U.S. patent application number 11/265410 was filed with the patent office on 2006-12-28 for reticulated material body support and method.
Invention is credited to Tom D. Mikkelsen, Kenneth E. Mitchell.
Application Number | 20060288491 11/265410 |
Document ID | / |
Family ID | 37595830 |
Filed Date | 2006-12-28 |
United States Patent
Application |
20060288491 |
Kind Code |
A1 |
Mikkelsen; Tom D. ; et
al. |
December 28, 2006 |
Reticulated material body support and method
Abstract
A body support comprising a top layer of flexible visco-elastic
material having an exposed convoluted top surface is disclosed. The
flexible visco-elastic material can have a reticulated or
non-reticulated cellular structure. In some embodiments, one or
more other layers of the body support comprises reticulated
visco-elastic foam, and can have at least one material property
responsive to temperatures in the range of a user's body heat. In
these and other embodiments, one or more of the other layers of
flexible material comprises non-visco-elastic foam, and can be
combined in a body support with one or more layers of visco-elastic
foam. The body support can include one or more layers of other
material types, including one or more layers of high-resilience
polyurethane foam.
Inventors: |
Mikkelsen; Tom D.;
(Kingsport, TN) ; Mitchell; Kenneth E.;
(Albuquerque, NM) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH, LLP
100 E WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Family ID: |
37595830 |
Appl. No.: |
11/265410 |
Filed: |
November 2, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11166594 |
Jun 24, 2005 |
|
|
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11265410 |
Nov 2, 2005 |
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Current U.S.
Class: |
5/740 |
Current CPC
Class: |
A47C 7/742 20130101;
A47C 27/122 20130101; A47C 7/029 20180801; A47G 9/10 20130101; A47C
27/144 20130101; A47C 27/15 20130101; Y10T 428/233 20150115; A47C
27/148 20130101 |
Class at
Publication: |
005/740 |
International
Class: |
A47C 17/00 20060101
A47C017/00 |
Claims
1. A support cushion, comprising: a first layer comprising
visco-elastic foam having an exposed top surface; and a bottom
surface opposite the top surface and separated from the top surface
by a distance defining a thickness of the support cushion; wherein
at least a portion of the exposed top surface of the top layer has
a convoluted shape.
2. The support cushion as claimed in claim 1, further comprising a
cover at least partially covering the exposed top surface of the
first layer.
3. The support cushion as claimed in claim 1, wherein the first
layer comprises a plurality of cells defining a reticulated
cellular structure, the cells of the reticulated cellular structure
comprising a skeletal plurality of supports through which
substantially open cell walls establish fluid communication between
an interior of the cell and interiors of adjacent cells.
4. The support cushion as claimed in claim 3, wherein the first
layer comprises foam having a density no less than about 30
kg/m.sup.3 and no greater than about 175 kg/m.sup.3, and a hardness
of no less than about 20 N and no greater than about 150 N at 40%
indentation force defection measured at about 22 degrees Celsius,
the layer of flexible foam comprising visco-elastic foam having at
least one material property responsive to a temperature change in a
range of 10-30.degree. C.
5. The support cushion as claimed in claim 4, wherein the first
layer comprises foam having a density no less than about 50
kg/m.sup.3 and no greater than about 130 kg/m.sup.3.
6. The support cushion as claimed in claim 4, wherein the first
layer comprises foam has a density no less than about 60 kg/m.sup.3
and no greater than about 110 kg/m.sup.3.
7. The support cushion as claimed in claim 1, further comprising a
second layer of polyurethane foam located beneath the first layer,
the second layer of polyurethane foam having a hardness of at least
about 50 N.
8. The support cushion as claimed in claim 1, further comprising a
second layer of polyurethane foam located beneath the first layer,
the second layer of polyurethane foam having a hardness of at least
about 80 N.
9. The support cushion as claimed in claim 1, further comprising a
second layer of flexible foam supporting the first layer, the
second layer of flexible foam having a plurality of cells defining
a reticulated cellular structure and having a temperature change
responsiveness of no greater than 10% change in hardness within a
temperature range of 10-30 degrees Celsius.
10. The support cushion as claimed in claim 9, wherein the first
layer comprises visco-elastic foam having a non-reticulated
visco-elastic cellular structure having a density no less than
about 30 kg/m.sup.3 and no greater than about 150 kg/M.sup.3; a
hardness of no less than about 30 N and no greater than about 175 N
at 40% indentation force defection measured at about 22 degrees
Celsius; and at least one material property responsive to a
temperature change in a range of 10-30.degree. C.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is hereby claimed to U.S. patent application Ser.
No. 11/166,594 filed on Jun. 24, 2005, the entire contents of which
are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] Conventional body supports can be found in a wide variety of
shapes and sizes, and are often adapted for supporting one or more
body parts of a user. As used herein, the term "body support"
includes without limitation any deformable element adapted to
support one or more parts or all of a human or animal in any
position. Examples of body supports include mattresses, pillows,
and cushions of any type, including those for use in beds, seats,
and in other applications.
[0003] Many body supports are constructed entirely or partially out
of 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. In many body
supports, 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 shape
based in part upon the temperature of the supported body part.
[0004] Although the number and types of body supports constructed
with one or more visco-elastic materials continue to increase, the
capabilities of such materials are often underutilized. In many
cases, this underutilization is due to poor body support design
and/or the choice of material(s) used in the body support.
