US20180110341A1 - Cushion system - Google Patents

Abstract

Embodiments of the disclosure include a cushion system, which may be part of a sleeping system or a seating system, for example. A seating system may comprise a cushion, which comprises a cushion cover; and one or more foam layers within the cushion cover, wherein the cushion is spring-free. The one or more foam layers may each comprise a plurality of substantially vertical air passageways which pass through the entire thickness of the corresponding foam layer. The one or more foam layers may comprise a base layer of foam; a middle sculpted layer of foam having for example a sculpted surface with a plurality of foam pillars projecting outward; and a top layer of foam with uniform thickness, with the sculpted layer sandwiched between the top and base layers.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims priority to U.S. patent Ser. No. 15/419,386 filed Jan. 30, 2017 and entitled “Ventilating Sleep System” which is a non-provisional of and claims priority to related U.S. provisional patent application Ser. No. 62/289,773 filed Feb. 1, 2016 and entitled “Mattress Ventilating Foundation and Sleep System”. This application also claims priority to U.S. patent Ser. No. 15/183,348 (entitled “Mattress Ventilating Foundation and Sleep System” and filed Jun. 15, 2016) and to related U.S. provisional patent application Ser. No. 62/175,767 (filed Jun. 15, 2015 and entitled “Mattress Ventilating Foundation and Sleep System”); and to U.S. patent application Ser. No. 14/681,278 (entitled “Independent Foam Spring Mattress” and filed Apr. 8, 2015), and to related provisional patent application Ser. No. 61/977,989 (entitled “Independent Foam Spring Mattress” and filed Apr. 10, 2014). Thus, this application claims priority to all six applications set forth above. All of the above-cited priority documents are hereby incorporated by reference for all purposes as if reproduced in their entirety to the extent that they are compatible (e.g. not inconsistent) with and/or do not directly contradict disclosure herein (e.g. the explicit disclosure herein would always govern/trump in instances of contradiction, inconsistency, or incompatibility).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
• Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
• For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
• FIG. 1A is a schematic diagram illustrating an exemplary sleep/bedding system, in which a mattress may be used atop one of two possible ventilating foundation exemplary variants;
• FIG. 1B is a schematic diagram illustrating an alternate exemplary sleep/bedding system, in which a mattress may be used atop one of two possible ventilating foundation exemplary variants;
• FIGS. 1Ca, 1Cb and 1Cc illustrate a detailed embodiment of a sleep/bedding system similar to that ofFIG. 1B and having an internal air input unit with optional HEPA filter and an access panel, withFIG. 1Ca showing a side view,FIG. 1Cb showing an end view (from the foot of the bed), andFIG. 1Cc showing a top view;
• FIGS. 1Da, 1Db and 1Dc illustrate a detailed embodiment of a sleep/bedding system similar to that ofFIG. 1B and having an external air input unit with optional HEPA filter and an access panel, withFIG. 1Da showing a side view,FIG. 1Db showing an end view (from the foot of the bed), andFIG. 1Dc showing a top view;
• FIG. 1E illustrates a perspective view of an exemplary sleep/bedding system similar toFIGS. 1Ca, 1Cb and 1Cc;
• FIGS.2A1 and2A2 illustrate an exemplary mattress embodiment (without the cover being shown, to allow viewing of internal components) which is an all-foam (e.g. spring-free) mattress configured for ventilation, with FIG.2A1 showing an exploded perspective view of an exemplary mattress and FIG.2A2 showing a cut-away (e.g. cross-section) elevation view of the exemplary mattress of FIG.2A1;
• FIGS.2B1 and2B2 illustrate an exemplary mattress embodiment (similar to that of FIG.2A1 in configuration, but comprising different foam materials for at least some of the layers) configured for ventilation, with FIG.2B1 showing an exploded perspective view of an exemplary mattress and FIG.2B2 showing a cut-away (e.g. cross-section) elevation view of the exemplary mattress of FIG.2B1;
• FIG. 3 illustrates a top/plan view of an exemplary base (sculpted) layer of foam (of the sort that might be used in FIG.2A1, for example);
• FIG. 4 illustrates a bottom/plan view of an exemplary middle sculpted foam layer (of the sort that might be used in FIG.2A1, for example);
• FIGS. 5A and 5B illustrate exemplary mattress embodiments configured for ventilation;
• FIGS. 6A and 6B illustrate detailed views of the middle sculpted foam layers;
• FIGS. 7A and 7B illustrate alternative detailed views of the middle sculpted foam layers; and
• FIG. 8 illustrates an exemplary base foam layer similar to that shown and described inFIG. 3.
• FIG. 9A illustrates an exemplary cushion embodiment (without the cover being shown, to allow viewing of internal components) which is an all-foam (e.g. spring-free) cushion configured for seating.
• FIG. 9B illustrates an exemplary cover that may be installed over the cushion shown inFIG. 9A.
• FIG. 10 illustrates a cut-away (e.g. cross-section) elevation view of an exemplary cushion embodiment.
• FIG. 11 illustrates a cut-away (e.g. cross-section) elevation view of another exemplary cushion embodiment.
• FIG. 12 illustrates a cut-away (e.g. cross-section) elevation view of another exemplary cushion embodiment.
• FIG. 13 illustrates a cut-away (e.g. cross-section) elevation view of another exemplary cushion embodiment.
• FIG. 14 illustrates a cut-away (e.g. cross-section) elevation view of an exemplary cushion embodiment comprising one or more pinholes through one or more layers of the cushion.
• FIG. 15 illustrates a cut-away (e.g. cross-section) elevation view of another exemplary cushion embodiment comprising one or more pinholes through one or more layers of the cushion.
• FIG. 16 illustrates a cut-away (e.g. cross-section) elevation view of another exemplary cushion embodiment comprising one or more pinholes through one or more layers of the cushion.
• FIG. 17 illustrates a cut-away (e.g. cross-section) elevation view of another exemplary cushion embodiment comprising one or more pinholes through one or more layers of the cushion.
• FIG. 18 illustrates an exploded perspective view of the cushion as described inFIG. 14.
• FIG. 19 illustrates another exploded perspective view of the cushion as described inFIG. 14.
• FIG. 20 illustrates an exploded perspective view of the cushion as described inFIG. 1.
DETAILED DESCRIPTION
• It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.
• The following brief definition of terms shall apply throughout the application:
• The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context.
• The term “foam” means a material in a lightweight cellular form, for example resulting from introduction of gas bubbles during manufacture to produce a consistent cell structure, and/or any of various light, porous, semirigid or spongy materials or cellular solids, usually the solidified form of a liquid full of gas bubbles, which may be used as a building material or for shock absorption, and includes open cell foams such as polyurethane foam, latex, memory foam, specialty memory foam, gel memory foam, gel latex foam or other gel foams, etc.;
• The term “IFD” means indentation force deflection, and describes a well-known measurement system for foam firmness;
• Directions, such as up (e.g. upward) and/or down (e.g. downward), typically are intended to be based on the mattress (or sleep system or foundation) in its normal sleeping position as understood by persons of skill; for example, the upper surface of the mattress might face the ceiling and/or serve as the sleep surface upon which the user might lie, while the bottom surface of the mattress might face the floor or ground and/or be placed atop a foundation;
• The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);
• If the specification describes something as “exemplary” or as an “example,” it should be understood that refers to a non-exclusive example:
• The terms “about” or “approximately” or the like, when used with a number may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field (for example, +/−10%); and
• If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.
• Typical sleep or bedding systems may have a conventional (typically inner-spring) cushion (or mattress) located atop a conventional box spring foundation unit. In such conventional sleep systems, there is typically no interaction between the mattress and the box spring foundation, other than the fact that the box spring foundation supports (e.g. underlies) the mattress. While conventional sleep systems may be sufficient for some sleepers/users, many users might desire and are looking for an improved sleep experience.
• For example, many users might find conventional sleep systems rather hot (especially when the mattress includes foam, and most especially when the mattress includes memory foam), resulting in a rather sweaty, uncomfortable night's sleep of the sort that may result in restlessness and lack of deep slumber. Other users may have allergy problems, and a conventional mattress may, over time, collect dust and other allergens that might trouble the user during sleep. Additionally, conventional inner-spring mattresses may not support the user's body as effectively as desired, perhaps resulting in discomfort.
• Similar cushions may also be used for seating systems, such as chairs, sofas, vehicle seats, and/or supplemental seating cushions, where these seating cushions may suffer from similar issues as the mattress (or sleep cushion) described above.
• The presently disclosed embodiments may address one or more of these issues. For example, disclosed embodiments may provide ventilation (e.g. airflow), such that the cushion may better breathe and/or disperse heat (e.g. improving sleep comfort while a user is atop the mattress, or comfort while a user is sitting on the cushion); disclosed embodiments may refresh the cushion, for example sucking out stale air with potential allergens (which could happen either when the user is atop the cushion or, alternatively, when the user is not on the cushion (for example, based on a timer)); and/or disclosed embodiments may provide superior comfort/support. The disclosed embodiments may comprise cushions, such as mattresses, which may be used in sleep systems. Additionally, the disclosed embodiments may comprise cushions which may be used in seating systems, where similar qualities and/or functions may be desired for sleep systems and seating systems.
• Embodiments of the disclosure typically include a cushion system, which may be part of a sleeping system or a seating system, for example. Such a cushion might comprise; a cover; and two or more foam layers comprising: a sculpted foam layer comprising a plurality of foam pillars (e.g. projecting out of at least one (sculpted) surface); and at least one additional foam layer (e.g. typically contacting either the lower or upper surface of the sculpted foam layer. Such cushion embodiment typically would be (metal) spring-free. In some cushion embodiments, the at least one additional foam layer would comprise a base layer of foam (e.g. underlying and in contact with the lower surface of the sculpted foam layer) and/or a top layer of foam (e.g. atop and in contact with the upper surface of the sculpted foam layer). Often, the sculpted foam layer would be sandwiched between the base layer and the top layer of foam (sometimes with other, intermediate (foam) layers therebetween). In some embodiments, the sculpted foam layer would have a single sculpted surface (e.g. with pillars of foam projecting outward), and such sculpted foam surface could be oriented either downward or upward (although typically if oriented upward there would be at least one foam layer located above it to provide a flat upper (e.g. sitting or sleeping) surface. So, typically in cushions having only two foam layers (e.g. only one additional foam layer in addition to the sculpted foam layer), if the sculpted layer is underlain by a base layer then the sculpted layer would be facing downward (e.g. with sculpted layer on the lower surface having pillars projecting downward to contact the base foam layer). In some cushion embodiments, the top and base foam layers may be connected (e.g. formed of a single layer/sheet of foam which has been bent/folded to enwrap the sculpted/middle foam layer. Various exemplary embodiments of such disclosed cushions will be described in more detail below, providing additional, exemplary details (for example with respect to sleep systems and/or seating systems).
• Often, disclosed embodiment sleep systems might have the cushion/mattress and foundation interact with each other (for example, being in fluid communication), to provide one or more such sleep benefits, as persons of skill will understand based on the disclosure below. Typical foundation embodiments might comprise an upper surface (of a cover) allowing airflow therethrough (and typically having an air flow unit (such as a fan or air pump) operable to direct air through the upper surface), while typical mattress embodiments might comprise a bottom surface (of a cover) (and in some embodiments a top surface of the cover) allowing airflow therethrough (and often also including air pathways (such as pinholes) vertically throughout the mattress). So, most disclosed sleep system embodiments typically might have a ventilation mattress atop a ventilation foundation, with airflow therebetween.
• Disclosed embodiments relate generally to mattress ventilation sleep systems (and/or related foundations and/or mattresses), which typically would include a mattress ventilation foundation in conjunction with a mattress (for example, typically located atop the foundation). Typically, the mattress ventilation foundation might comprise a support structure (such as support struts and structural frame, for example, which might be similar to a conventional box spring foundation), operable to support a mattress in a manner similar to a conventional mattress foundation (and which typically might be hollow); an air flow unit (such as a forced air supply unit (e.g. fan) operable to either blow air into the supported mattress atop the foundation or suck air from the supported mattress); and a cover (including an upper, support surface upon which the mattress would lay), which would typically include a means for airflow between the foundation (e.g. the air flow unit) and the supported mattress (e.g. an air permeable element/panel, such as one or more panels of high air flow mesh fabric located in the upper surface of the foundation cover, for example). In some embodiments, the air flow unit might include filtration (such as a HEPA filter), which might for example be located at the intake and/or outtake for the air flow unit. The air flow unit might be housed within the support structure of the foundation in some embodiments, while in other embodiments the air flow unit might be external to (for example, mounted onto) the support structure (for example, mounted onto the bottom surface of the cover/support structure and in fluid communication with the hollow cavity within the cover/support structure by an opening).
