Foam comfort layer with liquid pods and method of making same

Abstract

A comfort layer for a bedding or seating product has liquid pods sandwiched between plies of fabric. The plies of fabric are joined with seams thereby creating pockets, at least one liquid pod being inside each pocket. Each seam joining opposed plies of fabric around each of the liquid pods of the comfort layer may be segmented or solid, depending upon the fabric and type of seam.

What is claimed is: 
     
         1 . A comfort layer configured to overlay a core of a bedding or seating product, said comfort layer comprising:
 a first piece of foam;   a second piece of foam, at least one of the first and second pieces of foam having cutouts; and   liquid pods located in the cutouts, each of the liquid pods comprising a pouch surrounding a volume of liquid.   
     
     
         2 . The comfort layer of  claim 1  wherein the liquid contains at least some water. 
     
     
         3 . The comfort layer of  claim 1  wherein the pouch further surrounds a plurality of hydrogel beads. 
     
     
         4 . The comfort layer of  claim 1  wherein the pouches of the liquid pods are made of rubber. 
     
     
         5 . The comfort layer of  claim 1  wherein the pouches of the liquid pods are made of plastic. 
     
     
         6 . The comfort layer of  claim 1  wherein the pouches of the liquid pods are made at least partially of renewable material. 
     
     
         7 . The comfort layer of  claim 1  wherein the liquid is a natural oil. 
     
     
         8 . A comfort layer configured to overlay a core of a bedding or seating product, said comfort layer comprising:
 a first piece of foam having a plurality of cutouts extending upwardly from a lower surface of the first piece of foam;   a second piece of foam having a plurality of cutouts extending downwardly from an upper surface of the second piece of foam, the cutouts of the first and second pieces of foam being aligned to create receptacles; and   liquid pods located in at least some of the receptacles, each of the liquid pods comprising a pouch surrounding a volume of liquid.   
     
     
         9 . The comfort layer of  claim 8  wherein the liquid contains at least some water. 
     
     
         10 . The comfort layer of  claim 8  wherein the pouch further surrounds a plurality of hydrogel beads. 
     
     
         11 . The comfort layer of  claim 8  wherein the pouches of the liquid pods are made of rubber. 
     
     
         12 . The comfort layer of  claim 8  wherein the pouches of the liquid pods are made of plastic. 
     
     
         13 . The comfort layer of  claim 8  wherein the pouches of the liquid pods are made at least partially of renewable material. 
     
     
         14 . The comfort layer of  claim 8  wherein the liquid is a natural oil. 
     
     
         15 . A comfort layer configured to overlay a core of a bedding or seating product, said comfort layer comprising:
 a first piece of foam having a plurality of cutouts;   a second piece of foam having a plurality of cutouts, the cutouts of the first and second pieces of foam being aligned to create receptacles; and   liquid pods located in all of the receptacles, each of the liquid pods comprising a pouch surrounding a volume of liquid.   
     
     
         16 . The comfort layer of  claim 15  wherein the liquid contains at least some water. 
     
     
         17 . The comfort layer of  claim 15  wherein the pouch further surrounds a plurality of hydrogel beads. 
     
     
         18 . The comfort layer of  claim 15  wherein the pouches of the liquid pods are made of rubber. 
     
     
         19 . The comfort layer of  claim 15  wherein the pouches of the liquid pods are made of plastic. 
     
     
         20 . The comfort layer of  claim 15  wherein the liquid is a natural oil.