[0005] Based at least in part upon the limitations of existing body
supports and the high consumer demand for improved body supports in
a wide variety of applications, new body supports are welcome
additions to the art.
SUMMARY OF THE INVENTION
[0006] Some embodiments of the present invention provide a support
cushion, comprising a first layer comprising visco-elastic foam
having an exposed top surface; and a bottom surface opposite the
top surface and separated from the top surface by a distance
defining a thickness of the support cushion; wherein at least a
portion of the exposed top surface of the top layer has a
convoluted shape.
[0007] Further aspects of the present invention, together with the
organization and operation thereof, will become apparent from the
following detailed description of the invention when taken in
conjunction with the accompanying drawings, wherein like elements
have like numerals throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a sectioned perspective view of a body support
according to a first embodiment of the present invention;
[0009] FIG. 1A is a detail view of the material in a layer of the
body support illustrated in FIG. 1;
[0010] FIG. 1B is a detail view of the material in another layer of
the body support illustrated in FIG. 1;
[0011] FIG. 2 is a sectioned perspective view of a body support
according to another embodiment of the present invention
[0012] FIG. 2A is a detail view of the material in a layer of the
body support illustrated in FIG. 2;
[0013] FIGS. 2B-6 are sectioned perspective views of body supports
according to additional embodiments of the present invention;
[0014] FIG. 7-9 are exploded perspective views of body supports
according to additional embodiments of the present invention;
[0015] FIGS. 10-12 are sectioned perspective views of body supports
according to additional embodiments of the present invention;
[0016] FIG. 12A is a detail view of the material in a layer of the
body support illustrated in FIG. 12;
[0017] FIGS. 13-30 are sectioned perspective views of body supports
according to additional embodiments of the present invention;
[0018] FIGS. 31-34 are exploded perspective views of body supports
according to additional embodiments of the present invention;
[0019] FIG. 35 is a sectioned perspective view of a pillow
according to an embodiment of the present invention;
[0020] FIG. 36 is a sectioned perspective view of a pillow
according to another embodiment of the present invention;
[0021] FIG. 37 is a perspective view of a pillow according to
another embodiment of the present invention;
[0022] FIG. 38 is a cross-sectional view of the pillow illustrated
in FIG. 37, taken along lines 38-38 of FIG. 37;
[0023] FIG. 39 is a perspective view of a pillow according to
another embodiment of the present invention;
[0024] FIG. 40 is a cross-sectional view of the pillow illustrated
in FIG. 39, taken along lines 40-40 of FIG. 39;
[0025] FIG. 41 is a perspective view of a pillow according to
another embodiment of the present invention;
[0026] FIG. 42 is a cross-sectional view of the pillow illustrated
in FIG. 41, taken along lines 42-42 of FIG. 41; and
[0027] FIG. 43 is an exploded perspective view of a body support
and foundation assembly according to an embodiment of the present
invention.
[0028] Before the various embodiments of the present invention are
explained in detail, it is to be understood that the invention is
not limited in its application to the details of construction and
the arrangements of components set forth in the following
description or illustrated in the drawings. The invention is
capable of other embodiments and of being practiced or of being
carried out in various ways. Also, it is to be understood that
phraseology and terminology used herein with reference to device or
element orientation (such as, for example, terms like "front",
"back", "up", "down", "top", "bottom", and the like) are only used
to simplify description of the present invention, and do not alone
indicate or imply that the device or element referred to must have
a particular orientation. In addition, terms such as "first",
"second", and "third" are used herein and in the appended claims
for purposes of description and are not intended to indicate or
imply relative importance or significance. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless limited otherwise, the terms
"connected," "coupled," and variations thereof herein are used
broadly and encompass direct and indirect connections and
couplings. In addition, the terms "connected" and "coupled" and
variations thereof are not restricted to physical or mechanical
connections or couplings.
DETAILED DESCRIPTION
[0029] A body support 102 according to an embodiment of the present
invention is illustrated in FIGS. 1, 1A, and 1B, and comprises two
layers of material: a top layer 110 comprising open-celled
non-reticulated visco-elastic foam (sometimes referred to as
"memory foam" or "low resilience foam") and a bottom layer 112
comprising reticulated non-visco-elastic foam. In some embodiments,
the top layer 110 can rest upon the bottom layer 112 without being
secured thereto. However, in other embodiments, the top and bottom
layers 110, 112 are secured to one another by adhesive or cohesive
bonding material, by being bonded together during formation of the
top and bottom layers 110, 112, by tape, hook and loop fastener
material, conventional fasteners, stitches extending at least
partially through the top and bottom layers 110, 112, or in any
other suitable manner.
