US20160157628A1 - Multilayered cushion for mattress and furniture applications - Google Patents
Multilayered cushion for mattress and furniture applications Download PDFInfo
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- US20160157628A1 US20160157628A1 US14/962,768 US201514962768A US2016157628A1 US 20160157628 A1 US20160157628 A1 US 20160157628A1 US 201514962768 A US201514962768 A US 201514962768A US 2016157628 A1 US2016157628 A1 US 2016157628A1
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- Prior art keywords
- layer
- cushion
- height
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Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/122—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with special fibres, such as acrylic thread, coconut, horsehair
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/121—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with different inlays
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/127—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with reinforcement sheets, grids or the like
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/70—Upholstery springs ; Upholstery
Definitions
- This disclosure relates to a cushion that may be used for mattresses, furniture, or car seats, as examples.
- a cushion that may be used for mattresses, furniture, or car seats, as examples.
- most cushions are made of a single, solid material, which is either molded or cut from a larger block of material to fit a certain size. While foam is used for many applications, the softness and stiffness of foam is not easily changed.
- This disclosure relates to a multilayered cushion. Layers of different materials are arranged to provide desirable Indentation Load Deflection (ILD), stiffness, and/or softness values.
- ILD Indentation Load Deflection
- a multilayered cushion includes, among other things, a first layer of a first material, a second layer of the first material, and a third layer of a second material between the first and second layers.
- the second material is stiffer than the first material.
- FIG. 1 is a side view of a sample of a first material.
- FIG. 2 is a side view of an example multilayered cushion according to this disclosure.
- FIG. 3 is a close-up view of the encircled area in FIG. 1 , and illustrates the detail of the first material.
- the cushion may include layers of polyester, polypropylene, fiberglass, polyethylene, foam, or other polymeric fibers.
- the layers of different materials are arranged such that the ILD, stiffness, and/or softness meets specific values.
- ILD is an example measurement for “feel.”
- the ILD of a material is the amount of pounds (measured as resistant force) required to compress a sample of material to 25% of its original height.
- the ILD of 4 inch thick, 15 inch by 15 inch sample is the amount of pounds required to compress the sample to a height of 3 inches. ILD can also be measured as the original height continues to be compressed beyond a 25% reduction.
- FIG. 1 is a side view of the first sample 12 .
- the first sample 12 includes an upper surface 16 , a lower surface 18 , and opposing side surfaces 20 , 22 .
- the first sample 12 has an original height H 1 between the upper and lower surfaces 16 , 18 . In one example, the height H 1 is 4 inches (10.16 cm).
- the density of the first material is between 1.5-3.5 pounds per cubic foot (lb/ft 3 ) (about 36.84-43.25 kg/m 3 ), and in one particular embodiment the density is 2.5 lb/ft 3 (40.04 kg/m 3 ).
- the first material is a three-dimensional netted material of a plurality of helically arranged thermoplastic resin filaments, such as a material called Indura SpringTM, a product offered for sale by Indratech LLC.
- the first material includes thermoplastic resin filaments 24 partially thermally bonded to at least one of the other thermoplastic resin filaments 24 , at locations 26 .
- the thermoplastic resin filaments 24 are helically arranged and are randomly entangled with one another.
- FIGS. 1 and 3 show one example first material, other materials come within the scope of this disclosure.
- FIG. 2 shows an example cushion 28 from a side view.
- the cushion 28 is formed by dividing the first sample 12 at a point 30 ( FIG. 1 ) along its height H 1 .
- the point 30 is a distance D from the upper surface 16 , and in one example is a midpoint substantially between the upper and lower surfaces 16 , 18 .
- the height H 1 is 4 inches (10.16 cm)
- the distance D is 2 inches (5.08 cm).
- This disclosure is not limited to samples having heights H 1 of only 4 inches.
- this disclosure is not limited to examples where the cushion 28 is formed by “dividing” a single piece of the first material. Two separately formed pieces of the first material could be provided, for example.
