EP3275415A1

EP3275415A1 - Products with enhanced healthcare and wellbeing properties

Info

Publication number: EP3275415A1
Application number: EP17275079.6A
Authority: EP
Inventors: Charlesworth David Robert Wood; Carol Diane Hepburn
Original assignee: Baltex
Current assignee: Baltex
Priority date: 2016-07-29
Filing date: 2017-06-01
Publication date: 2018-01-31
Anticipated expiration: 2037-06-01
Also published as: EP3275415B1; PL3275415T3; GB2552550A; GB201613157D0

Abstract

The present invention relates to a product for providing support to a body part of a person, which is able to provide improved healthcare and wellbeing for a person, particularly in relation to minimising or preventing the formation of pressure ulcers, as well as providing relief from such ulcers.

Description

The present invention relates to a product for providing support to a body part of a person, which is able to provide improved healthcare and wellbeing for a person, particularly in relation to minimising or preventing the formation of pressure ulcers, as well as providing relief from such ulcers. Such products include, for example, a cushion or a mattress pad.

BACKGROUND

Any person who sits or lies still without moving their position for a prolonged period of time is much more susceptible to develop damage to the skin and underlying tissue, i.e. in the form of pressure ulcers or pressure sores. As used herein, these terms are interchangeable; however, the term 'pressure ulcers' will be predominantly used. People who are physically less able to move their position regularly, for example the elderly or those who are less mobile, such as those recovering from surgery or those who are predominantly bedridden, are particularly at risk of developing pressure ulcers.
The decubitus ulcer, or pressure ulcer, is an alteration in the integrity of the skin of a person, and is primarily caused by unrelieved pressure. Pressure ulcers can be treated with dressings and creams, but in recent years, pressure ulcers have become a global health concern. This is mainly because they can become costly and potentially life threatening complications if untreated, especially if they become infected. However, they are entirely preventable.
In the UK, about 500,000 people will develop at least one pressure ulcer each year, and about 1 in 20 people admitted to hospital because of a sudden illness will develop a pressure ulcer.
In the prevention and treatment of pressure ulcers, the appropriate support surface has become an important device in creating the right intervention and treatment programme for a person or patient. Pressure, shear and an inadequate microclimate have long since been recognised as some of the most intrinsic factors affecting the development of pressure ulcers in people who are either wheelchair bound, bedridden, or who are largely immobile.
The breathability of a person's skin and integrity of the skin, through the use of a satisfactory microclimate next to the skin, is of vital importance for the wellbeing of a person.
An inadequate microclimate is caused by poor breathability of materials used to manufacture the support surface which is next to a person's skin for a prolonged period of time. If the materials exhibit poor breathability, then the person's skin will also not be able to breathe satisfactorily. When this is the case, perspiration forms on the person's skin. If this cannot be easily removed because the materials making up the support surface do not possess good water vapour diffusion properties, then this leads to the formation of bacteria and poor hygiene on the person's skin. This can lead to discomfort for the person, and even the formation of further unwanted ailments, and eventually pressure ulcers.
In the current area of pressure relieving devices for seated patients, the most vulnerable areas for high pressure have been identified as the ischial tuberosities, the sacral area, and the coccygeal area. For patients confined to bed, then the ischial tuberosities, the sacral, and heel areas are the most vulnerable. It is therefore these areas of the body which require the greatest degree of support and improved microclimate.
However, there is currently a lack of ideal and affordable pressure-relieving devices which pay particular attention to the specific areas of high pressure experienced by a person, and which are able to provide satisfactory levels of pressure, shear and microclimate for a person's skin.
Therefore, in accordance with the invention, there is provided a product for providing support to a body part of a person, the product comprising:

(i) a first layer of a three-dimensional (3D) spacer fabric, and
(ii) a second layer of a three-dimensional spacer fabric;

