WO2010075300A1 - Support de corps comprenant un matériau gélatineux et procédé de fabrication d'un support de corps le comprenant - Google Patents

Support de corps comprenant un matériau gélatineux et procédé de fabrication d'un support de corps le comprenant Download PDF

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Publication number
WO2010075300A1
WO2010075300A1 PCT/US2009/069028 US2009069028W WO2010075300A1 WO 2010075300 A1 WO2010075300 A1 WO 2010075300A1 US 2009069028 W US2009069028 W US 2009069028W WO 2010075300 A1 WO2010075300 A1 WO 2010075300A1
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WO
WIPO (PCT)
Prior art keywords
foam
body support
layer
gel
pool
Prior art date
Application number
PCT/US2009/069028
Other languages
English (en)
Inventor
Kelly W. Chandler
Tom D. Mikkelsen
Original Assignee
Tempur-Pedic Management, Inc.
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 Tempur-Pedic Management, Inc. filed Critical Tempur-Pedic Management, Inc.
Publication of WO2010075300A1 publication Critical patent/WO2010075300A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/20—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in foamed material
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/10—Pillows
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G2009/008—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows using a liquid as filling material

Definitions

  • body support includes without limitation any deformable element or structure adapted to support one or more parts of (or the entire body of) a human or animal in one or more positions.
  • body supports include but are not limited to mattresses, pillows, and cushions of any type, including those for use in beds, seats, and other applications.
  • Body supports are often constructed entirely or partially out of foam material.
  • foam material For example, polyurethane foam is commonly used in many mattresses, pillows, and cushions, and can be used alone or in combination with other types of cushion materials.
  • visco-elastic material is used, providing the body support with an increased ability to conform to a user and to thereby distribute the weight or other load of the user.
  • Some visco-elastic body support materials are also temperature sensitive, thereby also enabling the body support to change firmness based at least in part upon the temperature of the body part(s) supported thereon.
  • reticulated foams both visco-elastic and non- visco-elastic have also gained in popularity.
  • Reticulated foams can provide added benefits of increased heat and moisture transfer due in large part to the relatively porous nature of reticulated foams. These characteristics are often highly desirable in body support applications of all types.
  • Some embodiments of the present invention provide a body support having a layer of reticulated foam with a first top surface and a first bottom surface opposite the first top surface; and a gelatinous material applied to a portion of the first top surface.
  • the reticulated foam can be visco-elastic foam, although non-visco-elastic foam can instead be used.
  • the body support can also include one or more additional layers of material, such as one or more additional layers of foam atop the first layer and/or one or more additional layers of foam beneath the first layer.
  • a method of assembling a body support comprises applying a gelatinous material on a portion of a top surface of a layer of visco-elastic or non-visco-elastic reticulated foam.
  • the method can also include positioning one or more additional layers of foam atop the first layer of reticulated foam and/or beneath the first layer of reticulated foam.
  • the method can include blocking or limiting passage of the gelatinous material into the material of the reticulated foam.
  • the present invention provides a body support assembly including a layer of foam having a top surface and defining multiple recesses in the top surface, and multiple pools of gel positioned in the respective recesses, such that the pools of gel extends less than all of the way through the layer of foam.
  • the foam can comprise reticulated visco-elastic foam.
  • a liner can be positioned between the pools of gel and the layer of foam.
  • the pools of gel are permitted to permeate the foam no more than 2 mm, and optionally can permeate the foam no more than 1 mm.
  • the pool can be from 3 mm to 100 mm deep, additionally, the pool can be from 6 mm to 75 mm deep, further the pool can be from 12 mm to 25 mm deep.
  • the present invention sets forth a body support assembly including a layer of foam having a top surface and defining a recess in the top surface, a liner positioned in the recess, and a pool of gel positioned in the recess on the liner.
  • the foam can comprise reticulated visco-elastic foam.
  • the pool of gel can include multiple pools of gel positioned in multiple recess in the top surface of the layer of foam.
  • the pool can be from 2 mm to 100 mm deep, such as 6 mm to 75 mm deep.
  • the pool can be from 12 mm to 25 mm deep.
  • FIG. 1 is a perspective view of a body support according to an embodiment of the present invention.
  • Fig. 2 is an exploded view of the body support of Fig. 1.
  • FIG. 3 is a cross-sectional view of a foam layer of a body support according to another embodiment of the present invention.