- the distance D measured from the upper surface 16 , can be referred to as a “depth,” and is also a location where the second sample 14 will be provided in the cushion 28 .
- the depth of the second sample will influence the properties of the cushion, as discussed below.
- the distance D can be provided at points 30 other than the midpoint between the upper and lower surfaces 16 , 18 .
- the first sample 12 has been divided into a first, upper layer 32 and a second, lower layer 34 .
- the first layer 32 has a height H 2 and the second layer 34 has a height H 3 .
- the heights H 2 and H 3 are equal to one another, and are each substantially 2 inches (5.08 cm).
- the example cushion 28 includes a third, middle layer 36 provided by the second sample 14 of the second material.
- the third layer 36 is bonded to the first and second layers 32 , 34 by adhesive and/or by tufting.
- the third layer 36 has a height H 4 , which is less than the heights H 2 and H 3 in this example.
- the height H 4 of the second sample 14 is within a range of 0.3-0.7 inches (about 0.76 cm to 1.78 cm).
- the height H 4 is 0.5 inches.
- the overall cushion height is substantially 4.5 inches (11.43 cm).
- the second material is stiffer than the first material. Further, in one example, the second material has a density within a range of 1.2-6.0 lb/ft 3 (about 28.83-35.24 kg/m 3 ). In one particular example the density of the second sample 14 is denser than the first material, and in one example is 3.0 lb/ft 3 (32.03 kg/m 3 ).
- One example of the second sample 14 is PET (polyethylene terephthalate), although other materials come within the scope of this disclosure.
- the resulting cushion 28 feels soft under low pressure, yet firm under high pressure.
- the above-described multilayered cushion would have a low ILD when at 25% compression (e.g., height reduced by 25% from the manufactured height), and a high ILD reading at 65% compression.
- the third layer 36 helps distribute the load to the lower layer 34 . For example, when single point deflections are applied to the upper layer 32 , the upper layer 32 will deform only under the point of contact, which means the amount of force deflected will be low and it will feel soft.
- the third, middle layer 36 will distribute the load more evenly over the lower layer 34 , which means the amount of force deflected would be much higher than if the cushion was completely made of a single material (such as in the example of FIG. 1 ).
- Table 1 shows the results of the cushion 28 based on variable depths D of the third layer 36 . As mentioned above, adjusting the depth D will provide the cushion 28 with different properties. Table 1 shows the response to the cushion 28 at different depths D, and specifically shows the ILD at 25% compression as well as the height loss after 10 thousand cycles of pounding.
- the first row shows the response of a standard 4 inch height sample of the first material without the third layer 36 (i.e., as substantially shown in FIG. 1 ).
- the next three rows show the response using sample of the first material having an original height H 1 of substantially 4 inches, and the third layer 36 having a height of H 3 substantially 0.5 inches.
- the depth D is 1 inch, for example, the height H 2 is 1 inch and the height H 3 is 3 inches—and vice versa when the depth D is 3 inches.
- an appropriate depth D can be selected.
- the cushion 28 can be “tuned” by adjusting the depth D of the third layer 36 to provide a higher ILD (for firm feel) and/or lower height loss (better resiliency).
Abstract
Description
- This disclosure claims the benefit of U.S. Provisional Application No. 62/089,531, filed Dec. 9, 2014, the entirety of which is herein incorporated by reference.
- This disclosure relates to a cushion that may be used for mattresses, furniture, or car seats, as examples. Currently, most cushions are made of a single, solid material, which is either molded or cut from a larger block of material to fit a certain size. While foam is used for many applications, the softness and stiffness of foam is not easily changed.
- This disclosure relates to a multilayered cushion. Layers of different materials are arranged to provide desirable Indentation Load Deflection (ILD), stiffness, and/or softness values.
- A multilayered cushion according to an exemplary aspect of the present disclosure includes, among other things, a first layer of a first material, a second layer of the first material, and a third layer of a second material between the first and second layers. The second material is stiffer than the first material.
