Optimized cushioning elements

Abstract

A cushioning element includes a plurality of interconnected walls that define hollow columns. The interconnected walls include voids. The voids have shapes, sizes, and positions that reduce an overall density and weight of the cushioning element without sacrificing its cushioning characteristics. The cushioning element may even be thinner than an existing, conventionally configured cushioning element while providing the same or improved cushioning. In some embodiments, the cushioning element may also include enlarged junctions between interconnected walls or other stiffening features. Methods for designing such cushioning elements are also disclosed.

What is claimed: 
     
         1 . A cushioning element, comprising:
 a plurality of interconnected walls formed from an elastomeric material, defining a plurality of hollow columns, with each hollow column of the plurality of hollow columns including:
 at least one stiffening feature; and 
 at least one void in at least one wall of the plurality of interconnected walls. 
   
     
     
         2 . The cushioning element of  claim 1 , wherein the at least one stiffening feature comprises an enlarged junction defining a corner of each hollow column at a location where walls of the plurality of interconnected walls join each other, each dimension across each end of the enlarged junction exceeding a thickness of each wall of the walls joined at the enlarged junction. 
     
     
         3 . The cushioning element of  claim 2 , wherein each corner of each hollow column comprises the enlarged junction. 
     
     
         4 . The cushioning element of  claim 1 , wherein the at least one stiffening feature is defined by the elastomeric material. 
     
     
         5 . The cushioning element of  claim 1 , wherein the at least one void comprises an opening in at least one wall of the plurality of interconnected walls. 
     
     
         6 . The cushioning element of  claim 5 , wherein the opening comprises a notch in an edge of the at least one wall. 
     
     
         7 . The cushioning element of  claim 5 , wherein the opening comprises a window in the at least one wall. 
     
     
         8 . The cushioning element of  claim 1 , wherein the elastomeric material comprises a gel. 
     
     
         9 . The cushioning element of  claim 8 , wherein the gel comprises a block copolymer and a plasticizer. 
     
     
         10 . The cushioning element of  claim 9 , wherein the block copolymer comprises a triblock copolymer. 
     
     
         11 . The cushioning element of  claim 10 , wherein the triblock copolymer comprises an A-B-A triblock copolymer. 
     
     
         12 . The cushioning element of  claim 1 , wherein the plurality of hollow columns buckle when at least a portion of the cushioning element is placed under a load. 
     
     
         13 . A cushioning element, comprising:
 a plurality of interconnected walls formed from an elastomeric material, defining a plurality of hollow columns, with each hollow column of the plurality of hollow columns including at least one void in a wall of the plurality of interconnected walls.   
     
     
         14 . The cushioning element of  claim 13 , wherein the at least one void comprises at least one notch formed in an edge of the wall. 
     
     
         15 . The cushioning element of  claim 14 , wherein the at least one notch is formed in a bottom edge of the wall. 
     
     
         16 . The cushioning element of  claim 13 , wherein the at least one void comprises a window formed in the wall. 
     
     
         17 . The cushioning element of  claim 13 , wherein the at least one void is formed in a plurality of walls of the plurality of interconnected walls defining each hollow column. 
     
     
         18 . The cushioning element of  claim 17 , comprising at least one void in each wall defining each hollow column. 
     
     
         19 . The cushioning element of  claim 13 , further comprising:
 at least one stiffening feature.   
     
     
         20 . The cushioning element of  claim 19 , wherein the at least one stiffening feature comprises an enlarged junction at a corner of each hollow column of the plurality of hollow columns, each dimension across each end of the enlarged junction exceeding a thickness of each wall of the plurality of interconnected walls joined at the enlarged junction. 
     
     
         21 . The cushioning element of  claim 19 , wherein the at least one stiffening feature comprises an enlarged junction at a plurality of corners of each hollow column of the plurality of hollow columns, each dimension across each end of the enlarged junction exceeding a thickness of each wall of the plurality of interconnected walls joined at the enlarged junction. 
     
     
         22 . The cushioning element of  claim 19 , wherein the at least one stiffening feature comprises an enlarged junction at each corner of each hollow column of the plurality of hollow columns, each dimension across each end of the enlarged junction exceeding a thickness of each wall of the plurality of interconnected walls joined at the enlarged junction. 
     
     
         23 . The cushioning element of  claim 13 , wherein the plurality of hollow columns buckle when at least a portion of the cushioning element is placed under a load. 
     
     
         24 . A method for designing a cushioning element with a plurality of interconnected walls defining an array of hollow columns, comprising:
 stiffening at least portions of the plurality of interconnected walls to enable minimization of a thickness of the cushioning element to provide predetermined compression and rebound characteristics; and/or   designing the plurality of interconnected walls to include voids.   
     
     
         25 . The method of  claim 24 , wherein stiffening at least portions of the plurality of interconnected walls comprises designing enlarged junctions at corners of the hollow columns to stiffen the corners, each dimension across each end of each enlarged junction exceeding a thickness of each wall of the plurality of interconnected walls joined at the enlarged junction. 
     
     
         26 . The method of  claim 24 , wherein designing the plurality of interconnected walls to include voids comprises designing the plurality of interconnected walls to include notches in edges of the plurality of interconnected walls and/or windows in the plurality of interconnected walls. 
     
     
         27 . The method of  claim 24 , comprising stiffening at least portions of the plurality of interconnected walls and designing the plurality of interconnected walls to include voids. 
     
     
         28 . The method of  claim 24 , further comprising:
 designing the array of hollow columns to buckle when placed under a load.