GB2502867A - Cushioning fabric - Google Patents

Cushioning fabric Download PDF

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Publication number
GB2502867A
GB2502867A GB1306094.2A GB201306094A GB2502867A GB 2502867 A GB2502867 A GB 2502867A GB 201306094 A GB201306094 A GB 201306094A GB 2502867 A GB2502867 A GB 2502867A
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GB
United Kingdom
Prior art keywords
fabric
cushioning
kpa
compression resistance
fabrics
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB1306094.2A
Other versions
GB201306094D0 (en
GB2502867B (en
Inventor
Subhash Chander Anand
Charlesworth David Robert Wood
Bryan Thomas Mcardle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ball & Son Ltd W
University of Bolton
Original Assignee
Ball & Son Ltd W
University of Bolton
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ball & Son Ltd W, University of Bolton filed Critical Ball & Son Ltd W
Publication of GB201306094D0 publication Critical patent/GB201306094D0/en
Publication of GB2502867A publication Critical patent/GB2502867A/en
Application granted granted Critical
Publication of GB2502867B publication Critical patent/GB2502867B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61GTRANSPORT, PERSONAL CONVEYANCES, OR ACCOMMODATION SPECIALLY ADAPTED FOR PATIENTS OR DISABLED PERSONS; OPERATING TABLES OR CHAIRS; CHAIRS FOR DENTISTRY; FUNERAL DEVICES
    • A61G7/00Beds specially adapted for nursing; Devices for lifting patients or disabled persons
    • A61G7/05Parts, details or accessories of beds
    • A61G7/057Arrangements for preventing bed-sores or for supporting patients with burns, e.g. mattresses specially adapted therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026Knitted fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B68SADDLERY; UPHOLSTERY
    • B68GMETHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G11/00Finished upholstery not provided for in other classes
    • B68G11/02Finished upholstery not provided for in other classes mainly composed of fibrous materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B68SADDLERY; UPHOLSTERY
    • B68GMETHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G5/00Resilient upholstery pads
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04BKNITTING
    • D04B21/00Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04BKNITTING
    • D04B21/00Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2479/00Furniture
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00Details of fabric structure established in the fabric forming process
    • D10B2403/02Cross-sectional features
    • D10B2403/021Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00Industrial
    • D10B2505/08Upholstery, mattresses

Landscapes

  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Textile Engineering (AREA)
  • Nursing (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Mechanical Engineering (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

A cushioning fabric comprises a combination of at least two different 3D fabrics: (i) 5mm to 8mm thick knitted spacer fabric with compression resistance from 25 to 100 kpa (at 40% compression stress value according to EN ISO 3386-1:1997); and (ii) 9mm to 15mm thick knitted spacer fabric with compression resistance in the range from 25mm to 100kpa. The cushion fabric may further comprise a 3d knitted cover fabric which is 2 to 7mm thick and has a compression resistance of10-50kpa. At least two of the layers of fabric may be held together by stitching or adhesive. The fabric may be used for mattresses or wheel-chair cushions to prevent pressure sores on an immobile patient.

