摘要：
Bedding components and processes for forming the bedding components includes an additive manufacturing process to produce a variable elastomeric lattice structure. The variable elastomeric lattice structure includes variations in strut diameter, cell diameter, strut shape, and combinations thereof. The bedding components include mattresses, pillows, coils, mattress toppers or the like and can also be in the form of inserts to provide different feels in different regions.
权利要求：
WO 2022/261202 CLAIMS What is claimed is: 1. A process for producing a three-dimensional variable density lattice structure for a bedding component, the process comprising: generating a contour map of pressure and/or a temperature map from an end user using a conventional bedding product; designing a polymeric lattice structure configured to minimize pressure points and/or temperature hot spots at locations of the bedding component observed from the contour map of pressure and/or the temperature map; and fabricating the polymeric lattice structure as an insert for use with the bedding component or as a replacement of at least a portion of the bedding component using an additive manufacturing process, wherein the number of pressure points and/or hot spots is reduced in the bedding component relative to the conventional bedding component without the polymeric lattices structure.
2. The process of claim 1, wherein the bedding component comprises a mattress, pillow, a mattress topper, a layer within a mattress, or a coil.
3. The process of claim 1, wherein the insert for the bedding component provides a different firmness property relative to the bedding component without the insert.
4. The process of claim 1, wherein the bedding component is a pillow and the polymeric lattice structure has a variable density comprising a different strut shape, or a different cell diameter, or a different strut diameter or combinations thereof to provide a variable firmness at different locations within the pillow.
5. The process of claim 1, wherein the bedding component comprises one or more cavities in at least one layer thereof configured to receive the insert, wherein a top surface of the insert and a top surface of the at least one layer are coplanar to one another.
6. The process of claim 5, wherein the one or more cavities have different dimensions within the at least one layer and the inserts have complementary dimensions configured to fill the one or more cavities.
7. The process of claim 5, wherein the insert is reconfigurable from a stored form having minimal surface area to a deployed form having maximal surface area for insertion into adjacent cavities in the at least one layer.
8. The process of claim 1, wherein the polymeric lattice structure comprises one or more interlocking components configured to interlock with at least one additional variable density polymeric lattice structure to form at least a portion of the bedding component. WO 2022/261202
9. The process of claim 1, wherein the polymeric lattice structure comprises variations in a selected one or more of a strut diameter, a cell diameter, and a strut shape.
10. The process of claim 1, wherein the polymeric lattice structure comprises an elastomeric polymer.
11. A bedding component comprising: an additively manufactured variable density elastomeric lattice structure comprising variations in a selected one or more of a strut diameter, a cell diameter, and a strut shape, wherein the variable density elastomeric polymeric lattice structure has a shape corresponding to at least a portion of the bedding component.
12. The bedding component of claim 11, wherein the bedding component is a pillow structure and the variable density elastomeric lattice structure defines a general shape of the pillow structure in its entirety.
13. The bedding component of claim 11, wherein the variable density elastomeric lattice structure is an insert configured to be inserted within a cavity of at least one layer of the bedding component.
14. The bedding component of claim 13, wherein the insert is reconfigurable from a stored shape to a deployed shape, wherein the stored shape is different from the deployed shape and the deployed shape is configured to be inserted into multiple cavities of a foam layer.
15. The bedding component of claim 11, further comprising at least one additional variable density elastomeric lattice structure configured to interlock with the variable density elastomeric structure.
16. The bedding component of claim 11, wherein the bedding component comprises multiple layers and the variable density elastomeric lattice structure defines at least one layer or a portion of the at least one layer of the bedding component.
17. The bedding component of claim 11, wherein the bedding component comprises multilayer mattress, a mattress topper, a pillow, a coil, or a portion of a mattress.
18. The bedding component of claim 11, wherein the bedding component is a multilayer mattress assembly including a mattress core comprising a coil layer, wherein the coil layer comprises a plurality of coils having the variable density elastomeric lattice structure.
19. The bedding component of claim 18, wherein the plurality of coils include tethered portion between adjacent ones of the plurality of coils to form a string. WO 2022/261202
20. A multilayer mattress assembly comprising: at least one layer comprising a plurality of coil springs, wherein the coil springs comprise additively manufactured variable density elastomeric coil structures, wherein the variable density elastomeric coil structures comprise different strut shapes, or different cell diameters, or different strut diameters or combinations thereof.
21. The mattress of claim 18, wherein the coil springs are configured to provide a linear spring rate.
22. The mattress of claim 18, wherein the coil springs are configured to provide a progressive spring rate.
23. The mattress of claim 18, wherein the coil springs are configured to provide a linear spring rate and a progressive spring rate.
24. A multilayered mattress assembly comprising: at least one layer comprising at least one additively manufactured elastomeric lattice structure.
25. The mattress of claim 24, wherein the at least one layer comprises a foam layer comprising one or more cavities, wherein the at least one additively manufactured elastomeric lattice structure is disposed in the one or more cavities.
26. The mattress of claim 25, further comprising a perforated foam layer overlying the at least one layer.
27. The multilayered mattress assembly of claim 25, wherein the at least one additively manufactured elastomeric lattice structure comprises a compact storage form and an expanded deployed form configured to be disposed within multiple cavities.
28. The multilayered mattress assembly of claim 24, wherein the at least one additively manufactured elastomeric lattice structure comprises at least one selected surface having an interlocking member configured to interlock with an adjacent additively manufactured elastomeric lattice structure having a complementary interlocking member.
29. The multilayered mattress assembly of claim 28, wherein the interlocking member comprises a protrusion and the complementary interlocking member comprises an opening, wherein the protrusion is configured to pressure fit within the opening to connect the at least one additively manufactured elastomeric lattice structure with the adjacent additively manufactured elastomeric lattice structure.
30. The multilayered mattress assembly of claim 24, wherein the at least one layer comprises a first additively manufactured elastomeric lattice structure comprising a first through hole extending from one surface to another surface; at least one adjacent additively WO 2022/261202 manufactured elastomeric lattice structure comprising a second through hole extending from one surface to another surface; and a rope extending through the first and second through holes to connect the first additively manufactured elastomeric lattice structure to the adjacent additively manufactured elastomeric lattice structure.
31. The multilayered mattress assembly of claim 24, wherein the at least one layer is a mattress core comprising a coil layer, wherein the coil layer comprises a plurality of coils having the variable density elastomeric lattice structure.
32. The multilayered mattress assembly of claim 24, wherein the plurality of coils comprises a tethered portion between adjacent ones of the plurality of coils to form a string.
33. The multilayered mattress assembly of claim 24, wherein the at least one additively manufactured elastomeric lattice structure has a variable density.
34. The multilayered mattress assembly of claim 24, wherein the at least one layer comprising at least one additively manufactured elastomeric lattice structure further comprises a channel extending between one or more of the additively manufactured elastomeric lattice structure.