CUSHIONING AND SUPPORT SYSTEM

Abstract

In some embodiments, a support structures can be formed from a support structure matrix comprising a plurality of spring structures embedded within the support structure matrix. The plurality of spring structures can be formed from the same material or a different material, and can have the same or different durometers. The plurality of spring structures can be configured to deform and return to its original shape after deformation. The orientation and structure of the spring structures can vary depending on a desired durometer and/or function within the support structure.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. Application No. 17/950,981, filed Sep. 22, 2022, which in turn claims the benefit of U.S. Provisional Application No. 63/248,317, filed Sep. 24, 2021. Both applications are incorporated herein by reference in their entirety.

FIELD

The present disclosure relates to cushion and support systems, such as mattresses and other furniture or supporting structures.

BACKGROUND

A current shortcoming in certain cushioning devices, such as gel-based mattresses, is that one or more cushioning and supportive systems can only exist in one of two states. That is, the cushioning and supportive systems of these products exist only in a first erect, uncompressed state, and a second fully compressed and collapsed state. Because these products only exist in one of these two states, they do not offer effective and adequate support to the user. Improvements to such conventional cushioning devices are desirable.

SUMMARY

In some embodiments, a support structure can comprise a support structure matrix comprising a plurality of layers and a plurality of spring structures embedded within the plurality of layers of the support structure matrix. The plurality of spring structures have a plurality of different durometers, and the plurality of spring structures are configured to deform and return to its original shape after deformation. In other embodiments, methods of forming a support structure having a plurality of spring structures are also disclosed.

The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B illustrates exemplary spring structures embedded in a support structure matrix;

FIG. 2 illustrates another exemplary spring structure embedded in a support structure matrix;

FIGS. 3A and 3B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 4A and 4B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 5A and 5B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 6A and 6B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 7A and 7B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIG. 8 illustrates exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 9A and 9B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 10A, 10B, and 10C illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIGS. 11A and 11B illustrate exemplary spring structures that can be embedded in a support structure matrix;

FIG. 12 illustrates exemplary spring layer structures of different durometers;

FIG. 13 illustrates exemplary spring layer structures of different durometers;

FIG. 14 illustrates a method of forming spring structures in a support structure matrix;

FIG. 15 illustrates a spring structures in a portion of a support structure matrix;

DETAILED DESCRIPTION

The following description proceeds with reference to the attached figures, which are part of the application.

As used in this application the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Furthermore, as used herein, the term “and/or” means any one item or combination of items in the phrase. In addition, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As used herein, the terms “e.g.,” and “for example,” introduce a list of one or more non-limiting embodiments, examples, instances, and/or illustrations.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed things and methods can be used in conjunction with other things and methods. Additionally, the description sometimes uses terms like “provide,” “produce,” “determine,” and “select” to describe the disclosed methods. These terms are high-level descriptions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art having the benefit of this disclosure.

As used herein, the term “gel-based mattress” refers to a mattress that contains at least one layer of a gel-infused matrix, such as memory foam or polyfoam.

As used herein, the term “embedded” refers to a material that is embedded into a matrix. In some embodiments, the embedded material extends at least 0.5 inches into the matrix and is a “deeply embedded material.” In some embodiments, the embedded material is “partially embedded,” which means that at least a portion of the material is exposed on at least one side of the layer. In other embodiments, the embedded material is entirely within the matrix and is a “fully embedded material.”

Described herein are cushioning and support systems that provide comfort and support beyond that support provided by conventional systems. The cushioning and support systems of the present disclosure include a single or series of springs, each including two or more layers of material having varying stiffness and/or hardness (e.g., as determined by a corresponding durometer number). The springs are configured to provide progressive resistance, as additional force is applied (e.g., the weight of the user), resulting in a true variable response and in increased comfort and supportive experience to the user.

In some embodiments, the examples provided herein are in reference to mattress systems that use elastomeric polymers. However, it should be understood that the cushioning systems described herein can also function in other cushioning applications, such as pillows, seat cushions (e.g., automotive and furniture), as well as any other application in which a comfortable and supportive structure is desirable.

FIGS. 1A, 1B, and 2 show a perspective view of a cross-sectional segment of a support structure (e.g., a mattress) and a plurality of springs of the present disclosure embedded within the matrix or substrate of the support structure. In representative examples, the support structure matrix can be made of an open or closed cell foam and/or expandable foam. In some examples, the matrix can be made of an elastomeric polymer (e.g., a gel), silicone, expanded metal, wood foam, bamboo foam, natural materials, or a combination thereof. In addition to, or in lieu of those materials listed, the matrix can also include a combination of compressible solid, liquid, and/or air materials and/or elements suitable for compression.

