Sign In to Follow Application
View All Documents & Correspondence

A Cushioning Component

Abstract: The present disclosure relates to a cushioning component (100). The cushioning component 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). The plurality of first ribs (12) and the plurality of second ribs (14) forming a grid structure defining an array of openings (20) with interconnected buckling walls, and an intersection (I) of the interconnected buckling walls is defined with a radius (r). The interconnected buckling walls are being structured to buckle on application of a load. The present disclosure also relates to mattress having the cushioning component (100). Figure 1a is the representative figure.

Get Free WhatsApp Updates!
Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
13 October 2023
Publication Number
02/2024
Publication Type
INA
Invention Field
MECHANICAL ENGINEERING
Status
Email
Parent Application
Patent Number
Legal Status
Grant Date
2024-08-23
Renewal Date

Applicants

COMFORT GRID TECHNOLOGIES PRIVATE LIMITED
7th Floor, Unit 7A, Techweb Centre, New Link Road, Near Raigad Military School, Jogeshwari West, Mumbai, Mumbai Suburban, Maharashtra, 400102, India

Inventors

1. Priyanka Salot
7th Floor, Unit 7A, Techweb Centre, New Link Road, Near Raigad Military School, Jogeshwari West, Mumbai, Mumbai Suburban, Maharashtra, 400102, IN
2. Harshil Salot
7th Floor, Unit 7A, Techweb Centre, New Link Road, Near Raigad Military School, Jogeshwari West, Mumbai, Mumbai Suburban, Maharashtra, 400102, IN

