Cushioning and support system

Abstract

In some embodiments, a support structures can be formed from a support structure matrix comprising a plurality of spring structures embedded within the support structure matrix. The plurality of spring structures can be formed from the same material or a different material, and can have the same or different durometers. The plurality of spring structures can be configured to deform and return to its original shape after deformation. The orientation and structure of the spring structures can vary depending on a desired durometer and/or function within the support structure.

We claim: 
     
         1 . A support structure comprising:
 a support structure matrix formed with a plurality of openings; and   a plurality of spring structures embedded within the plurality of openings of the support structure matrix, the spring structures comprising a spring material that is bonded to the support structure matrix;   wherein the plurality of openings comprise at least a plurality of first openings and a plurality of second openings, the first openings having a different size, shape, and/or orientation that is different from the second openings relative to the support structure matrix.   wherein the plurality of spring structures are configured to deform and return to its original shape after deformation.   
     
     
         2 . The support structure of  claim 1 , wherein the spring material of at least some of the spring structures comprise a thermoplastic elastomeric polymer. 
     
     
         3 . The support structure of  claim 2 , wherein the thermoplastic elastomeric polymer comprises styrenic block copolymers. 
     
     
         4 . The support structure of  claim 2 , wherein the thermoplastic elastomeric polymer comprises a rubber and/or a hydrogenated rubber. 
     
     
         5 . The support structure of  claim 1 , wherein the first openings and second openings comprise channels, and the channels of the first openings have a different depth than the channels of the second openings. 
     
     
         6 . The support structure of  claim 5 , wherein the channels of the first openings are interspersed between at least some channels of the second openings. 
     
     
         7 . The support structure of  claim 1 , wherein at least some of the plurality of openings are fully-embedded in the support structure matrix. 
     
     
         8 . The support structure of  claim 1 , wherein at least some of the plurality of openings are fully-embedded in the support structure matrix. 
     
     
         9 . The support structure of  claim 1 , wherein the support structure matrix comprises a plurality of layers that comprise at least a first layer, a second layer, and a third layer, and the first layer is bonded to the second layer, and the second layer is bonded to the third layer, 
 wherein the plurality of openings are formed in one or more of the first layer, second layer, and third layer.   
     
     
         10 . The support structure of  claim 1 , wherein at least some of the spring structures are vertically stacked to form a stacked spring system. 
     
     
         11 . The support structure of  claim 10 , wherein the stacked spring system comprises spring structures that have different wall thicknesses. 
     
     
         12 . The support structure of  claim 1 , wherein the spring material is the same in each of the plurality of openings. 
     
     
         13 . The support structure of  claim 1 , wherein the spring material is the same in each of the plurality of openings. 
     
     
         14 . The support structure of  claim 1 , wherein the spring material of the first plurality of openings is different than the spring material of the second plurality of openings. 
     
     
         15 . The support structure of  claim 1 , wherein at least some of the plurality of spring structures comprise ring-shaped structures. 
     
     
         16 . The support structure of  claim 1 , wherein at least some of the plurality of spring structures form honeycombed-shaped structures. 
     
     
         17 . The support structure of  claim 1 , wherein at least some of the plurality of spring structures are spaced apart from one another and positioned within different horizontal planes, such that some of the plurality of spring structures are at a different height than others of the plurality of spring structures. 
     
     
         18 . The support structure of  claim 1 , wherein the spring structure comprises an elastomer, silicone, expanded metal, wood foam, bamboo foam, natural materials, or a combination thereof. 
     
     
         19 . The support structure of  claim 1 , wherein the support structure is a mattress. 
     
     
         20 . The support structure of  claim 1 , wherein the support structure is a cushion for a seat and/or item of furniture.