WO2022125435A1

WO2022125435A1 - Variable stiffness mattress systems and related methods

Info

Publication number: WO2022125435A1
Application number: PCT/US2021/062004
Authority: WO
Inventors: Mark SMIDERLE
Original assignee: Soft-Tex International, Inc.
Priority date: 2020-12-10
Filing date: 2021-12-06
Publication date: 2022-06-16

Abstract

Variable stiffness body support systems (e.g., mattress or cushion systems) and related methods are disclosed. The body support systems include at least one cushion layer comprising an outer cover layer and at least one flexible foam layer positioned below the outer cover layer. The body support systems also include a plurality of rigid support members positioned below the at least one cushion layer and arranged along at least one of a width and a length dimension of the at least one cushion layer. The body support systems further include a plurality of drive units positioned below the rigid support members such that at least one drive unit is associated with each support member. The drive units are configured to selectively vary the position of the rigid support members along a thickness direction to variably compress zones of the at least one flexible foam layer to vary stiffnesses of the zones.

Description

VARIABLE STIFFNESS MATTRESS SYSTEMS AND RELATED METHODS

CROSS-REFERENCE TO RELATED APPLICATION

[001] The application claims priority benefit of U.S. Provisional Patent Application No. 63/123,596, filed on December 10, 2020, and entitled Variable Stiffness Mattress Systems and Related Methods, the entire contents of which are hereby expressly incorporated herein by reference in their entirety.

FIELD OF THE DISCLOSURE

[002] The present disclosure generally relates to body support systems (e.g., cushions and mattresses) having adjustable stiffness/firmness of portions thereof, and more specifically to body support systems with zones of foam and/or other cushioning material that selectively vary in thickness, and thereby stiffness/firmness, via at least one corresponding drive unit.

BACKGROUND

[003] Sleep plays an important role in a person’s overall health and enjoyment of life. The quality and quantity of sleep affect the body’s ability to function normally and the ability to reach peak performance. Physiologically, sleep affects brain activity, heart rate, blood flow, body temperature and other physiological parameters. Sleep deprivation shows a strong correlation to obesity, diabetes, stroke, depression, and hypertension.

[004] Restful sleep is at least partially dependent upon the level of comfort of an individual while lying prone on a mattress. Concentration of pressure on certain parts of the body and/or poor skeletal alignment are been linked to restless sleep. Sleeping on a mattress or other support surface that does not properly support and conform to the shape of a particular user’s body or to the curves of the particular user’s spine can significantly contribute to restlessness or inability to sleep.

[005] Traditionally sleep systems incorporate a mattress consisting of an outer layer of fabric and padding, surrounded by a series of spring coils. The fabric is stretched tightly across the padding to hold them in place, which in many cases creates a surface that is too hard.

The mattress is usually supported by a flexible box spring, thereby enabling the mattress to compress where needed. However, the stiffness of the box springs can cause it to push back against the mattress in areas of greatest compression.

[006] More recently, foam mattresses have been developed to provide adequate support without the use of spring coils. Current foam technology can be categorized according to load bearing capacity by time and temperature variables. Rates of recovery and thermal response rates of foam samples are also measured. Although conventional foam mattresses provide the advantage of shape conformity and thermal responsiveness, structural support is sacrificed, particularly in areas of highest load concentrations. Although changing the stiffness/firmness of a foam mattress can alleviate this problem to some degree, the optimal stiffness should be different depending on body type/shape/configuration and weight, for example. Bedding manufacturers tend to ignore body types and weight, and market sleep systems constructed under an inaccurate assumption that 95% of the population has the same body metrics. Further, personal preferences as to the stiffness/firmness and support of matters that is most comfortable differ from individual to individual, even within the same body types.

[007] Accordingly, what is needed is an improved body support system (e.g., cushions and mattresses) that can be selectively optimized to provide the desired structural support for an individual’s body configuration and preferences. Moreover, what is needed in the industry is a body support system, in which the stiffness/firmness can be selectively adjusted repeatedly, and without a significant manufacturing cost.

[008] Therefore, there is still a need of body support systems, and in particular mattress systems, with adjustable stiffness/firmness, and potentially support, which eliminates the problems discussed above.

[009] While certain aspects of conventional technologies have been discussed to facilitate disclosure of the invention, Applicants in no way disclaim these technical aspects, and it is contemplated that the claimed invention may encompass one or more of the conventional technical aspects discussed herein.

[0010] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY OF THE DISCLOSURE

[0011] Briefly, the present inventions satisfy the need for improved body support systems/devices with portions or zones that can be selectively (and repeatedly) optimized to provide a desired comfort (e.g., stiffness/firmness) and/or support for an individual according to their physiological needs and/or desires, without a significant increase in manufacturing costs that would normally be associated with such systems/devices.

[0012] Certain embodiments of the presently-disclosed variable stiffness/firmness body support (e.g., mattress and cushion) systems, and methods for making the and using the variable stiffness/firmness body support systems and components thereof, have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the variable stiffness/firmness body support systems and methods as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art.

