CA1322424C - Anatomically conformable foam support pad - Google Patents

Abstract

ANATOMICALLY CONFORMABLE FOAM SUPPORT PAD
Abstract of the Invention A convoluted foam pad for supporting a reclining human body on a bed including an area for supporting the shoulders of a body, an area for supporting the tail portion of a body and a general support area surrounding the shoulder and tail support areas for supporting the remainder of the body. In one embodiment the support area is formed by peaks arranged in rows, wherein each peak has a flat top and is spaced from any adjacent peak in the same row by a valley. The average valley thickness of the valleys in both the shoulder support area and the tail support area are less than the average valley thickness of the valleys in the general support area. In another embodiment, the shoulder and tail support areas are formed by parallel ribs separated and bounded by areas comprising flat-topped peaks and valleys. Another aspect of the invention is a method of manufacturing convoluted foam pads including compressing a foam block between two rollers having radially extended fingers of varying effective heights, cutting the compressed block into halves having varying peak heights and valleys having varying valley floor heights, and cutting the tops of the peaks off the create areas having lower volumes of foam than other areas.

EAS-5778:lwl/cf2/lw3 PREFO.01B

Description

1322~4 PREFO.OlB PATENT
~NATOMICALLY ~ONFO~NABLE FOA~ S~PPORT PAD
~kqround of the Invention This invention relates to pads for supporting the seated and recumbent human body which redistribute body weight away from bony prominent areas, which areas are the most susceptible to the formation of pressure ulcers and, in particular, to aonvoluted ~oam pads used for this purpose.
Two of the primary causes of pressure ulcers are pressure and moisture. The pressure results from the supporting surface resisting the force of gravity on the body. For mattresses, this pressure i~ typically t~e hiqhest beneath the 6houlder (the scapulae) and tail (the sacrum and trochanter), generally the areas of greatest ~5 mass and proiection. In these high pr~ssure areas, the pressure against the body can be sufficient to occlude the capillaries and l~mph vessels, thereby preventing the circulation of oxygen and nutrients to the skin. In addition, because airflow over these skin areas is typically prevented due to the ~urface of the mattress, greater amounts of moisture are excret~d for th~
- dissipation of heat and waste. Qver a ~ufficient period of time, the combination of high pressure and moisture will le~d to the formation of pressure ulcers.
25In an ~ffort to combat th~ formation of pressur~
ulcers among patient~, hocpitals utilize a number o~ types : of bed pads for their patients who fall into high risk categories. These product~ include ~atic air, water and ~oam ~upport pad~. Although~these pa~s cannot reduce the overall resistance of ~he ffl~ttress to the wei~ht of the body,~they~can reduce the level of pressure on the areas of highest pressur~ by redistributing ~he load ~nd allowing a : greater portion o~ the pad to ~upport: the body. Each of these type ~ o~ pads has di~eren~ advantages and ; 35 disad~antages.
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Generally, 6tatic ~ir and water support pad~ provide ~uperior high pressure reduction capabilities at the bony prominences, but permi~ only limited air flow and heat dissipation. In addit$on, both tatic n~r and wa~er support pads reguir~ filling, are fiusceptible to leaks and tend to "bottom out" (i.e., permit tha weiqht of the user to displace the air or water in the pad to the extent that the u~er is supported by the mattre~s, r~ther than by the air or water cushion). Static water BUpport pads ~150 are undesirable in that they ~re heavy and unwieldy to transport. Nhile pumps ~nd valves can be used to vary the pressure re~istance of the static air ~nd water pad~ over time, these features render the pad both ~xpensive and di~ficult to install and transport.
Convoluted foam pads, on the other hand, are generally relatively inexpensive and easily transported, while providing 6uperior ~ir ~low potential ~nd mo$~ture reduction capabilitie~. Unfor~unately, despite considerable ~tudy and e~fort, ~t has proved exceedingly difficult to develop an ~sily manufactured convoluted ~oam pad which is capable of providing pressure reduction characteri~tics comparable to ~ta~ic air and wa~er ~upport pa~s.
The ~anu~cture o~ convolut~d ~oam p~d~ continues to largely follow the method~ tau~ht by U.S. ~atent ~o.
- 3,431~802. The pads are typically ~ormed by ~eeding a foam block between two cooperating parallel cylind~r~, each o~ which has ~ undula~ed ~ur~ace. The cylind~r~ r~ a towards one another and are ~paced ~o ~ a~ bl~ck insertéd b~tween them is co~pre~ed between the cylinder6 ~nd i~ ~riven ag~inst a cuttin~ ~dge whiah ~lices t~@ block in hal~ ch hal~ generally compri~e~ ~lte~nat~ng rows o~ pe~k6 and v~lley~, ~n chec~er~oard fa6~0n. Tbe re~ulting halve~ ar~ perfectly ~at~hed ~ that when one h~ id upon the ~ther, the top~ of the peaks of one ~,, .
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half rest against the floor of the valleys of the other half forming a 601id block. In addition, although it is possible to manufacture pads which are not the mirror image or reflection of one another, this is rarely done, as it would typically result in only one usable half, thereby significantly increasing material costs.
One convoluted ~oam pad currently in use is disclosed in U.S. Patent No. 4,686,724. ~he pad is comprises alternating column~ of peaks and valleys in checkerboard fashion. Air channels are stamped, press cut or laser cut through the ~loor of the valley6 to the bottom face of the pad, lea~ing removable plugs used to selectively control the amount o~ aeration and dissipation of body heat permitted by the pad.
In one embodiment, the peaks of the pad are "topped off" to create a broken flat surface, interposed with valleys, with the distance between the floor of each valley and the bottom surface of the pad being constant. Within each valley is a channel extending from the valley floor to the flat bottom ~ace of the pad. The patent teaches that a skin area of 1.25 inches in diameter or lesc~ even though denied air circulation, can 6ustain it~elf from air circulating in an adjacent area. Therefore, by limiting each peak top to a diameter of 1.~5 inch~s or less, the occurrence o~ decubitus ulcers can, ~ccord$ng to the patent, be virtually eliminated. Unfortunately, the use of this uniform pad with its removable plugs has found little acoeptance in practice, perhaps ~ecause ~he removal ~nd replacement of the individual plugs is relatively difficult and time consuming.
A æecond con~oluted foam pad is disclosed in U.S.
Patent No. 4,620,337. The pad i~ designed to prev~nt the form~tion of decubitus ulcer~ ~y ~inimizing t~ a~oun~ o~
pres6ure exerted on the body. The pad has ~hree distinct ~ections: a convoluted head ~upporting ~ection; a ribbed torso ~upporting 6ection; and a convol~ted foot and leg .

