CN108143563B

CN108143563B - Foam cushion cover

Info

Publication number: CN108143563B
Application number: CN201710785891.XA
Authority: CN
Inventors: M·杜多尼斯
Original assignee: Intensive Therapeutics Inc
Current assignee: Intensive Therapeutics Inc
Priority date: 2017-09-04
Filing date: 2017-09-04
Publication date: 2021-04-09
Anticipated expiration: 2037-09-04
Also published as: CN108143563A

Abstract

A pallet includes a first chamber including at least one sheet, wherein the first chamber is configured to receive a mat including air pockets. A second chamber is sealed to the first chamber, wherein the second chamber includes a closed back end, a closed top end, a closed bottom end, a pair of closed side ends, and an open front end. A sheet including at least one aperture is sealed to the first chamber and faces the open end of the second chamber. A handle is provided that includes a longitudinal strip abutting a pair of side panels, wherein the pair of side panels are sealed to the first chamber, wherein when a force is applied to the first chamber, air contained in an air pocket of the cushion flows through at least one aperture in the panel and into the second chamber without flowing out of the second chamber.

Description

Foam cushion cover

Technical Field

Embodiments herein relate generally to medical devices, and more particularly to foam cushions.

Background

Proper positioning of paralyzed patients in a healthcare environment is a very important task. The patient must be positioned at the proper angle of rotation and any devices used to assist in supporting the patient must remain in place for the time prescribed by the clinical staff. One device for supporting a patient in an elevated lateral position is a polyurethane foam wedge pad. Foam wedges come in a variety of sizes, densities and colors. The foam wedges may be bare foam or padded, the purpose of which is to make the padding easy to clean and re-use from one patient to another. Currently available mattress cover designs may provide some protection to the foam wedges within the mattress cover, but there are limitations to how well the cushion can seal from contact with fluid and air contaminants.

The most common method of joining pieces of ticking together is sewing. Sewing is quick and cost-effective, but stitchbonding creates small holes in the fabric and leaves very little space between the two pieces of fabric to be stitched. Fluid and air can pass through these very small spaces, and checking for infiltration is very difficult and rarely done in a care environment. Another method of joining fabric pieces together to form a mattress cover is ultrasonic or Radio Frequency (RF) welding. This method uses a special adhesive and High Frequency (HF) energy to join the fabrics together and is the preferred method because it does not leave these similar small spaces found in the seam.

Regardless of whether the manufacturer chooses to use sewing or HF welding to join the seams of the foam cushion cover, the foam must retain the ability to displace air. The polyurethane foam is an open-cell structure, and serves as a cushion by supporting and discharging air using air. Quilting allows air to escape through the small spaces at the seams. Sewn and HF welded ticking typically uses zipper closures that allow air flow between the teeth of the zipper and allow these spaces to be passed at either end of the zipper. If the mattress cover is completely sewn or welded, mesh or metal vents must be used to allow air to flow into and out of the mattress. The sewn seams, zipper closures and vents all have the same potential for air and fluid borne pathogens to enter the foam pad. If the mat is contaminated, there is a high risk of the infectious material being transmitted from one user to another in the healthcare environment. Accordingly, there is a need for a new foam cushion cover that can reduce and/or eliminate the risk of cushion contamination and the spread of infectious pathogens.

Disclosure of Invention

In view of the above, an embodiment herein provides a pillow cover comprising a first chamber comprising at least one sheet, wherein the first chamber is configured to receive a cushion comprising air pockets; a second chamber sealed to the first chamber, wherein the second chamber comprises a closed back end, a closed top end, a closed bottom end, a pair of closed side ends, and an open front end; a sheet sealed to the first chamber and facing the open end of the second chamber, wherein the sheet comprises at least one aperture; and a handle comprising a longitudinal strip abutting a pair of side panels, wherein the pair of side panels are sealed to the first chamber, wherein when a force is applied to the first chamber, air contained in the air pocket of the cushion flows through the at least one aperture in the panel and into the second chamber, and does not exit the second chamber.

When the force is removed from the first chamber, air contained in the second chamber may flow through the at least one hole in the sheet and into the air pocket of the cushion. The cushion cover further includes a plurality of edges along the first chamber, the second chamber, the sheet, and a pair of side sheets of the handle, wherein the plurality of edges may be joined together by High Frequency (HF) welding. The open end of the second chamber includes a thickness defined by a width of the closed top end, the closed bottom end, and the pair of closed side ends of the second chamber. The thickness may be sufficiently configured to retain air expelled from the cushion without the edges being opened. Each of the first chamber, the second chamber, the sheet, and the handle comprise an HF weldable elastomer. The mat includes any one of a wedge shape, a rectangular shape, a square shape, and a semi-cylindrical shape. At least one of the sheets may be completely free of any openings. Each of the first chamber, the second chamber, the sheet, and the handle comprises a translucent material. The second chamber includes any one of a square, a rectangle, a wedge, and a circle.

