Patent Description:
Embodiments of the disclosure relate generally to elastomeric cushioning elements for compressible cushions, including mattresses, mattress toppers, seat cushions, etc., to coatings for the cushioning elements, and to methods of forming cushions including coated cushioning elements.

Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and/or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications. Cushioning materials may be used in combination with one another to achieve selected properties. A gel cushion is known for example from <CIT>.

<CIT>, describes cushion structures having interconnected walls that buckle. A first wall buckles when a threshold force is applied. Buckling of the first wall may cause buckling of a second wall, which may decrease the chance that the first wall will "bottom out. " Bottoming out would increase pressure on the portion of the cushioned object over the buckled portion of the cushion. One side of the cushion has walls spaced relatively close together, and the opposite side has walls spaced farther apart. That is, some walls of the cushion extend only partially through the cushion. The wider-spaced portions of the walls may buckle more easily than the closer-spaced portions of the walls when an irregularly shaped object presses against the walls.

<CIT>, describes a cushioning element having a top cushioning surface and a bottom base surface, and which includes an elastomeric material and a stabilizing material. Interconnected buckling walls formed of the elastomeric material are connected to the stabilizing material.

Cushioning materials, such as mattresses, are generally bulky objects that are difficult and costly to transport from a manufacturer to a retailer or a customer. Traditionally, mattresses have been packaged, shipped, and sold in a flat configuration, such that the mattresses have the same size and dimension in shipping as they do when placed atop a box spring or other mattress support to make a bed. Recently, there have been efforts directed toward compressing mattresses, and there have been methods described for compressing foam and coil mattresses for packaging. Methods have also been disclosed for compressing the foam and coil mattresses into a rolled shape. Examples of methods of roll-packing mattresses include: <CIT>; <CIT>; and <CIT>.

The invention discloses a cushion as claimed in claim <NUM>. Preferred features are set out in the dependent claims.

As used herein, the term "cushioning element" means and includes any deformable device intended for use in cushioning one body relative to another. As a non-limiting example, cushioning elements (e.g., mattresses, seat cushions, etc.) include materials intended for use in cushioning a person, animal, or object relative to another object (e.g., a bed frame, chair seat, etc.) that might otherwise abut against the person, animal, or object.

As used herein, the term "elastomeric polymer" means and includes a polymer capable of recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as "elastomers" in the art. Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).

As used herein, the term "elastomeric block copolymer" means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).

As used herein, the term "plasticizer" means and includes a substance added to another material (e.g., an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility, softness, or extensibility of the material. Mineral oil is an embodiment of a plasticizer. Hydrocarbon plasticizers may be aromatic or aliphatic.

As used herein, the term "elastomeric material" means and includes elastomeric polymers and mixtures of elastomeric polymers with plasticizers and/or other materials. Elastomeric materials are elastic (i.e., capable of recovering size and shape after deformation). Elastomeric materials include, without limitation, materials referred to in the art as "elastomer gels," "gelatinous elastomers," or simply "gels.

As used herein, any relational term, such as "first," "second," "top," "bottom," etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings and does not connote or depend on any specific preference, orientation, or order, except where the context clearly indicates otherwise.

As used herein, the term "and/or" means and includes any and all combinations of one or more of the associated listed items.

The illustrations presented herein are not meant to be actual views of any particular component, device, or system, but are merely idealized representations employed to describe embodiments of the present disclosure. Elements common between figures may retain the same numerical designation.

The present disclosure describes a cushion that may be roll-packed, folded, or otherwise compressed for display, storage, and/or shipping to a customer. For example, the cushion may be roll-packed into a cylindrical shape. The roll-packed cushion may be provided in a cylindrical bag. Cushions compressed and disposed in cylindrical bags may be easier to handle than cushions, such as mattresses that are traditionally packaged, shipped, and sold in a flat configuration.

