EP2692265B1 - Trägervorrichtung mit Gelschicht und Verfahren zu seiner Herstellung - Google Patents

Trägervorrichtung mit Gelschicht und Verfahren zu seiner Herstellung Download PDF

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Publication number
EP2692265B1
EP2692265B1 EP20130178771 EP13178771A EP2692265B1 EP 2692265 B1 EP2692265 B1 EP 2692265B1 EP 20130178771 EP20130178771 EP 20130178771 EP 13178771 A EP13178771 A EP 13178771A EP 2692265 B1 EP2692265 B1 EP 2692265B1
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Prior art keywords
layer
gel
mattress
foam
mold
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English (en)
French (fr)
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EP2692265A1 (de
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Matteo Mason
Massimo Losio
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Technogel Italia SRL
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Technogel Italia SRL
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Priority claimed from US13/563,391 external-priority patent/US20130000045A1/en
Priority claimed from US13/762,865 external-priority patent/US20130146211A1/en
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Publication of EP2692265A1 publication Critical patent/EP2692265A1/de
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/08—Fluid mattresses or cushions
    • A47C27/085—Fluid mattresses or cushions of liquid type, e.g. filled with water or gel
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/20—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in foamed material

Definitions

  • the present invention is generally directed to apparatuses designed for bodily support.
  • the invention is directed to mattresses or mattress toppers, comprising a gel layer and at least an additional layer, such as a foam layer, that provide an improved level of objective and subjective comfort, particularly pressure relief, as well as improved control of heat transfer.
  • the present invention is generally directed to a method of preparing apparatuses designed for bodily support, such as mattresses or mattress toppers, comprising a gel layer and at least an additional layer, such as a foam layer.
  • Such apparatuses are known in the art for providing support to the body of a user.
  • Such apparatuses generally comprise one or more layers of padding or cushioning to provide functional support of the user's body and to provide such support while also providing a level of comfort.
  • such apparatuses may also comprise mechanical supports, such as coil springs.
  • Advances in the art are generally directed to apparatuses that provide the functional support necessary in such apparatuses but also provide increased comfort or provide a decrease in the volume of materials necessary to provide the support.
  • US patent No. 6,701,556 to Romano et al. discloses mattress or cushion structures designed to improve pressure distribution while reducing the overall thickness of the mattress or cushion.
  • US patent No. 6,804,848 to Rose discloses an air support sleep system having an upper mattress air posturizing module and an adjustable air posturizing sleep surface.
  • Gel materials are generally known to provide good physical comfort and pressure relief. Further, gels are also known to exhibit a relatively high thermal conductivity. Accordingly, gels, such as polyurethane gels, are generally regarded as having a "cool" feel to the body, as body heat is perceptibly moved away from the body when in contact with the gel.
  • the US patent application No. 2004/058163 teaches using cork to adjust gel hardness, in particular for shoe soles. Further, the gels exemplified in this application have a Shore L hardness of 46 or of 55, 62, and 53, as indicated in the comparative tests of this application, that correspond to a hardness above 100 kPa at 40% compression on force deflection.
  • the technical aim of the present invention is therefore to improve the state of the art.
  • a purpose of the present invention is developing a mattress or mattress topper for supporting at least a portion of the body thereon such that the gel layer confers objective and subjective comfort at a same time.
  • Another aim of the present invention is developing a mattress or mattress topper for supporting at least a portion of the body thereon that provides increased comfort and pressure point relief for a user.
  • Still another purpose of the present invention is developing a mattress or mattress topper which is simple and practical to use, and simple and cheap to manufacture.
  • Another purpose of the present invention is developing a method for preparing a mattress or mattress topper for supporting at least a portion of the body thereon such that the gel layer confers objective and subjective comfort at a same time.
  • Another aim of the present invention is developing a method for preparing a mattress or mattress topper for supporting at least a portion of the body thereon that provides increased comfort and pressure point relief for a user.
  • Still another purpose of the present invention is developing a method for preparing a mattress or mattress topper which is simple cheap to manufacture.
  • the present invention provides an apparatus useful for bodily support, particularly support that, in addition to being functional, also provides increased comfort and pressure point relief for a user.
  • the apparatus is a mattress, or a mattress topper.
  • the apparatus is characterized by its use of a gel material exhibiting preferred physical characteristics for providing a pleasing "feel" to a user, as well as therapeutic benefits.
  • a method of the invention generally comprises providing a mold having one or more portions adapted for receiving a gel material, inserting a gel material into the mold, and at least partially curing the gel material to form a gel layer.
  • the gel material according to the present invention is stable, non-toxic, and generally known to provide a cushioning effect while maintaining a degree of structural stability and support.
  • the gel material has a hardness and elasticity that are within a preferred range, as more fully described herein.
  • This gel is resistant to hardening over time, has limited expandability, and is resistant to substance degradation (e.g. from migration of volatile agents, such as plasticizers).
  • the gel used according to the invention is also shock absorbent and resistant to vibration.
  • the gel material of the present invention is a polyurethane gel.
  • Polyurethanes are generally understood to be the product of the chemical reaction between a polyisocyanate compound and a polyfunctional alcohol (i.e. a polyol).
  • a polyfunctional alcohol i.e. a polyol
  • R1 and R2 can be various organic groups including, but not limited to, straight or branched chain or cyclic alkyl, alkenyl, or alkynyl groups, as well as various aryl groups.
  • the gel comprises a specific composition of:
  • the liquid dispersing agent of component (b) is one or more polyhydroxy compound having an average molecular weight between 1,000 and 12,000, or between 1,700 and 6,000 and an OH number between 20 and 112, or between 28 and 84, or between 30 and 56.
  • the dispersing agent should contain essentially no hydroxy compounds with a molecular weight below 800, or below 1,000.
  • Elastic gels which can be used in a version of the present invention, which are composed of a covalently crosslinked polyurethane matrix and a polyol which is firmly bonded therein (that is to say, without the danger of a troublesome exudation), may only be formed when the isocyanate or polyol components, which react with one another, have a certain minimum functionality, and when the polyol is essentially free of constituents with an OH number greater than 112 or a molecular weight below 1,000.
  • such gels can be prepared by the direct reaction of a polyisocyanate with a higher molecular weight polyhydroxy compound of the type described above if the characteristic isocyanate number is in the range of from approximately 15 to 60, or from 20 to 55, or from 25 to 45, and the polyurethane-forming components (isocyanate and hydroxyl compound) are both polyfunctional.
  • liquid OH-prepolymers of the type known to those skilled in polyurethane chemistry are formed instead of gels.
  • the product of the isocyanate functionality and the polyol functionality should be at least 5.2 or at least 6.2, or at least 8, or at least 10, or 12.
  • the stated minimum value of 5.2 may be attained when the characteristic isocyanate number is at the upper end of the acceptable range of the present invention (approximately 60) if a mixture composed of about equivalent quantities of a primary and a secondary hydroxy compound is employed as the polyol component.
  • the product of the isocyanate functionality and the polyol functionality determines different properties in the resulting gel, maintain the same conditions of the chain length. Therefore, gels which have this product different can be different as they have different properties.
  • the product of the functionalities should be at least 6.2, or 8. Where the characteristic isocyanate number is 30 and a purely primary or secondary polyol component is used, the product of the functionalities should be at least 9, or at least 10.
  • isocyanates for gel production those of the formula Q(NCO)n may preferably be used, wherein n represents 2 to 4 and Q denotes an aliphatic hydrocarbon radical having 6 to 18 C atoms, a cycloaliphatic hydrocarbon radical having 4 to 15 C atoms, or an aromatic hydrocarbon radical having 8 to 15 C atoms.
  • the isocyanates may be used in pure form or in the form of the conventional isocyanate modifications, such as urethanisation, allophantisation or biuretisation.
  • the polyurethane gels are particularly useful in the apparatuses according to the invention due in part to the balanced pressure distribution provided by the gel.
  • gels Unlike standard padding materials, which react to an applied pressure, such as a user sitting or lying of the padding, by deforming along only the axis of the applied pressure (i.e., the axis perpendicular to the plane of the padding), gels tend to exhibit tri-dimensional deformation properties.
  • the gel reacts to the applied pressure by deforming along three axes: the X and Y axes in the plane of the gel surface, as well as the Z axis that lies perpendicular to the plane of the gel surface.
  • This is preferable over the standard padding materials, which allow for an uncomfortable, and possibly damaging, accumulation of pressure at the pressure points.
  • the gel provides health advantages, such as increased blood circulation, encouragement of correct posture, and alleviation of pressure concentration, which can lead to serious conditions, such as bed sores, or other types of ulcerations.