Specification

FORM2 THE PATENTS ACT 1970 [39 OF 1970] & THE PATENTS RULES, 2003 COMPLETESPECIFICATION [See section 10 and Rule 13] TITLE: “A CUSHIONING COMPONENT” NAME AND ADDRESS OF THE APPLICANT: COMFORT GRID TECHNOLOGIES PRIVATE LIMITED, 7th Floor, Unit 7A, Techweb Centre, New Link Road, Near Raigad Military School, Jogeshwari West, Mumbai, Mumbai Suburban, Maharashtra, 400102, India NATIONALITY: Indian. The following specification particularly describes the invention and the manner in which it is to be performed. 2 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 component for use in mattress, pillows, chairs, sofa furniture and the like. BACKGROUND OF THE DISCLOSURE Typically, cushioning components have a wide range of applications such as mattresses, cushions, pillows, seating furniture and many more. These cushioning components are designed to deflect or deform under the application of load, thereby absorbing an impact and providing comfort to a user. Usually, the cushioning component is made of different materials such as polyethylene or polyurethane foams, vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible sheets, etc. Such constructions and structure of the cushioning components tend to have surfaces and wear after continuous usage over a period, thus causing discomfort and disruption to the user. Conventional cushioning components include springs and foam to impart feel and compression. Further, flexible sheets are provided that may be filled with fluid, which when depressed, in the vicinity of the loading also increases pressure in the remaining volume of the sheets. The response is resistive and bouncy, which is undesirable characteristics for the comfort of the user, thereby leading to reduced life span of the cushioning components as well. Additionally, surfaces of these conventional cushioning components like foam, memory foam, or coir have a uniform block structure, which fail to distribute load/weight thereby generating pressure points. Thus, usage of conventional cushioning component causes discomfort to user and adversely affects various body regions of the user. Also, cushioning components having the block structure have minimum space or air pockets to allow circulation of air, which tends to retain a body heat of the user causing heating and soreness to the user. Some of the conventional arts, such as US patent publication no. US20170254379A1 disclose elastomeric cushion members including perforated skins and related methods. Elastomeric cushion members of US20170254379A1 patent publication may include a plurality of interconnected buckling walls including an elastomeric material. The interconnected buckling 3 walls may together define a plurality of columns. A perforated skin may extend between at least some of the plurality of interconnected buckling walls of at least some of the plurality of columns. Methods of making elastomeric cushion members may involve interconnecting a plurality of buckling walls including an elastomeric material. The interconnected buckling walls may together define a plurality of columns. A perforated skin may be positioned to extend between at least some of the plurality of interconnected buckling walls of at least some of the plurality of columns. Such elastomeric cushion members offer good felxiblity under loading by uniform distribution of the 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. The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with conventional arts. SUMMARY OF THE DISCLOSURE The shortcomings of the prior art are overcome, and additional advantages are provided through the provision of cushioning component of the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein. In one non-limiting embodiment of the present disclosure a cushioning component is disclosed. The cushioning component includes 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. The plurality of first ribs and the plurality of second ribs form a grid structure defining an array of openings with interconnected buckling walls, and an intersection of the interconnected buckling walls is defined with a radius. The interconnected 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 first ribs and the plurality of second ribs are defined with a height ranging between 5 mm to 100mm, and a wall thickness ranging between 0.5mm to 6 mm. In an embodiment, the cushioning component includes a frame surrounding and laterally supporting at least one side of the grid structure. In an embodiment, the 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. In an embodiment, the radius at the intersection of the interconnected buckling walls is defined as at least one of an inner circular radius, an outer circular radius, non-circular radius such as an inner fillet radius, an outer fillet radius, and a chamfered radius. The radius ranges between 0.25mm to 9 mm. In another non-limiting embodiment of the disclosure, a mattress is disclosed. The mattress includes a bottom foam layer, a first felt layer on top of the bottom foam layer, a layer of spring coils positioned above the first felt layer and at least one cushioning component positioned above the layer of spring coils. At least one cushioning component includes 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. The plurality of first ribs and the plurality of second ribs form a grid structure defining an array of openings with interconnected buckling walls, and an intersection of the interconnected buckling walls is defined with a radius. The interconnected 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. In an embodiment, the mattress includes a second felt layer on top of the layer of spring coils, a side encasing foam layer extending between the first and the second felt layers and laterally surrounding at least one side of the layer of spring coils, a 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 5 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. 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 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. The plurality of first ribs and the plurality of second ribs form a grid structure defining an array of openings with interconnected buckling walls, and an intersection of the interconnected buckling walls is defined with a radius. The interconnected 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. 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. 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 combined to form a further embodiment of the disclosure. The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS The novel features and characteristics of the disclosure are set forth in the appended claims. The 6 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 1 illustrates a schematic perspective top view of a cushioning component, in accordance with an embodiment of the present disclosure; Figure 2 illustrates a schematic top view of the cushioning component of Figure 1; Figure 3a illustrates a magnified view of portion A of the cushioning component shown in Figure. 2, in accordance with an embodiment of the present disclosure; Figure 3b illustrates a magnified view of portion A of the cushioning component shown in Figure. 