~322~4 ~upporting Lection. As with most foam pads which are manu~actured from a block of uniform thickness, the sum of the distance from the bottom face of the pad t~ the top of any peak (the "peak height") and the di6tance from the bot~om face of the pad to the floor of any valley (the "base height" or "valley floor height") remains constant.
This arises from the fact that although the height of the undulating surface of the paired cylinders varies along their length, the opposing undulating surfaces are of an equal height.
The pad is designed on the premi~e that heavier portions of the body are less likely to develop pressure ulcers when they are supported by a portion of the pad with a lower peak to base ratio, and that lighter portions of the body are less likely to develop pressure ulcers when they are supported by a portion of the pad with a higher peak to base ratio. Accordingly, the xibs of the torso supporting section are shorter than the average height of the peaks of the head or leg supporting ~ections, and the floors of the valleys of the torso supporting ~ection are higher than the average height of the floors of the valleys of the head or leg supporting ~ections. Unfortunately, however, the pressure reduction capabilities of this pad ars significantly lower than the pressure reduction capabilities of static air or water support pads.
What i~ needed, ~herefore, is a convolu~ed ~oam pad which is easy to ~anufacture and provides high pressur~
area reduction capabilities comparable ~o the ~tatic air and water ~upport pads.
Summarv of the Invent~n ~he present invention solves these problems by providing an e~sily manufactured convoluted foam pad having pressure redis~ribution capabili~ies compara~le ~o the ~tatic air and water ~upport pads and a ~ethod of manufacturing the ~ame.

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One embodiment of the invention is a convoluted foam pad for 6upporting at least part of a human body having a solid flat lower face and a flat upper surface wherein at least one area of the pad provides less resistance to the weight o~ the body than other areas of the pad. Desirably, the area providing this decreased resistance corresponds to a protrudin~ portion of the body, thereby allowing the body to sink farther into the pad.
Another embodiment of the ~nvention ~s an elongate convoluted foam pad ~or ~upporting a reclining human body on a bed. ~he pad include~ an area for supporting the ~houlders of a body, an area for supporting the tail portion of the body and a general support area surrounding the shoulder and tail support ~reas for ~upporting the remainder of the body. Each support area i~ formed by flat-topped peaks arranged in rows, wherein each peak in the same row is spaced from any adjacent peak by a valley.
To decrease the average pressure levels on the shoulder and tail portions of the body, the average valley thickness (i.e., the average vertical distance between the valley ~loors ~nd the bottom of the portion of the pad directly beneath the respective valley floors) of the valleys in both the shoulder support area and the tail ~upport area are less than the average valley thickness of the valleys in the general ~upport area. This diminished valley thickn~ss has the dual e~fect of r~duoing th~
resistance of the~ pad to the weigh~ of the tail and ~houlder portions of the body and permitting th~ tail and 6houlder areas of the body to 6ink farther into the pad.
-~: 30 T~e increased de~ormation of the pad i~ slgni~icant in that, as the tail and shoulders of the ~ody ~i~k further :into the pad, the middle bac~ ~and extra~ities exert greater pressure against the genexal ~upport area of the pad. In addition, the farther the tall ~nd ~houlder : ~35 portions of the body ~ink into the pad, th~ greater the amount of total ~urface araa of ~he pad in contact w1th the 2~
tail and Ghoulders portion~ of the body, re~ulting in a decrease in the avera~e amount of resistance pressure exerted by the pad per ~quare inch in th~se critical areas.
Desirably, the pad has a flat upper face fonmed by the flat tops of the peaks of the pad which all lie substantially in a single plane and a ~olid flat lower face, without holes or cavities. ~he pad is desirably made from an open cell ~xpanded plastic polyurethane foam with a density of between 1-3 pound~ per cubic foot, and has a peak thickness of one inch or greater.
Another aspect of the invention i6 a method of manufacturing convoluted foam pads. The method includes compressing a foam block between two rollers having radially extended fingers of varying effective height~.
The compressed block iæ then cut into two halves to form pea~s and valleys. As a result of the varying effective heights of the fingers of the rollers, the peaks will have varying peak heights and the valleys will have varying valley floor heights. The tops of the peaks are then cut off to create areas having lower volu~es of foam than other areas. These low foam volume areas will tend to provide less resistance to pressure than the areas of the pad having a higher volume of foam.
Desirably, the tops of the peaks are cut ~o the top of each peak will b~ in ~ubstantially the ~ame plane.
Wh~re some of the corners of the peaks are connected by webbing, the methcd may also include the ~eparating ~ome of the peaks connected by webbing to decrea~e the resistance of the locale including the 6eparated peaks to pres~ure.
Brie~ Descr ption o~ the prawin~s These ~nd other features of the invention will now be described with re~erence to drawings for preferred embodiment which i in~ended to illu tra~e, and not to limit, the in~ention, and in which:
Figure 1 is a per6pective view illustrating a foam block being inserted between a pair of cylindrical rollers:

~322~24 Figure 2 is an enlarged partial perspective view illustrating the fingers of the roller~ of Figure 1;
~igure 3 is an enlarged exploded perspective view of one of the fingers of Figure 2;
Figure 4 is an illustration of two convoluted halves of a block after ~n~ertion into the apparatus of Figure 1;
Figure 5 illustrates the fit between the halves of the block of Figure 4;
Figure 6 illustrates the topping-off of the peaks of one of the halves o~ Figure 4;
Figure 7 illustrate-~ the half of Figure 6 after being saw cut;
Figure 8 illustrates the clip cutting of the half of Figure 7;
Figure 9 is a ~chematic plan view illustrating the general spacing of the tail and shoulder regions of a bed pad made in accordance with the principles of the present invention;
Figure 10 is a schematic plan view of a pillow made in ~0 accordance with the principles of th~ present invention illustrating the ~hape of the head and ~eck ~upport ~rea in phantom;
Figure 11 i5 a schematic plan YieW of a w~eelchair pad ~ade in accordance with the principles ~ the pre~ent invention illustrating the ~hape of the buttock and thigh ~upport area in phantom: .
Figure 12 is a per pective vî~w of the pillow of F~gure 10;
Figure 13 i~ a per~pective vi~w o~ the wheelchair pad of Fi~ure 11;
Figure 14 is a perspective view of ~he bed of ~i~ure 9;
~ igure 15 is a sectional view t~ken along line 1~-15 o~ Figure 14 illu~trating the varying v~lley thicknesses of the di~ferent areas o~ the bed pad;
~igure 16 i8 a per~pective view illu~trating a foam ~7-2 ~ ~ ~