<FIG> illustrates a perspective view of a cushion <NUM> according to some embodiments of the present disclosure. The cushion <NUM> may comprise an elastomeric cushioning element <NUM> between a top layer <NUM> and a bottom layer <NUM>. The top layer <NUM> may be provided on (e.g., attached to) a top surface <NUM> of the elastomeric cushioning element <NUM>. The bottom layer <NUM> may be provided on a bottom surface <NUM> of the elastomeric cushioning element <NUM>.

In some embodiments, the top layer <NUM> and the bottom layer <NUM> may comprise a foam material. In other embodiments, the top layer <NUM> may comprise a stretchable material secured to or integral with the elastomeric cushioning element <NUM>. In yet other embodiments, the cushion <NUM> may comprise additional layers.

<FIG> illustrates a simplified top view of the elastomeric cushioning element <NUM> having buckling walls <NUM>. The buckling walls <NUM> of the elastomeric cushioning element <NUM> may be interconnected to one another and may define hollow columns <NUM> or voids in an expanded form. As used herein, the term "expanded form" means and includes a state in which a cushioning element <NUM> has its original size and shape and wherein the buckling walls <NUM> are separated and define hollow columns <NUM>.

<FIG> illustrates buckling walls <NUM> oriented in two directions, intersecting at right angles, and defining square voids <NUM>. However, the buckling walls <NUM> may intersect at other angles and define voids <NUM> of other shapes, such as triangles, parallelograms, hexagons, etc. The elastomeric cushioning element <NUM> may comprise additional structures and configurations such as those structures and configurations described in, for example, <CIT>; <CIT>; <CIT>; and <CIT>.

The buckling walls <NUM> may be formed of an elastomeric material. Elastomeric materials are described in, for example, <CIT>; <CIT>; <CIT>; <CIT>. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc..

The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc. , of Houston, TX, under the trade name SEPTON® <NUM>, and from Kraton Polymers, LLC, of Houston, TX, under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the "A" blocks are styrene. The "B" block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers.

The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc. , of Mahwah, NJ, under the trade names BLANDOL® and CARNATION®.

In some embodiments, the elastomeric material may have a plasticizer-to-polymer ratio from about <NUM>:<NUM> to about <NUM>:<NUM> by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about <NUM>:<NUM> to about <NUM>:<NUM> by weight, or even from about <NUM>:<NUM> to about <NUM>:<NUM> by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about <NUM>:<NUM> by weight.

The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase-change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase-change temperature of the wax or other phase-change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase-change material may have a melting point from about <NUM> to about <NUM>.

The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis(<NUM>-(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxyphenyl) propionate), commercially available as IRGANOX® <NUM>, from BASF Corp. , of Iselin, NJ or as EVERNOX®-<NUM>, from Everspring Corp. USA, of Los Angeles, CA; octadecyl-<NUM>-(<NUM>,<NUM>-di-tert-butyl-<NUM> -hydroxyphenyl)propionate, commercially available as IRGANOX® <NUM>, from BASF Corp. or as EVERNOX® <NUM>, from Everspring Chemical; and tris(<NUM>,<NUM>-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® <NUM>, from BASF Corp. or as EVERFOS® <NUM>, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns <NUM> and <NUM> of <CIT>. The elastomeric material may include up to about <NUM> wt% antioxidants. For instance, the elastomeric material may include from about <NUM> wt% to about <NUM> wt% antioxidants.

In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of the cushioning element <NUM> after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, TN, under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.

In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and/or functional. That is, pigments may provide the cushioning element <NUM> with an appearance appealing to consumers. In addition, a cushioning element <NUM> having a dark color may absorb radiation differently than a cushioning element <NUM> having a light color.

The elastomeric material may include any type of gelatinous elastomer. For example, the elastomeric material may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® <NUM>) with four parts by weight of a <NUM>-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.

The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about <NUM>, from about <NUM> to about <NUM>, or less than about <NUM>.

In some embodiments, the cushioning element <NUM> may be compressed. For example, the cushioning element <NUM> may be roll-packed into a cylindrical shape. Methods of roll-packing a mattress are described in, for example, <CIT>; <CIT>; <CIT>.

