Pressure-relieving layer, multi-layer cushion, and method of manufacturing pressure-relieving layer

Abstract

The present application provides a pressure-relieving layer, a multi-layer cushion, and a method of manufacturing a pressure-relieving layer. The pressure-relieving layer includes an integrally formed foam base and a plurality of foam supports. The foam base includes grooves extending in a first direction, which are open at an upper surface of the foam base. Each groove is embedded with multiple foam supports.

What is claimed is: 
     
         1 . A pressure-relieving layer, comprising an integrally formed foam base and a plurality of foam supports, wherein the foam base comprises at least one groove extending in a first direction, with the at least one groove being open at an upper surface of the foam base, and each groove is embedded with multiple of the plurality of foam supports. 
     
     
         2 . The pressure-relieving layer according to  claim 1 , wherein
 the at least one groove and the plurality of foam supports form at least one pressure-relieving zone and a plurality of pressure-bearing zones on the foam base, the at least one pressure-relieving zone and the plurality of pressure-bearing zones being distributed at intervals along a second direction perpendicular to the first direction, and   each pressure-relieving zone is adjacent to one of the pressure-bearing zones on either side thereof.   
     
     
         3 . The pressure-relieving layer according to  claim 2 , wherein
 the at least one pressure-relieving zone comprises a first region, a second region, and a third region, wherein the first region is located in a middle of the foam base, and the second region and the third region are located on both sides of the first region, respectively.   
     
     
         4 . The pressure-relieving layer according to  claim 3 , wherein
 the second region and the third region each comprise a plurality of grooves therein,   a width of the second region along the second direction is greater than a width of the first region along the second direction, and   a width of the third region along the second direction is greater than the width of the first region along the second direction.   
     
     
         5 . The pressure-relieving layer according to  claim 3 , wherein a number of the grooves in the second region is greater than a number of the grooves in the first region, and a number of the grooves in the third region is greater than the number of the grooves in the first region. 
     
     
         6 . The pressure-relieving layer according to  claim 3 , wherein the second region and the third region each comprise at least two types of the foam supports therein. 
     
     
         7 . The pressure-relieving layer according to  claim 1 , wherein each of the foam supports comprises a supporting surface and a bottom surface opposite to each other, wherein the bottom surface is in contact with the groove, and the supporting surface forms a supporting part that is flush with the upper surface of the foam base. 
     
     
         8 . The pressure-relieving layer according to  claim 7 , wherein an outer contour of the foam support does not extend beyond the groove, and an area of the supporting part is not greater than an area of the bottom surface. 
     
     
         9 . The pressure-relieving layer according to  claim 7 , wherein the foam support comprises a plurality of slots or a plurality of protrusions on an upper portion thereof, the plurality of slots or the plurality of protrusions being uniformly distributed on the supporting surface. 
     
     
         10 . The pressure-relieving layer according to  claim 7 , wherein the supporting surface is planar, and an area of the supporting part is not greater than an area of the supporting surface. 
     
     
         11 . The pressure-relieving layer according to  claim 7 , wherein the supporting surface is curved, and an area of the supporting part is less than an area of the supporting surface. 
     
     
         12 . The pressure-relieving layer according to  claim 1 , wherein
 the foam base comprises a plurality of grooves which extend through the foam base along the first direction, and the plurality of grooves have a same width along a second direction; and   the multiple foam supports in each groove are arranged in a row and in contact with each other in sequence.   
     
     
         13 . The pressure-relieving layer according to  claim 12 , wherein the multiple foam supports in each groove have a same structure. 
     
     
         14 . The pressure-relieving layer according to  claim 12 , wherein the plurality of foam supports in different grooves have different structures. 
     
     
         15 . The pressure-relieving layer according to  claim 1 , wherein
 a thickness of the foam base is greater than or equal to a depth of each groove, and the depth of the groove is equal to a height of the foam support located in the groove; and   the depth of the groove ranges from 7 cm to 11 cm, and a volume of the foam support ranges from 2 cm 3  to 7 cm 3 .   
     
     
         16 . The pressure-relieving layer according to  claim 1 , wherein the groove extends through the foam base along the first direction, and the groove is provided with a foam encased at both ends thereof, wherein the foam encased is flush with side edges of the foam base. 
     
     
         17 . A multi-layer cushion, comprising an upper-layer foam, a lower-layer foam, and the pressure-relieving layer according to  claim 1 ; wherein the pressure-relieving layer is located between the upper-layer foam and the lower-layer foam. 
     
     
         18 . The multi-layer cushion according to  claim 17 , wherein
 the multi-layer cushion further comprises a spring layer and a supporting layer, and the supporting layer and the spring layer are arranged in sequence from top to bottom between the pressure-relieving layer and the lower-layer foam; and   the upper-layer foam is made of memory foam, and the lower-layer foam is made of regular foam.   
     
     
         19 . A method of manufacturing a pressure-relieving layer, comprising:
 providing a foam base, and processing a plurality of parallel grooves in the foam base, wherein the plurality of parallel grooves extend along a first direction and are open at an upper surface of the foam base;   providing a plurality of foam supports; and   embedding multiple of the plurality of foam supports in each groove to form the pressure-relieving layer;   wherein the foam supports have a first height, and the parallel grooves have a depth, and the first height is less than or equal to the depth.   
     
     
         20 . The method according to  claim 19 , wherein
 the groove extends through the foam base along the first direction, an outer contour of the foam support does not extend beyond the groove, and the foam support is affixed to the groove; and   top portions of the foam supports form a plurality of supporting parts that are flush with the upper surface of the foam base, the plurality of supporting parts being uniformly distributed above the groove and are arranged at intervals from each other.