CUSHIONS HAVING VOIDS IN A LOWER SURFACE

Info

Publication number: 20240008656
Type: Application
Filed: Sep 22, 2023
Publication Date: Jan 11, 2024
Applicant: SOFT-TEX GROUP, INC. (Latham, NY)
Inventors: Mark SMIDERLE (Midhurst), Lloyd J. WILSON (Saratoga Springs, NY), Fusheng XU (Glen Allen, VA)
Application Number: 18/472,776

Abstract

Mattresses, cushions, and body-support mats or pads are disclosed. Polymer(s) at least partially define a length, width and depth, the depth extending from an upper surface proximate to where a user rests to a lower surface opposite the upper surface. Voids in the polymer traverse at least a portion of the width. The plurality of voids are located at the lower surface and/or the upper surface and are defined by polymer walls and wall(s) of polymer walls define each polymer foot of polymer feet. A first region of a plurality of lower surface regions includes at least one foot of the plurality of polymer feet that has a first size. A second region of the plurality of lower surface regions includes at least one other foot having a second size. The at least one other foot spans a greater distance along the length than the at least one foot.

Description

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a by-pass continuation of PCT International Application No. PCT/US2022/021194, filed on Mar. 21, 2022, and entitled Mattresses, Cushions, and Body-Support Pads or Mats Having Voids and Grooves On At Least One Surface, which claims priority benefit of U.S. Provisional Patent Application No. 63/164,011, filed Mar. 22, 2021, and entitled Foam Mattresses, Foam Cushions, and Foam Body-Support Pads or Mats, of U.S. Provisional Patent Application No. 63/179,813, filed Apr. 26, 2021, and entitled Mattresses, Cushions, and Body-Support Pads or Mats Having Polymer Feet, of U.S. Provisional Patent Application No. 63/210,306, filed Jun. 14, 2021, and entitled Mattresses, Cushions, and Body-Support Pads or Mats Having Voids and Grooves, and of U.S. Provisional Patent Application No. 63/241,089, filed Sep. 6, 2021, and entitled Mattresses, Cushions, and Body-Support Pads or Mats Having Voids and Grooves on At Least One Surface, the entire contents of all of which are hereby expressly incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to mattresses, cushions, and body-support pads or mats and more particularly to mattresses, cushions and body-support pads or mats having voids and grooves on at least one surface.

BACKGROUND

Consumers often purchase and utilize bed assemblies with adjustable bases. Bed assemblies with adjustable bases can be convenient and enable a user to adjust the base of the bed so that a mattress supporting the user and positioned on top of the base can support the user at a desired ergonomic position. Movement of the adjustable base will cause a mattress located on top of the adjustable base to shift or move. Various techniques have been used to control mattress movement so that the mattress maintains its position centered on the adjustable base. For example, retainer bar assemblies may be secured to the foot portion of the adjustable base and/or at the head portion of the adjustable base in order to prevent the mattress from sliding or lifting in response to the adjustable base inclining or folding. Various other fixation devices are also used to limit movement of the mattress relative to the adjustable base and to keep the mattress in place so that a user does not have to readjust the mattress positioning when the adjustable base inclines or folds. Although this provides many advantages, these measures intended to limit the movement of the mattress and keep the mattress in place may also cause compression near the midpoint or pivot point of the mattress. In particular, inclining the head portion of the adjustable base and/or the foot portion of the adjustable base past a certain angle may cause the midpoint or pivot point of the mattress to bunch in the mattress material due to the folding or compression of the mattress.

When the adjustable base is set to incline at a relatively large angle, the bunching of the material near the midpoint or pivot point can lead to ridges on the surface of the mattress that become more pronounced the larger the incline of the mattress. These ridges and bunching can feel uncomfortable to a user resting on the mattress. In some cases, the ridges formed from the mattress bunching may not be as soft as the rest of the mattress, and this harder surface could potentially even result in a user developing sores or bruising in the regions of the body that are in contact with the ridges. Thus, a need exists to reduce the likelihood that ridges will form on the surface of the mattress when the mattress is compressed or folded as a result of inclining the adjustable base.

Another disadvantage that results from the ridges formed in a mattress due to compression or folding relates to mattress packing. One process often used to facilitate transport of a mattress is to fold or roll the mattress into a box for transportation and shipment. The rolling or folding can also result in ridges forming on the surface of the mattress. When the mattress is rolled or folded the ridges may cause air pockets that can take up space. These air pockets may limit the ability of the mattress to be folded or packed into a smaller box or package. Thus, a need exists to reduce the likelihood that ridges will form on the surface of the mattress, which may cause air pockets to form during folding, rolling, and packing.

While certain aspects of conventional technologies have been discussed to facilitate disclosure of the invention, Applicants in no way disclaim these technical aspects, and it is contemplated that the claimed invention may encompass one or more of the conventional technical aspects discussed herein.

In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY

Shortcomings of the prior art are overcome and additional advantages are provided through improved mattress, cushions, and body-support pads or mats disclosed herein. In particular, disclosed herein are mattresses, cushions, and body-support pads or mats that include a polymer such as a polymeric foam (e.g. Toluene Diisocyanate (TDI) foam or Methylenediphenyl diisocyanate (MDI) foam), or an elastomer. The polymer may include a first plurality of voids, gaps, or grooves located on the underside or lower surface of the polymer. Advantageously, the first plurality of voids, gaps, or grooves may allow for the polymer to fold or bend without causing the bunching and ridges on the top or resting surface of the mattress that is the side opposite the bottom side or underside that includes the first plurality of voids, gaps, or grooves. The polymer may further include a second plurality of voids, gaps, or grooves located on the topside or upper surface of the polymer. Advantageously, the second plurality of voids, gaps, or grooves may further allow for the polymer to fold or bend without causing the bunching and ridges on the top or resting surface of the mattress that is the side opposite the bottom side or underside that includes the first plurality of voids, gaps, or grooves.

It is also contemplated that the improved mattresses, cushions, and body-support pads or mats may prove useful in addressing other problems and deficiencies in a number of technical area. Therefore, the disclosed mattresses, cushions, and body-support pads or mats should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

Certain embodiments of the presently disclosed mattresses, cushions, and body-support pads or mats have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the mattresses, cushions, and body-support pads or mats as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art.

In one aspect, disclosed herein is a mattress that includes polymer defining a length and a width of the mattress. The polymer spans a depth that is perpendicular to the length and the width of the mattress and extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer, where the lower surface is opposite the upper surface that is proximate to where the user rests. The mattress further includes a first plurality of voids in the polymer that traverse at least a portion of the width of the mattress, where the first plurality of voids are located at the lower surface, and where the first plurality of voids are defined by polymer walls of the polymer. The mattress also includes a first plurality of polymer feet, wherein each polymer foot of the first plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the mattress includes a plurality of lower surface regions, where a first region of the plurality of lower surface regions includes multiple feet of the first plurality of polymer feet and at least one foot having a first size, and a second region of the plurality of lower surface regions includes at least one other foot of the first plurality of polymer feet that has a second size. Further, the at least one other foot having the second size spans a greater distance along the length of the mattress than the at least one foot having the first size.

