Patents by Inventor Russell B. Whatcott
Russell B. Whatcott has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11871861Abstract: A cushion includes a cover and a cushioning element having a top surface heat-fused to the cover. The cushioning element comprises an elastomeric material having a plurality of voids formed therein. At least 60% of a bottom surface of the cushioning element is exposed such that when the cushion is disposed over a surface at least 60% of the bottom surface of the cushioning element is in direct contact with the surface. Methods of forming the cushion include disposing a cover adjacent a mold, conforming the cover to a selected shape of the mold, injecting molten elastomeric material into the mold, bonding the molten elastomeric material to the cover, solidifying the molten elastomeric material to form the cushioning element, and separating the mold from the cover. The cushioning element maintains the cover in the selected shape.Type: GrantFiled: March 2, 2016Date of Patent: January 16, 2024Assignee: Purple Innovation, LLCInventors: Tony M. Pearce, Terry V. Pearce, Russell B Whatcott
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Publication number: 20230392047Abstract: An article of manufacture, such as a weighted blanket, a cushioning element, or the like, includes an elastomeric element that includes elongated elements that follow nonlinear, partially overlapping paths and voids between adjacent portions of the elongated elements. Such an elastomeric element may define a weighted layer of a weighted blanket, a cushioning layer of a cushioning element of the like. The elastomeric element may be secured directly to a substrate, such as a fabric layer. Alternatively, an adhesion layer may secure the elastomeric element to the substrate. An adhesion layer may cover only a portion of the substrate. A cover may be provided over the elastomeric element. Together, the cover and the substrate may contain the elastomeric element.Type: ApplicationFiled: August 15, 2023Publication date: December 7, 2023Inventors: James T. Grutta, Brett Pearson, Robert W. Taylor, David Ewell, Bob Watters, Brock Keith Harris, Dhyey Yogesh Acharya, Russell B. Whatcott
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Publication number: 20230380600Abstract: A cushioning element includes pressurizable cells. The pressurizable cells of the cushioning elements are grouped into a plurality of sets, with each set of pressurizable cells being independently pressurizable from every other set of pressurizable cells of the cushioning element. The pressurizable cells may extend across a widths of the cushioning element and be arranged in series along the length of the cushioning element. Such a cushioning element may be part of a cushion, such as a mattress, a mattress topper, or the like. Methods for manufacturing the cushioning elements are also disclosed.Type: ApplicationFiled: August 15, 2023Publication date: November 30, 2023Inventors: James T. Grutta, Russell B. Whatcott, Brett Pearson
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Publication number: 20230356497Abstract: A method for forming a cushioning element comprises molding a first cushioning element on a first side of a fabric and molding a second cushioning element on a second side of the fabric. The first cushioning element and second cushioning element may be superimposed. The fabric may include a first layer and a second layer that are superimposed, with the first cushioning element secured to and protruding from the first layer and the second cushioning element secured to and protruding from the second layer. Each of the first cushioning element and second cushioning element may include a plurality of interconnected walls formed from an elastomeric gel material. The walls of the first cushioning element and second cushioning element may be aligned or offset.Type: ApplicationFiled: July 17, 2023Publication date: November 9, 2023Inventors: Robert Wayne Taylor, Russell B. Whatcott, Matthew Eccles Rogers, Dhyey Y. Acharya, Lidia Saldaña
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Publication number: 20230356496Abstract: A cushioning element includes a fabric, a first cushioning element on a first side of the fabric, and a second cushioning element on a second side of the fabric. The first cushioning element and second cushioning element may be superimposed. The fabric may include a first layer and a second layer that are superimposed, with the first cushioning element secured to and protruding from the first layer and the second cushioning element secured to and protruding from the second layer. Each of the first cushioning element and second cushioning element may include a plurality of interconnected walls formed from an elastomeric gel material. The walls of the first cushioning element and second cushioning element may be aligned or offset.Type: ApplicationFiled: July 17, 2023Publication date: November 9, 2023Inventors: Robert Wayne Taylor, Russell B. Whatcott, Matthew Eccles Rogers, Dhyey Y. Acharya, Lidia Saldaña