2, in accordance with another embodiment of the present disclosure; Figure 3c illustrates a magnified view of portion A of the cushioning component shown in Figure. 2, in accordance with yet another embodiment of the present disclosure; Figure 4 illustrates a schematic view of a mattress comprising the cushioning component, in accordance with an embodiment of the present disclosure; Figure 5 illustrates a schematic view of a mattress comprising the cushioning component, in accordance with another embodiment of the present disclosure; and Figure 6a to Figure 6j illustrates a schematic views of the cushioning component arranged within mattress, in accordance with various embodiments of the present disclosure. The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein. 7 DETAILED DESCRIPTION The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other alternatives for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure. In the present disclosure, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure. The terms “comprises”, “comprising”, or any other variationsthereof, are intended to cover a nonexclusive inclusion, such that an arrangement, or process that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or process. In other words, one or more elements in an arrangement proceeded by “comprises… a” does not, without more constraints, 8 preclude the existence of other elements or additional elements in the arrangement. Embodiments of the present disclosure disclose a cushioning component for use in applications including but not limiting to bedding [mattress and/or pillows], seating, and other cushions. Generally, the cushioning component includes a plurality of layers of different types of materials deflect or deform under load. Usually, these cushioning components have uneven surfaces and wear after continuous usage over a period of time, thus causing discomfort and disruption to the user. Moreover, conventional cushioning components fail to distribute load/weight thereby generating pressure points. Further, the cushioning components having a block structure will have minimum space or air pockets to allow circulation of air, which tends to retain a body heat of the user causing heating and soreness to the user. 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 includes 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 forming a grid structure. The grid structure defines an array of openings with interconnected buckling walls and a point of intersection of the interconnected buckling walls is defined with a radius. The grid structure is configured to buckle when a load is 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. Also, provision of radius reduces stress concentration at the intersection points, thereby improving the usage life of the cushioning component. Referring to Figures 1 and 2 which are exemplary embodiments of the present disclosure illustrating a cushioning component identified with reference numeral 100. 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). In an example, second direction (B) may be perpendicularly or angularly oriented to the first direction (A). The plurality of first ribs (12) and plurality of 9 second ribs (14) are integrally arranged in an array to form a grid structure. The grid structure is defined with a top portion, a bottom portion, and a wall 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 which are configured to buckle when a load is applied 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 first ribs (12) and the second ribs (14) may be defined with a height (H1, H2) and wall thickness. The height (H1, H2) of the plurality of first ribs (12) and the second ribs (14) may range from about 5 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. Referring to Figure. 2, the cushioning component (100) with interconnected buckling walls is shown. As seen in Figure. 2, the array of openings (20) is formed by intersection of the first and second ribs (12 and 14) extending in different orientations i.e., first and the second directions (A and B). The intersection of the first rib (12) and the second rib (14) defines an intersection (I) of the interconnected buckling walls of the grid structure. The intersection (I) is defined with a radius (r) or radius of curvature to strengthen the point of intersection and to avoid stress concentration at the intersection (I). The provision of radius (r) uniformly distributes the load and adds additional strength to the intersection (I), thereby enhancing the usage life of the cushioning component (100). The provision 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. As shown in Figures. 3a-3c, the radius (r) at the intersection (I) of the interconnected buckling walls can be at least one of an inner circular radius, an outer circular radius, and a non-circular radius. In an exemplary embodiment, the radius ranges from about 0.25mm to 9mm. In an exemplary embodiment, as shown in Figure. 2, the interconnected buckling walls are defined by the first and second ribs (12 and 14) extending in the first and second directions (A and B), in which the second direction (B) is perpendicular to the first direction (A). Such configuration of the interconnected buckling walls defines an intersection point (I). Referring to Figure. 3a which shows 10 magnified view of portion A of the interconnected buckling walls shown in Figure. 2 with intersection point (I). As shown in Figure. 3a, the radius (r) at the intersection (I) of the interconnected buckling walls is defined as an inner circular radius or an inner fillet radius defining an inwardly facing curve or fillet. Such a configuration of the inwardly facing curve or fillet increases the strength of the intersection and thereby prevents breakage of the interconnected buckling walls. Now referring to Figure. 3b, the radius (r) at the intersection (I) of the interconnected buckling walls is defined as an outer circular radius or an outer fillet radius defining an outwardly facing curve or fillet. Such a configuration of the outwardly facing curve or fillet increases material density at the intersection and thereby enhances the strength of the intersection and prevents breakage of the interconnected buckling walls. Refence can now be made to Figure. 3c, the radius (r) at the intersection (I) of the interconnected buckling walls is defined as a non- circular radius or chamfer defining a chamfer between two adjoining walls inscribed in a radius of circle. Such a configuration of the chamfer increases material density at the intersection and thereby enhances the strength of the intersection and prevents breakage of the interconnected buckling walls. Referring again to Figures. 