  • Subjective comfort can be described as a "good feel” and can change from person to person. For example, while some individuals prefer a soft bed, others prefer a firm bed. Moreover, even the terms “soft” and “firm” can take on multiple definitions. Accordingly, one goal of the invention was to provide a process for preparing a support apparatus, such as a mattress or a mattress topper, and such apparatus, that would provide a good feel to a wide range of users. With the combination of the present invention, this result has been achieved, as further explained below. Objective comfort differs from subjective comfort. Objective comfort can be described as therapeutic comfort. This is the type of comfort that is not necessarily sensed by the body but is reflected in the overall effect on the body, such as improved sleep, improved relief of pressure points, and the like. Unfortunately, apparatuses that provide this type of therapeutic benefit do not also provide the good feel a user wants.
  • the mattress or mattress topper according to the present invention and the method for their preparation are the first apparatus and method with a gel of a specific composition having a hardness within a specific range and a hysteresis within a specific range, thus providing this combined subjective and objective support effect, particularly in consideration of the presence of the underlying support layer as well.
  • Gel materials useful in the apparatus and for the method of the invention are particularly beneficial for their ability to maximize pressure distribution, which can be seen through pressure mapping.
  • Pressure mapping is a clinical tool that measures interface pressure that occurs between a user and a support surface, such as a seat or a bed surface. With standard support cushions and paddings, pressure maps tend to reveal localized high pressure areas, which indicate an inability to evenly distribute pressure.
  • Gels, especially polyurethane gels, according to the invention are superior to standard supports because of their ability to distribute pressure away from pressure points, as demonstrated by pressure maps showing lower pressure readings at the pressure points.
  • Gels used according to the present invention are characterized by the specific physical properties they exhibit: hardness and elasticity. Optimization of these two properties exhibited by the gels allows for preparation of a gel layer (and ultimately an overall apparatus) providing both objective and subjective comfort and support.
  • gels according to the invention having a certain degree of hardness and a certain degree of elasticity provide therapeutic benefits (i.e. objective comfort), as previously described, but also provide a user with a good "feel" (i.e. subjective comfort).
  • the ability to provide both objective and subjective comfort is particularly useful because a support apparatus designed to provide therapeutic benefit to a user may not always feel good to the user. Conversely, what feels good to a user may not always provide therapeutic benefit to the user.
  • gels according to the invention having a hardness and elasticity within the presently specified ranges provide both objective and subjective comfort.
  • a person skilled in the relevant arts would be expected to seek out material having a good perceived comfort for use in preparing a support apparatus. For example, such a skilled person would be expected to choose a material having a hardness providing subjective comfort to the user.
  • the values for the physical properties described herein have been established through testing and evaluation to balance off-setting nature of various gel physical properties and arrive at a desired gel formulation that provides a good feel to the user but also provides therapeutic benefit.
  • the gel used in the present invention is the culmination of rigorous testing to provide a gel material having hardness and hysteresis values that give the gel a good feel to a variety of users while also providing therapeutic benefit.
  • the range of values provided herein provide for a gel material having properties and effects that are unexpected in light of the know art and that provide distinct benefits not provided by gel materials having hardness and hysteresis values outside of the disclosed ranges.
  • the test was a comparison of pressure distribution of a gel sheet used as a topper in a mattress construction.
  • the pressure distribution test has been carried out in order to understand the effect of different hardness and hysteresis in final property of gel sheet used as topper in mattress construction and to choose the right range of hardness and hysteresis.
  • Gel as every other material, has a range of hardness; in this range it is possible to choose different hardness for the specific purpose.
  • the identified range is 4.5 ⁇ 1.5 KPa.
  • the identified range is of 40% ⁇ 10% of hysteresis.
  • the combination was positioned over a block foam having the same density and hardness but having dimensions of 200 cm x 80 cm x 10 cm.
  • the properties of the test gels are provided in the Table 1.
  • the first four materials are inside the range of 15-85% of hysteresis, while two materials are out of this range to make the comparison. Only the first material is inside the claimed range of hardness and hysteresis according to the present invention.
  • Table 1 ID Hardness Hysteresis TGI0525 3.1 KPa 45.7% RE30 11 KPa 63% RE40 41 KPa 68% BTG 91 KPa 63% TGI0710 98 KPa 1% TGI0711 43.9 KPa 2.4%
  • Table 2 The specific gel composition of said materials is indicated in Table 2.
  • Table 2 ID Polyols OH number Product isocyanate functionality and polyol functionality Index TGI0525 long chain polyols between 20-112 12 30% RE30 mix long and short chain polyols a part between 20-112 and a second part > 112 8 33% RE40 short chain polyols > 112 12 25% BTG long chain polyols between 20-112 6 60% TGI0710 long chain polyols + plasticizer between 20-112 9 35% TGI0711 long chain polyols + plasticizer between 20-112 12 30%
  • Polyols are used both in the polyurethane matrix (a) formation and as the liquid dispersing agent (b).
  • both the polyurethane matrix (a) and the liquid dispersing agent (b) comprise polyols.
  • the distribution among (a) and (b) is regulated and determined by the index.
  • test method had five people of different height, weight, and gender, without any orthopedic pathologies to lie back on the mattress for five minutes.
  • pressure distribution was tested using an Xsensor X5 sensor map apparatus from X-Sensor Technology Corporation (Calgary Alberta Canada). This particular instrument uses software that separates the total sensor input into a number of individual sensor readings depending upon the pressure distribution.
  • the pressure map gives a visual indication of which material is the best pressure distributor. In other words, when the body pressure is widely distributed across the gel, a higher number of individual sensor readings are provided. In comparison, when the body pressure is less widely distributed across the gel, a lesser number of individual sensor readings are provided.
  • the raw data has been verified to establish multiple evaluations of the test materials.
  • the total percentage of sensors registering a pressure above the 36 mmHg threshold has been evaluated.
  • blood capillaries are closed above this value resulting in reduced blood flow (or no blood flow) to the skin.
  • the percentage of sensors over 36 mmHg pressure for the first person is very low for TG10525 (3.2%) and increase to 26% for TGlO710 and 28% for BTG. This means that one third of the body has the capillaries close. For TG10525 only a small amount of capillaries are closed, that reveal a higher comfort and a less probability that the body feel discomfort, allow a rest position through the sleep.
  • the percentage of sensors over 36 mmHg pressure is very low for TG10525 (1.1%) and increase to 11.4% for TGlO710 and 15.5% for BTG. Also according mean values, for TG10525 only a small amount of capillaries are closed, thus revealing a higher comfort and a less probability that the body feel discomfort, allowing a rest position through the sleep.
  • TGI0525 the best value is given from TGI0525.
  • the value follows the change in hardness and hysteresis, as a gel out of the hysteresis range doesn't fulfill the parameter of peak pressure.
  • the average pressure on the body for each gel layer has been evaluated. Less overall pressure correlates to a better subjective comfort. Accordingly, with the above testing procedure, a real-life evaluation of the subjective and objective comfort provided by the present inventive combination has been established.
  • Table 6 ID Average pressure (in mmHg) TGI0525 18,4 RE30 20,5 RE40 22,1 BTG 25,3 TGI0710 24,2 TGI0711 24,2
  • the table shows how, still for this parameter, the values change with hardness, reaching a higher value; so this means a higher level of discomfort, for higher hardness and hysteresis out of range.
  • sample TGI0525 consistently provided the benchmark for subjective and objective comfort.
  • Sample TGI0525 features a hysteresis of 45.7% and a hardness of 3.1 KPa, as shown in the table 1 above.
  • Samples RE30, BTG, TGI0710, and TGI0711 provided the worst results, these samples having hardness and/or hysteresis values outside of the identified ranges needed to provide the necessary subjective and objective comfort. It was surprising to find that simple variations in hardness and hysteresis could result in changes to one or both of subjective or objective comfort, sometimes depending upon the specific subject being tested.
  • Methods of the present invention demonstrate, surprisingly, that the identified and presently claimed ranges of hardness and hysteresis are crucial to providing a superior combination of both subjective and objective comfort, as compared with the characteristics of known supports. These properties are also linked to the specific combination of the gel.
  • Prior art does not disclose or suggest the claimed hardness and hysteresis ranges, nor does it teach or suggest the calibration/optimization of two variables at the same time-hardness and elasticity.
  • the presently claimed invention teaches the adjustment of multiple variables, and here, calibration of the two physical properties of hardness and elasticity was advantageously found to provide both objective (therapeutic) and subjective (good feel) comfort to the user.