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Patent number: 11725121Abstract: An article of manufacture, such as a weighted blanket, a cushioning element, or the like, includes an elastomeric element that includes elongated elements that follow nonlinear, partially overlapping paths and voids between adjacent portions of the elongated elements. Such an elastomeric element may define a weighted layer of a weighted blanket, a cushioning layer of a cushioning element of the like. The elastomeric element may be secured directly to a substrate, such as a fabric layer. Alternatively, an adhesion layer may secure the elastomeric element to the substrate. An adhesion layer may cover only a portion of the substrate. A cover may be provided over the elastomeric element. Together, the cover and the substrate may contain the elastomeric element.Type: GrantFiled: February 8, 2021Date of Patent: August 15, 2023Assignee: Purple Innovation, LLCInventors: James T. Grutta, Brett Pearson, Robert W. Taylor, David Ewell, Bob Watters, Brock Keith Harris, Dhyey Yogesh Acharya, Russell B. Whatcott
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Patent number: 11723476Abstract: A cushioning element includes pressurizable cells. The pressurizable cells of the cushioning elements are grouped into a plurality of sets, with each set of pressurizable cells being independently pressurizable from every other set of pressurizable cells of the cushioning element. The pressurizable cells may extend across a widths of the cushioning element and be arranged in series along the length of the cushioning element. Such a cushioning element may be part of a cushion, such as a mattress, a mattress topper, or the like. Methods for manufacturing the cushioning elements are also disclosed.Type: GrantFiled: February 28, 2022Date of Patent: August 15, 2023Assignee: Purple Innovation, LLCInventors: James T. Grutta, Russell B. Whatcott, Brett Pearson
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Publication number: 20230142851Abstract: A cover for a cushion includes a first panel, a second panel, and a primary receptacle defined between the first panel and the second panel. The primary receptacle may receive a primary cushioning element, such as a pillow, a pillow insert, or a fill material. At least one of the first panel and the second panel includes a secondary cushioning element. The secondary cushioning element may be defined from a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls that in turn define an array of open cells or columns. Each cell or column may have a hexagonal shape, imparting the array of open cells or columns with a honeycomb appearance. Methods for assembling a primary cushioning element with such a cover are also disclosed.Type: ApplicationFiled: January 12, 2023Publication date: May 11, 2023Inventors: Robert Wayne Taylor, Russell B. Whatcott, Matthew Eccles Rogers, Dhyey Y. Acharya, Lidia Saldaña
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Publication number: 20220296003Abstract: A mattress that includes a bottom mattress assembly and a top mattress assembly that may be assembled with each other. An internal overlap may be associated with the bottom mattress assembly and protrude beyond a top of a bottom core of the bottom mattress assembly to define a receptacle for a base portion of the top mattress assembly. A cover top and a cover bottom may be placed over the assembly and secured to each other at a location vertically below an upper extent of the internal overlap. The mattress may be modular and, thus, include a bottom mattress assembly selectable from a plurality of different configurations of bottom mattress assemblies and/or a top mattress assembly selectable from a plurality of different configurations of top mattress assemblies. Methods for assembling bottom mattress assemblies and top mattress assemblies with one another to provide a complete mattress are also disclosed.Type: ApplicationFiled: March 22, 2022Publication date: September 22, 2022Inventors: Russell B. Whatcott, Brock Keith Harris, Dhyey Yogesh Acharya, Wade Hoover
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Publication number: 20220273113Abstract: A cushioning element includes pressurizable cells. The pressurizable cells of the cushioning elements are grouped into a plurality of sets, with each set of pressurizable cells being independently pressurizable from every other set of pressurizable cells of the cushioning element. The pressurizable cells may extend across a widths of the cushioning element and be arranged in series along the length of the cushioning element. Such a cushioning element may be part of a cushion, such as a mattress, a mattress topper, or the like. Methods for manufacturing the cushioning elements are also disclosed.Type: ApplicationFiled: February 28, 2022Publication date: September 1, 2022Inventors: James T. Grutta, Russell B. Whatcott, Brett Pearson