²

According to one embodiment of the invention, the first layer of three-dimensional spacer fabric has a thickness of between about 5 mm and about 25 mm, a specified compression resistance in the range from about 2 to about 30 kPa, and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96; and the second layer of three-dimensional spacer fabric has a thickness of between about 12 mm to about 25 mm and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96.
According to one embodiment of the invention, if the first and second layers of the spacer fabric together constitute a thickness of about 20 mm or greater, then the product may only comprise these two layers. According to another embodiment of the invention, if the first and second layers of the spacer fabric together constitute a thickness of less than about 20 mm, then a further third layer of a spacer fabric is typically employed, due to the physiology of the anatomy, in order to provide sufficient comfort for a person. The third layer of the spacer fabric typically has a thickness of between about 6 mm to about 35 mm, and a water vapour transfer rate of at least about 600g/m²/24 hours according to ASTM E96.
The 3D spacer fabrics used are typically a knitted or woven fabric, such as warp knitted spacer fabrics.
Three dimensional spacer fabrics are well known in the art. Each individual layer of spacer fabric itself comprises first and second layers, e.g. upper and lower layers, which are interconnected by a spacer material, typically in the form of a yarn material. The spacer material typically knits into, and becomes integral with, each of the upper and lower layers of each individual layer of spacer fabric, often via a warp knitting process. The spacer material is typically a monofilament yarn.
The 3D spacer fabrics, such as the warp knitted spacer fabrics, have the ability to wick moisture and dissipate heat, which are the two most important properties that help to develop a desirable microclimate for the prevention of pressure ulcers. The spacer fabrics also have the ability to redistribute or spread pressure over a much larger area of the product, such as a cushion or mattress pad. However, in the case of immobile seated or supine patients, a higher level of pressure builds up in more specific areas, and this shows up as higher pressure points in the ischial tuberosities and sacral areas at the back of a cushion, and in the sacral, ischial tuberosities and heel areas of a mattress pad. The purpose of the invention is to reduce and redistribute this higher pressure across the whole of the product, thus minimising the pressure at these particular points or areas of the body, and consequentially reducing the incidence of pressure ulcers in these areas.
The 3D spacer fabrics may comprise any suitable material, such as, but not limited to, polyester (including 100% polyester), polyamide, polylactic acid, corn starch based yarns, filament and textured yarns. The fabrics may also include elastomeric yarns, for example a polyester-polyurethane copolymer, such as that marketed under the trade name Lycra®.
The invention is able to achieve this by having a product comprising a plurality of individual layers of 3D spacer fabrics. A minimum of at least two individual layers of 3D spacer fabrics are required for the product of the invention, with each of these two layers possessing specific properties of thickness, water vapour transfer rate, and, in the case of the first layer, also an amount of compression resistance. As mentioned above, the first three-dimensional spacer fabric has a thickness of between about 4 mm and about 35 mm, a specified compression resistance in the range from about 2 to about 30 kPa, and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96; and the second three-dimensional spacer fabric has a thickness of between about 10 mm to about 35 mm and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96.
Alternatively, the product may contain three, four, five or six layers of 3D spacer fabrics. According to one embodiment, the product contains three layers of 3D spacer fabrics; and according to a further embodiment, the product contains four layers of 3D spacer fabrics. These further layers may be situated above and/or below the first and second layers. Typically, in a product comprising four (or more) layers, they are situated both above and below the first and second layers. If there are only three layers, the third layer may be situated either above or below the first and second layers. Typically, the first and second layers are positioned adjacent each other within the product.
When the product contains three or four layers of 3D spacer fabrics, one or two of the layers may comprise one or more sections that have been cut out of the layer of 3D spacer fabric. If there are only three layers, then there is typically only one layer comprising one or more sections that have been cut out of the layer of 3D spacer fabric; if there are four layers, then there may typically be either one or two layers comprising one or more sections that have been cut out of the layer of 3D spacer fabric.
When a section has been cut out of a layer of a 3D spacer fabric, it is typically cut out down to the lower layer of that particular layer, i.e. the upper layer of the individual layer of spacer fabric and the spacer material between the upper and lower layers of the spacer fabric are removed. Also, the cut out section is typically located more towards an edge of the product, such as between about 5-10 cm from an edge - which will be the back of the cushion in its intended orientation, as it is intended that the person's buttocks will rest over this section.
When the product comprises three layers of 3D spacer fabric on top of each other, the layer having a section cut out of it will typically be a middle layer that is sandwiched between the other two layers. In this embodiment, the middle layer with the section cut out will be the first layer of 3D spacer fabric defined above. However, according to another embodiment, the top layer may also have a section cut out from it.
For convenience only, the product shall be described in more detail herein in terms of the embodiment where the product contains four layers of 3D spacer fabrics. However, this is a purely exemplary embodiment, and is in no way to be construed as being limiting upon the scope of the invention.
When the product comprises four layers of 3D spacer fabric on top of each other, there will be two outer layers and two further layers sandwiched between two outer layers. For ease of description, we shall refer to them as layers A, B, C and D, where A is the layer positioned nearest to the body of the person requiring the support, and layer D is the layer positioned at the bottom of the product, which is in contact with the bed or seat the person is positioned on, and thus distal from the surface of the product a person or patient would sit upon. Layers B and C are arranged between layers A and D, with B being the second layer down, and thus adjacent layer A, and layer C being the third layer down, and thus adjacent layer D.
In this embodiment, layers B and C correspond to the first and second layers defined hereinabove, respectively; while the layers A and D correspond to the third and fourth layers defined hereinabove, respectively.
It will be appreciated that while products such as conventional cushions, such those made using polyurethane foam, may be used equally effectively either way up, those in accordance with the invention should be oriented a specific way up, if the optimum effect is to be obtained from it.
In this arrangement, the layer or layers having a section cut out thereof will typically one or both of the middle layers B or C sandwiched between two outer layers A and D.
In one embodiment, both of the middle layers B and C each have a section cut out from them.
In another embodiment, only one of these middle layers B and C has a section cut out from it. When this is the case, then this layer is typically layer B, i.e. the second layer of 3D fabric down from the top in the ideal orientation.