  • top and bottom are used for the purpose of description and are not intended to indicate or imply relative importance, significance, unless otherwise specified.
  • the term “top” does not necessarily refer to the top most layer, and “bottom” does not necessarily refer to the bottom most layer.
  • a body support 10 or a portion of a body support according to an embodiment of the present invention is illustrated in Figs. 1-3.
  • the illustrated body support 10 includes a top surface 12 oriented to support the body of a user thereon, and a bottom surface 14 positioned to be proximate a frame, floor, other body support layer, or other surface to support the body support 10.
  • the body support 10 can include one or more layers of foam, and in some embodiments can also include one or more layers of other material.
  • the body support 10 illustrated in Figs. 1-3 is a mattress.
  • the body support 10 can take other forms, such as a mattress topper, overlay, or futon.
  • the features of the body support 10 described herein are applicable to any type of body support having any size and shape. By way of example only, these features are equally applicable to head pillows, seat cushions (including the base and/or back cushions of a seat), neck pillows, leg spacer pillows, eye masks, and any other structure used to support and/or cushion any part or all of the body of a human or animal.
  • body support refers to any and all of such structures (in addition to mattresses, mattress toppers, sleeper sofas, overlays, and futons, for example). It should also be noted that each of the body supports described and/or illustrated herein is presented in a particular form (i.e., in the form of a mattress). However, absent description herein to the contrary, any or all of the features described in connection with the mattress can be applied to any other type of body support having any other shape and size, including the various types of body supports mentioned above.
  • the body support 10 can include one or more layers of foam in stacked relation, and can be enclosed within a cover 16 of any type, such as a woven or non- woven material, a knitted material, a material comprising cotton, wool, or other natural fiber, polyester, rayon, nylon, foam, or other synthetic material, or a material that is liquid and vapor impermeable, liquid impermeable and vapor permeable, or liquid and vapor permeable.
  • Fig. 2 shows the body support of Fig. 1 with the cover 16 removed. As shown in Fig.
  • the body support 10 can include a first or top layer 20 having an upper surface that substantially coincides with the top surface 12 of the body support 10, and a lower surface 24 opposite the top surface 12.
  • the body support 10 can further include a second or bottom layer 26 having an upper surface 28 and a lower surface opposite the upper surface 28 and which substantially coincides with a bottom surface 14 of the body support 10.
  • the top layer 20 can comprise a foam material, such as a polyurethane or latex foam material, any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like.
  • the foam of the top layer 20 can be visco-elastic or non-visco-elastic, as desired.
  • visco-elastic foam can present unique advantages for the body support 10, including desirable tactile contact and pressure responsiveness features to enhance the comfort of a user on the body support 10.
  • the top layer 20 can also at least partially conform to the user's body, thereby distributing the force applied by the user's body upon the top layer 20.
  • the visco-elastic foam can be temperature-sensitive to the body heat of a user, thereby changing in firmness in response to receiving the body heat of a user thereon.
  • the visco-elastic or non-visco-elastic foam of the top layer 20 can be reticulated or non-reticulated.
  • Reticulated foam (visco-elastic or otherwise) is a cellular foam structure in which the cells of the foam are essentially skeletal.
  • the cells of the reticulated foam are each defined by a plurality of apertured windows surrounded by cell struts.
  • the cell windows of reticulated foam can be entirely gone (leaving only the cell struts) or substantially gone.
  • the foam is considered "reticulated” if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts).
  • windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts).
  • Such structures can be created by destruction or other removal of cell window material, or preventing the complete formation of cell windows during the manufacturing process of the foam.
  • the bottom layer 26 comprises visco-elastic or non-visco-elastic reticulated foam of any type (e.g., polyurethane, latex, or any of the suitable materials described above in connection with the top layer 20).
  • any type e.g., polyurethane, latex, or any of the suitable materials described above in connection with the top layer 20.
  • the reticulated foam of the bottom layer 26 can also perform a wicking function to draw moisture away from the top layer 20. Both the heat transfer and moisture wicking functions of the bottom layer 26 can cooperate with similar functions performed by the top layer 20 in those embodiments in which the top layer 20 is constructed of visco-elastic or non-visco-elastic reticulated foam.