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Patent number: 11179873Abstract: Extractor systems for extracting a flexible article of manufacture from a mold include an extraction roller, at least one track configured to support the extraction roller, and a trolley configured to carry the extraction roller from a first side of the mold toward a second, opposite side of the mold. Molding systems include a mold and an extractor system. Methods of extracting a flexible article of manufacture from a mold include separating a first platen and a second platen, positioning an extraction roller between the separated first and second platens, engaging the article of manufacture with a row of teeth positioned along the extraction roller, and rotating the extraction roller to wrap the article of manufacture about the extraction roller.Type: GrantFiled: May 26, 2020Date of Patent: November 23, 2021Assignee: Purple Innovation, LLCInventors: Russell B. Whatcott, Steve Bonney, Terry V. Pearce
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Patent number: 11174110Abstract: A mattress topper for fitting to a mattress may include a lower layer, a side layer configured to extend down along a side of the mattress, and an upper layer overlaying the lower layer and at least partially disposed between the lower layer and the side layer. The mattress topper may also include a seam including threads and extending along peripheral edges of the lower layer and the upper layer and extending through the lower layer, upper layer, and side layer, the lower layer and side layer bearing the threads of the seam. An air table may include a top panel including a plurality of vents extending through the top panel. A method of making a mattress topper with an air table may include lifting the mattress topper with the air table while performing sewing procedures on the mattress topper.Type: GrantFiled: January 25, 2018Date of Patent: November 16, 2021Assignee: Purple Innovation, LLCInventor: Russell B. Whatcott
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Publication number: 20210246336Abstract: An article of manufacture, such as a weighted blanket, a cushioning element, or the like, includes an elastomeric element that includes elongated elements that follow nonlinear, partially overlapping paths and voids between adjacent portions of the elongated elements. Such an elastomeric element may define a weighted layer of a weighted blanket, a cushioning layer of a cushioning element of the like. The elastomeric element may be secured directly to a substrate, such as a fabric layer. Alternatively, an adhesion layer may secure the elastomeric element to the substrate. An adhesion layer may cover only a portion of the substrate. A cover may be provided over the elastomeric element. Together, the cover and the substrate may contain the elastomeric element.Type: ApplicationFiled: February 8, 2021Publication date: August 12, 2021Inventors: James T. Grutta, Brett Pearson, Robert W. Taylor, David Ewell, Bob Watters, Brock Keith Harris, Dhyey Yogish Acharya, Russell B. Whatcott
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Publication number: 20200390247Abstract: A cover for a cushion includes a first panel, a second panel, and a primary receptacle defined between the first panel and the second panel. The primary receptacle may receive a primary cushioning element, such as a pillow, a pillow insert, or a fill material. At least one of the first panel and the second panel includes a secondary cushioning element. The secondary cushioning element may be defined from a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls that in turn define an array of open cells or columns. Each cell or column may have a hexagonal shape, imparting the array of open cells or columns with a honeycomb appearance. Methods for assembling a primary cushioning element with such a cover are also disclosed.Type: ApplicationFiled: June 15, 2020Publication date: December 17, 2020Inventors: Robert Wayne Taylor, Russell B. Whatcott, Matthew Eccles Rogers, Dhyey Y. Acharya, Lidia Saldaña