In another aspect disclosed herein is a cushion that includes polymer defining a length and a width of the cushion. The polymer spans a depth that is perpendicular to the length and the width of the cushion and extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer, where the lower surface is opposite the upper surface that is proximate to where the user rests. The cushion further includes a first plurality of voids in the polymer that traverse at least a portion of the width of the cushion, where the first plurality of voids are located at the lower surface, and where the first plurality of voids are defined by polymer walls of the polymer. The cushion also includes polymer feet, wherein each polymer foot of the polymer feet is defined by one or more walls of the polymer walls. Additionally, the cushion includes a plurality of lower surface regions, where a first region of the plurality of lower surface regions includes multiple feet of the polymer feet and at least one foot having a first size, and a second region of the plurality of lower surface regions includes at least one other foot of the polymer feet that has a second size. Further, the at least one other foot having the second size spans a greater distance along the length of the cushion than the at least one foot having the first size.

In another aspect disclosed herein is a body-support pad or mat that includes polymer defining a length and a width of the body-support pad or mat. The polymer spans a depth that is perpendicular to the length and the width of the body-support pad or mat and extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer, where the lower surface is opposite the upper surface that is proximate to where the user rests. The body-support pad or mat further includes a first plurality of voids in the polymer that traverse at least a portion of the width of the body-support pad or mat, where the first plurality of voids are located at the lower surface, and where the first plurality of voids are defined by polymer walls of the polymer. The body-support pad or mat also includes polymer feet, wherein each polymer foot of the polymer feet is defined by one or more walls of the polymer walls. Additionally, the body-support pad or mat includes a plurality of lower surface regions, where a first region of the plurality of lower surface regions includes multiple feet of the polymer feet and at least one foot having a first size, and a second region of the plurality of lower surface regions includes at least one other foot of the polymer feet that has a second size. Further, the at least one other foot having the second size spans a greater distance along the length of the body-support pad or mat than the at least one foot having the first size.

In another aspect, disclosed herein is a mattress that includes polymer defining a length and a width of the mattress. The polymer spans a depth that is perpendicular to the length and the width of the mattress and extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer, where the lower surface is opposite the upper surface that is proximate to where the user rests. The mattress further includes a first plurality of voids in the polymer that traverse at least a first portion of the width of the mattress, where the first plurality of voids are located at the lower surface, and where the first plurality of voids are defined by polymer walls of the polymer. The mattress also includes a first plurality of polymer feet, wherein each polymer foot of the first plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the mattress includes a plurality of lower surface regions, where a first region of the plurality of lower surface regions includes multiple feet of the first plurality of polymer feet and at least one foot having a first size, and a second region of the plurality of lower surface regions includes at least one other foot of the first plurality of polymer feet that has a second size. Further, the at least one other foot having the second size spans a greater distance along the length of the mattress than the at least one foot having the first size. The mattress further includes a second plurality of voids in the polymer that traverse at least a second portion of the width of the mattress, where the second plurality of voids are located at the upper surface, and where the second plurality of voids are defined by the polymer walls of the polymer. The mattress also includes a second plurality of polymer feet, wherein each polymer foot of the second plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the mattress includes a plurality of upper surface regions, where a first region of the plurality of upper surface regions includes multiple feet of the second plurality of polymer feet and at least one foot having a third size, and a second region of the plurality of upper surface regions includes at least one other foot of the second plurality of polymer feet that has a fourth size. Further, the at least one other foot having the fourth size spans a greater distance along the length of the mattress than the at least one foot having the third size.

In another aspect, disclosed herein is a cushion that includes polymer defining a length and a width of the cushion. The polymer spans a depth that is perpendicular to the length and the width of the cushion and extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer, where the lower surface is opposite the upper surface that is proximate to where the user rests. The cushion further includes a first plurality of voids in the polymer that traverse at least a first portion of the width of the cushion, where the first plurality of voids are located at the lower surface, and where the first plurality of voids are defined by polymer walls of the polymer. The cushion also includes a first plurality of polymer feet, wherein each polymer foot of the first plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the cushion includes a plurality of lower surface regions, where a first region of the plurality of lower surface regions includes multiple feet of the first plurality of polymer feet and at least one foot having a first size, and a second region of the plurality of lower surface regions includes at least one other foot of the first plurality of polymer feet that has a second size. Further, the at least one other foot having the second size spans a greater distance along the length of the cushion than the at least one foot having the first size. The cushion further includes a second plurality of voids in the polymer that traverse at least a second portion of the width of the cushion, where the second plurality of voids are located at the upper surface, and where the second plurality of voids are defined by the polymer walls of the polymer. The cushion also includes a second plurality of polymer feet, wherein each polymer foot of the second plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the cushion includes a plurality of upper surface regions, where a first region of the plurality of upper surface regions includes multiple feet of the second plurality of polymer feet and at least one foot having a third size, and a second region of the plurality of upper surface regions includes at least one other foot of the second plurality of polymer feet that has a fourth size. Further, the at least one other foot having the fourth size spans a greater distance along the length of the cushion than the at least one foot having the third size.

In another aspect, disclosed herein is a body-support pad or mat that includes polymer defining a length and a width of the body-support pad or mat. The polymer spans a depth that is perpendicular to the length and the width of the body-support pad or mat and extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer, where the lower surface is opposite the upper surface that is proximate to where the user rests. The body-support pad or mat further includes a first plurality of voids in the polymer that traverse at least a first portion of the width of the body-support pad or mat, where the first plurality of voids are located at the lower surface, and where the first plurality of voids are defined by polymer walls of the polymer. The body-support pad or mat also includes a first plurality of polymer feet, wherein each polymer foot of the first plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the body-support pad or mat includes a plurality of lower surface regions, where a first region of the plurality of lower surface regions includes multiple feet of the first plurality of polymer feet and at least one foot having a first size, and a second region of the plurality of lower surface regions includes at least one other foot of the first plurality of polymer feet that has a second size. Further, the at least one other foot having the second size spans a greater distance along the length of the body-support pad or mat than the at least one foot having the first size. The body-support pad or mat further includes a second plurality of voids in the polymer that traverse at least a second portion of the width of the body-support pad or mat, where the second plurality of voids are located at the upper surface, and where the second plurality of voids are defined by the polymer walls of the polymer. The body-support pad or mat also includes a second plurality of polymer feet, wherein each polymer foot of the second plurality of polymer feet is defined by one or more walls of the polymer walls. Additionally, the body-support pad or mat includes a plurality of upper surface regions, where a first region of the plurality of upper surface regions includes multiple feet of the second plurality of polymer feet and at least one foot having a third size, and a second region of the plurality of upper surface regions includes at least one other foot of the second plurality of polymer feet that has a fourth size. Further, the at least one other foot having the fourth size spans a greater distance along the length of the body-support pad or mat than the at least one foot having the third size.

