Support cushions including foam arches

Inventors: Brian Bryant (Fulton, MS); David Harris (Mantachie, MS); Timothy Strother (Iuka, MS)

Assignee: COMFORT REVOLUTION, LLC

A47C27/144 A47C27/148 A47C27/15

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Quick Facts

Patent No.: US 12702238
App. No.: 18/681,183
Granted: Aug 11, 2026
Kind: B2

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Abstract

A support cushion includes a tub defining a well and a plurality of foam arches positioned in the well. Each foam arch includes an upper curved portion, and each foam arch is positioned in the well such that each upper curved portion is opposite a bottom panel of the tub. A body supporting layer having a first surface and a second surface opposite the first surface is positioned over the well and atop the plurality of flexible foam arches.

Claims (36)

1 . A support cushion, comprising:

a tub including a flat bottom panel and a sidewall collectively defining a well;

a plurality of foam arches positioned in the well, each foam arch including an upper curved portion, an inner surface, an outer surface, and two end surfaces, and each foam arch positioned in the well such that each upper curved portion is opposite the bottom panel of the tub and the two end surfaces are positioned against the flat bottom panel of the tub, and such that the outer surface of each foam arch is positioned adjacent to and in contact with an outer surface of another one of the plurality of foam arches along a length of the outer surface extending from the upper curved portion to a respective one of the two end surfaces of each foam arch; and

a body supporting layer having a first surface and a second surface opposite the first surface, the second surface positioned over the well and atop the plurality of flexible foam arches,

wherein the inner surface of each foam arch is connected to itself to maintain a shape of each foam arch.

2 . The support cushion of claim 1 , wherein the well of the tub has a width, and wherein each foam arch has a length spanning the width of the well.

3 . The support cushion of claim 2 , wherein the tub has a longitudinal axis, and wherein the upper curved portion of each foam arch extends in a same direction as the longitudinal axis of the tub.

4 . The support cushion of claim 1 , wherein each foam arch is independent from each other foam arch.

5 . The support cushion of claim 1 , wherein each foam arch is encased in a fabric.

6 . The support cushion of claim 1 , wherein each foam arch is affixed to an adjacent foam arch.

7 . The support cushion of claim 1 , further including a fabric band extending along a longitudinal axis of the tub, the fabric band affixed to an edge surface of each foam arch to connect the plurality of foam arches.

8 . The support cushion of claim 1 , wherein each foam arch is in the shape of a round arch.

9 . The support cushion of claim 1 , wherein the body supporting layer and the plurality of foam arches are comprised of a flexible foam.

10 . The support cushion of claim 9 , wherein the body supporting layer is comprised of a visco-elastic foam.

11 . The support cushion of claim 9 , wherein the tub is comprised of a flexible foam; and wherein the flexible foam comprising the body supporting layer has a density less than a density of the flexible foam comprising the tub.

12 . The support cushion of claim 9 , wherein the sidewall of the tub includes an inner support encased in a flexible foam.

13 . A mattress assembly, comprising

a tub including a flat bottom panel and a sidewall collectively defining a well, the well having a width;

a plurality of foam arches positioned in the well, each foam arch having a length spanning the width of the well and including an upper curved portion, an inner surface, an outer surface, and two end surfaces, and each foam arch positioned in the well such that each upper curved portion is opposite the bottom panel of the tub and extends in a same direction as a longitudinal axis of the tub and the two end surfaces are positioned against the flat bottom panel of the tub, and such that the outer surface of each foam arch is positioned adjacent to and in contact with an outer surface of another one of the plurality of foam arches along a length of the outer surface extending from the upper curved portion to a respective one of the two end surfaces of each foam arch; and

a body supporting layer having a first surface and a second surface opposite the first surface, the second surface positioned over the well and atop the plurality of foam arches, and

wherein the inner surface of each foam arch is connected to itself to maintain a shape of each foam arch.

14 . The support cushion of claim 13 , wherein each foam arch is independent from each other foam arch.

15 . The support cushion of claim 13 , wherein each foam arch is encased in a fabric.

16 . The support cushion of claim 13 , wherein each foam arch is affixed to an adjacent foam arch.

17 . The support cushion of claim 13 , further including a fabric band extending along a longitudinal axis of the tub, the fabric band affixed to an edge surface of each foam arch to connect the plurality of foam arches.

18 . The support cushion of claim 13 , wherein each foam arch is in the shape of a round arch.

19 . The support cushion of claim 13 , wherein the body supporting layer and the plurality of foam arches are comprised of a flexible foam.

20 . The support cushion of claim 19 , wherein the body supporting layer is comprised of a visco-elastic foam.

21 . The support cushion of claim 19 , wherein the tub is comprised of a flexible foam; and wherein the flexible foam comprising the body supporting layer has a density less than a density of the flexible foam comprising the tub.

22 . The support cushion of claim 19 , wherein the sidewall of the tub includes an inner support encased in a flexible foam.

23 . A foam insert for use in a mattress assembly, the foam insert comprising:

a plurality of foam arches, each foam arch having a length and including edge surfaces on either end of the length of the foam arch, an outer surface, an inner surface opposite the outer surface, an upper curved portion extending perpendicular to a direction of the length of the foam arch, and a flat end portion opposite the upper curved portion;

a fabric band affixed to each edge surface of the plurality of foam arches and extending along a longitudinal axis of the plurality of foam arches to connect the plurality of foam arches together,

wherein the outer surface of each foam arch is positioned adjacent to and in contact with the outer surface of another one of the plurality of foam arches along a portion of each foam arch extending from the upper curved portion to a respective one of the end surfaces of each foam arch, and

wherein the inner surface of each foam arch is connected to itself to maintain a shape of each foam arch.

24 . The foam insert of claim 23 , wherein each of the foam arches is made by bending a slab of foam having a first surface, a second surface opposite from the first surface, and two end surfaces that extend between the first surface and the second surface along a long axis of the slab of foam such that the two end surfaces are brought towards each other to form the flat end portion of the foam arch.