  • the reticulated foam of the bottom layer 26 can help to prevent one or more areas of the top layer 20 from reaching an undesirably high temperature, and can also help to insure a more even distribution of heat across the bottom layer 26. Also, the reticulated structure of the foam in the bottom layer 26 enables significantly higher airflow into, out of, and through the bottom layer 26 - a characteristic of the bottom layer 26 that can reduce heat in the top and bottom layers 20, 26. Again, increased airflow capability can also be achieved by utilizing a reticulated foam in the top layer 20.
  • reticulated visco-elastic foam is used for the bottom layer 26 based upon the reduced hardness and slow recovery characteristics of reticulated visco- elastic foam. These features can be desired for enhanced user comfort in some applications.
  • the bottom layer 26 of reticulated foam has a hardness of at least about 20 N and no greater than about 150 N. In other embodiments, a bottom layer 26 having a hardness of at least about 30 N and no greater than about 100 N is utilized. In still other embodiments, a bottom layer 26 having a hardness of at least about 40 N and no greater than about 85 N is utilized.
  • the hardness of a material referred to herein is measured by exerting pressure from a plate against a sample of the material having length and width dimensions of 40 cm each (defining a surface area of the sample of material), and a thickness of 5 cm to a compression of 40% of an original thickness of the material at approximately room temperature (i.e., 21-23 degrees Celsius), wherein the 40% compression is held for a set period of time following the International Organization of Standardization (ISO) 2439 hardness measuring standard.
  • ISO International Organization of Standardization
  • the reticulated foam of the bottom layer 26 of the body support 10 can also have a density providing a relatively high degree of material durability.
  • the density of the bottom layer 26 can also impact other characteristics of the foam, such as the manner in which the respective surface responds to pressure, and the feel of the foam.
  • the bottom layer 26 has a density of no less than about 30 kg/m 3 and no greater than about 175 kg/m 3 .
  • a bottom layer 26 having a density of at least about 70 kg/m 3 and no greater than about 120 kg/m 3 is utilized.
  • a bottom layer 26 having a density of at least about 80 kg/m 3 and no greater than about 95 kg/m 3 is utilized.
  • the reticulated foam of the bottom layer 26 can be selected for responsiveness to any range of temperatures.
  • a temperature responsiveness in a range of a user's body temperatures can provide significant advantages.
  • a reticulated foam selected for the bottom layer 26 can be responsive to temperatures changes above at least 0 0 C.
  • the reticulated foam selected for the bottom layer 26 can be responsive to temperature changes within a range of at least about 10 0 C.
  • the reticulated foam selected for the bottom layer 26 can be responsive to temperature changes within a range of at least about 15°C.
  • a quantity of gelatinous material or gel 32 can be applied to the upper surface 28 of the bottom layer 26 of reticulated foam.
  • the gel can impart desirable characteristics to the body support 10, including an enhanced "bounce" of the body support 10 and desirable thermal properties without unacceptably impacting the firmness of the body support or sacrificing the desirable body conforming and softness characteristics of a visco-elastic foam top layer 20 (if used).
  • a quantity of gelatinous material 32 is shown on the upper surface 28 of the bottom layer 26.
  • the gelatinous material 32 is applied to a majority of the upper surface 28 of the bottom layer 26, whether in one or more relatively large regions as shown in Fig. 1, or in a larger number of discrete or connected regions, leaving numerous exposed areas of the upper surface 28.
  • the areas of the upper surface 28 covered by the gelatinous material 32 can have any shape desired, including without limitation circular, oval, or other rotund shapes, rectangular, square, triangular, or other polygonal shapes, star shapes, lines, waves, and other elongated shapes, and any combination of such shapes.
  • these areas can have the same size or any combination of sizes desired, and can be located in any regularly-spaced or irregularly- spaced arrangement (or can even be located randomly) on the bottom layer 26.
  • gelatinous material 32 may only be desired in certain locations of the body support 10, such as in an area of the body support corresponding to a user's head, torso, or legs. In such cases, any of the shapes and sizes of upper surface areas can be covered with the gelatinous material as described above.
  • the gelatinous material 32 sets substantially instantly or within a very short period of time (i.e., insufficient to permit the gelatinous material 32 to be lost within the reticulated cellular structure of the bottom layer 26 or to flow where the gelatinous material 32 is not desired).
  • the gelatinous material 32 is applied within a recesses 36 in the upper surface 28 of the bottom layer 26.
  • gel-impermeable barriers or liners 40 e.g., of thin polyurethane sheeting, foil, paper, and the like
  • the recesses 36 can form any pattern on the upper surface 28 of the bottom layer 26, and can have any of the shapes, sizes, and locations of the gelatinous material 32 described earlier.