These and other features and advantages of the disclosure and inventions will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects described herein are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings, which are not necessarily drawn to scale, wherein:

FIG. 1 depicts an elevational perspective view of a mattress and adjustable base, according to the prior art;

FIG. 2 depicts an elevational perspective view of a polymer of a mattress and an adjustable base, according to the present disclosure;

FIG. 3A depicts an elevational perspective view of a polymer of a mattress and an adjustable base, according to the present disclosure;

FIG. 3B depicts an elevational perspective view of the polymer of the mattress and adjustable base of FIG. 3A with an additional void at the foot portion of the polymer of the mattress, according to the present disclosure;

FIG. 3C depicts an elevational perspective view of the polymer of the mattress and adjustable base of FIG. 3A with a plurality of additional voids at the foot portion of the polymer of the mattress, according to the present disclosure;

FIG. 4A depicts a bottom view of a polymer of a mattress with a plurality of voids extending the width of the polymer of the mattress, according to the present disclosure;

FIG. 4B depicts a bottom view of the polymer of the mattress of FIG. 4A with an additional void extending the length of the polymer of the mattress, according to the present disclosure;

FIG. 4C depicts a bottom view of the polymer of the mattress of FIG. 4A with multiple voids extending the length of the polymer of the mattress, according to the present disclosure;

FIG. 4D depicts a bottom view of the polymer of the mattress of FIG. 4A with multiple voids extending the length of the polymer of the mattress, according to the present disclosure;

FIG. 4E depicts a bottom view of the polymer of the mattress of FIG. 4A with multiple voids extending the length of the polymer of the mattress, according to the present disclosure;

FIG. 5A depicts a side view of a polymer of a mattress with a plurality of voids along the length of the polymer of the mattress, according to the present disclosure;

FIG. 5B depicts a side view of a polymer of a mattress with a plurality of voids along the length of the polymer of the mattress, according to the present disclosure;

FIG. 5C depicts a side view of a polymer of a mattress with a plurality of voids along the length of the polymer of the mattress, according to the present disclosure;

FIG. 5D depicts a side view of a polymer of a mattress with a plurality of voids along the length of the polymer of the mattress, according to the present disclosure;

FIG. 6A depicts a side view of a polymer of a mattress with multiple grooves situated along the width of the polymer of the mattress, according to the present disclosure;

FIG. 6B depicts a side view of a polymer of a mattress with multiple grooves situated along the width of the polymer of the mattress, according to the present disclosure;

FIG. 6C depicts a side view of a polymer of a mattress with multiple grooves situated along the width of the polymer of the mattress, according to the present disclosure;

FIG. 7 depicts a side view of a polymer of a mattress with a plurality of dual-sided voids along the length of the polymer of the mattress, according to the present disclosure; and

FIG. 8 depicts a side view of a polymer of a mattress with a plurality of dual-sided voids along the length of the polymer of the mattress, according to the present disclosure.

DETAILED DESCRIPTION

Aspects of the present disclosure and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the details of the inventions. It should be understood, however, that the detailed description and the specific example(s), while indicating embodiments of inventions of the present disclosure, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

Approximating language, as used herein throughout disclosure, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” or “substantially,” is not limited to the precise value specified.

Described herein are mattresses, cushions and body-support pads or mats that include a polymer. The polymer defines a length and a width of the respective mattress, cushion, or body-support pad or mat. Further, the polymer spans a depth that is perpendicular to the length and the width, where the depth extends from an upper surface of the polymer that is proximate to where a user rests to a lower surface of the polymer that is opposite the upper surface. The polymer includes a first plurality of voids, gaps, or grooves that traverse a portion of the width and/or the length of the respective mattress, cushion, or body-support pad or mat, where the first plurality of voids, gaps, or grooves are located in the lower surface and are defined by polymer walls of the polymer. The first plurality of voids, gaps, or grooves in the polymer allow for the respective mattress, cushion, or body-support pad or mat to fold or bend in a manner that reduces bunching and ridges that typically form on the top or resting surface that supports the user when folding/bending the respective mattress, cushion, or body-support pad or mat. The first plurality of voids, gaps, or grooves in the polymer also allow for the respective mattress, cushion, or body-support pad or mat to be packed in a reduced volume and/or weight, which can lower shipping cost.

The polymer may further include a second plurality of voids, gaps, or grooves located in the upper surface of the polymer that traverse a portion of the width and/or the length of the respective mattress, cushion, or body-support pad or mat. The second plurality of voids, gaps, or grooves are located in the upper surface and are defined by polymer walls of the polymer. Advantageously, the second plurality of voids, gaps, or grooves may further allow for the polymer to fold or bend without causing the bunching and ridges on the top or resting surface of the respective mattress, cushion, or body-support pad or mat that is the side opposite the lower surface that includes the first plurality of voids, gaps, or grooves. The second plurality of voids, gaps, or grooves in the polymer also allow for the respective mattress, cushion, or body-support pad or mat to be packed in a reduced volume and/or weight, which can lower shipping cost.

For instance, as depicted in FIG. 1, existing mattresses such as mattress 100 that are folded or bent in response to an adjustable base/frame 150 being inclined typically causes bunching or ridges 199 near the midpoint or pivot point of the mattresses as depicted in mattress 100. The bunching and ridges 199 can cause discomfort and provide a hardened surface that can cause bedsores or bruising to a user.

In contrast, mattresses, cushions, and body-support pads or mats that include polymers having a plurality of voids, gaps and/or grooves that traverse a portion of the width and/or length of the mattress reduce the likelihood that ridges or bunching will form on the upper/resting surface from folding or bending the mattress.

Referring now to FIG. 2, a mattress 200 and adjustable base/frame 250 are depicted. In particular, the mattress 200 includes one or more polymer. Although not depicted in FIG. 2, the one or more polymer may be at least partially enclosed by a mattress cover according to various embodiments. For instance, the one or more polymer may be fully enclosed by the mattress cover. Further, the mattress cover may form the uppermost surface of the mattress that is proximate to where a user of the mattress rests as well as the bottommost surface that is in contact with the base 250. According to some embodiments, a fire-resistant material may be located near the uppermost surface, and in particular located between the mattress cover and the upper surface of the one or more polymer. According to various embodiments, the mattress cover may include a fabric that has a stretch capacity within a range of about 1% stretch to about 50% stretch, or more particularly within a range of about 10% stretch to about 40% stretch, 20% stretch to about 35% stretch, or at about 35% stretch. According to various embodiments, the fabric having the stretch capacity may be positioned along one or more sides that span the depth of the mattress. According to various embodiments, the fabric having the stretch capacity may additionally, or alternatively, be positioned along a bottom surface of the mattress 200. Further, the one or more polymer may be formed of isocyanate and polyol. In some embodiments, the one or more polymer may include polyisocyanurate and/or polyurethane. In various embodiments, the one or more polymer (or portions thereof) may additionally, or alternatively, include an elastomer such as latex.

As shown in FIG. 2, at least one of the one or more polymer of the mattress 200 includes a first plurality of voids 214 that traverse at least a portion of the width W1 of the mattress 200. Further, the first plurality of voids 214 are located about or in the lower surface 203 of the polymer of the mattress 200, where the lower surface 203 is opposite the upper surface 201 of the polymer or the mattress 200. The polymer spans a depth D1 that extends from the upper surface 201 to the lower surface 203. Various embodiments of the polymer may include one or more layers such as a first layer 234 proximate the upper surface 201 and a second layer 230 proximate the lower surface 203. Further, a third layer 232 may be located between the first layer 234 and the second layer 230. According to various embodiments, at least one layer of the multiple layers may include a different density than at least one other layer of the multiple layers. For instance, the first layer 234 may be less dense and softer than the second layer 230 and/or third layer 232. Also according to various embodiments, one or more of the layers of the multiple layers may include an additive such as, for example, a phase change material, calcium carbonate, silica, fly ash, barium sulfate, hydrocarbon gels, magnetic or magnetizable materials, foam digesters, etc. The one or more layers may also comprise different material compositions. For example, the first layer 234 may include a polymeric foam, and the second layer 230 and/or third layer 232 may include an elastomer. Various other modifications and configurations are also contemplated herein.