[0030] Each of the top and bottom layers 110, 112 can be
substantially flat bodies having substantially planar top and
bottom surfaces 116, 118, 120, 122 as shown in FIG. 1. However, in
other embodiments, one or more of the top and bottom surfaces 116,
118, 120, 122 of either or both top and bottom layers 110, 112 can
be non-planar, including without limitation surfaces having ribs,
bumps, and other protrusions of any shape and size, surfaces having
grooves, dimples, and other apertures that extend partially or
fully through the respective layer 110, 112, and the like. Such
alternative surface shapes are described in greater detail below in
connection with other embodiments of the present invention. Also,
depending at least in part upon the application of the body support
102 (i.e., the product defined by the body support 102 or in which
the body support 102 is employed), either or both of the top and
bottom layers 110, 112 can have shapes that are not flat. By way of
example only, either or both layers 110, 112 can be generally
wedge-shaped, can have a concave or convex cross-sectional shape,
can have a combination of convex and concave shapes, can have a
stepped, faceted, or other shape, can have a complex or irregular
shape, and/or can have any other shape desired. Examples of such
alternative shapes are presented in greater detail below in
connection with other embodiments of the present invention.
[0031] In some embodiments, the top layer 110 provides a relatively
soft and comfortable surface for a user's body or body portion
(hereinafter referred to as "body"). Coupled with the slow recovery
characteristic of the visco-elastic foam, the top layer 110 can
also conform to a user's body, thereby distributing the force
applied by the user's body upon the top layer 110. In some
embodiments, the top layer 110 has a hardness of at least about 30
N and no greater than about 175 N for desirable softness and
body-conforming qualities. In other embodiments, a top layer 110
having a hardness of at least about 40 N and no greater than about
110 N is utilized for this purpose. In still other embodiments, a
top layer 110 having a hardness of at least about 40 N and no
greater than about 75 N is utilized. Unless otherwise specified,
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 (e.g., 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.
[0032] The top layer 110 can also have a density providing a
relatively high degree of material durability. The density of the
foam in the top layer 110 can also impact other characteristics of
the foam, such as the manner in which the top layer 110 responds to
pressure, and the feel of the foam. In some embodiments, the top
layer 110 has a density of no less than about 30 kg/m.sup.3 and no
greater than about 150 kg/m.sup.3. In other embodiments, a top
layer 110 having a density of at least about 40 kg/m.sup.3 and no
greater than about 125 kg/m.sup.3 is utilized. In still other
embodiments, a top layer 110 having a density of at least about 60
kg/m.sup.3 and no greater than about 115 kg/m.sup.3 is
utilized.
[0033] The visco-elastic foam of the top layer 110 can be selected
for responsiveness to any range of temperatures. However, in some
embodiments, a temperature responsiveness in a range of a user's
body temperatures (or in a range of temperatures to which the body
support 102 is exposed by contact or proximity to a user's body
resting thereon) can provide significant advantages. For example, a
visco-elastic foam selected for the top layer 110 can be responsive
to temperature changes above at least about 0.degree. C. In some
embodiments, the visco-elastic foam selected for the top layer 110
can be responsive to temperature changes within a range of at least
about 10.degree. C. In other embodiments, the visco-elastic foam
selected for the top layer 110 can be responsive to temperature
changes within a range of at least about 15.degree. C.
[0034] As used herein and in the appended claims, a material is
considered "responsive" to temperature changes if the material
exhibits a change in hardness of at least 10% measured by ISO
Standard 3386 through the range of temperatures between 10 and 30
degrees Celsius.
[0035] With reference now to the illustrated embodiment of FIGS. 1,
1A, and 1B, the top layer 110 of the illustrated body support 102
comprises a cellular structure of flexible visco-elastic
polyurethane foam in which the walls of the individual cells are
substantially intact. In some embodiments, the bottom layer 112
comprising reticulated foam can reduce heat in the top layer 110,
due at least in part to the cellular structure of the foam of the
bottom layer 112. With reference to FIG. 1B, for example, the cells
of the foam of the bottom layer 112 are essentially skeletal
structures in which many (if not substantially all) of the cell
walls separating one cell from another do not exist. In other
words, the cells are defined by a plurality of supports or
"windows" and by no cell walls, substantially no cell walls, or by
a substantially reduced number of cell walls. Such a cellular foam
structure is sometimes referred to as "reticulated" foam. In some
embodiments, a foam is considered "reticulated" if at least 50% of
the walls defining the cells of the foam do not exist (i.e., have
been removed or were never allowed to form during the manufacturing
process of the foam).
[0036] Also, in some embodiments it is desirable that the bottom
layer 112 of reticulated non-visco-elastic foam be capable of
providing some degree of support that is substantially independent
of temperatures experienced by the top layer 110 when supporting a
user's body (i.e., independent of a user's body heat). Therefore,
the bottom layer 112 can comprise reticulated non-visco-elastic
foam that is substantially insensitive to temperature changes
within a range of between about 10.degree. C. and about 35.degree.
C. As used herein, a material is "substantially insensitive" to
temperature changes if the material exhibits a change in hardness
of less than 10% measured by ISO Standard 3386 through the range of
temperatures between 10 and 30 degrees Celsius. In some
embodiments, the bottom layer 112 can comprise reticulated
non-visco-elastic foam that is substantially insensitive to
temperature changes within a range of between about 15.degree. C.
and about 30.degree. C. In still other embodiments, a bottom layer
112 comprising reticulated non-visco-elastic foam that is
substantially insensitive to temperature changes within a range of
between about 15.degree. C. and about 25.degree. C. can be
used.
[0037] By virtue of the skeletal cellular structure of the bottom
layer 112 illustrated in FIGS. 1 and 1B, heat in the top layer 110
can be transferred away from the top layer 110, thereby helping to
keep a relatively low temperature in the top layer 110. Also, the
reticulated non-visco-elastic foam of the bottom layer 112 can
enable significantly higher airflow into, out of, and through the
bottom layer 112--a characteristic of the bottom layer 112 that can
also help to keep a relatively low temperature in the top layer
110.