Another embodiment provides a pillow mat comprising: a first chamber configured to fully house a cushion, wherein the cushion includes an air pocket; a sheet sealed to the first chamber and comprising at least one aperture; and a second chamber sealed to either of the sheet and the first chamber, wherein the second chamber comprises a collapsible air reservoir, wherein when a force is applied to the first chamber, air contained in the air pocket of the mat flows through the at least one hole in the sheet and into the air reservoir of the second chamber without flowing out of the second chamber.

When the force is removed from the first chamber, air contained in the air reservoir of the second chamber may flow into the at least one hole in the sheet and into the air pocket of the cushion. The pillow cover further includes a plurality of edges along the first cavity, the second cavity, and the sheet, wherein the plurality of edges may be joined together by HF welding. The cushion cover further includes a handle including a longitudinal strip abutting a pair of side panels, wherein the pair of side panels are sealed to the first chamber. The air reservoir may be sufficiently configured to retain air expelled from the cushion without causing the second chamber to be opened. Each of the first chamber, the second chamber, and the sheet comprises an HF weldable elastomer. The mat includes any one of a wedge shape, a rectangular shape, a square shape, and a semi-cylindrical shape. The first chamber may be completely free of any openings. Each of the first chamber, the second chamber, and the sheet comprises a translucent material. The second chamber includes any one of a square, a rectangle, a wedge, and a circle.

These and other aspects of the present embodiments will be better explained and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments and numerous specific details thereof, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

Drawings

The embodiments herein will be better understood with reference to the following detailed description of the drawings, in which:

FIG. 1 shows a perspective view of a pallet according to an embodiment herein;

FIG. 2 illustrates a perspective view of a first chamber of the pallet of FIG. 1 according to an embodiment herein;

FIG. 3 illustrates a perspective view of a handle with integral side panels of a pallet according to an embodiment herein;

FIG. 4 illustrates a perspective view of a foam cushion in accordance with an embodiment herein;

FIG. 5 illustrates a perspective view of a sheet of the first and second chambers of the pallet of FIG. 1 according to an embodiment herein;

fig. 6A shows a perspective front view of a second chamber from a high angle according to an embodiment herein;

FIG. 6B illustrates a perspective front view of the second chamber from a low angle according to an embodiment herein;

fig. 6C shows a perspective front view of a second chamber according to another embodiment herein;

FIG. 7 shows a perspective view of a pallet according to another embodiment herein;

FIG. 8A illustrates a perspective view of a cushion air displacement system in accordance with another embodiment herein;

FIG. 8B illustrates a perspective view of an empty air displacement chamber of the cushion air displacement system of 8A according to one embodiment herein;

FIG. 8C illustrates a perspective view of the air displacement chamber of FIG. 8B filled with air in accordance with an embodiment herein;

FIG. 9 shows a perspective view of a pallet according to another embodiment herein;

FIG. 10A illustrates a perspective view of a cushion air displacement system according to another embodiment herein;

FIG. 10B illustrates a top view of the cushion air displacement system of FIG. 10A according to one embodiment herein;

FIG. 11 illustrates a perspective view of a cushion air displacement system in accordance with another embodiment herein;

FIG. 12 shows a perspective view of a pallet according to another embodiment herein; and

fig. 13 shows a perspective view of a pillow cover according to an embodiment herein.

Detailed Description

The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

As noted above, there is a need for a new foam cushion cover that can reduce and/or eliminate the risk of cushion contamination and the spread of infectious pathogens. Embodiments herein provide a completely sealed and closed cushion cover enclosing a foam cushion. Referring now to the drawings, and more particularly to fig. 1 through 13, wherein like reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.

Fig. 1 shows a perspective view of a pallet 10 according to embodiments herein. The pallet 10 comprises two

chambers

15, 20. The first chamber 15 is sized to receive the cushion 25 with an HF weld joint 30 (in fig. 4). A wide variety of HF weldable elastomer materials may be used to construct the cushion cover 10. For example, HF weldable elastomers include, but are not limited to, polyvinyl chloride (PVC) and polyurethane. The handle 60 is configured to be attached to both

chambers

15, 20 using a pair of

side panels

65a, 65b (best shown in fig. 3).