These different embodiments or configurations with the different sections cut out each provide different levels of support for a person, depending on the load requirements. The configuration where both of the middle layers B and C each have a section cut out from them is more suitable for providing support for patients weighing up to about 160 kg, and the configuration where only layer B (or layer C) has a section cut out from it is more suitable for providing support for heavier patients, such as those weighing up to about 300 kg.
The sections are cut out from the layer or layers in specific areas of the layers, coinciding with areas of higher pressure for a person, in order best to encourage the redistribution of pressure in that area for the person. For example, the layer or layers may have sections removed in the region which would contact the ischial tuberosity area of a person, and/or in regions which would contact the sacral area and/or heel area of a person. In the case of a mattress pad, sections may be removed from areas which would contact all three of these parts of a person's body.
Where two layers each have sections removed therefrom, the sections are removed substantially from the corresponding areas of each layer, in order to give additional moulding and support. If desired, the section removed from the layer that is more distal from the person may have a larger area than the section removed from the layer positioned nearer to the person, e.g. the section removed from layer C would typically be larger than that removed from layer B.
According to another embodiment of the invention, further cuts or incisions may be provided on a top surface of one or both of the layers from which sections have been removed. These cuts are located around the section which has been removed, typically being made at the side edges of the removed section and intermittently around the complete circumference of the removed section. Typically, the cuts are positioned substantially equidistantly from the section that has been removed, and at a small distance from the edge, such as between about 1 cm to about 10 cm from the edge, more typically between about 1.5 to about 5 cm, more typically between about 2 cm to about 4 cm from the edge, such as about 2.54 cm (1 inch). The cuts are also typically made between about 2 cm to about 4 cm, such as about 2.54 cm (1 inch), apart from each other, around the circumference of the removed section.
According to another embodiment of the invention, the product comprises castellated foam.
The product of the invention uses a hinging effect of spacer fabric mesh when it is cut on one face only. It allows the material to collapse and absorb the pressure from the person sitting or lying on it, as it effectively distorts according to the shape of the patient. The oval shape of the distortion is more adapted to the shape of the body than the castellation that is currently used.
This is intended to encourage further moulding of the spacer fabric around the ischial tuberosity areas of the buttocks, which encourages the movement and redistribution of high pressure from this area to other contact areas with the cushion and in particular the thigh or leg areas.
Typically, these cuts are applied to the layer located nearer to the person being supported, i.e. layer B. When this is the case, and a section of the 3D spacer fabric is also removed from the layer below (layer C), then the size of the section removed from layer C is typically approximately the same size as that formed by the cuts around the removed section in layer above (i.e. layer B).
According to another embodiment of the invention, the product comprises first, second, third and fourth layers of a 3D spacer fabric, wherein the first layer of three-dimensional spacer fabric has a thickness of between about 4 mm and about 35 mm, a specified compression resistance in the range from about 2 to about 30 kPa, and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96; and wherein the second layer of three-dimensional spacer fabric has a thickness of between about 10 mm to about 35 mm and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96;
wherein the first and second layers are adjacent each other;
further comprising one or more shaped sections of a 3D spacer fabric located on top of the first layer; and
further comprising a third layer located on top of the first layer and the shaped sections of 3D spacer fabric, and a fourth layer located underneath the second layer.
The one or more shaped sections of 3D spacer fabric are intended to provide support and relief for a person's thighs. Typically, there are three shaped sections of 3D spacer fabric - one which is located centrally towards a front edge of a cushion product, which would be located between a person's thighs in a regular seating position, and which is contoured in shape; and one on each side of the cushion product, which would be located at the sides of a person's thighs in a regular seating position. However, only the central shaped section may be used, if desired. When all three are employed, the product takes on a wave-like appearance, which is more designed and shaped to fit a person's body.
The top layer - which we have denoted as layer A above - is typically overlaid on the contoured sections of 3D spacer fabric.
In this embodiment, sections may be cut out from one or two layers. In one alternative, only the first layer has a section cut out from it; however, in another alternative, both the first and second layers have sections cut out therefrom.
In the embodiment where sections are cut out from two layers, i.e. both of the first and second layers, the first layer also comprises incisions made around the section that has been removed. These incisions extend substantially down to the lower layer of the first layer, cutting through the upper layer and spacer material only.
According to a further embodiment of the invention, the product of the invention according to any of the embodiments defined hereinabove may further comprise a base layer (which we shall denote as layer E) positioned underneath the other layers. The base layer is typically of a more rigid material than any of the layers A-D, and, when present, is the layer most distal from the person sitting or lying on the product.
The product of the invention comprising the two or more layers is typically encased in a sealed outer covering, and then also a secondary removable cover, which is also typically made of warp knitted spacer fabric.
According to one embodiment of the invention, the product may be a cushion, such as a sofa cushion or a wheelchair cushion, or it may be a mattress pad. The invention is able to enhance the desirable properties of the uniquely contoured multi-layer spacer fabric cushions and mattress pads in order to spread the high pressure points over the whole area of novel and uniquely designed variety of pressure relieving cushions and mattress pads. The product is able to provide postural support, effective pressure distribution, and immersion and support of the pelvic bone and or heel section, sacrum and scapula areas, which is key to providing effective patient support; and, in the case of a cushion positioning for those sitting on a wheelchair cushion, or in the case of a mattress pad, comfortable supine positioning and pressure redistribution.
According to one particular embodiment of the invention, the product is to be used as a cushion for a seating system, such as a recliner chair, a sofa cushion or a wheelchair cushion. A seating system using the product of the invention provide postural support, an effective pressure distribution for maximum comfort of a person, and immersion and support of the pelvic bone.
In the embodiment where the product is a cushion, such as a wheelchair cushion, only two layers of the 3D spacer fabric are typically used. The cushion is constructed in such a way that leg abductors and adductors are provided by folding the spacer fabric back upon itself to provide a raised section. The combination of the abducting and adducting sections in conjunction with the excellent support to the pelvic bone as already described provide overall postural support to the cushion and any seating system using this configuration.
When the product is a cushion, it can be used as a postural support system which may be embedded within seating systems such as recliner chairs, wheelchairs, aircraft seats, vehicle seats (car, van or lorry), office chairs, or other cushioned seating surfaces.
Also provided within the present invention is a method of manufacturing a product as defined hereinabove, the method comprising:

