Wave springs and cushioning articles containing the same
Cushioning articles such as mattresses can include a three dimensional wave spring core. The wave spring includes a polymeric lattice spring structure including a plurality of alternating layers stackedly arranged to define a height of the wave spring, wherein each one of the alternating layers is defined by a single strand having one or more upward and downward undulations, wherein the alternating layers are arranged such that an upward undulation of one layer is connected to a downward undulation of the other layer to define a cell configured to receive a compressive force, wherein the lattice structure has a sinusoidal shape when viewed top down and is configured to have three dimensional structure.
1. A mattress comprising:
a base foam layer;
a sidewall disposed about a perimeter of the base layer to define a cavity having a length, a width and a height dimension; and
one or more three dimensional wave springs disposed within the cavity and configured to correspond to the length, the width and the height dimensions of the cavity, the one or more three dimensional wave springs comprising:
a lattice structure comprising a plurality of alternating strands stackedly arranged to define a height dimension of the wave spring, wherein each one of the alternating strands have one or more upward and downward undulations arranged such that an upward undulation of one strand is connected to a downward undulation of an adjacent strand to define multiple cells there between arranged in columns and configured to receive a compressive force, wherein the lattice structure further comprises a non-linear shape when viewed top down, wherein the non-linear shape of the lattice structure defines a length and a width dimension of the one or more three dimensional wave springs, and wherein the non-linear shape of the lattice structure when viewed top down is defined by a continuous sheet of the lattice structure folded back and forth over itself at defined intervals.
2. The mattress of claim 1 , wherein the non-linear shape of the lattice structure when viewed top down comprises a plurality of the lattice structures in a side by side relationship and coupled at contact points.
3. The mattress of claim 1 , wherein the height dimension of the one or more three dimensional wave springs is equal to the height dimension of the cavity.
4. The mattress of claim 1 , wherein the one or more three dimensional wave springs are formed of a polymer.
5. The mattress of claim 4 , wherein the polymer comprises nylon, polyethylenes, polypropylenes, polystyrenes, polyurethanes, polystyrene derivatives, acrylonitrile-butadiene-styrene copolymers, polyesters, poly-alpha-methyl-styrenes, polyvinyl chlorides, poly(meth)acrylates, polyacrylates, poly-acrylonitriles, polyacrylonitriles, phenolic resins, polyamides, polycarbonates, polyethers, polysulfone, polyvinyl acetate, polyether ketones, epoxy resin, melamine-formaldehyde resins, or derivatives or combinations or copolymers of the polymers mentioned and any blends of two or more polymers.
6. The mattress of claim 4 , wherein the polymer is selected to have an elastic modulus of about 800 MPa to about 1500 MPa.
7. The mattress of claim 1 , wherein the multiple cells have a height and a width, the height to width ratio of each cell being from about 1:3 to about 1:20.
8. The mattress of claim 1 , wherein each one of the multiple cells has a curvilinear shape or an elliptical shape.
9. The mattress of claim 1 , wherein each column of cells defined by the lattice structure contains from 2 to 20 cells.
10. The mattress of claim 1 , wherein the non-linear shape of the lattice structure is sinusoidal or diamond shaped.
11. A three dimensional polymeric wave spring comprising:
a lattice structure comprising a plurality of alternating strands of a polymer stackedly arranged to define a height dimension of the wave spring, wherein each one of the alternating strands have one or more upward and downward undulations arranged such that an upward undulation of one strand is connected to a downward undulation of an adjacent strand to define multiple cells there between arranged in columns and configured to receive a compressive force, wherein the lattice structure further comprises a non-linear shape when viewed top down, wherein the non-linear shape of the lattice structure defines a length and a width dimension of the one or more three dimensional wave springs, and wherein the non-linear shape of the lattice structure when viewed top down is defined by a continuous sheet folded back and forth over itself at defined intervals.
12. The three dimensional polymeric wave spring of claim 11 , wherein the non-linear shape of the lattice structure when viewed top down comprises a plurality of the lattice structures in a side by side relationship coupled at contact points.
13. The three dimensional polymeric wave spring of claim 11 , wherein the height dimension of the one or more three dimensional wave springs is equal to the height dimension of the cavity.
14. The three dimensional polymeric wave spring of claim 11 , wherein the polymer comprises nylon, polyethylenes, polypropylenes, polystyrenes, polyurethanes, polystyrene derivatives, acrylonitrile-butadiene-styrene copolymers, polyesters, poly-alpha-methyl-styrenes, polyvinyl chlorides, poly(meth)acrylates, polyacrylates, poly-acrylonitriles, polyacrylonitriles, phenolic resins, polyamides, polycarbonates, polyethers, polysulfone, polyvinyl acetate, polyether ketones, epoxy resin, melamine-formaldehyde resins, or derivatives or combinations or copolymers of the polymers mentioned and any blends of two or more polymers.
15. The three dimensional polymeric wave spring of claim 11 , wherein the polymer is selected to have an elastic modulus of about 800 MPa to about 1500 MPa.
16. The three dimensional polymeric wave spring of claim 11 , wherein the multiple cells have a height and a width, the height to width ratio of each cell being from about 1:3 to about 1:20.
17. The three dimensional polymeric wave spring of claim 11 , wherein each one of the multiple cells has a curvilinear shape or an elliptical shape.
18. The three dimensional polymeric wave spring of claim 11 , wherein each column of cells defined by the lattice structure contains from 2 to 20 cells.
19. The three dimensional polymeric wave spring of claim 11 , wherein the non-linear shape of the lattice structure is sinusoidal or diamond shaped.