block being inserted between a pair of cylindrical rollers of an alternative configuration;
Figure 17 i8 an enlarged partial perspective view illustrating the fingers of the rollers of Figure 16;
Figure 18 i8 an illustration of two convoluted halves of a block after insertion into the apparatus of Figure 16;
Figure 1~ is a perspective view of one of the halves of Figure 18 after being saw-cut;
Figure 20 is a sectional view taken along line 20-20 of Figure lg illu~trating the varying valley thicknesses of the different areas of the mattres~;
Figure 21 is a perspective view illu trating a foam block being inserted between a pair of cylindrical rollers of a second alternative con~iguration;
Figure 22 iB an enlarged partial perspective view illustrating the fingers of the rollar6 of Figure 21;
Figure 23 is an illustration of two convoluted halves of a block after insertion into the apparatus o~ Figure 21:
Figure 24 is a perspective view o~ one of the halves of Figure 23 a~ter being saw-cut; and Figure 25 is a cectional view taken ~long line 25 25 of Figure 24 illustrating the varying valley thicknesses o~
the different areas of the pad.
Detailed~esc~tion 4~ ~h~ ~xe~rred ~mb~im~n~
Figure 1 show~ an apparatus 11 for ~anufacturing convoluted foam pads. The apparatus 11 includ~ ~ pair of cooperating parallel rOller5, 13 and 14, each of which has a cylindxical body and an undulated ~urface. A~ more clearly ~hown in Pigur~ 2, th~ undulated ~urface of each roller i8 formed by a plurality o~ ger~ 15 o~ generally : rectangular cro~s Lection extending radi~lly from its cylindrical body. Naturally, if desir~d, ~nother ~hape of ~inger could be utilized. The ~ingers 15 ~re arranged in vertical and horizontal rows. Fingers in vertically adjacent rows are staggered vertically a circ~ferential di~tance appxoximately e~ual to ~he vertical width of the ~32242~

~inger~. Fingers in horizontally adjacen~ row~ are staggered horizontally a circumferential di~tance approximately equal to the horizontal width of the fingers.
The rotating rollers, 13 and 14, compresR and drive the foam block 19 agains~ a cutter (a guard 17 for which is shown in Figure 4~. As shown in Figure 1, the upper roller rotates counterclockwise and the lower rotates clockwise. This rotation is synchronized 50 the fingers 15 of the respective rollers are opposed by the spaces 21 between the ~ingers of the opposite roller, rather than directly by its fingers 15. In addition, to obtain pads which are virtually a mirror image of one another, all fingers 15 on a given side o~, and vertically adjacent to, the spaces of one roller have an effective height equal to the effective height of the finger of the opposing roller which opposes the space.
As best seen in Figuras 2 and 3, the radial height of each of the fingers 15 is equal. Selected fingers, however, have a greater effective radial height as a result of one or more flat rectangular caps 23 or plates being ~ecured to the radial outer end of the finger by a bolt 25 threadably ~ecured within a tapped bore 27 extending xadially through the center o~ the finger. Naturally, the thicknes~ of the caps 23 can be varied depending upon th~
given application. A counter~ink 29 may be provided around the bore 27 of the outer cap r ~ that the head of the bolt 2S is flush with the outer face 31 of the cap.
R~ferring to Figure 4, after the foam block 19 is compressed ~etween the roller6, it is driven against the cutter ~not shown) which 61ices the block 19 into halves 33. As ~hown in Figure 5, the resulting halve~ 33 are virtually a perfect mirror imag~ of one ano~her, with each peak 35 of one half corre~ponding to an adjacent p~ak 37 o~
equal ~ize on the other hal~. On ~he other hand, the variance in the ef~ective height of the ~ingers 15 results both ~n peak~ with varying peak heights P, ~nd valleys with _g_ ~322~

varyi~g valley floor heights V Because the pad is cut from a 6ingle block 19, however, the 6um of the valley Ploor height and the corresponding peak heiyht will equal a constant, so long as the block being cut i6 of uniform thi~kness.
By varying the effective height of the fingers less than one quarter of an inch, the he~ghts of the peaks 42 of the re ulting foam halves 33 can be var~ed 3-4 inches.
Naturally, since the block halves 33 are a mirror image of one another, the base height o~ the corresponding valleys 44 will ~ary an equal amount. Thu~, although the peak to base ratio of the pad can be made to vary widely, essentially the ~ame volume of foam is present to r~sist the weight ~f a given area of the body ~upported by the pad.
As shown in Figure 6, the tops 39 of the peak~ 42 are then rem~ved with a band saw 41 or other 6uitable cutting device, thereby leaving a rectangular pad 43 with a flat solid lower face 45 and a substantially flat upper face 47 comprised o~ the flat tops 49 of the peaks 42. As ~hown in Figure 7, the pad 43 comprises adjacent row~ of peaks 42 of generally rectangular cross section, each o~ which ~re separated by valley~ 44, also of generaliy rectangular cross section. 8ince the peaks 42 in adjacent rowæ are staggered, the overall e~fect is a checkerbDard pa~tern, with the corners of the peaks 42 in ad;acent row~ connected by webbing 51 extending between the peaks 42 to the floor of the valleys 44. The webbing 51 between some peaks 42 wi}l extend from the top of the peak downward to ~he floor of the ~alley between them. Between other peaks 42, especially those with lGwer vall~y heights, the webb.ing 51 will be ~paced below the tops of ~he peak~ 42 an~ extend downward tG the floor of the valley between th~m. For example, re~erring to Yigure 7, a peak 57, ~n ~ row of peak~ 59 be~ween a ~econd and third row of peaXs, 61 and 63, re~pectively, has a ~ir corner 65 connected by ~22~4 webbing 51 to a corner of a ~irst peak 67 in the ~econd row 61 and a second corner 69 which is connected by web~ing 51 to a corner of a ~econd peak 71 in the second row 61.
Likewise, the peak 57 has a third corner 73 wh~ch is connected by webbing 51 to a corner of a first peak 75 in the third row 63 and a fourth corner 77 which is connected by webbing 51 to a 6econd peak 79 in the th~rd row 63.
~ o obtain two senerally uniform pads from a 6ingle block 19 it is desirable that the tops of the peaks 42 are cut off at a point midway between the tops of the peaks 42 and the floor of the valleys 44. Although each of the remaining flat-topped peaks 42 will have a uniform peak height, the base height of the valley floors varies in proportion to the effective height of the finger which cr~ated it. Since the pad 43 has a flat lower face 45, the peak height of each peak is equal to its peak thickness (i.e., the vertical distance between the top of the peak and the bottom o the portion of the pad 43 directly beneath the peak). Naturally, if the lower face of the pad 43 included an opening beneath the peak, this would not be the case. ~ikewise, the valley floor height of each valley oP the illustrated pad 43 i8 egual to its valley thickness (i.e., the verkical distance between the valley floor and the bottom of the poxtion of the pad 43 directly beneath ~5 the vall~y floor)~ If the lower ~ace 45 of the pad 43 included an opening beneath the valley floor, h~w~ver, this would not be the ca~e.
By increasing the ef~ective height of the fingers 15 which correspond to ~he ar~a~ of the pad 43 suppor~ing the ~houlder and tail portions of the body, taller peaks 42 and lswer valleys 44 are ~or~ed in tho~e arsas:of the pad 43~
By evening out the height o~ the peaks 42 by ~opping them : off at a cer~ain height, one i8 l~ft with a ~m~ller volume of foam to resi~t the we~ght of the that portion of th~
;35 body. It has been found that the ~maller ~he volume of foam ~n a given area, the ~maller the level o~ resl~tanc~

