GB2570647A

GB2570647A - Mattress/Cushion and Kit

Info

Publication number: GB2570647A
Application number: GB1801273.2A
Authority: GB
Inventors: Noel Daly Patrick
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-01-26
Filing date: 2018-01-26
Publication date: 2019-08-07
Also published as: GB201801273D0

Abstract

A cushion or mattress comprising an envelope 12 with laminated inner 14 and outer 16 layers and a resilient core 17 formed from open cell foam with upper and lower layers made of viscoelastic form and a central layer of resilient foam wherein the envelope is impermeable to air and liquid, the inner layer is attached to an upper layer of the core and a plurality of micro channels are formed on the top of the envelope. The envelope 12 can form a sealed chamber which is filled by the core 17. A bore may be provided in the core to allow air flow. A removable cover to provide vapour diffusion may be provided. The envelope 12 may have carrying means such as a strap, harness or handle. The device is designed to reduce the incidence of pressure sores and to make it easier to clean.

Description

The present invention relates to a Cushion/Mattress, particularly an inflatable Cushion/Mattress and a kit comprising a Cushion/Mattress.

The provision of a Cushion/Mattress, e.g. a foam or air Cushion/Mattress, is well known in the art, especially for the purpose of alleviating, or reducing the incidence of, pressure sores. It is often desirable for Cushion/Mattress to be supplied for such use in a domestic or care home setting on an as-needed basis.

Inflatable Cushion/Mattress, for example self-inflating Cushion/Mattress comprising a foam material are known. These Cushions/Mattresses may be contained in covers which are typically weave-backed fabric with outer sprayed-on or spread-on plastic coatings. The Cushion/Mattress is placed inside covers. These covers can be removable by opening a zipper at one end of the cover, or by similar means. Such Cushions/Mattresses typically comprise standard foams and are usually made with more than one foam density/hardness to achieve a strategic absorption of load. The Cushion/Mattress described in US 5,282,286 can be actively pressurised by a pump system. The Wheelchair Cushion/Mattress has a coated knit/woven surface sealed to and encapsulating the foam core. During use, the coating is can be subject to wear and/or can easily be damaged, exposing the weave to the environment potentially resulting in contamination of the fabric or even the foam core. If the weave of the cover or the foam core units becomes contaminated, it is extremely difficult to clean, especially to disinfect, and specialist machinery may be required to achieve safe disinfection and/or decontamination. The process is expensive and inconvenient, and can be unsuccessful.

Thus, for the Cushion/Mattress outlined above, after use, especially after use in environments where a risk of contamination is high, such as in medical facilities, re-use of the Cushion/Mattress by or with another user can be problematic. For example, undesired microorganisms can be transferred by the Cushion/Mattress in case of an unsuccessful decontamination.

An inflatable air Cushion/Mattress is described in WO91/07937 and marketed by Frontier Therapeutics under the trade name “Repose”®. The Cushion/Mattress comprises skin sections sealed together around the edges of air chambers of the product and must be inflated by means of an air pump to a given pressure before use. The nature of the materials used to construct the “Repose”® Cushion/Mattress means that if a skin section is punctured it is not readily repairable and a new Cushion/Mattress must be obtained. Specifically, the Cushion/Mattress comprises an inner layer of air-impermeable material to which an outer layer of vapour permeable material is permanently attached in a bag like cover over the inner airimpermeable air Cushion/Mattress. In the event of contamination, it is not possible to access the inner air-impermeable layer without cutting the outer permeable cover to carry out a thorough cleaning or decontamination of the product. This is inconvenient and can, for example, increase the risk of cross-infection between patients significantly. For patients at risk from, or suffering from, pressure sores or open wounds, this can severely compromise the efficacy of treatment. As stated, the “Repose”® Cushion/Mattress does not wholly overcome the problem of cross-infection arising from successive uses of the Cushion/Mattress with different patients. If the outer permeable layer is damaged, microorganisms can pass the outer permeable layer and contaminate the Cushion/Mattress. Examples of such microorganisms include bacteria, fungi and viruses. For example, bacteria which are involved in typical hospital infections, such as Staphylococcus aureus, for example MRSA, MSSA, Clostridium difficile etc., can enter the “Repose”® Cushion/Mattress and remain in the Cushion/Mattress for a prolonged period of time or can grow/multiply. Also, a body support surface the Cushion/Mattress will be warmed by body heat of the user and can reach a temperature close to the temperature of the user’s body, e.g. approximately 37°C. As a result, the Cushion/Mattress can provide ideal incubating/growth and retention conditions for bacteria.