Description

CUSHIONING FABRIC
The present invention relates to a fabric, having particular, but not exclusive application in mattresses, cushions, other furniture and the like.
There is currently a lack of satisfactory and affordable mattresses, cushions and other furniture which prevent the formation of pressure sores on an immobile patient. Previous methods of dealing with this issue have proven to be costly.
The present invention has been made from a consideration of this problem.
According to a first aspect of the present invention there is provided a cushioning fabric comprising a combination of at least two different 3D fabrics defined as follows:-(i) from 5mm to 8mm of knitted spacer fabric with a specified range of compression resistance in the range from 25 to 100 kpa; and (U) from 9mm to 15mm of at least one knitted spacer fabric with a specified range of compression resistance in the range from 25mm to 1 Ookpa.
According to a second aspect of the present invention there is provided the use of a fabric of the first aspect of the invention as cushioning.
Cushions made using the cushioning fabric of the invention have various innovative and unique features. For example, they are much better at reducing peak pressures than polyurethane foam and they distribute the pressure evenly over much larger areas of the cushions or seats than polyurethane foam. Thicker warp-knitted spacer structures or several layers may be used to obtain higher thickness and increased pressure relief. The cushions of the invention conform to the shape of the body and minimize friction and shearing forces. They also provide a well-ventilated, comfortable surface that does not unduly restrict movement and maintains skin at a constant temperature. The cushions of the invention may be laundered in a washing machine, may be non-flammable and can easily be recycled, as conventionally they would be constructed from a single material type, for example polyester multi-filament and mono-filament yarns. The cushioning fibres of the invention have sufficient compressive strength to support the person without "bottoming out". They are particularly beneficial to people who are prone to developing pressure sores, due to prolonged periods of sitting in wheel chairs and other support systems.
In a preferred embodiment of the invention the cushioning fabric comprises a combination of three knitted 3D fabrics.
The cushioning fabric may comprise one or more additional 3D fabrics, such as 3D knitted or 3D nonwoven materials.
In a preferred embodiment the 3D knitted fabrics are made on different gauges of machine.
The individual 3D fabrics may be connected together by stitching and/or adhesive.
In one preferred embodiment of the invention the fabric comprises a construction of the following:-i) a 2 to 7mm spacer fabric-either warp-knitted or weft-knitted with a compression resistance in the range from 10 to 50 kpa, more preferably from 10 to 30 kpa and most preferably of substantially 23 kpa.
ii) at least one 6mm spacer fabric with a specified range of compression resistance in the range from 25 to 100 kpa, more preferably from 25 to kpa and most preferably of substantially 36 kpa.
Ui) at least one 12mm spacer fabric, also with a specified range of compression resistance in the range from 25 to 100 kpa, more preferably from 30 to 60 kpa and most preferably of substantially 43 kpa.
The compression resistance measurements were carried out at 40% CV (compression stress value) according to the European Standard EN ISO 3386-1:1997.
Trials carried out on the pressure and distribution reaction from the cushions to compression using the cushions of the invention, having either three or four different spacer fabrics, have established that one preferred combination of different warp-knitted Spacer structures is as follows: Direction of Fabric Spacer Fabric Quality Fabric Thickness Walewise Quality M3730 2.5mm (Cover) Walewise Quality M3600 6.0mm (Top) Walewise Quality M3420 11.0mm (Middle) Walewise Quality M3550 21.0mm (Bottom) Total Thickness: 40.5mm The combination of 3D fabrics within the fabrics of the invention provides excellent hydrostatic support and uniform pressure distribution. The combination of spacer fabrics conforms to different shapes and provides hydrostatic loading against uni-directional loading. It reacts from all angles.
The materials recover due to their superior resilience and consequently provide support for long periods of time and provide durability, unlike memory foams. The combination of materials offers uniform pressure distribution regardless of the shape of person or object placed on the cushion. The structure and layout of the monofilaments with different spacings can be adapted to provide differing degrees of hardness and support. The combination may also provide differing levels of breathability. The breathability of the materials used provides superior skin tone to people sitting or lying on cushions or mattresses made in this way due to the level of air circulation which results in better hydration to the patient or user's skin.