  • the gel used in the gel layer of the inventive apparatus is characterized by having a low degree of hardness, such hardness being measurable as the force deflection of the gel at a specific compression.
  • Gel hardness can be measured according to any known method, and a gel useful according to the invention can be identified as having a hardness in a specified range.
  • One method particularly useful according to the invention for measuring gel hardness is the testing method ISO 3386-1, as designated by the International Organization for Standardization (ISO).
  • the compression stress/strain characteristic is a measure of the load bearing properties of the material, and the testing method provides two formulas for calculating the compression force deflection in kilopascals (kPa), which provides a measured hardness of the material.
  • a gel according to the invention can be measured for a hardness determination through a compression load deflection test.
  • a 5cm x 5cm x 2.5cm gel sample is subjected to a compressive force, with a 70% maximum compression, and gel hardness is measured as the stress applied to the gel (in kPa) at 40% compression.
  • the gel according to the present invention has a measurable hardness that is in the range of 4.5 kPa ⁇ 1.5 kPa.
  • the gel used in the gel layer of the apparatus is characterized by having a measurable elasticity that is within a specified range.
  • a material In solid mechanics, a material is understood to behave elastically if it changes shape due to an applied load, and when the load is removed, the material recovers its original shape. The elasticity of a material is inversely proportional to its stiffness.
  • Hysteresis is a property of systems (usually physical systems) that do not instantly follow the forces applied to them, but react slowly, or do not return completely to their original state. Hysteresis, then, can be evaluated as the ability of a material, such as a gel, to return to its original shape after removal of a force on the gel.
  • a disk (described in the ISO 3386 test), moving at a specific speed value, compresses and then decompresses the gel, always moving at such specific speed value.
  • the disk applies a force to a gel, which leads to compression of the gel.
  • a gel exhibiting a low hysteresis percentage would be expected to be highly elastic, in other words, have a rapid and significantly complete return to its original shape.
  • a gel exhibiting a high hysteresis percentage would be expected to be less elastic, in other words have a more delayed and less complete return to its original shape.
  • the hysteresis of the present invention presents values that are such according to the speed indicated in the test ISO 3386 (that is a speed of value: 100 ⁇ 20 mm/min).
  • hysteresis is the value obtained for the ratio between the areas of the compression curve and the release curve according to the speed value of the disk indicated in the test ISO-3386. Changing the speed value also the hysteresis value will change.
  • such testing would typically be performed on a gel layer after the gel material has been allowed a sufficient time to cure or mature.
  • the gel materials used in the inventive apparatus and method exhibit an elasticity (or percentage hysteresis) that is not temperature dependent.
  • the gel material it is preferable for the gel material to have an elasticity that lacks temperature dependence within a range of temperatures that is well tolerated by potential users (e.g. temperatures in climatic conditions wherein a support apparatus incorporating the gel may be used).
  • the absence of temperature dependence is within a range of temperatures commonly found in dwellings (such as between about 10° C (50° F.) and about 45° C (110° F.)).
  • the gel used in the invention has a measurable hysteresis in the range of 40% ⁇ 10%.
  • viscoelastic foams commonly known as “memory foam” typically exhibit a glass transition temperature (Tg) at around room temperature.
  • Tg glass transition temperature
  • a memory foam product In a cold environment, a memory foam product will tend to be harder and less resilient. Conversely, in a warmer environment, a memory foam product will tend to be softer and more resilient. Accordingly, the product changes in response to the surrounding temperature, including temperature changes attributable to body heat flow.
  • Another additional important feature of the present invention is that a compact not-expanded material, as the gel of the present invention, with the above-indicated softness values was not considered suitable for life span needed for mattresses. However, tests were carried out and the mattress of the present invention had doubled the requested cycles.
  • the support apparatus of the invention can further comprise one or more additional support layers underlying the gel layer.
  • the additional support layer can include any type of material generally recognized in the art as being useful for providing support to at least a portion of the body of a user.
  • the additional support layer can comprise a layer of foam, which can take on any of the various embodiments generally useful for providing a cushioning effect or a supportive effect.
  • the additional support layer can also comprise springs, which are recognized as being useful for providing support to the body.
  • the layer of springs can take on any embodiment known in the art for providing effective support while also providing comfort for the user.
  • the spring layer can comprise a series of springs that are at least partially interconnected.
  • the spring layer can comprise a series of springs that are present as separate coils.
  • Further additional embodiments of spring layers are also encompassed by the present invention, which is not intended to be limited by the examples provided above.
  • the invention also encompasses apparatuses wherein the additional support layer comprises other materials known for providing support, including gas (such as air), cushioning materials, or paddings, textile layers, and also including materials providing structure, such as wood, metal, or rigid plastics.
  • the support apparatus comprises a gel layer and at least one additional support layer of a foam material.
  • the support apparatus comprises a gel layer and at least one additional support layer of springs.
  • the support apparatus comprises a gel layer, at least one additional support layer of springs, and at least one additional support layer of a foam material.
  • the one or more additional support layers are positioned underlying the gel layer such that there are no additional support layers positioned above the gel layer.
  • the additional support layers and the gel layer can be integrally attached or can be separate bodies.
  • integrally attached is intended to mean the layers are attached one to another by means such that the two layers are not separable without at least partially damaging one or multiple layers.
  • the layers may be integrally attached, such as by gluing, stapling, sewing. welding, or the like.
  • Foam support layers are particularly useful in combination with a gel layer, not only because of ease of "bonding” as described above, but also because of the various combinations provided.
  • convoluted foam may be used.
  • the foam may have one or more cavities for receiving all or part of the gel layer. When such cavities are present, the cavities may be on a "top” surface of the foam, a “bottom” surface of the foam, or on both a top and bottom surface of the foam.
  • the top surface or the bottom surface may be particularly defined as the surface intended for contact with the body of a user.
  • the additional support layer comprises a foam layer
  • the additional support layer comprises a foam layer having a thickness of at least about 5 cm.
  • the foam layer has a thickness of at least about 6 cm, at least about 7 cm, at least about 8 cm, at least about 9 cm, and at least about 10 cm.
  • the additional support layer may be of a lesser thickness than as described above.
  • the additional support layer in embodiments wherein the apparatus is a mattress topper, it is beneficial for the additional support layer to have a minimum thickness to avoid adding to the overall profile of the mattress topper.
  • the additional support layer preferably has a thickness of less than about 4 cm, less than about 3 cm, and less than about 2 cm.
  • the support apparatus of the invention also encompasses the addition of a covering overlying the gel layer.
  • the covering can generally comprise any type of material commonly used in coverings for the various types of support apparatuses encompassed by the invention. Such coverings include natural and synthetic materials. Further, such coverings can also include padding. For example, when the support apparatus is a mattress, the covering can be a padded mattress topper. Further, any type of upholstering material can be used as the cover in the present invention. Accordingly, the presence of the gel layer in no way limits the types of covers available for use in covering the support apparatus of the invention. Furthermore, other types of coverings are also encompassed by the invention.
  • the covering can comprise a film, such as a polyurethane film, a coating, such as a polymer that is non-reactive or non-tacky in a dried or cured state, or a foam.
  • the covering layer may be of a specific thickness.
  • the covering layer should be of minimal thickness to avoid masking the therapeutic benefits and pleasing feel of the gel layer.
  • the covering comprises a foam layer.
  • the foam layer it is preferable for the foam layer to have a thickness of less than about 5 cm.
  • the covering preferably has a thickness of less than about 4 cm, less than about 3 cm, and less than about 2 cm.
  • the support apparatus of the invention can include apparatuses, such as mattresses or mattress toppers.
  • the support apparatus comprises a bed mattress.
  • the support apparatus comprises a mattress topper.
  • the support apparatus of the invention comprising a gel layer overlying at least one additional support layer, such as a foam layer and a spring layer, derives benefit from multiple aspects of the invention.
  • the gel layer provides an improved pressure mapping for the various individuals that may use the support apparatus (i.e. the gel provides improved distribution of the pressure out and away from the pressure points).
  • the gel has the capability to absorb and transport heat with different parameters than other known support materials, such as foam, which generally acts as an insulator and traps heat against a user.
  • the gel layer in the apparatus of the invention can further comprise one or more fillers and can therefore be made according to predefined specifications to have a ⁇ value such that the perception of heat flow from the body of the user is optimized for comfort.
  • the filled gel layer can provide a perception of warmth often desired by a user but not act as a heat trap, such as foam.
  • the various benefits of the gel layer can be provided with only a relatively thin gel layer, while the bulk of the support apparatus can comprise more conventional materials.
  • the apparatus comprises a gel layer overlying at least one additional support layers.
