WO1997042859A1

WO1997042859A1 - Fluid-like foam support device

Info

Publication number: WO1997042859A1
Application number: PCT/US1997/008723
Authority: WO
Inventors: James D. Weinstein
Original assignee: Weinstein James D
Priority date: 1996-05-16
Filing date: 1997-05-16
Publication date: 1997-11-20

Abstract

A support device (61) having a plurality of support units (62a, 62b), each comprising a plurality of flexible, substantially vertical support columns (63), with the bottoms of the support columns (63) attached at equidistant intervals to a base member (65) and the tops of the support columns (63) attached at equidistant intervals to a substantially perpendicular support platform (64). The support columns (63) provide directional flexibility to the colums, upon compression, to provide a substantially uniform counter-force through a range of flexion of the support columns and corresponding downward deflection of the support device (61). Such uniform counterforce during compression simulates a fluid-like support system. The support columns (63) may be comprised of a solid, synthetic foam such as high density polyurethane. The support (62a, 62b) units preferably are arranged in a matrix to provide collective support. A stabilization frame and coextensive base member may be used in connection with such a matrix to align individual support units and prevent them from collapsing horizontally during compression. Foam may also be placed around and between the individual support units to provide lateral support.

Description

TITLE

FLUID-LIKE FOAM SUPPORT DEVICE

FIELD OF THE INVENTION

The present invention relates to the provision of a fluid-like cushioning effect through a solid, mechanical support device.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation-in-part application of a co- pending application Serial No. 08/649,023 filed May 16, 1996 entitled "Fluid-Like Foam Support Device" which is a divisional application of U.S. Patent Number 5,558,314 dated September 24, 1996 entitled "Fluid-Like Support Device".

BACKGROUND OF THE INVENTION

The standard cushioning support of solid construction (not a water mattress or gel flotation pad) interacts with a body in support whereby the counter-force providing support increases in direct proportion to the downward deflection of the cushioning device. This effect occurs in typical mattress springs and in standard foam or rubber foam constructions. Such cushioning support structures, as a result of such increasing counter-forces, do not fully conform to the body being supported and, instead, cause the body to conform in part to the shape of the support structure.

A water mattress, however, by virtue of hydro-static forces, provides a uniform support and counter-force to a supported body. The counter-forces exerted by a water mattress do not increase in linear response to the amount of deflection of the mattress structure. Consequently, the water mattress much more readily conforms to the shape and contour of the supported body.

Attempts have been made to imitate mechanically this desirable fluid-like support effect. One such means involves using a very thick, soft foam support member which can provide a uniform counter-force to support a rather large surface area and minimizes the counter-force at the greatest areas of deflection. Such a mechanical support member is not practical to use, however, because of the necessary size of such structure and the inconvenience involved in using it effectively.

The support device of the present invention overcomes these deficiencies through use of plurality of individual support units having two or more support columns which act together to provide a uniform counter-force through a given range of deflection. Such support columns are comprised of solid, synthetic foam such as polyethylene, latex or high density polyurethane. The support columns are formed to facilitate flexion in a desired direction, while providing a substantially uniform counter-force, which provides a desirable contribution to the field of cushioning support devices.

Accordingly, it is an object of the present invention to promote a solid, mechanical support device that offers a fluid-like cushioning effect in a practical and usable manner. The support device of the present invention has application in mattresses, seats for, among other things, automobiles, airplanes, theaters, and office and home furniture. SUMMARY OF THE INVENTION

The present invention generally comprises a support device of solid construction which provides a uniform, fluid¬ like counter-force through the range of deflection caused by the body being supported. In particular, the support device in accordance with this invention includes a plurality of support units, each having a plurality of support columns which attach to a base and which join together at a top area. Additionally, the cushioning support unit may include a flat support surface or platform at the top area to which the support columns support or attach. The support columns are formed to facilitate flexion in a selected, desired direction. In preferred embodiments, the support columns are comprised of solid, synthetic foam such as, in particular, Ethafoam^®, polyethylene, latex or high density polyurethane.