In one embodiment of the invention gels or other hardening agents such as resins may also be used to modify the performance of the combination of materials.
In order that the present invention may be more readily understood specific embodiments thereof will now be described by way of example only with reference to the accompanying drawings in which:-Fig. 1 is an illustrative photograph of a cushioning fabric in accordance with the invention; Fig. 2 is an illustrative photograph of a second cushioning fabric in accordance with the invention.
Figs. 3 to 6 illustrate the effects of loading; Fig. 7 comprises the distribution of the pressure on a seat with no cushion, with polyurethane foam and with a warp-knitted spacer fabric cushion of the invention; and Fig. 8 shows pressure mapping of cushions using the fabrics of the invention.
Referring to Fig. 1, a cushion has a cover fabric and at least two internal layers including one or two layers of a first 3D spacer fabric and one layer of a second 3D spacer fabric. A spacer fabric comprises two separate fabric faces knitted independently and then connected by a separate spacer yarn. These fabrics can be produced on both circular and flat knitting machines. Details of the first 3D spacer fabric are specified below. The first fabric is a 6mm thick warp-knitted spacer fabric produced on a 16 gauge double needle bar warp-knitting machine.
COVER FABRIC
Fabric description: Knitted Spacer Fabric -Weft Knit or Warp-knit Composition: 100% Polyester, Nylon or Natural Spun yarns or blend thereof Width 140 cm Weight 200-500 GM/M2 Thickness 2-7 mm Compression strength 10-50 kpa @ 40% Compression, ISO 3386-1
FIRST FABRIC
Fabric description Memory XD -Spacer
Composition 100% Polyester Colour White Width 140 cm Weight 500-800 GM/M2 Thickness Sto8mm BS EN ISO 5084 Compression strength 25-10 kpa @ 40% Compression, ISO 3386-1 The cushion further comprises a single layer of a second 3D fabric. The second 3D fabric is a 12mm thick spacer fabric produced on a 12 gauge double-needle bar warp-knitting machine. Details of the second fabric are set out below.
SECOND FABRIC
Fabric description Polyester Spacer XD
Composition 100% Polyester Colour White Width 200 cm Weight 800-1200 GM/M2 Thickness 9tol5mm BS EN ISO 5084 Compression strength 25-1 00 kpa@ 40% Compression, ISO 3386-Referring to Fig. 2 the fabric of the invention comprises a cover of 3mm spacer fabric with one layer out of the first fabric described hereinbefore and one layer of the second fabric described hereinbefore both the first and second fabrics being located inside the cover.
The features as described in Fig. 1 and Fig. 2 both provide superior uniform pressure distribution and hydrostatic support.
Ideally cushions should conform to body contours, thus increasing the area of the body supporting its weight and avoiding local points of high pressure. The harder the support surface the higher the pressures experienced.
A soft support surface is better able to distribute pressure evenly and reduce the pressure gradients that lead to tissue distortion. However, low tissue distortion support needs to take into account the difference between unidirectional (Uniaxial) and hydrostatic loading (see Figs. 3, 4 and 5).
Figure 3 illustrates hydrostatic loading, whilst Figure 4 depicts uniaxial loading, in which the body "bottoms out" and cause tissue distortion, resulting in capillary occlusion and the causing of pressure ulcers. One object of this invention is to provide a support system which emulates hydrostatic support, in that the patient is buoyant and "floats" e.g. without "bottoming out", as shown in Figure 4. Figures 5A, 5B and 5C illustrate the mechanism involved in uniaxial and hydrostatic loading. Figure 6a illustrates a hydrostatic support in which the reaction from different parts of the body are very similar which should result in an even distribution of pressure over the whole area of the body in contact with the pressure relieving cushion.
Research has confirmed that the cushions constructed from a combination of different number of spacer fabrics distribute the pressure evenly across the whole area of contact or the body with the cushions and moreover, they reduce the maximum or peak pressures experienced by the body, contact sitting on these cushions for long periods of time.
Research carried out has also demonstrated that the peak pressures at the buttocks on the seat with different cushion materials are different and are substantially reduced when sitting on Warp-knitted spacer cushions Figure 7c, when compared with a seat with no cushion, Figure 7a, and a seat with a polyurethane cushion, Figure 7b.
It is also interesting to observe in Figure 7 that the pressure is distributed over a larger area in warp-knitted cushions than in polyurethane foam cushions.
Pressure mapping trials carried out on cushions of the invention have also confirmed that the pressure distribution on the buttock are extremely uniform and the pressures generated at the buttock are from low to medium across the whole surface see Figure 8.
It is to be understood that the above described embodiments are by way of illustration only. Many modifications and variations are possible.