  • the recesses 36 are at least about 0.125 inches (about 0.3175 centimeter) deep and no greater than about 4 inches (about 10.16 centimeters) deep. In other embodiments, the recesses 36 are at least about 0.25 inches (about 0.635 centimeter) deep and no greater than about 3 inches (about 7.62 centimeters) deep. In still other embodiments, the recesses 36 are at least about 0.5 inches (about 1.27 centimeters) deep and no greater than about 1 inches (about 2.54 centimeters) deep. In some embodiments, the recesses 36 extend substantially the same distance into the upper surface 28 of the bottom layer 26. However, in other embodiments, the recesses 36 can extend varying distances into the upper surface 28 of the bottom layer 26, such as in different locations across the bottom layer where different quantities (i.e., thicknesses) of the gelatinous material 32 are desired.
  • the gelatinous material 32 can be a surface gel in some embodiments, such that the gelatinous material 32 does not significantly penetrate the upper surface 28 of the reticulated foam bottom layer 26 onto which the gelatinous material 32 is applied.
  • the gelatinous material 32 permeates about 1-2 mm into the reticulated foam bottom layer 26.
  • the amount of penetration into the reticulated foam bottom layer 26 can depend at least in part upon the type of reticulated foam used for the bottom layer 26 of the body support 10. For example, a deeper penetration (i.e., greater than 2 mm) can result in more reticulated foams, whereas little to no penetration can result in less reticulated foams.
  • the gelatinous material 32 can be applied to the upper surface 28 of the reticulated foam bottom layer 26 by pouring, rolling, wiping, brushing, setting, or otherwise inserting the gelatinous material 32 into the recesses 36. In still other embodiments, the gelatinous material 32 can be applied using other methods.
  • the gelatinous material 32 can even be applied to the underside of a reticulated foam layer, such as in cases where the layer is temporarily inverted to permit the gelatinous material to at least partially set, or where the gelatinous material 32 is temporarily held to the surface of the reticulated foam layer to at least partially set.
  • the gelatinous material 32 is a gel elastomer - a highly viscoelastic polymer gel that is flowable prior to setting, and that assumes a deformable and elastic shape when set.
  • a polyurethane gel can produce excellent results in some applications.
  • the gelatinous material 32 can be a polyurethane gel such as Voralast GE produced by The Dow Chemical Company, Midland, Michigan.
  • the gelatinous material 32 has a hardness of no greater than about 90 Shore OOO at room temperature (i.e., 21-23 Degrees Celsius).
  • a gelatinous material hardness of no greater than about 60 Shore OOO at room temperature can provide good performance results in a number of body support applications. In other embodiments, a gelatinous material hardness of no greater than about 40 Shore OOO at room temperature can provide good performance results in a number of body support applications. All such measurements are made after any necessary set time of the gelatinous material 32.
  • a desirable characteristic of some gels used in embodiments of the present invention is the density of such gels, as the density of such gels can correlate to the overall elastomeric properties of the gels.
  • the gelatinous material 32 has a density of no less than about 600 kg/m 3 and no greater than about 1000 kg/m 3 .
  • the gelatinous material 32 utilized in the illustrated embodiments of Figs. 1-3 will not harden over time as other materials may. Such hardening can compromise the comfort of the body support 10 in light of the fact that the softness and/or cushioning of the body support 10 can be adversely affected by the existence of a relatively hard layer of gel within the body support 10. This adverse impact can be more significant for body supports having one or more visco-elastic foam layers.
  • the gel 32 can be applied at any of a variety of temperatures, such as between about 0 degrees Celsius and about 100 degrees Celsius. In some embodiments, the gel 32 is applied at or near room temperature (i.e., between about 15 and about 20 degrees Celsius), such as in the case of many polyurethane gels suitable for functioning at room temperature. Accordingly, it may not be required to heat up the gel 32 prior to applying the gel 32 to one or more surfaces of the body support 10 as described herein.
  • the gelatinous material 32 permits transfer of stress and force therethrough to one or more foam layers (e.g., to the top and/or bottom layers 20, 26 in the illustrated embodiments).
  • one or more of the layers (e.g., layers 20, 26) of the body support 10 is individually enclosed (partially or fully) in a covering material (not shown), or is enclosed in a covering material with one or more other layers.
  • This covering material can be different from the cover 16 described above, although the covering material can be made of any of the materials also described above in connection with the cover 16.
  • each of the layers 20, 26 can be surrounded by a respective covering material of a fine mesh, cheesecloth or other relatively thin fabric, and the like.
  • the gelatinous material 32 can permeate the covering material to cover, and in some cases impregnate, the upper surface 28 of bottom layer 26 as described above.

