Foam cushion having reduced cross-section area foam profiles forming hollow portion(s) for deformation

Abstract

Cushions are disclosed herein. In one embodiment, a cushion is comprised of a plurality of foam profiles each having a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection. The plurality of foam profiles are arranged such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane. In this manner, hollow portions can be formed between adjacent foam profiles. At least one sheet of material is affixed to at least one of the top surface and the bottom surface of the plurality of foam profiles. When a compression force is imposed on the cushion, the hollow portions allow the foam profiles to adapt to deformation. Further, by providing the hollow portions, the cushion can more easily be rolled or wrapped for transport or storage.

1 . A cushion, comprising:
 a plurality of foam profiles each having a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection;   wherein the plurality of foam profiles are arranged such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane, and the bottom surfaces of the plurality of foam profiles are disposed in or substantially in a second plane parallel or substantially parallel to the first plane; and   at least one sheet of material affixed to at least one of the top surface and the bottom surface of the plurality of foam profiles.   
     
     
         2 . The cushion of  claim 1 , wherein the plurality of foam profiles are comprised of foamed material comprised from the group consisting of polypropylene, polypropylene copolymer, polystyrene, polyethylene, ethylene vinyl acetate (EVA), polyolefin, including metallocene catalyzed low density polyethylene, thermoplastic olefin (TPO), thermoplastic polyester, thermoplastic vulcanizates (TPVs), polyvinyl chlorides (PVCs), chlorinated polyethylene, styrene block copolymers, ethylene methyl acrylates (EMAs), ethylene butyl acrylates (EBAs), polyurethane, natural rubber, synthetic rubber, latex, silicone, ethylene propylene diene Monomer (M-class) rubber (EPDM), isoprene, chloroprene, neoprene, melamine-formaldehyde, and polyester. 
     
     
         3 . The cushion of  claim 1 , wherein the plurality of foam profiles are comprised of foamed material comprised from the group consisting of cross-linked polyolefin, rubber, or other polymers which have a glass transition temperature below 25 degrees C., and non-cross-linked polyolefin, rubber, or other polymers which have a glass transition temperature below 25 degrees C. 
     
     
         4 . The cushion of  claim 1 , wherein at least one of the plurality of foam profiles has a different density from at least one other of the plurality of foam profiles to produce at least two zones of firmness. 
     
     
         5 . The cushion of  claim 1 , wherein the plurality of foam profiles have a density in a range of 8 kg/m 3  to 100 kg/m 3 . 
     
     
         6 . The cushion of  claim 1 , wherein the plurality of foam profiles have a foam cell size in a range of 0.01 mm to 10 mm. 
     
     
         7 . The cushion of  claim 1 , wherein the plurality of foam profiles contain at least one of a flame retardant, a smoke suppressant, an antimicrobial agent, a fragrance, a color, or an additive. 
     
     
         8 . The cushion of  claim 1 , wherein the plurality of foam profiles are comprised of open cell foam, close cell foam, or open and close cell foam. 
     
     
         9 . The cushion of  claim 1 , wherein the plurality of foam profiles have a close cell content greater than 80%. 
     
     
         10 . The cushion of  claim 1 , wherein the at least one sheet of material is comprised of either a woven or non-woven sheet of material. 
     
     
         11 . The cushion of  claim 1 , wherein the at least one sheet of material is affixed to the plurality of foam profiles using an affixation means comprised from the group consisting of thermal welding and ultrasonic welding. 
     
     
         12 . The cushion of  claim 1 , further comprising at least one void disposed between the top surfaces of adjacent foam profiles among the plurality of foam profiles. 
     
     
         13 . The cushion of  claim 1 , wherein at least one of the plurality of foam profiles has a cross-section shape in the form of a circle, an ellipse, a triangle, a square, a rectangle, a trapezoid, a polygon having more than four sides, a profile having a concave surface, and a profile having a convex surface. 
     
     
         14 . The cushion of  claim 1 , wherein at least one of the plurality of foam profiles has a cross-section shape that includes an opening. 
     