  • the at least one additional support layers may include one or more of the following: a foam layer, a spring layer, a textile layer, a gas layer, a wood layer, a metal layer, and a plastic layer. Accordingly, the apparatus of the invention finds use in a wide variety of supports.
  • the apparatus of the invention could be used for supporting the entire body or only a portion of the body.
  • the gel layer comprises a gel having specific physical properties identified as providing increased support pressure and relief to a user, and also providing a user with an increased perception of comfort (i.e. a good "feel") but also increased support and pressure relief.
  • the gel layer is the outermost layer of the apparatus, facing the user.
  • the apparatus can also comprise a covering overlying the gel layer.
  • the covering layer is not of structure or thickness to substantially reduce or mask the comfort and support provided by the gel layer.
  • Non-limiting examples of coverings encompassed by the invention include a textile layer, a film layer, a coating layer, and a foam layer.
  • a mattress comprising a gel layer overlying a foam layer.
  • the mattress can comprise further support layers, such as a spring layer, and can also further comprise a covering, such as a textile layer.
  • a mattress topper comprising a gel layer overlying a foam layer, wherein the foam layer preferably is of a thickness that is substantially less than an average thickness of a standard mattress.
  • the foam layer of the mattress topper has a thickness of less than about 5 cm.
  • the mattress topper can comprise a covering overlying the gel layer.
  • small towers can help in the tridimensional deformation of the gel and the support apparatus itself under the weight of the user.
  • small towers are separated the one from the other by channels free of material that allow a free circulation of air in order to improve the ventilation of the surface of the support apparatus facing the user.
  • the gel layer 100 on the surface facing the user may be smooth or comprise a contoured surface.
  • the surface may include a plurality of small towers 102 of one or more shapes that arise from the planar surface thereof, separated by a gap 104.
  • the small towers 102 can help in the tridimensional deformation of the gel and the support apparatus itself under the weight of the user.
  • small towers 102 are separated the one from the other by channels 104 free of material, having a width of about 4-6mm that allow a free circulation of air in order to improve the ventilation of the surface of the support apparatus facing the user.
  • the gels described above, with the above-indicated hardness values have a viable lifespan double that of conventional gel layers.
  • a compact, not-expanded material, as the gel of the present invention, with the above indicated hardness values was previously not considered suitable for life span needed for mattresses. However, tests were carried out and the mattress of the present invention had doubled the requested cycles.
  • the tower structures 102 include a top surface 106 that extends a height above a lower surface 108 of the gel layer 100.
  • the tower structures 102 include a three-dimensional shape configured to have an area of the top surface 106 to be much larger than an area of the lateral sides 110 of the perimeter of the tower structure 102. In this way, the large surface area of the top surface 106 engages a portion of the body and is compressed. The compression is absorbed by bulging of the lateral surfaces 110 but a large contact area is maintained with the body to ensure that the contact pressure remains low. In this way, subjective and objective comfort is maintained.
  • the gel layer 100 may include tower structures 102 having a square shape, a rectangular shape, a circular shape, etc.
  • the area ratio of the top area 106 versus the lateral area 110 is preferably 3: 1 or greater.
  • the lateral sides 110 are preferably perpendicular to the lower layer surface 108 to permit bulging.
  • other shapes may be employed including, e.g., where long parallel plateaus of the towers 102 extend along the gel layer 100. These structures may be linear, zig-zag, curvy, etc.
  • FIG. 2 a top-down view of a gel layer of an embodiment of the present principles is shown, including a surface pattern of squares.
  • the tower structures 102 have a square cross-section and completely cover the gel layer 102.
  • FIG. 3 a top-down view of a gel layer of an embodiment of the present principles is shown, including a surface pattern of hexagons.
  • the tower structures 102 have a hexagonal cross-section, and towers 102 of partial-hexagonal cross-section may be used to fill the pattern along the edges, where full hexagons may not fit.
  • FIG. 4 a top-down view of a gel layer of an embodiment of the present principles is shown, including a surface pattern of circles.
  • the tower structures 102 have a hexagonal cross-section.
  • FIG. 5 a top-down view of a gel layer of an embodiment of the present principles is shown, including a surface pattern of zig-zag plateaus 102.
  • the tower structures 102 are shown as being continuous plateaus separated by gaps 104 on the gel layer 100.
  • the present invention also provides a method for preparing a support apparatus, such as a mattress or a mattress topper.
  • the invention is directed to a method for preparing a mattress that comprises a gel layer and a cover layer.
  • a method generally comprises the following steps: providing a mold; inserting a gel material into the mold to form the gel layer; and affixing a cover layer to the gel layer.
  • the mold comprises a vacuum-assist mold.
  • a method can further comprise the step of placing a release layer in the mold prior to the step of inserting the gel material into the mold.
  • the method for preparing a support apparatus comprises the following steps: providing a first foam layer comprising a foam piece having a surface with one or more cavities formed therein; inserting a gel material into the one or more cavities in the surface of the foam piece; and at least partially curing the gel material to form one or more gel layers.
  • This method of the invention is particularly characterized in that the foam layer of the support apparatus can function not only as a layer of the apparatus but also as the mold for the gel material.
  • the cavities in the foam can be prepared to be of a size, shape, and distribution such that a wide variety of apparatus gel/foam combinations can be prepared according to desired specifications and uses.
  • the present invention is directed to a method comprising the steps of providing a gel material that is a polyurethane gel; inserting the gel material into the mold, thereby forming a gel layer; wherein the gel layer faces a user; at least partially curing the gel layer; and affixing a cover layer to the gel layer, wherein the gel material has a hardness in the range of 4.5 kPa ⁇ 1.5 kPa when measured according to a method of ISO 3386-1, and wherein the gel material exhibits a hysteresis of 40% ⁇ 10%.
  • an exemplary method of the present invention for preparing a support apparatus does not comprise the co-molding of the gel layer and the foam layer, in order to avoid any kind of problems during the process itself. Moreover, in this way, there are more possibilities to vary the final shape and features of the mattress.
  • the invention provides a method for preparing a support apparatus comprising a foam layer and a gel layer.
  • a method comprises the following steps: providing a first foam layer comprising a foam piece with a surface that is at least partially convoluted; and applying a gel material to the convoluted surface of the foam layer to form a gel layer attached to the foam layer.
  • a method can comprise the step of affixing a cover layer to the apparatus.
  • the cover layer can comprise a second foam layer.
  • the gel material comprises a gel having specific physical properties identified as providing increased support pressure and relief to a user, and also providing a user with an increased perception of comfort (i.e. a good "feel").
  • the gel layer can be the outermost layer of the apparatus, i.e. it has a surface facing the user, therefore being in direct contact with the user.
  • another goal of the invention is to provide a process for preparing a support apparatus, such as a mattress or a mattress topper, that would provide therapeutic benefit (or objective comfort) in addition to subjective comfort. Only the combination of features of the present invention has allowed that, among a very large number of possible combinations.
  • various aspects of the invention further encompass preparation of support apparatuses comprising one or more additional support layers.
  • the gel layer comprises a gel of a specific composition, as better explained above.
  • a specific composition is particularly useful in modifying the objective and subjective comfort properties of the gel used in the gel layer.
  • a method of the present invention comprises if appropriate, a catalyst for the reaction between isocyanate groups and hydroxyl groups.
  • the polyol or polyols also act as a dispersing agent.
  • the higher-molecular weight polyols used in the present invention are preferably the polyhydroxy polyesters, polyhydroxy polyethers, polyhydroxy polythioethers, polyhydroxy polyacetals, polyhydroxy polycarbonates or polyhydroxy polyesteramides of the molecular weight range given above, which compounds are liquid at room temperature.
  • the process for the preparation of polyurethane gels of the present invention is preferably carried out at room temperature. However, increasing the temperature up to 100° C increases the reaction rate.
  • a support apparatus prepared according to a method of the invention further comprises one or more foam layers.
  • the gel layer and the foam layer can be integrally attached or can be separate bodies.
  • integrally attached is intended to mean the layers are attached one to another by means such that the two layers are not separable without at least partially damaging one or multiple layers.
  • the layers may be integrally attached, such as by gluing, stapling, sewing, welding, or the like.
  • the layers may be integrally attached through chemical bonding.
  • the gel layer comprises a polyurethane gel and the foam layer comprises a polyurethane foam
  • both layers have free isocyanate groups prior to curing (or maturation) of the gel or foam. Accordingly, when one layer is allowed to cure while adjacent the other layer, chemical bonding between the gel material and the foam material can occur.
  • a support apparatus prepared according to various aspects of the invention can comprise apparatuses such as mattresses.