13224~

of the foam to the weight of the body will be. By decreasing the volume of foam beneath these heavier portions of the body, the more the weight of the body portions to overcome the resistance cf the pad and sink into the ~oam. This, in turn, increases the 6urface area of the pad in contact with the body portion, thereby further diminishing the level of pressure exerted on the ckin of the body per unit area. In addition, ~ince both the shoulder and tail portion of the body protrude farther than the lighter portions, as the shouldar and tail portions sinX into the pad, the pressure of the pad on the less protruding portions (e.g., the middl2 of the back) will increase, thereby relieving pressure from the tail and shoulder portio~s of the body.
The pad of the present invention can be mad~ from a wid~ variety o~ types o~ foam of varying denslty and thickness. It has been found, however, that the desired combinatio~ of cushioning and support is obtained from an open cell expanded plastic polyurethane foam with a density of between one and three pounds per cubic foot, preferably 1.5 pounds. The peak and valley thickness of the pad 43 is desirably 6uf~icient to ensure that the body supported by the pad does not bottom out. For a bed pad 43 having a density of between 1-3 pounds, a peak thicknes~ of between 3-5 inches, and a valley thickness of ~pproxi~ately one half of an inch has been found to be sufficient to prevent bottom~ng out in most instances. In home health care applications, however, significant benefits can be realized ~rom a pad with a peak thickness as low as one inch and a valley thickn~ss as low as one-eighth of an inch, which : imposes ~ concavity to the bed surface for comfort, as : opposed to ther~peutic purposes~
At times, in addition to the etandardized pressure reduction capabilities o~ the pad 43, it is desirable in the case o~ burns or other localized injury to decr~ase the level of pre6sure resistance in ~ given area of the pad.
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As illu~trat~d in Figure 8 thi~ may be accomplished by cutting the webbing 51 connecting the corners o~ the peaks 42 in adjacent rows to ~eparate the peaks 42. Th~s has the effect of decreasing the "hammock effect" between the separated peaks. ~he hammock effect results from neighboring peaks resisting the tendency of a connected peak to be compressed below their level, much like two trees resist the tendency of a hammoc~ to sag to the ground in respon-~e to the weight on th2 hammock. The cutting of the webbing 51 largely eliminates this effect, thereby decreasing the capacity of the locale which includes the separated peak to resist the weight of a body.
Referring to Figure 9, there i5 shown a schematic view of a bed pad 43 manufactured in accordance with the principles of the present invention. As further ~hown in Figures 14, the bed pad 43 will generally have an overall length o~ between 60-90 inches and a width of between 25-40 inches, depending upon the length and width of the mattress being covered. For specialty beds, the length could vary between 30-90 inches and the width could vary between 20-90 inches. The illustrated pad 43 has a length of approximately 72 inches and a width of approximately 35 inches~ The shoulder ~upport area 81 and tail ~upport area 83 of the pad 43 are positioned to correspond to the normal ~5 position o~ the shoulder and tail portions o~ the body of - the intended user and are surrounded by the general support area 84 of the pad 43. The shoulder ~upport area 81 of the illustrated pad 43 is Fpaced twelve inches ~rom one end 85 of the pad, is centered betwe~n the ~ides 87 of the pad and has a width of 28.35 inches and~a length of 14.85 inches.
The width and length of the ~houlder support area B1, as well a~ its ~hape may vary, ~ut preferably the w~dth is between 25 and 33 inches, the length i~ between 12 and 17 inches and the shape is generally that of ~ ~u~hroom.
There is a gap of 6 inches be~ween the ~houlder and tail 5upport areas of the pad 43. The tail ~upport ~rea 83 of 132242~

the illu~trated pad 43 i~ elliptical ln ~hape, is centered between the sides of the pad, has a width of 17.55 inches and a length of 12.15 inches. Thi~ spaces the tail ~upport area 27 inches from the other end 89 of the pad. As with the shoulder support area 81, the width and length of the tail support area 83, as well as its ~hape, may vary, but preferably, the width is between lS and 20 inches, the length iB between 10 and 17 inches, and the area is generally elliptical or circular in shape. Naturally, an n additional support area could be added for the heels, if desired.
Although the ~izes of the peaks 42 and valleys 44 of the pad 43 ~ay be varied, the illu~trated pad has a uniform distribution of peaks of square cross ~ection. The peaks 42 of the general 8upport area, the shoulder 5upport area 81 and the tail support area 83 all have a peak thickness of 4 inches and a square ¢ross ~ection with a width of 1.35 inches. As best seen in Figure 15, to provide the desired low~red resistance and body contouring features, the valley thicknesses of the ~houlder and tail ~upport sections c~
the pad are less than the valley thickne~ses of the general ~upport area o~ the pad. Specifically, the valley thickness for both the ~houlder support area 81 and the tail ~upport area 83 is one half o~ one inch, while th~
valley thickness for the ~eneral support area is 3 inches.
Advantageously, the bed pad 43 i~ fo~med by ~eans of inserting a block 19 o~ foam lengthwise through a roller having a circumference equal to the length oP the bed pad 43, so that a pair o~ pads is formed by a single turn o~
th~ roller. Thus, the illustrated pad 43 would be ~ormed with two roll¢r~ each having a circumrerence o~ 72 înches.
The fingers 15 of eaoh roller corre ponding to the general support area of the pad 43 advantageously ex~nd radially 2.5 inches fro~ the cylindrical core of the roller and have a ~guare cross section with a width of .9 inches. ~his width may vary, but is preferably between 1.~5 and 2.0 :