[0013] One embodiment of the present disclosure provides a variable stiffness/firmness body support (e.g., cushion or mattress) system configured such that zones or areas thereof can be selectively varied or optimized to provide a desired stiffness/firmness (and potentially structural support) and for a user’s preference (regardless of their body type and weight). The variable stiffness body support system may include at least one cushioning layer, such as a foam layer, and a plurality of individually-controllable drive units that are positioned below respective areas or zones of the cushioning layer. The drive units are configured to selectively vary in length such that ends thereof that engage a bottom side or portion of differing zones or portions of the at least one cushion layer rise and lower in a thickness direction of the cushioning layer. The drive units may be physically supported there-below by a support frame, structure or member, and the top side of the at least one cushioning layer may be restrained from movement is a direction away from the top side thereof (along the thickness direction) via an outer layer. As such, as the drive units selectively lengthen/shorten in the thickness direction, and the ends thereof thereby rise/lower in the thickness direction, the zones/portions of the at least one cushioning layer become more/less compressed. As the compression of the zones of the at least one cushioning layer varies, the stiffness/firmness thereof varies. Since the drive units are selectively controllable, the systems provide for selectively controllable variable stiffness/firmness of zones/portions of the body support system.

[0014] In one aspect, the present disclosure provides a variable stiffness body support system that comprises at least one cushion layer, a plurality of rigid support members and a plurality of drive units. The at least one cushion layer comprises an outer cover layer and at least one flexible foam layer positioned below the outer cover layer. The plurality of rigid support members are positioned below the at least one cushion layer, and are arranged along at least one of a width and a length dimension of the at least one cushion layer. The plurality of drive units are positioned below the rigid support members such that each support member is associated with at least one drive unit. The drive units are configured to independently selectively vary the position of the rigid support members along a thickness direction to variably compress zones of the at least one flexible foam layer between the support members and the outer cover layer in the thickness direction and, thereby, vary stiffnesses of the zones.

[0015] In some embodiments, the plurality of support members and the plurality of drive units are arranged along the width and the length dimensions. In some embodiments, at least three support members and at least three drive units associated therewith are arranged along the width dimension. In some embodiments, at least three support members and at least three drive units associated therewith are arranged along the length dimension. In some embodiments, the zones extend essentially over the entire width of the mattress, and are arranged along the length of the mattress.

[0016] In some embodiments, the plurality of drive units comprise micro-motors. In some embodiments, the plurality of drive units comprise linear actuators. [0017] In some embodiments, the at least one flexible foam layer comprises polyurethane foam. In some embodiments, the at least one flexible foam layer comprises viscoelastic foam.

[0018] In some embodiments, the support members comprise plate members. In some such embodiments, the plate members comprise a planar top surface and/or a planar bottom surface. [0019] In some embodiments, the system further comprises a frame structure positioned below the plurality of drive units, the frame structure physically supporting the plurality of drive units. In some such embodiments, the outer cover layer extends about the frame structure.

[0020] In some embodiments, the outer cover layer extends about the at least one flexible foam layer. In some embodiments, the outer cover layer extends about the plurality of support members and the plurality of drive units. In some embodiments, the outer cover layer comprises a fabric layer. In some embodiments, the outer cover layer comprises a fire sock.

[0021] In some embodiments, the system further comprises a control unit configured to selectively control actuation of the drive units and, thereby, the position of the support members along the thickness direction to selectively variably compress the zones of the at least one flexible foam layer between the support members and the outer cover layer in the thickness direction to vary the stiffnesses of the zones. In some embodiments, the control unit is manually operable by a user. In some embodiments, the control unit comprises a remote control device that is configured to be manually operable by a user and control the control unit. In some embodiments, the remote control device is configured to wirelessly communicate with the control unit. In some embodiments, the remote control device and the control unit are coupled via at least one electrical communication wire. In some embodiments, the control unit comprises one or more visual indicator that indicates the relative stiffness of one or more of the zones. [0022] In some embodiments, the control unit comprises a plurality of predetermined selectable stiffness profiles that comprise differing stiffnesses and/or differing stiffness distributions of the zones. In some such embodiments, the predetermined selectable stiffness profiles comprise differing stiffness distributions of the zones, and wherein the predetermined selectable stiffness profiles correspond to identified lying positions of a user. In some such embodiments, the identified lying positions comprise at least three lying positions corresponding to the position of the user lying on their back, on their stomach and on their side.

[0023] In some embodiments, the stiffness of the zones can be selectively varied between about 5 lbs at 25% IFD to about 120 lbs at 25% IFD. In some embodiments, the stiffness of the zones can be selectively varied between about 10 lbs at 25% IFD to about 100 lbs at 25% IFD. In some embodiments, the stiffness of the zones can be selectively varied between about 10 lbs at 25% IFD to about 75 lbs at 25% IFD. In some embodiments, the stiffness of the zones can be selectively varied between about 10 lbs at 25% IFD to about 50 lbs at 25% IFD. In some embodiments, the stiffness of the zones can be selectively varied between a stiffness range that provides for about Yi inch to about 3 inches of deflection of the at least one cushion layer when the user is supported thereby.

[0024] In some embodiments, the system is configured as a mattress system. In some embodiments, the system is configured as a cushion system.

[0025] In another aspect, the present disclosure provides a method for adjusting the firmness of a body support system. The method comprises providing or obtaining any other body support systems described hereinabove. The method further comprises selectively varying the position of the rigid support members along the thickness direction to variably compress the zones of the at least one flexible foam layer between the support members and the outer cover layer in the thickness direction to selectively adjust the stiffnesses of the zones.