[0038] Like the top layer 110, the bottom layer 112 can have a
density providing a relatively high degree of material durability.
Also, the density of the foam in the bottom layer 112 can also
impact other characteristics of the foam, such as the manner in
which the bottom layer 112 responds to pressure, and the feel of
the foam. In some embodiments, the bottom layer 112 has a density
of no less than about 20 kg/m.sup.3 and no greater than about 80
kg/M.sup.3. In other embodiments, a bottom layer 112 having a
density of at least about 25 kg/m.sup.3 and no greater than about
60 kg/m.sup.3 is utilized. In still other embodiments, a bottom
layer 112 having a density of at least about 30 kg/m.sup.3 and no
greater than about 40 kg/m.sup.3 is utilized.
[0039] Also, in some embodiments, the bottom layer 112 has a
hardness of at least about 50 N and no greater than about 300 N. In
other embodiments, a bottom layer 112 having a hardness of at least
about 80 N and no greater than about 250 N is utilized. In still
other embodiments, a bottom layer 112 having a hardness of at least
about 90 N and no greater than about 180 N is utilized.
[0040] The body support 102 illustrated in FIGS. 1-1B can have a
bottom layer 112 that is at least as thick as the top layer 110,
thereby providing a significant ventilation and/or heat dissipation
layer that, in some embodiments, is relatively temperature
insensitive. In some embodiments, the bottom layer 112 is at least
half the thickness as the top layer 110. In other embodiments, the
bottom layer 112 is at least about the same thickness as the top
layer 110. In still other embodiments, the bottom layer 112 is at
least about 2 times as thick as the top layer 110.
[0041] The body support 102 illustrated in FIGS. 1, 1A, and 1B is a
mattress, mattress topper, overlay, or futon, and is illustrated in
such form by way of example only. It will be appreciated that the
features of the body support 102 described above are applicable to
any other type of body support having any size and shape. By way of
example only, these features are equally applicable to head
pillows, seat cushions, seat backs, neck pillows, leg spacer
pillows, eye masks, and any other element used to support or
cushion any part or all of a human or animal body. Accordingly, as
used herein and in the appended claims, the term "body support" is
intended to refer to any and all of such elements (in addition to
mattresses, mattress toppers, overlays, or futons). It should also
be noted that each of the body supports described and illustrated
herein is presented in a particular form, such as a mattress,
mattress topper, overlay, futon, or pillow. However, absent
description herein to the contrary, any or all of the features of
each such body support 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.
[0042] FIGS. 2 and 2A illustrate another embodiment of a body
support according to the present invention. This embodiment employs
much of the same structure and has many of the same properties as
the embodiments of the body support described above in connection
with FIGS. 1-1B. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 1-1B.
Reference should be made to the description above in connection
with FIGS. 1-1B for additional information regarding the structure
and features, and possible alternatives to the structure and
features of the body support illustrated in FIGS. 2 and 2A and
described below. Structure and features of the embodiment shown in
FIGS. 2 and 2A that correspond to structure and features of the
embodiment of FIGS. 1-1B are designated hereinafter in the 200
series of reference numbers.
[0043] Like the embodiment illustrated in FIGS. 1-1B, the body
support 202 illustrated in FIGS. 2 and 2A has a top layer 210
comprising open-celled non-reticulated visco-elastic foam and an
underlying layer 212 comprising reticulated non-visco-elastic foam.
In some embodiments, the body support 202 can therefore provide the
desirable softness, body-conforming, ventilation, and heat transfer
properties described above. The body support 202 illustrated in
FIGS. 2 and 2A further comprises a bottom layer 214 beneath the
layer of reticulated non-visco-elastic foam 212. Therefore, the
layer 212 of reticulated non-visco-elastic foam is a middle layer
212 located between the top and bottom layers 210, 214 of the body
support 202.
[0044] The bottom layer 214 of the body support 202 illustrated in
FIGS. 2 and 2A comprises a cellular structure of flexible
polyurethane foam, as best shown in FIG. 2A. In some embodiments,
the middle layer 212 can rest upon the bottom layer 214 without
being secured thereto. However, in other embodiments, the middle
and bottom layers 212, 214 are secured to one another in any of the
manners described above with reference to the possible types of
connection between the top and bottom layers 110, 112 in the
illustrated embodiment of FIGS. 1-1B. In this regard, it should be
noted that absent description herein to the contrary, any adjacent
layers of material in any of the body support embodiments disclosed
herein can be permanently or releasably secured to one another in
any of the manners described above (with reference to the possible
types of connection between the top and bottom layers 110, 112 in
the illustrated embodiment of FIGS. 1-1B), or can be
unconnected.
[0045] Each of the top, middle, and bottom layers 210, 212, 214 can
be substantially flat bodies having substantially planar top and
bottom surfaces 216, 218, 220, 222, 224, 226 as shown in FIG. 2.
However, any or all of the top and bottom surfaces can have any of
the non-planar shapes described above in connection with the
surfaces 116, 118, 120, 122 in the illustrated embodiment of FIGS.
