Cushion system

Abstract

Embodiments of the disclosure include a cushion system, which may be part of a sleeping system or a seating system, for example. A seating system may comprise a cushion, which comprises a cushion cover; and one or more foam layers within the cushion cover, wherein the cushion is spring-free. The one or more foam layers may each comprise a plurality of substantially vertical air passageways which pass through the entire thickness of the corresponding foam layer. The one or more foam layers may comprise a base layer of foam; a middle sculpted layer of foam having for example a sculpted surface with a plurality of foam pillars projecting outward; and a top layer of foam with uniform thickness, with the sculpted layer sandwiched between the top and base layers.

What is claimed is: 
     
         1 . A seating system comprising:
 a cushion, which comprises:
 a cushion cover; and 
 one or more foam layers within the cushion cover; 
   wherein the cushion is spring-free;   wherein the one or more foam layers each comprise a plurality of substantially vertical air passageways which pass through the entire thickness of the corresponding foam layer; and   wherein the one or more foam layers comprise:
 a base layer of foam; 
 a middle sculpted layer of foam having a sculpted lower surface with a plurality of foam pillars projecting downward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and 
 a top layer of foam with uniform thickness, which is located above the middle sculpted layer. 
   
     
     
         2 . The seating system of  claim 1 , wherein the middle sculpted layer of foam further comprises a sculpted upper surface with a plurality of foam pillars projecting upward. 
     
     
         3 . A cushion comprising:
 a cover; and   one or more foam layers comprising:
 at least one sculpted foam layer comprising a plurality of foam pillars; and 
 at least one additional foam layer. 
   
     
     
         4 . The cushion of  claim 3 , wherein the cushion is part of the seating system. 
     
     
         5 . The cushion of  claim 3 , wherein the cushion is spring-free. 
     
     
         6 . The cushion of  claim 3 , wherein the one or more foam layers each comprise a plurality of substantially vertical air passageways. 
     
     
         7 . The cushion of  claim 6 , wherein at least some of the substantially vertical air passageways in the foam layers align to provide continuous airflow paths from the bottom surface of the cushion to an upper surface of the cushion. 
     
     
         8 . The cushion of  claim 3 , wherein the one or more foam layers comprise:
 a base layer of foam;   a middle sculpted layer of foam having a sculpted lower surface with a plurality of foam pillars projecting downward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and   a top layer of foam with uniform thickness, which is located above the middle sculpted layer.   
     
     
         9 . The cushion of  claim 8 , wherein the middle sculpted layer of foam further comprises a sculpted upper surface with a plurality of foam pillars projecting upward. 
     
     
         10 . The cushion of  claim 9 , wherein the sculpted upper surface of the middle sculpted layer of foam comprises pillars of a different size than the sculpted lower surface of the middle sculpted layer of foam. 
     
     
         11 . The cushion of  claim 8 , wherein the base layer of foam comprises a thickness that is approximately double the thickness of the top layer of foam. 
     
     
         12 . The cushion of  claim 3 , further comprising an outer wrap configured to wrap around at least a portion of the one or more foam layers and positioned between the one or more foam layers and the cover. 
     
     
         13 . The cushion of  claim 12 , wherein the outer wrap comprises polyethylene terephthalate (PET). 
     
     
         14 . The cushion of  claim 3 , wherein the one or more foam layers comprise:
 a base layer of foam;   a middle sculpted layer of foam having a sculpted upper surface with a plurality of foam pillars projecting upward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and   a top layer of foam with uniform thickness, which is located above the middle sculpted layer.   
     
     
         15 . The cushion of  claim 3 , wherein the cover comprises an air permeable element in a bottom surface of the cover. 
     
     
         16 . A cushion for use in a seating system, the cushion comprising:
 one or more foam layers, at least one foam layer comprising a plurality of foam pillars;   a cushion cover configured to surround the one or more foam layers; and   an outer wrap located between the one or more foam layers and the cushion cover, configured to wrap around at least a portion of the foam layers, wherein the cushion is spring-free.   
     
     
         17 . The cushion of  claim 16 , wherein the one or more foam layers comprise:
 a base layer of foam;   a middle sculpted layer of foam having a sculpted lower surface with a plurality of foam pillars projecting downward, wherein the middle sculpted layer of foam is located atop and in contact with the base layer of foam; and   a top layer of foam with uniform thickness, which is located above the middle sculpted layer.   
     
     
         18 . The cushion of  claim 16 , wherein the base layer of foam comprises a thickness that is approximately double the thickness of the top layer of foam. 
     
     
         19 . The cushion of  claim 16 , wherein the middle sculpted layer comprises a dual independent foam pillar layer comprising a plurality of foam pillars projecting downward from a bottom surface of the middle sculpted layer, and comprising a plurality of foam pillars projecting upward from a top surface of the middle sculpted layer. 
     
     
         20 . The cushion of  claim 16 , wherein the middle sculpted layer comprises a solid edge portion without any foam pillars located about at least a portion of the outer edge of the middle sculpted layer.