[0026] These and other features and advantages of the disclosure and inventions will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings. The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The subject matter, which is regarded as the invention(s), is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, aspects, and advantages of the disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings, which are not necessarily drawn to scale, wherein:

[0028] FIG. 1 illustrates a top view depicting a variable stiffness/firmness body support system in accordance with an embodiment of the disclosure.

[0029] FIG. 2 illustrates an elevational perspective view of a portion of the variable stiffness/firmness body support system of FIG. 1 in accordance with an embodiment of the disclosure.

[0030] FIG. 3 illustrates a side cross-sectional view of the variable stiffness/firmness body support system of FIG. 1 in accordance with an embodiment of the disclosure.

[0031] FIGS. 4A and 4B illustrate side cross-sectional views along a width and length, respectively, of the variable stiffness/firmness body support system of FIG. 1 selectively configured in a first exemplary variable stiffness profile in accordance with an embodiment of the disclosure.

[0032] FIGS. 5A and 5B illustrate side cross-sectional views along a width and length, respectively, of the variable stiffness/firmness body support system of FIG. 1 selectively configured in a second exemplary variable stiffness profile in accordance with an embodiment of the disclosure.

[0033] While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof are shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

DETAILED DESCRIPTION

[0034] Aspects of the present disclosure and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the details of the inventions. It should be understood, however, that the detailed description and the specific example(s), while indicating embodiments of inventions of the present disclosure, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure. [0035] Approximating language, as used herein throughout the disclosure, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” or “substantially,” is not limited to the precise value specified. For example, these terms can refer to less than or equal to 5% and greater than or equal to -5%, such as less than or equal to 2% and greater than or equal to -2%, such as less than or equal to 1% and greater than or equal to -1%, such as less than or equal to 0.5% and greater than or equal to -0.5%, such as less than or equal to 0.2% and greater than or equal to -0.2%, such as less than or equal to 0.1% and greater than or equal to -0.1%, such as less than or equal to 0.05% and greater than or equal to -0.05%. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value.

[0036] The term “user” is used herein to refer to a mammal (e.g., human or animal, such as a pet or livestock) that utilizes the variable stiffness/firmness body support systems disclosed herein to physically support at least a portion themselves. For example, a user may sit or lay on a top or upper surface or portion of a variable stiffness/firmness body support system so that at least a portion of the user’s body weight is physically supported by the variable stiffness/firmness body support system.

[0037] The terms “stiffness” and “firmness” (also referred to as “plushness”) are used synonymously herein to refer to the body support system’s comfort on initial touch by a user, or how soft or firm the body support system feels to the user. Stiffness/firmness refers to the comfort feel of a body support system and how hard or soft it is, such as how much a user “sinks” in, is “cradled” by, or deflects the body support system during use. Stiffness/firmness is a subjective quality of a body support system, such as a mattress or cushion. Stiffness/firmness is a way of describing the feel of a body support system specifically in terms of comfort. Being supported (e.g., laying or sitting) on concrete would be one extreme level of firmness, while an opposite extreme would be like floating on a cloud. Firmness is often described as being very subjective because what may feel comfortable to one user can be uncomfortable to another user. Firmness, essentially, is a subjective measure of how soft or hard a body support system feels to a user when the user is supported thereby (e.g., sits or lays down on the body support system). [0038] How a particular body support system feels, with respect to stiffness/firmness, to a user is typically dictated by the user’s height, weight, gender, preferred/usual sleeping position(s), and personal preference. The stiffness/firmness of a body support system is critical to a comfortable feeling during use by a user. For this reason, it is common to see body support systems offered in a number of different firmness levels to allow users to find a model that will suit their preferences. As described further below, the body support systems disclosed herein allow or provide for variable stiffnesses and stiffness profiles that are user selectable and variable.

[0039] Body support systems, such as mattresses and cushions, are often generally categorized with respect to their firmness. For example, terms like “extra firm,” “medium-firm,” “plush,” and others may be used to describe the firmness of body support systems. As another example, some refer to a firmness scale of body support systems. Such a scale may include: a #1 firmness or “extremely soft/plush” designation to refer to a body support system with a maximum softness with lots of sink; a #2-#3 or “soft” designation to refer to quite soft and plush designation to refer to a body support system with definite sink and a significant amount of hug and sinkage, such as in the about 1.5-3 inch range; a #4-#6 or “medium” designation to refer to a body support system with a common firmness level that offers a middle-ground with some plushness but more limited sink, such as sinkage and hug in the about 1-2 inch range; a #7-#9 or “firm” designation to refer to a body support system with much harder mattress with limited softness and sinkage or hug, such as in the range of about 1 inch or less; and #10 or “extremely firm” designation to refer to a body support system with no softness, plushness or sink. The body support systems of the present disclosure provide for variable stiffness body support systems that can be selectively vary to any one of such firmness/stiffness.

