Note: Descriptions are shown in the official language in which they were submitted.
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ALL-FOAM MATTRESS ASSEMBLIES WITH FOAM ENGINEERED CORES
HAVING THERMOPLASTIC AND THERMOSET MATERIALS, AND RELATED
ASSEMBLIES AND METHODS
PRIORITY APPLICATION
[0001] The
present application claims priority to U.S. Patent Application Serial No.
61/724,556 filed on November 9, 2012 entitled "All-foam Mattress Assemblies
With
Foam Engineered Cores Having Thermoplastic and Thermoset Materials, And
Related
Assemblies And Methods," which is incorporated herein by reference in its
entirety.
RELATED APPLICATIONS
[0002] This
application is related to U.S. Patent Application Serial No. 13/630,435,
filed on September 28, 2012, entitled "Cellular Mattress Assemblies and
Related
Methods," which claims priority to U.S. Provisional Patent Application Serial
No.
61/541,434 filed on September 30, 2011, entitled "Cellular Mattress Assemblies
and
Related Methods," both of which are incorporated herein by reference in their
entireties.
[0003] This
application is related to U.S. Patent Application Serial No. 13/458,239,
filed on April 27, 2012, entitled "Unitary Composite/Hybrid Cushioning
Structure(s) And
Profile(s) Comprised Of A Thermoplastic Foam(s) And A Thermoset Material(s)
and
Related Methods," which claims priority to U.S. Provisional Patent Application
Serial
No. 61/480,780, filed on April 29, 2011, entitled "Unitary Composite/Hybrid
Cushioning
Structure(s) And Profile(s) Comprised Of A Thermoplastic Foam(s) And A
Thermoset
Material(s) and Related Methods," both of which are incorporated herein by
reference in
their entireties.
[0004] This
application is also related to U.S. Patent Application Serial No.
12/716,804, filed on March 3, 2010, entitled "Unitary Composite/Hybrid
Cushioning
Structure(s) and Profile(s) Comprised of A Thermoplastic Foam(s) and A
Thermoset
Material(s)," which claims priority to U.S. Provisional Patent Application No.
61/157,970, filed on March 6, 2009, entitled "Composite/Hybrid Structures and
Formulations of Thermoset Elastomer Foams and Thermoplastic Engineered
Geometry
Foam Profiles," both of which are incorporated herein by reference in their
entireties.
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[0005] This
application is related to U.S. Design Patent Application Serial No.
29/403,050, filed on September 30, 2011, entitled "Edge Support Cushion,"
which is
incorporated herein by reference in its entirety.
BACKGROUND
Field of the Disclosure
[0006] The
field of the disclosure relates generally to cushioning structures. The
cushioning structures can be used for any cushion applications desired,
including but not
limited to mattresses, seats, foot and back support, and upholstery, as non-
limiting
examples.
Technical Background
[0007]
Cushioning structures are employed in support applications. Cushioning
structures can be employed in bedding and seating applications, for example,
to provide
cushioning and support. Cushioning structures may also be employed in devices
for
safety applications, such as helmets and automobiles for example.
[0008]
Cushioning structures have evolved into relatively-heavy assemblies weighing
sometimes considerably more than fifty (50) pounds to provide the required
high and low
stiffness desired by users. For example, it may be desirable to provide a
cushioning
material or device in which a body or object will easily sink therein a given
distance
before the applied weight is supported. As another example, it may be desired
to provide
surfaces having low stiffness initially during application of weight, while
the underlying
structure needs to have high stiffness for support.
[0009] A queen-
size innerspring mattress may weigh more than sixty-five (65)
pounds due to the various components required to deliver the high and low
stiffness
performance. An example of a cushioning structure employing layers of varying
thicknesses and properties for discussion purposes is provided in a mattress
10 of FIG.
1A as is known in the art. As illustrated therein, an innerspring 12 is
provided. The
innerspring 12 is comprised of a plurality of traditional spring coils 14
arranged in an
interconnected matrix to form a flexible core structure and support surfaces
of the
mattress 10. The spring coils 14 are also connected to each other through
interconnection
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helical wires 18. The innerspring 12 is disposed on top of a box spring 22 to
provide
base support.
[0010] To
provide a cushioning structure with high and low stiffness features, various
layers of sleeping surface or padding material 26 can be disposed on top of
the
innerspring 12. The padding material 26 provides a cushioning structure for a
load
placed on the mattress 10. In this regard, the padding material 26 may be made
from
various types of foam, cloth, fibers and/or steel to provide a generally
repeatable
comfortable feel to the individual seeking a place to either lie, sit, or rest
the body as a
whole or portions thereof. To provide the cushioning structure with high and
low
stiffness features, the padding material 26 may consist of multiple layers of
materials that
may exhibit different physical properties.
[0011] For
example, foam polymer materials, particularly thermoset materials having
a relatively heavy density of at least two (2) pounds per cubic foot, can be
used as
materials of choice for the padding material 26. The foam polymer materials
provide a
level of cushion, unlike steel spring structures, or the like. One or more
intermediate
layers 30 underneath the uppermost layer 28 may be provided to have greater
stiffness
than the uppermost layer 28 to provide support and pressure spreading that
limits the
depth to which the body or portions thereof sinks. A bottom layer 32 may be
provided
below the intermediate layers 30 and uppermost layer 28. The uppermost layer
28, the
intermediate layers 30, and the bottom layer 32 serve to provide a combination
of desired
cushioning characteristics. Upholstery 34 may be placed around the entire
padding
material 26 and innerspring 12 to provide a fully assembled mattress 10.
[0012] As
mattress technology evolves, all-foam mattresses have been developed in
an effort to deliver the stiffness ad comfort requirements needed by users.
The result is a
foam mattress with a weight generally more than a comparable innerspring
mattress. For
example, a queen-sized all-foam mattress may easily weigh over one-hundred
(100)
pounds. FIG. 1B depicts a cross-sectional view of a mattress 36 made
exclusively with
foam and having multiple layers 38(1)-38(5) having bottom surfaces 40(1)-40(5)
and top
surfaces 42(1)-42(5), respectively. Each layer may contribute desirable
stiffness and
comfort performance characteristics at the expense of weight. The bottom
surfaces
40(1)-40(5) and the top surfaces 42(3)-42(5) may generally be co-planar, but,
for
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example, top surfaces 42(1), 42(2) may include ribs, bumps, or protrusions
44(1)-44(2)
which do not appear to significantly reduce the weight of the mattress 36.
[0013] In
manufacturing of a mattress, one person generally can no longer easily lift a
mattress. In logistics where the mattress is transported from the
manufacturing facility to
the user, and in transportation and storage locations within a supply chain, a
single
logistics person also generally can no longer lift a mattress. It is also
becoming more
difficult for a homemaker to make a bed given the mattress thickness and
heavier weight.
Mattresses generally also require rotating and/or flipping the mattress on a
regular basis
and this is difficult for even two people to accomplish.
[0014] What is
needed is a mattress that includes all the performance characteristics
and standard dimensions of conventional mattresses yet is easier to transport
when
changing locations, and handle when making the bed. The mattress should also
provide
users a practical opportunity to flip and/or rotate the mattress as desired.
SUMMARY OF THE DETAILED DESCRIPTION
[0015]
Embodiments disclosed herein include all-foam mattress assemblies with
foam engineered cores having thermoplastic and thermoset materials, and
related
assemblies and methods. All-foam mattress assemblies use foam-based materials,
such
as thermoplastic and thermoset, to provide cushioning and support
characteristics for a
user in the sleeping area of a mattress during sleep or rest. The all-foam
mattress
assemblies may include foam comfort layer(s), foam transitional layer(s), and
a foam
engineered core. The all-foam engineered core may lessen a density of a
mattress
assembly by comprising thermoset member(s), and engineered geometric
thermoplastic
material profile(s) adjacent to the thermoset member(s). The engineered
geometric
thermoplastic material profile(s) may be disposed in a parallel or
substantially parallel
arrangement. In this manner, the all-foam engineering core may provide
cushioning and
support characteristics with reduced density compared to a foam mattress
providing
similar cushioning and support through solid thermoset layers.
[0016] In this
regard, in one embodiment an all-foam mattress assembly is provided.
The all-foam mattress assembly may include at least one foam comfort layer to
receive a
load of a user. The all-foam mattress assembly may also include at least one
foam
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transitional layer receiving the load from the at least one foam comfort
layer. The at least
one foam transitional layer may have a density more than a density of the at
least one
form comfort layer. The all-foam mattress assembly may also include a foam
engineered
core comprising a plurality of engineered geometric thermoplastic material
profiles
disposed in a parallel arrangement, a plurality of thermoset members disposed
in the
parallel arrangement and adjacent to the plurality of engineered geometric
thermoplastic
material profiles, bulk-free volume, and a deck. The plurality of engineered
geometric
thermoplastic material profiles and the plurality of thermoset members are
collectively
configured to receive the load conveyed from the at least one foam
transitional layer and
convey the load to the deck. In this manner, the foam engineering core may be
customized to deliver various cushioning characteristics.
[0017] In
another embodiment, an all-foam mattress assembly is provided. The all-
foam mattress assembly may include at least one foam comfort layer to receive
a load of
a user. The all-foam mattress assembly may include at least one foam
transitional layer
receiving the load from the at least one foam comfort layer. The at least one
foam
transitional layer having a density more than a density of the at least one
form comfort
layer. The all-foam mattress assembly may include the foam engineered core
comprising
a plurality of engineered geometric thermoplastic material profiles disposed
in a parallel
arrangement, a plurality of thermoset members disposed in the parallel
arrangement and
adjacent to the plurality of engineered geometric thermoplastic material
profiles, and a
deck. The plurality of engineered geometric thermoplastic material profiles
and the
plurality of thermoset members may collectively be configured to receive the
load
conveyed from the at least one foam transitional layer and to convey the load
to the deck.
Collectively, an unloaded density of the at least one foam comfort layer, the
at least one
foam transitional layer, and the foam engineered core may comprise a density
between
0.8 pounds per cubic foot and 3.0 pounds per cubic foot. In this manner, the
mattress
assembly may be of a low-density to be more easily transported.
[0018] In
another embodiment, an all-foam mattress assembly is provided. The all-
foam mattress assembly may include at least one foam comfort layer to receive
a load of
a user. The all-foam mattress assembly may include at least one foam
transitional layer
receiving the load from the at least one foam comfort layer. The at least one
foam
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transitional layer may have a density more than a density of the at least one
form comfort
layer. The all-foam mattress assembly may also include a foam engineered core
comprising a plurality of engineered geometric thermoplastic material profiles
and a
plurality of thermoset members. The plurality of engineered geometric
thermoplastic
material profiles and the plurality of thermoset members may be collectively
configured
to receive the load conveyed from the at least one foam transitional layer and
to convey
the load to the deck. The foam engineered core may comprise bulk-free volume.
In this
manner, the all-foam mattress assembly may be manufactured with a lower
density to
enable easier maintenance by the user, for example, when rotating and/or
flipping the
mattres s.
[0019] In
another embodiment, an all-foam mattress assembly is provided. The all-
foam mattress assembly may include at least one foam comfort layer to receive
a load of
a user. The all-foam mattress assembly may include at least one foam
transitional layer
receiving the load from the at least one foam comfort layer, the at least one
foam
transitional layer having a density more than a density of the at least one
form comfort
layer. The all-foam mattress assembly may include a foam engineered core being
less
dense than the at least one foam transitional layer. The foam engineered core
comprises a
plurality of engineered geometric thermoplastic material profiles, bulk-free
volume, a
deck, and plurality of thermoset members collectively configured with the
plurality of
engineered geometric thermoplastic material profiles to receive the load
conveyed from
the at least one foam transitional layer and to convey the load to the deck.
In this manner,
the all-foam mattress assembly may be utilized as part of a mattress that may
be more
easily maintained by a single user in regards to changing sheets and flipping
the mattress.