In operation, the support device provides a substantially uniform counter-force over a range of downward deflection resulting from flexion of the support columns. More specifically, the support device experiences an initial compression phase, followed by a flexion phase, upon downward deflection. In the compression phase, the counter-force is built quickly until the flexion phase begins to act . During the flexion phase, the counter-force tends to remain substantially constant despite continued downward excursion of the device and the body being supported by it . As downward deflections occur through the flexion phase, during which substantially uniform counter-force is applied to the body in support, a fluid-like flotation support is simulated. Similar to a fluid support, the counter-force acting over the surface area of the supported body, through a range of deflections, is substantially uniform and the surface elements of the support device have horizontal mobility. The device's resistance to deformation, the duration of the flexion phase and the amount of counter-force provided to the body supported by the device vary according to the length, width and general shape of the columns and the elasticity of the foam comprising the individual support units. A thick column, for example, will provide a greater resistance to deformation and will also provide a higher uniform counter-force during compression or flexion.

In accordance with the preferred embodiment of this invention, the support columns can have a straight, bent or curved form. Such support columns are spaced equidistant from each other in order to provide uniform support and are symmetric in relation to the vertical center of the support structure. In a preferred embodiment employing two bent or curved support columns, the shape formed by the support columns, from a side view before compression, can vary and may include, without limitation, a circle, oval, figure eight, diamond or rhomboid.

The cross-sectional area of each support column preferably defines a circle or a rectangle, although other geometric shapes such as, without limitation, an oval, diamond, triangle or rhomboid may be defined by this cross- section. The cross-sectional shape of the support columns may vary along the lengths of such columns. When compressive forces are applied to the top of the support device, as when the device provides support to a body, the support columns of each support unit preferably flex symmetrically so as to provide stability to the support unit. Specifically, an outward, inward or angled symmetrical deflection of the support columns (with reference to the vertical center of the support unit) provides lateral stability together with the desired substantially constant counter-force during deflection. Where lateral support is otherwise provided to a support unit, however, such as in the support matrices described below, symmetrical deflection of the support columns is not necessary.

In the preferred embodiment of this invention comprising foam support columns, flexion of foam support columns can be facilitated in desired directions by making vertical or horizontal cuts or slits in such columns. Such slits or cuts can be made to the exterior or interior of the support columns and also at the point where the columns join the base member to help guide the direction in which the columns will deflect during compression. Foam support columns can also be pre-set to desired directions of flexion by flexing the columns along their length in the desired direction of flexion, which may be either inward or outward, and attaching these column members, as bent, to the base member and top area of each support unit. Such pre-bending of the foam support columns, although it may increase the initial compression phase, provides necessary stability to the device as a whole. Also in the preferred embodiment of this invention employing foam support columns, it is further preferred that the base member and support platform, if employed, are also comprised of foam, and that all such elements of each support unit, i.e., the support columns, the base member and the support platform, if employed, are cut or formed from a single piece of foam. Alternatively, each individual element of the support structure can be formed separately from foam and joined together by glue or other means of attachment.

The support columns in a given support unit may have different lengths, degrees of pre-bending or different numbers or locations of bends or slits to provide a contoured effect to the surface of the support device.

In the support device, the individual support columns should remain substantially perpendicular to the compressive forces to function in the desired manner. If the support columns bend in other than the desired direction of flexion, the support device will lose its desired effect. There are several means to maintain the stability of a support column.

First, on an individual basis, a support unit can be designed with a broad stable base and wide support columns . This design will facilitate flexion in a desired direction. This design is more readily accomplished through use of a single piece of foam from which the support unit, including the columns and base, are cut or formed.

Collectively, individual support units preferably are arranged in a matrix to provide collective support, as well as lateral support and column stability. In particular, adjacent support units can be alternated with respect to their respective directions of flexion. Preferably, where support units having two support columns are utilized, adjacent support units are positioned such that they flex in directions which are perpendicular to one another. Additional lateral support can be provided in the matrix of the support device by allowing adjacent support units to come into contact with each other at the maximum point of flexion.

Support column stability can also be increased through the use of a coextensive support platform which attaches to the top of each individual support unit. Preferably, this coextensive support platform is comprised of foam, as well . This coextensive support platform helps maintain the individual support units in desired positions with respect to one another and inhibits lateral deflection. Alternatively, individuals support platforms for individual support units can be flexibly attached or connected together to provide the same effect .

Utilizing the same principle, column stability also can be provided through the use of a coextensive base member and/or attaching individual base members of each support together.