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Patent number: 10807811Abstract: A mattress topper for fitting to a mattress may include a lower layer, a side layer configured to extend down along a side of the mattress, and an upper layer overlaying the lower layer and at least partially disposed between the lower layer and the side layer. The mattress topper may also include a seam including threads and extending along peripheral edges of the lower layer and the upper layer and extending through the lower layer, upper layer, and side layer, the lower layer and side layer bearing the threads of the seam. An air table may include a top panel including a plurality of vents extending through the top panel. A method of making a mattress topper with an air table may include lifting the mattress topper with the air table while performing sewing procedures on the mattress topper.Type: GrantFiled: March 7, 2016Date of Patent: October 20, 2020Assignee: Purple Innovation, LLCInventor: Russell B. Whatcott
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Publication number: 20200282616Abstract: Extractor systems for extracting a flexible article of manufacture from a mold include an extraction roller, at least one track configured to support the extraction roller, and a trolley configured to carry the extraction roller from a first side of the mold toward a second, opposite side of the mold. Molding systems include a mold and an extractor system. Methods of extracting a flexible article of manufacture from a mold include separating a first platen and a second platen, positioning an extraction roller between the separated first and second platens, engaging the article of manufacture with a row of teeth positioned along the extraction roller, and rotating the extraction roller to wrap the article of manufacture about the extraction roller.Type: ApplicationFiled: May 26, 2020Publication date: September 10, 2020Inventors: Russell B. Whatcott, Steve Bonney, Terry V. Pearce
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Patent number: 10661492Abstract: Extractor systems for extracting a flexible article of manufacture from a mold include an extraction roller, at least one track configured to support the extraction roller, and a trolley configured to carry the extraction roller from a first side of the mold toward a second, opposite side of the mold. Molding systems include a mold and an extractor system. Methods of extracting a flexible article of manufacture from a mold include separating a first platen and a second platen, positioning an extraction roller between the separated first and second platens, engaging the article of manufacture with a row of teeth positioned along the extraction roller, and rotating the extraction roller to wrap the article of manufacture about the extraction roller.Type: GrantFiled: November 17, 2017Date of Patent: May 26, 2020Assignee: Purple Innovation, LLCInventors: Russell B. Whatcott, Steve Bonney, Terry V. Pearce
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Publication number: 20190152107Abstract: Extractor systems for extracting a flexible article of manufacture from a mold include an extraction roller, at least one track configured to support the extraction roller, and a trolley configured to carry the extraction roller from a first side of the mold toward a second, opposite side of the mold. Molding systems include a mold and an extractor system. Methods of extracting a flexible article of manufacture from a mold include separating a first platen and a second platen, positioning an extraction roller between the separated first and second platens, engaging the article of manufacture with a row of teeth positioned along the extraction roller, and rotating the extraction roller to wrap the article of manufacture about the extraction roller.Type: ApplicationFiled: November 17, 2017Publication date: May 23, 2019Inventors: Russell B. Whatcott, Steve Bonney, Terry V. Pearce
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Publication number: 20190075884Abstract: An insole for a shoe includes an insole body of elastomeric material having a first major surface and a second major surface opposite the first major surface. A distance between the first major surface and the second major surface is between about 1 mm and about 10 mm. The elastomeric material defines a plurality of voids extending through the elastomeric material from the first major surface to the second major surface. Each void has a dimension between about 1 mm and about 3 mm in a plane parallel at least one of to the first major surface and the second major surface. A minimum distance between adjacent voids is between about 0.5 mm and about 3 mm. A shoe insole includes such a cushion. A method of forming an insole for a shoe includes providing an elastomeric material within a mold to form an insole body of elastomeric material.Type: ApplicationFiled: September 11, 2017Publication date: March 14, 2019Inventors: Tony M. Pearce, Terry V. Pearce, Russell B. Whatcott, Shawn David Moon, Dhyey Acharya
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Patent number: D951670Type: GrantFiled: January 16, 2020Date of Patent: May 17, 2022Assignee: Purple Innovation, LLCInventors: Russell B. Whatcott, Dhyey Y. Acharya