[0020] In
another embodiment, an all-foam mattress assembly is provided. The all-
foam mattress assembly may include at least one foam comfort layer to receive
a load of
a user. The all-foam mattress assembly may include at least one foam
transitional layer
receiving the load from the at least one foam comfort layer. The at least one
foam
transitional layer may have a density more than a density of the at least one
form comfort
layer. The all-foam mattress assembly may also include a foam engineered core
comprising a plurality of engineered geometric thermoplastic material profiles
disposed
in a parallel arrangement, a plurality of thermoset members disposed in the
parallel
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arrangement and adjacent to the plurality of engineered geometric
thermoplastic material
profiles, and a deck. The plurality of engineered geometric thermoplastic
material
profiles and the plurality of thermoset members may be collectively configured
to receive
the load conveyed from the at least one foam transitional layer and to convey
the load to
the deck. The at least one foam transitional layer may comprise between
fifteen (15)
percent and fifty (50) percent bulk-free volume, and the at least one foam
transitional
layer is configured to support the load through the at least one foam comfort
layer. In
this manner, the foam all-mattress assembly may be less dense and thereby more
easily
transported from the factory to the user.
[0021] In
another embodiment, an all-foam mattress assembly is provided. The all-
foam mattress assembly may include at least one foam comfort layer to receive
a load of
a user. The all-foam mattress assembly may include at least one foam
transitional layer
receiving the load from the at least one foam comfort layer. The at least one
foam
transitional layer may have a density more than a density of the at least one
form comfort
layer. The all-foam mattress assembly may include a foam engineered core
comprising a
plurality of engineered geometric thermoplastic material profiles disposed in
a parallel
arrangement, a plurality of thermoset members disposed in the parallel
arrangement and
adjacent to the plurality of engineered geometric thermoplastic material
profiles, and a
deck. The plurality of engineered geometric thermoplastic material profiles
and the
plurality of thermoset members may be collectively configured to receive the
load
conveyed from the at least one transitional layer and to convey the load to
the deck. The
foam engineered core may include bulk-free volume. In this manner, a low cost
all-foam
mattress assembly may be provided.
[0022] In
another embodiment, an all-foam mattress assembly is provided. The all-
foam mattress assembly may include at least one foam comfort layer to receive
a load of
a user. The all-foam mattress assembly may include at least one foam
transitional layer
receiving the load from the at least one foam comfort layer. The at least one
foam
transitional layer may have a density more than a density of the at least one
foam comfort
layer. The all-foam mattress assembly may include a foam engineered core
comprising a
plurality of engineered geometric thermoplastic material profiles disposed in
a parallel
arrangement, a plurality of thermoset members disposed in the parallel
arrangement and
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adjacent to the plurality of engineered geometric thermoplastic material
profiles, a load
allocation member, and a deck. The plurality of engineered geometric
thermoplastic
material profiles and the plurality of thermoset members may be collectively
configured
to receive the load conveyed from the at least one foam transitional layer via
the load
allocation member and to convey the load to the deck. A strain of a combined
height of
the load allocation member, plurality of engineered geometric thermoplastic
material
profiles, and the plurality of thermoset members have a stress-strain
relationship
represented by Y being less than or equal to 0.012143*X^4 - 0.7467*X^3 +
10.03761*X^2 + 346.196*X - 123.5391, wherein X being strain measured in
percent of
the foam engineered core, and Y being a corresponding stress in pascals for
values of X
between 15 to 42 percent. In this manner, the foam engineered core may provide
the
comfort characteristics desired by the user with a lower mattress density.
[0023] The all-
foam mattress assembly may include at least one foam comfort layer
to receive a load of a user, and the at least one foam comfort layer may
include a comfort
layer stress-strain relationship. The all-foam mattress assembly may include
at least one
foam transitional layer receiving the load from the at least one foam comfort
layer. The
at least one foam transitional layer may have a density more than a density of
the at least
one form comfort layer. The all-foam mattress assembly may include a foam
engineered
core comprising a plurality of engineered geometric thermoplastic material
profiles
disposed in a parallel arrangement, a plurality of thermoset members disposed
in the
parallel arrangement and adjacent to the plurality of engineered geometric
thermoplastic
material profiles, and a deck. The plurality of engineered geometric
thermoplastic
material profiles and the plurality of thermoset members may be collectively
configured
to receive the load conveyed from the at least one foam transitional layer and
to convey
the load to the deck. A stress of the foam engineered core is greater for any
given foam
transitional layer strain as compared to the foam comfort layer stress-strain
relationship
and is less as compared to the support layer stress-strain relationship. In
this manner, the
performance of the all-foam mattress assembly may be customized to provide a
desired
stress-strain relationship at a lower density and manufacturing cost.
[0024]
Additional features and advantages will be set forth in the detailed
description
which follows, and in part will be readily apparent to those skilled in the
art from that
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description or recognized by practicing the embodiments as described herein,
including
the detailed description that follows, the claims, as well as the appended
drawings.
[0025] It is
to be understood that both the foregoing general description and the
following detailed description present embodiments, and are intended to
provide an
overview or framework for understanding the nature and character of the
disclosure. The
accompanying drawings are included to provide a further understanding, and are
incorporated into and constitute a part of this specification. The drawings
illustrate
various embodiments, and together with the description serve to explain the
principles
and operation of the concepts disclosed.
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIG. 1A
is an exemplary prior art mattress employing an innerspring of wire
coils illustrating a mattress that may be difficult to transport, flip, and
rotate because of
its weight and density;
[0027] FIG. 1B
is an exemplary prior art all-foam mattress employing multiple layers
of foam illustrating a second example of a mattress that may be difficult to
move because
of its weight and thickness;
[0028] FIG. 2
is a top perspective view of an exemplary mattress assembly depicted
within a mattress to illustrate the all-foam mattress assembly relative to the
mattress;
[0029] FIG. 3A
is a front side view of the mattress assembly depicted within the
mattress of FIG. 2 to illustrate the relative positions of at least one
comfort layer, at least
one transitional layer, and a foam engineered core comprising a plurality of
thermoset
members and a plurality of engineered geometric thermoplastic material
profiles ;
[0030] FIG. 3B
is a front side close-up view of a portion of the foam engineered core
of FIG. 3A including a load distribution member, one of a plurality of
thermoset
members, one of a plurality of engineered geometric thermoplastic material
profiles
having an arch-shape, and one of a plurality of thermoplastic support members
to
illustrate various components which may convey the load of the user within the
foam
engineered core;
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[0031] FIGS. 4
and 5 are a right side view and a top view, respectively, of the all-
foam mattress assembly depicted within the mattress of FIG. 2 to illustrate
the all-foam
mattress assembly extending across a sleeping area;
[0032] FIGS. 6
and 7 are a front side exploded view and a left side exploded view,
respectively, of the all-foam mattress assembly of FIG. 2 to illustrate
individual
components of the all-foam mattress assembly of FIG. 2;
[0033] FIGS.
8A-8D are front side views, respectively, of other configuration
examples of a mattress assembly having various heights illustrating other
examples of the
all-foam mattress assembly of FIG. 2;
[0034] FIG. 9A
is an exemplary cushioning structure comprised of a thermoset
material bonded to a thermoplastic material with a stratum;
[0035] FIG. 9B
is an exemplary cushioning structure comprised of a thermoset
material adjacent to a thermoplastic material without a stratum;
[0036] FIG. 10
is an exemplary chart of performance curves showing strain (i.e.,
deflection) under a given stress (i.e., pressure) for the thermoplastic
material of FIG. 9,
thermoset material of FIG. 9, and cushioning structure of FIG. 9 to illustrate
their
individual and combined support characteristics;
[0037] FIG.
11A is a stress-strain chart for an exemplary mattress made of typical
low-density thermoset material, illustrating strain on an x-axis and stress on
a y-axis;
[0038] FIG.
11B is a stress-strain chart for a second exemplary mattress which is
"too hard," and the stress-strain chart includes strain on an x-axis and
stress on a y-axis;
[0039] FIG.
11C is a stress-strain chart for a third exemplary mattress which is
initially "too soft" and then "too hard," and the stress-strain chart includes
strain on an x-
axis and stress on a y-axis;
[0040] FIG.
11D is a stress-strain chart for a fourth exemplary mattress which is
initially "slightly harder" than the third embodiment of the mattress of FIG.
8C, and
abruptly "bottoms-out," and the stress-strain chart includes strain on an x-
axis and stress
on a y-axis;
[0041] FIG.
11E is a stress-strain chart for a fifth exemplary mattress which is
initially gradually comforting, then supportive without bottoming out, and the
stress-
strain chart includes strain on an x-axis and stress on a y-axis;
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[0042] FIG. 12
provides an exemplary chart of stress-strain performance curves
showing strain (deflection) under a given stress (pressure) for different
types of
thermoplastic foam cushioning structures to show the ability to engineer a
cellular
thermoplastic foam profile to provide the desired firmness and support
characteristics in a
cushioning structure;
[0043] FIG. 13
is a stress-strain diagram showing stress-strain performance curves
for a first example of a portion of a foam engineered core depicted in FIGS.
14 and 15A,
a second example of a portion of a foam engineered core depicted in FIGS. 16
and 17,
and a third example of a portion of a foam engineered core depicted in FIGS.
18 and 19
illustrating the stress-strain performance impact of different configurations
of thermoset,
thermoplastic and bulk-free volume to reduce density of the mattress;
[0044] FIGS.
14 and 15A are a side view of the first example of the portion of the
foam engineered core and a top perspective view, respectively, of the first
example of the
portion of the foam engineered core in an exemplary mattress assembly within a
mattress;
[0045] FIG.
15B stress-strain diagram showing a stress-strain performance curve for
a the first example of a portion of a foam engineered core depicted in FIGS.
14 and 15A,
when the thermoset material is bonded to the thermoplastic material with a
stratum and a
stress-strain performance curve when there is no stratum illustrating that the
stratum
makes the first example of a portion of a foam engineered core more stiff;
[0046] FIGS.
16 and 17 are a side view of the second example of the portion of the
foam engineered core and a top perspective view, respectively, of the second
example of
the portion of the foam engineered core in an exemplary mattress assembly
within a
mattres s;
[0047] FIGS.
18 and 19 are a side view of the third example of a portion of a foam
engineered core and a top perspective view, respectively, of the third example
of the
portion of the foam engineered core in an exemplary mattress assembly within a
mattress;
[0048] FIG. 20
is a top perspective view of another exemplary mattress having at
least one foam comfort layer, at least one foam transitional layer, and a foam
engineered
core illustrating a different exemplary embodiment of a plurality of thermoset
members, a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
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[0049] FIG. 21
is a top perspective view of another exemplary mattress having at
least one foam comfort layer, at least one foam transitional layer, and a foam
engineered
core illustrating another exemplary embodiment of a plurality of thermoset
members, a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
[0050] FIG. 22
is a top perspective view of another exemplary mattress having at
least one foam comfort layer, at least one foam transitional layer, and a foam
engineered
core illustrating another exemplary embodiment of a plurality of thermoset
members, a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
[0051] FIG. 23
is a top perspective view of another exemplary mattress having at
least one foam comfort layer, at least one foam transitional layer, and a foam
engineered
core illustrating another exemplary embodiment of a plurality of thermoset
members, a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
[0052] FIG. 24
is a front side view of another exemplary mattress having at least one
foam comfort layer, at least one foam transitional layer, and a foam
engineered core
illustrating another exemplary embodiment of a plurality of thermoset members,
a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
[0053] FIG. 25
is a top perspective view of another exemplary mattress having at
least one foam comfort layer, at least one foam transitional layer, and a foam
engineered
core illustrating another exemplary embodiment of a plurality of thermoset
members, a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
[0054] FIG. 26
is a top perspective view of another exemplary mattress having at
least one foam comfort layer, at least one foam transitional layer, and a foam
engineered
core illustrating another exemplary embodiment of a plurality of thermoset
members, a
plurality of engineered geometric thermoplastic material profiles, and a
plurality of
thermoplastic support members;
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[0055] FIGS.
27A-27I are top perspective views of alternative cellular thermoplastic
foam profiles that may serve as one of a plurality of thermoplastic support
members
within a foam engineered core, or may be encapsulated or filled with a
thermoset material
to serve as one of a plurality of engineered geometric thermoplastic material
profiles
within the foam engineered core;
[0056] FIGS.
