease of transportation without causing any damage to the mattress (300).
Further, other embodiments of the mattress are disclosed from Figures 9a to 9j illustrates various configuration of the cushioning component 100 within a mattress (200, 300). As shown in Figure 9a and Figure 9b, 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 9c and 9d, 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 9e to 9g. Further, the cushioning component (100) may be provided as top layer for one or more foam layers (25) as shown in Figures 9h to Figure 9j. 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 is 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) can be provided between suitable layers within the mattresses (200, 300), cushions, pillows, seating furniture (400) and many more. Further, as shown in Figure 10a and Figure 10b, the cushioning component (100) of required height may be included as a seating cushion of a chair (400). The cushioning component (100) may be embedded with fabric layers, to protect from any damage to the grid structure.

The cushioning component (100) allows object/ user to sink deeply because of the buckling of the gris structure when subjected to the load. Further, the dense grid structure formed by at least one of plurality of first and second ribs (12, 14) and/or reinforcing ribs (16) provide a surface area to expand and resist higher load/weights. The cushioning component (100) with less dense grid structure formed by at least one of plurality of first and second ribs 12, 14 provides larger surface area, where the plurality of first and second ribs (12,14) deform and expand, thereby resisting lower load/weights. The cushioning component (100) of the present disclosure is compressible and includes plurality of ribs (12, 14, 16) within it that buckle under and distribute the load preventing formation of peak pressure points on surface of the cushioning component (100) and mattress (200, 300). In an example if a surface area of the load is small the walls will buckle down and give pressure relief. However, if the surface area of the load is large the walls will buckle less than of the surface area of the load is small and retain firmly to support the surface area of larger the loads. Further, the presence of plurality of openings (20) enables proper ventilation and flow of air, thereby providing cooling comfort to the user. The cushioning component (100) due to buckling provides larger surface to resist load and thereby supporting larger surface area of user’s body. Also, smaller surface region of user’s body like hips, shoulders, head can be supported by limited number of plurality of ribs. This is achieved when the at least one of plurality of first and second ribs (12,14) and the reinforcing ribs (16) buckles and provide cushioning comfort to the user. This buckling technology helps optimum weight distribution, thereby minimizing pressure points and generation of heat, unlike conventional cushioning components.
In an embodiment, the first and second plurality ribs (12, 14,16) may have substantially high rigidity, good fatigue and tensile strength. The helps to absorb impact load and buckle in the event of application of load/weight, thereby retaining its shape and configuration without permanent deformation due to continuous usage of the cushioning component (100) and mattress (200, 300).
Examples:
The below examples show a mattress (200, 300) with elastomeric grid cushioning component aids in distributing weight and provides a) cushioning / pressure relief to body curvatures and b) support under the spine

Example 1: The below example shows how the mattress responds as a human weighing 80 kg sleeps on it.
In the first mattress with elastomeric grid cushion, the walls of the grid will buckle down more under hips (lower surface area of the body) and will provide more cushioning and comfort) whereas the walls of the grid will buckle down only 0.2 cm under the back (which is a bigger surface area ) of the body. Thus the Grid structure helps provide a mix of comfort and support by even weight distribution and ensure better quality of Sleep.
Whereas, on the 2nd mattress which is made with Polyurethane foam of 30 density (soft mattress), the foam will sink down across body parts irrespective of different surface areas

Test with a human weighing 80 kgs Mattress with Elastomeric cushion of 2 inches as top layer Foam mattress with 30 density top layer (soft mattress)
buckling at hips cm 1 1 to 1.5 cm
buckling under center point of back cm 0.2 1 to 1.5 cm
Example 2: The below example shows how the mattress responds as a human weighing 80 kg sleeps on it.
In the first mattress with elastomeric grid cushion, the walls of the grid will buckle down more under hips (lower surface area of the body) and will provide more cushioning and comfort) whereas the walls of the grid will buckle down only 0.2 cm under the back (which is a bigger surface area ) of the body. Thus, the grid structure helps provide a mix of comfort and support by even weight distribution and ensure better quality of Sleep.
Whereas on the 2nd mattress which is made with Polyurethane foam of 50 density(hard mattress), the foam will not sink even under body curvatures like hips and will create lot of pressure which leads to tossing & turning at night.

Test with a human weighing 80 kgs Mattress with Elastomeric cushion of 2 inches as top layer Foam mattress with 50 density top layer (hard mattress)
buckling at hips cm 1 0.2
buckling under center point of back cm 0.2 0

Below shows the pressure mapping done by a device called tekscan on both the grid mattress and the hard mattress with foam 50 density. The left is the grid mattress which shows more green and blues which means no to low pressure. However as shown on the right scan, there are lot of reds in the hips and shoulder areas showing the high pressure generated as the inability of foam / uniform block to buckle/sink causing pressure and discomfort. The test conducted on both sleeping positions of back and side sleeper shows similar results. The results can be observed in Figures 11 and 12 respectively, where Figure 11 shows test performed while sleeping on back of the user and Figure 12 test done while sleeping on side by the user.
In an embodiment, the size, configuration of the cushioning component (100) and the mattress (200, 300) may be varied according to the application requirement.
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.
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 phrases should 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 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, 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, 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 NUMERALS