The first plurality of voids 214 are defined by polymer walls such as walls 290, 292 depicted in FIG. 2 that define void 218. The voids 214 allow for separation of the walls when the mattress 200 is folded or bent, which is why the void 218 depicted near the axis point or the point of the mattress 200 corresponding to the location 252 where the base 250 inclines appears wider than the other voids 214. The first plurality of voids 214 depicted in FIG. 2 are substantially congruent and traverse the width W1 of the mattress 200. However, when the mattress 200 is not bent and the base 250 is flat, the void 218 is the same width as the other voids 214. In various embodiments, the first plurality of voids 214 form a crease separating a first wall (e.g. wall 290) from a second wall (e.g. wall 292) where the one or more walls that define the first plurality of voids 214 further define polymer feet and the first wall forms a first foot that is separate from a second foot defined by the second wall. Specifically, each polymer foot of the polymer feet is defined by one or more walls of the polymer walls. Further, the crease may extend in the depth direction away from the lower surface 203 towards the upper surface 201 and stop at a cylindrical internal pocket 216 that is devoid of polymer and may be proximal to the upper surface 201.

The thickness of the voids 214 and the number of voids 214 directly influence the size of the polymer feet and the number of polymer feet. During formation of the mattress 200, the polymer may initially be devoid of any voids 214. After the polymer is cut or molded to the desired length L1 and width W1, portions of the polymer may be cut out and removed from the mattress 200 to form the voids 214. For example, if five voids are formed in the lower surface 203 of the polymer, then the walls defining the voids would further define six feet along the lower surface 203 of the polymer. According to various embodiments, multiple voids of the first plurality of voids 214 may be regularly spaced at set intervals. In other embodiments, the voids 214 may be placed at irregular intervals. According to various embodiments, at least some of the first plurality of voids 214 may be congruent and/or parallel, and according to one embodiment, all of the voids 214 may be congruent and/or parallel. The size of the voids 214 may also determine of the polymer feet. For instance, if the voids 214 are relatively thick, then the size and thickness of the polymer feet may be smaller. According to various embodiments, the voids 214 may be parallel channels that traverse the width of the mattress, and the thickness of the parallel channels may be within a range of about 0.1 inch to about 6 inches, a range of about 1 inch to about 5 inches, a range of about 2 inches to about 4 inches, or more specifically about 4 inches thick.

Additionally, the first plurality of voids 214 may have various heights. According to one embodiment, one void of the first plurality of voids 214 may be taller than one or more other voids of the first plurality of voids 214. In other embodiments, the first plurality of voids 214 may be the same height or there may be one or more voids having a first height and one or more other voids having a second height. Further, in some embodiments, one or more additional voids may have a third height. The height of the first plurality of voids 214 may extend in a depth direction that corresponds to the depth D1 of the mattress 200. For example, the one or more of the voids 214 may extend away from the lower surface 203 and towards the upper surface 201 a height of at least one inch. In various embodiments, each of the voids 214 may have a height of at least one inch. Further, one or more of the voids of the first plurality of voids 214 may extend in a depth direction corresponding to the depth D1 a distance/height within a range of about 1 inch to about 5 inches, or more particular a distance of about 5 inches. For instance, the total depth D1 of the polymer of the mattress 200 may be 10 total inches, with the 4 inches most proximate to the upper surface 201 having one or more layers and the lowermost 6 inches of the polymer including a base material (e.g. polymeric foam, an elastomer, etc.) into which the first plurality of voids 214 are cut. One or more of the first plurality of voids 214 may extend the entire height of the 6-inch base, or may only extend a height of 5 inches extending from the lower surface 203 towards the upper surface 201.

Advantageously, the larger (i.e. thicker and taller) the voids 214 and the more polymer that is removed, the more compactly the mattress 200 can fold or roll during packing so that the mattress 200 can be transported and shipped less expensively. Additionally, by packing the mattress into a smaller box or packaging, shipping and transportation costs are reduced, the mattress takes up less space on the shelves in stores, and it is easier for consumers or delivery companies to transport the mattress to homes. In some embodiments, the first plurality of voids 214 may remove at least 5% volume of the polymer that defines the length and width of the mattress 200. In particular, the first plurality of voids 214 may remove between 5% volume and 60% volume of the polymer that defines the length and width of the mattress, between 10% volume and 30% volume of the polymer defined by the length and width of the mattress, between 15% volume and 20% volume of the polymer defined by the length and the width of the mattress, or about 19% volume of the polymer defined by the length and the width of the mattress. Additionally, the first plurality of voids 214 may enable a cleaner fold 240 when the mattress 200 is inclined. By having a single fold 240 that bends inward rather than forming ridges that protrude from the upper surface 201 of the mattress 200, the mattress 200 may be more comfortable when positioned in an inclined position.

Further, the mattress 200 may include a plurality of regions, where each region is defined by the polymer feet and the plurality of regions correspond to a plurality of lower surface regions. For instance, a first region 202 may include a first lower surface region of the polymer that includes multiple polymer feet with at least one foot 210 of the multiple polymer feet that has a first size that is different from another polymer foot 212 of a lower surface region that corresponds to a second region 204 of the mattress 200. In particular, the other foot 212 of the polymer feet has a size that spans a greater distance along the length L1 of the mattress 200 than the at least one foot 210 that has the first size. Specifically, the other foot 212 is thicker than the at least one foot 210. According to various embodiments, the first region 202 may include multiple voids, and the multiple voids may be parallel and/or congruent. In various embodiments, the second region 204 may include multiple voids defining the feet such that the second region 204 has one or more feet 212 that are larger in size than the feet 210 of the first region 202. According to various embodiments, the mattress 200 may also include a third region 206 that includes at least two feet of the polymer feet 210. In one embodiment the at least two feet of the third region 206 may mirror, in size and in shape, multiple feet of the first region 202 such that a foot of first region 202 is the same size as a foot of the third region 206. In various embodiments, one or more feet 212 of the second region 204 may be larger than one or more feet 210 of the third region 206. In particular, at least one foot of the at least two feet of the third region 206 may have a size that is smaller and spans less of a distance along the length of the mattress 200 than at least one foot of the second region 204.

Further, according to various embodiments at least one polymer foot of the polymer feet extends the width of the mattress, multiple feet of the polymer feet extend the width of the mattress, or each foot of the polymer feet extends the width of the mattress.

FIGS. 3A-3C depict a mattress 300 that may comprise and/or may be similar to the mattress 200 described above with reference to FIG. 2, and the description contained herein directed thereto equally applies to mattress 300 but may not be repeated herein for brevity sake. Like or similar components and aspects of mattress 200 to mattress 300 of FIGS. 3A-3C are thereby indicated by like reference numerals preceded with “3”. Mattress 300 is depicted with the first region 302 being inclined and the third region 306 being raised but to a lesser extent than the first region 302. The first region 302 is inclined at a larger angle than the third region 306, and the two inclines still provide clean folds 340 near the midpoint of the mattress 300. As described above, the clean folds prevent ridges from protruding from the upper surface 301 of the mattress 300. The manner in which the base 350 is inclined with the larger angle for the first region 302 resulted in one void 318 widening due to the compressive forces applied to the polymer. In contrast, the manner in which the base 350 is inclined in the area about the third region 306 causes a void 320 to narrow such that one of the feet 310 of the third region 306 contacts one of the feet 312 of the second region 304.