28A-28D are a top perspective view and three (3) front side views,
respectively, of four (4) related exemplary embodiments of cushion structures
that may
be used as one or more of a plurality of engineered geometric thermoplastic
material
profiles and one or more of a plurality of thermoset members within a foam
engineered
core;
[0057] FIGS.
29A and 29B are front side views, respectively, of two (2) related
exemplary embodiments of cushion structures that may be used as one or more of
a
plurality of engineered geometric thermoplastic material profiles and one or
more of a
plurality of thermoset members within a foam engineered core to illustrate in
FIG. 29B
that ends shown in the cushion structure in FIG. 29A may be closed off to form
additional openings;
[0058] FIG. 30
is a front side view of an exemplary embodiment of a cushion
structure that may be used as one or more of a plurality of engineered
geometric
thermoplastic material profiles and one or more of a plurality of thermoset
members
within a foam engineered core;
[0059] FIGS.
31A and 31B are front side views of two (2) related exemplary
embodiments of cushion structures that may be used as one or more of a
plurality of
engineered geometric thermoplastic material profiles and one or more of a
plurality of
thermoset members within a foam engineered core;
[0060] FIG. 32
is a front side view of an exemplary embodiment of a cushion
structure that may be used as one or more of a plurality of engineered
geometric
thermoplastic material profiles and one or more of a plurality of thermoset
members
within a foam engineered core;
[0061] FIG. 33
is a front side view of an exemplary embodiment of a cushion
structure that may be used as one or more of a plurality of engineered
geometric
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thermoplastic material profiles and one or more of a plurality of thermoset
members
within a foam engineered core;
[0062] FIG. 34
is a front side view of an exemplary embodiment of a cushion
structure that may be used as one or more of a plurality of engineered
geometric
thermoplastic material profiles and one or more of a plurality of thermoset
members
within a foam engineered core;
[0063] FIGS.
35A and 35B are front side views of two (2) related exemplary
embodiments of cushion structures that may be used as one or more of a
plurality of
engineered geometric thermoplastic material profiles and one or more of a
plurality of
thermoset members within a foam engineered core; and
[0064] FIGS.
36A-36D are front side views of four (4) related exemplary
embodiments of cushion structures that may be used as one or more of a
plurality of
engineered geometric thermoplastic material profiles and one or more of a
plurality of
thermoset members within a foam engineered core.
DETAILED DESCRIPTION
[0065]
Reference will now be made in detail to the embodiments, examples of which
are illustrated in the accompanying drawings, in which some, but not all
embodiments are
shown. Indeed, the concepts may be embodied in many different forms and should
not
be construed as limiting herein; rather, these embodiments are provided so
that this
disclosure will satisfy applicable legal requirements. Whenever possible, like
reference
numbers will be used to refer to like components or parts.
[0066]
Embodiments disclosed herein include all-foam mattress assemblies with
foam engineered cores having thermoplastic and thermoset materials, and
related
assemblies and methods. All-foam mattress assemblies use foam-based materials,
such
as thermoplastic and thermoset, to provide cushioning and support
characteristics for a
user in the sleeping area of a mattress during sleep or rest. The all-foam
mattress
assemblies may include foam comfort layer(s), foam transitional layer(s), and
a foam
engineered core. The all-foam engineered core may lessen a density of a
mattress
assembly by comprising thermoset member(s), and engineered geometric
thermoplastic
material profile(s) adjacent to the thermoset member(s). The engineered
geometric
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thermoplastic material profile(s) may be disposed in a parallel or
substantially parallel
arrangement. In this manner, the all-foam engineering core may provide
cushioning and
support characteristics with reduced density compared to a foam mattress
providing
similar cushioning and support through solid thermoset layers.
[0067] In this
disclosure, an exemplary all-foam mattress assembly of a mattress will
be discussed first in detail with reference to FIGS. 3A through 8D to
introduce structures
and related concepts which may result in a lower density mattress assembly.
Next, the
fundamentals of the design of all-foam mattress assemblies may be discussed in
sequence. Material selection will be discussed in relation to FIGS. 9A through
11E and
density reduction efforts in the foam engineered core. Then, different
thermoplastic
profiles will be discussed in relation to FIG. 12 that may provide the proper
stress-strain
profile for support and comfort for the user while reducing density of the
foam
engineered core. Next, the introduction of bulk-free volume in combination
will different
thermoplastic foam profiles will be discussed in reference to FIGS. 13 through
19 will be
discussed in density reduction efforts. Lastly, different embodiments of foam
engineered
cores with reference to FIGS. 20 through 26 and thermoplastic profiles with
reference to
FIGS. 27A through 36D may be introduced which may be used within the foam
engineered core to reduce density yet provide customized comfort and support
to benefit
the user.
[0068] In this
regard, FIGS. 2-3A and 4-7 depict a perspective view, a front side
view, a right-side view, a top view, a front-side exploded view, and a left
side exploded
view of an exemplary all-foam mattress assembly 50-1 of a mattress 51-1. The
all-foam
mattress assembly 50-1 may include at least one foam comfort layer 52(1)-
52(n), at least
one foam transitional layer 54, and a foam engineered core 56. The foam
engineered
core 56 may comprise a plurality of engineered geometric thermoplastic
material profiles
58(1)-58(n) disposed in a parallel or substantially parallel arrangement. A
plurality of
thermoset members 60(1)-60(n) may be disposed in the parallel or substantially
parallel
arrangement and adjacent to the plurality of engineered geometric
thermoplastic material
profiles 58(1)-58(n). The foam engineered core 56 may also include at least
one deck
62(1), 62(2). These components of the all-foam mattress assembly 50-1 are now
introduced in detail.
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[0069] It is
noted, to provide clarity in respect to other mattress terminology, that the
engineered geometric thermoplastic profiles 58(1)-58(n) in combination with
the
thermoset members 60(1)-60(p) are an embodiment of a "transition layer." In
addition,
the decks 62(1), 62(2) are an embodiment of "at least one support layer."
[0070] As the
all-foam mattress assembly 50-1 in FIG. 2 depicts, the at least one
foam comfort layer 52(1)-52(2) may contain two (2) layers; however, there may
be only
one (1) layer or more than two (2) layers. The foam comfort layers 52(1),
52(2) may
receive a load Fw from a user (not shown) and directly or indirectly convey
that load Fw
to the foam engineered core 56 via the foam transitional layer 54 so that the
user may be
supported with a comfort characteristic as discussed below. The foam comfort
layers
52(1), 52(2) may include conveyance surfaces 64(1), 64(2), respectively,
facing the foam
transitional layer 54 and configured to directly or indirectly convey the load
Fw to the
foam transitional layer 54. The conveyance surfaces 64(1), 64(2), of the foam
comfort
layers 52(1), 52(2), respectively, may be planar to more uniformly convey the
load Fw to
the foam transitional layer 54 and to reduce manufacturing cost.
[0071] The
foam comfort layers 52(1), 52(2) may be in closer proximity to the user
as compared to the foam transitional layer 54 and the foam engineered core 56.
Accordingly, the foam comfort layers 52(1), 52(2) may include thermoset
material, for
example, viscoelastic foam to provide a soft comfortable surface near the user
that may
be configured to provide minimal resistance and readily deflect to conform to
a shape of
the user's body contacting the mattress 51-1. The foam comfort layers 52(1),
52(2) may
be soft consistent with an impression load deflection (ILD) rating of eight
(8) to twenty
(20). ILD is a measurement of foam firmness. Firmness is independent of foam
density;
although it is frequently believed that higher density foams are firmer, it is
possible to
have high density foams that are soft ¨ or low density foams that are firm,
depending on
the ILD specification. ILD specification relates to comfort. It is a
measurement of the
surface feel of the foam. ILD may be measured by indenting, or in other words
compressing, a foam sample twenty-five (25) percent of its original height.
The amount
of force required to indent the foam is its twenty-five (25) percent ILD
measurement.
The more force required, the firmer the foam. Flexible foam ILD measurements
can
range from ten (10) pounds (supersoft) to about eighty (80) pounds (very
firm).
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[0072] The
mattress 51-1 may include upholstery (not shown) comprising, for
example, fabric disposed between the user and the foam comfort layers 52(1),
52(2) for
texture, heat dissipation, or hygienic reasons. The upholstery may be hidden
from view
but may form an outer surface of the mattress 51-1.
[0073] With
continuing reference to FIGS. 2-3A and 4-7, the foam transitional layer
54 may be disposed between the foam comfort layers 52(1)-52(2) and the foam
engineered core 56. The foam transitional layer 54 may receive the load Fw
from the
foam comfort layers 52(1)-52(2), and subsequently convey the load Fw to the
foam
engineered core 56. The foam transitional layer 54 may also comprise thermoset
to
provide softness and comfort to the user. However, the foam transitional layer
54 may be
rated between fifteen (15) and forty (40) ILD to provide more gradually more
support to
the user than may be offered by the foam comfort layers 52(1)-52(2). The
higher ILD
rating may result because the thermoset of the foam transitional layer 54 may
have a
higher density than the foam comfort layers 52(1)-52(2). In this manner, the
foam
transitional layer 54 may prevent rotating and/or flipping the mattress
rotating and/or
flipping the mattress the all-foam mattress assembly 50-1 from deflecting as
much under
the load Fw.
[0074] The
foam transitional layer 54 may include a load receiving surface 66 to
receive the load Fw directly or indirectly from the foam comfort layers 52(1)-
52(2). The
load receiving surface 66 may face the user and may also be planar or
substantially
planar-shaped to allow horizontal movement between the foam transitional layer
54 and
the foam comfort layers 52(1)-52(2). The load Fw receiving surface 66A of the
foam
transitional layer 54 may communicate with the conveyance surfaces 64(1),
64(2) of the
foam comfort layers 52(1)-52(2). In this manner, there may be less motion
transfer
throughout the mattress 51-1 as the foam transitional layer 54 may be more
isolated from
disturbance forces directed orthogonal to the load Fw. It is also noted that
the motion
isolation may be enhanced by placing thin substances (not shown) with high
surface
lubricity, for example, silicone, between the foam transitional layer 54 and
the foam
comfort layers 52(1)-52(2).
[0075] It is
noted that the mattress 51-1 includes optional side supports 55 and
optional side support cushions 57 which may be disposed around a perimeter of
the foam
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engineered core 56. The optional side supports 55 and optional side support
cushions 57
may be configured to provide additional strength around a perimeter of the
mattress 51-1
as the user mounts and dismounts from the mattress 51-1. The optional side
supports 55
and optional side support cushions 57 may be covered by either the foam
comfort layers
52(1)-52(2) and/or the foam transitional layer 54 as depicted in FIG. 2. The
optional side
supports 55 and optional side support cushions 57 are outside a sleeping area
53 of the
mattress 51-1 and thereby considered outside of the all-foam mattress assembly
50-1.
The sleeping area 53 of the mattress 51-1 may be configured to receive the
load Fw of the
user when not mounting or dismounting the mattress 51-1.
[0076] Next,
the foam engineered core 56 may provide additional support to the all-
foam mattress assembly 50-1, yet provide a comfort contribution to deliver
gradually
increased resistance to the load Fw while decreasing the overall density of
the all-foam
mattress assembly 50-1. The foam engineered core 56 may include the engineered
geometric thermoplastic material profiles 58(1)-58(n), disposed in a parallel
arrangement
as discussed above. In this way, the engineered geometric thermoplastic
material profiles
58(1)-58(n) may support the foam transitional layer 54 across the all-foam
mattress
assembly 50-1.
[0077] The
foam engineered core 56 may also include a load distribution member 68
configured to receive the load Fw conveyed by the foam transitional layer 54
and more
uniformly distribute the load Fw across multiple ones of the engineered
geometric
thermoplastic material profiles 58(1)-58(n). In this manner, the user may
perceive the
engineered geometric thermoplastic material profiles 58(1)-58(n) less and
instead sense a
more uniform sleeping environment free of pronounced "bumps," which may
facilitate a
more comfortable sleeping experience for the user. The load distribution
member 68 may
comprise, for example, thermoplastic for relative rigidity and strength. The
load
distribution member 68 may also preferably include a low density composition,
for
example, less than 1.6 pounds per cubic foot to reduce the density of the all-
foam
mattress assembly 50-1.