In some embodiments, the roll-packing machine may apply a load sufficient to transform the cushioning element <NUM> to a compressed form. As used herein, the term "compressed form" means and includes a state in which the cushioning element <NUM> has a size and shape different from its original size and shape, wherein adjacent buckling walls <NUM> are pressed together and may be collapsed such that voids <NUM> may not exist. The cushion <NUM> including the cushioning element <NUM> in compressed form may be packaged, such as in a cylindrical bag, and shipped to a customer. To use the cushion <NUM>, the customer may remove the cushion <NUM> from the packaging and allow the cushion <NUM> and the cushioning element <NUM> to return to its original size and shape.

It has been observed that the elastomeric material, according to embodiments of the present disclosure, may be sufficiently sticky such that the cushioning element <NUM> may not return to the expanded form after the cushion <NUM> is removed from the bag. That is, the buckling walls <NUM> may stick to one another or remain stuck to one another after the cushion <NUM> is removed from the bag. In some embodiments, the cushioning element <NUM> may not return to the expanded form within a reasonable amount of time (e.g., less than approximately eight hours). In other embodiments, the elastomeric cushioning element <NUM> may not return to the expanded form without manually or mechanically manipulating (e.g. pulling on) the cushioning element <NUM> to separate the buckling walls <NUM>. However, when the cushioning element <NUM> is formed as part of the cushion <NUM>, the layers <NUM> or <NUM> may inhibit direct access to the elastomeric cushioning element <NUM> and may hinder manipulation of the elastomeric cushioning element <NUM> in order to separate the buckling walls <NUM>. This sticking together of polymeric materials is referred to in the art as "blocking. " To enable the elastomeric cushioning element <NUM> to return to the expanded form from the compressed form, a surface of the elastomeric cushioning element <NUM> may have a coating material on surfaces of the buckling walls <NUM>. In particular, the coating material may be a thin film covering all or portions of the buckling walls <NUM>. For example, the sides of the buckling walls <NUM> defining voids <NUM> in the cushioning element <NUM> may have the coating material thereon.

The coating material includes stearic acid, a metal stearate (e.g., magnesium stearate, calcium stearate, or calcium stearate), propylene glycol, and triethanolamine. In some embodiments, the coating material may be substantially free of zinc stearate. Such a coating material is available as a slurry from Ocean Chemical Industry, of Sao Paulo, Brazil, under the trade name RuberZol RA <NUM>. The coating material may be formulated to be non-toxic. The coating material may be formulated to hinder adhesion of the buckling walls <NUM> when the cushioning element <NUM> is in a compressed form such that the buckling walls <NUM> are pressed together.

<FIG> illustrates a flowchart of a method <NUM> of applying the coating material to a surface of the cushioning element <NUM> of <FIG>. At action <NUM>, the cushioning element <NUM> may be formed. In some embodiments, the cushioning element <NUM> may be molded. By way of non-limiting example, the cushioning elements <NUM> may be molded as described in <CIT>. A molten elastomeric gel may be injected into a mold by the processes described in, for example, <CIT>; or <CIT>. The buckling walls <NUM> may be formed by the injection of the molten elastomeric gel into the mold. The elastomeric gel may be solidified (e.g., by cooling) and removed from the mold to form the cushioning element <NUM>. The cushioning element <NUM> may be formed without the use of a mold release.

At action <NUM>, one or more surfaces of the cushioning element <NUM> may be coated with the coating material. In some embodiments, the cushioning element <NUM> may be disposed in a bath containing a coating composition (e.g., a coating material plus a carrier, solvent, diluent, etc., that can be removed from the coating material, such as by evaporation). In other embodiments, the cushioning element <NUM> may be sprayed with the coating composition, the coating composition may be poured over the cushioning element <NUM>, or the cushioning element <NUM> and the coating composition may be mixed in a rotating drum.