In connection with the use of either a coextensive or inter-connected individual support platforms and base members, additional stability can be provided further by attaching the coextensive or inter-connected support platform(s) and base member (s) to a frame located around the periphery of the support device. As an alternative to the coextensive or inter-connected support platform(s) , a support device can be constructed using a coextensive inner foam support piece, located on a horizontal plane between the tops and bottoms of each individual support unit in the support device. The inner support piece has holes located within it through which each of the individual support units pass . The holes are formed so as to guide the individual support units in the appropriate and desired direction of flexion during compression of the support device.

Finally, as a further alternative, foam can be placed between adjacent support units with this foam operable to provide vertical stability and guide the individual support units in the desired direction of flexion. Preferably this foam is softer than that used in the individual support units and is comprised of soft latex.

In all embodiments, individual support units of differing heights can be utilized to provide a contoured surface to the support device as a whole.

Other objects and a fuller understanding of the invention will be had by referring to the following description of the Presently Preferred Embodiments of the Invention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric frontal view of a preferred embodiment of the support unit of this invention.

FIG. 2 is an isometric frontal view of the embodiment of this invention illustrated in FIG. 1 under compression. FIG. 3 is an isometric frontal view of an alternative embodiment of the support unit of this invention.

FIG. 4 is an isometric frontal view of an alternative embodiment of the support unit of this invention.

FIG. 5 is an isometric frontal view of an alternative embodiment of the support unit of this invention.

FIG. 6 is an isometric frontal view of an alternative embodiment of the support unit of this invention.

FIG. 7 is a side view of the support device of this invention with two support units positioned to provide lateral support .

FIG. 8 is an isometric view of a preferred embodiment of the support device of this invention.

FIG. 9 is an isometric view of an alternative embodiment of the support device of this invention.

FIG. 10 is a graph depicting test results of the counter- force provided by alternative embodiments of the support units of this invention during a range of deflections.

FIG. 11 is a graph demonstrating the uniform counter- force provided by the support unit of this invention during a range of deflection.

PRESENTLY PREFERRED EMBODIMENTS OF THE INVENTION

Referring to FIGS. 1 and 2, support unit 10 in accordance with a preferred embodiment of this invention comprises two support columns 11 and 12 which are joined at top area 13 and bottom area 14 and also at base 16. Support columns 11 and 12 may, alternatively, attach separately to base 16 such that they do not attach to each other. Support unit 10, as depicted in FIGS. 1 and 2, is formed or molded from a single piece of solid, synthetic foam such as polyethylene, latex or high density polyurethane. In a preferred embodiment, polyethylene-based Ethafoam^® is used. Alternately, support columns 11 and 12, together with base 16, may be separately formed or molded from foam and attached to each other to form unit 10 by glue or other attachment means. Base 16 also may be comprised of a material other than foam. A foam composition for the columns 11 and 12 is necessary, however, in order to allow for desired flexion in such columns .

In FIGS. 1 and 2, the preferred embodiment of the invention depicted therein comprises support columns 11 and 12 having a rectangular cross-section. This cross-sectional area for the support columns may also define other geometric shapes, including, without limitation, a circle, oval, triangle, diamond and rhomboid. In addition, the cross- sectional area of support columns 11 and 12 may change in terms of both geometric shape and area along the length of support columns 11 and 12.

Referring to FIG. 1, the geometric shape formed by the two support columns 11 and 12, before compression is an oval (as depicted in the side view shown in FIG.1) . Such support columns can also be bent, molded or formed to define other geometric shapes including, without limitation, an oval, figure eight, diamond or rhomboid. Referring to FIGS. 3 and 4 in particular, the preferred embodiments of this invention employing two support columns may also resemble, without limitation, a diamond such as support unit 23 in FIG. 3 or a figure eight such as support unit 24 in FIG 4. Further, referring to FIG. 5, the preferred embodiments of the invention may employ support columns which do not join at their top or bottom areas. In particular, in FIG. 5, support columns 27 and 28 attach to base 29 without joining each other. Such design provides improved lateral stability. In addition, more than two support columns can be employed. In FIGS. 1 through 4, all support columns are spaced equidistant from each other and are symmetrically shaped in reference to the vertical center of the support unit so as to provide uniform flexion and support. In alternative embodiments, support columns having different lengths, shapes or bends may be employed.