[0078] The
load distribution member 68 may include a first surface 70A and a second
surface 70B. The first surface 70A may also be planar or substantially planar-
shaped to
allow the foam transitional layer 54 to move in a horizontal plane PG (FIG.
3A) with
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respect to the load distribution member 68 of the foam engineered core 56. The
second
surface 66B of the foam transitional layer 54 may communicate with the first
surface 70A
of the load distribution member 68. In this manner, there may be less motion
transfer
throughout the mattress 51-1 as the foam engineered core 56 may be more
isolated from
disturbance forces directed orthogonal to the load Fw. It is also noted that
the motion
isolation may be enhanced by placing thin substances (not shown) with high
surface
lubricity, for example, silicone, between the second surface 66B of the foam
transitional
layer 54 and the first surface 70A of the load distribution member 68.
[0079] With
continued reference to FIGS. 2-3A and 4-7, the foam engineered core 56
may also include the thermoset members 60(1)-60(n) as discussed above. The
engineered geometric thermoplastic material profiles 58(1)-58(n) and the
thermoset
members 60(1)-60(n) may be configured to collectively receive the load Fw from
the
load distribution member 68. The term "collectively" in this disclosure refers
to sharing
the burden of the load Fw, so that the load Fw may be distributed among
multiple
members in a parallel relationship instead of a serial relationship. In this
manner,
performance characteristics of the plurality of engineered geometric
thermoplastic
material profiles 58(1)-58(n) and the plurality of thermoset members 60(1)-
60(n) may be
jointly contributed.
[0080] Within
the foam engineered core 56, the plurality of engineered geometric
thermoplastic material profiles 58(1)-58(n) may be spaced apart a distance Dsg
(FIG.
3A) and bulk-free volume 76 (FIG. 3A) may be disposed between. As the distance
Dsg
may be increased, a density of the all-foam mattress assembly 50-1 may be
decreased, as
volume between the engineered geometric thermoplastic material profiles 58(1)-
58(n)
may be purposefully occupied by less dense structures or bulk-free volume 76
disposed
within the distance Dsg. For example, the foam engineered core 56 may further
include a
plurality of thermoplastic support members 72(1)-72(p) arranged in the
parallel
arrangement and disposed between the engineered geometric thermoplastic
material
profiles 58(1)-58(n) and thermoset members 60(1)-60(n). The thermoplastic
support
members 72(1)-72(p) may be made of low-density foam, for example, polyethylene
with
a density of 1.6 pounds per cubic feet or less to facilitate weight savings.
In addition, the
thermoplastic support members 72(1)-72(p) may include one or more first spring
bore
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74A(1)-74A(p) and/or one or more second spring bore 74B(1)-74B(p) which may be
occupied by bulk-free volume 76. The first spring bores 74A(1)-74A(p) and/or
second
spring bores 74B(1)-74B(p) may extend through the thermoplastic support
members
72(1)-72(p) to provide a performance contribution across the first spring
bores 74A(1)-
74A(p) and/or second spring bores 74B(1)-74B(p). In addition, the first spring
bores
74A(1)-74A(p) and/or second spring bores 74B(1)-74B(p) may be configured to
gradually close when subjected to the load Fw.
[0081] The
volume between the plurality of thermoplastic support members 72(1)-
72(p) and the plurality of engineered geometric thermoplastic material
profiles 58(1)-
58(n) may also be occupied by the bulk free volume 76 and reduce the density
of the all-
foam mattress assembly 50-1. The bulk-free volume 76 may reduce the density of
the
all-foam mattress assembly 50-1 because the bulk-free volume 76 is free of
solid mass.
The bulk-free volume 76 may be air or a low-pressure vacuum environment.
Further, the
bulk-free volume 76 is separate from air bubbles disposed within the plurality
of closed
cells which may be contained within either thermoplastic or thermoset
material. The
thermoplastic support members 72(1)-72(n-1), as well as the engineered
geometric
thermoplastic material profiles 58(1)-58(n), and the plurality of thermoset
members
60(1)-60(n) may be collectively configured to receive the load Fw conveyed
from the
foam transitional layer 54 and convey the load Fw to the decks 62(1), 62(2).
[0082] The
thermoplastic support members 72(1)-72(p) may also include a plurality
of first grooves 78A(1)-78A(p) (FIG. 3A) and a plurality of second grooves
78B(1)-
78B(p) (FIG. 6) opposite the first grooves 78A(1)-78A(p). The first grooves
78A(1)-
78A(p) and the second grooves 78B(1)-78B(p) may be configured to gradually
close
when the thermoplastic support members 72(1)-72(p) may be subjected to the
load Fw.
In this manner, the thermoplastic support members 72(1)-72(p) may more easily
compress under the load Fw and contribute comparatively less resistance to the
load Fw
than the engineered geometric thermoplastic material profiles 58(1)-58(n).
[0083] The
engineered geometric thermoplastic material profiles 58(1)-58(n) and/or
the thermoplastic support members 72(1)-72(p) may be secured to the load
distribution
member 68. For example, they may be secured using a thermal bond, a cohesive,
an
adhesive, and/or may be formed together as part of a molding process or
extrusion
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process. In this manner, the engineered geometric thermoplastic material
profiles 58(1)-
58(n) and/or the thermoplastic support members 72(1)-72(p) may remain in the
parallel
arrangement even after repeated cycles of being burdened with the load Fw.
[0084] FIG. 3B
comprises a close-up of the thermoset member 60(n), the
thermoplastic support member 72(p), and the engineered geometric thermoplastic
material profile 58(n), but the details also may apply to the thermoset
members 60(1)-
60(n-1), the thermoplastic support members 72(1)-72(p-1), and the engineered
geometric
thermoplastic material profiles 58(1)-58(n-1). With reference to FIG. 3B, the
thermoset
members 60(1)-60(n) may be adjacent to the engineered geometric thermoplastic
material
profiles 58(1)-58(n) which may comprise a plurality of hollow circular
profiles 80(1)-
80(n) which may have, for example, an arch-shape. Each of the engineered
geometric
thermoplastic material profiles 58(1)-58(n) may be secured to and protrude
from the load
distribution member 68. The hollow circular profiles 80(1)-80(n) include a
plurality of
inner thermoplastic surfaces 82(1)-82(n) forming a plurality of hollow
passageways
84(1)-84(n) and a plurality of outer thermoplastic surfaces 86(1)-86(n)
surrounding at
least one of the thermoset members 60(n). Each of the thermoset members 60(1)-
60(n)
may also abut against and/or be secured to complementary ones of the
engineered
geometric thermoplastic material profiles 58(1)-58(n) with an adhesive, a
cohesive, or a
thermal bond. In this manner, the movement of the thermoset members 60(1)-
60(n) and
the engineered geometric thermoplastic material profiles 58(1)-58(n) may be
linked while
directly or indirectly conveying the load Fw to the decks 62(1), 62(2) to
provide a
customizable stress-strain relationship as discussed below in a later section
of this
disclosure.
[0085] Next,
the decks 62(1), 62(2) of the foam engineered core 56 may include first
surfaces 88A(1), 88A(2) and second surfaces 88B(1), 88B(2) which respectively
may
planar to isolate motion orthogonal to the load Fw. The decks 62(1), 62(2) may
be
comprise a strong lightweight thermoplastic, for example, polyethylene. The
decks
62(1), 62(2) may be relatively stiff to provide a structural foundation for
the all-foam
mattress assembly 50-1. It is also noted that at least one of the second
surfaces 88B(1),
88B(2) may be supported by a rigid structure, for example, a bed frame, for
safety
reasons.
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[0086] FIGS.
8A-8D depict front views of other examples of the all-foam mattress
assembly 50-1 which may be optimized for heights H2-H5 and performance and the
details of the differences with mattress assembly 10-1 will now be discussed.
FIG. 8A
depicts a front view of an exemplary all-foam mattress assembly 50-2 of a
mattress 51-2.
The all-foam mattress assembly 50-2 may comprise two (2) of the foam comfort
layers
52(1) and 52(2) contributing two (2) inches of height A2; three (3) of the
foam
transitional layers 54(1)-54(3) contributing three (3) inches of height B2;
and a foam
engineered core 56 contributing five and one-half (5.5) inches of height C2. A
cover pad
and/or upholstery 90 may contribute another one-half inch of height D2. In
this manner,
the mattress 51-2 of a height H2 of eleven (11) inches may be created.
[0087] FIG. 8B
depicts a front view of an exemplary all-foam mattress assembly 50-
3 of a mattress 51-3. The all-foam mattress assembly 50-3 may comprise one (1)
foam
comfort layer 52(1) contributing two (2) inches of height A3; three (3) of the
foam
transitional layers 54(1)-54(3) contributing three (3) inches of height B3;
and a foam
engineered core 56 contributing six and one-half (6.5) inches of height C3. A
cover pad
and/or upholstery 90 may contribute another one-half inch of height D3. In
this manner,
the mattress 51-3 of a height H3 of twelve (12) inches may be created.
[0088] FIG. 8C
depicts a front view of an exemplary all-foam mattress assembly 50-
4 of a mattress 51-4. The all-foam mattress assembly 50-4 may comprise two (2)
of the
foam comfort layers 52(1), 52(2) contributing three (3) inches of height A4;
two (2) of the
foam transitional layers 54(1),54(2) contributing two (2) inches of height B4;
and a foam
engineered core 56 contributing seven and one-half (7.5) inches of height C4.
A cover
pad and/or upholstery 90 may contribute another one-half inch of height D4. In
this
manner, the mattress 51-4 of a height H4 of thirteen (13) inches may be
created.
[0089] FIG. 8D
depicts a front view of an exemplary all-foam mattress assembly 50-
of a mattress 51-5. The all-foam mattress assembly 50-5 may comprise two (2)
of the
foam comfort layers 52(1), 52(2) contributing four (4) inches of height A5;
two (2) of the
foam transitional layers 54(1), 54(2) contributing two (2) inches of height
B5; and a foam
engineered core 56 contributing seven and one-half (7.5) inches of height C5.
A cover
pad and/or upholstery 90 may contribute another one-half inch of height D5. In
this
manner, the mattress 51-5 of a height H5 of fourteen (14) inches may be
created.
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[0090] Now
that the details of the all-foam mattress assembly 50-1 of a mattress 51-1
have been introduced, details of materials used in the foam engineered core 56
and
related embodiments are now discussed in more detail. The fundamental
performance
and density of the foam engineered core 56 of the all-foam mattress assembly
50
originates from foam materials comprising thermoplastic and thermoset. FIG. 9A
is an
exemplary cushioning structure 100 as a hybrid comprised of a thermoset sample
material
102 adjacent to a thermoplastic sample material 104., which both maybe found
in the
foam engineered core 56 of the all-foam mattress assembly 50. Materials may
significant
change the performance of the all-foam mattress assembly 50 in response to the
weight
Fw of the user and also have a significant impact on the overall density of
the all-foam
mattress assembly 50.
[0091] The
thermoplastic material 104 and the thermoset material 102 may be
cohesively or adhesively bonded together to provide the cushioning structure
100, or may
merely be adjacent to one another. The cushioning structure 100 may also be
bonded
together with a stratum 101 as shown in FIG. 9. The stratum 101 may be formed
where
an outer surface 103A of the thermoset material 102 contacts or rests against
an inner
surface 103B of the thermoplastic material 104, cohesively or adhesively
bonding the
inner surface 103B to the outer surface 103A in the presence of a coupling
agent 105, for
example, an amino-silane such as N-(2-aminoethyl)-3-
aminopropyltrimethoxysilane
similar to Product SIA0591.0 made by Gelest, Incorporated of Morrisville,
Pennsylvania,
USA. The coupling agent 105 may substantially remain part of the cushioning
structure
100 after the stratum 101 may be formed. In this regard, the cushioning
structure 100
exhibits a combination of characteristics of the support characteristics of
the
thermoplastic material 104 and the resiliency and cushioning characteristics
of the
thermoset material 102. The thermoplastic material 104 is provided to provide
support
characteristics desired for the cushioning structure 100. The thermoplastic
material 104
could be selected to provide a high degree of stiffness to provide structural
support for
the cushioning structure 100. The thermoset material 102 can provide
resiliency and
softer cushioning characteristics to the cushioning structure 100.