1-1B. Also, depending at least in part upon the application of the
body support 202 (i.e., the product defined by the body support 202
or in which the body support 202 is employed), either or both of
the top, middle, and bottom layers 210, 212, 214 can have a shape
that is not flat, including any of the shapes described above in
connection with the illustrated embodiment of FIGS. 1-1B.
[0046] Absent description herein to the contrary, any or all of the
layers of material in any of the body support embodiments disclosed
herein can be substantially flat, or can have any shape that is not
flat, including any of the shapes described above in connection
with the illustrated embodiment of FIGS. 1-1B. Also absent
description herein to the contrary, the surfaces of either or both
opposite faces of any or all of the layers of material in any of
the body support embodiments disclosed herein can be substantially
planar, or can instead have any of the non-planar shapes described
above in connection with the surfaces 116, 118, 120, 122 in the
illustrated embodiment of FIGS. 1-1B.
[0047] In some embodiments, the bottom layer 214 is a supportive
layer providing a relatively stiff substrate upon which the top and
middle layers 210, 212 lie, while still having a degree of
deformability to provide user comfort (to the extent that the
user's weight affects the shape of the bottom layer 214).
Therefore, the bottom layer 214 can comprise a foam having a
relatively high resilience capable of providing significant support
to the top and middle layers 210, 212. The bottom layer 214 can
have a resilience greater than that of the other layers 210, 212 in
the body support 202. In some embodiments, the bottom layer 214 has
a hardness of at least about 50 N and no greater than about 300 N
for a desirable degree of support and comfort. In other
embodiments, a bottom layer 214 having a hardness of at least about
80 N and no greater than about 250 N is utilized for this purpose.
In still other embodiments, a bottom layer 214 having a hardness of
at least about 90 N and no greater than about 180 N is
utilized.
[0048] Depending at least in part upon the thickness and material
properties of the top and middle layers 210, 212, in some
embodiments the bottom layer 214 can be exposed to substantial body
heat from a user resting upon the body support 202. In such
embodiments, the foam of the bottom layer 214 can be selected to be
substantially insensitive to temperature changes (as defined above)
within a range of between about 10.degree. C. and about 35.degree.
C., thereby retaining the supportive properties desired for the
bottom layer 214 throughout a range of body temperatures to which
the bottom layer 214 may be exposed. In some embodiments, the
bottom layer 214 can comprise foam that is substantially
insensitive to temperature changes within a range of between about
15.degree. C. and about 30.degree. C. In still other embodiments, a
bottom layer 214 of foam that is substantially insensitive to
temperature changes within a range of between about 15.degree. C.
and about 25.degree. C. can be used.
[0049] Like the top and middle layers 210, 212, the bottom layer
214 can have a density providing a relatively high degree of
material durability. Also, the density of the foam in the bottom
layer 214 can also impact other characteristics of the foam, such
as the manner in which the bottom layer 214 responds to pressure,
and the feel of the foam. In some embodiments, the bottom layer 214
has a density of no less than about 20 kg/m.sup.3 and no greater
than about 80 kg/m.sup.3. In other embodiments, a bottom layer 214
having a density of at least about 25 kg/m.sup.3 and no greater
than about 60 kg/m.sup.3 is utilized. In still other embodiments, a
bottom layer 214 having a density of at least about 30 kg/m.sup.3
and no greater than about 40 kg/m.sup.3 is utilized.
[0050] The body support 202 illustrated in FIG. 2 can have a bottom
layer 214 that is at least as thick as the combination of the top
and middle layers 210, 212, thereby providing substantial support
for the top and middle layers 210, 212. In some embodiments, the
bottom layer 214 is at least about 2/3 of the combined thickness of
the top and middle layers 210, 212. Also, in some embodiments, the
bottom layer 214 is at least about half the combined thickness of
the top and middle layers 210, 212.
[0051] FIG. 2B illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 1-2A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 1-2A.
Reference should be made to the description above in connection
with FIGS. 1-2A for additional information regarding the structure
and features, and possible alternatives to the structure and
features of the body support illustrated in FIG. 2B and described
below. Structure and features of the embodiment shown in FIGS. 2B
that correspond to structure and features of the embodiment of
FIGS. 1-2A are designated hereinafter with primed numbers in the
200 series of reference numbers.
[0052] Like the embodiment illustrated in FIGS. 2 and 2A, the body
support 202 illustrated in FIG. 2B has a top layer 210' comprising
open-celled non-reticulated visco-elastic foam, an underlying layer
212' comprising reticulated non-visco-elastic foam, and a bottom
layer 214' comprising a cellular structure of flexible polyurethane
foam (which, in some embodiments, comprises a foam having a
relatively high resilience, a temperature insensitivity, a density,
and/or a thickness as described in greater detail above in
connection with FIGS. 2 and 2A). Accordingly, the body support 202'
can provide the desirable softness, body-conforming, ventilation,
and heat transfer properties described above, while also providing
support for the top and middle layers 210', 212'.
[0053] As described above, some embodiments of the present
invention employ one or more layers of material having one or more
surfaces that are non-planar, such as surfaces that have ribs,
bumps, and other protrusions of any shape and size, surfaces having
grooves, dimples, and other apertures that extend partially or
fully through the respective layer, and the like. The body support
202' illustrated in FIG. 3 is an example of such a body support.