With reference to FIGS. 1 and 2, where support members 11 and 12 are comprised of foam, slits 17, 18, 19 and 20 can be added to support unit 10 to aid the flexion of support columns 11 and 12 in desired directions. Such slits can be positioned anywhere on the interior or exterior of support columns 11 and 12, and are not limited to the number and location of the slits illustrated in FIGS. 1 and 2. In addition, such slits or cuts can be used with other support column shapes including those depicted in FIGS. 3 and 4. Undercuts 21 and 22, which are located at the point where support columns 11 and 12 join base 16, further aid the positioning of the flexion of support columns 11 and 12. Such undercuts may also be employed with other support column shapes . Referring specifically to FIG. 2, support structure 1 is positioned for operation such that top 13 receives the weight or force from the body to which support unit 10 is to provide support. Upon experiencing such weight or force, support columns 11 and 12 flex or bend outwardly as support unit 10 compresses, and as is shown in FIG. 2. In the preferred embodiment of the invention depicted in FIG. 2, the outward bending or flexion of support columns 11 and 12, as well as that of the analogous support columns in FIGS. 3 and 4, is symmetrical with reference to the vertical center of support unit 10. Support columns 11 and 12 may also be formed, molded or bent to flex symmetrically inward or at some other angle with reference to the vertical center of support unit 10. In alternative embodiments, support columns may all flex in the same direction or non-symmetrically.

Referring to FIG. 6, support unit 30 is a further alternate preferred embodiment of the invention comprising two support columns 31 and 32 joined separately to base 33 and support platform 34. As with FIG. 5, separating support columns 31 and 32 at the point of attachment to base 33 and support platform 34 adds stability of support unit 30 during compression, i.e., it is less likely to deflect laterally. Base 33 and support platform 34 may be comprised of the same foam material as support columns 31 and 32, but also may be comprised of other materials. If the same material is used for all elements of this embodiment, they may be cut or formed from a single piece of foam or cut or formed separately and then joined together by glue or other adhesive means. Support platform 34 provides direct support to a portion of the surface area of a body in support . Similar support platforms may be used in other embodiments of the invention, including without limitation, those depicted in FIGS. 1 - 5.

In the embodiment where support columns 31 and 32 are cut or formed separately, it is preferred that they have straight or linear shape before attachment . During the attachment of support columns 31 and 32 to base 33 and support platform 34, support columns are then bent in the manner depicted in FIG. 6. This bending aids the deflection of support columns 31 and 32 in a symmetrically outward direction during compression of support unit 30. Support columns 31 and 32 can alternatively be bent during attachment so as to cause deflection or flexion symmetrically inward or at some other angle with reference to the vertical center of support structure 30. As with the preferred embodiment generally discussed in connection with FIG. 1, additional support columns may also be added to support unit 30, with all support columns preferably being spaced equidistant from each other and having symmetric shapes and flexion.

Alternatively, support columns having different lengths, shapes and/or points of bending may be used to provide a slope or angle of inclination to support platform 34. In a matrix of support units, support units with varying degrees of slope or inclination and heights for each unit can be positioned to provide a contoured support surface. In preferred embodiments, such variations in slope and height of support units in a support device are provided through use of support platforms having identical lengths but different angles of pre-bending.

Referring to FIG. 6, support device 51 depicts identical support units 52a and 52b which are aligned in a matrix to collectively provide cushioned support to a body. In this preferred embodiment of this invention, such alignment involves placing unit 52a adjacent to identical support unit 52b in such a manner that unit 52b is rotated ninety degrees along its vertical axis 53 in orientation to unit 52a. Such alignment allows support column 54 of unit 52a to deflect into the opening 55 created between support columns 56 and 57 of unit 52b when units 52a and 52b are under compression, without inhibiting the flexion of support column 54. Narrowed regions 58 can be formed or cut into support columns 56 and 57 to further aid the receipt of support column 54 by unit 52b without inhibiting the flexion of support column 54.

In a preferred embodiment, units 52a and 52b are aligned close enough to each other such that contact occurs between units 52a and 52b at the greatest range of deflection. Such contact provides lateral inhibition to the possible sideways collapse of units 52a and 52b.

Units 52a and 52b are preferably part of a larger matrix of similar individual support units, each interacting with another in the same manner that units 52a and 52b interact. More specifically, support columns 56 and 57 would each flex outward into adjacent support units, which, in turn, would interact with other support units. Unit 52b would also receive a support column form a support located on the side of unit 52b opposite to unit 52a. Such a matrix of support units additionally can be employed where more than two support columns exist in an individual support unit .