As shown FIG. 1A, the springs 100a-100d are partially-embedded in the support structure 104. The springs can be cylindrical in shape and situated within the support structure 102 in a sequential or linear manner along the length and/or width of the support structure 104. For example, FIGS. 1A and 1B illustrate springs 100a-100d within a given segment of the support structure 104 as being axially spaced from one another and aligned along a common axial direction within the same horizontal plane (e.g., from one end of the support structure to the other end in the Y direction).

In FIG. 1A, the springs 100a-100d comprise portions with different materials and/or different properties. For example, upper portions 101a-101d can be formed of a first material having a first durometer and lower portions 103a-103d can be formed of a second material having a second (different) durometer. Thus, for example, the upper portions can be configured with a lower durometer material to provide a softer, more flexible, upper portion while the lower portions can be formed with a higher durometer material to provide increased firmness, or vice versa if desired.

In other embodiments, the springs 100a-100d can comprise a single materials (with a single durometer). For example, as shown in FIG. 1B, the springs 100a-100d are formed with a single material. The single durometer example of FIG. 1B can also be formed with multiple layers (e.g., as shown in FIG. 1A), with each layer having the same material with the same durometer.

As illustrated in the drawing of FIG. 2, however, two or more springs 200 can also be arranged in a similar sequential manner but situated such that two or more springs 200 are located within different horizontal planes. In some cases, the spring material is partially-embedded, in other cases, the spring material (e.g., of 200c) is “fully embedded.” Spring material that is partially embedded can be formed, for example, by delivering material from one or more sides of a support structure layer.

Similar to the examples shown in FIGS. 1A and 1B, the springs 200 of FIG. 2 can be axially spaced from one another and aligned along a common axial direction (e.g., the Y direction). In contrast, however, the springs 200a-200d of FIG. 2 have different vertical positions relative to one another within the support structure 202 of the support structure 204 (e.g., in the Z direction of FIG. 2). As a specific example, the left most spring 200a can be situated such that the spring 200a is located in a different horizontal plane than the other springs 200b-200d and an upper portion of the spring 200a extends upwardly beyond the support structure surface 206. Whereas the right most spring 200d can be situated such that the upper most surface of the spring 200d is flush with the top support structure surface 206, while the two middle springs 200b-200c are embedded entirely within the body of the matrix 202.

In some examples, the springs need not be arranged sequentially or aligned along a common axial direction (e.g., the X or Y direction), but can be offset from one another. In other examples, the springs extending beyond the top surface of the support structure can be configured or positioned along the surface of the support structure to contact directly or indirectly a particular portion of the user’s body (e.g., the lower back, shoulders, neck, etc.). In still further examples, one or more springs can extend beyond a first matrix layer and into a second matrix layer.

In some examples, such as where material of the support structure matrix is positioned between the lower most surface of the spring and the bottom surface of the support structure, the material composing the matrix can provide a certain degree of resistance in addition to the resistance provided by that spring. Such additional resistance as provided by the matrix can, for example, be determined by the material characteristics of that matrix’s material, such as a top cover layer of a support structure (e.g., a mattress).

In representative examples, the body of the support structure matrix can be fashioned as to form molds to fabricate one or more springs. For instance, the matrices of FIGS. 1A, 1B, and/or FIG. 2 can be formed (e.g., during processing, via pre-cutting, etc.) to have a cylindrical, hollowed out portion which can be used to form the springs (e.g., springs 100, 200). In such examples, a matrix can be fashioned to form all of the springs within that matrix, including springs of different shapes and/or arrangements (e.g., FIGS. 8-11). In other such examples, the matrix can be fashioned to form only a fraction of the total springs within that given matrix. In further examples, each spring can be assembled and/or formed separately (e.g., via an injection molding process) and installed within the matrix.

Although the springs are described as being embedded and/or associated with a single support structure matrix, it should be understood that any support structure comprising the springs of the present disclosure can include two or more support structure matrices, each which can have their own combination and/or arrangement of springs. A support structure which includes multiple matrices in this way can, for example, be layered atop one another, with or without other materials therebetween.