(i) providing a first layer of a three-dimensional (3D) spacer fabric, and
(ii) providing a second layer of a three-dimensional spacer fabric;

²

The invention will now be described further by way of example with reference to the following figures, which are intended to be illustrative only and in no way limiting upon the scope of the invention.

Figure 1 depicts an end-on cross sectional view of a cushion according to one embodiment of the invention.
Figure 2 depicts a plan view of Layer B of the cushion of the embodiment shown in Figure 1.
Figure 3 depicts a plan view of Layer C of the cushion of the embodiment shown in Figure 1.
Figure 4 depicts a plan view of the bottom Layer D of the cushion of the embodiment shown in Figure 1.
Figure 5 depicts an end-on cross-sectional view of a cushion according to a further embodiment of the invention.
Figure 6 depicts a plan view of Layer B of the cushion of the embodiment shown in Figure 5.
Figure 7 depicts a plan view of Layer C of the cushion of the embodiment shown in Figure 5.
Figure 8 depicts a plan view of the bottom Layer D of the cushion of the embodiment shown in Figure 5.
Figure 9 depicts a front cross-sectional view of a cushion according to a further embodiment of the invention.
Figure 10 depicts a reverse cross-sectional view of a cushion according to this further embodiment of the invention.
Figure 11 depicts a side profile view of a cushion according to this further embodiment of the invention.
Figure 12 depicts a front cross-sectional view of a cushion according to a further embodiment of the invention.
Figure 13 depicts a reverse cross-sectional view of a cushion according to this further embodiment of the invention.
Figure 14 shows an overhead perspective of the first layer of a cushion comprising the shaped sections of 3D spacer fabric according to the embodiments of the invention depicted in Figures 9-13.