Other Cushion/Mattress comprising foam with an outer cover of, for example, coated woven cover or similar materials are also widely known in the retail market. These Cushions/Mattresses are easily damaged in a medical or therapeutic environment because of the flimsy nature of the outer coating materials used in their cover construction.

Standard Cushion/Mattress or mattresses are also unnecessarily high (in terms of product thickness from base to top) as they typically require a significant bulk/volume of foam to adequately support a patient and to provide a certain degree of pressure reduction or redistribution, which is required to carry load and prevent development of a pressure ulcer. By using these high Cushion/Mattress or mattresses the user, e.g. a patient, is at greater risk of falling from the Cushion/Mattress or in the case of a hospital bed and mattress, the height of the safety sides along the outer sides/periphery of the bed are minimised due the higher than necessary mattress underneath. This is particularly dangerous where the user is elderly or confused and where the safety sides (also known as cot sides) are a vital component in keeping the user on the mattress and/or inside the bed.

In addition, the applicant previously developed a Cushion/Mattress with similar construction (EP2408337) to that which is claimed in this current patent application. However, EP2408337 is different to the product claimed in this application, as it does not have 3 layer foam interior core which comprises top layer of viscoelastic foam, centre layer of resilient foam and base layer of viscoelastic foam. This three layer interior foam construction provides effective force translation both at the top and bottom of the Cushion/Mattress surface thereby efficiently spreading loads and pressure. In addition, this claimed product is also different to EP2408337 due to the elimination of the reinforcing element/layer which is bonded into the base fabric layers.

It is an object of the present invention to overcome or at least reduce the problems associated with the prior art.

This is achieved by a Cushion/Mattress with a substantially air- and liquidimpermeable envelope of at least two layers of material, which is at least partially attached to a resilient core of an open-cell foam material inside the envelope.

As used herein, the term Cushion/Mattress refers to a Cushion/Mattress, pillow, mat, mattress, mattress cover, mattress overlay, a supporting structure, such as a support for a body portion or part, e.g. a heel support, a pad-like support for a user, or the like. The Cushion/Mattress can be suitable for use in a domestic, hospital or care home setting on an asneeded basis.

According to a first aspect of the present invention there is provided a Cushion/Mattress, comprising an envelope comprising at least an inner and outer layer of material and a resilient core of an open-cell foam material inside the envelope. The envelope is substantially air- and liquidimpermeable. The inner layer is at least partially attached, e.g. bonded such as heat bonded, to the outer layer and the resilient core so as to provide a plurality of microchannels of an outer surface of at least a top portion of the envelope. The plurality of microchannels of the outer surface of at least a top portion of the envelope, particularly of the outer layer, substantially corresponds with a topology of a surface of the open-cell foam material of the resilient core to which the inner layer is attached. Advantageously, the microchannels provide for an improved vapour diffusion and/or ventilation of a user.

The liquid impermeable envelope prevents or at least reduces contamination. A liquid, such as body fluid, water, or the like, cannot pass the envelope and contaminate the resilient core. Moreover, the Cushion/Mattress can be cleaned easily and instantly. It will be appreciated that the envelope comprising at least the inner and outer layer of material also has an improved air-tightness, even under load and over time.