  • a method of the invention can be used in the preparation of an apparatus in a substantially complete form (i.e "requiring no further essential components to perform its support function) or can be used in the preparation of a component part of an apparatus (i.e., a component that can be combined with one or more further components to form a substantially complete support apparatus).
  • a mattress component could be a mattress topper that could be combined with an existing mattress.
  • a method for preparing a support apparatus comprising a gel layer and a second layer.
  • the second layer comprises a foam layer.
  • a method generally comprises providing a gel layer, providing a second layer, and affixing the gel layer to the second layer.
  • a method can further comprise one or more steps related to preparing the gel layer, preparing the second layer, or preparing both the gel layer and the second layer.
  • a method can still further comprise applying one or more further layers to the support apparatus, particularly in embodiments wherein the second layer is a foam layer.
  • a method according to a version of the present invention comprises the following steps: providing a polyurethane gel that is obtained by providing a gel material of the above-indicated composition:
  • the liquid dispersing agent of component (b) that is one or more polyhydroxy compound having an average molecular weight between 1,000 and 12,000 or between 1,700 and 6,000 and an OH number between 20 and 112 or between 28 and 84 or between 30 and 56, wherein the dispersing agent does not contain hydroxy compounds with a molecular weight below 1,000 or below 800.
  • a method according to the invention comprises a step of preparing the polyurethane matrix by reacting isocyanate and polyol compounds and, in the preparation of the polyurethane matrix, the product of the isocyanate functionality and the polyol functionality is at least 5.2 or at least 6.2 or at least 8 or at least 10 or 12.
  • a method according to the present invention comprises an optional step of providing a catalyst for the reaction between isocyanate groups and hydroxyl groups.
  • the invention is particularly characterized in that the various aspects provided herein is fully adaptable to a number of different processing modes.
  • various aspects of the invention can be used in continuous processing methods or can be used in discrete methods where individual articles are prepared.
  • Such advantages are more fully described below in relation to particular embodiments of the invention; however, the invention is not limited to steps described only in relation to a particular embodiment. Rather, various aspects of the invention may be adapted to particular manufacturing strategies and plans as would be envisioned by the skilled artisan.
  • a method comprises providing a mold, inserting a gel material into the mold to form a gel layer, and affixing a cover layer to the gel layer.
  • the gel material may be at least partially cured (or matured) to form the gel layer prior to affixing the cover layer.
  • the cover layer is a foam layer.
  • the cover layer is a textile layer.
  • a mold used according to the invention can be any type of conventional mold that would be recognized as useful in forming one or both of a gel layer and a foam layer.
  • the size of the mold can vary depending upon the support apparatus being prepared. Further, the size of the mold can vary depending solely upon the dimensions of the gel layer being prepared in the method. In one particular embodiment, wherein the apparatus being prepared is a mattress, the dimensions of the mold used are substantially similar to the dimension of the mattress being prepared.
  • a double (or full) size mattress generally has a width and length of about 135 cm (about 54 inches) by 190 cm (about 75 inches). Accordingly, when preparing a mattress for a double bed, a mold used according to the invention would have similar dimensions.
  • a support apparatus prepared according to the present invention to be a mattress can be prepared such that the apparatus is dimensioned to be a mattress (i.e., have the length, width, and thickness of a standard mattress).
  • the support apparatus can be sized to have at least one dimension of a standard mattress size.
  • the support apparatus could be sized to the width of a mattress, the length of a mattress, or both the length and width of a mattress.
  • the support apparatus can be specifically dimensioned for a specific application.
  • the support apparatus can be prepared such that it is dimensioned to be a mattress topper.
  • the mattress topper can have a thickness in the range of about 0.2 cm to about 9 cm, about 0.3 cm to about 8 cm, about 0.4 cm to about 7 cm, about 0.5 cm to about 6 cm, about 0.1 cm to about 5 cm, about 0.25 cm to about 5 cm, or about 0.5 cm to about 5 cm.
  • FIG. 6 shows a mold with a mattress thereon prepared according to the method described above.
  • the mold 20 is a vacuum-assist mold and includes a vacuum tube 23 attached to the mold 20 and exiting therefrom to suitable vacuum means (not shown).
  • the mold 20 has an interior surface 25 formed by sidewalls 27 and is adapted for receiving the materials used in preparing the mattress, said sidewalls 27 having a height useful to define a cavity for containing at least the desired thickness of the gel layer of the mattress.
  • the mold 20 comprises further components necessary for providing vacuum suction to the interior surface of 25 of the mold 20.
  • this method of the invention is not limited to the use of a vacuum-assist mold, and the mold apparatus illustrated in FIG. 6 is provided only as one embodiment of the invention and should not be construed as limiting thereof.
  • the method described above can further comprise providing a release layer prior to inserting the gel material.
  • the release layer 40 lines the interior surface 25 of the mold 20.
  • the release layer can comprise any material useful for facilitating removal of the gel layer from the mold.
  • the release layer can further function as a covering for the gel layer to avoid direct contact of the gel layer with an individual or another component of a support apparatus, particularly to avoid the "tacky" feel often characteristic of a gel, even subsequent to complete curing or maturation of the gel material.
  • a release layer is not required.
  • the mold could comprise a finish that substantially functions as an inherent release layer, such as in the case of a mold having at least a portion of the interior surface coated with a TEFLON® layer.
  • the release layer comprises a polymer film, such as a polyurethane film.
  • the polymer film can be of varying thickness, for example in the range of about 0.01 mm to about 2 mm. In one embodiment, the polymer film has a thickness of about 0.025 m to about 1 mm. Preferably, the polymer film is of a minimum thickness to provide effective release of the gel layer from the mold and also to avoid tearing over long-term use as a covering for the gel layer. In one embodiment, the polymer film is a polyurethane film.
  • the release layer can comprise a liquid coating layer.
  • the material used in the liquid coating can be any liquid material generally recognized as being useful for disallowing attachment of a gel material, such as polyurethane gel, to a surface, such as wood, metal, plastic, or ceramic, that may be used in a mold.
  • a gel material such as polyurethane gel
  • Non-limiting examples of materials useful in a liquid coating according to the invention include silicones and fluorocarbons.
  • the liquid coating can be applied to the mold by any means generally recognized as useful in the art including, but not limited to, spraying, brushing, rolling, dipping, and the like.
  • the release layer can comprise a waxy layer.
  • a waxy layer according to the invention can comprise any material recognized as being a wax (e.g., a low-melting organic mixture or compound of high molecular weight that is solid at room temperature and generally similar in composition to fats and oils except that it contains no glycerides).
  • waxes useful according to the invention include animal waxes (e.g. beeswax), vegetable waxes (e.g. carnauba), mineral waxes (e.g. fossil or earth waxes, such as silicon based waxes, or petroleum waxes, such as paraffin), ethylenic polymers and polyol ether-esters (e.g. CARBOWAX®), chlorinated naphthalenes (e.g. halowax), and hydrocarbon-type waxes.
  • animal waxes e.g. beeswax
  • vegetable waxes e.g. carnauba
  • mineral waxes
  • the release layer can comprise a powder.
  • the release layer can comprise a non-reactive powder, such as magnesium silicate hydroxide (i.e. talc), or a similar powder.
  • the coverage of the release layer is generally limited by the dimensions of the mold.
  • a polymer film it may be useful to use a film having dimensions greater than the dimensions of the mold, thereby allowing the release layer to have free edges extending outside the edges of the gel layer.
  • the free edges of the release layer can be later trimmed or used in further, optional process steps as more fully described below.
  • the gel in a continuous, automated process, can be inserted by a flow-regulated nozzle under computer control, wherein a defined volume of gel is flowed or sprayed into the mold, thereby filling the mold with gel to a defined thickness.
  • the gel in a discrete manufacturing process, could be poured into the mold under human control.
  • the gel can be referred to as the gel layer 50.
  • the gel layer 50 is allowed to at least partially cure prior to proceeding with the remaining process steps.
  • curing it is intended to mean that the gel is allowed to undergo chemical reactions that may be taking place in the transformation of the gel material from a raw material to its finished, gelled state.
  • such chemical reactions can include reaction of isocyanate moieties and alcohol moieties to form polyurethane, as fully described above.
  • Curing which can also be referred to as maturation, may also encompass a physical component wherein the gel material transforms from a liquid to a gelled state.
  • curing is an optional step that is actually preferably omitted in certain embodiments. such as where chemical bonding between the gel layer and another layer is desired.
  • the present method further comprises affixing a cover layer to the gel layer.