Referral numerals Description
100 Cushioning component
10 Frame
10a, 10b, 10c, and 10d First side, second side, third side and fourth side
12 A plurality of first ribs
14 A plurality of second ribs
16 Reinforcing ribs
20 Openings
25 Foam layer
26 spring coils layer
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
270 Fabric 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

400
Chair
A First direction
B Second direction
C Third direction
A-A Axis

WE CLAIM:
1. A cushioning component (100), comprising:
a plurality of first ribs (12) extending in a first direction (A); and a plurality of second ribs (14) intersecting the plurality of first ribs (12) and extending in a second direction (B) perpendicular to the first direction (A), the plurality of first ribs (12) and the second ribs (14) forming a grid structure having a top portion and a bottom portion, wherein the grid structure defining an array of openings (20) with interconnected buckling walls,
wherein the array of openings (20) with interconnected buckling walls configured to buckle when a load applied on at least one of the top portion and the bottom portion, 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, comprises a plurality of reinforcing
ribs (16) intersecting the plurality of first ribs (12) and the second ribs (14) and extending
in a third direction (C) forming a predetermined angle to the first and second direction
(A,B).
3. The cushioning component (100) as claimed in claim 1, wherein the plurality of first ribs
(12) and the second ribs (14) are defined with a predetermined height (H1, H2) ranging
between 5 mm to 100mm.
4. The cushioning component (100) as claimed in claim 1, wherein the plurality of first ribs
(12) and the second ribs (14) defined with a predetermined wall thickness ranging between
0.5mm to 6 mm.
5. 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.

6. The cushioning component (100) as claimed in claim 1, wherein at least one of the plurality of first ribs (12) and the plurality of second ribs (14) is defined with a draft angle with respect to a vertical axis (A-A) of the cushioning component (100).
7. The cushioning component (100) as claimed in claim 6, wherein the draft angle is the range of -5 degree to +5 degree with respect to the vertical axis (A-A) of the cushioning component (100).
8. The cushioning component (100) as claimed in claim 1, wherein the grid structure is coated with a powdered material.
9. The cushioning component (100) as claimed in claim 1, wherein cushioning component (100) is manufactured by a material including one of an elastomeric material, a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, silica gel, polymer, liquid silicon and any suitable material.
10. The cushioning component 100 as claimed in claim 9, wherein the material comprises a hardness on a Shore A scale of less than 10.
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 cushioning component (100) comprising; and
a plurality of first ribs (12) extending in a first direction (A); and
a plurality of second ribs (14) intersecting the plurality of first ribs
(12) and extending in a second direction (B) perpendicular to the first
direction (A), the plurality of first ribs (12) and the second ribs (14) forming
a grid structure having a top portion and a bottom portion, wherein the grid

structure defining an array of openings (20) with interconnected buckling
walls
wherein the array of openings (20) with interconnected buckling walls configured to buckle when a load applied on at least one of the top portion and the bottom portion, 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 12, wherein a side encasing foam layer (260) 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).
14. The mattress (200) as claimed in claim 11, comprises a fabric layer (270) secured to at least one of the top portion and the bottom portion of the cushioning component (100).
15. The mattress (200) as claimed in claim 11, comprises an upper foam layer (250) secured above the at least one cushioning component (100).
16. The mattress (200) as claimed in claim 12, comprises a transition foam layer (240) positioned over the second felt layer (230b) and below the cushioning component (100).
17. The mattress (200) as claimed in claim 16, comprises a support foam layer (255) positioned between the transition foam layer (240) and the upper foam layer (250) and laterally surrounding the cushioning component (100).
18. A mattress (300) comprising:
a bottom foam layer (310);
at least one cushioning component (100) positioned above the bottom foam layer (310), the cushioning component (100) comprising; and

the cushioning component (100) comprising; and
a plurality of first ribs (12) extending in a first direction (A); and a plurality of second ribs (14) intersecting the plurality of first ribs (12) and extending in a second direction (B) perpendicular to the first direction (B), the plurality of first ribs (12) and the second ribs (14) forming a grid structure having a top portion and a bottom portion, wherein the grid structure defining an array of openings (20) with interconnected buckling walls
wherein the array of openings (20) with interconnected buckling walls configured to buckle when a load applied on at least one of the top portion and the bottom portion, for uniformly distributing the load across the cushioning component (100), and return to an original state upon removal of the load;
19. The mattress (300) as claimed in claim 18, comprises an upper foam layer (330) secured above the at least one cushioning component (100).
20. The mattress (300) as claimed in claim 18, comprises a support foam layer (355 laterally surrounding the cushioning component (100).
21. The mattress (300) as claimed in claim 18, comprises a fabric layer (370) secured to at least one of the top portion and the bottom portion of the cushioning component (100).
22. The mattress as claimed in claim 18, comprises a transition foam layer (320) positioned above the bottom foam layer (310).