In Figure 1, a cushion 2 is shown, having an exterior removable cover 4 and a sealed cover 6, located underneath the removable cover 4. This has a thickness of 2.5 mm. The four different layers of the 3D spacer fabric of this embodiment of the invention are all contained and arranged within the sealed cover 6.
The top or uppermost layer 8 (previously described hereinabove as layer A) of the 3D spacer fabric is the uppermost layer immediately adjacent the sealed cover 6, and is most proximal to the surface 10 of the cushion 2 upon which a person would sit. This is also illustrated by the presence of the contour in the surface 10. The top layer 8 extends across the full width of the cushion 2, and is also contoured to follow the curve of the contour. This layer 8 has a thickness of 6 mm.
The next layer 14 (previously described hereinabove as layer B) is located immediately underneath the top layer 8 of the 3D spacer fabric, and has a thickness of 20 mm. This layer 14 has had a section 16 cut out from it, and also comprises further cuts 18 around the removed section 16, which cuts 18 extend most of the way through the layer 14, but not completely through it. These cuts 18 create portions 20 and 22 of the layer 14 which are only connected to the remainder of the layer 14 by a smaller piece thereof, and which can thus follow the contour 12 and slope slightly inwards towards the central space of the cushion created by the removed sections 16 and 28 (the latter of which is discussed below), when providing support to a person sitting thereon.
The next layer 26 (previously described hereinabove as layer C) is located immediately underneath the layer 14 of the 3D spacer fabric, and also has a thickness of 20 mm. A section 28 has also been removed from this layer 26. The size of this removed section 28 corresponds with the position of the cuts 18 made around the removed section 16 in layer 14.
It will be appreciated that the cross-section to provide the view in Figure 1 is taken from a point within the removed sections 16 and 28.
This embodiment of the invention, with sections removed from both of the layers 14 and 26, is more suitable for providing support for heavier patients, such as those weighing up to about 300 kg.
The bottom layer 30 (previously described hereinabove as layer D) is located immediately underneath the layer 26 of the 3D spacer fabric, and is adjacent the sealed cover 6. This layer 30 is complete, with no sections being removed therefrom. It also has a thickness of 20 mm.
In Figure 2, an overhead view of the layer 14 can be seen, with the section 16 having already been cut out of it. The further cuts 18 in the layer 14 can also be seen around the removed section 16. These cuts are intermittent around the removed section 16, but allow for a greater degree of moulding and re-distribution of pressure from the more highly affected areas, such as the ischial tuberosity. The cuts 18 extend most of the way through the layer 14, but not all of the way through it, as shown in Figure 1.
In Figure 3, an overhead view of the layer 26 can be seen, with the section 28 having already been cut out of it. As mentioned, the size of this removed section 28 corresponds with the position of the cuts 18 made around the removed section 16 in layer 14.
In Figure 4, an overhead view of the layer 30 can be seen. This layer 30 is complete, with no sections having been removed.
In Figure 5, another embodiment of the invention is depicted. A cushion 32 is shown, having an exterior removable cover 34 and a sealed cover 36, located underneath the removable cover 34. The four different layers of the 3D spacer fabric of this embodiment of the invention are all contained and arranged within the sealed cover 36. The dimensions of all the layers are the same as those in Figure 1.
The top layer 38 (previously described hereinabove as layer A) of the 3D spacer fabric is the uppermost layer immediately adjacent the sealed cover 36, and is most proximal to the surface 40 of the cushion 32 upon which a person would sit. This is also illustrated by the presence of the contour in the surface 40. The top layer 38 extends across the full width of the cushion 32 with no sections removed, and also follows the curve of the contour.
The next layer 44 (previously described hereinabove as layer B) is located immediately underneath the top layer 38 of the 3D spacer fabric. This layer 44 has had a section 46 cut out from it, and also comprises further cuts 48 around the removed section 46, which cuts 48 extend most of the way through the layer 44, but not completely through it. These cuts 48 create portions 50 and 52 of the layer 44 which are only connected to the remainder of the layer 44 by a smaller piece thereof, and which are pushed downwards as a result when providing support to a person sitting thereon.
The next layer 56 (previously described hereinabove as layer C) is located immediately underneath the layer 44 of the 3D spacer fabric. This layer 56 is complete, with no sections being removed therefrom.
It will be appreciated that the cross-section to provide the view in Figure 5 is taken from a point within the removed section 46.