[0092] With
continued reference to FIG. 9A, a relative density pi of the
thermoplastic material 104 as compared to a density 132 of the thermoset
material 102 can
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control the responsiveness of the combined cushioning properties, and can also
control
the weight of the cushioning structure 100. For example, the density pi of the
thermoplastic material 104 could be in the range between a half (0.5) to
thirty (30) pound
per cubic foot (or eight (8) to four-hundred eighty (480) kilograms per cubic
meter), as an
example. However, the density pi of the thermoplastic material 104 is
preferably one and
one-half (1.5) pound per cubic foot. The density p2 of the thermoset material
102 may be
between one (1) to fifteen (15) pounds per cubic foot (or sixteen (16) to two-
hundred
forty (240) kilograms per cubic meter), as an example. However, the density p2
of the
thermoset material 102 is preferably from 1.8 to 2.5 pound per cubic foot. The
weight of
the cushioning structure 100 may be reduced by the replacement of the
thermoset
material 102 with the thermoplastic material 104 because the preferable
density pi of the
thermoplastic material 104 may be less than the preferable density p2 of the
thermoset
material 102.
[0093] Non-
limiting examples of thermoset materials that can be used to provide the
thermoset material 102 in the cushioning structure 100 include polyurethanes,
natural and
synthetic rubbers, such as latex, silicones, ethylene propylene diene Monomer
(M-class)
(EPDM) rubber, isoprene, chloroprene, neoprene, melamine-formaldehyde, and
polyester, and derivatives thereof. The density p2 of the thermoset material
102 may be
provided to any density desired to provide the desired resiliency and
cushioning
characteristics to the cushioning structure 100, and can be soft or firm
depending on
formulations and density. The thermoset material 102 could also be foamed.
Further, if
the thermoset material 102 selected is a natural material, such as latex for
example, it
may be considered biodegradable. Further, bacteria, mildew, and mold cannot
live in
certain thermoset foams. Also note that although the cushioning structure 100
illustrated
in FIG. 9 is comprised of at least two materials, the thermoplastic material
104 and the
thermoset material 102, more than two different types of thermoplastic and/or
thermoset
materials may be provided in the cushioning structure 100.
[0094] Non-
limiting examples of thermoplastic materials that can be used to provide
the thermoplastic material 104 in the cushioning structure 100 include
polypropylene,
polypropylene copolymers, polystyrene, polyethylenes, ethylene vinyl acetates
(EVAs),
polyolefins, including metallocene catalyzed low density polyethylene,
thermoplastic
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olefins (TP0s), thermoplastic polyester, thermoplastic vulcanizates (TPVs),
polyvinyl
chlorides (PVCs), chlorinated polyethylene, styrene block copolymers, ethylene
methyl
acrylates (EMAs), ethylene butyl acrylates (EBAs), and the like, and
derivatives thereof.
The density pi of the thermoplastic material 104 may be provided to any
density desired
to provide the desired weight and support characteristics for the cushioning
structure 100.
Further, the thermoplastic material 104 may be selected to also be inherently
resistant to
microbes and bacteria, making the thermoplastic material 104 desirable for use
in
cushioning structures and related applications. The thermoplastic material 104
can also
be made biodegradable and fire retardant through the use of additive master
batches.
[0095] It may
be desired to control the combined cushioning properties of the
cushioning structure 100 in FIG. 9B. For example, it may be desired to control
the
degree of support or firmness provided by the thermoplastic material 104 as
compared to
the resiliency and cushioning characteristics of the thermoset material 102.
In this
regard, as an example, the thermoplastic material 104 is provided as a solid
block of
height E1, as illustrated in FIG. 9B. The thermoset material 102 is provided
of height E2,
as also illustrated in FIG. 9B. The relative volume of the thermoplastic
material 104 as
compared to the thermoset material 102 can control the combined cushioning
properties,
namely the combined support characteristics and the resiliency and cushioning
characteristics, in response to the load Fw of the user. These combined
characteristics
can also be represented as a unitary strain or deflection for a given stress
or pressure, as
previously discussed.
[0096]
Further, by controlling the volume of the thermoplastic material 104 and the
thermoset material 102, the same combined cushioning properties may be able to
be
provided in a smaller overall volume or area. For example, with reference to
FIG. 9B,
the individual heights E1 and E2 may be less important in providing the
combined
cushioning characteristics of the cushioning structure 100 than the ratio of
the respective
heights Ei and E2 Thus, the overall height E3 (i.e., E1 together with E2) of
the cushioning
structure 100 may be reduced by providing distinct, non-bonded layers of
cushioning
structures.
[0097]
Further, the thermoplastic material 104 and thermoset material 102 may each
have different indentation load deflections (ILDs). The thermoplastic material
104 of the
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cushioning structure 100 can be provided as a cellular thermoplastic foam
profile, if
desired. By providing the thermoplastic material 104 of the cushioning
structure 100 as a
cellular foam profile, control of the shape and geometry of the cushioning
structure 100
can be provided, as desired. For example, the extrusion foaming art, with the
ability to
continuously produce and utilize specific die configurations having the
ability to
geometrically design and profile elements for cushioning support, is a method
to obtain
the desired thermoplastic engineered geometry foam profiles to be used with a
thermoset
material or materials to provide the cushioning structure 100. In this manner,
the
cushioning structure 100 can be provided for different applications based on
the desired
geometric requirements of the cushioning structure. Machine direction (MD)
attributes
as well as transverse direction (TD) attributes may be employed to extrude a
thermoplastic foam profile. However, other methods of providing thermoplastic
foam
profiles may also be employed, including molding, casting, thermal forming,
and other
processes known to those skilled in the art.
[0098]
Thermoset foam profiles can be obtained in emulsified form and are frothed to
introduce air into the emulsion to reduce density, and are then cured
(vulcanized) to
remove additional waters and volatiles as well as to set the material to its
final
configuration. The cost of thermoset materials can be further reduced through
the
addition of fillers such as ground foam reclaim materials, nano clays, carbon
nano tubes,
calcium carbonate, fly ash, and the like, as well as corc dust, as this
material can provide
for increased stability to reduce the overall density and weight of the
thermoset material.
Further, thermoplastic foams, when used in combination with a thermoset foam,
will
occupy volume within a cushion structure, thereby displacing the heavier-
weight, more
expensive thermoset materials, such as latex rubber foam, as an example.
[0099] In this
regard, embodiments disclosed herein allow a cushioning structure to
be provided in a customized, engineered profile by providing a customized,
engineered
thermoplastic foam profile. A thermoset material is provided in the engineered
thermoplastic foam profile to provide the cushioning structure. In this
manner, the shape
and resulting characteristics of the cushioning structure can be designed and
customized
to provide the desired combination of resiliency and cushioning, and support
characteristics for any application desired.
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[00100] FIG. 9B is a side view of the thermoplastic material 104 and the
thermoset
material 102 of FIG. 9A wherein the thermoplastic material 104 and the
thermoset
material 102 are adjacent to each other but not secured to each other with a
stratum 101.
In this manner, the thermoplastic material 104 and the thermoset material 102
may be
less restricted to move with respect to each other. In this manner, forces
(not shown)
angled non-orthogonal to the outer surface 103A and inner surface 103B may be
better
prevented from being transferred between the outer surface 103A and inner
surface 103B
to provide motion isolation.
[00101] For example, FIG. 10 is a stress-strain diagram 106 showing a stress-
strain
relationship 108 for the thermoplastic material 104 and a stress-strain
relationship 110 for
the thermoset material 102. The stress-strain diagram 106 also includes a
stress-strain
relationship 112 for the cushion structure 100 of FIG. 9. The stress-strain
relationship
112 of the cushion structure 100 may be disposed between those of the
thermoset
material 102 and the thermoplastic material 104, which both contribute their
performance
characteristics to the cushion structure 100.
[00102] FIGS. 11A-11E show further stress-strain relationships illustrating
different
performance characteristics which may be achieved by modifying the material
attributes
of the cushion structure 100. For example, FIG. 11A depicts a performance
curve 114(1)
of a mattress assembly formed of low-density thermoset which may be too soft.
The user
may sink in the sleeping surface to a depth that is too deep and then "bottom
out." FIG.
11B depicts a performance curve 114(2) reflecting a mattress that is too hard.
The user
may apply a variety of weight to the mattress causing a variety of stress, but
the mattress
surface may not move much in response, resulting in a user experience
analogous to
sleeping on a floor.
[00103] The shape of the performance curve may be as important as the slope of
the
performance curve. For example, FIG. 11C depicts a performance curve 114(3) of
a
mattress that is initially too soft as the user first applies their weight to
the all-foam
mattress assembly. The all-foam mattress assembly offers no transition zone
and
immediately is too hard resulting in a negative overall experience for the
user.
[00104] FIG. 11D depicts a performance curve 114(4) for a mattress that is
initially
harder than the performance curve 114(3) of FIG. 11C, but yet also delivers a
negative
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user experience because there is an abrupt "bottoming-out" at some strain
amount where
the performance curve 114(4) steepens too rapidly. The user may find the
initial
performance of the mattress prior to the bottoming-out as pleasant, but the
bottoming-out
quite unsettling.
[00105] FIG. 11E depicts a performance curve 114(5) of a mattress that
provides the
most ideal user experience. The initial strain is provided without being too
soft and there
is gradual strain with increasing stress provided by the user. As higher
amounts of strain
are reached, there is no bottoming out as was experienced in the performance
curves
114(3) and 114(4). Instead, the mattress allows a gradual linear response that
is
supportive as the stress and strain are increased.
[00106] Now that the material selection has been discussed above in relation
to the
reduction efforts in FIGS. 9A through 11E, different thermoplastic profiles
are discussed
in relation to FIG. 12 that may provide the proper stress-strain profile for
support and
comfort for the user while reducing density of the foam engineered core 56.
[00107] In this regard, FIG. 12 provides an exemplary chart 116 of performance
curves showing strain (deflection) under a given stress (pressure) for
different types of
thermoplastic foam cushioning structures to show the advantage of using
thermoplastic in
combination with thermoset to provide the desired firmness and support
characteristics in
the cushioning structure 100. A performance curve 118 illustrates the result
of testing of
strain for a given stress of an exemplary solid block of low density
polyethylene foam
before being engineered into a particular profile. Performance curves 120, 122
represent
the result of testing of strain for a given stress of two exemplary
polyethylene foam
extrusion profiles formed from the low density polyethylene foam represented
by the
performance curve 118. As illustrated in FIG. 12, the low density polyethylene
foam
represented by the performance curve 118 supports a higher load or stress than
the two
polyethylene foam extrusion profiles represented by the performance curves
120, 122 of
the same or similar density. Further, as illustrated in FIG. 12, the
polyethylene foam
extrusion profile represented by the performance curve 120 illustrates strain
for a given
stress that has a greater propensity to support a higher load than the
exemplary
polyethylene foam extrusion profile represented by the performance curve 122.
Thus, a
thermoplastic foam profile can be engineered to be less supportive to be more
similar to
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thermoset material in the cushioning structure 100 depending on the support
characteristics for the cushioning structure 100 desired. The cushioning
structure 100
may be analogous to the foam engineered core where the same thermoset and
thermoplastic may be used to achieve the desired cushioning and support
characteristics
which may be quantified using a stress-strain curve.
[00108] Now that the different thermoplastic profiles have been discussed
above in
relation to the reduction efforts in FIG. 12, the introduction of bulk-free
volume 76 in
combination with various thermoplastic profiles will be discussed in FIG. 13
through 19
for three (3) different thermoplastic profiles and foam mattress cores of all-
foam mattress
assemblies to provide the proper stress-strain profile for support and comfort
for the user
while reducing density of the foam engineered core 56.
In this regard, FIG. 13 is a stress-strain chart 130 depicting stress-strain
relationships
131, 132, 134, 136 for embodiments of portions 75, (see FIG. 3B), 138 (see
FIG. 14),
140 (see FIG. 16), 142 (see FIG. 18) of foam engineered cores, respectively.