' 1~22~2k inches. The ~pace between the opposing rollers, 13 and 14, is roughly one quarter o~ an lnch, with this distance being xhortened where the rollers are provided with caps.
The fingers 15 of the roller corresponding to the ~houlder support area 81 and the tail ~upport ~rea 83 are advantageously formed by fingers 15 with an effective finger height of 2.6875 inches, resulting from the placing of caps 23 having a combined thickne6s of 3/16 o~ an inch onto the end of the fingers 15, The resulting bed pad 43 is 4 inches thick with a valley thickness of .5 inches which is sufficient to prevent b~ttoming out in most cases.
In a test comparing a bed pad, generally conforming to the specifications s t forth above, with ~tatic water, static air and other convoluted foam support pads, the bed pad of the present invention no~ only demonstrated pressure relief capabilities, in the scapulae, sacrum and trochanter areas, superior to the other convolut2d foam bed pads tested, but demonstrated pressure redistribution capabilities in these areas comparable to the static air and water support pads tested. Speci~ically, the pads tested are as follows:
Model Pesination Manufacturer Trademark _ No. _~ype 25 Foam #l* Pre-Foam, Inc. HIGHFLOAT 5095020 ~oam Water Lotus Healthcare Products LOTUS HM3666 water 30 Air Gaymar Industries, ~ncO SOF-C~RE SC-402 air Foam #2 Bio Clinic Company BIOGARD 669030 foam 35 Foam #3 Span Amerlca Medical Systems, : Inc. GEO-MATT 50960-581 foam Foam #4 Pre-Foam, Inc. PR~VENT P141 foam ~ * Foam Pad #1 i~ a pad ~ade in accordance wi~h the : principles o~ the present inYe~tion.
summary oX the test results are ~et ~orth below in ~322~2~ -the following table:
. P~essure Lçvçl Pad Scapulae Sacrum Trochanter ~esiqnation lmm Hq) ~mm Hq~ (mm Hq~
Foam #1* 24.02 28.28 44.22 Water 22.44 25.96 46.74 ~ir 32.36 33.15 40.57 Foam #2 29.~6 34.40 47.17 Foam #3 23.04 31.97 49.73 Foam #~ 28.04 36.88 45.97 Thus, there is provided a convoluted foam bed pad which is both ~imple and inexpensive to manufacture and which provides hîgh pressure redistribution capabilities comparable to static air and water support pads.
The method and teachings of the present invention can be used to manufacture pads of a wide variety o~ shapes and sizes. Specifically, the method of the present invention c~n be used to manufacture pillows and wheelchalr pads which conform to the 6hapP of the body, thereby ~ncreasing the total surface area of the pad resi~ting the body weight of the us~r.
Flgure~ lO and 12 show a p~llow g3 having a generally T-6haped head and neck 6uppor~ ar~a 95 and ~
general 8upport area 97. A5 with the be~ pad 43, the pillow 93 is formed by peak~ 99 ~rranged in row~, wherein each peak ha a flat top, i~ ~paced from: any ~djacent peak in the ~ame row by a valley 101 and has gen~rally identical peak thicknes6es. The tops of :the pe~ks ~re all in ~: suhstantially th~ sa~e plane, thsreby provid~ng a pillow 93 of pl~asing appearance which can be used wi~ stand~rd pill~ covers. ~o ~ncrease the pillow'~ oapacity to conform to the head an~ neck o~ the uæerr ~khe average valley thickness of the head and neck ~upport rea 95 is ~322~

less than khe average valley thickness of the general support area 97. Although the dimen~ions of the pillow 33 can obviously be varied widely, depending upon the desired application, the illustrated pillow 93 has a width of 21 inches and a depth of 14 inches, with a uniform peak thickness o~ 4 inches. The truncated stem 103 of the T-shaped head and neck upport area 95 extends toward the center of tbe pillow 93 ~rom one end 105, i~ centered between the 6ides 106 of the pillow and has a width of 4.05 inches. The crossbar 107 of the T-shaped head and neck support area 95 extends from one ~ide of the pillow to the other, is ~paced 4.05 inches frsm the end of the pillow from which the stem portion extends, and has a depth of 4.05 inches. Thi~ spaces the stem portion 5.90 inches from the opposite end 111 of the pillow. The desir~d contouring e~fect ~ay be obtained from a T-shaped head and neck upport area 95 with an average valley thickness of 1/2 an inch and the general æupport area 97 with a uniform valley thickness of 3 inches.
Figures 11 and 13 show a wheelchair pad 113 having a generally U-shaped buttock and thigh support area 115 and a general support area 117. As with the pillow 93 and bed pad 43, the wheelchair pad 113 is formed by psaks 119 arranged in rows, wherein each peak has a ~lat top, is ~paced from any adjacent peak in the ~ame row by a valley 121 and has generally identical peak thickne~ he tops of the peak~ are also aIl in substantially the 6ame plane, thereby providing a whe~lchair pad 113 of plea~ing appearance. To increa~e the wheelchair pad'~ capacity to conform to the buttocks and thigh~ of the user, the av~rage valley ~hicXne~s o~ the but~oc~ and thigh ~upport area 115 is less than the average valley thickness o~ the general ~upport ar2a 117~ Although the di~ensions of ~he wheelchair pad 113 can obviously be varied, depen~ing upon the size of the chair and the user, the illustrated wheelchair pad 113 has a width of 18 inches ~nd a depth Or ~3~2~4 16 inche6, with a uniform peak thickne~s of 4 1/2 ~nches.
The legs 123 o~ the T-shaped buttock and thi~h ~upport area 115 extend toward the opposite end of the wheelchair pad from one end, are spaced 2.2g5 inches from th~ sides of the wheelchair pad and have a w~dth of 4.05 inches. An arcuate connecting portion 125 connectc the two legs of the U-shaped buttock and thigh support area 115, i6 apaced 1-1/4 inches from the opposite end of the wheelchair pad, and has a width of 4.05 inches. The desired contouring effect may be obtained from a U-shaped buttock and thigh 5upport area 115 with an average valley thickness o~ 3/4 inches and the general support area 117 with a uniform valley thickness o~ 3 1/2 inches.
As illustrated in Figures 16-20, the method and teachings of the pre~ent in~ention can be used to manufacture an anatomically, conformable convoluted foam pad, particularly adapted to be used as a mattress, rather than a mattress overlay.
Figure 16 shows an apparatus 126 for ~anufacturing convoluted foam mattresses. ~he apparatus 127 includes a pair of cooperating parallel rollers 127 and 129, each of which has a central undulated ~urface 131 and a cylindrical body 133, including a pair of ends, 135 and 137. ~s shown in Figures 16 and 17, at each end of the roller is an expo~ed cylindrical sur~ace 139. The undulated sur~ace 131 of each roller is foxmed by a plurality of fingers 141 of generally xectangular cross-~ection extending radially ~rom it5 cylindrical body 133. The fingers 141 in vertically adjacent rows are 6taggered vertioally a circumferential distance approximately e~ual to the vertical width of the ~inger~ 141, ~nd fingers 141 in horizontally ~djacent rows are ~taggered horizontally a circumfer~n~ial di~tance approximately equal to the horizontal width o~ the fingers 141.
The rotating rollers~ 127 and 129, compress and drive a foam block 143 against the cutker (a guard 144 for which ~32~
is ~hown in Figure 18). The upper roller 127 rotate~
counterclockwise and the lower roller 129 rotate6 clockwise in a synchronized manner 80 that the fingers 141 of the resp~ctive rollers are opposed by the spaces between the fingers of the opposite roller. In addition, tha cylindrical ~urfaces 139 of the ends, 135 and 137 of the upper roller 127 are opposed by the cylindrical surfaces 139 o~ the respective ends, 135 and 137, of the opposite roller 129~ All fingers 141 on a given side o~, and vertically adjacent to, tha 6paces of one roller have an effective height equal to the effective height of the finger of the opposing roller which opposes the space. As shown in Figure 17, the radial height of most of the fingers 141 is equal. Selected finger6 141, however, have a greater effectiYe radial height as a result of one or more ~lat, rectangular caps 145 or plates being secured to the outer end of the ~inger.
As shown in Figure 18, after the foam block 143 is compressed between the rollers, 127 and 129, it is driven against the cutter (not ~hown) which ~lices the block into halves, 149 and 151, which are a perfect mirror image of one another, 80 that each peak 152 of one half corresponds to an adjacent peak of equal ~ize on the other half.
However, variance in the effective height o~ the finger~
141 results both in peaks with varying peak thicknesses and valleys with vaxying valley thicknesses. Because the mattress is cut from a single block, however~ the sum o~
the v~lley thickne~ses and the corresponding peak thicknesses will equal a constant, ~o long as the block being cut i~ of uni~orm thickness. Likewise, the cylindrical surfaces 139 of the ends of each roller co~press the foa~ in identical amount, ~o that the portion of the bl~ck 143 compressed ketween the cylindrical surfaces 139 of the rollers is rlat, with each portion of the mattress corre~ponding to the cylindrical ~uY~ace of the ends sf the rollers ~orming an elongate rail 153 of ~32~
identical thickness extending the length of the mattress.
The tops of the peaks formed by the cooperating undulating surfaces are then removed with a band saw or other suitable cutting device at a point ~idway between the tops of the peaks and the floor of the valleys, in the manner illustrated in Figure 6, leaving an elongate rectangular mattress 155 (Figure 19-20) with a flat, solid, lower face 157 and a substantially flat, upper face 159 comprised of the flat tops of a plurality of peaks 161 and a pair o~ elongate rails 153 extending the length of the mattress. As shown in Figure 19, the portion of the mattress between the rails 153 comprises ad~acent rows of peaks 161 of generally rectangular cross-section, each o~
which are separated ~y a plurality of valleys 162, also generally rectangular cross-section. Since the peaks 161 in adjacent rows are staggered, the overall e~fect is a checker board pattern with two flat elongate borders formed by the mattress' two rails 153.
By increasing the effective height of the ~ingers which correspond to the areas o~ the pad supporting the shoulder and tail portions of the body, taller peaks and lower valleys are formed in tho~e areas of the ~attress.
By evening out the heights of the peaks 161 by topping them off at a certain height, one is left with a ~maller volume o~ foam in the shoulder and tail 8upport areas to resist the weight of those respective portion of the body and, as a re ult, the ~attress provide~ less resistance ~o these heavier body portions, thereby increasing the ability of the ma~tress to conform to ~he anatomy of the user.
Xeferring to Figure 19, the ~attress 155 ~anufactured in accordance with the principle of the present invention desirably haæ a thicXness in excess of 5 inches, an overall length of between 30 and 90 inches and an ov~raIl width of between 20 and 90 inches, depending upon ~he leng~h and width of the bed frame, and the len~th and width o~ the box springs being utilized. For ~pecialty bedsO the length .