• Typically, the foundation cover would surround/enclose/encompass the support structure on all sides, and the foundation cover would be airtight/air impermeable (e.g. formed of an airtight material such as fabric overtop a polyvinyl substrate, for example) except for the attachment/fluid communication port (e.g. inlet/outlet/opening) for the air flow unit (which allows fluid communication between the external environment and the hollow cavity within the foundation, for example) and the means for airflow between the foundation and the supported mattress (e.g. air permeable element/panel, such as high airflow mesh panel(s)). For example, the bottom and side surfaces of the foundation cover would typically be airtight (except for the inlet/outlet/opening for the air flow unit), while the upper surface of the foundation cover (which would typically support and/or contact the bottom surface of the mattress) would include the means for airflow between the foundation (e.g. the air flow unit) and the supported mattress (e.g. at least one air permeable element/panel, such as one or more panels of high air flow mesh fabric located in the upper surface of the foundation cover, for example). In some embodiments, the entire upper surface of the foundation cover might be formed of high airflow mesh fabric, while in other embodiments, the upper surface might include a plurality of panels of such high airflow mesh fabric and/or other means for allowing airflow between the foundation and the supported mattress (such as air passageways).
• Typically, air might flow through the hollow cavity of the foundation to the upper surface of the foundation cover (as directed by the air flow unit, for example), but alternatively, there could be tubing or ducts leading from the air flow unit to the upper surface of the foundation cover (e.g. to specific locations on the upper surface of the foundation cover corresponding to the pinholes in the supported mattress thereupon). In such embodiments, it might not be necessary for the bottom and sides of the foundation cover to be airtight.
• Additionally, some embodiments of the air flow unit might optionally comprise a climate control unit, which might cool and/or heat air flowing through the air flow unit (for example, before the air flows into the supported mattress atop the foundation). In some embodiments, the climate control unit would be located within the housing for the air flow unit, while in other embodiments, the climate control unit might be located external to such housing (e.g. it may be either separate or combined with the blower portion of the air flow unit). Similarly, embodiments of the air flow unit might optionally comprise an air ionizer (for electric sterilization of air prior to entering the foundation) and/or an ultraviolet germicidal irradiation light (for irradiating light sufficiently to substantially destroy harmful microbes, such as bacteria, prior to entering the foundation). As with the optional climate control unit, the air ionizer and/or UV germicidal irradiation light units could be located within the housing for the air flow unit or (in other embodiments) located external to such housing (e.g. each may be either separate or combined with the blower portion of the air flow unit). Typically, the air flow unit might be controlled/operated by a controller, which might be a separate device and which might allow for remote control of the air flow device (e.g. the blower and/or climate control unit). In some embodiments, the controller and/or air flow unit may include a timer, for example allowing the user to set the air flow unit for a regular (for example daily or weekly) refresh cycle. And typically, the air flow unit would be electrically powered (for example with a plug allowing power to be drawn from a standard electrical wall socket).
• So typically in operation, air might be drawn into the foundation (for example by the air flow unit, through the intake opening/fluid communication port), and then forced out the upper surface (for example through a high airflow mesh fabric upper surface or panel(s)) and into the supported mattress. This may allow for a supported mattress to be refreshed with clean air and/or may enhance sleep comfort for a user lying atop the mattress. Alternatively, air might be sucked out of the supported mattress (for example by operating the air flow unit in reverse to create suction), into the foundation (for example through the upper surface of the cover of the foundation, perhaps through one or more high air flow mesh panels), and out the air flow unit's outtake opening/fluid communication port (which might be the same intake opening if the air flow device is operated for blowing instead of suction in some embodiments). In some embodiments, the air flow unit might be operable to run in forward (e.g. blowing mode) and/or reverse (e.g. suction mode). So in some embodiments, the air flow unit might be run in reverse (for example, suction mode to suck air from the supported mattress) to refresh the mattress (e.g. a refresh cycle, which in some embodiments might be periodically run), while the air flow unit might be run in forward (for example, blowing mode to blow fresh (e.g. filtered) and/or climate controlled (e.g. cooled or heated) and/or ionized and/or UV sanitized air into the supported mattress) to enhance sleep comfort atop the supported mattress (for example, improving allergy conditions and/or temperature and/or airflow for the user atop the supported mattress, perhaps while the user is actually lying atop/sleeping on the mattress).
• While it is possible that any sort of mattress might be used to some advantage atop such a ventilation foundation, more typically specialized air flow (e.g. ventilation) mattress embodiments might be used in conjunction with the disclosed foundation embodiments. For example, the mattress might comprise a mattress cover having a bottom surface which includes a means for airflow between the foundation and the supported mattress (e.g. into and/or out of the mattress, for example at least one air permeable element/panel). For example, in some embodiments the bottom surface of the mattress cover might be formed of or include one or more panels of high airflow mesh fabric (or alternatively, the bottom surface of the mattress cover might include air passageways, which might correspond to those of the upper surface of the foundation cover). In some embodiments, the top surface of the mattress cover might also comprise air permeable element/panel or other means of airflow into/out of the mattress (e.g. high airflow mesh or loosely woven fabric panel(s)). And in some embodiments, the remainder of the mattress cover might be (substantially) air impermeable. Furthermore, the mattress might comprise one or more (and typically a plurality of) primarily vertical air pathways (e.g. pin holes), operable to allow air flow vertically throughout the mattress (for example from the bottom of the mattress to the top of the mattress). In some embodiments, the mattress might be an all-foam and/or spring-free mattress. For example, the mattress might be formed entirely of layers of foam, and each layer of foam might include vertical pin holes, at least some of which align to provide continuous airflow passages/pathways/pinholes vertically throughout the mattress.
• Some such mattress embodiments might include one or more foam layers having a sculpted surface with a plurality of foam pillars. For example, some embodiments might have a base layer of foam (e.g. the bottom layer of foam) with an upward facing sculpted surface (e.g. the pillars of foam facing/projecting upward), and another layer of foam (typically a middle foam layer, located somewhere between the base foam layer and the uppermost (sleep surface) layer of foam) with a downward facing sculpted surface (e.g. the pillars of foam facing/projecting downward). Typically, the sculpted foam layers would each have scoring (e.g. a series of grooves/gaps) forming a grid on one surface (termed the sculpted surface), with the grid pattern resulting in a plurality of foam pillars projecting outward from a common, unified slab/base of foam (e.g. the surface opposite the sculpted surface typically would be flat, such that the foam pillars would all be joined together into an integral whole layer at their bases/bottoms). The sculpted foam layer(s) might effectively replace the support functionality of the springs while also often providing added benefits. For example, a sculpted foam surface (e.g. foam pillars) may provide more flexibility in adjusting to various body contours than metal springs, and therefore may be more effective in reducing pressure points against the human body than traditional metal springs in conventional mattresses. More specifically, the layer(s) of foam with a sculpted surface would typically include a plurality of foam pillars (or blocks), each of which is freestanding (e.g. independent) with respect to the other pillars, but all of which are joined together into a single integral base (which typically has a flat exterior surface). So, the base portion of the pillars are all joined together (e.g. a common base), while the remaining freestanding portion of the layer of foam comprises a plurality of independent pillars separated from one another by a gap or groove on all sides. Stated another way, the sculpted layer(s) of foam may comprise each a base portion (which typically is a uniform flat sheet of foam) and a pillar portion (which typically comprises a plurality of independent pillars or blocks of foam, each of which is completely separate from the other pillars), with the pillar portion being securely attached to a surface of the base portion (so in effect the pillars project out from the flat base portion). Thus, the sculpted surface of the sculpted layer of foam would typically be the distal surface of the pillars (or pillar portion). Typically, the sculpted layer of foam may be formed by cutting a pattern of grooves in one surface (which would then become the sculpted surface) of an initially uniform (e.g. flat sheet with constant thickness) sheet of foam, thereby forming a plurality of foam pillars which extend out from the base portion (with the pillar portion and the base portion integrally forming a single layer of foam having different shapes/characteristics on opposing sides). Thus, the sculpted layer of foam might also be termed a contour cut layer of foam in some embodiments (since in many embodiments the layer of foam is sculpted via cutting, for example contour cutting). In other embodiments, it may be possible to form the sculpted layer of foam by molding (with the mold forming the pillar portion projecting outward from the base portion). Typically, the substantially one entire surface of the sculpted foam layer (e.g. the entire sculpted surface) would be entirely comprised of such pillars (e.g. substantially the entire sculpted surface of the sculpted foam layer would be formed of pillars), although in other embodiments the sculpted surface might have pillars only on a portion of the sculpted surface.
• Typical mattress embodiments might have vertical pin holes passing through (at least) the base portion of the sculpted foam layers, and such pin holes might typically be positioned to align with the grooves/gaps between the foam pillars (so that air could flow continuously through the vertical pin holes and the grooves to pass from one surface of the sculpted foam layer all the way through to the other surface of the sculpted foam layer). In some embodiments, the base layer of foam would comprise a foam component having a sculpted surface (typically with pillars facing upward) surrounded by foam edge support perimeter rails (which typically would be solid blocks of foam encompassing the sides of the base foam component with sculpted surface, and typically having an uncompressed height approximately equal to the uncompressed height of the base foam component (e.g. the upper surface of the edge support perimeter rails would typically be approximately the same as the uncompressed height of (e.g. flush with) the upper surface of the foam pillars of the base foam component with sculpted surface).
• Typically, mattress embodiments would have at least one (foam) layer located between the base sculpted foam layer (which typically would have the sculpted surface (e.g. foam pillars) facing upward) and the middle sculpted foam layer (which typically would have the sculpted surface (e.g. foam pillars) facing downward), and would have at least one (foam) layer located above the middle sculpted foam layer (e.g. a sleep surface layer (typically of foam) would be located atop the middle sculpted foam layer). In some embodiments, the foam pillars of the base sculpted foam layer would be larger (e.g. the cross-section/footprint/outer surface of the pillars would be larger) than the foam pillars of the middle sculpted foam layer. And as mentioned above, typically the various (foam) layers of the mattress would each have vertical pin holes, at least some of which would align to provide continuous airflow from the bottom to the top of the mattress. For example, in some embodiments all (foam) layers located above the base layer of foam might have vertical pinholes which entirely align, even though the base foam layer might have less vertical pinholes spaced further apart such that only some of the pinholes in the remaining layers align with pinholes in the base layer. Although the base layer in some embodiments may have fewer pinholes spaced further apart than the other layers of foam, air may be operable in some such embodiments to move through the grooves in the base portion (e.g. since the pinholes in the base portion may be in fluid communication with the grooves in the base portion) to the pinholes in the upper layers of foam which are not aligned with the pinholes in the base layer of foam.
• Typically, the sculpted layer of foam would have a plurality of foam pillars forming the sculpted surface, and the pillars would be configured within the sculpted foam layer and the mattress as a whole to essentially be limited to movement only (or in some embodiments, primarily) in the vertical direction (e.g. without any horizontal/sideways movement of the pillars during use of the mattress). In other words, the configuration of the foam layers of the mattress (for example, with the layers placed in contact in such a way as to minimize shear or torsion in the pillars during construction (e.g. essentially placing the pillars only in compression) and with the layers perhaps laminated together) would typically ensure that compression on the top (e.g. sleep surface) of the mattress would be transmitted to the foam pillars entirely as a vertical (e.g. compression) force (without, for example, introducing any (e.g. substantial) horizontal, shear, or torsion forces to the foam pillars) for each affected foam pillar. Additionally, each pillar of foam in the sculpted layer would typically be configured for essentially independent movement (e.g. each pillar moves independent of the other surrounding/proximate pillars). This independence might arise due to the contour cuts (e.g. grooves/gaps) separating the foam pillars and/or the fact that the base of the foam pillars would be linked by conformable foam (e.g. in the form of an integrated base of foam linking all pillars together). So, embodiments might have pillars of the sculpted foam layer configured for essentially independent movement and/or essentially only vertical movement during usage of the mattress (e.g. by a user lying atop the mattress). Typical embodiments might have the pillars configured for independent movement essentially only in the vertical direction. For example, each foam pillar might be operable to move vertically without substantially imparting any vertical movement to surrounding/proximate foam pillars in the sculpted foam layer. Thus, movement by one foam pillar typically might not impart any movement to other foam pillars in proximity within the sculpted foam layer (such that each pillar movement would independently relate to its own loading from the sleep surface above). So, each foam pillar of an exemplary sculpted foam layer in a disclosed mattress embodiment may be operable to only (or in some embodiments primarily) carry/support compression forces from directly above the foam pillar. Of course, Applicant does not intend to be bound by theory, but rather simply notes that the presently disclosed embodiments may perform/operate differently and/or better. Such configuration of the sculpted foam layer (with regard to movement) may be quite different from the typical movement allowed/provided by conventional metal springs (e.g. coil springs in a mattress). Conventional coil spring mattresses have a series of springs which typically are linked by wire across their top surfaces. Thus, the coil springs do not move independently (e.g. movement by one coil spring necessarily affects the surrounding coil springs due to the rigid nature of the linking wire frame) and the linking wire frame at the top of the coil springs may typically introduce non-vertical (e.g. non-compression) forces into the springs (such that the coil springs may flex and move horizontally and/or torsionally, for example, in response to a user atop the mattress sleep surface). Thus, the disclosed embodiments (with foam pillars in a spring-less mattress) may perform quite differently in operation than a conventional spring mattress. Applicant notes that disclosed mattress embodiments typically do not include traditional springs, but for example might be termed all-foam mattresses (e.g. all the cushion/support elements are foam) and/or (metal/coil) spring-free mattresses (e.g. no springs, even if the mattress embodiment may include some other cushion/support element(s) in addition to or instead of one or more foam elements).