This embodiment of the invention, with a section only having been removed from layer 44, is more suitable for providing support for patients weighing up to about 160 kg.
The bottom layer 60 (previously described hereinabove as layer D) is located immediately underneath the layer 56 of the 3D spacer fabric, and is adjacent the sealed cover 6. This layer 60 is complete, with no sections being removed therefrom.
In Figure 6, an overhead view of the layer 44 can be seen, with the section 46 having already been cut out of it. Further cuts 48 in the layer 44 can also be seen around the removed section 46. These cuts are intermittent around the removed section 46, but allow for a greater degree of moulding and re-distribution of pressure from the more highly affected areas, such as the ischial tuberosity. The cuts 48 extend most of the way through the layer 44, but not all of the way through it.
In Figure 7, an overhead view of the layer 56 can be seen. Unlike in the embodiment shown in Figure 3 above, this layer 56 is complete, with no sections having been removed.
In Figure 8, an overhead view of the layer 60 can be seen. This layer 60 is also complete, with no sections having been removed.
In Figure 9, a front cross-sectional profile of a cushion according to a further embodiment of the invention can be seen.
A cushion 64 is shown, having an exterior removable cover 66 and a sealed cover 68, located underneath the removable cover 66. The four different layers of the 3D spacer fabric of this embodiment of the invention are all contained and arranged within the sealed cover 68.
The top layer 70 (previously described hereinabove as layer A) of the 3D spacer fabric is the uppermost layer immediately adjacent the sealed cover 68, and is most proximal to the surface of the cushion 64 upon which a person would sit.
Underneath the top layer 70 are three shaped sections of 3D spacer fabric 72, 74 - one positioned centrally (72), and one at either side of the cushion (74). The 'wave-like' contour appearance 78 of the cushion containing these three shaped sections of 3D spacer fabric 72, 74 can clearly be seen. The central shaped section 72 is position so it would be located between a person's thighs in a regular seated position.
The top layer 70 extends across the full width of the cushion 64 with no sections removed, and also follows the curve of the contour of the surface of the cushion.
The next layer 80 (previously described hereinabove as layer B) is located immediately underneath the top layer 70 of the 3D spacer fabric. The next layer 82 (previously described hereinabove as layer C) is located immediately underneath the layer 80 of the 3D spacer fabric; The next layer 84 (previously described hereinabove as layer D) is located immediately underneath the layer 82 of the 3D spacer fabric; and a base layer 86 (previously described hereinabove as layer E) is located immediately underneath the layer 84 of the 3D spacer fabric. In the front cross-sectional profile shown in Figure 9, none of the layers 70, 80, 82 or 84 have any sections shown to have been cut out.
The reverse cross-sectional profile is shown in Figure 10. As with the profile shown in Figure 9, the top layer 70 extends across the full width of the cushion 64 with no sections removed, and also follows the curve of this contour 88.
In this cross-sectional profile, it can be seen that the layer 80 has had a section cut out from it and also comprises further cuts 90 around the removed section, which cuts 90 extend most of the way through the layer 80, but not completely through it. These cuts 90 create portions 92 and 94 of the layer 80 which are only connected to the remainder of the layer 80 by a smaller piece thereof (i.e. the lower layer of fabric), and which are pushed downwards as a result when providing support to a person sitting thereon.
The next layer 82 (layer C) located immediately underneath the layer 80 of the 3D spacer fabric also has a section removed therefrom; while the layer 84 located immediately underneath the layer 82 does not have any section removed. The base layer 86 is again seen located immediately underneath the layer 84.
The side profile view of the cushion 64 shown in Figure 11 shows the central shaped section 72 of 3D spacer fabric, and a recess 96 which is formed by the removal of the sections in the layers 80 and 82, and which becomes more apparent when a person sits on the cushion 64.
The front and reverse profiles of a variant of this embodiment are shown in Figures 12 and 13. In Figure 12, it can be seen that the profile is essentially the same as in Figure 9, though in this figure the optional base layer is not included. The difference can be seen in Figure 13, as the layer 82 in this variant does not have a section removed.
In Figure 14, an overhead perspective of the first layer of a cushion comprising the shaped sections of 3D spacer fabric according to the embodiments of the invention depicted in Figures 9-13 can be seen, with the central shaped section 72 and the side shaped sections 74 visible, as well as the removed section 98 positioned towards the back of the layer.
The invention will now be described further by way of example with reference to the following examples which are intended to be illustrative only and in no way limiting upon the scope of the invention.