1 and 2, the cushioning component (100) 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 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 plurality of first and second ribs (12,14) are longitudinal membersintegrally 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) may have a shape of square or rectangle 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. Further, the cushioning component (100) is manufactured using an elastomeric material which may include an elastomeric polymer. The elastomericmaterial may be a gelatinous elastomer(also 11 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, polypropylene, 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 and other powders. In an embodiment, the coating may be at least one of lubricant, and glidant. In another embodiment, the glidant may be selected from the group comprising Starch, Talc, Colloidal Silica. In an exemplary embodiment, the cushioning component (100) is manufactured by a thermoplastic molding process, where the mold [not shown] in the shape of interconnected buckling walls of a defined thickness may be filled with the molten material and solidified to form the cushioning component (100). The mold may be defined with radius (r) at the intersections thereby the molten material when solidified, assumes the shape defined by the mold and thereby defining the radius (r) at the intersection (I) of the interconnected buckling walls. The provision of the radius (r) facilitates easy removal of the cushioning component (100) from the mold and also prevents breaking of the buckling walls during ejection or removal from the mold. In some embodiments, the cushioning component (100) may be manufactured by any other manufacturing process. Further, as illustrated in Figure 4, the present disclosure discloses a mattress (200) comprising a bottom foam layer (210) forming a base of the mattress (200). The mattress (200) includes a first felt layer (230a) positioned on top of the bottom foam layer (210). Further, a layer of spring coils (220) is positioned above the first felt layer (230a). In an embodiment, a second felt layer (230b) is provided on top of the layer of spring coils (220). More specifically, the layer of spring coils (220) may be disposed between the first and second felt layers (230a, 230b) to securely hold and protect the layer of spring coils (220). In an embodiment, height of the first and second felt layer (230a, 230b) may range between 2 mm to 30 mm. Further, the first and the second felt layers (230a, 230b) include at least one of thick cloth, polyester wadding, polyester blend fabric, spun 12 fabric cotton, non-woven fabric, felt fabric layers and any combination thereof. In an embodiment, a side encasing foam layer (260) is provided such that it extends between the first and the second felt layers (230a, 230b) and laterally surrounds at least one side of the layer of the spring coils (220). The side encasing foam layer (260) may be provided to laterally surround all sides of the layer ofspring coils(220). Thisside encasing foam layer (260)laterally secureslayer of the spring coils (220) and prevents misalignment of the layer of the spring coils (220) with respect to adjacent layers of the mattress (200) and also helps to ensure there is support on the edges of the cushioning material (100). A predetermined height of the side encasing foam layer (260) may be 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). The height of the transition foam layer (240) may range between 5 mm to 50mm. The mattress (200) includes a cushioning component (100) having 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). 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 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 (200). In an exemplary embodiment, the array of openings (20) is formed by intersection of the first and second ribs (12 and 14) extending in different orientations i.e., first and the second directions (A and B). The intersection of the first rib and the second rib (12 and 14) defines an intersection of the interconnected buckling walls of the grid structure. The intersection (I) is defined with a radius (r) or radius of curvature to strengthen the point of intersection and to avoid stress concentration at the intersection (I). The provision of radius (r) uniformly distributes the load and adds additional 13 strength to the intersection (I), thereby enhancing the usage life of the cushioning component (100). The mattress (200) further includes a support foam layer (255) that is positioned between the transition foam layer (240) and the upper foam layer (250) and laterally surrounds the at least one cushioning component (100) as shown in Figure 4. 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/or 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 (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) to store and allow access to the mattress (200). This packaging cover (274) allows ease of transportation without causing any damage to the mattress (200). In a non-limiting embodiment, themattress(200) may include one ormore layers ofthe cushioning component (100), upper, lower and transition foam layers (210, 240, 250), layer of spring coils (220), the first and second felt layers (230a, 230b) and can be arranged in an any combination thereof as per user’s comfort and application requirement. Referring to Figure 5 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 14 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 is applied and return to an original state upon removal of the load. In an exemplary embodiment, the array of openings (20) is formed by intersection of the first and second ribs (12 and 14) extending in different orientations i.e., first and the second directions (A and B). The intersection of the first rib and the second rib (12 and 14) defines an intersection of the interconnected buckling walls of the grid structure. The intersection (I) is defined with a radius (r) or radius of curvature to strengthen the point of intersection and to avoid stress concentration at the intersection (I). The provision of radius (r) uniformly distributes the load and adds additional strength to the intersection (I), thereby enhancing the usage life of the cushioning component (100). More specifically, the grid structure formed in combination of the plurality of first and second ribs (12, 14) along with radius at intersection, provides denser grid structure at the bottom portion of the cushioning component (100). In an embodiment, a transition foam layer (320) is positioned above the bottom foam layer (310) and below the cushioning component (100). The transition foam layer (320) provides a stabilizing base to the cushioning component (100) and aids in better bonding and strength of the mattress (300). 