     
         15 . The cushion of  claim 1 , wherein a ratio of a width of the top surfaces of the plurality of foam profiles to a width of the bottom surfaces of the plurality of foam profiles is greater than 1.5. 
     
     
         16 . The cushion of  claim 1 , further comprising at least one end foam profile disposed on an end of the plurality of foam profiles. 
     
     
         17 . The cushion of  claim 16 , wherein the at least one end foam profile is comprised of a first end foam profile disposed on a first end of the plurality of foam profiles and a second end foam profile disposed on a second end of the plurality of foam profiles opposite the first end. 
     
     
         18 . The cushion of  claim 1 , further comprising at least one hollow section disposed in at least one of the plurality of foam profiles. 
     
     
         19 . The cushion of  claim 18 , further comprising a filler material disposed in the at least one hollow section. 
     
     
         20 . The cushion of  claim 19 , wherein the filter material is comprised from the group consisting of a bicellular material, a thermoset material, and a thermoplastic material. 
     
     
         21 . The cushion of  claim 19 , further comprising a vacuum disposed in the at least one hollow section. 
     
     
         22 . The cushion of  claim 1 , wherein the plurality of foam profiles are at least partially melted down on their top surfaces to form a pattern such as islands and grooves. 
     
     
         23 . The cushion of  claim 1 , further comprising an open cell foam layer disposed on the top surface of the plurality of foam profiles. 
     
     
         24 . The cushion of  claim 1 , further comprising two or more strips of re-closable fasteners disposed on at least a portion of the at least one sheet of material. 
     
     
         25 . The cushion of  claim 1 , further comprising at least one cut disposed between ends of at least one of the plurality of foam profiles. 
     
     
         26 . The cushion of  claim 1 , wherein at least one of the plurality of foam profiles provides at least two different zones of firmness. 
     
     
         27 . The cushion of  claim 1  providing in an apparatus comprised from the group consisting of a mattress, a bed, a seat, furniture, a mat, a beach mat, a camping mat, an athletic mat, padding, and a protection pad. 
     
     
         28 . A method of providing a cushion, comprising:
 providing a plurality of foam profiles each having a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection;   arranging the plurality of foam profiles such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane, and the bottom of the plurality of foam profiles are disposed in or substantially in a second plane parallel or substantially parallel to the first plane; and   affixing at least one sheet of material to at least one of the top surface and the bottom surface of the plurality of foam profiles.   
     
     
         29 . The method of  claim 28 , wherein providing the plurality of foam profiles comprises providing at least one first foam profile among the plurality of foam profiles of a first density and at least one second foam profile among the plurality of foam profiles of a second density different from the first density. 
     
     
         30 . The method of  claim 28 , wherein affixing the at least one sheet of material is comprised of welding the at least one sheet of material to the at least one of the top surface and the bottom surface of the plurality of foam profiles. 
     
     
         31 . The method of  claim 28 , further comprising at least one void disposed between the top surfaces of adjacent foam profiles among the plurality of foam profiles. 
     
     
         32 . The method of  claim 28 , wherein providing the plurality of foam profiles further comprises providing at least one of the plurality of foam profiles having a cross-section shape that includes an opening. 
     
     
         33 . The method of  claim 28 , further comprising disposing at least one end foam profile on an end of the plurality of foam profiles. 
     
     
         34 . The method of  claim 28 , further comprising disposing at least one hollow section in at least one of the plurality of foam profiles. 
     
     
         35 . The method of  claim 34 , further comprising disposing a filler material in the at least one hollow section. 
     
     
         36 . The method of  claim 28 , further comprising at least partially melting the plurality of foam profiles down on their top surfaces to form a pattern such as islands and grooves. 
     
     
         37 . The method of  claim 28 , further comprising providing two or more strips of re-closable fasteners disposed on at least a portion of the at least one sheet of material. 
     
     
         38 . The method of  claim 28 , further comprising disposing at least one cut between ends of at least one of the plurality of foam profiles. 
     
     
         39 . The method of  claim 28 , further comprising providing at least two different zones of firmness in the plurality of foam profiles.