Also, the body support 202' illustrated in FIG. 3 is an example of
the manner in which a non-planar top surface 216' of the top layer
210' can be employed to provide additional features for the body
support 202'. In particular, the non-planar top surface 216' of the
illustrated body support 202' is convoluted. The features of the
convoluted surface are described in greater detail below in
connection with the illustrated embodiment of FIG. 4.
Alternatively, the non-planar top surface 216' can take any of the
other forms also described below in connection with the illustrated
embodiment of FIG. 4 and/or described above in connection with the
illustrated embodiment of FIGS. 1-1B.
[0054] In some embodiments, the non-planar top surface 216' of the
top layer 210' of visco-elastic foam can provide an enhanced degree
of heat dissipation. Also or alternatively, the non-planar top
surface 216' can provide desirable pressure distribution in a
manner that is different from that of a planar top surface
216'.
[0055] As described in greater detail below, any of the body
support embodiments disclosed herein can be provided with one or
more covers covering any part or all of such body supports. By way
of example, the body support 202' illustrated in FIG. 2B has a
cover 272' enclosing all three layers 210', 212', 214' of the body
support 202'. Further details regarding the features and
construction of the cover 272', as well as the possible
alternatives thereof, are discussed in greater detail below in
connection with the illustrated embodiment of FIG. 43.
[0056] Used in conjunction with a body support 202' having a top
layer 210' of visco-elastic foam having a convoluted top surface
216', the cover 272' can provide a desirable appearance for the
body support 202'. The cover 272' can comprise a material that
enables a user to see the shape of some or all of the non-planar
top surface 216' of the body support 202'. For example, although
not illustrated in FIG. 2B, the top surface of the cover 272' can
show at least part of the convolutions of the underlying top layer
210'. The degree to which the shape of the non-planar top surface
216' is visible beneath the cover 272' is dependent at least in
part upon the thickness of the cover 272', the cover material, and
the fit of the cover 272' on the body support 202' (e.g., taut or
loose fit). It will be appreciated that the cover 272' as described
herein can cover any part or all of other non-planar top surfaces
216' of the top visco-elastic layer 210', and can provide any
degree of visibility of the underlying top layer shape.
[0057] Although the body support 202' illustrated in FIG. 2B has a
top layer 210' of visco-elastic foam (having a convoluted top
surface 216') atop a layer 212' of reticulated non-visco-elastic
foam and a layer 214' of relatively high-resilience foam, it should
be noted that any of the body support embodiments disclosed herein
having a top layer comprising visco-elastic foam (whether
non-reticulated or reticulated as described in greater detail
below) can have a non-planar top surface as just described.
[0058] FIG. 3 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 2 and 2A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 2 and 2A.
Reference should be made to the description above in connection
with FIGS. 2 and 2A for additional information regarding the
structure and features, and possible alternatives to the structure
and features of the body support illustrated in FIG. 3 and
described below. Structure and features of the embodiment shown in
FIG. 3 that correspond to structure and features of the embodiment
of FIGS. 2 and 2A are designated hereinafter in the 300 series of
reference numbers.
[0059] Like the body support 202 illustrated in FIGS. 2 and 2A, the
body support 302 illustrated in FIG. 3 comprises a top layer 310 of
open-celled non-reticulated visco-elastic foam, beneath which lie
middle and bottom layers 312, 314 of the body support 302. However,
the materials of the middle and bottom layers 312, 314 are switched
compared to the body support 202 illustrated in FIGS. 2 and 2A.
Accordingly, the middle layer 312 of the body support 302
illustrated in FIG. 3 comprises a relatively resilient flexible
polyurethane foam, and the bottom layer 314 of the body support 302
comprises reticulated non-visco-elastic foam. The relatively highly
resilient foam of the middle layer 312 is described in greater
detail above in connection with the embodiment illustrated in FIGS.
2 and 2A, while the reticulated non-visco-elastic foam of the
bottom layer 314 is described in greater detail above in connection
with the embodiment illustrated in FIGS. 1-1B.
[0060] In the embodiment illustrated in FIG. 3, the non-reticulated
visco-elastic foam can be provided with a desired degree of support
by the adjacent underlying layer of relatively highly resilient
foam, rather than by a layer of such material underlying another
intermediate layer as shown in FIG. 2. In the structure illustrated
in FIG. 3, the middle layer 312 can provide enhanced user support,
depending at least in part upon the thicknesses of the top and
middle layers 310, 312. In some embodiments, the bottom layer 314
of reticulated non-visco-elastic foam can reduce heat in the middle
layer 312 (and in some embodiments, the top layer 310 as well), due
at least in part to the reticulated cellular structure of the foam
of the bottom layer 314.
[0061] The body support 302 illustrated in FIG. 3 can have a middle
layer 312 that is at least about as thick as the top layer 310 to
provide a desirable degree of support for the top layer 310. In
some embodiments, the middle layer 312 can be at least about twice
as thick as the top layer 310 for this purpose. In other
embodiments, a middle layer 312 that is at least about three times
as thick as the top layer 310 is used for this purpose.
[0062] With further reference to FIG. 3, the body support 302 can
have a bottom layer 314 that is at least about 0.07 times as thick
as the combined thickness of the top and middle layers 310, 312 to
carry heat away from the middle layer 312 (and in some embodiments,
the top layer 310 as well). In some embodiments, the bottom layer
314 can be at least about 0.15 times as thick as the combined
thickness of the top and middle layers 310, 312 for this purpose.