EXAMPLES

Pressure mapping tests were carried out using a Rigid Cushion Loading Indenter (RCLI) as a template to represent the typical human 'buttocks' (BS ISO 16840 - 2:2007). The load was applied using a 'Denison Universal Tester' (heavy duty). These pressure mapping tests were carried out on different embodiments of the present invention, and also with a conventionally used polyurethane foam cushion.

'ASD4' (shaped full recess only) [tested to weight range = 50.2 kg-76.5 kg (8 - 12st)]

'ASD5' (shaped partial recess only) [tested to weight range = 50.2 kg-76.5 kg (8 - 12st)]

'Baltex AS300' - Contoured Development [tested to weight range = 50.2 kg-76.5 kg (8 - 12st)]

'ASD4-S' (new AS400) Fully Contoured development [tested to weight range = 50.2 kg-76.5 kg (8-12st)]

Conventional Polyurethane Foam (Comparison) [tested to weight = 76.5 kg (12st)]

ASD4 = the embodiment shown in Figure 1
ASD5 = the embodiment shown in Figure 5
ASD4-S = the embodiment shown in Figures 9-11.

It can therefore be seen that the maximum and mean pressure profiles after 15 minutes for a load at 0.750 kN/76.5 kg (12 st) for the various embodiments of the invention are 105.1, 134.6, 135.6 and 123.4 mmHg. These values are all significantly lower than the 200.0 mmHg which is observed for the conventional polyurethane foam.
It therefore follows that a person of limited mobility who sits on one of the cushion products of the invention has a much lower level of pressure being applied at specific pressure points in their body, which will desirably result in a much lower incidence of pressure sores and ulcers.
It is of course to be understood that the present invention is not intended to be restricted to the foregoing examples which are described by way of example only.