• While typical sleep system embodiments would comprise a mattress embodiment atop a foundation embodiment, other embodiments might be focused on only the mattress or only the foundation. In other words, disclosed mattress embodiments could alternatively be used with conventional foundation elements (or even separately/alone), and disclosed foundation embodiments could alternatively be used with conventional mattress elements (although doing so might reduce potential benefits available through the joint use of disclosed mattress embodiment(s) with disclosed foundation embodiment(s), since the joint use of ventilation mattress atop ventilation foundation may provide for improved fluid communication therebetween). A preferred embodiment, however, would typically place a mattress configured to allow airflow/air transfer (e.g. airflow) through its bottom surface (and perhaps also typically having some means of air distribution throughout the mattress (e.g. pinholes) for air passing through the bottom surface of the mattress) atop a foundation configured to provide airflow/air transfer (for example, forced airflow, which might be suction and/or blowing) through its upper surface.
• Turning now to the figures for specific exemplary embodiments,FIG. 1A illustrates exemplary embodiment(s) of a ventilated sleep system100 (typically comprising a mattress and a foundation), with a ventilatedmattress140 used in conjunction with (typically directly atop) a ventilation foundation (such as either120aor120b, which basically differ regarding the location of theair flow unit130a). Themattress140 has abottom surface142 which allows airflow into and/or out of themattress140. For example, thebottom surface142 of themattress140 cover might be formed of or comprise high airflow mesh fabric (for example 150gsm 100% polyester spacer mesh fabric restricting airflow CFM less than about 35% at 3 PSI). In some embodiments, the upper surface of themattress140 might also allow airflow into/out of the mattress140 (for example, with the upper surface of themattress140 cover being formed of or comprising high airflow mesh fabric, similar to that used for thebottom surface142 of the mattress cover as described above).
• Eitherfoundation120a(with anair flow unit130aexternal to the support structure of the foundation and/or cover of the foundation, for example externally mounted on the foundation, perhaps underneath the foundation at or near the foot end of the bed, for example centered from side to side, and in fluid communication with the foundation hollow cavity via inlet/intake/opening132a) or120b(withair flow unit130blocated within the foundation support structure and/or cover, for example mounted internally on the bottom/base panel of the foundation, perhaps within the foundation at or near the foot end of the bed, for example on the left side when looking at the foundation from the foot, and in fluid communication with the external environment via inlet/intake/opening132b) might optionally be used with themattress140, with themattress140 being located atop eitherfoundation120aor120bto form the ventilatedsleep system100. In bothfoundation120aand120b, theupper surface122aor122b, respectively, of thefoundation120a/bwould be configured to allow airflow out of the foundation (for example, into amattress140 directly atop (and in contact with) the foundation. So for example, theupper surface122aor122bof the foundation cover might be formed of or comprise high airflow mesh fabric (similar to that described above with respect to thebottom surface142 of the mattress cover, for example, to allow airflow communication between the foundation and themattress140, for example). And typically, the foundation might be held above the floor by a frame orlegs111a,b(which might be similar to conventional bed frames used for conventional box springs, for example, and which might provide sufficient clearance from the floor to allow the required airflow for operation of the ventilation mattress system). Typically, the frame would not interfere with or block the inlet/intake/opening132a/bfor theair flow unit130a,b.
• So inFIG. 1A, air might pass into thefoundation120a,b, for example through a filter such as a HEPA filter and/or through a climate control unit (which might, for example, be operable to cool and/or heat the air) via anair flow unit130a,b, passing through thefoundation120a/b(e.g. hollow cavity) to exit through theupper surface122a,bof thefoundation120a/band enter thebottom surface142 of themattress140 in order to pass (vertically) through at least a portion of themattress140. In such a system, theair flow unit130a,bmight pump air into themattress140 through thefoundation120a/b. Alternatively, air might flow through the system in reverse, with theair flow unit130a,bsucking air out of themattress140 and into thefoundation120a/b(and then out to the external environment). Theair flow unit130a,btypically might displace about 100-300 CFM, and typically might operate at less than about 6 dB. In some embodiments, the upper surface of themattress140 might also allow for airflow (for example, being formed of or comprising high airflow mesh or loosely woven fabric panels, similar to those previously described). In some embodiments, the high airflow fabric panels throughout the sleep system (or at least for the upper foundation cover surface and lower mattress cover surface) might all be similar and/or formed of the same material. In some embodiments, theair flow unit130a,bmight be configured to allow for forward and reverse operation (e.g. operable to allow air to be blown into or sucked out of themattress140 by thefoundation120a/b). The arrows inFIG. 1A illustrate potential airflow in the system, as persons of skill would understand.
• Typically, the foundation(s)120a,bofFIG. 1A would comprise a hollow structure (formed for example by support struts and a structural frame), and air would be pumped into/out of the hollow structure cavity (for example by theair flow unit130a,b). In other words, in such embodiments, air would simply flow through the hollow cavity of thefoundation120a/bas it interacts with themattress140 and the outside environment. So for example, external air might be drawn into the hollow cavity of thefoundation120a/bthrough the inlet/intake/opening132a,b, flow through the hollow cavity to the upper surface of thefoundation120a,b, flow out of thefoundation120a/bthrough theupper surface122a,band into themattress140 through themattress bottom surface142, and then pass through at least a portion of the mattress140 (and in some embodiments, air might flow all the way through themattress140 and optionally might flow out the upper surface of the mattress140). Alternatively, air might flow into the hollow cavity of thefoundation120a,bthrough theupper surface122a,b(for example, sucking air from themattress140 through thebottom surface142 of the mattress140), through the hollow cavity of thefoundation120a,b, and out of thefoundation120a,bvia an inlet/intake (which in the case would actually serve as an outtake) and/or opening132a,bto the external environment.
• FIG. 1B illustrates an alternative embodiment sleep/bedding system, similar to that ofFIG. 1A. One version of thefoundation120bofFIG. 1B may have an access panel, which for example might allow for easy access to change the HEPA filter and/or to provide maintenance or repair to theair flow unit130b.FIGS. 1Ca, 1Cb and 1Cc illustrate in more detail an exemplary sleep/bedding system embodiment similar toFIG. 1B, having an internal (e.g. mounted/located within the foundation frame/cover)air flow unit130b, withFIG. 1Ca showing a side view,FIG. 1Cb showing an end view of the foot of the bed, andFIG. 1Cc showing a top view. Typically, in the embodiment ofFIGS. 1Ca, 1Cb and 1Cc theair flow unit130bmight be located at (e.g. in proximity to) the foot of the bed within the foundation. For example, the optional HEPA filter might be located over the air intake, with air then flowing through the blower to be expelled into the hollow cavity of thefoundation120b. In some embodiments, there may be an access panel, for example located on the upper surface of thefoundation120babove the HEPA filter or air intake orair flow unit130b. The access panel might be a hinged section (for example, operable to open by pivoting upward) of the upper foundation surface (although in some embodiments, the access panel portion of theupper foundation120bcover might not be air permeable, for example to help direct air through the blower and into the foundation).
• FIGS. 1Da, 1Db and 1Dc illustrate in more detail an exemplary sleep/bedding system embodiment similar toFIG. 1B, having an external (e.g. mounted/located outside thefoundation120bframe/cover, for example mounted beneath thefoundation120b)air flow unit130a(shown inFIG. 1B), withFIG. 1Da showing a side view,FIG. 1Db showing an end view of the foot of the bed, andFIG. 1Dc showing a top view. Typically, theair flow unit130aofFIGS. 1Da-1Dc might be mounted to the bottom surface of the foundation at or in proximity to the foot of the bed (perhaps located towards the center between the sides). And again, there may be an access panel, which for example might typically be located on the housing of the air flow unit to allow access to the HEPA filter and/or blower.FIG. 1E illustrates an exemplary sleep/bedding system in 3D perspective view, showing that externally the sleep/bedding system would resemble a conventional mattress atop a conventional box-spring foundation unit (e.g. a typical conventional bed).
• FIGS.2A1 and2A2 illustrate anexemplary ventilation mattress240A, which is an all-foam (or spring-free) mattress formed of a plurality of foam layers (with the base layer being a sculpted foam layer having the sculpted surface (with foam pillars) facing upward, a middle sculpted foam layer having the sculpted surface (with foam pillars) facing downward, a sleep surface layer, at least one foam layer (e.g. transition layer) between the middle sculpted foam layer and the base sculpted foam layer, and/or a foam layer located between the sleep surface layer and the middle sculpted foam layer). While FIG.2A1 shows the foam components of the mattress (e.g. with the cover removed) in perspective view, FIG.2A2 shows a side cross-section view of the same mattress. FIGS.2B1 and2B2 illustrate a similar all foam mattress (e.g. with the foam components removed from the cover), and differs primarily in the particular foam material selected (with the embodiment of FIG.2A1 being formed of conventional high density foam (e.g. all component foam layers are formed of conventional high density foam), and the embodiment of FIG.2B1 having the top two layers formed of memory foam, for example gel memory foam, while the remaining layers are formed of conventional high density foam). And in some embodiments, all such foam layers would be adhered into an integrated whole (e.g. laminated) and/or enclosed/encased in a cover, thereby forming an integrated mattress.
• So in FIG.2A1, themattress240A comprises a base layer of foam242 (which comprises a sculptedfoam element243 with the sculpted surface (e.g. the foam pillars) facing/extending upward) located as the bottom layer of foam in themattress240A, a middlesculpted foam layer250 with the sculpted surface (e.g. foam pillars) facing/projecting downward and located above the base layer (although typically not directly above or in contact with the base layer), atransition foam layer260 located between (and typically in contact with) the base layer of sculptedfoam242 and the middle layer of sculptedfoam250, a top (sleep surface) foam layer270 (typically located as theuppermost foam layer250 in themattress240A), and (optionally) a second (e.g. penultimate) layer offoam280 located between the top (sleep surface)foam layer270 and the middlesculpted foam layer250. FIG.2A1 shows the foam layers of themattress240A without the cover (not shown), illustrating the order and orientation of the foam layers in this mattress embodiment. Typically, the foam layers are arranged one atop another in the order described above, with proximate layers contacting one another (e.g. thebase foam layer242 is the bottom layer, thetransition foam layer260 is located atop and in contact with thebase layer242, the middlesculpted foam layer250 is located atop and in contact with the transition layer, the second (penultimate)foam layer280 is located atop and in contact with the middlesculpted foam layer250, and the top (sleep surface)foam layer270 is located atop and in contact with the second (penultimate)foam layer280 and forms the upper foam layer of themattress240A). Typically, the layers would all be encased within a cover (not shown here), and typically the cover would have a bottom surface with means for airflow (for example, one or more panels of high airflow mesh fabric). Also, in some embodiments, the upper surface of the cover might include means for airflow (for example, an air permeable element, such as one or more panels of high airflow mesh fabric).
• In FIG.2A1, thebase layer242 comprises a sculpted foam element/layer243 with upward facing sculpted surface (e.g. foam pillars248 projecting upward and separated by a series (e.g. grid) of gaps or grooves or cuts247), and edge support perimeter rails offoam244 which surround/encase the sculptedfoam element243 on all sides (e.g. about/around the perimeter of the sculpted foam element243). Typically, the edge support perimeter rails244 might be formed of the same foam as the base layer sculptedfoam element243 and/or might have the same uncompressed height as the sculpted foam element243 (e.g. the upper surface of the edge support perimeter rails244 might be approximately level with the upper surface of thefoam pillars248 of the sculptedfoam element243 when both are uncompressed). In the embodiment of FIG.2A1, thefoam pillars248 would typically have a square rectangular outer surface (and/or cross-section) of about 4 inches by 4 inches, and the gaps/grooves247 forming the grid resulting in thefoam pillars248 might typically have a width of about 0.75 inches and a depth of about 3 inches. So for example, the gaps/grooves247 in the base layer sculptedfoam element243 might typically have a depth ranging from about ½ to ⅔ the total height for thebase layer242, for example about 60% in some exemplary embodiments. In addition, the joined bases of thefoam pillars248 of the sculptedfoam element243 typically would have a plurality of pinholes (e.g. essentially vertical air passageways), as will be described in greater detail below. In alternate embodiments, the pinholes might pass through both the base portion and the pillar portion of one or more of the sculpted foam layers.