[0040] While the disclosed body support systems are configured to vary in firmness/stiffness, it is noted that firmness/stiffness may impact other qualities of the body support systems, such as airflow, temperature, contouring properties, support, durability and odor. For example, firmness is not the same as “support.” The term “support” refers to how well a body support system promotes spinal or anatomical alignment when a user is being supported by the body support system. A body support system that offers pressure point relief and keeps the spine in a proper position during use, for example, is supportive regardless of how hard or soft that body support system is (i.e., how firm the body support system is). While firmness can be highly subjective, support is not. Firmness typically describes the uppermost layer(s) of a body support system that determine the body support system’s comfort levels, while support typically describes the core and lower layers of the body support system that determine how the body support system encourages proper spinal/anatomical alignment and relieve pressure.

[0041] As another example, although the firmness and the density of body support systems are often fairly closely linked, they’re not identical. Density is an objective measurement of pounds per cubic foot. Generally speaking though, denser body support systems tend to be a little firmer systems.

[0042] One metric that is utilized to attempt to define or standardize a measurement for the firmness/stiffness of body support systems, such as mattresses and cushion systems, is Indentation Load Deflection (ILD)/Indentation Force Deflection (IFD). ILD is a measurement in the firmness level of a body support system. The higher the number, the more firm it is and vice versa for lower numbers.

[0043] ILD is a value that represents the force needed to compress natural latex, polyurethane and several other types of foam that are often utilized in body support systems. ILD is used across many body support system industries, such as with mattress, car seat and furniture body support ty systems. The ILD measurement value is given to an individual layer of foam within a body support system and not the entire finished system. As such, an ILD measurement may provide a general firmness rating like soft, medium or firm to a body support system, the individual foam layer(s) within the body support system will have their own ILD rating.

[0044] ILD is a unit of measurement that references the number of pounds (lbs) of pressure or force that is needed to indent foam of 4 inches thick to a depth by 25%. The rating is referred to as the ILD rating or the 25% ILD rating. When measuring ILD, a foam sample of material measuring 15 inches x 15 inches x 4 inches is used. A 50 square inch circular indenter is used to compress the material a total of 25 percent of its thickness. Normally, the firmness of foam layer(s) within body support system foams (e.g., viscoelastic memory foam layers) can range from supersoft (less than 10 lbs. @ 25% IFD) to semi-rigid (as high as 120 lbs. @ 25% IFD). [0045] While IFD is useful to provide a metric to gauge the firmness/stiffness of a body support system, it does have some limitations. For example, ILD only measures the firmness of one or more foam layers in a body support system and not any of the other layers’ firmness. Further, ILD of a layer can vary in response to things like humidity and heat.

[0046] The disclosed variable stiffness body support systems may be configured as or form a bedding system, device or product (or a portion thereof), such as a mattress, mattress cartridge, mattress topper, mattress cover, mattress protector, mattress pad or liner, mattress component, mattress accessory, pillow or the like. The disclosed variable stiffness body support systems may also be configured as or form a pad or mat (or a portion thereof). The disclosed variable stiffness body support systems may also be configured as or form a non-bedding body support cushion, such as a furniture cushion, automobile/plane/boat seat, child carrier, neck support, leg spacer, pet accessory (e.g., pet bed, pet carrier insert and other pet apparel), exercise equipment cushion or any other cushion configured to support at least a portion of a user (or a portion thereof).

[0047] As shown in FIGS. 1-3, an exemplary variable stiffness body support system 10 according to the present disclosure may define a width W, length L and thickness T dimensions/directions. The system 10 may include a plurality of layers 12 that define an upper or top surface or side 14, and a lower or bottom surface or side 16, that are spaced along the thickness T dimension. In use, a user rests on the top side 14 of the system 10, and is physically supported (at least in part) by the plurality of layers 12. For example, a user may lay down or sit down on the top side 14 of the system 10, and the plurality of layers 12 may transfer the applied weight of the user to the bottom side 16. It is noted that in use, one or more additional layers or members may be positioned over the top side 14 such that the user does not directly contact the top side 14 and/or under the bottom side 16 such that the bottom side 16 does not directly contact a ground or support surface.

[0048] As shown in FIG. 1, the variable stiffness body support system 10 may include a plurality of zones, areas or portions 18 that the stiffness/firmness thereof can be selectively and individually (at least in part) controlled, varied, adjusted and selected by a user. In some embodiments, the system 10 may include or define a plurality of the variable stiffness zones 18 arranged or extending across the width W dimension of the system 10. For example, the system 10 may include at least two variable stiffness zones 18 arranged along the width W of the system 10, at least three variable stiffness zones 18 arranged along the width W of the system 10, at least four variable stiffness zones 18 arranged along the width W of the system 10, at least six variable stiffness zones 18 arranged along the width W of the system 10, at least seven variable stiffness zones 18 arranged along the width W of the system 10, or at least eight variable stiffness zones 18 arranged along the width W of the system 10.

[0049] However, the system 10 may include any number of variable stiffness zones 18 arranged along the width W of the system 10. For example, in some embodiments the system 10 may only include a single variable stiffness zone 18 that extends along the width W of the system 10. The variable stiffness zones 18 also may or may not extend across the entirety of the width W of the system 10, and may or may not be contiguous or immediately adjacent (e.g., they may be immediately adjacent each other or spaced out along the width W direction).