The coating composition may include the coating material and one or more additional materials. For example, the coating composition may include water, stearic acid, a metal stearate, propylene glycol, and triethanolamine. In some embodiments, the coating composition may contain at least about <NUM>% water by weight, at least about <NUM>% water by weight, at least about <NUM>% water by weight, or even at least about <NUM>% water by weight. The water may be used to disperse the coating material. The amount of water in the coating composition may at least partially determine the amount of the coating material that will remain on the cushioning element <NUM>. In some embodiments, the coating composition may include another solvent that can evaporate, such as an alcohol, in addition to or instead of water.

The cushioning element <NUM> may be contacted with the coating composition immediately or within about <NUM> minutes after the cushioning element <NUM> has been formed (e.g., removed from the mold). In other embodiments, the cushioning element <NUM> may be contacted with the coating composition more than <NUM> minutes after the cushioning element <NUM> has been formed.

In embodiments in which the cushioning element <NUM> is disposed into a bath, the bath may be sized and configured to accommodate at least one cushioning element <NUM>. In some embodiments, the bath may be sized and configured to accommodate at least four cushioning elements <NUM>. The number of cushioning elements <NUM> that may be provided in the bath and simultaneously coated may depend on the dimensions of the cushion element <NUM>. In some embodiments, the cushioning element <NUM> may continuously pass through the cleaning composition.

The cushioning element <NUM> may have any selected dimensions based on the intended use. For example, if the cushion <NUM> is a mattress for a king size bed, the cushioning element <NUM> may be approximately <NUM> inches (<NUM>) by about <NUM> inches (<NUM>), with a thickness of approximately <NUM> inches (<NUM>), and weigh approximately <NUM> lbs. If the cushion <NUM> is a mattress for a queen size bed, the cushioning element <NUM> may be approximately <NUM> inches (<NUM>) by <NUM> inches (<NUM>), with a thickness of approximately <NUM> inches (<NUM>), and weigh approximately <NUM> lbs. If the cushion <NUM> is a mattress for an extra-long twin size bed, the cushioning element <NUM> may be approximately <NUM> inches (<NUM>) by <NUM> inches (<NUM>), with a thickness of approximately <NUM> inches (<NUM>), and weigh approximately <NUM> lbs. In some embodiments, the cushioning element <NUM> may have any other selected thickness, such as approximately <NUM> inches (<NUM>) or approximately <NUM> inches (<NUM>), and weights may scale accordingly.

Various surfaces of the cushioning element <NUM>, including the buckling walls <NUM>, the top surface <NUM>, and the bottom surface <NUM>, may be coated with the coating composition, which includes the coating material. In some embodiments, and as illustrated in <FIG>, the cushioning element <NUM> may be coated by passing the cushioning element <NUM> into a bath <NUM> of the coating composition. The cushioning element <NUM> may be guided into and out of the bath <NUM> by one or more rollers <NUM>. The rollers <NUM> may be configured to push the cushioning element <NUM> under the surface of the coating composition, such that the cushioning element <NUM> is at least partially immersed in the coating composition. Some of the rollers <NUM> may be connected to a drive mechanism (e.g., a belt or shaft connected to a motor) to continuously move the cushioning element <NUM> through the bath <NUM> (e.g., to deliver the cushioning element <NUM> to the bath <NUM> and lift the cushioning element <NUM> out of the bath <NUM>). The cushioning element <NUM> may become coated with the coating composition after exposure for a short period of time, such as within about <NUM> seconds, within about <NUM> seconds, or even within about <NUM> second. If the cushioning element <NUM> includes corners, crevices, holes, etc., having relatively small dimensions, the exposure time of the cushioning element <NUM> to the coating composition may be increased. In some embodiments, the cushioning element <NUM> may be contacted with the coating composition multiple times to sufficiently flow and penetrate to cover the entire cushioning element <NUM>. The cushioning element <NUM> need not sit in the coating composition once covered.

The continuous process illustrated in <FIG> may have advantages with respect to process control, because the amount and concentration of the coating composition can be controlled by automatic valves, pumps, etc., and cushioning elements <NUM> can be more consistently and uniformly coated, as compared to batch processes.