• In FIG.2A1, the transition layer offoam260 would typically be a flat sheet of foam with a plurality of pinholes265 (e.g. essentially vertical air passageways). In the embodiment of FIG.2A1, thetransition foam layer260 would typically have the same width and length dimensions (e.g. depending on whether themattress240A is a twin, full/double, queen, king, etc.) as the base foam layer242 (e.g. including both the sculptedfoam element243 and the surrounding edge support perimeter rails244), although in other embodiments (in which thefoam pillars248 are lower than the surrounding edge support perimeter rails244, for example by a height approximately equal to the thickness of the transition layer, thetransition foam layer260 might be sized to fit over just the sculptedfoam element243 of the base foam layer242 (e.g. so that it would be located within the edgesupport perimeter rails244 as well).
• The middlesculpted foam layer250 of FIG.2A1 would typically be sized (e.g. width and length) approximately the same as thebase foam layer242 and/or the transition foam layer260 (and typically the same as the layers atop it as well), and would be oriented with the sculpted surface (e.g. foam pillars258) facing/projecting downward. In the embodiment of FIG.2A1, thefoam pillars258 would typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches, and the gaps/grooves257 forming the grid resulting in the foam pillars might typically have a width of about 0.375 inches and a depth of about 1.75 inches. So for example, the gaps/grooves257 in the middlesculpted foam layer250 might typically have a depth ranging from about ½ to ⅔ the total height for the middle sculpted layer, for example about 55-60% in some exemplary embodiments. In addition, the joined bases of thefoam pillars258 of the middlesculpted foam layer250 typically would have a plurality of pinholes255 (e.g. essentially vertical air passageways), as will be described in greater detail below. Typically, thepinholes255 of the middlesculpted foam layer250 would be spaced and/or oriented/located the same (identically) as thepinholes265 in the transition foam layer260 (and typically also the same as the layers located above it), with thepinholes255 aligning vertically with thepinholes265. And typically, at least some of thepinholes255/265 would also align with thepinholes245 in the base foam layer242 (e.g. the sculptedfoam element243 of the base layer foam242). For example, everyother pinhole255/265 might align with a pinhole245 (and groove/gap247) in the sculpted foam element of the base layer.
• The second (penultimate)foam layer280 and the top (sleep surface)foam layer270 would typically each be a flat sheet of foam with a plurality ofpinholes285,275 respectively (e.g. essentially vertical air passageways). In the embodiment of FIG.2A1, both the second (penultimate)foam layer280 and the top (sleep surface)foam layer270 would typically have the same width and length dimensions (e.g. depending on whether themattress240A is a twin, full/double, queen, king, etc.) as thebase foam layer242, thetransition foam layer260, and/or the middlesculpted foam layer250. And, thepinholes285,275 of the second (penultimate)foam layer280 and the top (sleep surface)foam layer270 respectively would typically be spaced and/or oriented/located the same (identically) as thepinholes265 in thetransition foam layer260 and thepinholes255 in the middlesculpted foam layer250, with thepinholes285,275 aligning vertically with thepinholes265,255. Thus, thepinholes265,255,285, and275 of FIG.2A1 would typically align to form continuous airflow pathways from the upper surface of thebase foam layer242 upward to the upper surface of themattress240A (although in other embodiments, only some of the pinholes might align). And typically, at least some of thepinholes285,275 would also align with thepinholes245 in the base foam layer242 (e.g. the sculptedfoam element243 of the base foam layer242). For example, everyother pinhole285,275 might align with a pinhole245 (and groove/gap247) in the sculptedfoam element243 of thebase foam layer242. In other embodiments, thepinholes265,255,285, and275 might all align with thepinholes245 in the base foam layer242 (e.g. the pinholes in all the layers could be spaced equally so they all align to form continuous air flow pathways from the bottom surface of the mattress to the upper surface of themattress240A).
• Similarly, FIG.2A2 shows a cross-section view of the foam elements of themattress240A shown in FIG.2A1. In this embodiment, thebase foam layer242 typically would have an uncompressed height of about 5 inches, thetransition foam layer260 typically would have an uncompressed height of about 1.25 inches, the middlesculpted foam layer250 typically would have an uncompressed height of about 3 inches, the second (penultimate)foam layer280 typically would have an uncompressed height of about 1.75 inches, and the top (sleep surface)foam layer270 typically would have an uncompressed height of about 1.25 inches. In FIG.2A2, the middle sculpted foam layers250 would typically vary in firmness, from softest at the top to hardest/firmest at the bottom. For example, the top (sleep surface)foam layer270 would typically be the softest layer of foam (for example, IFD of about 14), the second (penultimate)foam layer280 would typically be somewhat firmer that the top layer (for example, IFD of about 20), the middlesculpted foam layer250 would typically be somewhat firmer than the second (penultimate) foam layer280 (for example, IFD of about 35), thetransition foam layer260 typically would be somewhat firmer than the middle sculpted layer (for example, IFD of about 45), while thebase foam layer242 might typically have the same firmness as the transition foam layer260 (for example, IFD of about 45). In other embodiments, thebase layer242 might be somewhat firmer than thetransition layer260. Typically, the edge support perimeter rails244 would have the same firmness (e.g. IFD) and/or be formed of the same foam as the sculptedfoam element243 of the base layer. In other embodiments, the firmness of the various layers may differ and/or may vary differently from the descriptions above. And in FIG.2A2, the thickness (e.g. lateral width) of the edge support perimeter rails typically would be about 4 inches (or in other embodiments, about the same size as one of the foam pillar's248 square rectangular outer surface (and/or cross-section) sides).
• FIG.2A2 also shows the alignment of thepinholes265,255 (and gap257),285, and275, and the fact that everyother pinhole265,255,285,275 aligns with a pinhole245 (and gap247) of thebase foam layer242 in this embodiment. The alignment of pinholes may allow continuous airflow upward from the bottom surface of themattress240A to the upper surface of themattress240A and/or downward from the upper surface of themattress240A to the bottom surface of themattress240A, as illustrated by the exemplary airflow arrows (except along the perimeter edges where the edge support perimeter rails244 may not have pinholes, in some embodiments). In some embodiments, the pinholes may be hole-punched into the foam sheets/layers, while in other embodiments the pinholes might be formed for example by molding of the foam sheets/layers). And in some embodiments, the gaps/grooves247,257 might be cut/scored into the foam to form the sculpted surface(s), while in other embodiments the gaps/grooves247,257 might be formed for example by molding (e.g. due to the shape of the foam mold forming the layer(s)). The upper surface of the top (sleep surface)foam layer270 forms the sleep surface272 (although typically there would be a cover, not shown here, lying atop/encasing the foam).
• So in some embodiments, the mattress might comprise at least two sculpted foam layers (with each having a sculpted surface with a plurality of pillars) with a transition foam layer (and typically only one such transition foam layer) therebetween. The upper sculpted foam layer would typically be oriented with its sculpted surface facing downward (although in other embodiments, it could face upward and/or there might not be a foam (transition) layer between the two sculpted foam layers), while the lower/bottom sculpted foam layer (e.g. the base layer) would typically be oriented with its sculpted surface facing upward. And typically (although optionally), there would be one or more foam layers located above the uppermost sculpted foam layer (e.g. the middle sculpted foam layer), with these top foam layers having a softer IFD than that of the middle sculpted foam layer. A series of pinholes in the foam layers (perhaps in conjunction with the gaps/grooves forming the sculpted surface of the sculpted foam layers) would allow for airflow vertically throughout the mattress (or at least through a plurality of foam layers of the mattress). And typically, the foam layers would be enclosed/encased within a cover, which typically would have a bottom/lower surface which is air permeable (for example, formed of or comprising high airflow mesh fabric, typically allowing airflow comparable to the upper/top surface of the ventilation foundation upon which such a mattress would typically operate). So as discussed above, the mattress embodiment would typically have a bottom cover surface allowing airflow therethrough (e.g. one or more panels restricting airflow cubic feet per minute less than about 35% at 3 PSI), and the ventilation foundation (upon/atop which the mattress embodiment would typically be used) typically would also have an upper/top cover surface allowing airflow therethrough (for example, similar to the airflow allowed by the bottom surface of the cover of the mattress), such that the joint mattress-foundation sleep/bedding system embodiment typically would effectively allow airflow between the foundation and the mattress (for example, based on an airflow unit in or on the foundation).
• FIGS.2B1 and2B2 show asimilar foam mattress240B formed of multiple layers of foam (typically within a cover (not shown)). The embodiment of FIGS.2B1 and2B2 is substantially the same in structure as the embodiment of FIGS.2A1 and2A2, primarily differing in the foam material used. For example, in FIG.2B1, the top two layers might be memory foam (for example, gel memory foam). Persons of skill will understand that the foam materials and/or characteristics of the layers of foam for such exemplary mattresses may differ, for example being selected based on the specific needs of the particular mattress.
• FIG. 3 illustrates an exemplary base foam layer242 (similar to that of FIG.2A1, for example), showing the sculpted surface (e.g. upper surface) of the sculpted foam element243 (withfoam pillars248 separated by gaps/grooves247 in a grid) and the edgesupport perimeter rails244 in plan view (of the upper, sculpted surface). As noted above, the foam edgesupport perimeter rails244 surround and abut all four sides of the sculptedfoam element243, and they each may typically have a width (e.g. lateral dimension) approximately equal to one of the sides of the square rectangular outer surface (and/or cross-section) of thefoam pillars248. Typically (as shown inFIG. 3), all of thefoam pillars248 would be equally sized (for example, they might all be equally sized with a square cross-section, as for example formed by a grid of gaps/grooves247 in which the longitudinal grooves/gaps247 are equally spaced, and the lateral gaps/grooves247 are also equally spaced apart by the same amount as the longitudinal gaps, for example forming a grid that resembles a checkerboard). So for example in the embodiment ofFIG. 3, thefoam pillars248 would typically have a square rectangular outer surface (and/or cross-section) of about 4 inches by 4 inches, and the gaps/grooves247 forming the grid resulting in thefoam pillars248 might typically have a width of about 0.75 inches and a depth of about 3 inches.
• FIG. 3 also shows thepinholes245 in thebase foam layer242, which are typically located in the joined base portion of thefoam pillars248 of thebase foam layer242 so that they exit into the gaps/grooves247 separating thefoam pillars248. In other words, thepinholes245 typically do not pass through the projectingfoam pillar248 portion of thebase foam layer242 sculptedfoam element243, but rather pass only though the integral base portion of the sculpted foam element243 (e.g. the bottom portion where the foam pillars are joined together into an integral whole) such that thepinholes245 extend upward from the bottom of thebase foam layer242 to exit within the gaps/grooves247 between thefoam pillars248. Thepinholes245 ofFIG. 3 typically might have a diameter of about 0.5 inches (and typically would all be about the same size), and typically would be spaced apart approximately 3.937 inches. So for example, thepinholes245 typically might be located within the gaps/grooves247 at locations in proximity to the corners of eachfoam pillar248 of the base foam layer242 (e.g. at the grid groove intersections).
• Similarly,FIG. 4 illustrates an exemplary middle sculpted foam layer250 (similar to that of FIG.2A1, for example), showing the sculpted surface (e.g. the bottom surface) (withfoam pillars258 separated by gaps/grooves257 in a grid) in plan view (of the sculpted surface). Typically (as shown inFIG. 4), all of thefoam pillars258 would be equally sized (for example, they might all be equally sized with a square cross-section, as for example formed by a grid of gaps/grooves257 in which the longitudinal gaps/grooves257 are equally spaced, and the lateral gaps/grooves are also equally spaced apart by the same amount as the longitudinal gaps, for example forming a grid that resembles a checkerboard). So for example in the embodiment ofFIG. 4, thefoam pillars258 would typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches, and the gaps/grooves257 forming the grid resulting in thefoam pillars258 might typically have a width of about 0.375 inches and a depth of about 1.75 inches. While the embodiment of FIG.2A1, for example, has thefoam pillars258 of the middle sculpted foam layer sized to be about ¼ the size of thefoam pillars248 of the base layer (e.g. 2 inches by 2 inches versus 4 inches by 4 inches, such that each 4×4 pillar in the base layer of FIG.2A1, for example, might have four 2×2 pillars in the middle sculpted layer located above it); in other embodiments, the ratio of the foam pillar sizing may vary (for example, thefoam pillars258 could be the same size as thefoam pillars248 in some embodiments, or thefoam pillars258 might be ½, ⅓, ⅛, or 1/16 the size of thefoam pillars248 in other embodiments). Typically, the sizing ratio would be such that at least some of the gaps/grooves257 in the middle sculpted foam layer would align with at least some of the gaps/grooves247 of the base layer (since that may be important to aid in alignment of pinholes in some embodiments, as well as perhaps providing consistent support and/or comfort characteristics).