The stress-
strain relationship 132 provides the most support because it requires the most
stress to
create a given strain. The stress-strain relationship 134 may be the most
flexible, because
it requires the least stress to create a given strain. The stress-strain
relationship 136 may
not too stiff or most flexible, because it requires a medial amount of stress
to create a
given strain. The stress-strain relationships 131, 132, 134, 136 for the
portion of the
foam engineered core 56 may be represented numerically by a fourth order
polynomial
with the following coefficients in Table 1 based on the equation Y =
aLi*X4+a3*X3+a2*X2+ai*X+ao, wherein the X is strain in percent, and Y = stress
in
pascals for values of X between 15 to 42 percent. Using the fourth order
polynomial for
stress-strain relationship 132, for example, for a strain of 40 percent, X =
40, and Y =
11,809 pascals.
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[00109] Table 1: Polynomial Coefficients of Fourth Order Polynomial Best Fit
Lines For FIG. 13 ¨ Stress-Strain Relationships 131, 132, 134, 136
Stress- Stress- Stress- Stress-
strain strain strain strain
Polynomial relationship relationship relationship relationship
Coefficient "131" "132" "134" "136"
a4 0.012143 0.0013636 0.0029545 0.0029924
a3 -0.7467 0.13636 -0.187879 -0.1118687
a2 10.03761 -7.06061 2.174242 0.5568182
ai 346.196 273.182 98.9177 171.3276
ao -123.5391 -39.3939 11.4719 44.3723
[00110] FIG. 14 depicts a side view of the foam engineered core 138 and FIG.
15A
depicts a portion of a foam engineered core 138 in an exemplary all-foam
mattress
assembly 50-6 of a mattress 51-6. The portion of the foam engineered core 138
may
comprise an engineered geometric thermoplastic material profile 58-6 thermally
bonded
to a load distribution member 68, with the engineered geometric thermoplastic
material
profile 58-6 surrounding a thermoset member 60-6 which may be bonded to the
engineered geometric thermoplastic material profile 58-6 with a stratum 101.
In this
manner, a stiffer version of the foam engineered core 138 may be created. It
is also noted
that the portion of the foam engineered core 138 includes fifty (50) percent
thermoplastic,
thirty-two (32) percent thermoset, and eighteen (18) percent bulk-free volume
76. The
thermoplastic of the engineered geometric thermoplastic material profile 58-6
may be, for
example, polyethylene with a density of fifteen (15) pounds per cubic foot.
The
thermoset of the thermoset member 60-6 may be, for example, polyurethane with
a
density between 1.8 and 2.6 pounds per cubic foot. The bulk-free volume 76 may
be
considered to have a zero (0) weight contribution. Accordingly, a less dense
embodiment
of the all-foam mattress assembly 50-6 may be created by replacing portions of
the
thermoset member 60-6 with either bulk-free volume 76 and/or the engineered
geometric
thermoplastic material profile 58-6.
[00111] It is noted that a preferred stress strain relationship for the
portion of the foam
engineered core 56 may be within a range of acceptable values as perceived by
users and
may be less than the stress-strain relationship 131 and/or the stress-strain
relationship
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132. The preferred stress-strain relationship may also be greater than the
stress-strain
relationship 134 and/or the stress-strain relationship 136. In this manner, a
foam
engineered core 56 with low density may provide the cushion and support
characteristics
desired by the user.
[00112] The density of the thermoplastic used, the density of the thermoset
used, as
well as the volumetric percentages of thermoplastic, thermoset, and bulk
volume are
shown in Table 2 for the embodiment of the portion of the foam engineered core
56
shown in FIG. 14 as well as those shown in FIGS. 2, 16 and 18.
[00113] Table 2: Thermoplastic Density, Thermoset Density, and Volumetric
Percentages of Thermoset, Thermoplastic and Bulk-Free Volume For Portions of
The Foam Engineered Cores
Themo- Themo- Themo-
plastic set plastic Themo s et Bulk-Free
Density Density Volume Volume Volume
Embodiment (lb s/ft3) (lb s/ft3) (percent) (percent)
(percent)
FIG. 2 1.5 2.0 51 16 33
FIG. 14 1.5 2.0 50 32 18
FIG. 16 1.5 2.3 36 26 38
FIG. 18 1.5 2.0 51 17 32
[00114] It is noted that the portion of the foam engineered core 138 may
comprise an
engineered geometric thermoplastic material profile 58-6 thermally bonded to a
load
distribution member 68, with the engineered geometric thermoplastic material
profile 58-
6 surrounding and adjacent to a thermoset member 60-6 and free of a stratum
101'. In
the case where the portion of the foam engineered core 138 of FIG. 14 may be
free of the
stratum 101, then the stress-strain relationship 134, represented in FIG. 15B
as stress-
strain relationship 134', may be lowered to the stress-strain relationship 137
as shown in
a chart 135 depicted in FIG. 15B. In this manner removing the stratum 101'
causes the
portion of the foam engineered core 138 of FIG. 14 to be more flexible.
[00115] FIG. 16 depicts a side view of the foam engineered core 140 and FIG.
17
depicts a portion of a foam engineered core 140 in an exemplary all-foam
mattress
assembly 50-7 of a mattress 51-7. The portion of the foam engineered core 140
may
comprise an engineered geometric thermoplastic material profile 58-7 thermally
bonded
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to a load distribution member 68-7, with the engineered geometric
thermoplastic material
profile 58-7 surrounding a thermoset member 60-7 which may be bonded to the
engineered geometric thermoplastic material profile 58-7. In this manner, a
less stiff
version of the foam engineered core 140 may be created. It is also noted that
the portion
of the foam engineered core 140 includes thirty-six (36) percent
thermoplastic, twenty-six
(26) percent thermoset, and thirty-eight (38) percent bulk-free volume 76. The
thermoplastic of the engineered geometric thermoplastic material profile 58-7
may be, for
example, polyethylene with a density of fifteen (15) pounds per cubic foot.
The
thermoset of the thermoset member 60-7 may be, for example, polyurethane with
a
density between 1.8 and 2.6 pounds per cubic foot. The bulk-free volume 76 may
be
considered to have a zero (0) weight contribution. Accordingly, a less dense
embodiment
of the all-foam mattress assembly 50-7 may be created by replacing portions of
the
thermoset member 60-7 with either bulk-free volume 76 and/or the engineered
geometric
thermoplastic material profile 58-7.
[00116] FIG. 18 depicts a side view of the foam engineered core 142 and FIG.
19
depicts a portion of a foam engineered core 142 in an exemplary all-foam
mattress
assembly 50-8 of a mattress 51-8. The portion of the foam engineered core 142
may
comprise an engineered geometric thermoplastic material profile 58-8 thermally
bonded
to a load distribution member 68, with the engineered geometric thermoplastic
material
profile 58-8 surrounding a thermoset member 60-8 which may be bonded to the
engineered geometric thermoplastic material profile 58-8. In this manner, a
medial
stiffness version of the foam engineered core 142 may be created. It is also
noted that the
portion of the foam engineered core 142 includes forty-one (41) percent
thermoplastic,
twenty-two (22) percent thermoset, and thirty-seven (37) percent bulk-free
volume 76.
The thermoplastic of the engineered geometric thermoplastic material profile
58-8 may
be, for example, polyethylene with a density of fifteen (15) pounds per cubic
foot. The
thermoset of the thermoset member 60-8 may be, for example, polyurethane with
a
density between 1.8 and 2.6 pounds per cubic foot. The bulk-free volume 76 may
be
considered to have a zero (0) weight contribution. Accordingly, a less dense
embodiment
of the all-foam mattress assembly 50-8 may be created by replacing portions of
the
thermoset member 60-8 with either bulk-free volume 76 and/or the engineered
geometric
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thermoplastic material profile 58-8. It is noted that this portion of the foam
engineered
core 142 comprises a thermoplastic support member 72-8 which contains a first
spring
bore 74A-8.
[00117] Now that the bulk-free volume 76 has been discussed in combination
with
various thermoplastic profiles in FIG. 13 through 19 for three (3) different
thermoplastic
profiles, different embodiments of foam engineered cores with reference to
FIGS. 20
through 26 are now discussed as a possibility to reduce density of the foam
engineered
core 56.
[00118] FIG. 20 depicts a top perspective view of another exemplary all-foam
mattress assembly 148-1 within another exemplary mattress 150-1 having the
foam
comfort layers 52(1), 52(2), the foam transitional layer 54, and a foam
engineered core
56. The differences between the all-foam mattress assembly 148-1 and the all-
foam
mattress assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and
foster
clarity.
[00119] With continuing reference to FIG. 20, the foam engineered core 56 may
include the load distribution member 68 and the decks 62(1), 62(2). The foam
engineered core 56 may also include the plurality of thermoset members 60(1)-
60(n)
adjacent to the plurality of engineered geometric thermoplastic material
profiles 58(1)-
58(n) in a parallel arrangement. The foam engineered core 56 may also include
a
plurality of thermoplastic support members 72(1)-72(p) disposed between the
plurality of
engineered geometric thermoplastic material profiles 58(1)-58(n). The foam
engineered
core 56 may also include bulk-free volume 76, in this case within the
thermoplastic
support members 72(1)-72(p) and between the engineered geometric thermoplastic
material profiles 58(1)-58(n). It is noted that the exemplary mattress 150-1
includes
optional side supports 154(1), 154(2) and optional side support cushions
156(1), 156(2)
which may be disposed around a perimeter of the foam engineered core 56. In
this
manner, the combination of the engineered geometric thermoplastic material
profiles
58(1)-58(n) and the bulk-free volume 76 utilized in the mattress 150-1 results
in a lighter,
less dense mattress which is easier to maintain and transport.
[00120] FIG. 21 depicts a top perspective view of another exemplary all-foam
mattress assembly 148-2 within another exemplary mattress 150-2 having the
foam
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comfort layers 52(1), 52(2), the foam transitional layer 54, and a foam
engineered core
56. The differences between the all-foam mattress assembly 148-2 and the all-
foam
mattress assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and
foster
clarity.
[00121] With reference to FIG. 21, the foam engineered core 56 may include the
load
distribution member 68 and the decks 62(1), 62(2). The foam engineered core 56
may
also include the plurality of thermoset members 60(1)-60(n) adjacent to the
plurality of
engineered geometric thermoplastic material profiles 58(1)-58(n) in a parallel
arrangement. The foam engineered core 56 may also include bulk-free volume 76,
in this
case between the engineered geometric thermoplastic material profiles 58(1)-
58(n). It is
noted that the exemplary mattress 150-2 includes optional side supports
154(1), 154(2)
and optional side support cushions 156(1), 156(2) which may be disposed around
a
perimeter of the foam engineered core 56. In this manner, the combination of
the
engineered geometric thermoplastic material profiles 58(1)-58(n) and the bulk-
free
volume 76 utilized in the mattress 150-2 results in a lighter, less dense
mattress which is
easier to maintain and transport.
[00122] FIG. 22 depicts a top perspective view of another exemplary all-foam
mattress assembly 148-3 within another exemplary mattress 150-3 having the
foam
comfort layers 52(1), 52(2), the foam transitional layer 54, and a foam
engineered core
56. The differences between the all-foam mattress assembly 148-3 and the all-
foam
mattress assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and
foster
clarity. With reference to FIG. 22, the foam engineered core 56 may include
the load
distribution member 68 and the decks 62(1), 62(2). The foam engineered core 56
may
also include the plurality of thermoset members 60(1)-60(p) adjacent to the
plurality of
engineered geometric thermoplastic material profiles 58(1)-58(n) in a parallel
arrangement. The foam engineered core 56 may also include bulk-free volume 76,
in this
case between the engineered geometric thermoplastic material profiles 58(1)-
58(n). It is
noted that the exemplary mattress 150-3 includes optional side supports
154(1), 154(2)
and optional side support cushions 156(1), 156(2) which may be disposed around
a
perimeter of the foam engineered core 56. In this manner, the combination of
the
engineered geometric thermoplastic material profiles 58(1)-58(n) and the bulk-
free
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volume 76 utilized in the mattress 150-3 results in a lighter, less dense
mattress which is
easier to maintain and transport.