.

~32~
could vary between 30-90 inches and the width could vary between 20-90 inches. Likewise, the ~lat rails 153 of the mattress 155 desirably have a width of between 2 and 6 inches and may extend over any portion of the length of the mattress, but desirably at least half o~ the mattress' length and, preferably, the entire length of the mattress.
The rails 153 have a greater volume of foam per unit area, and provide an area of increased resistance, to provide support when getting on to or of~ of the mattress. In the illustrated mattress the rails 153 have a width of 3 inches and extend the length of the mattress. The illustrated mattress has a length of approximately 72 inches and a width of approximately 35 inches.
A mattress manufactured in accordance with the principles of the pressnt inventio~ can alternatively be designed so that breaks in the flat rails are positioned to correspond with the hinge points about which most hospital beds are bendable. Such breaks in the flat rails, if configured to the same peak and valley dimensions of the general support area of the mattress ~ake the mattress easier to bend with the hinged bed at that point.
Between the mattress rails 153 is a general support area 163. The general support area 6urrounds a shoulder ~upport area 165 and a tail ~upport area 167 which are positioned to correspond to the normal position of the ~houlder and tail portions of the body of the intended user. The ~houlder cupport ar~a 165 of the illustrated mattrPss is spaced 1~ inches from one end of the pad, it is centered between the sides of the mattres6 ~nd has a width o~ 28.35 inches and a l~ngth of ~4.85 inches~ The width and l~ngth of the Rhould~r support area 165, a~ w~ll as its ~hape may vary, but preferably the width i~ be~weQn 25 and 33 inches, the length i~ between 12 and 17 inch~s and the shape is generally that of a ~uhroom. There i~ a gap o~ 6 inches between the shoulder and tail ~upport area~, 165 and 167 t respectively, ~f the mattres~. The ta~l ~upport area 13224~4 167 of the illu~trated mattress is elliptical in ~hape, it is centered between the sides of the mattress and has a width of between 17.55 inche~ a~d a length o~ 12.15 inches.
This spaces the tail ~upport area 167 27 inches from the other end of the mattress. As with the ~houlder support area 165, the width and length of the tail ~upport area 167, as well as its shapQ, may vary, but preferably, the width is between 15 and 20 inche~, the length is between 10 and 17 inches, and the area i8 generally elliptical or circular in shape.
In some applications, it may be desirable to u~e a longer foam block in manufacturing the mattress, so as to take advantage of the dif~erence between the circumference of the rollers, 127 and 129, and the length of the block.
As will be readily appreciated, this will result in a greater angular rotation of the rollers, 127 and 129, to cause, for example, a repeat of the ~houlder support area pattern. Where block length i8 planned to exceed the roll circum~erence, a portion of the shoulder support area can be designed to provide ~or an additional heel support araa running approximately 2/3 of the distance across the pad involving up to the last 12" of the pad. Such a h~el Eupport area wou~ld provide a general 60ftenlng of this portion of the pad and ac~ommodate ~he heels and bones of 2S the lower leg. When such alternate heel fiUppOrt areas are provided and configured in a fashion e~nsi~tent with the peak and valley dimensions of the shoulder and tail ~upporting areas, ~ore o~ the total weight of the lower leg will be supported by the back of the pat~ent~s legs redi ~ributing potentially high localized pressure points which typically exist at the heel ~nd bones o~ t~e ankle.
~uch provisions may prove particularly ben~iclal to patient~ being treated for vascular ulcers of the lower leg.
Becau~e the illustrated ~attress posce~se~ a flat, rectangular overall conflguration, it may ~e di~icult to .
' ' ' ' ' ' . ' ' ' ' .. .. . .