As discussed in more detail below, the spring material for any of the spring structures described herein can be the same or different throughout the support structure. Thus, for example, in some embodiments, the same spring material can be used throughout the support structure (or a layer thereof). Thus, although the shape, size, and/or orientations of the spring structures may vary, the spring material remains the same throughout. In other embodiments, the spring material may vary within the support structure (or a layer thereof). Thus, for example, a first spring material may form some spring structures and one or more other spring materials may form additional spring structures.

Turning now to FIGS. 3-11, the springs of the present disclosure can comprise single layer (e.g., as shown in FIGS. 1 and 2,) or they can comprise two or more layers stacked in a vertical arrangement. As shown in FIGS. 3A and 3B, for example, each spring 300, 302 can include two or more layers. Each spring 300, 302 can be cylindrical in shape and have an opening extending through the center of each spring 300, 302, from the bottom most surface to the upper most surface. Each layer of the spring 300 and spring 302, as such, can be ring-like in shape and arranged coaxially with one another in a vertical arrangement such that the layers are stacked. In the stacked arrangement, adjacent layers of springs can contact each other (e.g., a top surface of a bottom spring can contact a bottom surface of a top spring), or they can be separated by other materials. For example, two springs can be separated by a portion of the support structure matrix that extends between the two adjacent surfaces or they can be separated by another structure, of the same or different material, such as a ring-shaped spacer formed of one or more elastomeric polymers, silicone, expanded metal, wood foam, bamboo foam, natural materials, compressible solids, liquids, and/or air materials.

The number of stacked ring-shaped layers can vary. FIG. 3A shows two stacked ring-shaped layers, while FIG. 3B shows 9 layers. In some cases the number of layers can be between 2 and 300, and in other cases, the number of layers can exceed 300, such as 300-1,000, or even more such as 10,00-10,000.

As illustrated in the drawing of FIG. 3, each layer of both the spring 300 and spring 302 can have the same inner and outer diameters. As will be explained, however, the inner and outer diameters can differ between two or more layers.

In some examples, the layers of one spring can have a depth or height which differs from a depth or height of the layers of another spring. For instance, the spring 300 and spring 302 can have the same overall height. However, the spring 300 to the left of FIG. 3 includes two layers, whereas the spring 302 to the right of FIG. 3 includes 9 layers. In some embodiments, both springs 300 and 302 can be provided in a single support structure such that the overall heights are the same, but the individual heights of stacked springs vary. In this case, each layer of the spring 302 has a depth/height less than a depth/height of the layers of spring 300, since only two layers form the spring 300. In a similar manner, two or more layers within a single spring can have a depth/height that differs from one another.

As shown in the drawings of FIGS. 4A, 4B and FIGS. 5A and 5B, each layer of the springs can have a hardness, as determined by a durometer number, which differs from one or more other layers. FIGS. 4A and 5A show a standard view of a structure with a plurality of layers, while FIGS. 4B and 5B show an exploded view of the same structures. Similar figures are shown for other embodiments herein.

For instance, the spring 400 of FIGS. 4A and 4B, shown in both assembled and exploded views, depicts a spring with three layers, each layer having a different hardness from the adjacent layer immediately above it. Specifically, the spring 400 has a first upper layer 411 having a hardness of Shore OO-20, a second middle layer 413 having a hardness of Shore OO-40, and a third bottom layer 415 having a hardness of Shore OO-70. In this configuration, the spring 400 can be said to have increasing hardness from the upper most layer to the lower most layer, or inversely, decreasing hardness from the lower most layer to the upper most layer. As such, each layer of increasing hardness moving down the length of the spring 400 can provide support to the adjacent layer immediately above it. Meaning, in the case of the spring 400 of FIGS. 4A and 4B, the middle layer can provide support to the upper layer as the upper layer is deformed and compressed, while the bottom layer can provide support to both the upper and middle layers as both layers become deformed and compressed.

In an opposite manner, as shown on FIGS. 5A and 5B, a spring 500 can, in some examples, decrease in hardness from an upper most layer to the lower most layer, or inversely, increasing hardness from the lower most layer to the upper most layer. As an example and as shown on FIG. 5B, the spring 500 has a first upper layer 511 having a hardness of Shore OO-80, a second middle layer 513 having a hardness of Shore OO-50, and a third bottom layer 515 having a hardness of Shore OO-30. In such configurations, the spring 500 can, for example, provide a firmer upper surface nearest the top surface of support structure matrix (e.g., FIGS. 1 and 2), but provide increasing softness or provide more “give” as increasing weight or downward force is applied.