FIG. 8 depicts support device 61 with a matrix of support units 62a and 62b. Support units 62a and 62b each have two support columns 63 which are comprised of solid synthetic foam. The number of individual support units 62 in support device 61 can vary. The support units in support device 61, including support units 62a and 62b, are positioned in a matrix in the same manner as described with respect to FIG. 7. More specifically, adjacent support units are rotated 90° with respect to each such that they flex in planes which are perpendicular to one another. Each support unit is attached at its top to support platform 64 and at its bottom to base 65.

Support platform 64 is contoured; that is, the center area of support platform 64 is lower in length than the edges. Such contouring is especially useful when designing a support device for use in chairs or other devices which provide a cushion for a seated person. Contouring may have application for other needs, as well. In the case of a seated person, it is preferable for the support platform to provide support over its entire surface area. Without contouring, testing has shown that a support platform comprised of foam must be approximately 4 to 5 inches thick in order to distribute support over the entire surface of the support platform--an approximate 3 inch dower displacement occurs near the center of the support platform before support is provided along its edges. With contouring, on the other hand, a support platform can be less thick--1.5 to 2 inches. Support device 61 demonstrates one method of such contouring. More specifically, support platform 64 has a uniform thickness, and the support units located within the matrix of support device 61 have differing heights. In particular, support unit 62a has an extended top area 67 which provides a greater height to support unit 62a in relation to support unit 62b. Support units of differing heights are positioned within the matrix of support device 61 to shape and provide a contour to support platform 64.

Alternatively, the support units within support device 61 can have the same height, and support platform 64 can be cut or formed out of a piece of foam so that the bottom of support platform 64 is flat, and the upper surface of support platform

64 is contoured in the desired shape.

As a further alternative, support units of similar heights can be employed, together with a flat support platform, but with the entire support device 61 being placed on top of a contoured, hard surface area, which provides a contoured shape to support device 61 as a whole.

Support platform 64 can be comprised of a single piece of foam or by individual support platforms corresponding to each support unit which are flexibly attached to each other. Base

65 can be comprised of similar alternative constructions.

Attachment of the tops and bottoms of each support unit within support device 61 to support platform 64 and base 65 provides lateral stability to each support unit . Additional stability is provided by sidewalls 66, which are attached along the entire perimeter of support device 61. In FIG. 8, the front sidewall is cut away to depict the support units within. Sidewalls 66 are attached by glue or other adhesive means to support platform 64 and base 65.

As a further alternative with respect to support device 61, a framework comprised of metal or some other rigid substance can be positioned around the perimeter of sidewall 66 to provide further stability and lateral support to support device 61.

Another preferred embodiment of the invention is shown in FIG. 9, with support units 72 aligned in a matrix within support device 71. As depicted, support units 72 are not rotated with respect to one another, but instead are aligned to flex in the same direction throughout support device 71.

The bottoms of each support unit 72 are attached to coextensive base 74. Alternatively, individual base members of each individual support unit can be attached together by glue or other adhesive means. Lateral support is provide dot support device 71 and, in particular, the upper areas of the individual support units through use of support piece 75. Support piece 75 has holes located throughout which correspond to the positions of the individual support units in the matrix of support device 72. Each individual support unit 72 is designed with an extended upper area 77 which passes through the holes in support piece 75. During compression of support device 71, these holes within support piece 75 maintain each individual support unit along its vertical axis. Preferably, support platform 78 is placed on the tops of each individual support unit to provide a large surface area. Support platform 78 can be contoured in the manner described with respect to support device 61 in Fig. 8.

In the interior area of support device 71, the individual support units are positioned between foam inner walls 76 which run the length of support device 71, parallel to the planes of flexion of each individual support unit. As depicted in FIG. 9, foam inner walls can also be situated along the vertical planes descending from lines a-b and c-d to form a foam inner grid within device 71. These inner foam walls are preferably comprised of a foam, such as soft latex, which is more easily compressed than that used in connection with the individual support unit. As such, the inner foam walls help to provide lateral support but do not inhibit the compressive properties of the individual support units. As an additional benefit, employing inner foam walls, as depicted in support device 71, can help extend the useful life of support device 71 by aiding the return of support device 71 to its non-compressed state after use. As a result, the compressive wear on support units 72 is lessened.

Inner foam walls, as depicted in support device 71, can also be employed in connection with the matrix described in connection with support device 61 in Fig. 8. More specifically, inner foam walls can be used to form a grid which encompasses all sides of individual support units located within the matrix of a support device. Similarly, support piece 75 can also be used in connection with other embodiments such as support device 61.