- The drawings can be briefly described as follows:
-
FIG. 1 is a side view of a sample of a first material. -
FIG. 2 is a side view of an example multilayered cushion according to this disclosure. -
FIG. 3 is a close-up view of the encircled area inFIG. 1 , and illustrates the detail of the first material. - This disclosure relates to a multilayered cushion for mattresses, furniture, or car seats, as examples. In particular, the cushion may include layers of polyester, polypropylene, fiberglass, polyethylene, foam, or other polymeric fibers. The layers of different materials are arranged such that the ILD, stiffness, and/or softness meets specific values.
- ILD is an example measurement for “feel.” The ILD of a material is the amount of pounds (measured as resistant force) required to compress a sample of material to 25% of its original height. In one example, the ILD of 4 inch thick, 15 inch by 15 inch sample is the amount of pounds required to compress the sample to a height of 3 inches. ILD can also be measured as the original height continues to be compressed beyond a 25% reduction.
- One example cushion according to this disclosure is formed by separating a
first sample 12 of a first material (FIG. 1 ) and providing asecond sample 14 of a second material (FIG. 2 ) between two layers of the first material.FIG. 1 is a side view of thefirst sample 12. As shown, thefirst sample 12 includes anupper surface 16, alower surface 18, and opposingside surfaces first sample 12 has an original height H1 between the upper andlower surfaces - In this example, the density of the first material is between 1.5-3.5 pounds per cubic foot (lb/ft3) (about 36.84-43.25 kg/m3), and in one particular embodiment the density is 2.5 lb/ft3 (40.04 kg/m3). While different types of materials come within the scope of this disclosure, in one particular example the first material is a three-dimensional netted material of a plurality of helically arranged thermoplastic resin filaments, such as a material called Indura Spring™, a product offered for sale by Indratech LLC.
- In that example, and with reference to
FIG. 3 , the first material includesthermoplastic resin filaments 24 partially thermally bonded to at least one of the otherthermoplastic resin filaments 24, atlocations 26. Thethermoplastic resin filaments 24 are helically arranged and are randomly entangled with one another. Again, whileFIGS. 1 and 3 show one example first material, other materials come within the scope of this disclosure. -
FIG. 2 shows anexample cushion 28 from a side view. In this example, thecushion 28 is formed by dividing thefirst sample 12 at a point 30 (FIG. 1 ) along its height H1. In this example, thepoint 30 is a distance D from theupper surface 16, and in one example is a midpoint substantially between the upper andlower surfaces cushion 28 is formed by “dividing” a single piece of the first material. Two separately formed pieces of the first material could be provided, for example. - The distance D, measured from the
upper surface 16, can be referred to as a “depth,” and is also a location where thesecond sample 14 will be provided in thecushion 28. The depth of the second sample will influence the properties of the cushion, as discussed below. To this end, the distance D can be provided atpoints 30 other than the midpoint between the upper andlower surfaces - In the example cushion of
FIG. 2 , thefirst sample 12 has been divided into a first,upper layer 32 and a second,lower layer 34. Thefirst layer 32 has a height H2 and thesecond layer 34 has a height H3. In this example, because thepoint 30 was a midpoint of the height H1, the heights H2 and H3 are equal to one another, and are each substantially 2 inches (5.08 cm). - The
example cushion 28 includes a third,middle layer 36 provided by thesecond sample 14 of the second material. Thethird layer 36 is bonded to the first andsecond layers third layer 36 has a height H4, which is less than the heights H2 and H3 in this example. In one particular example, where the height H1 is 4 inches, the height H4 of thesecond sample 14 is within a range of 0.3-0.7 inches (about 0.76 cm to 1.78 cm). In one particular embodiment, the height H4 is 0.5 inches. In that same embodiment, the overall cushion height is substantially 4.5 inches (11.43 cm). - In this example, the second material is stiffer than the first material. Further, in one example, the second material has a density within a range of 1.2-6.0 lb/ft3 (about 28.83-35.24 kg/m3). In one particular example the density of the