• FIG. 4 also shows thepinholes255 in the middlesculpted foam layer250, which are typically located in the joined base portion of thefoam pillars258 of the middlesculpted foam layer250 so that they exit into the gaps/grooves257 separating thefoam pillars258. In other words, thepinholes255 typically do not pass through the projectingfoam pillar258 portion of the middlesculpted foam layer250, but rather pass only though the integral base portion of the middle sculpted foam layer250 (e.g. the bottom portion where thefoam pillars258 are joined together into an integral whole) such that thepinholes255 extend downward from the top of the middlesculpted foam layer250 to exit within the gaps/grooves257 between thefoam pillars258. Thepinholes255 ofFIG. 4 typically might have a diameter of about 0.25 inches (and typically would all be about the same size), and typically would be spaced apart approximately 1.9685 inches. So for example, thepinholes255 typically might be located within the gaps/grooves257 at locations in proximity to the corners of eachfoam pillar258 in the middle sculpted foam layer250 (e.g. at the grid groove intersections). As discussed above, the pinholes in the foam layers (of an exemplary mattress) above the middle sculpted foam layer250 (as well as perhaps an underlying transition layer) typically would be sized and spaced (e.g. located) identical to those in the middlesculpted foam layer250, in order to form continuous airflow pathways upward.
• FIG. 5A illustrates anexemplary ventilation mattress540, which is an all-foam (or spring-free) mattress formed of a plurality of foam layers (with the base layer being a sculpted foam layer having the sculpted surface (with foam pillars) facing upward, a middle sculpted foam layer having the sculpted surface (with foam pillars) facing downward, a sleep surface layer, at least one foam layer (e.g. transition layer) between the middle sculpted foam layer and the base sculpted foam layer, and/or a foam layer located between the sleep surface layer and the middle sculpted foam layer).FIG. 5B illustrates a similar all foam mattress (e.g. with the foam components removed from the cover), and differs primarily in the middle layer construction. In some embodiments, all such foam layers would be adhered into an integrated whole (e.g. laminated) and/or enclosed/encased in a cover, thereby forming an integrated mattress.
• So inFIG. 5A, the mattress540 comprises a base layer of foam242 (which comprises a sculpted foam element with the sculpted surface (e.g. the foam pillars) facing/extending upward) located as the bottom layer of foam in the mattress540 (wherein the base foam layer242 may be similar to the base foam layer242 described above), a middle sculpted foam layer550 with the sculpted surface (e.g. foam pillars) facing/projecting downward and located above the base foam layer242 (although typically not directly above or in contact with the base foam layer242), a transition foam layer260 located between (and typically in contact with) the base layer of sculpted foam242 and the middle layer of sculpted foam550 (wherein the transition foam layer260 may be similar to the transition foam layer260 described above), a top (sleep surface) foam layer270 (typically located as the uppermost foam layer in the mattress, wherein the top (sleep surface) foam layer270 may be similar to the top (sleep surface) foam layer270 described above), and (optionally) a second (e.g. penultimate) foam layer280 located between the top (sleep surface) foam layer270 and the middle sculpted foam layer550 (wherein the second foam layer280 may be similar to the second foam layer280 described above).
• FIG. 5A shows the layers foam of themattress540 without the cover (not shown), illustrating the order and orientation of the foam layers in this mattress embodiment. Typically, the foam layers are arranged one atop another in the order described above, with proximate layers contacting one another (e.g. thebase foam layer242 is the bottom layer, thetransition foam layer260 is located atop and in contact with the base layer, the middlesculpted foam layer550 is located atop and in contact with thetransition foam layer260, the second (penultimate)foam layer280 is located atop and in contact with the middlesculpted foam layer550, and the top (sleep surface)foam layer270 is located atop and in contact with the second (penultimate)foam layer280 and forms the upper foam layer of the mattress540). Typically, the layers would all be encased within a cover (not shown here), and typically the cover would have a bottom surface with means for airflow (for example, one or more panels of high airflow mesh fabric). Also, in some embodiments, the upper surface of the cover might include means for airflow (for example, an air permeable element, such as one or more panels of high airflow mesh fabric).
• InFIG. 5A, thebase foam layer242 comprises a sculpted foam element/layer243 with upward facing sculpted surface (e.g. foam pillars248 projecting upward and separated by a series (e.g. grid) of gaps or grooves or cuts247), and edge support perimeter rails244 of the foam which surround/encase the sculptedfoam element243 on all sides (e.g. about/around the perimeter of the sculpted foam element243). Typically, the edge support perimeter rails244 might be formed of the same foam as the base layer sculptedfoam element243 and/or might have the same uncompressed height as the sculpted foam element243 (e.g. the upper surface of the edge support perimeter rails244 might be approximately level with the upper surface of thefoam pillars248 of the sculptedfoam element243 when both are uncompressed).
• In the embodiment ofFIG. 5A, thefoam pillars248 would typically have a square rectangular outer surface (and/or cross-section) of about 4 inches by 4 inches, and the gaps/grooves247 forming the grid resulting in the foam pillars might typically have a width of about 0.75 inches and a depth of about 3 inches. So for example, the gaps/grooves247 in the base layer might typically have a depth ranging from about ½ to ⅔ the total height for the base layer, for example about 60% in some exemplary embodiments. In addition, the joined bases of the foam pillars of the sculptedfoam element243 typically would have a plurality of pinholes265 (e.g. essentially vertical air passageways), as will be described in greater detail below. In alternate embodiments, the pinholes might pass through both the base portion and the pillar portion of one or more of the sculpted foam layers.
• InFIG. 5A, the transition foam layer offoam260 would typically be a flat sheet of foam with a plurality of pinholes265 (e.g. essentially vertical air passageways). In the embodiment ofFIG. 5A, thetransition foam layer260 would typically have the same width and length dimensions (e.g. depending on whether the mattress is a twin, full/double, queen, king, etc.) as the base foam layer242 (e.g. including both the sculptedfoam element243 and the surrounding edge support perimeter rails244), although in other embodiments (in which the foam pillars are lower than the surrounding edge support perimeter rails, for example by a height approximately equal to the thickness of the transition layer, thetransition foam layer260 might be sized to fit over just the sculptedfoam element243 of the base foam layer242 (e.g. so that it would be located within the edgesupport perimeter rails244 as well).
• The middlesculpted foam layer550 ofFIG. 5A would typically be sized (e.g. width and length) approximately the same as thebase foam layer242 and/or the transition foam layer260 (and typically the same as the layers atop it as well), and would be oriented with the sculpted surface (e.g. foam pillars554) facing/projecting downward. In the embodiment ofFIG. 5A, thefoam pillars554 would typically have a square/rectangular outer surface (and/or cross-section) of about 4 inches by 4 inches, and the gaps/grooves557 forming the grid resulting in the foam pillars might typically have a width of about 0.375 inches and a depth of about 1.75 inches. So for example, the gaps/grooves557 in the middlesculpted foam layer550 might typically have a depth ranging from about ½ to ⅔ the total height for the middlesculpted foam layer550, for example about 55-60% in some exemplary embodiments. In addition, the joined bases of the foam pillars of the middlesculpted foam layer550 typically would have a plurality of pinholes555 (e.g. essentially vertical air passageways), as will be described in greater detail below.
• In the embodiment shown inFIG. 5A, thepinholes555 of the middlesculpted foam layer550 may be spaced and/or oriented/located the same (identically) as thepinholes245 of thebase foam layer242. And typically, at least some of thepinholes555 may align with thepinholes265 in the transition foam layer260 (as well as the layers located above it), with some of thepinholes265 aligning with thepinholes555. For example, everyother pinhole265 might align with apinhole255 in the middlesculpted foam layer550.
• The middlesculpted foam layer550 may also comprise an additional set ofpillars552 located on the top surface of the middlesculpted foam layer550. In the embodiment ofFIG. 5A, thetop pillars552 may be sized differently than the bottom foam pillars554 (for example, thetop pillar552 might be ¼ the (cross-section) size of thebottom foam pillars554, with fourtop pillars552 for each corresponding bottom pillar, although in other embodiments the top andbottom foam pillars552,554 could be the same size). In the embodiment ofFIG. 5A, thepinholes555 may align with everygroove557 in thebottom foam pillars554, while thepinholes555 may align with everyother groove553 in thetop pillars552. In some embodiments, thegrooves553 of thetop pillars552 may align with thepinholes275,285 of the top (sleep surface)foam layer270 and second (penultimate)foam layer280.
• The second (penultimate)foam layer280 and the upper (sleep surface)foam layer270 would typically each be a flat sheet of foam with a plurality ofpinholes285,275 respectively (e.g. essentially vertical air passageways). In the embodiment ofFIG. 5A, both the second (penultimate)foam layer280 and the upper (sleep surface)foam layer270 would typically have the same width and length dimensions (e.g. depending on whether the mattress is a twin, full/double, queen, king, etc.) as thebase foam layer242, thetransition foam layer260, and/or the middlesculpted foam layer550. And, thepinholes285,275 of the second (penultimate)foam layer280 and the top (sleep surface)foam layer270 respectively would typically be spaced and/or oriented/located the same (identically) as thepinholes265 in thetransition foam layer260 and optionally thepinholes555 in the middlesculpted foam layer550, with thepinholes285,275 aligning vertically with thepinholes265,555. Thus, thepinholes265,555,285, and275 ofFIG. 5A would typically align to form continuous airflow pathways from the upper surface of thebase foam layer242 upward to the upper surface of the mattress (although in other embodiments, only some of the pinholes might align). And typically, at least some of thepinholes285/275 would also align with thepinholes245 in the base foam layer242 (e.g. the sculptedfoam element243 of the base layer). For example, everyother pinhole285,275 might align with a pinhole245 (and groove/gap247) in the sculptedfoam element243 of thebase foam layer242. In other embodiments, thepinholes265,555,285, and275 might all align with thepinholes245 in the base foam layer242 (e.g. the pinholes in all the layers could be spaced equally so they all align to form continuous air flow pathways from the bottom surface of the mattress to the upper surface of the mattress).
• InFIG. 5A, the foam layers would typically vary in firmness, from softest at the top to hardest/firmest at the bottom. For example, the top (sleep surface)foam layer270 would typically be the softest layer of foam (for example, IFD of about 14), the second (penultimate)foam layer280 would typically be somewhat firmer that the top layer (for example, IFD of about 20), the middlesculpted foam layer550 would typically be somewhat firmer than the second (penultimate) layer280 (for example, IFD of about 35), thetransition foam layer260 typically would be somewhat firmer than the middle sculpted foam layer550 (for example, IFD of about 45), while thebase foam layer242 might typically have the same firmness as the transition foam layer260 (for example, IFD of about 45). In other embodiments, thebase foam layer242 might be somewhat firmer than thetransition foam layer260. Typically, the edge support perimeter rails244 would have the same firmness (e.g. IFD) and/or be formed of the same foam as the sculptedfoam element243 of thebase foam layer242. In other embodiments, the firmness of the various layers may differ and/or may vary differently from the descriptions above. In some embodiments, the thickness (e.g. lateral width) of the edgesupport perimeter rails244 typically would be about 4 inches (or in other embodiments, about the same size as one of thefoam pillar248 square rectangular outer surface (and/or cross-section) sides).
• The alignment of pinholes may allow continuous airflow upward from the bottom surface of the mattress to the upper surface of themattress540 and/or downward from the upper surface of the mattress to the bottom surface of the mattress540 (except along the perimeter edges where the edge support perimeter rails may not have pinholes, in some embodiments). In some embodiments, the pinholes may be hole-punched into the foam sheets/layers, while in other embodiments the pinholes might be formed for example by molding of the foam sheets/layers).
• So in some embodiments, the mattress might comprise at least two sculpted foam layers (with each having a sculpted surface with a plurality of pillars) with a transition foam layer (and typically only one such transition foam layer) therebetween. The upper sculpted foam layer would typically be oriented with its sculpted surface facing downward (although in other embodiments, it could face upward and/or there might not be a foam (transition) layer between the two sculpted foam layers and/or the upper sculpted foam layer might have both an upper and lower sculpted surface), while the lower/bottom sculpted foam layer (e.g. the base layer) would typically be oriented with its sculpted surface facing upward. And typically (although optionally), there would be one or more foam layers located above the uppermost sculpted foam layer (e.g. the middle sculpted foam layer), with these top foam layers having a softer IFD than that of the middle sculpted foam layer. A series of pinholes in the foam layers (perhaps in conjunction with the gaps/grooves forming the sculpted surface of the sculpted foam layers) would allow for airflow vertically throughout the mattress (or at least through a plurality of foam layers of the mattress). And typically, the foam layers would be enclosed/encased within a cover, which typically would have a bottom/lower surface which is air permeable (for example, formed of or comprising high airflow mesh fabric, typically allowing airflow comparable to the upper/top surface of the ventilation foundation upon which such a mattress would typically operate). So as discussed above, the mattress embodiment would typically have a bottom cover surface allowing airflow therethrough (e.g. one or more panels restricting airflow cubic feet per minute less than about 35% at 3 PSI), and the ventilation foundation (upon/atop which the mattress embodiment would typically be used) typically would also have an upper/top cover surface allowing airflow therethrough (for example, similar to the airflow allowed by the bottom surface of the cover of the mattress), such that the joint mattress-foundation sleep/bedding system embodiment typically would effectively allow airflow between the foundation and the mattress (for example, based on an airflow unit in or on the foundation).