[0050] As also shown in FIG. 1, in some embodiments, the system 10 may include or define a plurality of the variable stiffness zones 18 arranged or extending across the length L dimension of the system 10. For example, the system 10 may include at least two variable stiffness zones 18 arranged along the length L of the system 10, at least three variable stiffness zones 18 arranged along the length L of the system 10, at least four variable stiffness zones 18 arranged along the length L of the system 10, at least six variable stiffness zones 18 arranged along the length L of the system 10, at least seven variable stiffness zones 18 arranged along the length L of the system 10, or at least eight variable stiffness zones 18 arranged along the length L of the system 10. [0051] However, the system 10 may include any number of variable stiffness zones 18 arranged along the length L of the system 10. For example, in some embodiments the system 10 may only include a single variable stiffness zone 18 that extends along the length L of the system 10. The variable stiffness zones 18 also may or may not extend across the entirety of the length L of the system 10, and may or may not be contiguous or immediately adjacent (e.g., they may be immediately adjacent each other or spaced out along the length L).

[0052] The size and shape of the variable stiffness zones 18 may also vary. For example, as shown in FIG. 1, the variable stiffness zones 18 may be at least generally square or rectangular shapes. However, the variable stiffness zones 18 may be circular or any other regular or irregular shape. The size of the variable stiffness zones 18 may be related, at least in part, to the size of the system 10. For example, in some embodiments, the variable stiffness zones 18 may comprise at least 36 square inches, at least one square foot, at least 1-1/2 square feet, or at least 2 square feet.

[0053] The arrangement of the variable stiffness zones 18 also may vary. For example, as shown in FIG. 1, the variable stiffness zones 18 may be arranged in columns extending along the length L direction, and rows extending along the width W direction. However, the system 10 can include any differing layout, pattern or arrangement of the variable stiffness zones 18 across the surface area of the system 10.

[0054] As shown in FIGS. 2 and 3, the plurality of layers 12 of the system 10 include at least one cushion layer comprising an outer cover layer 28 and at least one flexible foam layer 20 positioned underneath or within the outer cover layer 28. It is noted that the at least one cushion layer may include other layers in addition to the cover layer 28 and at least one foam layer 20. For example, the at least one cushion layer may include at least one additional cushioning layer, such as a batting, fiber, fill, gel/water, fabric or any other layer underlying and/or overlying the cover layer 28 and/or the at least one foam layer 20. As another example, the at least one cushion layer may include a fire sock or fire resistive layer.

[0055] The outer cover layer 28 and at least one flexible foam layer 20 may extend over at least a portion of the width W and length L of the system 10, and define at portion of the thickness T of the system 10, as shown in FIGS. 2 and 3. As also shown, the variable stiffness zones 18 correspond to width W and length L portions of the flexible foam layer 20. In some embodiments, the entirety of the at least one foam layer 20 comprises or forms the variable stiffness zones 18. In some other embodiments, at least one portion of the at least one flexible foam layer 20 may not form or comprise a variable stiffness zone 18.

[0056] The at least one foam layer 20 may comprise at least one foam layer 20 arranged in the width W, length L and thickness T directions. In some embodiments, the at least one foam layer 20 comprises a single layer. In some other embodiments, the at least one foam layer 20 comprises a plurality of layers. The at least one foam layer 20 may include at least one polyurethane layer, such as a viscoelastic foam layer. In some embodiments the at least one foam layer 20 may comprise a non-polyurethane or viscoelastic foam layer, such as a latex foam layer.

[0057] As shown in FIG. 3, the outer cover layer 28 may extend over the at least one foam layer 20 along the width W and length L directions, and over/along the sides of the at least one foam layer 20 along the thickness T direction. In some embodiments, the outer cover layer 28 extends about (e.g., partially or fully encases or encloses) the at least one foam layer 20. In some embodiments, the outer cover layer 28 comprises a fabric layer, such as a woven and/or stitched fabric layer. In some embodiments, the outer cover layer 28 comprises a fire resistant layer or sock. The outer cover layer 28 may comprise a minimal amount of stretch such that pressure applied thereto via drive units 24 of the system 10, as described further below, only minimally deforms or deflects the outer cover layer 28 outwardly in the thickness T direction and, thereby, results in compression of the at least one foam layer 20 in the thickness T direction/dimension. [0058] As also shown in FIGS. 2-5B, the system 10 comprises an array of a plurality of rigid support members 22 positioned below the at least one cushion layer (specifically the at least one foam layer 20 thereof) and arranged along at least one of the width W and the length L dimension of the at least one cushion layer (and specifically the at least one foam layer 20 thereof). Each of the variable stiffness zones 18 includes at least one rigid support members 22 positioned below a respective portion of the at least one foam layer 20. In some embodiments each variable stiffness zones 18 includes one rigid support members 22 positioned below the respective portion of the at least one foam layer 20. In some other embodiments, one or more variable stiffness zones 18 includes a plurality of the rigid support members 22 positioned below a respective portion of the at least one foam layer 20.

[0059] In some other embodiments, the rigid support members 22 comprise plate members, as shown in FIGS. 2-5B. For example, the plate members may include a planar top surface and/or a planar bottom surface. The rigid support members 22 are substantially stiff and strong such that they are able to support and/or apply a force to at least a portion of the at least one cushion layer (specifically the at least one foam layer 20 thereof) along the width W and length L directions of the variable stiffness zones 18. In some embodiments, the rigid support members 22 may be formed of metal, wood, a rigid plastic material or a combination thereof.