second sample 14 is denser than the first material, and in one example is 3.0 lb/ft3 (32.03 kg/m3). One example of thesecond sample 14 is PET (polyethylene terephthalate), although other materials come within the scope of this disclosure. - Given the arrangement and combination of materials described above, the resulting
cushion 28 feels soft under low pressure, yet firm under high pressure. In particular, the above-described multilayered cushion would have a low ILD when at 25% compression (e.g., height reduced by 25% from the manufactured height), and a high ILD reading at 65% compression. Essentially, thethird layer 36, with its increased stiffness, helps distribute the load to thelower layer 34. For example, when single point deflections are applied to theupper layer 32, theupper layer 32 will deform only under the point of contact, which means the amount of force deflected will be low and it will feel soft. But as that single point is pushed down further, the third,middle layer 36 will distribute the load more evenly over thelower layer 34, which means the amount of force deflected would be much higher than if the cushion was completely made of a single material (such as in the example ofFIG. 1 ). - Table 1 shows the results of the
cushion 28 based on variable depths D of thethird layer 36. As mentioned above, adjusting the depth D will provide thecushion 28 with different properties. Table 1 shows the response to thecushion 28 at different depths D, and specifically shows the ILD at 25% compression as well as the height loss after 10 thousand cycles of pounding. The first row shows the response of a standard 4 inch height sample of the first material without the third layer 36 (i.e., as substantially shown inFIG. 1 ). The next three rows show the response using sample of the first material having an original height H1 of substantially 4 inches, and thethird layer 36 having a height of H3 substantially 0.5 inches. When the depth D is 1 inch, for example, the height H2 is 1 inch and the height H3 is 3 inches—and vice versa when the depth D is 3 inches. -
TABLE 1 ILD at 25% Height Loss Compression after 10k cycles Standard sample of material 36 5.0 % Third layer 36 at 1 inch depth (D) 46 3.7 % Third layer 36 at 2 inch depth (D) 48 2.6 % Third layer 36 at 3 inch depth (D) 44 3.5% - Depending on the particular application, an appropriate depth D can be selected. In other words, the
cushion 28 can be “tuned” by adjusting the depth D of thethird layer 36 to provide a higher ILD (for firm feel) and/or lower height loss (better resiliency). - It should be understood that terms such as “generally,” “substantially,” and “about” are not intended to be boundaryless terms, and should be interpreted consistent with the way one skilled in the art would interpret those terms. Further, terms such as “upper” and “lower” are used with reference to the orientation of the cushion in the figures, and should not be considered limiting.
- The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
- Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
- One of ordinary skill in this art would understand that the above-described embodiments are exemplary and non-limiting. That is, modifications of this disclosure would come within the scope of the claims. Accordingly, the following claims should be studied to determine their true scope and content.
Claims (16)
Priority Applications (1)
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US14/962,768 US20160157628A1 (en) | 2014-12-09 | 2015-12-08 | Multilayered cushion for mattress and furniture applications |
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US201462089531P | 2014-12-09 | 2014-12-09 | |
US14/962,768 US20160157628A1 (en) | 2014-12-09 | 2015-12-08 | Multilayered cushion for mattress and furniture applications |
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US20160157628A1 true US20160157628A1 (en) | 2016-06-09 |
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US14/962,768 Abandoned US20160157628A1 (en) | 2014-12-09 | 2015-12-08 | Multilayered cushion for mattress and furniture applications |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160066700A1 (en) * | 2014-09-05 | 2016-03-10 | Yao I Fabric Co., Ltd. | Air permeable cushioning structure |
US20160174725A1 (en) * | 2014-02-23 | 2016-06-23 | C-Eng Co., Ltd. | Core material for cushion, and cushion |
US10806272B2 (en) * | 2016-06-30 | 2020-10-20 | Airweave Inc. | Mattress core material and bed mattress |
US11304536B2 (en) * | 2016-07-28 | 2022-04-19 | Airweave Inc. | Bedding and bedding cover sheet |
US11807143B2 (en) | 2021-12-02 | 2023-11-07 | Lear Corporation | Vehicle seating system and method for producing same |
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Cited By (6)
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