MATTRESSES, CUSHIONS, AND BODY-SUPPORT PADS OR MATS WITH DEFORMABLE WALLS HAVING FIBER STRANDS EMBEDDED THEREIN
Mattresses, cushions, and body-support mats or pads include a plurality of layers extending in a depth direction from a resting surface, where the resting surface is capable of supporting user(s), to a lower surface, the lower surface being opposite the resting surface. The plurality of layers include a comfort layer that forms an upper layer proximate to the resting surface, where the comfort layer includes deformable walls separated by voids and the deformable walls include a plurality of fiber strands embedded in a cushioning media.
1 . A method for manufacturing a mattress, the method comprising:
forming at least one mattress layer comprising deformable walls separated by voids, the deformable walls defined by a cushioning media and a plurality of polymeric fiber strands embedded throughout a volume of the cushioning media; and
adjusting a concentration of the polymeric fiber strands such that the concentration of polymeric fiber strands is greater in an upper portion of each deformable wall than in a lower portion of each deformable wall to form a gradient of said polymeric fiber strands across a thickness of the deformable walls.
2 . The method of claim 1 , wherein the at least one mattress layer comprises a height within a range of about 0.5 inches to about 4 inches.
3 . The method of claim 1 , wherein the voids comprise through holes extending from a top surface to a bottom surface of the at least one mattress layer.
4 . The method of claim 1 , wherein the voids partly extend from a top surface to a bottom surface of the at least one mattress layer.
5 . The method of claim 1 , wherein the deformable walls are configured as buckling walls capable of buckling due to pressure applied by an object.
6 . The method of claim 1 , wherein the deformable walls are interconnected to form a repeating pattern.
7 . The method of claim 6 , wherein the repeating pattern comprises a rectangular grid pattern, a weave pattern, a grid-like array of pillars or a triangular-shaped grid pattern.
8 . The method of claim 7 , wherein the pillars comprise a columnar shape, a cross-shaped support pillar, an H-shaped support pillar, a T-shaped support pillar, a hexagonal shape or a combination comprising at least one of the foregoing.
9 . The method of claim 1 , wherein the deformable walls are positioned in a columnar shape.
10 . The method of claim 1 , wherein the deformable walls comprise a plurality of individually supported spring-like structures positioned in an array.
11 . The method of claim 1 , wherein one or more of the deformable walls are irregularly shaped.
12 . The method of claim 1 , further comprising forming an edge-support surrounding at least a portion of the periphery of the at least one mattress layer.
13 . The method of claim 12 , wherein the edge-support comprises the deformable walls.
14 . The method of claim 12 , wherein the edge-support comprises the cushioning media.
15 . The method of claim 12 , wherein the edge support comprises the plurality of fiber strands embedded in the cushioning media.
16 . The method of claim 12 , wherein the edge-support comprises a support structure having a higher rigidity than the deformable walls.
17 . The method of claim 12 , wherein the edge-support comprises a polymeric foam.
18 . The method of claim 12 , wherein the edge-support comprises a girdle to retain shape of one or more of the deformable walls.
19 . The method of claim 12 , wherein the edge-support is configured to provide structural support to the deformable walls.
20 . The method of claim 1 , wherein the deformable walls further comprise an additive material.