' ~32~2~
determine its correct head-to-~oot end orientation if cov~red in a permanent uphol~tered cover. To mitigate this potential problem, in ~uch instances, ~t ~ay be desirable to use the principles of the present invention to provide a second shoulder ~upport area at the opposite end of the block from the first shoulder ~upport area, 80 that the first and second shoulder support areas are symmetrical about the tail ~upport area.
This modification provides the ~ame general ~houlder and tail support for the body without regard for head-to-foot end orientation. At the same time, because of the lack of body mass and projection in the general area of the back or side of the knees, there is very little increased deformation in the area of the unused should~r support area and, no significant change in the pressures recorded at the primary bony prominent areas of the body.
Although the sizes of the peaks 161 and valleys 162 of the mattress may be varied, the convoluted portion of the illustrated mattress has a uniform distribution of peaks of square cross-section. The peaks 1~1 of the general support area 163, the shoulder ~upport area 16S and the tail support area 167 all have a peak thickness of 6 inches in a ~quare cross-~ection with a width of 1.35 inches. As best seen in Figure 20, to provide the desired lower re~i~tance and body contouring eatures, the v~lley thicknesses of the ~houlder and tail ~upport sections, 165 and 167, of the mattress are less than the vaIley thicknesses of the general support area 163 of the mattress. Spec1~ically~
the valley thickness for both the ~houlder ~upport area 165 and the tail ~upport area 167 is ~2 of one lnch while the valley thickness for the general 8upport area i~ 3 inches.
Referring now to Figures 21-25, the principles of the present inuention can be u~ed to fflanufacturP an anatomically conforming bed overlay or posturi2er for home health care application~.
Figure 21 6how~ an apparatus 169 ~or ~anufacturing , , - ~

, ,' , , 1322~2~
convoluted f~a~ posturizer6. The apparatus include6 a pair of cooperating rollers, 171 and 173, e~ch of which has a cylindrical body 175. Each roller includes three sections 176 having an undulated surface and a pair of æections 177 formed by rows of ribs. The undulated surface of each roller is ~ormed by a plurality of fingers 179 o~ generally rectangular cross-section extending radially from its cylindrical body 175. The fingers 179 are arranged in vertical and horizontal rows. The fingers 179 in vertically adjacent rows are staggered vertically a circumferential distance approximately equal to the vertical width of the fingers. Fingers 179 in horizontally adjacent rows are staggered horizontally a circum~erential distance approximately equal to the horizontal width of the fingers. ~he ribbed sections 177 are formed by vertically spaced ribs 181, each of which extends the length of the section and extends radially outward ~rom the cylindrical body 175 of the roller. The ribs 181 are spaced vertically from one another, a circumferential distance approximately equal to the vertical width of the ribs 181.
Advantageously, the rollers 171 and 173 are configured so that when the side of a fsam block 183 is inserted between the rollers, the rollers, 171 and 173, form a constant pattern, regardless of the width of the block 183.
This enables the same rollers to be utilized to form - posturlzers having a width corresponding to a twin, queen or king-size bed.
The rotating rollers 171 and 173 compres~ and drive the foam block 183 against a cutter (a guard 185 for which is shown in Figure 23~ hown in ~igure 21, the upper roller 171 rotates counterclockwi e and the low~r roller 173 rotates clockwi~e. This rotation is ~ynchroniz~d ~o that the finger~ 179 of the respective roller~ are opposed by the Epaces betwee~ the fingers of the opposik~ roller, rather than directly by it~ ~ingers 179. Likewise, the ribs 181 of the upper roiler 1~1 are opposed by the ~paces ~32242~

between the ribs 181 of the lower roller 173, rather thandirectly by its rib6 181. As best ~een in Figure 21, the effective height of each of the finger6 179 i~ equal and the radial height of each o~ the ribs 181 is equal, although the effective height of each of the ribs 181 i6 greater than the effective height o~ each of ~he fingers 179.
Referring to Figure 23, after the foam block i~
compressed betw~en the rollers, it is driven against the cutter (not ~hown) which 61ices the block into halves 187.
The resulting halves 187 are a perfect mirror ~mage of one another with each peak 189 o~ one half corresponding to an adjacent peak 189 of egual size on the other hal~, and each xib 191 of one hal~ corresponding to an adjacent rib 191 of equal size on the other half. Since the effective height of each o~ the fingers 179 is equal, each p~ak 189 has an identical peak height and each valley 193 has an identical valley thickness. Likewise, 6ince the effective height o~
each of the ribs 177 is equal, each rib 191 of the posturizer has an identical peak height and each valley has an identical valley thickness.
~he tops of the peaks and ribs are removed with a band saw or other suitable cutting device at a point midway between ~he tops of the peaks ~nd ~he floor o~ the valleys leaving an elongate rectangular posturizer 195 (Fi~ure 24-25) with a flat, solid, lower surface 197 and a substantially 1at, upper 6ur~ce 199 compri~ed of the flat tops of the peaks 189 and the flat ~ops of the ribs 191.
As shown: in Figure 24, the posturizer is ~ormed by ~ head 30 suppbrt area 201 adjacent one o~ the ends o~ ~he posturlzer for supporting the head o~ a body, a ~houlder support area 203 adjacent the head ~upport area 201 for suppor~ing the shoulder portion of a body, ~ middle back fiUppOrt area 205 adjacent the ~houlder support area 203 ~or supporting the ~iddle b~ck portion of a body, a ta~l ~upport ~rea 20~
adjacent the middle back ~spport ~rea 205 for supporting .