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 length and width of the mattress (300). The mattress (300) comprises a support foam layer (355) that is positioned between the transition foam layer (320) and an upper foam layer (330) and laterally surroundsthe at least one cushioning component (100) asshown in Figure 5. This support foam layer (355) is provided to support the at least one cushioning component (100) at the edges to maintain the positioning and alignment of the cushioning component (100) and any damage to the grid structure is averted. Also, the side encasing helps provide an edge 15 support to the mattress which prevents damage 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 (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) to store and allow access of the mattress (300). This packaging cover (345) allows ease of transportation without causing any damage to the mattress (300). Further, other embodiments of the mattress are disclosed from Figures 6a to 6j illustrates various configuration of the cushioning component (100) within a mattress (200, 300). As shown in Figure 6a and Figure 6b, 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 6c and 6d, 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 6e to 6g. Further, the cushioning component (100) may be provided as top layer for one or more foam layers (25) as shown in Figures 6h to Figure 6j. The predetermined height of the foam layer (25), the layer of spring coils (26) and the felt layers (27) and the cushioning component (100) may vary as per application requirements of the mattress (200, 300). Further, each layer of the mattress (200, 300) can be positioned to joined to other layers by any adhesive material, mechanical fastening 16 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) allows object/ user to sink deeply because of the buckling of the grids 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) provide a surface area to expand and resist higher load/weights. 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. In an embodiment, the cushioning component (100) with radius at intersection of the buckling walls increases strength and prevents breaking of the buckling walls during tangential loading, thereby improves usage life of the cushioning component (100). In an embodiment, the cushioning component (100) with radius at intersection of the buckling walls reduces breaking of buckling walls during ejection or removal from the mold. 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 17 “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrasesshould not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogousto “at least one of A, B, and C, etc.” is used, in generalsuch a construction isintended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogousto “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systemsthat have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.” While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments 18 disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims. Referral Numeral: Referral numerals Description 100 Cushioning component 10 Frame 10a, 10b, 10c, and 10d First side, second side, third side and fourth side 12 First ribs 14 Second 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 19 345 Packaging cover 355 Support foam layer 370 Fabric layer A First direction B Second direction 20 We claim: 1. A cushioning component (100), comprising: 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); the plurality of first ribs (12) and the plurality of second ribs (14) forming a grid structure defining an array of openings (20) with interconnected buckling walls, and an intersection (I) of the interconnected buckling walls is defined with a radius (r); and wherein, the interconnected buckling walls 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 first ribs (12) and the plurality of second ribs (14) are defined with a height (H1, H2) ranging between 5 mm to 100mm. 3. The cushioning component (100) as claimed in claim 1, wherein the plurality of first ribs (12) and the plurality of second ribs (14) are defined with a wall thickness (t) ranging between 0.5mm to 6 mm. 4. 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. 5. The cushioning component (100) as claimed in claim 1, wherein the cushioning component (100) is manufactured from a material including one of an elastomeric material, a thermoplastic elastomer, polypropylene, silicon, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, silica gel, polymer, and liquid silicon. 6. The cushioning component (100) as claimed in claim 1, wherein the radius (r) at the intersection (I) of the interconnected buckling walls is defined as at least one of an inner circular radius, an outer circular radius, and a non-circular radius. 7. The cushioning component (100) as claimed in claim 6, wherein the radius (r) at the 21 intersection (I) of the interconnected buckling walls is defined as at least one of an inner fillet radius, an outer fillet radius, and a chamfered radius. 8. The cushioning component (100) as claimed in claim 1, wherein the radius (r) at the intersection (I) of the interconnected buckling walls ranges between 0.25mm to 9 mm. 9. 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: 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); the plurality of first ribs (12) and the plurality of second ribs (14) forming a grid structure defining an array of openings (20) with interconnected buckling walls, and an intersection (I) of the interconnected buckling walls is defined with a radius (r); and wherein, the interconnected buckling walls are being structured to buckle on application of load for uniformly distributing the load across the at least one cushioning component (100) and return to an original state upon removal of the load. 10. The mattress (200) as claimed in claim 9, comprises a second felt layer (230b) on top of the layer of spring coils (220). 11. The mattress (200) as claimed in claim 10, comprises a side encasing foam layer (260) laterally surrounding at least one side of the layer of spring coils (220). 12. The mattress (200) as claimed in claim 9, comprises a fabric layer (270) secured to at least one of the top portion and the bottom portion of the at least one cushioning component (100). 13. The mattress (200) as claimed in claim 9, comprises an upper foam layer (250) secured 22 above the at least one cushioning component (100). 14. The mattress (200) as claimed in claim 10, comprises a transition foam layer (240) positioned over the second felt layer (230b) and below the at least one cushioning component (100). 15. The mattress (200) as claimed in claim 14, comprises a support foam layer (255) positioned laterally surrounding the at least one cushioning component (100). 16. A mattress (300), comprising: a bottom foam layer (310); at least one cushioning component (100) positioned above the bottom foam layer (310), the at least one cushioning component (100) comprising: 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); the plurality of first ribs (12) and the plurality of second ribs (14) forming a grid structure defining an array of openings (20) with interconnected buckling walls, and an intersection (I) of the interconnected buckling walls is defined with a radius (r); and wherein, the interconnected buckling walls are being structured to buckle on application of load for uniformly distributing the load across the at least one cushioning component (100) and return to an original state upon removal of the load. 17. The mattress (300) as claimed in claim 16, comprises an upper foam layer (330) secured above the at least one cushioning component (100). 18. The mattress (300) as claimed in claim 16, comprises a support foam layer (355 laterally surrounding the at least one cushioning component (100). 19. The mattress (300) as claimed in claim 16, comprises a fabric layer (370) secured to at least one of the top portion and the bottom portion of the at least one cushioning component (100). 23 20. The mattress as claimed in claim 16, comprises a transition foam layer (320) positioned above the bottom foam layer (310).