More generally, the various means providing for lateral support, as described in connection with support devices 61 and 71 in FIGS. 8 and 9 respectively, can be used interchangeably. These means of providing lateral support include; (i) rotating adjacent individual support units with respect to one another in the matrix of a support device, (ii) attaching the tops and bottoms of individual support units to a coextensive support platform and/or base, (iii) connecting individual support platforms and/or bases, (iv) employing sidewalls, (v) employing a nonflexible framework around the perimeter of the support device, (vi) employing a support piece such as support piece 75 in FIG. 9, and (vii) employing inner support walls.

Testing of the support units described by this invention and, in particular, individual support units similar to those identified as units 10 and 30 in FIGS. 1 and 6 have confirmed that such support units provide a uniform counter-force through a midrange of deflection, thereby providing the desired fluid-like support effect. Test results utilizing different foam compositions for the support units are summarized below.- SUPPORT DEVICE 10

(FIG. 1)

Latex Block

Deflection Counter-Force (inches) (lbs.)

Test 1 Test 2 Test 3

.5 4.6 5.8 5.0 1.0 6.7 7.5 7.0 1.5 7.8 9.1 9.0 2.0 9.6 11.2 12.0

SUPPORT DEVICE 10

(FIG. 1) Latex Flex Columns

Deflection Counter-Force (inches) (lbs.)

Test 1 Test 2

.5 4.6 4.8

1.0 5.4 5.6 1.5 6.2 5.8 2.0 6.0 6.8

SUPPORT DEVICE 30

(FIG. 1) Latex Flex Columns

Deflection Counter- -Force (inches) (lbs. .)

Test 1 Test 2

.5 5.2 5.6

1.0 6.2 6.0 1.5 6.6 6.5 2.0 6.8 6.3 2.5 7.4 7.2 3.0 8.8 8.1 These test results have been depicted graphically in FIG. 10. Utilizing the design of support device 30 (FIG. 6) provides the best results--the counter-force remains within a range of approximately 2 pounds between .5 and 2.5 inches of displacement. These test results are similar to the desired fluid-like effect depicted in more general graphical terms in FIG. 11.

FIG. 11 is a graph reflecting the counter-force versus displacement relationship of the support structures. On the x-axis, increasing downward displacement of the support structures is reflected as one moves from the origin. On the y-axis, the increasing counter-force asserted by the column support device is reflected. Fig. 9 shows the two phases of compression and flexion. During the compression phase, the counter-force builds quickly until the flexion phase begins. After the flexion phase begins, the counter-force remains constant. In preferred embodiments of the invention, all deflections or flexion of the support columns occur in the substantially flat portion of the curve.

The flat portion of the compression-deflection curve corresponds to the substantially uniform pressure which occurs during flexion, with the beginning of this flat portion of the curve corresponding to the point at which the support columns begin to flex (flexion point pressure) . From this point until flexion is complete, during which time a large compression of the support device occurs, and the distance between the top area of the support device and the base decreases significantly, the counter-pressure tends to remain constant by nature of the properties of the support columns.

Factors determining the initial level of compression are, for the foam embodiment: (1) relative thickness of the support columns, (2) the design of the bends in the support columns, and (3) the inherent characteristics of the foam, which must be of a firm, but flexible, composition.

The flexion point pressure determines how much support each support device provides. For example, a seat design employing a matrix of twenty (20) support units, with each such unit having a flexion point pressure of twelve (12) pounds, will support 240 pounds before "bottoming out" and losing its fluid-support effect. Similarly, a support device supporting a human trunk of 15" x 30" might have approximately 50 units of support. If each unit has flexion point pressure of six (6) pounds, the support device could support 300 pounds. The flexion point pressure for a particular support unit can be designed into a unit by varying the parameters discussed above. Testing of particular designs to arrive at a particular flexion point pressure can be done through use of a standard grocery-type scale.

Claims

WHAT IS CLAIMED IS:

1. A support unit having a vertical center and comprising: a. a base member; and b. a plurality of support columns, each said support column having a top and bottom, with the bottoms of said support columns attached at equidistant intervals to said base member and the tops of said support columns joined together, each said support column comprised of a solid, synthetic foam flexible along the entire length of said column, and said support columns further being positioned and operable to flex, in response to application of a compressive force against said support platform, a substantially uniform counter-force through a range of flexion of said support columns and corresponding compression of said support unit .