• FIG. 5B shows asimilar foam mattress542 formed of multiple layers of foam (typically within a cover (not shown). The embodiment ofFIG. 5B is substantially the same in structure as the embodiment ofFIG. 5A, primarily differing in the construction of the middlesculpted foam layer560. In the embodiment ofFIG. 5B the middlesculpted foam layer560 would typically be sized (e.g. width and length) approximately the same as thebase foam layer242 and/or the transition foam layer260 (and typically the same as the layers atop it as well), and would be oriented with the sculpted surface (e.g. foam pillars556) facing/projecting downward. In the embodiment ofFIG. 5A, thefoam pillars554 would typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches, and the gaps/grooves557 forming the grid resulting in the foam pillars might typically have a width of about 0.375 inches and a depth of about 1.75 inches. So for example, the gaps/grooves in the middle sculpted layer might typically have a depth ranging from about ½ to ⅔ the total height for the middle sculpted layer, for example about 55-60% in some exemplary embodiments. In addition, the joined bases of the foam pillars of the middlesculpted foam layer560 typically would have a plurality of pinholes555 (e.g. essentially vertical air passageways), as will be described in greater detail below. Typically, thepinholes555 of the middlesculpted foam layer560 would be spaced and/or oriented/located the same (identically) as thepinholes265 in the transition foam layer260 (and typically also the same as the layers located above it), with thepinholes555 aligning vertically with thepinholes265. And typically, at least some of thepinholes555/265 would also align with pinholes in the base foam layer242 (e.g. the sculptedfoam element243 of the base layer). For example, everyother pinhole555,265 might align with a pinhole (and groove/gap247) in the sculptedfoam element243 of thebase foam layer242.
• The middlesculpted foam layer560 may also comprise an additional set ofpillars552 located on the top surface of the middlesculpted foam layer560. In the embodiment ofFIG. 5A, thetop pillars552 may be sized the same (identical) as thebottom foam pillars554. In the embodiment ofFIG. 5A, thepinholes555 may align with everygroove557 in thebottom foam pillars554, and thepinholes555 may align with everygroove553 in thetop pillars552.
• FIGS. 6A-6B illustrate detailed views of the middlesculpted foam layers550 and560. The middlesculpted foam layer550 ofFIG. 6A may comprisetop pillars552 andbottom pillars554 that differ in size. For example, thetop pillars552 may typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches, while thebottom pillars554 may typically have a square rectangular outer surface (and/or cross-section) of about 4 inches by 4 inches. The middlesculpted foam layer560 ofFIG. 6B may comprisetop pillars552 andbottom pillars556 that are the same in size. For example, thetop pillars552 may typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches, and thebottom pillars556 may also typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches. Typically, the foam pillars of the middle sculpted foam layer would be sized with respect to the pillars of the base layer of foam within a range including 1-to-1-4-to-1 with respect to cross-section (such that the foam pillars of the middle sculpted foam layer each range in size from being equally sized to the base layer pillars down to being a quarter the size of the base layer pillars (i.e. four middle sculpted layer pillars per one base layer pillar)), with each top foam pillar of the middle sculpted foam layer often being equally sized and each bottom foam pillar of the middle sculpted foam layer often being equally sized. So for example, the base layer foam pillars might be 4×4 inches in cross-section, and the middle sculpted foam layer might have pillars that are 4×4 inches or 2×2 inches (for example, the bottom pillars of the middle sculpted foam layer could be 4×4 inches or 2×2 inches, while the top pillars of the middle sculpted foam layer could be 2×2 inches (or 4×4 inches)).
• Additionally, thepinholes555 in the middlesculpted foam layers550 and560 may align with thegrooves557 in thebottom foam pillars554,556 in both embodiments. Therefore, thepinholes555 of the middlesculpted foam layer550 ofFIG. 6A may be fewer in number and spaced differently than thepinholes555 of the middlesculpted foam layer560 ofFIG. 6B.
• In the embodiment shown inFIG. 6A, the middlesculpted foam layer550 may be formed of one piece of foam, wherein thepillars552/554 andpinholes555 may be formed by sculpting and/or molding a single piece of foam. In the embodiment shown inFIG. 6B, the middlesculpted foam layer560 may be formed of one piece of foam, wherein thepillars552/556 andpinholes555 may be formed by sculpting and/or molding a single piece of foam.
• FIGS. 7A-7B illustrate alternative detailed views of the middlesculpted foam layers550 and560. InFIGS. 7A-7B, themiddle layers550 and560 may comprise two different types of foam joined together using adhesive. Themiddle layers550 and560 may be similar to those described inFIGS. 6A-6B, except that the layers may be formed of two pieces of foam instead of one.
• In the embodiment shown inFIG. 7A, the middlesculpted foam layer550 may be formed of two pieces of foam, wherein thepillars552 andpartial pinholes555 may be formed by sculpting and/or molding a first piece offoam720, and thepillars554 andpartial pinholes555 may be formed by sculpting and/or molding a second piece offoam722. Then, the two pieces offoam720 and722 may be joined together and laminated to form the middlesculpted foam layer550.
• In the embodiment shown inFIG. 7B, the middlesculpted foam layer560 may be formed of two pieces of foam, wherein thepillars552 andpartial pinholes555 may be formed by sculpting and/or molding a first piece offoam720, and thepillars556 andpartial pinholes555 may be formed by sculpting and/or molding a second piece offoam724. Then, the two pieces offoam720 and724 may be joined together and laminated to form the middlesculpted foam layer560.
• FIG. 8 illustrates an exemplarybase foam layer242 similar to that shown and described inFIG. 3.
• Further embodiments of the disclosure may include similar cushion embodiments that may be used in seating support systems. Such a cushion may comprise similar foam materials, similar support features, and similar layers to the previously disclosed embodiments. The density of the foam material of the various layers of the cushion may be similar to the foam materials of the previously described embodiments. Additionally, the IFD of the foam material of the various layers of the cushion may be similar to the IFD of the foam materials of the previously described embodiments. A seating support system may comprise a cushion for use in a chair, a sofa, a vehicle seat, a supplemental seat cushion, or any other seating system. Thus, the disclosed seating cushion embodiments may be configured for use upon a support element (including a frame) for a chair, sofa, etc. (which may include a back support/frame and/or back cushion in some embodiments, in addition to a seating support frame).
• FIG. 9A illustrates a general diagram of anexemplary cushion900, which may be part of a seating cushion support system, and which is an all-foam (or spring-free) cushion formed of a plurality of foam layers with at least one layer being a sculpted foam layer having the sculpted surface (with foam pillars958) facing upward and/or downward. Thefoam pillars958 may be similar to the foam pillars described in previous embodiments.
• FIG. 9B illustrates acover910 that may be installed over the foam layers of thecushion900.FIG. 9A shows the foam components of the cushion (e.g. with thecover910 removed) in perspective view. In some embodiments, all such foam layers would be adhered into an integrated whole (e.g. laminated) and/or enclosed/encased in thecover910, thereby forming an integrated cushion.FIGS. 10-17 illustrate different exemplary embodiments of such all foam cushion (e.g. with the foam components removed from the cover910).
• As shown inFIG. 9A, thecushion900 comprises abase foam layer940 located as the bottom layer of foam in thecushion900, a middlesculpted foam layer950 with a sculpted surface (e.g. foam pillars958 separated by gaps/grooves957) facing/projecting upward and/or downward and located above thebase foam layer940, a top foam layer960 (typically located as theuppermost foam layer260 in the cushion900), and anouter wrap902 configured to wrap around at least a portion of the assembledlayers940,950, and960 of thecushion900. Thetop foam layer960 may form a top “sitting”surface904, where a user may sit upon thecushion900.FIG. 9 shows the layers foam of thecushion900 without the cover (not shown), illustrating the order and orientation of the foam layers in this cushion embodiment. Typically, the foam layers are arranged one atop another in the order described above, with proximate layers contacting one another, e.g. thebase layer940 is the bottom layer, the middlesculpted foam layer950 is located atop and in contact with thebase layer940, and thetop layer960 is located atop and in contact with the middlesculpted foam layer950 and forms the upper foam layer of the cushion900), with theouter wrap902 covering a bottom surface of thebase foam layer940 and covering a top surface of thetop foam layer960, such that the middlesculpted foam layer950 typically could be sandwiched between and in (direct) contact with thetop layer960 and thebottom layer940.
• In some embodiments, the middlesculpted foam layer950 may also be called an independent foam spring component, where thefoam pillars958 may also be called “foam springs” separated by the gaps/grooves957. As shown inFIG. 9A, thefoam pillars958 may comprise a rectangular shape (or more specifically an approximately square shape). However, thefoam pillars958 may comprise any shape, such as a circular (cross-section) shape (or cylindrical shape for the overall foam pillar/spring), a triangular shape, a rounded shape, a rectangular shape with rounded edges, or any other shape that may be defined by gaps/grooves957 in the material of the middlesculpted foam layer950.
• Theouter wrap902 may typically comprise a synthetic fiber material configured to provide protection for the foam layers of the cushion900 (e.g., from damage by fluids, sharp objects, and/or other substances). In some embodiments, theouter wrap902 may comprise a material configured to reduce friction between theouter wrap902 and thecover910 that may be installed over thecushion900. The reduced friction provided by theouter wrap902 may allow thecushion900 to move within thecover910 to return to an original position within thecover910, for example after a user has sat upon thecushion900. For example, in some embodiments, theouter wrap902 may comprise polyethylene terephthalate (PET), i.e. polyester or the brand name Dacron.
• Typically, as shown inFIG. 9B, the layers would all be encased within thecover910, and thecover910 may have a bottom surface with means for airflow (for example, one or more panels of high airflow mesh fabric) in some embodiments. Also, in some embodiments, the upper surface of thecover910 might include means for airflow (for example, an air permeable element, such as one or more panels of high airflow mesh fabric). Thecover910 may comprise azipper912 located on a “back” portion of thecushion900 and cover910 (e.g. facing the back portion of the seating unit/frame). Additionally, thecover910 may comprise an airpermeable element914 in one or more surfaces of thecover910, wherein the airpermeable element914 may facilitate airflow into and out of the foam layers of thecushion900. In some embodiments, the airpermeable element914 may comprise a mesh material. Regardless, the cover typically would be configured to be sufficiently durable for a seating surface (e.g. to endure friction caused by user interaction with the seating surface, for example).
• FIG. 10 shows a side cross-section view of an exemplary embodiment of thecushion900. InFIG. 10, thebase layer1040 comprises a solid layer of foam and thetop layer1060 comprises a solid layer of foam. The middlesculpted foam layer1050 ofFIG. 9 would typically be sized (e.g. width and length) approximately the same as thebase layer1040 and/or the top layer (and typically the same as the layers atop it as well), and would be oriented with the sculpted surface (e.g. foam pillars1058) facing/projecting downward. In some embodiments, thefoam pillars1058 may typically have a square rectangular outer surface (and/or cross-section) of about 2 inches by 2 inches. In another embodiment, thefoam pillars1058 may have a square rectangular outer surface (and/or cross-section) of about 4 inches by 4 inches.
• In some embodiments, the height (or thickness)1052 of the middlesculpted foam layer1050 may be approximately 3 inches, and the gaps/grooves1057 forming the grid resulting in the foam pillars might typically have a width of about 0.375 inches and a depth of about 1.75 inches. So for example, the gaps/grooves1057 in the middlesculpted foam layer1050 might typically have a depth ranging from about ½ to ⅔ the total height for the middlesculpted foam layer1050, for example about 55-60% in some exemplary embodiments.
• Thetop layer1060 may comprise a height (or thickness)1062 of between approximately 1 to 4 inches. Thebase layer1040 may comprise a height (or thickness)1042 of between approximately 1 to 4 inches. The total thickness of the cushion900 (including the outer wrap902) may be between approximately 5 inches and 8 inches.
• In some embodiments, thecushion900 may comprise “front”section1010 of thecushion900 where the middlesculpted foam layer1050 is solid, without anyfoam pillars1058 or gaps/grooves1057 (e.g. a wider area of sold foam without gaps or grooves of the sort that might form intermediate foam pillars/springs). Thisfront section1010 may be configured to support a front edge of thecushion900 when a user is sitting on thecushion900, where thefront section1010 may be configured to be located such that a user might sit on thecushion900 with their knees located proximate to thefront section1010 of thecushion900. Thefront section1010 may optionally be configured to provide increased rigidity in this specific portion of thecushion900, which may provide improved support based on how a user sits upon the cushion900 (e.g. to prevent edge collapse). In some embodiments, thefront section1010 may extend approximately 4 inches from the outer edge of thecushion900 toward the middle of thecushion900. In some embodiments, thefront section1010 may extend less than approximately 4 inches from the outer edge of thecushion900 toward the middle of thecushion900.
• In some embodiments, the “front” section described above may be part of solid edge portion (i.e., forming the front section1010) of the middlesculpted foam layer1050 that extends around the entire outer edge of the middlesculpted foam layer1050. For example, thecushion900 may comprise a front edge (i.e., the front section1010), a back edge, and two side edges, where the solid edge portion may create a border including the front edge, the back edge, and the two side edges of the middlesculpted foam layer1050. In some embodiments, the solid edge portion may extend approximately 4 inches from the outer edge of thecushion900 toward the middle of thecushion900. In some embodiments, the solid edge portion may extend less than approximately 4 inches from the outer edge of thecushion900 toward the middle of thecushion900. In other embodiments, such solid edge portion might only be located on front and back sides of the cushion (e.g. allowing the cushion to be flipped for increased life without impacting the edge collapse performance)