Batch processes may be used, and may be particularly beneficial for testing and scale-up purposes. Any container may be used to contain the coating composition, so long as the container can hold at least a portion of the cushioning element <NUM> to be coated. For example, a horse trough may be partially filled with the coating composition, and a cushioning element <NUM> for use in a king-size mattress may be dunked in the horse trough. As another example, a <NUM>-gallon (<NUM>-liter) bucket may be partially filled with the coating composition, and a cushioning element <NUM> for use in a seat cushion may be dunked in the bucket.

In some embodiments, the cushioning element <NUM> may be coated without using a bath <NUM>. For example, the coating composition may be sprayed onto the surface of the cushioning element <NUM> using a compressed air sprayer. In other embodiments, the coating composition may be shaken or poured over a surface of the cushioning element <NUM>. The coating composition may also be brushed or rubbed onto the surface of the cushioning element <NUM> mechanically or manually.

At action <NUM> (<FIG>), a portion of the coating composition (typically the water or other solvent) may be removed from the cushioning element <NUM>. In some embodiments, excess coating composition may be removed by manually shaking or blowing on the cushioning element <NUM>. In other embodiments, the excess coating composition may fall away from the cushioning element <NUM> naturally (e.g., without applying a manual or mechanical stimulus). The excess coating composition, if any, may be collected and reused to coat other cushioning elements <NUM>.

For example, after the cushioning element <NUM> leaves the bath <NUM> (<FIG>), the cushioning element <NUM> may be exposed to air for a period of time to dry. In some embodiments, the cushioning element <NUM> may be dried for less than <NUM> minute, for between <NUM> minute and <NUM> minutes, for between <NUM> minutes and <NUM> minutes, for at least <NUM> minutes, for between about <NUM> minutes and about <NUM> minutes, or for more than <NUM> minutes. The length of time for which the cushioning element <NUM> is dried may vary based on the dimensions of the cushioning element <NUM>, the amount of water or other material in the coating composition, the temperature at which the cushioning element <NUM> is dried, or any other parameter. Drying the cushioning element <NUM> may cause evaporation of the water or other material from the coating composition, leaving the coating material on surfaces of the cushioning element <NUM>. In some embodiments, the cushioning element <NUM> may be dried by passing heated air over it, such as by using fans and/or electric heating elements. In other embodiments, such as when the cushioning element <NUM> is coated immediately after formation (e.g., after removal from a mold), the cushioning element <NUM> may be warm when coated, and heat of the cushioning element <NUM> may contribute to drying the cushioning element <NUM>. Though heat and air circulation may be used to dry the cushioning element <NUM>, neither is required. That is, the cushioning element <NUM> may be dried even without heat or air circulation.

In some embodiments, the coating composition as received from a supplier may include water or another solvent. Additional water may be added to the coating composition to yield any selected concentration. For example, if the coating composition is received as a slurry, the slurry may be diluted by adding from about <NUM>% to about <NUM>% slurry with from about <NUM>% to about <NUM>% water, by weight, such as from about <NUM>% to about <NUM>% slurry with from about <NUM>% to about <NUM>% water. Increasing the amount of water in the coating composition may decrease the amount of the coating material that remains on the cushioning element <NUM> after drying. Thus, the beneficial effect of coating the cushioning element <NUM> may be achieved using less of the coating material, which may decrease material costs and weight.

In some embodiments, the coating material provided on the cushioning element <NUM> may tint or discolor the surface of the cushioning element <NUM> such that it may be visibly discerned that the cushioning element <NUM> has been coated. In other embodiments, the coating material provided on the cushioning element <NUM> may not be visible. For example, an amount of coating material remaining on the cushioning element <NUM> after drying a coating composition having at least <NUM>% water by weight may not be visible to the naked eye. The amount of coating material may be selected such that the coating material does not flake off, bleed onto adjacent materials, discolor the cushioning element <NUM>, or have a detectable odor. In certain embodiments, the coating material may enhance the generally nonsticky feel of the surface of the cushioning element <NUM>. In some embodiments, a person familiar with the feel of coated and uncoated material of the cushioning elements may discern by touching or rubbing the cushioning element <NUM> whether a particular cushioning element includes the coating material.