Accordingly, the hardness of one or more springs can be said to increase or decrease incrementally across the longitudinal length of the springs depending on their respective layers, such as those configurations described above in reference to the springs 400, 500. In some examples, however, the hardness of the springs need not increase or decrease incrementally across the length of the spring. For instance, the springs can have a middle layer which has a hardness greater than or lesser than both the adjacent upper and lower layers.

In some examples, the springs can have any combination of layers with distinct degrees of hardness. As one example, the spring 302 of FIG. 3B, which has nine individual layers, can have layers of alternating hardness such that, for instance, one layer has a hardness relatively softer than the layer immediately preceding it and subsequent to it (and vice versa). Another example can include the same spring 302 of FIG. 3B, in which the layers within the bottom half of the spring increase incrementally in hardness upward and the layers within the upper half of the spring decrease incrementally in hardness, also upward. In such a configuration, for example, the layers with the highest degree of hardness will be located within the middle layers of the spring. In some examples, the layers can have any variation of hardness ranging from Shore D-10 to Shore OOO-1.

In representative implementations, each layer of the springs can comprise one or more elastomeric polymers which allow each layer to deform and return to its original size and shape after deformation. Elastomeric polymers can include, for instance, homopolymers, copolymers, and/or elastomeric polymers comprising blocks or groups of linked homopolymers. In some implementations, a plasticizer can be added to the elastomeric polymer, for example, to increase plasticity, decrease viscosity and/or friction, and can make elastomeric polymer softer and more flexible. Plasticizers can include hydrocarbon fluids such as mineral oils, and can be aliphatic or aromatic, for instance.

Each layer of the springs can comprise a thermoplastic elastomeric polymer (TPEG) which has thermoplastic and elastic qualities. A TPEG can, for example, include elastomeric polymers and/or a plasticizer such that the TPEG is capable of deforming and returning to its original shape and size after deformation. Generally, TPEGs can be melted when heated and formed into a plastic when cooled, such as to form the hybrid spring elastomeric polymers described herein. The TPEG can be a Bio-based and/or fossil-based. For example, the TPEG can be derived from sources such as corn, beets, cellulose, vegetable oil, soya beans, sugar cane, and/or any other suitable plant matter. TPEG can also comprise styrenic block copolymers (e.g., SEPTON®, Kraton polymers, etc.). The TPEG used herein can also include a rubber and/or a hydrogenated rubber, such as ethylene/propylene, ethylene/butylene, or ethylene/ethylene/propylene, etc., which can be plasticized with hydrocarbon fluids.

One or more TPEGs can also be combined with antioxidants, which can, for example, improve the longevity of the product and reduce the effects of thermal degradation in manufacturing (e.g., IRGANOX®, EVERNOX®, etc.). TPEGs can also be formulated to avoid the need for external support, such as a barrier, so the layers have sufficient structural integrity as to not break under normal use.

In some implementations, the layers of the springs of the present disclosure can also be composed of silicone, polyurethane, and/or polyvinyl chloride (PVC).

As shown on FIGS. 6A, 6B and 7A, 7B, each layer of the springs can have inner and outer dimensions which differ from one or more other layers. The springs 600a-600b depicted in FIGS. 6A and 6B, for instance, illustrate that each of the layers of the spring can have the same outer diameter, but different inner diameters. A wall thickness of each layer, i.e., the thickness of material between the inner and outer diameters of the layer, can be varied along the length of the springs 600a-600b by varying the inner diameter of the layers. For example, as best illustrated by the exploded views of the left and right springs 600a-600b of FIG. 6B, the wall thickness of each layer can decrease or increase along the length of the spring, from the lower most layer to the upper most layer, respectively. FIG. 6B shows spring 600a with a decreasing wall thickness from the bottom to the top (e.g., from bottom layer 611 to middle layer 613 to top layer 615), while spring 600b has an increasing wall thickness from bottom to the top (e.g., from bottom layer 617 to middle layer 619 to top layer 621). In this manner, spring 600a would have a softer, more flexible upper surface (relative to the lower layer) and spring 600b would have a firmer, less flexible upper surface (relative to the lower layer).

In other examples, the inner diameter and wall thickness of each layer can be varied in any combination and/or arrangement. One layer can, for instance, have a wall thickness greater than each adjacent layer such that the wall thicknesses of the spring does not increase or decrease linearly along its length.