In other embodiments, a bottom layer 314 that is at least about
0.25 times as thick as the combined thickness of the top and middle
layers 310, 312 is used for this purpose.
[0063] FIG. 4 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 1-1B. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 1-1B.
Reference should be made to the description above in connection
with FIGS. 1-1B for additional information regarding the structure
and features, and possible alternatives to the structure and
features of the body support illustrated in FIG. 4 and described
below. Structure and features of the embodiment shown in FIG. 4
that correspond to structure and features of the embodiment of
FIGS. 1-1B are designated hereinafter in the 400 series of
reference numbers.
[0064] Like the body support 102 illustrated in FIGS. 1-1B, the
body support 402 illustrated in FIG. 4 comprises a top layer 410
comprising open-celled non-reticulated visco-elastic foam, beneath
which lies a bottom layer 412 comprising reticulated
non-visco-elastic foam. However, the top surface 420 of the bottom
layer 412 has a non-planar shape beneath the substantially planar
bottom surface 418 of the top layer 410. In the embodiment of FIG.
4, the top surface 420 of the bottom layer 412 has a plurality of
protrusions 428 extending toward the top layer 410. The protrusions
428 can be generally conical in shape, can be frusto-conical, or
can have rounded tips as shown in FIG. 4.
[0065] The protrusions 428 of the bottom layer 412 and the bottom
surface 418 of the top layer 410 define a plurality of passages 430
between the top and bottom layers 410, 412. The passages 430 permit
movement of air between the top and bottom layers 410, 412, thereby
improving heat transfer within the body support 402. Also or
alternatively, heat in one or more locations of the body support
402 can be dissipated into and through the passages 430 between the
top and bottom layers 410, 412. The improved heat transfer enabled
by the passages 430 can be used to cool both layers 410, 412, and
can be particularly useful in reducing heat in the top layer 410
closest to the user.
[0066] In some embodiments, the passages 430 between the top and
bottom layers 410, 412 have an average height of no less than about
0.5 cm and no greater than about 10 cm. In other embodiments, the
passages 430 have an average height of no less than about 1 cm and
no greater than about 5 cm. In still other embodiments, passages
430 having an average height of no less than about 1 cm and no
greater than about 3 cm are utilized. It will be appreciated that
the average height of the passages 430 can depend at least in part
upon the height of the protrusions 428 in the illustrated
embodiment of FIG. 4. In other embodiments, the same average
passage heights described above can still be employed using other
types of protrusions alone or in combination with apertures as
described in greater detail below.
[0067] As an alternative or in addition to the generally
cone-shaped protrusions 428 illustrated in FIG. 4, the top surface
420 of the bottom layer 412 can have any other type of protrusion
or combinations of types of protrusions desired, including without
limitation pads, bumps, pillars, and other localized protrusions,
ribs, waves (e.g., having a smooth, sawtooth, or other profile),
and other elongated protrusions, and the like. Also or
alternatively, the top surface 420 of the bottom layer 412 can have
any number and type of apertures, including without limitation
recesses, dimples, blind holes, through holes, grooves, and the
like, any or all of which can be defined in whole or in part by any
of the types of protrusions just described.
[0068] The passages 430 between the top and bottom layers 410, 412
of the body support 402 can be defined by protrusions 428,
apertures, or any combination of protrusions 428 and apertures.
Although the protrusions 428 and/or apertures need not necessarily
be in any arrangement (e.g., a repeating or non-repeating pattern)
on the bottom layer 412, in some embodiments the protrusions 428
are located on the bottom layer 412 in such a manner. For example,
the generally cone-shaped protrusions 428 of the bottom layer 412
in the embodiment illustrated in FIG. 4 are regularly spaced across
the top surface 420 of the bottom layer 412. In some embodiments,
the areas of the top surface 420 located between the generally
cone-shaped protrusions 428 can be recessed, and in some
embodiments can cooperate with the protrusions 428 to resemble an
egg-crate-shaped surface or any other surface shape desired.
[0069] Also, the protrusions 428 and/or apertures in the bottom
layer 412 can define passages 430 that have a constant or
substantially constant height. However, in other embodiments, the
protrusions 428 and/or apertures in the bottom layer 412 can define
passages 430 having a height that varies at different locations
between the top and bottom layers 410, 412. Therefore, the passage
height between the top and bottom layers 410, 412 can be expressed
as an average height as described above.
[0070] In the illustrated embodiment of FIG. 4, the protrusions 428
are located on substantially the entire top surface 420 of the
bottom layer 412. However, in other embodiments, the protrusions
428 can be located on less than all of the entire top surface 420,
such as in one or more regions of the body support 402. Similarly,
apertures at least partially defining the passages 430 can be
defined in one or more regions or in substantially the entire top
surface 420 of the bottom layer 412.
