Composite cushioning system

Abstract

A composite cushioning system including a coil spring layer, a topper layer, and a cover surrounding all of it. The topper is provided in one of several embodiments. A first embodiment has an elastomeric layer disposed between a lower foam layer and an upper fabric layer, all held together in a tufted appearance using a plurality of buttons. A second embodiment includes a smaller area elastomeric layer within a foam border and covered by a fabric-foam layer. A third embodiment includes an elastomeric layer enclosed in a fabric cover. A fourth embodiment includes an elastomeric layer melt fused to a lower foam layer bordered by a support structure. A fifth embodiment includes upper and lower elastomeric layers formed around an intervening fabric layer, wherein the fabric layer extends from edge of the elastomeric layers, with the excess fabric layer being held between corresponding upper and lower foam borders.

1 - 17 . (canceled) 
     
     
         18 . A composite cushioning system, comprising:
 a spring base layer having an array of coil springs surrounded by cushioning foam, including an upper foam layer;   a topper layer disposed on the upper foam layer and co-extensive with said spring base layer, said topper layer comprising an elastomeric layer formed by a grid of elastomeric walls defining intervening cells; and   an outer cover enclosing said spring base layer and said topper layer;   
       wherein said topper layer further comprises an inferior cushioning layer, the elastomeric layer is a median elastomeric layer disposed on the inferior cushioning layer, and further comprising a superior fabric layer disposed on the median elastomeric layer; said topper layer further comprises a plurality of buttons connecting said superior fabric layer to said inferior cushioning layer through said median elastomeric layer; wherein said plurality of buttons are aligned in rows to form an array where each of the plurality of buttons passes through a cell of the median elastomeric layer; and wherein the elastomeric layer is a thermoplastic rubber formed using a plastic injection molding machine. 
     
     
         19 . The composite cushioning system of claim  1 , wherein said outer cover comprises a padded cushioning material.