[0060] As also shown in FIGS. 2-5B, the system 10 further comprises a plurality of drive units 24 positioned below the rigid support members 22 such that each support member 22 is associated with at least one drive unit 24. The drive units 24 are configured to independently selectively vary the position of the rigid support members 22 along the thickness T direction to variably compress the variable stiffness zones 18 of the at least one flexible foam layer 20 between the support members 22 and the outer cover layer 28 in the thickness T direction to vary the stiffnesses of the zones 18, as shown in FIGS. 3-5B.

[0061] As the plurality of the variable stiffness zones 18 may be arranged across the width W dimension of the system 10, the plurality of support members 22 and drive units 24 may thereby also be arranged across the width W dimension of the system 10. For example, the system 10 may include at least two support members 22 and drive units 24 arranged along the width W of the system 10, at least three support members 22 and drive units 24 arranged along the width W of the system 10, at least four support members 22 and drive units 24 arranged along the width W of the system 10, at least six support members 22 and drive units 24 arranged along the width W of the system 10, at least seven support members 22 and drive units 24 arranged along the width W of the system 10, or at least eight support members 22 and drive units 24 arranged along the width W of the system 10.

[0062] However, the system 10 may include any number of support members 22 and drive units 24 arranged along the width W of the system 10. For example, in some embodiments the system 10 may only include a single support members 22 and drive units 24 along the width W of the system 10. The support members 22 and drive units 24 also may or may not extend across the entirety of the width W of the system 10, and may or may not be contiguous or immediately adjacent (e.g., they may be immediately adjacent each other or spaced out along the width W direction). [0063] Similarly, as the variable stiffness zones 18 may be arranged across the length L dimension of the system 10, the plurality of support members 22 and drive units 24 may thereby also be arranged across the length L dimension of the system 10. For example, the system 10 may include at least two support members 22 and drive units 24 arranged along the length L of the system 10, at least three support members 22 and drive units 24 arranged along the length L of the system 10, at least four support members 22 and drive units 24 arranged along the length L of the system 10, at least six support members 22 and drive units 24 arranged along the length L of the system 10, at least seven support members 22 and drive units 24 arranged along the length L of the system 10, or at least eight support members 22 and drive units 24 arranged along the length L of the system 10.

[0064] However, the system 10 may include any number of support members 22 and drive units 24 arranged along the length L of the system 10. For example, in some embodiments the system 10 may only include a single support member 22 and drive member 24 along the length L of the system 10. The support members 22 and drive units 24 also may or may not extend across the entirety of the length L of the system 10, and may or may not be contiguous or immediately adjacent (e.g., they may be immediately adjacent each other or spaced out along the length L). [0065] The drive units 24 may comprise any mechanism, system or apparatus that is configured to selectively and controllably vary or adjust in length (and maintain its length) to vary the position of the support members 22 along the thickness T direction, and thereby ultimately variably compress the at least one cushion layer (specially, the at least one foam layer 20 thereof). For example, in some embodiments the drive units 24 may comprise micro-motors. In some other embodiments, the drive units 24 may comprise linear actuators. The drive units 24 may comprise gears, pulleys, belts, chains, rods, power screws or any other mechanism or configuration to effectuation the movement of the support members 22 along the thickness T direction and, thereby, the variable compression of at least the at least one foam layer 20 of the at least one cushion layer.

[0066] As shown in FIGS. 2-5B, in some embodiments the system 10 may comprise a support or frame structure, member, device or the like 26 positioned below the plurality of drive units 24 and configured to physically support the plurality of drive units 24. The frame structure 26 may provide a base or foundation for the drive units 24 that resists movement thereof downwardly in the thickness T direction. In this way, as the drive units 24 lengthen in the thickness T direction, the drive units 24 act to raise the support members 22 in the thickness T direction and, thereby, compress at least the at least one foam layer 20 of the at least one cushion layer between the support members 22 and the outer cover layer 28.

[0067] As shown in FIG. 3, in some embodiments, the outer cover layer 28 may extend about (e.g., partially or fully encases or encloses) the at least one foam layer 20, the support members 22, the drive units 24 and the frame structure 26. In some other embodiments, the outer cover layer 28 may not extend about the frame structure 26, and/or may be coupled or fixed to the frame structure 26.

[0068] In some embodiments, the system 10 may be configured such that the drive units 24 are controllable such that the stiffness of the at least one foam layer 20 within the variable stiffness zones 18 can be selectively varied between about 5 lbs at 25% IFD to about 120 lbs at 25% IFD. In some embodiments, the system 10 may be configured such that the drive units 24 are controllable such that the stiffness of the at least one foam layer 20 within the variable stiffness zones 18 can be selectively varied between about 10 lbs at 25% IFD to about 100 lbs at 25% IFD. In some embodiments, the system 10 may be configured such that the drive units 24 are controllable such that the stiffness of the at least one foam layer 20 within the variable stiffness zones 18 can be selectively varied between about 10 lbs at 25% IFD to about 75 lbs at 25% IFD. In some embodiments, the system 10 may be configured such that the drive units 24 are controllable such that the stiffness of the at least one foam layer 20 within the variable stiffness zones 18 can be selectively varied between about 10 lbs at 25% IFD to about 50 lbs at 25% IFD. In some embodiments, the system 10 may be configured such that the drive units 24 are controllable such that the stiffness of the at least one cushion layer of the variable stiffness zones 18 can be selectively varied between a stiffness range that provides for about Yi inch to about 3 inches of deflection of the at least one cushion layer when a user is supported thereby. In some embodiments, the system 10 may be configured such that the drive units 24 are controllable such that the stiffness of the at least one foam layer 20 of the variable stiffness zones 18 can be selectively varied between a stiffness range that provides for about Yi inch to about 3 inches of deflection of the at least one foam layer 20 when a user is supported thereby.

