Cushions having voids in a lower surface

Abstract

Mattresses, cushions, and body-support mats or pads are disclosed. Polymer(s) at least partially define a length, width and depth, the depth extending from an upper surface proximate to where a user rests to a lower surface opposite the upper surface. Voids in the polymer traverse at least a portion of the width. The plurality of voids are located at the lower surface and/or the upper surface and are defined by polymer walls and wall(s) of polymer walls define each polymer foot of polymer feet. A first region of a plurality of lower surface regions includes at least one foot of the plurality of polymer feet that has a first size. A second region of the plurality of lower surface regions includes at least one other foot having a second size. The at least one other foot spans a greater distance along the length than the at least one foot.

What is claimed is: 
     
         1 . A body support cushion, comprising:
 one or more polymer layers at least partially defining a length and a width of the cushion, wherein the one or more polymers span a depth that is perpendicular to the length and the width of the cushion and extend from an upper surface of the one or more polymer layers that is proximate to where a user rests to a lower surface of the one or more polymer layers that is opposite the upper surface;   a plurality of voids in at least one polymer layer of the one or more polymer layers, the plurality of voids fully traversing the width of the cushion, wherein the plurality of voids extend from the lower surface and form polymer walls of the at least one polymer layer;   a plurality of polymer feet formed by the at least one polymer layer via the plurality of voids, wherein each polymer foot is defined by adjacent polymer walls; and   a plurality of lower surface regions formed of the plurality of voids and the plurality of polymer feet, the plurality of lower surface regions comprising a first region that includes a plurality of first feet of a first size, and a second region that includes a plurality of second feet of a second size,   wherein each second foot of the second size spans a greater distance along the length of the cushion than each first foot of the first size.   
     
     
         2 . The cushion of  claim 1 , wherein the first and second regions are adjacent to each other along the length of the cushion. 
     
     
         3 . The cushion of  claim 2 , wherein the plurality of lower surface regions further comprises a third region that includes at least one third foot of a third size that spans a distance along the length of the cushion that differs from at least one of the first and second sizes. 
     
     
         4 . The cushion of  claim 3 , wherein each third foot of the third size spans a smaller size along the length of the cushion than each second foot of the second size. 
     
     
         5 . The cushion of  claim 4 , wherein the third size is substantially the same as the first size. 
     
     
         6 . The cushion of  claim 4 , wherein the second region is arranged between and adjacent to the first and third regions along the length of the cushion. 
     
     
         7 . The cushion of  claim 6 , wherein the first region is positioned at a first end of the cushion along the length direction, the third the is positioned at a second end of the cushion along the length direction, and the second region extends between the first and second regions along the length direction. 
     
     
         8 . The cushion of  claim 1 , wherein the plurality of voids extend parallel to each other. 
     
     
         9 . The cushion of  claim 1 , wherein the plurality of voids remove between 10% volume and 30% volume of the one or more polymer layers defined by the length and the width of the cushion. 
     
     
         10 . The cushion of  claim 1 , wherein each of the plurality of voids extend in a depth direction corresponding to the depth of at least one inch from the lower surface towards the upper surface. 
     
     
         11 . The cushion according to  claim 10 , where at least one void of the first plurality of voids extends in a depth direction corresponding to the depth a first distance from the lower surface towards the upper surface and at least one other void of the first plurality of voids extends in the depth direction a second distance from the lower surface towards the upper surface, wherein a third void of the first plurality of voids extends in the depth direction a third distance from the lower surface towards the upper surface, wherein the third distance is longer than both the first distance and the second distance 
     
     
         12 . The cushion of  claim 1 , wherein the one or more polymer layers comprise one or more of a polyurethane layer, a polyisocyanurate layer and a polyol layer. 
     
     
         13 . The cushion of  claim 1 , wherein the one or more polymer layers include a first polymer layer proximate the upper surface, and a second polymer layer proximate the lower surface that differs from the first polymer layer, wherein the plurality of voids extend into the second polymer layer and not the first polymer layer, and wherein the plurality of polymer feet are formed of the second polymer layer. 
     
     
         14 . The cushion of  claim 13 , wherein the first polymer layer and the second polymer layer comprise different densities and are formed of differing polymer materials. 
     
     
         15 . The cushion of  claim 1 , wherein the cushion further comprises at a plurality grooves in at least one polymer layer of the one or more polymer layers, the plurality of grooves extending along the length of the cushion, and wherein the plurality of grooves extend from the lower surface and intersect at least one of the plurality of voids. 
     
     
         16 . The cushion of  claim 15 , wherein each of the plurality of grooves extend in the depth direction from the lower surface within a range of about 1 inch to about 5 inches, and wherein the plurality of grooves are substantially evenly spaced apart in the width direction. 
     
     
         17 . The cushion of  claim 1 , wherein the one or more polymer layers further comprise a plurality of perforations that at least partially traverse the depth of the one or more polymer layers, wherein each of the plurality of perforations comprise a diameter within a range of about 0.25 inches to about 3 inches, and remove a total volume of the one or more polymers within a range of about 5% to about 15%. 
     
     
         18 . The cushion of  claim 1 , wherein at least one of the plurality of voids is at least partially filled with at least one material having a density lower than, and a stretchability greater than, that of the at least one polymer layer of the one or more polymer layers. 
     
     
         19 . The cushion of  claim 1 , wherein at least one of the plurality of voids comprises a gas pocket, the gas pocket comprising at least one of a gas release valve and at least one gas filling valve, and being filled with a gas selected from the group consisting of air, nitrogen, and argon. 
     
     
         20 . The cushion according to  claim 1 , wherein the body support cushion is configured as a mattress, a body-support pad or a body-support mat.