, - ~ ~22~2~

the tail ~ection of a body and a leq and feet support area 20~ adjacent the tail support area 207 and the other end of the posturizer for ~upporting the legs and feet of a body.
The head support area 201, the middle back ~upport area 205 and the leg and feet 6upport area 209 are formed by adjacent rows of peaks 213 of generally rectangular cross-section, each of which are separated by valleys 215, also of generally rectangular cross~section. The overall affect of the peaks and valleys is a checkerboard pattern, with the corners of the peaks 213 in ad~acent rows connected by webbing extending between the peaks to the floor of the valleys 215.
In contrast, the shoulder support area 203 and the tail ~upport area 207 are formed by rows of horizontally spaced longitudinally extending ribs 217, wherein each rib is 6eparated from the adjacent rib 217 by a longitudinally extending valley 219. The overall affect of the ribs and valleys is a corrugated pattern.
In previous embodiments, the ef~ective height of the fingers which corresponded to the areas of the pad supporting the ~houlder and tail 6ections of the body have been increased to form taller peaks and lower valleys in those areas of the pad. By topping off the peaks at a certain height, sne was left with a smaller volume o~ foam to rasist the weight o~ that portion of the body.
Since the e~ective height of the ribs 181 of the roller~ i~ greater than the e~fective height of the ~ingers 179, the ribs have a greater peak height and valleys o~ lower valley thickness than the peaks and valleys formed by the ~inger~. After the tops of the ribs and peaks are removed, the ~houlder and tail ~upport ~reas, formed by the rows of rib~ ~17 and vall~ys 21~, have a lower foam contenk (i.e., a smaller amount of foam of uniform density per unit volume) than the head, ~iddle bacX
and leg and feet ~upport area~ 201, 205, and 209, respectively, formed by the adjacent rows of peaks 213 ~nd ~32%~2!~
valleys 215. Accordingly, the ~houlder and tail portion~
of the body are ~ore able to overcome the resistance of the posturizer and sink into the ~houlder and tail 8upport areas 203 and 207, thereby increasing the surface area of the posturizer in cont~ct with the 6houlder nnd tail portion of the body and diminishing the level of pressure exerted on the skin per unit area. Likewise, as the shoulder and tail portion of the body protrude farther into the shoulder and tail support areas, 203 and 207, of the pad, the pressure of the head, middle back and leg and feet support areas 201, 205 and 209 on the less protruding portions (e.g., the 6ide) will increase, thereby relieving pressure from the tail and shoulder portions o~ the body.
Referring to Figure 24, the anatomically conforming posturizer 195 will generally have an overall length of between 60-90 inches and a width of between 25-40 inches, depending upon the length and width of the mattress being covered, and a thickness of between 1-3 inches. Further, for specialty beds, the length may vary between 30-90 inches and the width may vary between 20-90 inches.
The illustrated posturizer 195 has a length of approximately 72 inches and a width of approxi~ately 35 inches. The leg and feet 6upport area 209 has a length of approximately 29 inches. The tail support area 207 has a length of approxima~ely 11 inches. The middle back 8upport area 205 has a length of approximately 9 inche~. The ~houlder 6upport area 203 has a length o~ approxi~ately 15 inches, and the head support ar~a 201 has a length of approximately 9 inches. Further, the po~turizer has a thicXness of 2 inches and, therefore, a uniform peak height of 2 inches, a valley thickness o~ 1/4 inch in th~ ~houlder : and tail ~upport areas 203 and 207, and a valley ~hickness of 1-1/4 inches in the head, ~iddle back and leg and ~eet upport area~ 201, 205 and 209. Naturally, the length and thickness of the support areas ~ay vary depen~ing upon the average ~ize of the body to be ~upported.
-27~

Claims (20)

1. An elongate convoluted foam pad for supporting a reclining human body on a bed, comprising:
a bottom;
a shoulder support area for supporting the shoulder portion of a body formed by peaks arranged in rows, wherein each peak has a substantially flat top and is spaced from any adjacent peak in the same row by a valley;
a tail support area for supporting the tail portion of said body formed by peaks arranged in rows, wherein each peak has a substantially flat top and isspaced from any adjacent peak in the same row by a valley; and a general support area surrounding said shoulder support area and said tail support area formed by peaks arranged in rows, wherein each peak has a substantially flat top and is spaced from any adjacent peak in the same row by avalley, said valleys of said shoulder support area, said valleys of said tail support area and said valleys of said general support area each having an average valley thickness, wherein each of said peaks has a substantially uniform peak thickness and wherein said average valley thickness of said valleys in said shoulder support area and said average valley thickness of said valleys in said tail support area are less than said average valley thickness of said valleys in said general support area.

2. The pad of claim 1, wherein all of said substantially flat tops are included in a single plane.

3. The pad of claim 2, wherein said pad is formed from a polyurethane foam having a density of between one and three pounds per cubic foot.

4. The pad of claim 3, wherein said peaks have a peak thickness between one and five inches.

5. The pad of claim 4, wherein some of said peaks have corners and some of said corners are connected to other of said comers of other peaks by webbing.

6. The pad of claim 5, wherein at least some of said corners are not connected by webbing, thereby providing a locale of decreased resistance to pressure.

7. A convoluted foam pad for supporting a human body on a bed, comprising:
a bottom;
a general support area;
a shoulder support area; and a tail support area, each of said areas comprising adjacent rows of peaks having substantially flat tops and generally rectangular cross sections which form corners, said peaks in each row being separated by valleys and said peaks in adjacent rows being staggered, said valleys of said shoulder support area, said valleys of said tail support area and said valleys of said general support area each having an average valley thickness, said average valley thickness of said valleys in said general support area being greater than said average valley thickness of said valleys in said shoulder support area and greater than said average valley thickness of said valleys in said tail support area, said peaks of said valleys forming a checkerboard pattern wherein at least some of said corners of said peaks in adjacent rows are connected by webbing.

8. The pad of claim 7, wherein at least some of said corners of said peaks in adjacent rows are not connected by webbing, thereby decreasing the resistance of the locale including the nonconnected corners to pressure.

9. A convoluted foam pillow for supporting the head and neck of a body, comprising:
a bottom;
a general support area formed by peaks arranged in rows, wherein each peak has a substantially flat top and is spaced from any adjacent peak in the same row by a valley; and a generally T-shaped head and neck support area formed by peaks arranged in rows, wherein each peak has a substantially flat top and is spaced from any adjacent peak in the same row by a valley, wherein each of said peaks has a substantially uniform peak thickness, said valleys of said general support area and said valleys of said head and neck support area each having an average valley thickness, wherein said average valley thickness of said valleys in said head and neck support area is less than said average valley thickness of said valleys in said general support area, thereby forming an area of greater capacity to conform to the shape of said head and said neck of said body.

10. The pillow of claim 9, wherein all of said substantially flat tops are included in a single plane.

11. The pillow of claim 10, wherein said pillow is formed from a polyurethane foam having a density of between one and three pounds per cubic foot.

12. The pillow of claim 11, wherein said peaks have a peak thickness between one and five inches.

13. The pad of claim 12, wherein said peaks form corners and some of said corners of said peaks are connected to said corners of other of said peaks by webbing.

14. The pad of claim 13, wherein at least some the corners of said peaks are not connected by webbing, thereby providing a locale of decreased resistance to pressure.

15. A convoluted foam wheelchair pad for supporting the thigh and buttocks of a body on a wheelchair, comprising:
a bottom;
a general support area formed by peaks arranged in rows, wherein each peak has a substantially flat top and is spaced from any adjacent peak in the same row by a valley; and a generally U-shaped thigh and buttock support area formed by peaks arranged in rows, wherein each peak has a substantially flat top and is spaced from any adjacent peak in the same row by a valley, wherein each of said peaks has a substantially uniform peak thickness, said valleys of said general support area and said valleys of said thigh and buttock support area each having an average valley thickness, wherein said average valley thickness of said valleys in said thigh and buttock support area is less than said average valley thickness of said valleys in said general support area, thereby forming an area of greater capacity to conform to the shape of said thighs and buttocks of said body.

16. The pad of claim 15, wherein all of said substantially flat tops are included in a single plane.

17. The pad of claim 16, wherein said pad is formed from a polyurethane foam having a density of between one and three pounds per cubic foot.

18. The pad of claim 17, wherein said peaks have a peak thickness between one and five inches.

19. The pad of claim 18, wherein said peaks form corners and some of said corners of said peaks are connected to the corners of other peaks by webbing.

20. The pad of claim 19, wherein at least some of said corners are not connected by webbing to other of said peaks, thereby providing a locale of decreased resistance to pressure.