Fig. 2, with reference to fig. 1, shows a perspective view of the first chamber 15 of the pallet 10 of fig. 1 according to an embodiment herein. The first chamber 15 comprises a pair of

laminae

16, 17 connected by a spine 18, wherein the spine 18 is configured to be slightly curved. The first sheet 16 includes a first side edge 19a, a second side edge 19b, and a side edge 22. Second sheet 17 includes a first side 21a, a second side 21b, and a side edge 23. The spine 18 is positioned opposite the lateral edges 22, 23. In one embodiment, first sheet 16, second sheet 17, and spine 18 may be configured as a single folded piece of fabric.

Fig. 3, with reference to fig. 1 and 2, shows a perspective view of a handle 60 of the pallet 10 according to an embodiment herein. The handle 60 includes a longitudinal strip 70 connecting a pair of

side panels

65a, 65 b. The handle 60 not only assists the mechanism in conveniently carrying the pallet 10, it also provides a structure that surrounds the sides of the pallet 10 by a pair of

sides

65a, 65b, such that the pair of

sides

65a, 65b are HF welded on the sides to the first chamber 15.

The side panel 65a includes a pointed end 66a sized and configured to match the contour of the spine 18 of the first chamber 15. The side panel 65a further comprises an inclined top edge 67a and an oppositely positioned and substantially straight bottom edge 68 a. The side panel 65a further includes a rear end 69a located opposite the tip 66 a. The rear end 69a is higher than the tip 66a so that the overall shape of the side panel 65a is triangular/wedge-shaped. The rear end 69a further includes an upper rear edge 71a and a lower rear edge 72a that are separated by a first side 73a of the longitudinal strip 70. The first corner 74a of the longitudinal strip 70 allows the first side portion 73a to be positioned substantially orthogonally relative to the longitudinal strip 70.

The lateral piece 65b includes a pointed end 66b sized and configured to match the contour of the spine 18 of the first chamber 15. The side panel 65b further comprises an inclined top edge 67b and an oppositely positioned and substantially straight bottom edge 68 b. The side panel 65b further includes a rear end 69b located opposite the pointed end 66 b. The rear end 69b is higher than the tip 66b so that the overall shape of the side piece 65b is triangular/wedge-shaped. The rear end 69b further includes an upper rear edge 71b and a lower rear edge 72b that are separated by a second side 73b of the longitudinal strip 70. The second corner 74b of the longitudinal strip 70 allows the first side portion 73b to be positioned substantially orthogonally relative to the longitudinal strip 70. In one embodiment, the longitudinal belt 70 may be integrated into the pair of

side panels

65a, 65b by a tapered bond, which in this configuration eliminates the

edges

71a, 71b, 72a, 72 b.

Fig. 4, with reference to fig. 1-3, illustrates a perspective view of a foam pad 25 according to an embodiment herein. The foam pad 25 includes a tip 11 sized to match the contour of the spine 18 of the first chamber 15 such that when the foam pad 25 is inserted into the first chamber 15, the tip 11 is snug against the spine 18. The foam pad 25 further includes an angled top 31, a pair of

sides

33a and 33b, and a back 34, such that the overall shape of the

sides

33a, 33b is triangular/wedge-shaped. The rear portion 34 is positioned opposite the tip 11 such that the overall shape of the foam pad 25 is triangular/wedge-shaped. The foam cushion 25 further includes a plurality of air pockets 32. According to one embodiment, a resilient pad may be used for the foam pad 25. The resilient pad may be used to protect the foam pad from moisture transmission on the order of marks that may occur over time.

Fig. 5, with reference to fig. 1-4, illustrates a perspective view of the sheet 35 of the first chamber 15 and the second chamber 20 according to an embodiment herein. The sheet 35 of the first chamber 15 comprises at least one small hole 40 which allows the passage of air in both directions (indicated by the curved arrows in fig. 5). The tab 35 is configured to be connected to the side edges 22, 23 of the pair of

sheets

16, 17 of the first chamber 15. In one embodiment, first sheet 16, second sheet 17, spine 18, and sheet 35 may be made from a single piece of cloth, wherein a seam may connect them into a sheath into which cushion 25 may be inserted.

