Multilayer load bearing structure

Abstract

Support elements and support structures form the basis of ergonomic body supports for chairs, mattresses and other structures. The support elements may be individually designed according to their location and body support function. Thus, the structures that include the support elements may provide point-tailored support for any part of the body to enhance comfort, fit, and proper anatomical support.

1 . A body support structure comprising:
 an upper support layer comprising a first plurality of peaks and a first plurality of valleys;   a lower base layer comprising a second plurality of peaks and a second plurality of valleys, wherein the first plurality of peaks is vertically aligned with the second plurality of valleys; and   an intermediate layer comprising an elastomeric material disposed between the upper support layer and the lower base layer.   
     
     
         2 . The body support structure of  claim 1  wherein the intermediate layer is engaged by the first and second plurality of peaks. 
     
     
         3 . The body support structure of  claim 1  wherein the upper support layer and the lower base layer are moveable from an unloaded condition toward each other to a loaded condition in response to an applied load, with the first plurality of peaks moveable toward and into said second plurality of valleys as the upper support layer and lower base layer are moved to the loaded condition, and wherein the intermediate layer is deformable in response to the relative movement of said upper support layer and said lower base layer. 
     
     
         4 . The body support structure of  claim 3  wherein the intermediate layer is substantially planar when the upper support layer and lower base layer are in the unloaded condition. 
     
     
         5 . The body support structure of  claim 1  wherein at least some adjacent ones of the first plurality of peaks are separated by a first distance and at least some adjacent others of the first plurality of peaks are separated by a second distance different than the first distance. 
     
     
         6 . The body support structure of  claim 5  wherein at least some of the second plurality of valleys underlying the at least some of the first plurality of peaks are separated by the first distance and at least some others of the second plurality of valleys underlying the at least some others of the first plurality of peaks are separated by the second distance. 
     
     
         7 . The body support structure of  claim 1  wherein at least one of the first plurality of peaks has a first height and at least one of the second plurality of valleys underlying the at least one of the first plurality of peaks has a first depth, the first height and the first depth providing a pre-selected travel distance for the at least one of the first plurality of peaks relative to the at least one of the second plurality of valleys. 
     
     
         8 . The body support structure of  claim 7  wherein at least another of the first plurality of peaks has a second height different than the first height and at least another of the second plurality of valleys underlying the at least another of the first plurality of peaks has a second depth different than the first depth. 
     
     
         9 . A body support structure comprising:
 an upper support layer comprising a first plurality of peaks and a first plurality of valleys, wherein at least some adjacent ones of the first plurality of peaks are spaced apart a first distance and at least some other adjacent ones of the first plurality of peaks are spaced apart a second distance different than the first distance;   a lower base layer comprising a second plurality of peaks and a second plurality of valleys, wherein the first plurality of peaks is vertically aligned with the second plurality of valleys, wherein at least some adjacent ones of the second plurality of valleys underlying the at least some adjacent ones of the first plurality of peaks are spaced apart the first distance, and at least some other adjacent ones of the second plurality of valleys underlying the at least some other adjacent ones of the first plurality of peaks are spaced apart the second distance; and   an intermediate layer comprising an elastomeric material disposed between the upper support layer and the lower base layer.   
     
     
         10 . The body support structure of  claim 9  wherein the intermediate layer is engaged by the first and second plurality of peaks. 
     
     
         11 . The body support structure of  claim 9  wherein the upper support layer and the lower base layer are moveable from an unloaded condition toward each other to a loaded condition in response to an applied load, with the first plurality of peaks moveable toward and into said second plurality of valleys as the upper support layer and lower base layer are moved to the loaded condition, and wherein the intermediate layer is deformable in response to the relative movement of said upper support layer and said lower base layer. 
     
     
         12 . The body support structure of  claim 11  wherein the intermediate layer is substantially planar when the upper support layer and lower base layer are in the unloaded condition. 
     
     
         13 . A method of supporting a user on a body support structure comprising:
 applying a body load to a body support structure and thereby applying a load to an upper support layer comprising a first plurality of peaks and a first plurality of valleys;   applying an applied load with the first plurality of peaks to a first side of an intermediate layer comprising an elastomeric material;   applying a reactive load to an opposite side of the intermediate layer with a second plurality of peaks configured on a lower base layer;   moving the first plurality of peaks toward the second plurality of valleys; and   deforming the intermediate layer between the upper support layer and the lower base layer, wherein the lower base layer further comprises a second plurality of valleys, wherein the first plurality of peaks is vertically aligned with the second plurality of valleys and the second plurality of peaks is vertically aligned with the first plurality of valleys.   
     
     
         14 . The method of  claim 13  wherein the intermediate layer is substantially planar prior to the applying of the body load. 
     
     
         15 . The method of  claim 13  wherein at least some adjacent ones of the first plurality of peaks are separated by a first distance and at least some adjacent others of the first plurality of peaks are separated by a second distance different than the first distance. 
     
     
         16 . The method of  claim 15  wherein at least some of the second plurality of valleys underlying the at least some of the first plurality of peaks are separated by the first distance and at least some others of the second plurality of valleys underlying the at least some others of the first plurality of peaks are separated by the second distance. 
     
     
         17 . The method of  claim 13  wherein at least one of the first plurality of peaks has a first height and at least one of the second plurality of valleys underlying the at least one of the first plurality of peaks has a first depth, the first height and the first depth providing a pre-selected travel distance for the at least one of the first plurality of peaks relative to the at least one of the second plurality of valleys. 
     
     
         18 . The method of  claim 17  wherein at least another of the first plurality of peaks has a second height different than the first height and at least another of the second plurality of valleys underlying the at least another of the first plurality of peaks has a second depth different than the first depth.