In some embodiments, the cushioning element <NUM> may have a ratio of a mass of the coating material to a mass of the elastomeric material ratio from about <NUM>:<NUM> to about <NUM>:<NUM>, such as from about <NUM>:<NUM> to about <NUM>:<NUM>, or about <NUM>:<NUM>.

At action <NUM>, additional layers may be provided above and/or below the cushioning element <NUM>. In some embodiments, the top layer <NUM> may be formed (e.g., attached) over the top surface <NUM> of the cushioning element <NUM>, and the bottom layer <NUM> may be formed (e.g., attached) under the bottom surface <NUM> of the cushioning element <NUM> (see <FIG>).

Cushioning elements <NUM> described herein may have advantages over uncoated cushioning elements. For example, cushioning elements <NUM> having a coating material thereon and provided in the cushion <NUM> that is subsequently compressed, packaged, and removed from the packaging, may return to the expanded form immediately and/or in less than eight hours. Further, the buckling walls <NUM> may separate without manual or mechanical forces being applied, that is, when the cushioning element <NUM> is left undisturbed after removal from its packaging. This quick expansion without additional end-user manipulation may allow for immediate use of the cushion <NUM>, and may make roll-packing of cushions a more beneficial shipping option.

In some embodiments, the coating composition may be used as a lubricant for a wet saw. That is, after the cushioning element <NUM> is coated, and typically before the cushioning element <NUM> is dried, the cushioning element <NUM> may be cut to a selected size and shape. The coating composition may limit or prevent binding of the elastomeric material of the cushioning element <NUM> on a saw blade as the saw blade cuts the cushioning element <NUM>. Production time and costs may be decreased because a separate lubricant need not be supplied. Furthermore, wash and dry cycles typically associated with conventional cutting lubricants may be avoided.

In experiments, a cushion having an elastomeric cushioning element without any coating provided on a surface thereof was roll-packed. After the cushion was roll-packed in the compressed form, the cushion was packaged, and subsequently removed from the packaging such that the cushion could return to its original size and shape. However, the cushion failed to return to its original size and shape within eight hours. In other similar experiments conducted on cushions including an uncoated elastomeric cushioning element, some cushions failed to return to the original size and shape within <NUM> days, and other cushions never returned to the original size and shape without manually pulling apart the buckling walls.

In other experiments, an elastomeric cushioning element was coated with a talc powder, which is a common antiblock additive. The cushion including the talc-coated cushioning element, was similarly roll-packed, packaged, and subsequently removed from the packaging such that the cushion could return to its original size and shape. Similar to the uncoated elastomeric cushioning element, the buckling walls of the cushion did not unstick, and the cushion failed to return to its original size and shape within eight hours. Generally, no improvement was observed between the uncoated elastomeric cushioning element and the talc-coated elastomeric cushioning element.

In yet further experiments, an elastomeric cushioning element was coated with surfactants such as glycerin and DAWN® dishwashing liquid. The cushion including the surfactant-coated cushioning element, was similarly roll-packed, packaged, and subsequently removed from the packaging such that the cushion could return to its original size and shape. Similar to the uncoated and talc-coated elastomeric cushioning element, the buckling walls of the cushion did not unstick, and the cushion failed to return to its original size and shape within eight hours. Generally, no improvement was observed between the surfactant-coated elastomeric cushioning element, the uncoated elastomeric cushioning element, and the talc-coated elastomeric cushioning element.

Claim 1:
A cushion (<NUM>), comprising:
a cushioning element (<NUM>) comprising an elastomeric material forming a plurality of intersecting buckling walls (<NUM>) defining a plurality of hollow columns (<NUM>) in an expanded form, wherein the elastomeric material comprises an elastomeric polymer and a plasticizer consisting of mineral oil; and
a coating composition comprising a coating material over at least one surface of the intersecting buckling walls; the coating material comprising stearic acid, a metal stearate, propylene glycol, and triethanolamine.