Further, as depicted in FIGS. 3B and 3C, in addition to a plurality of voids 314 that at least partially traverse the width W1 of the mattress 300, the mattress 300 also includes at least one groove 360 about or in the lower surface 303, where the at least one groove 360 extends the length L1 of the mattress 300. According to various embodiments, the at least one groove 360 includes multiple grooves. Further, according to various embodiments, a groove of the at least one groove 360 may have a height that extends in a depth direction corresponding to the depth D1 extending away from the lower surface 303 that is a height/distance of at least one inch. More particularly, according to various embodiments, one or more grooves of the at least one groove 360 may extend in the depth direction a height/distance within a range of about 1 inch to about 5 inches, or a height/distance of 5 inches. As described above with respect to mattress 200, if the mattress 300 has a depth D1 of 10 inches with the base layer being 6 inches, the at least one groove 360 may extend the full height of the base layer or traverse the lower 5 inches of the base layer. According to various embodiments where the at least one groove 360 includes multiple grooves, the multiple grooves may be the same height/distance, or one or more of the grooves have a first height and one or more other grooves have a second height. Further, multiple grooves of the at least one groove 360 may have a height of at least one inch, a height within a range of about 1 inch to about 5 inches, or have a height of about 5 inches. In some embodiments, each groove of the multiple grooves may have a height of at least one inch, a height within a range of about 1 inch to about 5 inches, or have a height of about 5 inches. As depicted in FIG. 3C, the at least one groove 360 may include one or more first grooves 362 having a first height and one or more other grooves 364 having a second height. Additionally, although not shown, one or more additional grooves may include a third height.

Additionally, the at least one groove 360 may include a thickness within a range of about 0.1 inch to about 6 inches, within a range of about 1 inch to about 5 inches, within a range of about 2 inches to about 4 inches, or be about 4 inches. Advantageously, by removing volume from the polymer by the at least one groove 360, the mattress 300 may further be more tightly packed or compressed into a box or package for transportation and shipment. According to one embodiment, the at least one groove 360 may remove an additional volume beyond the volume already removed by the plurality of voids 314. According to various embodiments, based on the thickness, height, and number of grooves, the at least one groove 360 may remove between 1% volume and 60% volume of the polymer defined by the length L1 and width W1 of the mattress 300, may remove between 5% and 30% volume, may remove between 10% and 20% volume, or may remove 19% volume.

Referring now to FIGS. 4A-4E, various embodiments of lower surfaces 403 of a mattress 400 are depicted. Mattress 400 may comprise and/or may be similar to the mattress 200 and/or mattress 300 described above with reference to FIGS. 2-3C, and the description contained herein directed thereto equally applies to mattress 400 but may not be repeated herein for brevity sake. Like or similar components and aspects of mattress 200 and mattress 300, to mattress 400 of FIGS. 4A-4E are thereby indicated by like reference numerals preceded with “4”. The mattress 400 includes a first region 402, a second region 404, and various embodiments may further include a third region 406. The first region 402 and third region 406 include smaller feet 410 than the larger feet 412 of the second region 404. The mattress 400 also includes a plurality of voids 414, where the number, thickness, and shape of the voids determine the number, shape, and size of the feet. As depicted in FIGS. 4B-4E, the mattress 400 may further includes at least one groove 460 that extends the length L1 of the mattress 400. The number, thickness, and shape of the at least one groove 460 may impact the amount of polymer that is removed, which can allow for the mattress 400 to be folded and compressed to a greater extent for packaging and shipment.

FIGS. 5A-5D depict side views of a mattress 500 with a plurality of voids 514 along the length of the mattress 500. Mattress 500 may comprise and/or may be similar to mattresses 200, 300 and/or 400 described above with reference to FIGS. 2-4E, and the description contained herein directed thereto equally applies to mattress 500 but may not be repeated herein for brevity sake. Like or similar components and aspects of mattresses 200, 300, 400, to mattress 500 of FIGS. 5A-5D are thereby indicated by like reference numerals preceded with “5”. Mattress 500 includes a first region 502, a second region 504 and a third region 506 with the first region 502 and the third region 506 having feet 510 of a first size that are smaller than the feet 512 of the second region. The feet 510 of the first region 502 and/or third region 506 may not be identical and may have various thicknesses, depths, shapes, etc. either within each respective region (i.e., within first region 502 or within third region 506) or when comparing feet 510 of the first region 502 to feet 510 of the third region 506. Similarly the feet 512 of the second region 504 may have varying sizes, shapes, depths, etc., but all feet 512 of the second region 504 would span a greater distance along the length L1 of the mattress 500 (i.e., would be thicker) than any of the feet 510 of the first region 502 and/or third region 506. For example, referring to FIG. 5A, foot 524 is smaller in thickness than foot 522, which is also smaller in thickness than foot 526. However, feet 524, 522, and 526 are all larger than feet 510. Advantageously, by having thicker feet 512 in the second region 504, more support is provided to a user of the mattress 500 at the heaviest areas of the user (e.g., the hips, midsection, and/or shoulders). The voids 514 can be more frequent, thicker, deeper, larger, etc. in the first region 502 and the third region 506 because there is less weight applied by the user to these regions of the mattress 500. Further, according to various embodiments, the voids 514 may not traverse certain layers, such as layers 532 or 534 of the mattress 500 in order to provide a smooth resting surface upon which the user rests.

As depicted in FIG. 5B, the shape of foot 525 of feet 512 is slightly different than foot 523 of feet 512, even though both are larger than feet 510. The different shapes may allow for different amounts of support to the user at the user's pressure points in order to provide maximum support. Referring now to FIG. 5C, as depicted, the voids 514 may include rectangular channels 527, and the rectangular channels may have varying thickness, which may determine the size of the feet. For instance, the mattress 500 may include rectangular channels 527 of a larger thickness 515 to form the smaller feet 510, and the mattress 500 may include rectangular channels 527 of a smaller thickness 517 to form the larger feet 512. Referring now to FIG. 5D, the voids 514 may include circular channels 519, which advantageously may allow the smaller feet 510 and/or the larger feet 512 to have more surface area in contact with the base situated below the mattress 500.

Referring now to FIGS. 6A-6B, a side view of a mattress 600 is depicted that has multiple grooves 660 situated along the width W1 of the mattress 600. Mattress 600 may comprise and/or may be similar to mattresses 200, 300, 400 and/or 500 described above with reference to FIGS. 2-5D, and the description contained herein directed thereto equally applies to mattress 600 but may not be repeated herein for brevity sake. Like or similar components and aspects of mattresses 200, 300, 400, 500 to mattress 600 of FIGS. 6A-6C are thereby indicated by like reference numerals preceded with “6”. The mattress 600 may include multiple layers 630, 632, 634, according to various embodiments, with the grooves 660 being cut into the base layer 630. The grooves 660 may include various heights such as height 662 or height 664. The different heights may be determined based on the amount of folding or rolling that may occur during packing at the various locations. For example, if the mattress 600 needs only a partial fold at a particular location, then a smaller height such as height 662 may be preferred for that particular location, whereas if a full fold is needed for packing then a larger height such as height 664 may be preferred. Further, the mattress 600 may include a single groove or a plurality of grooves, and the grooves may have varying thicknesses.