  • the cover layer can comprise any material useful for providing additional structure or support to the gel layer or any material useful for simply acting as a barrier layer between the gel layer and another layer or a user.
  • the cover could comprise a textile layer, a foam layer, a natural material, such as leather, a synthetic material, or the like.
  • the cover layer can also be a material otherwise useful as a release layer, such as polymer film. a textile layer, a liquid coating layer, a waxy layer, or a powder layer.
  • the cover layer comprises a foam layer 60, which has a length and width substantially corresponding to the length and width of the gel layer 50; however, the foam layer 60 can have a variable thickness.
  • the foam layer may be desirable for the foam layer to be of minimal thickness (e.g., less than or equal to the thickness of the gel layer) to emphasize the benefits of the gel layer without imparting unnecessary bulk to the mattress topper.
  • affixing is intended to refer to any method of fastening, joining, or attaching the gel layer to the foam layer that may be recognized as useful.
  • Affixing the layers can comprise a physical bonding of the layers as well as a chemical bonding of the layers.
  • Non-limiting examples of physical bonding whereby the layers are affixed include gluing, stitching, and welding.
  • the affixation of the layers can be facilitated solely by the inherent "tackiness" of the gel layer.
  • Chemical bonding of the layers can occur in any process wherein the gel layer and the foam layer comprise free reactive groups capable of reacting with one another.
  • the gel layer may comprise a polyurethane gel material
  • the foam layer may comprise a polyurethane foam material.
  • a method may further comprise affixing the free edges of the release layer, when applicable, to the gel layer and/or the cover layer.
  • affixing can be accomplished by any means recognizable as useful including, but not limited to gluing, stitching, and welding.
  • the method further comprises combining the cover layer and the gel layer with one or more additional layers.
  • the additional support layer can include any type of material generally recognized in the art as being useful for providing support to at least a portion of the body of a user.
  • the additional support layer can comprise a layer of foam, which can take on any of the various embodiments generally useful for providing a cushioning effect or a supportive effect.
  • the additional support layer can also comprise springs. which are recognized as being useful for providing support to the body.
  • the layer of springs can take on any embodiment known in the art for providing effective support, while also providing comfort for the user.
  • the spring layer can comprise a series of springs that are at least partially interconnected.
  • the spring layer can comprise a series of springs that are present as separate coils.
  • Further additional embodiments of spring layers are also encompassed by the present invention, which is not intended to be limited by the examples provided above. Further, the additional layers can be affixed to one or both of the gel layer and the cover layer.
  • the additional layer is not required, but it can rather be merely associated with the gel layer and the cover layer in a readily separable fashion.
  • the additional layer could comprise a cavity foam, and the support apparatus formed of the gel layer and the cover layer could be prepared as an insert for the cavity in the foam.
  • Non-limiting examples of additional layers for combination with the gel layer and the cover layer include a foam layer, a spring layer, a textile layer, a gas layer, a wood layer, a metal layer, a plastic layer, and combinations thereof.
  • a method can comprise inserting a gel material into the cavities of the foam piece, thereby forming a support apparatus comprising a gel layer and a foam layer, wherein the foam layer also serves as the mold for the gel.
  • a method can include further steps depending upon the type of apparatus being prepared. For instance, in one embodiment, a method can further comprise at least partially curing the gel layer. In another embodiment, a method can further comprise affixing a second foam layer to the gel layer.
  • the second foam layer may be of dimensions useful for covering the gel layer, or the second foam layer may be of large dimensions, such as being useful for covering substantially the entire surface of the foam layer, including the gel layers formed therein.
  • the invention can still further comprise applying a covering layer (particularly to the gel layer), such as a polymer film, a textile layer, or a liquid or powder coating layer.
  • a covering layer particularly to the gel layer
  • a method can encompass combination with one or more further support layers, such as previously described herein.
  • the mold can comprise still further materials.
  • the mold comprises one or more layers of a support material having one or more cavities formed therein for receiving the gel material.
  • the mold can simply be a foam piece as described above, wherein the foam has a defined average thickness and has a surface with one or more cavities formed therein.
  • the mold comprises a textile layer having one or more cavities formed therein.
  • the mold comprises a sandwich textile comprising a foam layer between a first textile layer and a second textile layer, wherein the foam layer has one or more cavities formed therein.
  • the apparatus prepared according to the invention comprises a foam layer 60 having a surface with two cavities (left and right) formed therein.
  • the left cavity 65 is filled with a gel layer 50 that is partially cut away to reveal the cavity 65.
  • the right cavity is also filled with a gel layer, but the gel layer is covered with a cover layer 62.
  • the cover layer 62 is shown partially cut away to reveal the underlying gel layer 50.
  • the foam layer When performing a method according to this embodiment of the invention, it is particularly useful for the foam layer to be of a substantial thickness for imparting structure to the apparatus.
  • the foam layer has a thickness of at least about 5 cm.
  • the foam layer has a thickness of at least about 6 cm, at least about 7 cm, at least about 8 cm, at least about 9 cm, and at least about 10 cm.
  • the second foam layer When a second foam layer is used as the cover layer, it is generally preferable for the second foam layer to be of a thickness such that the beneficial properties of the gel layer are not negated by the foam.
  • the second foam layer has a thickness of less than about 5 cm.
  • the second foam layer has a thickness of less than about 4 cm, less than about 3 cm, or less than about 2 cm.
  • the second foam layer has a thickness of about 0.25 cm to about 5 cm, about 0.5 cm to about 4 cm, or about 0.75 cm to about 3 cm.
  • the foam layer can further be characterized by the shape, positioning, and dimensions of the cavities formed therein.
  • the cavities may substantially cover the top surface of the foam as one continuous cavity or a plurality of cavities.
  • the cavities may be formed in strategic positions in the foam layer, such as to substantially correspond to certain body parts of a user or to impart specific beneficial effects.
  • the cavities can take on specific shapes, such as to correspond to the shape of a specific body part of a user generally or to again impart beneficial properties.
  • the cavities formed in the foam layer have a depth of about 10% to about 90% of the average thickness of the foam layer. More particularly, the cavities have a depth of about 20% to about 80% or about 30% to about 70% of the average thickness of the foam layer.
  • the cavities formed in the foam layer have a depth of about 0.25 cm to about 20 cm, about 0.5 cm to about 18 cm, about 1 to about 18 cm, about 2 cm to about 17 cm, about 3 cm to about 16 cm, and about 5 cm to about 5 cm.
  • the depth of the cavities can vary on the same foam layer.
  • a foam layer could comprise two or more cavities, each having different depths.
  • the foam layer could comprise a single cavity, wherein the depth of the cavity varies within the cavity.
  • the foam layer can still further be characterized by the percentage of the surface area of the foam layer encompassed by the cavities.
  • the cavities formed in the surface of the foam comprise about 1 % to about 95% of the surface area of the foam layer.
  • the cavities comprise about 5% and about 95% of the surface area of the foam layer, about 10% to about 95%, about 15% to about 95%, about 20% to about 95%, about 25% to about 95%, about 30% to about 95%, or about 50% to about 95% of the surface area of the foam layer.
  • the cavities comprise at least about 5%, at least about 10%, at least about 25%, at least about 50%, or at least about 75% of the surface area of the foam layer.
  • FIG. 8 Another embodiment of a support apparatus prepared according to this method of the invention is illustrated in FIG. 8 , as shown therein, a foam layer 60 is used as a mold and has a cavity 65 formed therein (revealed in the cut away portion of the gel layer) to receive the gel layer 50.
  • the gel layer 50 can encompass a significant percentage of the surface of the foam layer 60.
  • the foam layer 60 further comprises a series of raised portions 67 formed near the ends of the foam layer 60 wherein the foam material has only been partially removed (i.e., being covered with only a thin layer of gel) or has not been removed at all (as in the embodiment of FIG. 8 ).
  • This further illustrates the highly customizable nature of the invention in the ability to prepare a variety of apparatus conformations of the gel layer and the foam layer merely by altering the cavity formation in the foam layer.
  • the foam layer can be convoluted.
  • a support apparatus prepared according to one method of the invention using convoluted foam is illustrated in FIG. 9 , which provides a cross-sectional view of the apparatus.
  • the surface of the foam layer 60 is convoluted, thereby providing a plurality of recesses for receiving the gel material.
  • convoluted is intended to mean that the surface of the foam has been shaped to have a pattern, generally a repeating pattern, wherein the surface is characterized by having ridges 75 and recesses 77, as illustrated in FIG. 9 .
  • convoluted can further mean that the foam is patterned such that at least a portion of the foam folds back upon itself.