2. The support device of Claim 1, wherein said columns are further positioned and operable to flex, in response to application of a compressive force against said support platform, in a uniform symmetric manner with reference to each other and the vertical center of said support unit.

3. The support device of Claim 1, wherein each said support unit is further comprised of a support platform to which the tops of said support columns are attached at equidistant intervals.

4. The support device of Claim 1 or 3 , wherein said support unit comprised of and constructed from a single piece of solid, synthetic foam.

5. The support device of Claim 1 or 4, wherein said foam is selected from the group consisting of polyethylene, latex and high-density polyurethane.

6. The support device of Claim 1 or 2, wherein slits are included in the interior or exterior of said support columns, said slits being used to guide and assist the flexion of the support members in a desired direction while aid support device is under compression.

7. The support device of Claim 1 or 2, wherein each said support column is bent along its length during attachment to said base and said support platform to facilitate flexion of said support columns in a desired direction while said support device is under compression.

8. A support device comprising a plurality of inter¬ connected support units positioned to form a matrix with an outer perimeter, each said support unit having a vertical center and comprising: a. a base member; b. a support platform; and b. a plurality of support columns, each said support column having a top and bottom, with the bottoms of said support columns attached at equidistant intervals to said base member and the tops of said support columns attached at equidistant intervals to said support platform, each said support column comprised of solid, synthetic foam flexible along the entire length of said column, and said support columns further being positioned and operable to provide, in response to application of a compressive force against said support platform, a substantially uniform counter-force through a range of said support columns and corresponding compression of said support unit.

9. The support device of Claim 8, wherein said support columns are further positioned and are operable to flex, in response to application of a compressive force against said support platform, in a uniform symmetric manner with reference to each other and the vertical center of said support unit.

10. The support device of Claim 8, wherein each said support unit is comprised of and constructed from a single piece of solid, synthetic foam.

11. The support device of Claim 8 or 10, wherein said foam is selected from the group consisting of polyethylene, latex and high density polyurethane.

12. The support device of Claim 8 or 9, wherein slits are included in the interior or exterior of aid support columns, aid slits being used to guide and assist the flexion of the support members in a desired direction while said support device is under compression.

13. The support device of Claim 8 or 9, wherein each said support column is bent along its length during attachment to said base and said support platform to facilitate flexion of said support columns in a desired direction.

14. The support device of Claim 8, wherein each said support platform is flexibly attached to adjacent support platforms .

15. The support device of Claim 7, wherein said support device further comprises a coextensive support platform to which said support platform at each said support unit attaches.

16. The support device of Claim 16, wherein said coextensive support platform attaches directly to said support columns in each said support unit and forms said support platform for each said support unit.

17. The support device of Claim 8, wherein each said base member is flexibly attached to adjacent base members.

18. The support device of Claim 8, where said support device further comprises a coextensive base member to which said base member at each said support unit attaches .

19. The support device of Claim 18, wherein said coextensive base member attaches directly to said support columns in each said support unit and forms said base member fo reach said support unit.

20. The support device of Claim 8, wherein said support device further comprises a nonflexible stabilizing frame which is positioned around the outer perimeter of said support device.

21. The support device of Claim 8 or 9, wherein said support columns flex symmetrically outward from the vertical center of each said support unit and said support units are positioned such that the space created between adjacent support columns in each of said support units, when deflected outward upon compression, increases in width and receives the support column of at least one adjacent support unit during compression.

22. The support device of Claim 8, wherein said support device further includes inner support walls comprised of foam and located between said support units to provide lateral support to said support units and said support device.

23. The support device of Claim 8, wherein the upper surface of said support platform is contoured.

24. The support device of Claim 8, wherein said support device further comprises side walls of solid, synthetic foam which are attached to said base member and said support platform along the outer perimeter of said support device.

25. The support device of Claim 24, wherein said foam is selected from the group consisting of polyethylene, latex and high density polyurethane.

26. The support device of Claim 8, wherein said support device further includes a horizontal support piece, said support piece having holes located throughout which correspond onto the position of said individual support units in the matrix of said support device and through which the tops of said support units pass to provide lateral support to said support units.

27. The support device of Claim 22, wherein said foam comprising said inner support walls is more easily compressible than said foam comprising said support units.

28. The support device of Claim 23, wherein said foam comprising said inner support walls is comprised of soft latex.