According to various embodiments of mattresses 200, 300, 400, 500, and/or 600 described above, any one of the aforementioned mattresses may further include one or more polymers having one or more perforations. For example, the one or more perforations may at least partially traverse the depth of the one or more polymers, or more particularly may extend the full depth of the one or more polymers. Further, the one or more perforations may include a diameter within a range of about 0.25 inches to about 3 inches, a range of about 0.5 inches to about 2 inches, a range of about 0.75 inches to about 1.5 inches, or more particularly a diameter of about 1 inch. The one or more perforations may remove at least 1% of a total volume of the one or more polymers. For instance, the one or more perforations may remove a total volume of the one or more polymers that is within a range of about 1% to about 20%, a range of about 5% to about 15%, a range of about 8% to about 12%, or about 10% total volume of the one or more polymers.

In some embodiments, the mattresses, cushions, and body-support pads or mats disclosed herein may comprise dual-sided voids, gaps and/or grooves. That is, a respective mattress, cushion, or body-support pad or mat may comprise a first plurality of voids, gaps and/or grooves located about or in the lower surface of the polymer of the respective mattress, cushion, or body-support pad or mat, and a second plurality of voids, gaps and/or grooves located about or in the upper surface of the polymer of the respective mattress, cushion, or body-support pad or mat.

In one embodiment, the second plurality of voids, gaps, and/or grooves may differ from the first plurality of voids, gaps, and/or grooves in terms of at least one of dimension, configuration, and quantity of the voids, gaps and/or grooves, such as shape, thickness, height, number, and layout or arrangement of the voids, gaps and/or grooves. For example, the first plurality of voids, gaps and/or grooves located about or in the lower surface of the polymer of the respective mattress, cushion, or body-support pad or mat can be any one of the voids and grooves or combinations thereof described above in FIGS. 2-6C; and the second plurality of voids, gaps and/or grooves located about or in the upper surface of the polymer of the respective mattress, cushion, or body-support pad or mat can be any other one of the voids and grooves or combinations thereof described above in FIGS. 2-6C.

In another embodiment, the second plurality of voids, gaps, and/or grooves may be the same as the first plurality of voids, gaps, and/or grooves in terms of at least one of dimension, configuration, and quantity of the voids, gaps and/or grooves, such as shape, thickness, height, number, and layout or arrangement of the voids, gaps and/or grooves. For example, the first plurality of voids, gaps and/or grooves located about or in the lower surface of the polymer of the respective mattress, cushion, or body-support pad or mat, and the second plurality of voids, gaps and/or grooves located about or in the upper surface of the polymer of the respective mattress, cushion, or body-support pad or mat, can both be any same one of the voids and grooves or combinations thereof described above in FIGS. 2-6C. For instance, the second plurality of voids and/or grooves may mirror the first plurality of voids and/or grooves with respect to a middle surface of the polymer of the respective mattress, cushion, or body-support pad or mat. The middle surface is located between and parallel to the upper surface and the lower surface of the polymer of the respective mattress, cushion, or body-support pad or mat.

In some embodiments, the second plurality of voids, gaps, and/or grooves may be arranged in the upper surface to offset the first plurality of voids, gaps, and/or grooves in the direction of the length and/or width of the respective mattress, cushion, or body-support pad or mat, such that the middle, center or symmetry line of at least one of the second plurality of voids, gaps, and/or grooves does not overlap with the middle, center or symmetry line of corresponding one of the first plurality of voids, gaps, and/or grooves. The middle, center or symmetry line is a vertical line in the direction of depth of the respective mattress, cushion, or body-support pad or mat. Such offset can provide a balanced pressure distribution on the polymer of the respective mattress, cushion, or body-support pad or mat when a user sits or lies on the respective mattress, cushion, or body-support pad or mat, which can provide desired load support and comfort while allowing for reducing the volume and/or weight of the respective mattress, cushion, or body-support pad or mat for decreasing shipping cost, in addition to prevention of the bunching and ridges caused by folding or bending without causing the respective mattress, cushion, or body-support pad or mat.

As disclosed herein, the description of the first plurality of voids, gaps and/or grooves located about or in the lower surface of the polymer of the respective mattress, cushion, or body-support pad or mat as described above with reference to FIGS. 2-6C equally applies to the second plurality of voids, gaps and/or grooves located about or in the upper surface of the polymer of the respective mattress, cushion, or body-support pad or mat. Therefore, detailed description of the second plurality of voids, gaps and/or grooves may not be repeated herein for brevity sake.

Specifically, in addition to the first plurality of voids, gaps and/or grooves located about or in the lower surface of the polymer of the respective mattress, cushion, or body-support pad or mat as disclosed above in FIGS. 2-6C, the respective mattress, cushion, or body-support pad or mat may further comprise a second plurality of voids, gaps and/or grooves located about or in the upper surface of the at least one polymer of the one or more polymers of the respective mattress, cushion, or body-support pad or mat. The second plurality of voids and/or grooves may traverse at least a second portion of the width and/or length of the respective mattress, cushion, or body-support pad or mat. The second plurality of voids and/or grooves are also defined by the corresponding polymer walls located about or in the upper surface of the at least one polymer of the one or more polymers of the respective mattress, cushion, or body-support pad or mat.

Accordingly, the second plurality of voids and/or grooves define a second plurality of polymer feet, wherein each polymer foot of the second plurality of polymer feet is defined by one or more walls of the corresponding polymer walls located about or in the upper surface.

Similarly, the respective mattress, cushion, or body-support pad or mat may further comprise a plurality of upper surface regions, wherein a first region of the plurality of upper surface regions includes at least one foot of the second plurality of polymer feet that has a third size, and wherein a second region of the plurality of upper surface regions includes at least one other foot of the second plurality of polymer feet that has a fourth size. The at least one other foot having the fourth size spans a greater distance along the length of the respective mattress, cushion, or body-support pad or mat than the at least one foot having the third size.

Accordingly, in some embodiments, a mattress, cushion, or body-support pad or mat disclosed herein may comprise: one or more polymers at least partially defining a length and a width of the respective mattress, cushion, or body-support pad or mat, wherein the one or more polymers span a depth that is perpendicular to the length and the width of the respective mattress, cushion, or body-support pad or mat, and that extend from an upper surface of at least one polymer of the one or more polymers that is proximate to where a user rests to a lower surface of the at least one polymer of the one or more polymers, and wherein the lower surface is opposite the upper surface that is proximate to where the user rests; a first plurality of voids in the at least one polymer of the one or more polymers, the first plurality of voids traversing at least a first portion of the width of the mattress, wherein the first plurality of voids are located about the lower surface, and wherein the first plurality of voids are defined by polymer walls of the at least one polymer of the one or more polymers; a first plurality of polymer feet, wherein each polymer foot of the first plurality of polymer feet is defined by one or more walls of the polymer walls; a plurality of lower surface regions, wherein a first region of the plurality of lower surface regions includes at least one foot of the first plurality of polymer feet that has a first size, and wherein a second region of the plurality of lower surface regions includes at least one other foot of the first plurality of polymer feet that has a second size; a second plurality of voids in the at least one polymer of the one or more polymers, the second plurality of voids traversing at least a second portion of the width of the respective mattress, cushion, or body-support pad or mat, wherein the second plurality of voids are located about the upper surface, and wherein the second plurality of voids are defined by the polymer walls of the at least one polymer of the one or more polymers; a second plurality of polymer feet, wherein each polymer foot of the second plurality of polymer feet is defined by one or more walls of the polymer walls; and a plurality of upper surface regions, wherein a first region of the plurality of upper surface regions includes at least one foot of the second plurality of polymer feet that has a third size, and wherein a second region of the plurality of upper surface regions includes at least one other foot of the second plurality of polymer feet that has a fourth size. The at least one other foot having the second size spans a greater distance along the length of the respective mattress, cushion, or body-support pad or mat than the at least one foot having the first size; and the at least one other foot having the fourth size spans a greater distance along the length of the respective mattress, cushion, or body-support pad or mat than the at least one foot having the third size.