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  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Otolaryngology (AREA)
  • Pulmonology (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

L'invention porte sur un ensemble support de corps, qui comprend une couche de mousse ayant une surface supérieure et définissant de multiples cavités dans la surface supérieure, et de multiples flaques de gel positionnées dans les cavités respectives, de telle sorte que les flaques de gel s'étendent sur moins de la totalité du chemin à travers la couche de mousse. La mousse peut comprendre de la mousse viscoélastique réticulée. Une doublure peut être positionnée entre les flaques de gel et la couche de mousse. Les flaques de gel peuvent imprégner la mousse sur pas plus de 2 mm, et, facultativement, peuvent imprégner la mousse sur pas plus de 1 mm. La flaque peut avoir une profondeur de 3 mm à 100 mm, et, de plus, la flaque peut avoir une profondeur de 6 mm à 75 mm, et, en outre, la flaque peut avoir une profondeur de 12 mm à 25 mm.
PCT/US2009/069028 2008-12-24 2009-12-21 Support de corps comprenant un matériau gélatineux et procédé de fabrication d'un support de corps le comprenant WO2010075300A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14063908P 2008-12-24 2008-12-24
US61/140,639 2008-12-24

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WO2010075300A1 true WO2010075300A1 (fr) 2010-07-01

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013040543A3 (fr) * 2011-09-15 2013-05-10 Tempur-Pedic Management, Inc. Soutien corporel modifié avec du gel visqueux et procédé de fabrication d'un soutien corporel au moyen de celui-ci
WO2014142959A1 (fr) * 2013-03-15 2014-09-18 Tempur-Pedic Management, Llc Composite de mousse et ses procédés de fabrication
US9980578B2 (en) 2012-07-27 2018-05-29 Tempur-Pedic Management, Llc Body support cushion having multiple layers of phase change material

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5636395A (en) * 1995-02-06 1997-06-10 Serda; Jarrett F. M. Mattress pad with gel filled chambers coupled to a foam cushion
US20050166330A1 (en) * 2004-01-31 2005-08-04 Williams Carla M. Particulate filler mattress
US20060288490A1 (en) * 2005-06-24 2006-12-28 Tempur World, Llc Reticulated material body support and method
US20070246157A1 (en) * 2006-04-25 2007-10-25 Technogel Gmbh & Co. Process for preparing an apparatus comprising a gel layer

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5636395A (en) * 1995-02-06 1997-06-10 Serda; Jarrett F. M. Mattress pad with gel filled chambers coupled to a foam cushion
US20050166330A1 (en) * 2004-01-31 2005-08-04 Williams Carla M. Particulate filler mattress
US20060288490A1 (en) * 2005-06-24 2006-12-28 Tempur World, Llc Reticulated material body support and method
US20070246157A1 (en) * 2006-04-25 2007-10-25 Technogel Gmbh & Co. Process for preparing an apparatus comprising a gel layer

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013040543A3 (fr) * 2011-09-15 2013-05-10 Tempur-Pedic Management, Inc. Soutien corporel modifié avec du gel visqueux et procédé de fabrication d'un soutien corporel au moyen de celui-ci
US9980578B2 (en) 2012-07-27 2018-05-29 Tempur-Pedic Management, Llc Body support cushion having multiple layers of phase change material
US10765228B2 (en) 2012-07-27 2020-09-08 Tempur World, Llc Body support cushion having multiple layers of phase change material
WO2014142959A1 (fr) * 2013-03-15 2014-09-18 Tempur-Pedic Management, Llc Composite de mousse et ses procédés de fabrication

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