Claims

A product for providing support to a body part of a person, the product comprising:
(i) a first layer of a three-dimensional (3D) spacer fabric, and

(ii) a second layer of a three-dimensional spacer fabric;
wherein the first layer of three-dimensional spacer fabric has a thickness of between about 4 mm and about 35 mm, a specified compression resistance in the range from about 2 to about 30 kPa, and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96; and
wherein the second layer of three-dimensional spacer fabric has a thickness of between about 10 mm to about 35 mm and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96.
A product according to claim 1, wherein the first layer of three-dimensional spacer fabric has a thickness of between about 5 mm and about 25 mm; and the second layer of three-dimensional spacer fabric has a thickness of between about 12 mm to about 25 mm.
A product according to claim 1 or claim 2, wherein the product further comprises a third layer of a three-dimensional spacer fabric;
wherein the third layer optionally has a thickness of between about 6 mm to about 35 mm, and a water vapour transfer rate of at least about 600g/m²/24 hours according to ASTM E96;
wherein the product further optionally comprises a fourth layer of a three-dimensional spacer fabric.
wherein the first and second layers are optionally adjacent each other; further comprising one or more shaped sections of a 3D spacer fabric located on top of the first layer; and further comprising a third layer located on top of the first layer and the shaped sections of 3D spacer fabric, and a fourth layer located underneath the second layer. wherein a shaped section of a 3D spacer fabric is optionally located centrally towards a front edge of a cushion product, such that it would be located between a person's thighs in a regular seating position.
A product according to claim 3, further comprising a shaped section of a 3D spacer fabric located on each side of the cushion product, such that they would be located at the sides of a person's thighs in a regular seating position.
A product according to any preceding claim, wherein one or more of the layers each has a section removed therefrom.
A product according to claim 5, wherein only one of the layers has a section removed therefrom, wherein the one layer having a section removed therefrom is optionally the second layer.
A product according to claim 5, wherein two of the layers each independently have a section removed therefrom, wherein the two layers each having a section removed therefrom are optionally the second layer and the third layer.
A product according to any of claims 5-7, wherein the second layer comprises a plurality of further individual incisions positioned around the section that has been removed, wherein the incisions are optionally positioned substantially equidistantly from the section that has been removed, and wherein the incisions are optionally positioned from about 1 to about 10 cm from the section that has been removed.
A product according to any of claims 5-8, wherein the section removed from the third layer is larger than the section removed from the second layer, wherein the section removed from the third layer is optionally substantially the same size as an area formed by the incisions around the section that has been removed in the second layer.
A product according to any of claims 5-9, wherein the section or sections which are removed from the layer or layers is/are located in order to provide enhanced support to one or more of the ischial tuberosities, sacral or heel region of a person's body.
A product according to any preceding claim, wherein the 3D spacer fabrics comprise a material selected from polyester, polyamide, polylactic acid, corn starch based yarn, filament and textured yarn, and elastomeric yarn.
A product according to any preceding claim, wherein the product is a cushion or mattress pad.
A product according to any preceding claim for the prevention and treatment of a pressure ulcer.
A method of manufacturing a product according to any preceding claim, the method comprising:
(i) providing a first layer of a three-dimensional (3D) spacer fabric, and

(ii) providing a second layer of a three-dimensional spacer fabric;
wherein the first layer of three-dimensional spacer fabric has a thickness of between about 4 mm and about 35 mm, a specified compression resistance in the range from about 2 to about 30 kPa, and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96; and
wherein the second layer of three-dimensional spacer fabric has a thickness of between about 10 mm to about 35 mm and a water vapour transfer rate greater than 1000g/m²/24 hours according to ASTM E96; and

iii) combining the first and second layers, with the first layer being located on top of the second layer.
Use of a product according to any of claims of 1-12 in providing physical support to a person.