The second plurality of voids may mirror the first plurality of voids with respect to a middle surface of the at least one polymer, the middle surface located between and parallel to the upper surface and the lower surface of the at least one polymer. The second plurality of voids may differ from the first plurality of voids in terms of at least one of dimension, configuration, and quantity. The one or more polymers of the respective mattress, cushion, or body-support pad or mat may further comprise at least one groove in the upper surface of the at least one polymer that extends the length of the respective mattress, cushion, or body-support pad or mat. The at least one groove in the upper surface of the at least one polymer may mirror the at least one groove in the lower surface of the at least one polymer with respect to the middle surface of the at least one polymer. The at least one groove in the upper surface of the at least one polymer may differ from the at least one groove in the lower surface of the at least one polymer in terms of at least one of dimension, configuration, and quantity.

FIG. 7 depicts a side views of an example mattress (cushion, or body-support pad or mat) 700 having dual-sided voids, gaps and/or grooves in various embodiments. The mattress 700 may comprise a first plurality of voids 714 and a second plurality of void 724 along the length of the mattress 700. Mattress 700 may comprise and/or may be similar to mattresses 200, 300, 400, 500 and/or 600 described above with reference to FIGS. 2-6C, and the description contained herein directed thereto equally applies to mattress 700 but may not be repeated herein for brevity sake. Like or similar components and aspects of mattresses 200, 300, 400, 500, 600, to mattress 700 of FIG. 7 are thereby indicated by like reference numerals preceded with “7”.

The mattress 700 may include a plurality of lower surface regions including, for example, a first lower surface region 702 and a second lower surface region 704 having feet 710. The feet 710 of the first lower surface region 702 and/or second lower surface region 704 may not be identical and may have various thicknesses, depths, shapes, etc. either within each respective region (i.e., within the first lower surface region 702 or within the lower surface second region 704) or when comparing feet 710 of the first lower surface region 702 to feet 710 of the second lower surface region 704. For example, the foot 710a of the second lower surface region 704 may span a greater distance along the length L1 of the mattress 700 (i.e., would be thicker) than the foot 710b of the first lower surface region 702.

The mattress 700 may include a plurality of upper surface regions including, for example, a first upper surface region 732 and a second upper surface region 734 having feet 720. The feet 720 of the first upper surface region 732 and/or second upper surface region 734 may not be identical and may have various thicknesses, depths, shapes, etc. either within each respective region (i.e., within the first upper surface region 732 or within the upper surface second region 734) or when comparing feet 720 of the first upper surface region 732 to feet 720 of the second upper surface region 734. For example, the foot 720a of the first upper surface region 732 may span a greater distance along the length L1 of the mattress 700 (i.e., would be thicker) than the foot 720b of the first upper surface region 732. As another example, the foot 720c is shaped differently than other feet 720.

The second plurality of voids 724 are, as depicted, different from the first plurality of voids 714. The second plurality of voids 724 including widthwise channels of a parallelogram cross-section are arranged at an angle with respect to the upper surface of the polymer so that displacement is minimal to provide maximum support but weight and packing size of the mattress 700 could be decreased when a user rests on the mattress 700.

In various embodiments, the second plurality of voids may comprise voids of any suitable configurations. For example, FIG. 8 depict a side view of an example mattress (cushion, or body-support pad or mat) 800 having dual-sided voids, gaps and/or grooves. The mattress 800 may comprise a first plurality of voids 814 and a second plurality of void 824 along the length of the mattress 800. Mattress 800 may comprise and/or may be similar to mattresses 200, 300, 400, 500, 600 and/or 700 described above with reference to FIGS. 2-67, and the description contained herein directed thereto equally applies to mattress 800 but may not be repeated herein for brevity sake. Like or similar components and aspects of mattresses 200, 300, 400, 500, 600, 700, to mattress 800 of FIG. 8 are thereby indicated by like reference numerals preceded with “8”.

The mattress 800 may include a plurality of lower surface regions including, for example, a first lower surface region 802 and a second lower surface region 804 having feet 810. The feet 810 of the first lower surface region 802 and/or second lower surface region 804 may not be identical and may have various thicknesses, depths, shapes, etc. either within each respective region (i.e., within the first lower surface region 802 or within the lower surface second region 804) or when comparing feet 810 of the first lower surface region 802 to feet 810 of the second lower surface region 804.

The mattress 800 may include an upper surface region 832 having feet 820. The second plurality of voids 824 are, as depicted, different from the first plurality of voids 814. The second plurality of voids 824 including widthwise channels of a zigzag cross-section are arranged in the upper surface of the polymer so that displacement is minimal to provide maximum support but weight and packing size of the mattress 800 could be decreased when a user rests on the mattress 800.

In some embodiments, at least one of the first and/or second plurality of voids may be partially filled with at least one material having a density lower than and a stretchability greater than a density and a stretchability of the polymer of the one or more polymers, respectively. The at least one material may include, but not limited to, another polymer, a foam, a latex, and/or any other suitable material. For example, the at least one material may fill the at least one of the plurality of voids partially in the height of the at least one void, in the thickness of the at least one void, and/or in the width of the mattress.

In some embodiments, at least one of the first and/or second plurality of voids may be fully filled with the at least one material. For example, the at least one material may fill the at least one of the plurality of voids fully in the height of the at least one void, in the thickness of the at least one void, and/or in the width of the mattress.

In some embodiments, the at least one groove in the upper surface and/or the lower surface of the polymer may be partially filled with the at least one material. For example, the at least one material may fill the at least one groove partially in the height of the at least one groove, in the thickness of the at least one groove, and/or in the length of the mattress.

In some embodiments, the at least one groove in the upper surface and/or the lower surface of the polymer may be fully filled with the at least one material. For example, the at least one material may fill the at least one groove fully in the height of the at least one groove, in the thickness of the at least one groove, and/or in the length of the mattress.

In some embodiments, at least one of the first and/or second plurality of voids may be partially filled with at least one gas pocket. The at least one gas pocket may be configured to have at least one gas release valve and at least one gas filling valve, and the at least one gas pocket may be filled with a gas selected from the group consisting of air, nitrogen, argon, and/or any other suitable gas. For example, the at least one gas pocket may fill the at least one of the plurality of voids partially in the height of the at least one void, in the thickness of the at least one void, and/or in the width of the mattress.