  • Convoluted foam for use in the present invention can be prepared in a variety of process, such as would be recognizable to the skilled artisan. Accordingly, the convoluted surface of the foam layer can take on a variety of conformations. For example, in FIG. 9 , portion A of the foam is shown having crest, or fin-like ridges 75 with relatively narrow recesses 77 between the ridges 75. Alternatively, portion B of the foam illustrates more of a sinusoidal wave-like pattern, wherein the ridges 75 are more widely spaced by the recesses 77. Of course, as previously noted, these embodiments are only illustrative of the various convoluted surfaces that could be formed in the foam layer.
  • the gel layer 50 in FIG. 9 is shown as filling the area between the ridges of the convoluted foam layer 60.
  • the gel material can be applied to the foam layer 60 in an amount such that the gel layer 50 only partially fills the area between the ridges 75 of the foam layer 60.
  • the gel material could be applied in an amount such that the gel layer completely fills the area between the ridges 75 of the foam layer 60 and further rises above the ridges 75.
  • a method comprises providing a foam layer comprising a foam piece having a surface that is at least partially convoluted and applying a gel material to the convoluted surface of the foam layer to form a gel layer thereon.
  • a method can further comprise affixing a cover layer (such as a second foam layer) to the gel layer.
  • the gel layer can be at least partially cured prior to affixing the cover layer to the gel layer.
  • the support apparatus prepared according to a method of the present invention generally comprises a gel layer and a second layer, such as a cover layer.
  • the cover layer comprises a foam layer.
  • the apparatus comprises a foam layer, a gel layer, and optional further layers, particularly a cover layer.
  • the cover layer can be applied to the gel layer, or to the apparatus overall.
  • the apparatus can comprise a gel layer and a cover layer, the cover layer can be capable of covering only a top surface of the gel layer or completely surrounding the gel layer.
  • the apparatus can comprise a gel layer, a cover layer (such as a foam layer), and a further cover layer.
  • the cover layer can generally comprise any type of material commonly used in coverings for the various types of support apparatuses encompassed by the invention.
  • Such coverings include natural and synthetic materials.
  • such coverings can also include padding.
  • the support apparatus is a mattress
  • the covering can be a padded mattress topper.
  • any type of upholstering material can be used as the cover in the present invention. Accordingly, the presence of the gel layer in no way limits the types of covers available for use in covering the support apparatus prepared according to the methods of the invention.
  • other types of coverings are also encompassed by the invention.
  • the covering can comprise a film, such as a polyurethane film, a coating, such as a polymer that is non-reactive or non-tacky in a dried or cured state, or a foam.
  • the cover layer can include texturing, thereby providing a three-dimensional effect to the cover layer.
  • the apparatus prepared according to the invention can be customized through management of shaping or cavity formation in the foam layer.
  • different levels of support and comfort can be achieved through varying combinations of gel surface area, cavity shape, cavity placement, and cavity depth.
  • the foam layer can comprise a single cavity covering only a small percentage or almost all of the surface area of the foam layer.
  • the foam layer can also comprise a complex pattern of cavities formed across the surface of the foam layer.
  • the cavities can beneficially be positioned for strategic and therapeutic benefits.
  • a method of the invention comprises preparation of a mattress
  • the cavities formed in the foam layer can be arranged in one or more areas of the foam layer corresponding to a particular body part of a potential user of the mattress.
  • the cavity may correspond to trunk area of a user to allow for beneficial contouring of the gel layer to the body (particularly the back) of the user.
  • This method of the invention is particularly adaptable for continuous manufacturing processes.
  • a single foam piece could be carried along a process line.
  • the appropriate cavities could be formed, at a station down the line, the gel could be inserted into the cavities, at yet another station, optional further layers could be applied to the gel layer, and at still another station the individual apparatuses could be cut free from the continuous foam.
  • Similar manufacturing methods could be particularly adapted to methods incorporating convoluted foam layers.
  • the present invention can further be adapted to "stop-and-go" manufacturing according to certain methods encompassed by the invention.
  • a method can comprise the use of a conventional mold, wherein the components of the apparatus to be prepared are place in the mold, allowed to cure or foam, and then removed from the mold after a suitable amount of time.
  • the foam material used in a method of the invention can comprise any type of foam material generally recognized as useful in the field.
  • foam material generally recognized as useful in the field.
  • polyurethane foams are particularly preferred.
  • other foams could also be used.
  • latex foams could also be used according to the invention.
  • the invention generally comprises preparing a support apparatus according to a method comprising the following steps: preparing a gel layer comprising a first surface and an opposing surface and having a release layer affixed to at least one of the surfaces; preparing a foam layer having a surface adapted for receiving at least a portion of the gel layer; and affixing the gel layer to the foam layer.
  • the affixing step can comprise various methods, such as gluing, stitching, welding, and combinations thereof. Accordingly, it is possible, according to the invention, to prepare various components of the support apparatus separately and then combine the individual components into a completed apparatus.
  • sample shape For each gel sample, the sample shape, optional filler material, exemplary use, hardness (measured as force deflection at 40% compression), and percent hysteresis are provided.
  • sample shape “regular” indicates a sample 5 cm wide x 5 cm long x 2.5 cm thick
  • cylinder indicates cylindrical sample having a diameter of 5 cm and being 3 cm thick
  • tower indicates a sample 5 cm wide x 5 cm long x 1.7 mm thick having four square projections arising from the top thereof, each being 2 cm wide x 2 cm long x 0.8 mm thick.
  • Sample ID 12 is provided as a comparative example of a gel that would not be useful according to the invention.

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  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Claims (20)

  1. Matratze oder Matratzenauflage zum Stützen von zumindest einem Teil des Körpers darauf, die eine Gelschicht (50, 100) und mindestens eine Stützschicht aus einem Schaumstoffmaterial (60) umfasst, wobei die Gelschicht (50, 100) über der mindestens einen Stützschicht aus einem Schaumstoffmaterial (60) liegt, wobei die Gelschicht (50, 100) ein Polyurethangel umfasst, wobei die Gelschicht (50, 100) eine einem Benutzer zugewandte Oberfläche umfasst, dadurch gekennzeichnet, dass diese Gelschicht (50, 100) ein Gel mit einer Härte von 4,5 kPa ±1,5 kPa und einer Hysterese von ungefähr 40% ±10% umfasst, so dass die Gelschicht (50, 100) gleichzeitig objektiven und subjektiven Komfort verleiht.
  2. Matratze oder Matratzenauflage nach Anspruch 1, die eine oder mehrere zusätzliche Stützschichten umfasst, die aus der Gruppe ausgewählt sind, die aus einer Schaumstoffschicht (60), einer Federschicht, einer Textilschicht, einer Gasschicht, einer Holzschicht, einer Metallschicht, einer Kunststoffschicht und Kombinationen davon besteht.
  3. Matratze oder Matratzenauflage nach Anspruch 1, die eine über der Gelschicht liegende Abdeckung umfasst, wobei diese Abdeckung aus der Gruppe ausgewählt ist, die aus einer Textilschicht, einer Folienschicht, einer Überzugsschicht und einer Schaumstoffschicht (60) besteht, und über der Gelschicht angeordnet ist.
  4. Matratze oder Matratzenauflage nach Anspruch 1, wobei keine über der Gelschicht angeordneten zusätzlichen Stützschichten vorhanden sind.
  5. Matratze oder Matratzenauflage nach einem der vorhergehenden Ansprüche, wobei die Gelschicht (50, 100) integral an mindestens einer der einen oder mehreren zusätzlichen Stützschichten angebracht ist.
  6. Matratze oder Matratzenauflage nach Anspruch 1, wobei das Schaumstoffmaterial Noppenschaumstoff ist oder wobei der Schaumstoff einen oder mehrere Hohlräume zum Aufnehmen der Gelschicht umfasst.
  7. Matratze oder Matratzenauflage nach Anspruch 1, wobei die Gelschicht (50, 100) und die Schaumstoffschicht (60) chemisch miteinander verbunden sind.
  8. Matratze oder Matratzenauflage nach Anspruch 1, wobei die Gelschicht (50, 100) eine Dicke von mindestens 8 mm hat.
  9. Matratze oder Matratzenauflage nach Anspruch 1, wobei die dem Benutzer zugewandte Oberfläche eine dem Benutzer zugewandte Oberfläche umfasst, die glatt ist oder die eine Vielzahl von kleinen Aufsätzen (102) umfasst, die sich von einer ebenen Oberfläche (108) derselben erheben, oder die kleine Aufsätze (102) umfasst, die durch Kanäle (104) ohne Material voneinander getrennt sind, die eine freie Luftzirkulation ermöglichen, oder wobei die dem Benutzer zugewandte Oberfläche eine konturierte Oberfläche des Polyurethangels umfasst, die Aufsatzstrukturen (102) umfasst.