The envelope is further skin-friendly and provides good comfort to a user, with characteristics similar to air or gel based Cushion/Mattress. In addition, as the envelope is substantially capable of stretching, shear and friction forces on the user’s skin and tissues are advantageously reduced. The envelope allows the Cushion/Mattress to conform very closely to the shape of the user so that an area of contact between the user and the Cushion/Mattress is maximised, which reduces a pressure experienced by the user when using the Cushion/Mattress, which results from the user’s weight, is reduced. This can further minimise or reduce the incidence of pressure sores or the like.

The material of the inner and outer layers can be varied depending of the intended use. For example, for users whose risk of developing pressure sores is lower, a relatively heavier grade polymeric material for the outer layer can be more appropriate. For users at greater risk of pressure sores, the outer layer should be made as light and compliant as possible.

At least partial attachment of the inner layer to the outer layer and the resilient core is advantageous as movement of the envelope with respect to the resilient core is prevented or at least reduced.

In an embodiment, the envelope provides a sealed chamber for the resilient core. As a result, a thickness of the Cushion/Mattress can advantageously be reduced, for example to a thickness that is in a range of 5 cm to 18 cm, as air enclosed in the sealed chamber can carry a large part of the load generated by the user/occupant of the Cushion/Mattress. This also allows for an advantageously reduced thickness of the resilient core. A reduced thickness of the Cushion/Mattress further allows that, for example, bed sides (safety sides) can have a reduced height.

In an embodiment, the sealed chamber is substantially filled by the resilient core.

In embodiments, the inner and outer layers have the same or a different material. The material can be thermoplastic.

Preferably, the inner layer is bonded to the outer layer and the resilient core.

The inner layers are capable of allowing bonding to the resilient core and/or to the outer layer. Additionally or alternatively, a bonding material may be incorporated between the inner and outer layer and/or the resilient core.

In embodiments, the foam material has a thickness which is in a range of 5 cm to 18 cm.

The core can have at least one recess. Preferably, the at least one recess is capable of providing fluid flow in the core. Additionally or alternatively, the recess can be located at a periphery of the resilient core. For example, the core can have 1,2, 3, 4, 5 or more recesses.

In embodiments the resilient core is substantially co-extensive with the envelope. Preferably, the foam core has the arrangement of having a layer of viscoelastic temperature sensitive foam on both top and bottom of the resilient core. For example the foam arrangement may be 2.5cm top viscoelastic foam layer, 11cm middle more resilient layer and bottom 2.5cm viscoelastic foam layer. This allows the mattress to distribute loads on top of the cushion/mattress whilst at the same time absorbing loads and pressure at the base of the cushion/mattress. This top and bottom viscoelastic foam arrangement provides greater pressure and load distribution while at the same time allowing the entire cushion/mattress to be turned over in a 4 way fashion, turning on either/both X and Y axes on a regular basis can serve to enhance the life span of the resilient core of the cushion/mattress whilst at the same time spreading pressure and load over the top and bottom surfaces of the cushion/mattress.

At least one handling means can be attached to the envelope. Particularly, the at least one handling means is selected from a strap, knob, carry bag, harness, side handle or the like.

The foam material has a more open-celled construction than is conventional in the art. Foams used in conventional Cushion/Mattress or mattresses typically have a very tight closed cell structure. A consequence is that air does not easily pass through the foam. The open-cell foam material ofthe invention provides an improved airflow through the resilient core to allow pressure transfer within the sealed cell.

In some embodiments a removable cover that overlays at least the top portion and that is capable of providing vapour diffusion is comprised.

The washable, sealed envelope of multi-layer high stretch outer layer, which is at least partially attached to the resilient core, and which is sealed around the periphery ofthe Cushion/Mattress provides a complete and durable barrier to contamination and a smooth surface which can easily be cleaned or decontaminated, for example by using antibacterial wipes, standard disinfectants and/or standard cleaning substances. The Cushion/Mattress is lightweight (at least in relation to gel-filled Cushion/Mattress), easily transportable, minimises the danger of crossinfection when used successively two or more users, and which provides a desired level of comfort and benefit.

According to a second aspect of the invention there is provided a kit comprising a removable cover capable of providing vapour diffusion and a Cushion/Mattress as hereinbefore and hereinafter described.