In some embodiments, at least one of the first and/or second plurality of voids may be fully filled with the at least one gas pocket. For example, the at least one gas pocket may fill the at least one of the plurality of voids fully in the height of the at least one void, in the thickness of the at least one void, and/or in the width of the mattress.

In some embodiments, the at least one groove in the upper surface and/or the lower surface of the polymer may be partially filled with the at least one gas pocket. For example, the at least one gas pocket may fill the at least one groove partially in the height of the at least one groove, in the thickness of the at least one groove, and/or in the length of the mattress.

In some embodiments, the at least one groove in the upper surface and/or the lower surface of the polymer may be fully filled with the at least one gas pocket. For example, the at least one gas pocket may fill the at least one groove fully in the height of the at least one groove, in the thickness of the at least one groove, and/or in the length of the mattress.

In some embodiments, the first and/or second plurality of voids may be formed by layering a plurality of sub-layer polymers of the polymer of the one or more polymers, along the width or the length or both the width and the length.

In some embodiments, the at least one groove in the upper surface and/or the lower surface of the polymer may be formed by layering a plurality of sub-layer polymers of the one or more polymers, along the width or the length or both the width and the length.

In some embodiments, the mattresses, cushions, or body-support pads or mats disclosed herein may include at least one non-skid bottom material coupled to the lower surface of the one or more polymers. In some embodiments, the at least one non-skid bottom material may be coupled to a bottom surface of the mattress cover that is in adjacent to the lower surface of the one or more polymers. The bottom surface of the mattress cover or the lower surface of the one or more polymers may be in contact with a top surface of the adjustable bed frame, such that the at least one non-skid bottom material can prevent the mattress from unnecessary sliding with respect to the top surface of the adjustable bed frame.

In some embodiments, the at least one non-skid material may include, but not limited to, selectively placed grips/adhesives, a full sheet of non-skid material, hook-and-loop fasteners, buttons, zippers, creases, or any other suitable materials/patterns/mechanisms that would increase the coefficient of friction between the mattress and the adjustable bed frame. For example, the at least one non-skid materials may be slip resistant fabric that offers grip in wet, dry, hot and cold conditions. The slip resistant fabric may include Polyvinyl chloride (PVC).

In some embodiments, the lower surface of the one or more polymers may be configured to have perforations that might facilitate stretch if the non-skid material is not very flexible and stretchable. In some embodiments, the non-skid material may be a laminate positioned along the bottom of each individual polymer foot. Portions of the polymer feet may be exposed and the mattress cover attaches or hooks to the sidewalls of the polymer feet so that the polymer feet provide the coefficient of friction that would be missing with a standard mattress cover.

The descriptions provided above for mattresses 200, 300, 400, 500, 600, 700, and/or 800 are equally applicable to any cushion and/or body-support pad or mat.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), “contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

As used herein, the terms “comprising,” “has,” “including,” “containing,” and other grammatical variants thereof encompass the terms “consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the invention.

Claims

1. A body support cushion, comprising:

one or more polymer layers at least partially defining a length and a width of the cushion, wherein the one or more polymers span a depth that is perpendicular to the length and the width of the cushion and extend from an upper surface of the one or more polymer layers that is proximate to where a user rests to a lower surface of the one or more polymer layers that is opposite the upper surface;

a plurality of voids in at least one polymer layer of the one or more polymer layers, the plurality of voids fully traversing the width of the cushion, wherein the plurality of voids extend from the lower surface and form polymer walls of the at least one polymer layer;

a plurality of polymer feet formed by the at least one polymer layer via the plurality of voids, wherein each polymer foot is defined by adjacent polymer walls; and

a plurality of lower surface regions formed of the plurality of voids and the plurality of polymer feet, the plurality of lower surface regions comprising a first region that includes a plurality of first feet of a first size, and a second region that includes a plurality of second feet of a second size,

wherein each second foot of the second size spans a greater distance along the length of the cushion than each first foot of the first size.

2. The cushion of claim 1, wherein the first and second regions are adjacent to each other along the length of the cushion.

3. The cushion of claim 2, wherein the plurality of lower surface regions further comprises a third region that includes at least one third foot of a third size that spans a distance along the length of the cushion that differs from at least one of the first and second sizes.

4. The cushion of claim 3, wherein each third foot of the third size spans a smaller size along the length of the cushion than each second foot of the second size.

5. The cushion of claim 4, wherein the third size is substantially the same as the first size.

6. The cushion of claim 4, wherein the second region is arranged between and adjacent to the first and third regions along the length of the cushion.

7. The cushion of claim 6, wherein the first region is positioned at a first end of the cushion along the length direction, the third the is positioned at a second end of the cushion along the length direction, and the second region extends between the first and second regions along the length direction.

8. The cushion of claim 1, wherein the plurality of voids extend parallel to each other.

9. The cushion of claim 1, wherein the plurality of voids remove between 10% volume and 30% volume of the one or more polymer layers defined by the length and the width of the cushion.

10. The cushion of claim 1, wherein each of the plurality of voids extend in a depth direction corresponding to the depth of at least one inch from the lower surface towards the upper surface.

11. The cushion according to claim 10, where at least one void of the first plurality of voids extends in a depth direction corresponding to the depth a first distance from the lower surface towards the upper surface and at least one other void of the first plurality of voids extends in the depth direction a second distance from the lower surface towards the upper surface, wherein a third void of the first plurality of voids extends in the depth direction a third distance from the lower surface towards the upper surface, wherein the third distance is longer than both the first distance and the second distance

12. The cushion of claim 1, wherein the one or more polymer layers comprise one or more of a polyurethane layer, a polyisocyanurate layer and a polyol layer.

13. The cushion of claim 1, wherein the one or more polymer layers include a first polymer layer proximate the upper surface, and a second polymer layer proximate the lower surface that differs from the first polymer layer, wherein the plurality of voids extend into the second polymer layer and not the first polymer layer, and wherein the plurality of polymer feet are formed of the second polymer layer.

14. The cushion of claim 13, wherein the first polymer layer and the second polymer layer comprise different densities and are formed of differing polymer materials.

15. The cushion of claim 1, wherein the cushion further comprises at a plurality grooves in at least one polymer layer of the one or more polymer layers, the plurality of grooves extending along the length of the cushion, and wherein the plurality of grooves extend from the lower surface and intersect at least one of the plurality of voids.

16. The cushion of claim 15, wherein each of the plurality of grooves extend in the depth direction from the lower surface within a range of about 1 inch to about 5 inches, and wherein the plurality of grooves are substantially evenly spaced apart in the width direction.

17. The cushion of claim 1, wherein the one or more polymer layers further comprise a plurality of perforations that at least partially traverse the depth of the one or more polymer layers, wherein each of the plurality of perforations comprise a diameter within a range of about 0.25 inches to about 3 inches, and remove a total volume of the one or more polymers within a range of about 5% to about 15%.

18. The cushion of claim 1, wherein at least one of the plurality of voids is at least partially filled with at least one material having a density lower than, and a stretchability greater than, that of the at least one polymer layer of the one or more polymer layers.

19. The cushion of claim 1, wherein at least one of the plurality of voids comprises a gas pocket, the gas pocket comprising at least one of a gas release valve and at least one gas filling valve, and being filled with a gas selected from the group consisting of air, nitrogen, and argon.

20. The cushion according to claim 1, wherein the body support cushion is configured as a mattress, a body-support pad or a body-support mat.