  10. Matratze oder Matratzenauflage nach Anspruch 9, wobei die Aufsatzstrukturen (102) eine obere Fläche (106) aufweisen, die mindestens dreimal größer als eine Seitenfläche (110) ist, oder wobei diese Aufsatzstrukturen (102) einen rechteckigen Querschnitt haben oder wobei diese Aufsatzstrukturen (102) einen sechseckigen Querschnitt haben oder wobei diese Aufsatzstrukturen (102) einen kreisförmigen Querschnitt haben oder wobei diese Aufsatzstrukturen (102) parallele gekrümmte Hochflächen sind.
  11. Matratze oder Matratzenauflage nach Anspruch 9 oder 10, wobei die Aufsatzstrukturen (102) eine dreidimensionale Durchbiegung aufweisen, die durch einen Druck nach unten auf die konturierte Oberfläche bewirkt wird, so dass verdrängtes Material von den Aufsatzstrukturen (102) eine Lücke (104) zwischen den Aufsatzstrukturen (102) belegt.
  12. Matratze oder Matratzenauflage nach einem der vorhergehenden Ansprüche von 9 bis 11, wobei die Gelschicht (50, 100) eine Dicke von 8-15 mm hat und die Lücke (104) zwischen den Aufsatzstrukturen (102) 4-6 mm misst.
  13. Verfahren zur Herstellung einer Matratze oder Matratzenauflage, die eine Gelschicht (50, 100) umfasst, wobei dieses Verfahren Folgendes umfasst:
    Bereitstellen einer Form (20);
    Anordnen einer Trennschicht (40) in der Form (20);
    Bereitstellen eines Gelmaterials, das ein Polyurethangel ist;
    Einbringen des Gelmaterials in die Form (20), wobei eine Gelschicht (50, 100) ausgebildet wird;
    wobei die Gelschicht (50, 100) eine einem Benutzer zugewandte Oberfläche umfasst;
    zumindest teilweises Aushärten der Gelschicht (50, 100); und
    Anbringen einer Deckschicht (62) an der Gelschicht (50, 100);
    wobei dieses Gelmaterial eine Härte im Bereich von 4,5 kPa ±1,5 kPa, gemessen nach dem Verfahren gemäß ISO 3386-1, hat und wobei dieses Gelmaterial eine Hysterese von 40% ±10% aufweist.
  14. Verfahren nach Anspruch 13, wobei die Trennschicht (40) in der Form (20) angeordnet wird und ein Material umfasst, das aus der Gruppe ausgewählt ist, die aus einer Polymerschicht, einer Textilschicht, einer flüssigen Überzugsschicht, einer Wachsschicht und einer Pulverschicht besteht, oder wobei die Trennschicht (40) ein Material mit einem freien Rand umfasst, und wobei das Verfahren ferner das Anbringen des freien Rands des Materials an der Gelschicht (50, 100) umfasst.
  15. Verfahren nach Anspruch 14, wobei der Schritt des Anbringens des freien Rands des Materials an der Gelschicht (50, 100) ein Verfahren umfasst, das aus der Gruppe ausgewählt ist, die aus Verleimen, Vernähen und Schweißen besteht.
  16. Verfahren nach Anspruch 13, wobei der Schritt des Bereitstellens der Gelschicht (50, 100) mit der dem Benutzer zugewandten Oberfläche das Bereitstellen dieser Oberfläche umfasst, die glatt ist oder die eine Vielzahl von kleinen Aufsätzen (102), die sich von einer ebenen Oberfläche (106) derselben erheben, umfasst oder die kleine Aufsätze (102) umfasst, die durch Kanäle (104) ohne Material voneinander getrennt sind, die eine freie Luftzirkulation ermöglichen.
  17. Verfahren nach Anspruch 13, wobei der Schritt des Anbringens der Deckschicht (62) an der Gelschicht (50, 100) ein Verfahren umfasst, das aus der Gruppe ausgewählt ist, die Verleimen, Vernähen und Schweißen umfasst, oder wobei die Deckschicht (62) ein Material umfasst, das aus der Gruppe ausgewählt ist, die aus einer Schaumstoffschicht (60), einer Polymerfolie, einer Textilschicht, einer flüssigen Überzugsschicht, einer Wachsschicht und einer Pulverbeschichtungsschicht besteht.
  18. Verfahren nach Anspruch 13, wobei die Form (20) eine Form mit Vakuumunterstützung umfasst oder wobei die Form (20) eine oder mehrere Schichten eines Tragmaterials mit einem oder mehreren darin ausgebildeten Hohlräumen (65) zum Aufnehmen des Gelmaterials umfasst oder wobei die Form (20) eine Schaumstoffschicht (60) umfasst, die ein Schaumstoffstück mit einer Dicke und mit einer Oberfläche mit einem oder mehreren darin ausgebildeten Hohlräumen (65) umfasst, oder wobei die Form (20) eine Textilschicht mit einem oder mehreren darin ausgebildeten Hohlräumen (65) umfasst oder wobei die Form (20) ein Sandwich-Textil umfasst, das eine Schaumstoffschicht (60) zwischen einer ersten Textilschicht und einer zweiten Textilschicht umfasst, wobei diese Schaumstoffschicht (60) einen oder mehrere darin ausgebildete Hohlräume (65) aufweist, oder wobei die Form (20) ein Schaumstoffstück mit einer Oberfläche umfasst, die zumindest teilweise gewunden ist.
  19. Verfahren nach Anspruch 18, wobei der eine oder die mehreren Hohlräume (65) eine Fläche umfassen, die 1% bis 95% der Oberfläche des Schaumstoffstücks umfasst, oder wobei sich der eine oder die mehreren Hohlräume (65) in einem Bereich befinden, der einem Bereich des Körpers des Benutzers der Matratze oder Matratzenauflage entspricht, oder wobei der eine oder die mehreren Hohlräume (65) eine Tiefe von 10% bis 90% der Dicke der Schaumstoffschicht (60) haben.
  20. Verfahren nach Anspruch 13, das das Kombinieren von mindestens der Gelschicht (50, 100) und der Deckschicht (62) mit einer oder mehreren zusätzlichen Schichten umfasst, die aus der Gruppe ausgewählt sind, die aus einer Schaumstoffschicht (60), einer Federschicht, einer Textilschicht, einer Gasschicht, einer Holzschicht, einer Metallschicht, einer Kunststoffschicht und Kombinationen davon besteht.
EP20130178771 2012-07-31 2013-07-31 Trägervorrichtung mit Gelschicht und Verfahren zu seiner Herstellung Active EP2692265B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/563,391 US20130000045A1 (en) 2005-03-21 2012-07-31 Support apparatus with gel layer
US13/762,865 US20130146211A1 (en) 2006-04-25 2013-02-08 Process for preparing an apparatus comprising a gel layer

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EP2692265A1 EP2692265A1 (de) 2014-02-05
EP2692265B1 true EP2692265B1 (de) 2015-03-04

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Cited By (1)

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Publication number Priority date Publication date Assignee Title
EP3196221A1 (de) 2016-01-25 2017-07-26 Technogel Italia S.R.L. Temperaturgeregelte polyurethangele

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US6269504B1 (en) 1998-05-06 2001-08-07 Hill-Rom Services, Inc. Mattress or cushion structure
DE19957397C1 (de) 1999-11-29 2001-07-19 Technogel Gmbh & Co Kg Formkörper aus Polyurethan und Verfahren zu seiner Herstellung
US20040058163A1 (en) 2000-05-18 2004-03-25 Peter Gansen Composite material
DE10254678B4 (de) * 2002-11-22 2005-11-17 Technogel Gmbh & Co. Kg Formkörper, insbesondere für ein Sitzpolster
US6804848B1 (en) 2003-03-14 2004-10-19 Comfortaire Corporation High-profile mattress having an upper low-profile module with an air posturizing sleep surface
US20070246157A1 (en) * 2006-04-25 2007-10-25 Technogel Gmbh & Co. Process for preparing an apparatus comprising a gel layer
AU2009350434B2 (en) * 2009-07-29 2014-11-27 Technogel Italia S.R.L. Modular support element

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3196221A1 (de) 2016-01-25 2017-07-26 Technogel Italia S.R.L. Temperaturgeregelte polyurethangele
EP3415543A1 (de) 2016-01-25 2018-12-19 Technogel Italia S.R.L. Temperaturgeregelte polyurethangele

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