In addition to, or in lieu of having varied inner diameters, the right and left springs 700a-700b depicted in FIGS. 7A and 7B illustrate that the layers of a spring can have dissimilar outer diameters. As shown in both the assembled and exploded views of the left and right springs 700a-700b, the outer diameter of each layer can decrease or increase along the length of the spring, from the lower most layer to the upper most layer, respectively. For example, FIG. 7B shows spring 700a with a decreasing wall inner diameter from the bottom to the top (e.g., from bottom layer 711 to middle layer 713 to top layer 715), while spring 700b has an increasing inner wall diameter from bottom to the top (e.g., from bottom layer 717 to middle layer 719 to top layer 721) In other examples, the outer diameter of each layer can be varied in any combination and/or arrangement. For example, one layer can have an outer diameter greater than each adjacent layer such that the outer diameter of the spring does not increase or decrease linearly along its length.

As shown on FIG. 8, the springs described herein can have arrangements other than the stacked arrangement of the springs depicted on FIGS. , 1-7 (e.g., spring 800). For example, rather than being arranged vertically, the springs can be positioned horizontally within a support structure matrix. In particular, the second spring 802 from the left on FIG. 8 shows that the layers on the outer most ends of the spring can lie within the same horizontal plane. In such examples, the layers can be coaxial with one another and aligned along a common axis of their respective support structure matrix.

In some examples, the layers of springs need not be coaxially aligned. As one example, each layer can be arranged side-by-side with one another in a vertical arrangement. As one example and as illustrated on FIG. 8, each layer of a spring 804 can be connected to an adjacent layer at their circumferential outer surfaces such that the layers are vertically aligned, but not coaxially aligned. As another example, the spring 806 depicted in FIG. 8 shows that, in some instances, the layers need not be in contact with one another, but can be axially spaced from one another along a horizonal plane (or vertical plane).

FIGS. 9-11 show that the springs, and the layers thereof can be provided in various geometric shapes, combination of shapes, and/or patterns. As shown in FIGS. 9A and 9B, for example, springs can be formed of two or more square layers (e.g., spring 900), triangular layers (e.g., spring 902), hexagonal layers (e.g., spring 904), and/or any combination thereof (e.g., spring 906). Other geometric shapes can include ovals, parallelograms, pentagons, circles, ovals, helical (e.g., in a spring-like shape), wave patterns, and/or any combination thereof, and those already listed.

As shown in FIGS. 10A and 10B, two or more layers of the springs described herein can be formed of geometric patterns. As one specific example, a spring 1000 depicted in FIGS. 10A and 10B can have two or more layers 1002, 1004, each layer comprising a pattern of repeating hexagonal cells grouped together and arranged side-by-side. As such, the layers of the spring 1000 of FIG. 10 can be said to have a honeycomb pattern. In other examples, however, one or more layers can be formed of a pattern of other repeating geometric shapes, such as squares, triangles, ovals, parallelograms, pentagons, circles, helical shapes, wave patterns, and/or any combination thereof.

In other embodiments, the spring 1000 can comprise a single materials (with a single durometer). For example, as shown in FIG. 10C, springs 1000 is formed with a single material. Although shown as a single layer in FIG. 10C, it should be understood that the single durometer example of FIG. 10C can also be formed with multiple layers (e.g., as shown in FIG. 10B), but with each layer having the same material with the same durometer.

In some examples, such as that illustrated in FIGS. 11A and 11B, one or more layers of a spring 1100 can be formed of a geometric pattern which is a relatively larger or smaller version of the geometric pattern of any of the other layers. For instance, the spring 1100 depicted on FIG. 11 has a first layer 1102 formed of a geometric pattern of repeating squares, which is a relatively larger version of the square geometric pattern that forms the second layer 1104.

As best shown in FIG. 11B, any two layers of the springs described herein can also have a solid dividing layer 1106 between those layers (e.g., first layer 1102 and second layer 1104), as opposed to the two layers being connected and/or in contact with one another. In such configurations, the dividing layer can distribute the downward force applied to the adjacent upper layer, to the adjacent lower layers. In some examples, a spring can include two or more dividing layers between two layers and/or distributed among many layers.