[0069] As shown in FIGS. 2-5B, the system 10 may include/comprise a control unit 50 that is configured to selectively control actuation of the drive units 24 and, thereby, the position of the support members 22 along the thickness T direction to selectively variably compress the variable stiffness zones 18 of the at least one cushion layer (specially, the at least one foam layer 20 thereof) between the support members 22 and the outer cover layer 28 in the thickness T direction to vary the stiffnesses of the zones 18. The control unit 50 is preferably configured to be manually operable by a user. The control unit 50 may allow for individual selective adjustment (and/or group adjustment) of the drive units 24, and thereby individual selective adjustment or variance of the stiffness/firmness of the variable stiffness zones 18. In this way, a user can vary the stiffness of the variable stiffness zones 18 into any pattern or profile, and in any available/achievable stiffness, as they require or desire. For example, the zones 18 can vary in stiffness along the width W and/or length L directions of the system, and can vary over time (e.g., for differing individuals and/or to accommodate changes in stiffness preferences or desires over time).

[0070] As also shown in FIGS. 2-5B, in some embodiments, the control unit 50 may comprise a remote control device 52 that is configured to be manually operable by a user and control the control unit 50. In some embodiments, as shown in FIGS. 3-5B, the remote control device 52 and the control unit 50 are coupled such that the remote control device 52 communicates wirelessly with the control unit 50 (e.g., via infrared, Bluetooth, WIFI, etc.). In one such embodiment, the remote control device 52 may comprise a user’s smartphone, tablet and/or computer. In some embodiments, as shown in FIG. 2, the remote control device 52 and the control unit 50 are coupled via at least one electrical communication wire, and the remote control device 52 communicates with the control unit 50 via the at least one electrical communication wire.

[0071] In some embodiments, the control unit 50 (such as the remote deice 52 thereof, for example) may include one or more visual and/or indicator that indicates the relative stiffness of one or more of the variable stiffness zones 18.

[0072] In some embodiments, the control unit 50 comprises memory that includes a plurality of predetermined selectable stiffness profiles that comprise differing stiffnesses and/or differing stiffness distributions of the variable stiffness zones 18. A user may thereby select one of the profiles to automatically adjust all the variable stiffness zones 18 according to the selected profile. In one such embodiment, the predetermined selectable stiffness profiles comprise differing stiffness distributions of the variable stiffness zones 18, and the predetermined selectable stiffness profiles correspond to identified lying positions of a user. For example, the identified lying positions may comprise at least three lying positions corresponding to the position of the user lying on their back, on their stomach and on their side.

[0073] Two exemplary differing stiffness adjustments of the system 10 are shown in system 10A in FIGS. 4A and 4B and system 10B in FIGS. 5A and 5B. As shown in FIGS. 4A and 5A, a user adjusted the stiffness of zones 18 of a left side portion of the width W1 of a portion of the system 10A to be greater than the stiffness of zones 18 of a right side portion of the width Wl, while the user adjusted the stiffness of zones 18 of left and right side portions of the width W2 of a corresponding portion of the system 10B about the same. Further, as also shown in FIGS. 4A and 5 A, a central/medial or intermediate zone 18 along the width Wl of the portion of the system 10A was adjusted to be stiffer than the left and right side zones 18 thereof, while central/medial or intermediate zones 18 along the width W2 of the portion of the system 10B were adjusted to be softer/less stiff than the left and right side zones 18 thereof (and softer/less stiff that the central zone 18 along the width Wl of the system 10A).

[0074] As shown in FIGS. 4B and 5B, a user adjusted the stiffness of the zones 18 extending lengths LI, L2 of corresponding portions of the two systems 10 A, 10B to include a similar stiffness profile. As shown, central/medial or intermediate zones 18 of the lengths LI, L2 of the corresponding portions of the two systems 10A, 10B was adjusted to be less stiff than top or head and bottom or foot zones 18 of the lengths LI, L2, and the top or head and bottom or foot zones 18 of the lengths LI, L2 were adjusted to differing stiffnesses. However, as shown in FIGS. 4B and 5B, the zones 18 extending along the length LI of the system 10A were each adjusted to be stiffer than the corresponding zones 18 extending along the length L2 of the system 10B. [0075] As one of ordinary skill in the art would recognize, the systems 10 disclosed herein allow for a user to adjust the stiffnesses of the variable stiffness zones 18 to create any stiffness profile or configuration thereof (via variable compression of the at least one foam layer 20) as desired. [0076] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), “contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

[0077] As used herein, the terms “comprising,” "has," “including,” "containing," and other grammatical variants thereof encompass the terms “consisting of’ and “consisting essentially of.”