As shown in fig. 5, 6A, and 6B, with reference to fig. 1-4, the second chamber 20 according to an embodiment herein is further illustrated, wherein the second chamber 20 includes a closed back end 26, a closed top end 24, a closed bottom end 37, a pair of closed side ends 27a and 27B, and an open front end 36. Typically, the second chamber 20 is configured in an open configuration. The closed rear end 26 has a front surface 50 that is exposed to the open front end 36. The second chamber 20 includes a first front side 28a and a second front side 28b along a front upper edge 29a and a front lower edge 29 b.

The second chamber 20 may also be constructed of HF weldable elastomer joined by HF weld joints 30. The second chamber 20 is welded to the sheet 35 of the first chamber 15, wherein the sheet 35 has air displacement hole(s) 40 such that the sheet 35 is welded to the second chamber 20 at

edges

28a, 28B, 29a, 29B to create an air reservoir 55 defined by the space between the sheet 35, side ends 27a and 27B, top end 24, bottom end 37, and rear end 26 (fig. 6A and 6B depict the air reservoir 55 in a dashed circle, however the air reservoir 55 includes the entire inner box area defined by the second chamber 20). During manufacture, when the second chamber is welded to the sheet 35, the second chamber 20 is flattened to prevent it from containing air. After the sheet 35 is welded to the first chamber 15 containing the cushion 25, the air reservoir 55 provides space for air displacement in the foam cushion 25 inside the first chamber 15 when a force is applied to the first chamber 15. As shown in fig. 6C, one or more creases 80 are provided in

sheets

24, 37, 27a, 27b to assist second chamber 20 in lying flat when foam pad 25 is uncompressed.

When the weight of the part of the body supported by the cushion 25 compresses the foam cushion 25, air is displaced into the air reservoir 55 and contained therein until the weight is removed. When the weight is removed, a vacuum is created by the open cell structure of the foam pad 25 and air will be drawn from the displacement air reservoir 55 back into the foam pad 25. Since the entire pallet 10, including the two

chambers

15 and 20, is sealed by HF welding, there is no possibility of contact with fluids or air in the surrounding environment.

The closed system pallet 10 allows for more efficient cleaning of the mat 25. The entire mat 25 may be immersed in the fluid cleaning solution without risk of infiltration through seams, zipper closures, or vents. Full immersion in fluid is also an effective means of determining whether the mattress cover 10 has been damaged or destroyed in any way by determining whether air bubbles are generated from within the mattress 25.

The type of cushion 25 provided by the embodiments herein includes a foamed patient positioning wedge, but the arrangement of the pallet 10 may be used with any type of cushion that uses polyurethane foam as a support means. 7-13, referring to FIGS. 1-6C, examples of other types of cushions and air displacement chambers and systems according to various embodiments are shown. In these embodiments, the air displacement chamber is an externally located chamber that extends outwardly away from the cushion and may be configured as a square, rectangular, tubular, circular/button, wedge, or the like. Examples of other cushions include mattresses, wheelchair pads, foot lift pads, arm support pads, elbow pads, and the like.

Fig. 7 shows a substantially rectangular and externally configured air displacement chamber 120 connected to the pallet 110, wherein the air displacement chamber 120 includes apertures 140 for delivering air to the chamber 120. The holes 140 are shown in phantom/phantom lines in fig. 7 to illustrate their placement at the pallet 110/replacement chamber 120 interface. In other words, the apertures 140 are not configured to allow air to pass out of the displacement chamber 120. Fig. 8A shows the user 100 seated on the wheelchair cushion 210. The air displacement chamber 220 is configured as a remote displacement chamber connected to the pallet 210 by a tube 225. Fig. 8B, with reference to fig. 8A, shows the chamber 220 empty. Fig. 8C, with reference to fig. 8A and 8B, shows the chamber 220 filled with air (the arrows in fig. 8C indicate the air flow filling the chamber 220). Fig. 9 shows a substantially semi-cylindrical pillow cover 310 with an external air displacement chamber 320. The padded sleeve 310 may be used as a knee holster by the user 300. Fig. 10A shows a substantially circular air expansion chamber 420 connected to a pillow cover 410. In fig. 10A, air fills chamber 420 creating an outwardly protruding bulge from pillow mat 410. Fig. 10B, with reference to fig. 10A, shows a top view of a substantially circular air expansion chamber 420. Fig. 11 shows a substantially wedge-shaped air expansion chamber 520 connected to a pillow cover 510, wherein the air displacement chamber 520 includes apertures 540 for delivering air to the displacement chamber 520. The holes 540 are shown in phantom/phantom in fig. 11 to indicate their placement at the pallet 510/replacement chamber 520 interface. In other words, the apertures 540 are not configured to allow air to pass out of the displacement chamber 520. Fig. 12 shows a substantially square or rectangular pallet 610 with an outside air displacement chamber 620. Pillow cover 610 may be used as a leg lift pad by user 600. Fig. 13 shows a substantially U-shaped pillow cover 710 with an external air displacement chamber 720. User 700 may use pillow cover 710 in the manner described in U.S. patent No. 6,634,045, the entire contents of which are incorporated herein by reference in their entirety.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