FIGS. 12 and 13 illustrate additional embodiments of multi-durometer layers, in which each foam layer comprises springs (e.g., elastomeric polymer springs) with different durometers as described herein. For example, as shown in FIG. 12, a spring 1200 can comprise a plurality of different section, each having a plurality of different types of layers (i.e., with different durometers). Spring 1200 can comprise, for example, a first series of layers 1211 (horizontal) formed with a first durometer (durometer 1), a second series of layers 1213 (vertical) formed with a second durometer (durometer 2), and a third series of layers 1215 formed with a third durometer (durometer 3) and these three series of layers can be stacked to form a support structure with a plurality of layers (or series of layers) of different durometers.

Alternatively, each section of spring 1200 (e.g., 1211, 1213, or 1215) can form its own spring structure for a particular application. Thus, for example, the first series of layers 1211 can form a spring structure for a mattress or other application without layers 1213 and 1215. Similarly, the second series of layers 1213 and the third series of layers 1215 can also be used independently and separately from the other layers, such that layers 1213 or layers 1215 can form the spring structure for particular application. Of course, as described elsewhere herein, the number of layers for any of these structures can vary, whether functioning in a stacked arrangement (1200) or not (e.g., 1211, 1213, 1215 independently).

FIG. 13 illustrates an example in which a plurality of layers 1300 is formed by adjacent layers that have different spring structures (e.g., elastomeric polymer springs) to form multiple durometers resulting in a variable spring force support system with multiple layers (e.g., 2-100+) of elastomeric polymer-supported substrate . For example, the spring (e.g., elastomeric polymer spring) in each substrate can be calibrated to an increasing or decreasing durometer (as described above) to provide the desired variable spring force for the system. The spring insertions (e.g., elastomeric polymer springs) can be along the same or multiple axis. Or transposed on either side of one or more of the foam (or other substrate) elements.

As shown in FIG. 13, different spring durometers can be positioned adjacent each other to create different durometer layers. In addition, the position and location of spring members can be varied to further modify function and/or durometer. For example, FIG. 13 shows adjacent layers (first, second, and third layers) having springs positioned on a top portion, lower portion, or both, of different layers. In embodiments where the springs are adjacent one another (e.g., in contact with adjacent springs), the springs can be bonded to the adjacent spring structure. For example, an elastomeric polymer spring on a bottom surface of a top layer can be bonded to an elastomeric polymer spring on a top surface of a bottom layer. The spring can also be bonded to the foam of the layer.

Alternatively, each individual layer depicted in FIG. 13 can form an independent support structure (e.g., a mattress, cushion, or other such structure). Thus, for example, a mattress or other support structure can be formed entirely from one of the individual layers shown in FIG. 13, such as the top portion with a single durometer layer adjacent the top surface.

The spring members disclosed herein can be deeply embedded, such that it is embedded at least 0.5 inches from a surface of the matrix of the layer, or fully embedded so that the spring member does not extend to a surface of the matrix of the layer.

As discussed above, including for example with respect to FIGS. 1A, 1B and 2A, 2B, a plurality of springs of the present disclosure can be embedded within the matrix or substrate of the support structure. For example, the support structure (e.g., an open or closed cell foam and/or expandable foam) can act as a mold for receiving a spring material (e.g., an elastomeric polymer or other material as described herein) within portions of the support structure. In FIGS. 1A, 1B, cylindrical-shaped openings are formed (e.g., pre-formed and/or cut) in the support structure so that the spring material can be received in the openings. As discussed above, the openings can be fully embedded within the support structure (e.g., so that spring material must be delivered internally to the support structure) and/or the openings can be partially embedded in the support structure (e.g., so that the spring material can be delivered into the openings from a side of the support structure, such as the top.

FIG. 15 shows another embodiment in which a plurality of partially-embedded openings 1605 (e.g., channels and/or slits) are formed in a support structure 1602 (e.g., a foam mattress). The partially-embedded openings 1605 can be formed in any suitable manner to define a spring-material receiving area.

In some embodiments, the openings 1605 can comprise different size or type openings. For example, as shown in FIGS. 2A and 2B, two or more springs can be located within different horizontal planes. In FIG. 15, the openings are shown having two different configurations. In particular, in FIG. 15, the openings are openings with different depths, and the different depths in this case alternate across the width and/or length of the structure. Although the depths alternate ever other opening, it should be understood that different arrangements and/or patterns could be utilized. For example, the depths could alternate after any number (e.g., every 3-6 openings) and the number of each depth can vary such that there can be a different number of openings for one depth than another.