According to a third aspect of the invention there is provided a Cushion/Mattress system comprising a removable cover capable of providing vapour diffusion and a Cushion/Mattress as hereinbefore and hereinafter described.

Embodiments of the invention will now be described with reference to the accompanying drawings by way of example only.

Figure 1 shows a schematic cross sectional view of an embodiment of a Cushion/Mattress according to the invention,

Figure 2 shows a Plan view of the Cushion/Mattress as shown in Fig. 1,

Fig. 1 shows a schematic cross sectional view of an embodiment of a Cushion/Mattress 10 according to the invention, with an envelope 12 with an inner layer 14 and an outer layer 16 of material. A resilient core 17 of an open-cell foam material is positioned inside the envelope 12. At a top portion 18 of the envelope 12 the outer layer 16 is attached to the resilient core 17 by the inner layer 14. Additionally a plurality of microchannels of an outer surface 20 can be provided.

It will be appreciated that the resilient core 17 can comprise more than one suitable core elements. For example, in one configuration, the resilient core 17 can comprise a first core element, such as a viscoelastic foam, which faces a user when in use, and resilience and/or hardness of the foam of the core elements can be adapted to an intended purpose.

Particularly, the second core element can have an open-cell, high resilience foam material, which provides good support and durability.

Particularly, the third core element, such as a viscoelastic foam, can have an open-cell structure which acts as a pressure reducing base.

The first and third core elements can have a viscoelastic temperature sensitive foam material. It will be appreciated that this provides good comfort, load transfer and pressure reduction as well as heat sensitive conformity to the user to provide good pressure relief as well as providing a “4 Way” turn function i.e. The Cushion/Mattress can be turned over and can be turned on its X or Y axes.

Fig. 2 shows a Plan View of the Cushion/Mattress 10 as shown in Fig. 1,

Claims

1. A Cushion/Mattress (10) comprising:

an envelope (12) comprising at least an inner and outer layer (14, 16) of specialised multi-laminated material, and a resilient core (17) of an open-cell foam material with a viscoelastic foam top layer, a resilient foam centre layer and a viscoelastic foam base layer inside the envelope (12) characterised in that said envelope (12) is substantially air- and liquidimpermeable, and that the inner layer (14) is at least partially attached to the outer layer (16) and the resilient core (17) with a plurality of microchannels of an outer surface (20) of at least a top portion of the envelope.

2. The Cushion/Mattress as claimed in claim 1 or 2 wherein the envelope (12) provides a sealed chamber for the resilient core (17).

3. The Cushion/Mattress as claimed in claim 3 or 4 wherein the sealed chamber is substantially filled by the resilient core (17).

4. The Cushion/Mattress as claimed in any one of the preceding claims wherein the foam material has a thickness being in a range of 5 cm to 18 cm.

5. The Cushion/Mattress as claimed in any one of the preceding claims wherein the resilient core (17) has at least one recess capable of providing fluid flow within the core.

6. The Cushion/Mattress as claimed in claim in any one of the preceding claims wherein the at least one recess is at least one bore extending longitudinally and/or transversally in or through the resilient core (17).

7. The Cushion/Mattress as claimed in any one of the preceding claims wherein the resilient core (17) is substantially co-extensive with the envelope (12).

8. The Cushion/Mattress as claimed in any one of the preceding claims, wherein at least one handling means is attached to the envelope such that, the Cushion/Mattress is moveable.

9. The Cushion/Mattress as claimed in any one of the preceding claims, wherein the at least one handling means is selected from a strap, knob, carry bag, harness, side handle.

10. The Cushion/Mattress as claimed in any one ofthe preceding claims further comprising a removable cover that overlays at least the top portion (18) and that is capable of providing vapour diffusion

11 .A Kit comprising a removable cover capable of providing vapour diffusion and a Cushion/Mattress (10) as defined in any one of the preceding claims.

12. A Cushion/Mattress system comprising a removable cover capable of providing vapour diffusion and a Cushion/Mattress (10) as defined in any one of claims 1 to 12.