Documents

Application Documents

# Name Date
1 202321069250-STATEMENT OF UNDERTAKING (FORM 3) [13-10-2023(online)].pdf 2023-10-13
2 202321069250-FORM FOR STARTUP [13-10-2023(online)].pdf 2023-10-13
3 202321069250-FORM FOR SMALL ENTITY(FORM-28) [13-10-2023(online)].pdf 2023-10-13
4 202321069250-FORM 1 [13-10-2023(online)].pdf 2023-10-13
5 202321069250-EVIDENCE FOR REGISTRATION UNDER SSI(FORM-28) [13-10-2023(online)].pdf 2023-10-13
6 202321069250-EVIDENCE FOR REGISTRATION UNDER SSI [13-10-2023(online)].pdf 2023-10-13
7 202321069250-DRAWINGS [13-10-2023(online)].pdf 2023-10-13
8 202321069250-DECLARATION OF INVENTORSHIP (FORM 5) [13-10-2023(online)].pdf 2023-10-13
9 202321069250-COMPLETE SPECIFICATION [13-10-2023(online)].pdf 2023-10-13
10 202321069250-FORM-9 [26-10-2023(online)].pdf 2023-10-26
11 202321069250-STARTUP [30-10-2023(online)].pdf 2023-10-30
12 202321069250-FORM28 [30-10-2023(online)].pdf 2023-10-30
13 202321069250-FORM 18A [30-10-2023(online)].pdf 2023-10-30
14 Abstact.jpg 2023-11-20
15 202321069250-FORM-26 [04-01-2024(online)].pdf 2024-01-04
16 202321069250-FER.pdf 2024-03-20
17 202321069250-FORM 3 [09-05-2024(online)].pdf 2024-05-09
18 202321069250-FORM 3 [15-05-2024(online)].pdf 2024-05-15
19 202321069250-OTHERS [25-05-2024(online)].pdf 2024-05-25
20 202321069250-FER_SER_REPLY [25-05-2024(online)].pdf 2024-05-25
21 202321069250-DRAWING [25-05-2024(online)].pdf 2024-05-25
22 202321069250-COMPLETE SPECIFICATION [25-05-2024(online)].pdf 2024-05-25
23 202321069250-Proof of Right [08-07-2024(online)].pdf 2024-07-08
24 202321069250-US(14)-HearingNotice-(HearingDate-31-07-2024).pdf 2024-07-09
25 202321069250-Correspondence to notify the Controller [26-07-2024(online)].pdf 2024-07-26
26 202321069250-Written submissions and relevant documents [14-08-2024(online)].pdf 2024-08-14
27 202321069250-PETITION UNDER RULE 137 [14-08-2024(online)].pdf 2024-08-14
28 202321069250-FORM 3 [14-08-2024(online)].pdf 2024-08-14
29 202321069250-PatentCertificate23-08-2024.pdf 2024-08-23
30 202321069250-IntimationOfGrant23-08-2024.pdf 2024-08-23
31 202321069250-POST GRANT EVIDENCE OPPOSITION [24-02-2025(online)].pdf 2025-02-24
32 202321069250-Form-4 u-r 138 [23-04-2025(online)].pdf 2025-04-23
33 202321069250_(E-9-7-2025-MUM)-Notice_US25(3)-(20-05-2025).pdf 2025-05-20
34 202321069250-Written Statement and Evidence [21-05-2025(online)].pdf 2025-05-21
35 202321069250-Form-4 u-r 138 [20-06-2025(online)].pdf 2025-06-20
36 202321069250-Statement and Evidence [22-07-2025(online)].pdf 2025-07-22
37 202321069250-Annexure [22-07-2025(online)].pdf 2025-07-22
38 202321069250-Response to office action [18-09-2025(online)].pdf 2025-09-18

Search Strategy

1 Search202321069250E_24-02-2024.pdf
2 Search202321069250AE_28-06-2024.pdf

ERegister / Renewals

3rd: 16 Sep 2024

From 13/10/2025 - To 13/10/2026