[00123] FIG. 23 depicts a top perspective view of another exemplary all-foam
mattress assembly 148-4 within another exemplary mattress 150-4 having the
foam
comfort layers 52(1), 52(2), the foam transitional layer 54, and a foam
engineered core
56. The differences between the all-foam mattress assembly 148-4 and the all-
foam
mattress assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and
foster
clarity. With reference to FIG. 23, the foam engineered core 56 may include
the load
distribution member 68 and the decks 62(1), 62(2). The foam engineered core 56
may
also include the plurality of thermoset members 60(1)-60(n) adjacent to the
plurality of
engineered geometric thermoplastic material profiles 58(1)-58(n) in a parallel
arrangement. The foam engineered core 56 may also include bulk-free volume 76,
in this
case between the engineered geometric thermoplastic material profiles 58(1)-
58(n). It is
noted that the exemplary mattress 150-4 includes optional side supports
154(1), 154(2)
and optional side support cushions 156(1), 156(2) which may be disposed around
a
perimeter of the foam engineered core 56. In this manner, the combination of
the
engineered geometric thermoplastic material profiles 58(1)-58(n) and the bulk-
free
volume 76 utilized in the mattress 150-4 results in a lighter, less dense
mattress which is
easier to maintain and transport.
[00124] FIG. 24 depicts a front side view of another exemplary all-foam
mattress
assembly 148-5 within another exemplary mattress 150-5 having the foam comfort
layers
52(1), 52(2), the foam transitional layer 54, and a foam engineered core 56.
The
differences between the all-foam mattress assembly 148-5 and the all-foam
mattress
assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and foster
clarity.
With reference to FIG. 24, the foam engineered core 56 may include the load
distribution
member 68 and the decks 62(1), 62(2). The foam engineered core 56 may also
include
the plurality of thermoset members 60(1)-60(n) adjacent to the plurality of
engineered
geometric thermoplastic material profiles 58(1)-58(n) in a parallel
arrangement. The
foam engineered core 56 may also include bulk-free volume 76, in this case
between and
within the engineered geometric thermoplastic material profiles 58(1)-58(n).
It is noted
that the exemplary mattress 150-5 includes optional side supports 154(1),
154(2) and
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optional side support cushions 156(1), 156(2) which may be disposed around a
perimeter
of the foam engineered core 56. In this manner, the combination of the
engineered
geometric thermoplastic material profiles 58(1)-58(n) and the bulk-free volume
76
utilized in the mattress 150-5 results in a lighter, less dense mattress which
is easier to
maintain and transport.
[00125] FIG. 25 depicts a top perspective view of another exemplary all-foam
mattress assembly 148-6 within another exemplary mattress 150-6 having the
foam
comfort layers 52(1), 52(2), the foam transitional layer 54, and a foam
engineered core
56. The differences between the all-foam mattress assembly 148-6 and the all-
foam
mattress assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and
foster
clarity. With reference to FIG. 25, the foam engineered core 56 may include
the load
distribution member 68 and the decks 62(1), 62(2). The foam engineered core 56
may
also include the plurality of thermoset members 60(1)-60(n) adjacent to the
plurality of
engineered geometric thermoplastic material profiles 58(1)-58(n) in a parallel
arrangement. The foam engineered core 56 may also include a plurality of
thermoplastic
support members 72(1)-72(p) disposed between the plurality of engineered
geometric
thermoplastic material profiles 58(1)-58(n). The foam engineered core 56 may
also
include bulk-free volume 76, in this case between the engineered geometric
thermoplastic
material profiles 58(1)-58(n) and within the thermoplastic support members
72(1)-72(p).
It is noted that the exemplary mattress 150-6 includes optional side supports
154(1),
154(2) and optional side support cushions 156(1), 156(2) which may be disposed
around
a perimeter of the foam engineered core 56. In this manner, the combination of
the
engineered geometric thermoplastic material profiles 58(1)-58(n) and the bulk-
free
volume 76 utilized in the mattress 150-6 results in a lighter, less dense
mattress which is
easier to maintain and transport.
[00126] FIG. 26 depicts a top perspective view of another exemplary all-foam
mattress assembly 148-7 within another exemplary mattress 150-7 having the
foam
comfort layers 52(1), 52(2), the foam transitional layer 54, and a foam
engineered core
56. The differences between the all-foam mattress assembly 148-7 and the all-
foam
mattress assembly 50-1 of FIG. 2 may be discussed to eliminate redundancy and
foster
clarity. With reference to FIG. 26, the foam engineered core 56 may include
the load
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distribution member 68 and the decks 62(1), 62(2). The foam engineered core 56
may
also include the plurality of thermoset members 60(1)-60(n) adjacent to the
plurality of
engineered geometric thermoplastic material profiles 58(1)-58(n) in a parallel
arrangement. The foam engineered core 56 may also include a plurality of
thermoplastic
support members 72(1)-72(p) disposed between the engineered geometric
thermoplastic
material profiles 58(1)-58(n). The foam engineered core 56 may also include
bulk-free
volume 76, in this case between the engineered geometric thermoplastic
material profiles
58(1)-58(n) and within the thermoplastic support members 72(1)-72(p). It is
noted that
the exemplary mattress 150-7 includes optional side supports 154(1), 154(2)
and optional
side support cushions 156(1), 156(2) which may be disposed around a perimeter
of the
foam engineered core 56. In this manner, the combination of the engineered
geometric
thermoplastic material profiles 58(1)-58(p) and the bulk-free volume 76
utilized in the
mattress 150-7 results in a lighter, less dense mattress which is easier to
maintain and
transport.
[00127] Now that different embodiments of foam engineered cores with reference
to
FIGS. 20 through 26 have been introduced, different embodiments of
thermoplastic
profiles may be discussed in regard to FIGS. 27 through 36D as potential
components to
reduce density of the foam engineered core 56.
[00128] FIGS. 27A-27I are top perspective views of alternative cellular
thermoplastic
foam profiles 160A-160I, respectively, that may serve as one of a plurality of
thermoplastic support members within a foam engineered core, or may be
encapsulated
or filled with a thermoset material to serve as one of a plurality of
engineered geometric
thermoplastic material profiles within the foam engineered core. The
thermoplastic foam
profiles 160A-160I may be provided according to any of the embodiments
disclosed
herein for providing a thermoplastic foam profile, a thermoplastic foam
profile with
thermoset disposed therein, or a unitary composite cushioning structure with
thermoset
bonded to thermoplastic with a stratum. As illustrated therein, thermoplastic
foam
profiles 160A-160I may be constructed out of a thermoplastic material
including foam.
The thermoplastic foam profiles 160A-160I may have one or more chambers 162A-
162I,
which may be open or closed and which can either be left void or filled with a
thermoset
material to provide a unitary composite cushioning structure. The
thermoplastic foam
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profiles 160A-160I can also be encapsulated with a thermoset material in
addition to or in
lieu of being filled with a thermoset material as part of a composite
structure. All other
possibilities for thermoplastic foam profiles, thermoset materials, and
unitary composite
cushioning structures discussed above are also possible for the thermoplastic
foam
profiles 160A-160I in FIGS. 27A-27I.
[00129] As another example, FIGS. 28A and 28B are a perspective view and a
side
view, respectively, of another exemplary cushioning structure 170 which may
serve
within the foam engineered core 56 as either one of the thermoplastic support
members
72(1)-72(n) or as one of the engineered geometric thermoplastic material
profiles 58(1)-
58(n). The cushioning structure 170 may be comprised of a plurality of unitary
cushioning structures 172. The unitary cushioning structures 172 may be
attached to
each other either cohesively or adhesively in a side-by-side arrangement or
extruded as
one piece, wherein each comprises an outer material 174 with openings 176, 178
disposed therein. A core material 180 may be disposed in either or both of the
openings
176, 178 if desired, as shown in the cushioning structure 170 in FIG. 28A.
Each of the
cushioning structure 170 may be configured to be extruded with the openings
176, 178
present as one piece. The outer material 174 may be comprised of a cellular
thermoplastic material and the core material 180 comprised of thermoset
material, or vice
versa. Alternatively, the core material 180 may not be included to provide
hollow
portions disposed within the openings 176, 178.
[00130] As another example, FIG. 28C illustrates a side profile of another
exemplary
cushioning structure 182 which may serve within the foam engineered core 56 as
the
engineered geometric thermoplastic material profiles 58(1)-58(n) and the
thermoset
members 60(1)-60(n). The cushioning structure 182 may be comprised of a
plurality of
unitary cushioning structures 184. The unitary cushioning structures 184 may
be
attached to each other either cohesively or adhesively in a side-by-side
arrangement or
extruded as one piece, wherein each may comprise an outer material 186 with
openings
188, 190 disposed therein. A core material 192 may be disposed in either or
both of the
openings 188, 190 if desired, as shown in FIG. 28C. Each of the unitary
cushioning
structure 184 may be extruded with the openings 188, 190 present as one piece.
The
outer material 186 may be comprised of a cellular thermoplastic material and
the core
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material 192 may be comprised of thermoset material, or vice versa.
Alternatively, the
core material 192 may not be included to provide hollow portions disposed
within the
openings 188, 190. Additional openings 194 may be formed by the arrangement of
the
unitary cushioning structures 184 being disposed side-by-side.
[00131] As another example, FIG. 28D illustrates a side profile of another
exemplary
unitary composite cushioning structure 196 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 196
may be
comprised of a plurality of unitary cushioning structures 198. The unitary
cushioning
structures 198 may be attached to each other either cohesively or adhesively
in a side-by-
side arrangement or extruded as one piece, wherein each comprises an outer
material 200
with openings 202A, 202B, 204 disposed therein. A core material 206 may be
disposed
in some or all of the openings 202A, 202B, 204 if desired, as shown in FIG.
28D. Each
of the unitary cushioning structures 198 may be extruded with the openings
202A, 202B,
204 present as one piece. The outer material 200 may be comprised of a
cellular
thermoplastic material and the core material 206 may be comprised of thermoset
material, or vice versa. Alternatively, the core material 206 may not be
included to
provide hollow portions disposed within the openings 202A, 202B, 204.
Additional
openings 208 may be formed by the arrangement of the unitary cushioning
structures 198
being disposed side-by-side.
[00132] As another example, FIG. 29A illustrates a side profile of another
exemplary
unitary composite cushioning structure 210 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 210
may
comprise a first layer 212 of a closed composite cushioning structure 214A to
provide a
base cushioning and support structure. The unitary composite cushioning
structure 210
comprises an outer material 216 arranged to provide side-by-side triangular
structures
218A-218C each having openings 220A-220C disposed therein. A core material
222A-
222C may be disposed in the openings 220A-220C, if desired. The outer material
216
may be extruded with the openings 220A-220C present as one piece. The outer
material
216 may be comprised of a cellular thermoplastic material and the core
material 222A-
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222C comprised of thermoset material, or vice versa. Alternatively, the core
material
222A-222C may not be included to provide a hollow portion disposed within the
openings 220A-220C. With continuing reference to FIG. 29A, a second layer 224
may
comprise a composite cushioning structure 214B that may be the same as the
structure
214A provided in the first layer 212, but flipped one-hundred eighty (180)
degrees and
disposed on top of the first layer 212 and secured either cohesively or
adhesively. In this
manner, additional openings 226A, 226B may be disposed in the unitary
composite
cushioning structure 210. FIG. 29B illustrates a unitary composite cushioning
structure
210' that may be the same as the unitary composite cushioning structure 210,
except that
ends 228A, 228B may be closed off to form additional openings 230A, 230B.
[00133] As another example, FIG. 30 illustrates a side profile of another
exemplary
unitary composite cushioning structure 232 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 232
may
comprise a first layer 234 of a closed composite cushioning structure 236A to
provide a
base cushioning and support structure. The closed composite cushioning
structure 236A
comprises an outer material 238 arranged to provide three (3) side-by-side
circular
structures 240A-240C each having openings 242A-242C disposed therein. A core
material 244A-244C may be disposed in the openings 242A-242C if desired. The
outer
material 238 may be extruded with the openings 242A-242C present as one piece.
The
outer material 238 may be comprised of a cellular thermoplastic material and
the core
material 244A-244C comprised of thermoset material, or vice versa.
Alternatively, the
core material 244A-244C may not be included to provide a hollow portion
disposed
within the openings 242A-242C. With continuing reference to FIG. 30, a second
layer
246 comprised of a composite cushioning structure 236B that may be the same as
provided in the first layer 234 may be provided and disposed atop the first
layer 234 and
secured either cohesively or adhesively.