Claims

1. A pallet, comprising:

a first chamber comprising at least one sheet, wherein the first chamber is configured to fully house a cushion comprising an air pocket;

a second chamber sealed to the first chamber, wherein the second chamber comprises a closed back end, a closed top end, a closed bottom end, a pair of closed side ends, and an open end, wherein the second chamber comprises a collapsible reservoir and is flattened during manufacture to prevent it from containing air;

a flap sealed to the first chamber and facing the open end of the second chamber, wherein the flap comprises at least one aperture;

a handle comprising a longitudinal strip abutting a pair of side panels, wherein the pair of side panels are sealed to the first chamber; and

a plurality of edges along the first chamber, the second chamber, the sheet, and the pair of side sheets of the handle, wherein the plurality of edges are joined together by high frequency welding,

wherein when a force is applied to the first chamber, air contained in the air pocket of the cushion flows through the at least one aperture of the sheet and into the second chamber, but not out of the second chamber;

wherein when the force is removed from the first chamber, the air contained in the second chamber flows through the at least one hole in the sheet and into the air pocket of the cushion; and

wherein the first chamber is welded to the second chamber by the tab.

2. The pillow cover of claim 1, wherein the open end of the second chamber comprises a thickness defined by the closed top end, the closed bottom end, and a width of the pair of closed side ends of the second chamber.

3. The cushion cover of claim 2, wherein the thickness is sufficiently configured to retain air exhausted from the cushion without the plurality of edges being opened.

4. The pallet of claim 1, wherein each of the first chamber, the second chamber, the tab, and the handle comprises a high frequency weldable elastomer.

5. The pallet of claim 1, wherein the cushion comprises any one of a wedge shape, a rectangular shape, and a semi-cylindrical shape.

6. The pallet of claim 1, wherein the at least one tab is completely devoid of any openings.

7. The pallet of claim 1, wherein each of the first chamber, the second chamber, the flap, and the handle comprises a translucent material.

8. The pallet of claim 1, wherein the second chambers comprise any of rectangular, wedge-shaped, and circular.

9. A pallet, comprising:

a first chamber configured to fully house a cushion, wherein the cushion includes an air pocket;

a sheet sealed to the first chamber and comprising at least one aperture;

a second chamber sealed to either of the sheet and the first chamber, wherein the second chamber comprises a collapsible reservoir; and

a plurality of edges along the first chamber, the second chamber, and the sheet, wherein the plurality of edges are joined together by high frequency welding,

wherein when a force is applied to the first chamber, air contained in the air pocket of the cushion flows through the at least one hole of the sheet and into the air reservoir of the second chamber without flowing out of the second chamber;

wherein when the force is removed from the first chamber, the air contained in the air reservoir of the second chamber flows through the at least one hole in the sheet and into the air pocket of the cushion;

wherein the first chamber is welded to the second chamber by the tab.

10. The pallet of claim 9, further comprising a handle comprising a longitudinal strip abutting a pair of side panels, wherein the pair of side panels are sealed to the first chamber.

11. The cushion cover of claim 9, wherein the air reservoir is sufficiently configured to retain air exhausted from the cushion without causing the second chamber to be opened.

12. The pallet of claim 9, wherein each of the first cavity, the second cavity, and the sheet comprises a high frequency weldable elastomer.

13. The pallet of claim 9, wherein the cushion comprises any one of a wedge shape, a rectangular shape, and a semi-cylindrical shape.

14. The pallet of claim 9, wherein each of the first chamber, the second chamber, and the sheet comprises a translucent material.

15. The pillow cover of claim 9, wherein the second chamber comprises any one of a rectangular shape, a wedge shape, and a circular shape.

16. A pallet, comprising:

a sheet sealed to the first chamber and comprising at least one aperture;

a plurality of edges along the first chamber, the second chamber, the sheet, wherein the plurality of edges are joined together by high frequency welding,

wherein the first chamber is welded to the second chamber by the tab.

17. The pillow cover of claim 16, wherein the air contained in the air reservoir of the second chamber flows through the at least one hole in the sheet and into the air pocket of the cushion when the force is removed from the first chamber.