[0078] The phrase “consisting essentially of’ or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods. [0079] All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

[0080] Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

[0081] Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

[0082] While several aspects and embodiments of the present invention have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1. A variable stiffness body support system, comprising: at least one cushion layer comprising an outer cover layer and at least one flexible foam layer positioned below the outer cover layer; a plurality of rigid support members positioned below the at least one cushion layer and arranged along at least one of a width dimension and a length dimension of the at least one cushion layer; and a plurality of drive units positioned below the rigid support members such that each rigid support member is associated with at least one drive unit, wherein the drive units are configured to independently selectively vary positions of the rigid support members along a thickness direction to variably compress zones of the at least one flexible foam layer between the support members and the outer cover layer in the thickness direction to vary stiffnesses of the zones.

2. The body support system according to claim 1, wherein the plurality of rigid support members and the plurality of drive units are arranged along the width and length dimensions.

3. The body support system according to any of the preceding claims, wherein at least three rigid support members and at least three drive units associated therewith are arranged along the width dimension.

4. The body support system according to any of the preceding claims, wherein at least three rigid support members and at least three drive units associated therewith are arranged along the length dimension.

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5. The body support system according to any of the preceding claims, wherein the plurality of drive units comprise micro-motors.

6. The body support system according to any of the preceding claims, wherein the plurality of drive units comprise linear actuators.

7. The body support system according to any of the preceding claims, wherein the at least one flexible foam layer comprises polyurethane foam.

8. The body support system according to any of the preceding claims, wherein the at least one flexible foam layer comprises viscoelastic foam.

9. The body support system according to any of the preceding claims, wherein the rigid support members comprise plate members.

10. The body support system according to claim 9, wherein the plate members comprise a planar top surface and/or a planar bottom surface.

11. The body support system according to any of the preceding claims, further comprising a frame structure positioned below the plurality of drive units, the frame structure physically supporting the plurality of drive units.

12. The body support system according to claim 11, wherein the outer cover layer extends about the frame structure.

13. The body support system according to any of the preceding claims, wherein the outer cover layer extends about the at least one flexible foam layer.

14. The body support system according to any of the preceding claims, wherein the outer cover layer extends about the plurality of rigid support members and the plurality of drive units.

15. The body support system according to any of the preceding claims, wherein the outer cover layer comprises a fabric layer.

16. The body support system according to any of the preceding claims, wherein the outer cover layer comprises a fire sock.

17. The body support system according to any of the preceding claims, further comprising a control unit that is configured to selectively control actuation of the drive units and, thereby, the positions of the rigid support members along the thickness direction to selectively variably compress the zones of the at least one flexible foam layer between the rigid support members and the outer cover layer in the thickness direction to vary stiffnesses of the zones.

18. The body support system according to claim 17, wherein the control unit is configured to be manually operable by a user.

19. The body support system according to claims 17 or 18, wherein the control unit comprises a remote control device that is configured to be manually operable by the user and control the control unit.

20. The body support system according to claim 19, wherein the remote control device is configured to wirelessly communicate with the control unit.

21. The body support system according to claim 19, wherein the remote control device and the control unit are coupled via at least one electrical communication wire.

22. The body support system according to any of claims 17-21, wherein the control unit comprises a plurality of predetermined selectable stiffness profiles that comprise differing stiffnesses and/or differing stiffness distributions of the zones.

23. The body support system according to claim 22, wherein the predetermined selectable stiffness profiles correspond to identified lying positions of a user.

24. The body support system according to claim 23, wherein the identified lying positions comprise at least three lying positions corresponding to positions of the user lying on their back, on their stomach and on their side.

25. The body support system according to any of claims 17-24, wherein the control unit comprises one or more visual indicator that indicates a relative stiffness of one or more of the zones.

26. The body support system according to any of the preceding claims, wherein the zones extend essentially over the entire width of the body support system, and are arranged along the length of the body support system.

27. The body support system according to any of the preceding claims, wherein the stiffness of the at least one flexible foam layer within the zones can be selectively varied between about 5 lbs at 25% IFD to about 120 lbs at 25% IFD.

28. The body support system according to any of the preceding claims, wherein the stiffness of the at least one flexible foam layer within the zones can be selectively varied between about 10 lbs at 25% IFD to about 100 lbs at 25% IFD.

29. The body support system according to any of the preceding claims, wherein the stiffness of the at least one flexible foam layer within the zones can be selectively varied between about 10 lbs at 25% IFD to about 75 lbs at 25% IFD.

30. The body support system according to any of the preceding claims, wherein the stiffness of the at least one flexible foam layer within the zones can be selectively varied between about 10 lbs at 25% IFD to about 50 lbs at 25% IFD.

31. The body support system according to any of the preceding claims, wherein the stiffness of the zones can be selectively varied between a stiffness range that provides for about Yi inch to about 3 inches of deflection of the at least one cushion layer when the user is supported thereby.

32. The body support system according to any of the preceding claims, wherein the body support system is configured as a mattress system.

33. The body support system according to any of the preceding claims, wherein the body support system is configured as a cushion system.

34. A method for adjusting a firmness of a body support system, comprising: providing or obtaining the body support system of any of the previous claims; and

31 selectively varying the positions of the rigid support members along the thickness direction to variably compress the zones of the at least one flexible foam layer between the rigid support members and the outer cover layer in the thickness direction to selectively adjust the stiffnesses of the zones.

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