[00134] As another example, FIG. 31A illustrates a side profile of another
exemplary
unitary composite cushioning structure 248 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 248
may be
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comprised of a first layer 250 of a closed unitary composite cushioning
structure 252 to
provide a base cushioning and support structure. The unitary composite
cushioning
structure 252 may comprise an outer material 254 with openings 256 disposed
therein. A
core material 258 may be disposed in the openings 256 if desired. The outer
material 254
may be extruded with the openings 256 present. The outer material 254 may be
comprised of a cellular thermoplastic material and the core material 258 may
be
comprised of thermoset material, or vice versa. Alternatively, the core
material 258 may
not be included to provide a hollow portion disposed within the outer material
254. With
continuing reference to FIG. 31A, a second layer 260 of an open cushioning
structure
262 comprised of an outer material 264 having a structure 266 with an opening
268
disposed therein.
[00135] As another example, FIG. 31B illustrates a side profile of another
exemplary
unitary composite cushioning structure 270 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 270
may be
comprised of a first layer 272 of a closed unitary composite cushioning
structure 274 to
provide a base cushioning and support structure. The closed unitary composite
cushioning structure 274 comprises an outer material 276 with openings 278
disposed
therein. A core material 280 may be disposed in the openings 278 if desired.
The outer
material 276 may be extruded with the openings 278 present. The outer material
276
may be comprised of a cellular thermoplastic material and the core material
280
comprised of thermoset material, or vice versa. Alternatively, the core
material 280 may
not be included to provide a hollow portion disposed within the outer material
276. With
continuing reference to FIG. 31B, a second layer 282 of an open cushioning
structure
284 comprised of an outer material 286 having a structure 288 with an opening
290
disposed therein. It is noted that the structure 288 of FIG. 31B may be larger
than the
structure 266 of FIG. 31A to provide additional support for the user.
[00136] As another example, FIG. 32 illustrates a side profile of another
exemplary
unitary composite cushioning structure 300 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 300
may be
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comprised of a first layer 302 of a closed unitary composite cushioning
structure 304 to
provide a base cushioning and support structure. The closed unitary composite
cushioning structure 304 comprises an outer material 306 with openings 308
disposed
therein. A core material 310 may be disposed in the openings 308 if desired.
The outer
material 306 may be extruded with the openings 308 present. The outer material
306
may be comprised of a cellular thermoplastic material and the core material
310
comprised of thermoset material, or vice versa. Alternatively, the core
material 310 may
not be included to provide a hollow portion disposed within the outer material
306.
[00137] With continuing reference to FIG. 32, a second layer 312 of closed
cushioning structures 314A, 314B comprised of an outer materials 316A, 316B
having
openings 318A, 318B disposed therein with extension members 320A, 320B may be
disposed atop the first layer 302 in the Y direction either cohesively or
adhesively. A
core material 322A, 322B may be disposed within the openings 318A, 318B of the
cushioning structures 314A, 314B if desired. The cushioning structures 314A,
314B may
be comprised of a cellular thermoplastic material and the core materials 322A,
322B may
comprise thermoset material, or vice versa. Alternatively, the core materials
322A, 322B
may not be included to provide a hollow portion disposed within the cushioning
structures 314A, 314B.
[00138] As another example, FIG. 33 illustrates a side profile of another
exemplary
unitary composite cushioning structure 324 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 324
may
contain the same second layer 312 as in FIG. 32. However, a first layer 326 of
the
unitary composite cushioning structure 324 may comprise an alternative closed
unitary
composite cushioning structure 328 to provide a base cushioning and support
structure.
The unitary composite cushioning structure 324 comprises an outer material 330
with
openings 332 disposed therein. The openings 332 are semi-circular shaped in
this
embodiment. A core material 334 may be disposed in the openings 332 if
desired. The
outer material 330 may be extruded with the openings 332 present. The outer
material
330 may be comprised of a cellular thermoplastic material and the core
material 334
comprised of thermoset material, or vice versa. Alternatively, the core
material 334 may
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not be included to provide a hollow portion disposed within the outer material
330.
Circular voids 332A, 332B may be disposed on ends 334A, 334B of the first
layer 326.
[00139] As another example, FIG. 34 illustrates a side profile of another
exemplary
unitary composite cushioning structure 336 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 336
may
comprise a first layer 338 including a closed unitary composite cushioning
structure 340
to provide a base cushioning and support structure. The closed unitary
composite
cushioning structure 340 may comprise an outer material 342 with openings 344,
346,
348 disposed therein with a core material 350 disposed in the openings 344,
346, 348 to
provide the closed unitary composite cushioning structure 340. The outer
material 342
may be extruded with the openings 344, 346, 348 present, or the openings 344,
346, 348
may be portions of the outer material 342 cut from internal portions. The
outer material
342 may be comprised of a cellular thermoplastic material and the core
material 350
comprised of thermoset material, or vice versa. Alternatively, the core
material 350 may
not be included to provide a hollow portion disposed within the outer material
342.
[00140] With continuing reference to FIG. 34, a second layer 352 of a
cushioning
structure 354 may be provided in the form of an arch-shaped member with an
open
profile disposed atop of the first layer 338 in the Y direction either
cohesively or
adhesively. A core material 356 may be disposed within the cushioning
structure 354 if
desired. The cushioning structure 354 may comprise a cellular thermoplastic
material and
the core materials 356 may comprise thermoset material, or vice versa.
Alternatively, the
core material 356 may not be included to provide a hollow portion disposed
within the
cushioning structure 354.
[00141] As another example, FIG. 35A illustrates a side profile of another
exemplary
unitary composite cushioning structure 358 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 358
may be
comprised of a first layer 360 of closed unitary composite cushioning
structures 362A,
362B arranged side-by-side and cohesively or adhesively attached to each other
to
provide a base cushioning and support structure. Each of the unitary composite
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cushioning structures 362A, 362B comprise an outer material 364A, 364B with
openings
366A, 366B, 368A, 368B, 370A, 370B disposed therein with a core material 372A,
372B
disposed in the openings 366A-370B to provide the unitary composite cushioning
structures 362A, 362B. The outer materials 364A, 364B may be extruded with the
openings 366A-370B present, or the openings 366A-370B may be portions of the
outer
materials 364A, 364B cut from internal portions. The outer materials 364A,
364B may
comprise a cellular thermoplastic material and the core materials 372A, 372B
may
comprise thermoset material, or vice versa. Alternatively, the core materials
372A, 372B
may not be included to provide a hollow portion disposed within the outer
materials
364A, 364B.
[00142] With continuing reference to FIG. 35A, a second layer 374 of
cushioning
structures 376A, 376B arranged side-by-side and each provided in the form of
an arch-
shaped member with an open profile is disposed on top of the first layer 360
in the Y
direction either cohesively or adhesively. Core materials 378A, 378B may be
disposed
within the cushioning structures 376A, 376B if desired. The cushioning
structures 376A,
376B may comprise a cellular thermoplastic material and the core materials
378A, 378B
may comprise thermoset material, or vice versa. Alternatively, the core
materials 378A,
378B may not be included to provide a hollow portion disposed within the
cushioning
structures 376A, 376B.
[00143] As another example, FIG. 35B illustrates a side profile of another
exemplary
unitary composite cushioning structure 380 which may serve within the foam
engineered
core 56 as the engineered geometric thermoplastic material profiles 58(1)-
58(n) and the
thermoset members 60(1)-60(n). The unitary composite cushioning structure 380
may be
similar to the unitary composite cushioning structure 358 in FIG. 35A, except
that the
first layer provides a modified profile. In this regard, the unitary composite
cushioning
structure 380 may comprise a first layer 382 of closed unitary composite
cushioning
structures 384A, 384B arranged side-by-side and cohesively or adhesively
attached to
each other to provide a base cushioning and support structure. Each of the
unitary
composite cushioning structure 384A, 384B may comprise an outer material 386A,
386B
with openings 388A, 388B, 390A, 390B, 392A, 392B disposed therein with a core
material 394A, 394B disposed in the openings 388A-392B to provide the unitary
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composite cushioning structures 384A, 384B. The outer materials 386A, 386B may
be
extruded with the openings 388A-392B present, or the openings 388A-392B may be
portions of the outer materials 386A, 386B cut from internal portions. The
outer
materials 386A, 386B may comprise a cellular thermoplastic material and the
core
materials 394A, 394B may comprise thermoset material, or vice versa.
Alternatively, the
core materials 394A, 394B may not be included to provide a hollow portion
disposed
within the outer materials 386A, 386B.
[00144] With continuing reference to FIG. 35B, a second layer 396 of
cushioning
structures 398A, 398B arranged side-by-side and each provided in the form of
an arch-
shaped member with an open profile is disposed on top of the first layer 382
in the Y
direction either cohesively or adhesively. Core materials 400A, 400B may be
disposed
within the cushioning structures 398A, 398B if desired. The cushioning
structures 398A,
398B may comprise a cellular thermoplastic material and the core materials
400A, 400B
may comprise thermoset material, or vice versa. Alternatively, the core
materials 400A,
400B may not be included to provide a hollow portion disposed within the
cushioning
structures 398A, 398B.
[00145] As another example, FIG. 36A illustrates a side profile view of
another
unitary composite cushioning structure 402(1). The unitary composite
cushioning
structure 402(1) may include an outer material 404 having the closed profile.
The profile
of the unitary composite cushioning structure 402(1) may comprise a base
portion 406
and a head portion 408 having neck portions 410A, 410B disposed therebetween.
The
profile of the neck portions 410A, 410B may define the size and shape of the
head
portion 408. A core material 412 may be disposed inside an opening 414
disposed in the
outer material 404 to provide the unitary composite cushioning structure
402(1). The
outer material 404 may comprise a cellular thermoplastic material and the core
material
412 may comprise thermoset material, or vice versa. Alternatively, the core
material 412
may not be included to provide a hollow portion disposed within the outer
material 404.
[00146] As another example, FIG. 36B illustrates a side profile view of
another
unitary composite cushioning structure 402(2). The unitary composite
cushioning
structure 402(2) may include an outer material 416 having an open profile with
opening
418. The profile of the unitary composite cushioning structure 402(2) may
comprise a
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base portion 420 and a head portion 422 having neck portions 424A, 424B
disposed
therebetween. The profile of the neck portions 424A, 424B may define a size
and shape
of the head portion 422. A core material 426 may be disposed inside the base
portion
420. The base portion 420 may comprise a cellular thermoplastic material and
the core
material 426 may comprise thermoset material, or vice versa. An intermediate
material
428 may be disposed inside the head portion 422, which may be disposed around
a core
material 430, as illustrated in FIG. 36B. The outer material 416, the
intermediate
material 428, and the core material 426 may comprise a cellular thermoplastic
material or
thermoset materials, in any combination of each.
[00147] FIGS. 36C and 36D illustrate the same head portion 422 in FIG. 36B,
but
with different base portion arrangements. In FIG. 36C, a unitary composite
cushioning
structure 402(3) is provided that provides core material 426A, 426B only in
smaller,
separate designated portions of the base portion 420. In the unitary composite
cushioning
structure 402(4) in FIG. 36D, a base portion 432 may be provided which
includes a
different profile with a base material 434 not including openings for
disposition of a core
material. It is noted that the unitary composite cushioning structures 402(1)-
402(4) may
serve within the foam engineered core 56 as the engineered geometric
thermoplastic
material profiles 58(1)-58(n) and the thermoset members 60(1)-60(n).
[00148] Many modifications of the embodiments set forth herein will come to
mind to
one skilled in the art to which the embodiments pertain having the benefit of
the
teachings presented in the foregoing descriptions and the associated drawings.
Therefore,
it is to be understood that the description and claims are not to be limited
to the specific
embodiments disclosed and that modifications and other embodiments are
intended to be
included within the scope of the appended claims. It is intended that the
embodiments
cover the modifications and variations of the embodiments provided they come
within the
scope of the appended claims and their equivalents. Although specific terms
are
employed herein, they are used in a generic and descriptive sense only and not
for
purposes of limitation.
46