• In some embodiments, thetop layer1060 may comprise a high resiliency foam material with an IFD between approximately 25 and 35. In some embodiments, thebase layer1040 may comprise a high resiliency foam material with an IFD between approximately 25 and 35. In some embodiments, the foam materials of thetop layer1060 and thebase layer1040 may be similar. In some embodiments, the middlesculpted foam layer1050 may comprise an IFD between approximately 50 and 60. In other words, the middlesculpted foam layer1050 may comprise a foam material that is more firm than the foam material of thetop layer1060 and/or thebase layer1040.
• FIG. 11 shows a side cross-section view of another similar exemplary embodiment of thecushion900, where thetop layer1160 and thebase layer1140 may be formed by asingle foam piece1170 that has been folded around the middle sculpted foam layer1050 (e.g. bracketing/enclosing the sculpted layer on the bottom, top, and front sides). Thebase layer1140 may contact thefoam pillars1058 separated by gaps/grooves1057 and may be formed by a base portion of thesingle foam piece1170. Thetop layer1160 may form the top “sitting” surface of thecushion900 and may be formed by a top portion of thesingle foam piece1170. In the embodiment shown inFIG. 11, a foldedportion1172 of the single foam piece1170 (e.g., located between thebase layer1140 and the top layer1160) may be positioned to form thefront section1010 of the cushion900 (as described inFIG. 10). The foldedportion1172 may provide optional increased rigidity for thefront section1010 of thecushion900. Additionally, the middlesculpted foam layer1050 may not extend all the way through thefront section1010 of the cushion, due to the foldedportion1172.
• FIG. 12 shows a side cross-section view of another similar exemplary embodiment of thecushion900, where thethickness1242 of thebase layer1240 may be more than thethickness1262 of thetop layer1260. As an example, thethickness1262 of thetop layer1260 may be approximately half of thethickness1242 of thebase layer1240.
• FIG. 13 shows a side cross-section view of another similar exemplary embodiment of thecushion900, where the middlesculpted foam layer1350 may comprise the row offoam pillars1358 separated by gaps/grooves1357 on the bottom surface of the middlesculpted foam layer1350 and may compriseadditional foam pillars1354 separated by gaps/grooves1353 on the top surface of the middlesculpted foam layer1350. In some embodiments, the middlesculpted foam layer1350 may also be called a dual independent foam spring component, where thefoam pillars1358 and1354 may also be called “foam springs” separated by the gaps/grooves1357 and1353.
• Typically, the sizing ratio would be such that at least some of the gaps/grooves1357 on the bottom surface of the middlesculpted foam layer1350 would align with at least some of the gaps/grooves1353 of the top surface of the middle sculpted foam layer1350 (since that may be important to provide consistent support and/or comfort characteristics). In some embodiments, thefoam pillars1358 and thefoam pillars1354 may comprise similar sizes and/or shapes and/or alignment/orientation, while in other embodiments thefoam pillars1358 and thefoam pillars1354 may comprise different sizes and/or shapes and/or alignment/orientation.
• In the embodiment shown inFIG. 13, thethickness1352 of the middlesculpted foam layer1350 may be larger than thethickness1362 of thetop layer1360 and/or thethickness1342 of thebase layer1340. In other words, with the addition of thefoam pillars1354 to the top surface of the middlesculpted foam layer1350, thethickness1352 of the middlesculpted foam layer1350 may comprise at least half of the total thickness of thecushion900. As shown inFIGS. 12 and 13, thecushion900 may or may not comprise a defined “front” section1010 (or solid edge portion) as described inFIGS. 10 and 11.
• In some seating cushion embodiments, one or more of the foam layers of the cushion may comprise pinholes (e.g. (vertical) air passageways).FIG. 14 shows a side cross-section view of another exemplary embodiment of thecushion900 that may be similar to the above described embodiments, but may comprise a plurality of pinholes through one or more of the layers of thecushion900. The pinholes may be similar to those described in previous embodiments. As shown inFIG. 14, the components of thecushion900 may be similar to those described with respect toFIG. 10, where each of the layers may comprise a plurality of pinholes through the layers. For example, thetop layer1460 may be similar to thetop layer1060, but may further comprise pinholes1465 (e.g. essentially vertical air passageways), as will be described in greater detail below. Additionally, thebase layer1440 may be similar to thebase layer1040, but may further comprisepinholes1445, and the middlesculpted foam layer1450 may be similar to the middlesculpted foam layer1050, but may further comprisepinholes1455 through the joined bases of thefoam pillars1458 which may align with the gaps/grooves1457.
• Typically, thepinholes1455 of the middlesculpted foam layer1450 would be spaced and/or oriented/located the same (identically) as thepinholes1465 in thetop layer1460, with thepinholes1455 aligning vertically with thepinholes1465. And typically, at least some of thepinholes1455/1465 would also align with thepinholes1445 in thebase layer1440. Thus, thepinholes1445,1455, and1465 ofFIG. 14 would typically align to form continuous airflow pathways from the bottom surface of thebase layer1440 upward to the upper surface of the cushion900 (although in other embodiments, only some of the pinholes might align).
• In some embodiments, thecushion900 may comprise “front”section1410 of thecushion900 where the middlesculpted foam layer1450 is solid, without anyfoam pillars1458 or gaps/grooves1457. Thisfront section1410 may be configured to support a front edge of thecushion900 when a user is sitting on thecushion900, where thefront section1410 may be configured to be located such that a user might sit on thecushion900 with their knees located proximate to thefront section1410 of thecushion900. Thefront section1410 may optionally be configured to provide increased rigidity in this specific portion of thecushion900, which may provide improved support based on how a user sits upon thecushion900.
• In some embodiments, the height (or thickness)1452 of the middlesculpted foam layer1450 may be between approximately 1 to 4 inches. Thetop layer1460 may comprise a height (or thickness)1462 of between approximately 1 to 4 inches. Thebase layer1440 may comprise a height (or thickness)1442 of between approximately 1 to 4 inches. The total thickness of the cushion900 (including the outer wrap902) may be between approximately 3 inches and 12 inches. In some embodiments, the total thickness of the cushion900 (including the outer wrap902) may be between approximately 5 inches and 8 inches.
• FIG. 15 shows a side cross-section view of another exemplary embodiment of thecushion900 that may be similar to above described embodiments, and may comprise a plurality of pinholes through one or more of the layers of thecushion900. As shown inFIG. 15, the components of thecushion900 may be similar to those described with respect toFIG. 11, where each of the layers may comprise a plurality of pinholes through the layers. For example, thetop layer1560 may be similar to thetop layer1160, but may further comprise pinholes1565 (e.g. essentially vertical air passageways), as will be described in greater detail below. Additionally, thebase layer1540 may be similar to thebase layer1140, but may further comprisepinholes1545, and the middlesculpted foam layer1450 may be similar to the middlesculpted foam layer1050, but may further comprisepinholes1455 through the joined bases of thefoam pillars1458 which may align with the gaps/grooves1457.
• Thetop layer1560 and thebase layer1540 may be formed by asingle foam piece1570 that has been folded around the middlesculpted foam layer1450. Thebase layer1540 may contact the foam pillars1558 separated by gaps/grooves1557 and may be formed by a base portion of thesingle foam piece1570. Thetop layer1560 may form the top “sitting” surface of thecushion900 and may be formed by a top portion of thesingle foam piece1170. In the embodiment shown inFIG. 15, a foldedportion1572 of the single foam piece1570 (e.g., located between thebase layer1540 and the top layer1560) may be positioned to form thefront section1410 of the cushion900 (as described inFIG. 10). The foldedportion1172 may provide optional increased rigidity for thefront section1410 of thecushion900. Additionally, the middlesculpted foam layer1450 may not extend all the way through thefront section1410 of the cushion, due to the foldedportion1572.
• As shown inFIG. 15, thesingle foam piece1570 may comprise a plurality ofpinholes1545 positioned within thebase layer1540 and may comprise a plurality ofpinholes1565 positioned within thetop layer1560. Thepinholes1545 and1565 may or may not continue into the foldedportion1572 of thesingle foam piece1570.
• FIG. 16 shows a side cross-section view of another exemplary embodiment of thecushion900 that may be similar to the above described embodiments, and may comprise a plurality of pinholes through one or more of the layers of thecushion900. As shown inFIG. 16, the components of thecushion900 may be similar to those described with respect toFIG. 12, where each of the layers may comprise a plurality of pinholes through the layers. For example, thetop layer1660 may be similar to thetop layer1260, but may further comprisepinholes1665. Additionally, thebase layer1640 may be similar to thebase layer1240, but may further comprisepinholes1645, and the middlesculpted foam layer1450 may be similar to the middlesculpted foam layer1050, but may further comprisepinholes1455 through the joined bases of thefoam pillars1458 which may align with the gaps/grooves1457.
• FIG. 16 shows a side cross-section view of another exemplary embodiment of thecushion900, where thethickness1642 of thebase layer1640 may be more than thethickness1662 of thetop layer1660. As an example, thethickness1662 of thetop layer1660 may be approximately half of thethickness1642 of thebase layer1640.
• FIG. 17 shows a side cross-section view of another exemplary embodiment of thecushion900 that may be similar to the above described embodiments, and may comprise a plurality of pinholes through one or more of the layers of thecushion900. As shown inFIG. 17, the components of thecushion900 may be similar to those described with respect toFIG. 13, where each of the layers may comprise a plurality of pinholes through the layers. For example, thetop layer1760 may be similar to thetop layer1360, but may further comprisepinholes1765. Additionally, thebase layer1740 may be similar to thebase layer1340, but may further comprisepinholes1745, and the middlesculpted foam layer1750 may be similar to the middlesculpted foam layer1350, but may further comprisepinholes1755 through the joined bases of thefoam pillars1758 and1754 where thepinholes1755 may align with the gaps/grooves1757 and1753.
• As shown inFIG. 17, the middle sculptedlayer1750 may comprise a row offoam pillars1758 separated by gaps/grooves1757 on the bottom surface of the middle sculptedlayer1750 and may compriseadditional foam pillars1754 separated by gaps/grooves1753 on the top surface of the middle sculptedlayer1750. Typically, the sizing ratio would be such that at least some of the gaps/grooves1757 on the bottom surface of the middlesculpted foam layer1750 would align with at least some of the gaps/grooves1753 of the top surface of the middle sculpted foam layer1750 (since that may be important to provide consistent support and/or comfort characteristics). In the embodiment shown inFIG. 17, thethickness1752 of the middlesculpted foam layer1750 may be larger than thethickness1762 of thetop layer1760 and/or thethickness1742 of thebase layer1740. In other words, with the addition of thefoam pillars1754 to the top surface of the middlesculpted foam layer1750, thethickness1752 of the middlesculpted foam layer1750 may comprise at least half of the total thickness of thecushion900.
• FIG. 18 illustrates an exploded view of the foam layers of thecushion900 shown inFIG. 14, where the middlesculpted foam layer1450 may comprise a plurality offoam pillars1458 directed toward the bottom surface of the cushion (i.e., adjacent to the base layer1440).
• FIG. 19 illustrates another exploded view of the foam layers of thecushion900 shown inFIG. 14, where the middlesculpted foam layer1450 may be positioned with thefoam pillars1458 directed toward the top surface of the cushion (i.e., adjacent to the top layer1460) instead of the bottom surface of the cushion (as shown inFIG. 18). The middlesculpted foam layer1450 may be used in either configuration within thecushion900.
• FIG. 20 illustrates an exploded view of the foam layers of thecushion900 shown inFIG. 17, where the middlesculpted foam layer1750 may comprise a plurality offoam pillars1758 directed toward the bottom surface of the cushion (i.e., adjacent to the base layer1740) and may comprise a plurality of foam pillars directed toward the top surface of the cushion (i.e., adjacent to the top layer1760).
• It should be recognized that in some embodiments, seating cushions similar to those described inFIGS. 9A, B-20 might only have one additional foam layer in addition to the sculpted (e.g. independent foam spring) layer. This might be the case for thinner cushions, for example (e.g. cushions less than approximately 5 inches in thickness). And in various embodiments, the sculpted foam (e.g. independent foam spring) layer may be oriented downward or upward (or have pillars on both the top and bottom surfaces). Most typically, when only having two foam layers, the foam pillars would project downward and be underlain by a base layer of foam, while the seating surface would be flat.
• For additional details that may be relevant for some embodiments (particularly some mattress embodiments and/or systems having mattress embodiments), U.S. patent application Ser. No. 14/681,278 (entitled “Independent Foam Spring Mattress” and filed Apr. 8, 2015, along with related provisional patent application No. 61/977,989 entitled “Independent Foam Spring Mattress” and filed Apr. 10, 2014) is hereby incorporated by reference for all purposes as if reproduced in its entirety to the extent that it is compatible (e.g. not inconsistent) with and/or does not directly contradict disclosure herein (e.g. the explicit disclosure herein would always govern/trump in instances of contradiction, inconsistency, or incompatibility). Specifically, details about the foam layers and/or formation of the foam layers from the incorporated by reference U.S. patent applications might be used in some embodiments (for example, within a mattress cover as described herein).
• While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.
• Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.
• Use of broader terms such as “comprises”, “includes”, and “having” should be understood to provide support for narrower terms such as “consisting of”, “consisting essentially of”, and “comprised substantially of”. Use of the terms “optionally,” “may,” “might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.
• While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.
• Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims (20)