The openings 1605 can be filled with a spring material. In some embodiments, the spring material is the same in each opening. In others, the spring material can change depending on the depth of the opening and/or the position of the opening along the support structure 1602. FIG. 15 illustrates the openings 1605 filled with the same material, having the same durometer throughout the support structure 1602.

As described herein, one or more mold shapes (e.g., channels of one or more depths) can be provided. Thus, for example, referring to FIG. 15, which shows a portion of a support structure with spring materials, a plurality of channels 1605 can be formed with two or more different depths. In the embodiment shown in FIG. 15, there are two different depth channels which alternate along the length and/or width of the support structure. The spring material in each can be the same material, although the different channel depths provide different cushioning response even with the same material.

Thus, in some embodiments, the spring material can be deposited into openings of the support structure (e.g., channels or other shapes) in a flowable state (e.g., a liquified, elastomeric polymer). As the flowable spring material (e.g., liquified elastomeric polymer) is deposited into the openings, the spring material solidifies and bonds to the walls of the spring structure forming a combined cushioning system. Thus, for example, if the spring material is an elastomeric polymer and the support structure is a foam, the bonding of the two materials forms a synergistic combination of elastomeric polymer and foam member that provides a desired amount of cushioning (e.g., spring effect) and also increasing the resilience of the foam member.

The specific embodiments disclosed herein are not limiting of the invention, but rather are examples of a broad array of different embodiments that the inventors have envisioned that include the technology disclosed herein. Any of the features or characteristics disclosed herein can be combined in any way with any of the other features or characteristics disclosed herein, as well as with any other known support structure technologies, to form a variety of different embodiments that include or relate to the inventive technology disclosed herein.

Claims

1. A support structure comprising:

a support structure matrix formed with a plurality of openings; and

a plurality of spring structures embedded within the plurality of openings of the support structure matrix, the spring structures comprising a spring material that is bonded to the support structure matrix;

wherein the plurality of openings comprise at least a plurality of first openings and a plurality of second openings, the first openings having a different size, shape, and/or orientation that is different from the second openings relative to the support structure matrix.

wherein the plurality of spring structures are configured to deform and return to its original shape after deformation.

2. The support structure of claim 1, wherein the spring material of at least some of the spring structures comprise a thermoplastic elastomeric polymer.

3. The support structure of claim 2, wherein the thermoplastic elastomeric polymer comprises styrenic block copolymers.

4. The support structure of claim 2, wherein the thermoplastic elastomeric polymer comprises a rubber and/or a hydrogenated rubber.

5. The support structure of claim 1, wherein the first openings and second openings comprise channels, and the channels of the first openings have a different depth than the channels of the second openings.

6. The support structure of claim 5, wherein the channels of the first openings are interspersed between at least some channels of the second openings.

7. The support structure of claim 1, wherein at least some of the plurality of openings are fully-embedded in the support structure matrix.

8. The support structure of claim 1, wherein at least some of the plurality of openings are fully-embedded in the support structure matrix.

9. The support structure of claim 1, wherein the support structure matrix comprises a plurality of layers that comprise at least a first layer, a second layer, and a third layer, and the first layer is bonded to the second layer, and the second layer is bonded to the third layer,

wherein the plurality of openings are formed in one or more of the first layer, second layer, and third layer.

10. The support structure of claim 1, wherein at least some of the spring structures are vertically stacked to form a stacked spring system.

11. The support structure of claim 10, wherein the stacked spring system comprises spring structures that have different wall thicknesses.

12. The support structure of claim 1, wherein the spring material is the same in each of the plurality of openings.

13. The support structure of claim 1, wherein the spring material is the same in each of the plurality of openings.

14. The support structure of claim 1, wherein the spring material of the first plurality of openings is different than the spring material of the second plurality of openings.

15. The support structure of claim 1, wherein at least some of the plurality of spring structures comprise ring-shaped structures.

16. The support structure of claim 1, wherein at least some of the plurality of spring structures form honeycombed-shaped structures.

17. The support structure of claim 1, wherein at least some of the plurality of spring structures are spaced apart from one another and positioned within different horizontal planes, such that some of the plurality of spring structures are at a different height than others of the plurality of spring structures.

18. The support structure of claim 1, wherein the spring structure comprises an elastomer, silicone, expanded metal, wood foam, bamboo foam, natural materials, or a combination thereof.

19. The support structure of claim 1, wherein the support structure is a mattress.

20. The support structure of claim 1, wherein the support structure is a cushion for a seat and/or item of furniture.