Claims (10)

  1. CLAIMS1. A cushioning fabric comprising a combination of at least two different 3D fabrics defined as follows:- (i) from 5mm to 8mm of knitted spacer fabric with a specified range of compression resistance in the range from 25 to 100 kpa; and (ii) from 9mm to 15mm of at least one knitted spacer fabric with a specified range of compression resistance in the range from 25mm to lOOkpa.
  2. 2. A cushioning fabric as claimed in claim 1, wherein said fabrics (i) and (ii) are covered with a cover fabric.
  3. 3. A cushioning fabric as claimed in claim 2, wherein the cover fabric is defined as follows:- (Di) from 2 to 7mm of 3D knitted spacer fabric with a compression resistance in the range from 10 to 50 kpa.
  4. 4. A cushioning fabric as claimed in any preceding claim, wherein the compression resistance of the first fabric (i) is in the range from 10 to 30 kpa.
  5. 5. A cushioning fabric as claimed in any preceding claim, wherein the compression resistance of the second fabric (ii) is in the range from 25 to 50 kpa.
  6. 6. A cushioning fabric as claimed in claim 2, wherein the cover fabric has a compression resistance in the range from 30 to 60 kpa.
  7. 7. A cushioning fabric as claimed in any preceding claim, wherein at least two 3D fabrics are connected together by stitching and/or an adhesive.
  8. 8. A cushioning fabric as claimed in any preceding claim, comprising at least one further 3D fabric.
  9. 9. A cushioning fabric substantially as described herein with reference to Fig. 1 or Fig. 2.
  10. 10. The use of a fabric as claimed in claim 1 as cushioning.
GB1306094.2A 2012-04-04 2013-04-04 Cushioning fabric Active GB2502867B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB1206001.8A GB201206001D0 (en) 2012-04-04 2012-04-04 Cushioning fabric

Publications (3)

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GB201306094D0 GB201306094D0 (en) 2013-05-22
GB2502867A true GB2502867A (en) 2013-12-11
GB2502867B GB2502867B (en) 2014-08-27

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GB1306094.2A Active GB2502867B (en) 2012-04-04 2013-04-04 Cushioning fabric

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015101632A1 (en) * 2013-12-31 2015-07-09 Sense Textile B.V. A 3-dimensional knitted textile spacer fabric and use thereof in a system for health care
EP3031435A1 (en) * 2014-12-09 2016-06-15 Medstrom Limited Mattress or mattress overlay
EP3275415A1 (en) * 2016-07-29 2018-01-31 Baltex Products with enhanced healthcare and wellbeing properties
GB2569653A (en) * 2017-12-22 2019-06-26 Regis Fabrics Ltd Laminated fabric article

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004339652A (en) * 2003-05-16 2004-12-02 Asahi Kasei Fibers Corp Three-dimensional knitted fabric laminate
JP2006296616A (en) * 2005-04-19 2006-11-02 Asahi Kasei Fibers Corp Mat for bed
EP1775362A1 (en) * 2005-10-13 2007-04-18 Müller Textil GmbH Textile spacer fabric with zones of different compression hardness

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004339652A (en) * 2003-05-16 2004-12-02 Asahi Kasei Fibers Corp Three-dimensional knitted fabric laminate
JP2006296616A (en) * 2005-04-19 2006-11-02 Asahi Kasei Fibers Corp Mat for bed
EP1775362A1 (en) * 2005-10-13 2007-04-18 Müller Textil GmbH Textile spacer fabric with zones of different compression hardness

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015101632A1 (en) * 2013-12-31 2015-07-09 Sense Textile B.V. A 3-dimensional knitted textile spacer fabric and use thereof in a system for health care
EP2918715A1 (en) * 2013-12-31 2015-09-16 Sense Textile B.V. A 3-dimensional warp knitted textile spacer fabric and use thereof as a decubitus preventing mini mattress
EP3031435A1 (en) * 2014-12-09 2016-06-15 Medstrom Limited Mattress or mattress overlay
EP3275415A1 (en) * 2016-07-29 2018-01-31 Baltex Products with enhanced healthcare and wellbeing properties
GB2569653A (en) * 2017-12-22 2019-06-26 Regis Fabrics Ltd Laminated fabric article

Also Published As

Publication number Publication date
GB201306094D0 (en) 2013-05-22
GB2502867B (en) 2014-08-27
GB201206001D0 (en) 2012-05-16

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