What is claimed is:

1. A seating system comprising:

a cushion, which comprises:

a cushion cover; and

one or more foam layers within the cushion cover;

wherein the cushion is spring-free;

wherein the one or more foam layers each comprise a plurality of substantially vertical air passageways which pass through the entire thickness of the corresponding foam layer; and

wherein the one or more foam layers comprise:

a base layer of foam;

a middle sculpted layer of foam having a sculpted lower surface with a plurality of foam pillars projecting downward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and

a top layer of foam with uniform thickness, which is located above the middle sculpted layer.

2. The seating system ofclaim 1, wherein the middle sculpted layer of foam further comprises a sculpted upper surface with a plurality of foam pillars projecting upward.

3. A cushion comprising:

a cover; and

one or more foam layers comprising:

at least one sculpted foam layer comprising a plurality of foam pillars; and

at least one additional foam layer.

4. The cushion ofclaim 3, wherein the cushion is part of the seating system.

5. The cushion ofclaim 3, wherein the cushion is spring-free.

6. The cushion ofclaim 3, wherein the one or more foam layers each comprise a plurality of substantially vertical air passageways.

7. The cushion ofclaim 6, wherein at least some of the substantially vertical air passageways in the foam layers align to provide continuous airflow paths from the bottom surface of the cushion to an upper surface of the cushion.

8. The cushion ofclaim 3, wherein the one or more foam layers comprise:

a base layer of foam;

a middle sculpted layer of foam having a sculpted lower surface with a plurality of foam pillars projecting downward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and

a top layer of foam with uniform thickness, which is located above the middle sculpted layer.

9. The cushion ofclaim 8, wherein the middle sculpted layer of foam further comprises a sculpted upper surface with a plurality of foam pillars projecting upward.

10. The cushion ofclaim 9, wherein the sculpted upper surface of the middle sculpted layer of foam comprises pillars of a different size than the sculpted lower surface of the middle sculpted layer of foam.

11. The cushion ofclaim 8, wherein the base layer of foam comprises a thickness that is approximately double the thickness of the top layer of foam.

12. The cushion ofclaim 3, further comprising an outer wrap configured to wrap around at least a portion of the one or more foam layers and positioned between the one or more foam layers and the cover.

13. The cushion ofclaim 12, wherein the outer wrap comprises polyethylene terephthalate (PET).

14. The cushion ofclaim 3, wherein the one or more foam layers comprise:

a base layer of foam;

a middle sculpted layer of foam having a sculpted upper surface with a plurality of foam pillars projecting upward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and

a top layer of foam with uniform thickness, which is located above the middle sculpted layer.

15. The cushion ofclaim 3, wherein the cover comprises an air permeable element in a bottom surface of the cover.

16. A cushion for use in a seating system, the cushion comprising:

one or more foam layers, at least one foam layer comprising a plurality of foam pillars;

a cushion cover configured to surround the one or more foam layers; and

an outer wrap located between the one or more foam layers and the cushion cover, configured to wrap around at least a portion of the foam layers, wherein the cushion is spring-free.

17. The cushion ofclaim 16, wherein the one or more foam layers comprise:

a base layer of foam;

a middle sculpted layer of foam having a sculpted lower surface with a plurality of foam pillars projecting downward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and

a top layer of foam with uniform thickness, which is located above the middle sculpted layer.

18. The cushion ofclaim 16, wherein the base layer of foam comprises a thickness that is approximately double the thickness of the top layer of foam.

19. The cushion ofclaim 16, wherein the middle sculpted layer comprises a dual independent foam pillar layer comprising a plurality of foam pillars projecting downward from a bottom surface of the middle sculpted layer, and comprising a plurality of foam pillars projecting upward from a top surface of the middle sculpted layer.

20. The cushion ofclaim 16, wherein the middle sculpted layer comprises a solid edge portion without any foam pillars located about at least a portion of the outer edge of the middle sculpted layer.

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