[0071] As described above, passages 430 between the top and bottom
layers 410, 412 of the embodiment illustrated in FIG. 4 can be
defined between a substantially planar bottom surface 418 of the
top layer 410 and a plurality of protrusions 428 and/or apertures
on the top surface 420 of the bottom layer 412. In this regard,
passages 430 capable of performing ventilation and/or heat
dissipating functions can be defined between the substantially
planar bottom surface 418 of the top layer 410 and any non-planar
top surface 420 of the bottom layer 412. In other embodiments,
passages 430 can be defined between a non-planar bottom surface 418
of the top layer 410 and a substantially planar top surface 420 of
the bottom layer 412. The non-planar bottom surface 418 of the top
layer 410 can have any of the protrusion and/or recess features
described above in connection with the top surface 420 of the
bottom layer 412 illustrated in FIG. 4. Therefore, the description
above regarding the non-planar top surface 420 of the bottom layer
412 applies equally to the bottom surface 418 of the top layer 410.
In still other embodiments, passages 430 can be defined between a
non-planar bottom surface 418 of the top layer 410 and a non-planar
top surface 420 of the bottom layer 412. The non-planar surfaces
418, 420 can have any of the protrusion and/or recess features
described above in connection with the top surface 420 of the
bottom layer 412 illustrated in FIG. 4.
[0072] FIG. 5 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 2 and 2A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 2 and 2A.
Reference should be made to the description above in connection
with FIGS. 2 and 2A for additional information regarding the
structure and features, and possible alternatives to the structure
and features of the body support illustrated in FIG. 5 and
described below. Structure and features of the embodiment shown in
FIG. 5 that correspond to structure and features of the embodiment
of FIGS. 2 and 2A are designated hereinafter in the 500 series of
reference numbers.
[0073] As described in greater detail above with regard to the body
support 202 illustrated in FIGS. 2 and 2A, the body support 502
illustrated in FIG. 5 comprises a top layer 510 comprising
open-celled non-reticulated visco-elastic foam, a middle layer 512
comprising reticulated non-visco-elastic foam, and a bottom layer
514 comprising flexible cellular polyurethane foam having a
relatively high resilience. However, the top surface 524 of the
bottom layer 514 has a non-planar shape beneath the substantially
planar bottom surface 522 of the middle layer 512. The non-planar
shape of the top surface 524 can take any of the forms described
above in connection with the non-planar top surface 420 of the
bottom layer 412 illustrated in FIG. 4, and can be defined by a
plurality of protrusions 528 (as shown in FIG. 5) and/or a
plurality of apertures as also described above. Passages 530 can be
defined between the substantially planar bottom surface 522 of the
middle layer 512 and the non-planar top surface 524 of the bottom
layer 514. In other embodiments, such passages 530 can be defined
between a non-planar bottom surface 522 of the middle layer 512 and
a substantially planar top surface 524 of the bottom layer 514, or
between a non-planar bottom surface 522 of the middle layer 512 and
a non-planar top surface 524 of the bottom layer 514, wherein the
non-planar surface(s) can be defined in any of the manners
described above in connection with the illustrated embodiment of
FIG. 4.
[0074] Passages 530 running between the middle and bottom layers
512, 514 illustrated in FIG. 5 can provide the body support 502
with a capacity for ventilation and/or with an increased ability to
dissipate heat from the middle layer 512 of reticulated
non-visco-elastic foam, which can receive a user's body heat from
the top layer 510 of non-reticulated visco-elastic foam. The
skeletal structure of the cells in the middle layer 512 can enable
heat to be transferred from the top layer 512 to and through the
passages 530. Although heat transfer in lateral directions (i.e.,
toward the edges of the body support 502) can still occur in the
middle layer 512 of reticulated non-visco-elastic foam based at
least in part upon the cell structure of such foam, the passages
530 can enhance this heat transfer.
[0075] FIG. 6 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 3. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 3. Reference
should be made to the description above in connection with FIG. 3
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 6 and described below. Structure and
features of the embodiment shown in FIG. 6 that correspond to
structure and features of the embodiment of FIG. 3 are designated
hereinafter in the 600 series of reference numbers.
[0076] As described in greater detail above with regard to the body
support 302 illustrated in FIG. 3, the body support 602 illustrated
in FIG. 6 comprises a top layer 610 comprising open-celled
non-reticulated visco-elastic foam, a middle layer 612 comprising
flexible cellular polyurethane foam having a relatively high
resilience, and a bottom layer 614 comprising reticulated
non-visco-elastic foam. However, the top surface 620 of the middle
layer 612 has a non-planar shape beneath the substantially planar
bottom surface 618 of the top layer 610. The non-planar shape of
the top surface 620 can take any of the forms described above in
connection with the non-planar top surface 420 of the bottom layer
412 illustrated in FIG. 4, and can be defined by a plurality of
protrusions 628 (as shown in FIG. 6) and/or a plurality of
apertures as also described above. Passages 630 can be defined
between the substantially planar bottom surface 618 of the top
layer 610 and the non-planar top surface 620 of the middle layer
612. In other embodiments, the passages 630 can be defined between
a non-planar bottom surface 618 of the top layer 610 and a
substantially planar top surface 620 of the middle layer 612, or
between a non-planar bottom surface 618 of the top layer 610 and a
non-planar top surface 620 of the middle layer 612, wherein the
non-planar surface(s) can be defined in any of the manners
described above in connection with the illustrated embodiment of
FIG. 4.
[0077] Passages 630 running between the top and middle layers 610,
612 illustrated in FIG. 6 can provide the body support 602 with a
capacity for ventilation and/or with an increased ability to
dissipate heat from the top layer 612 of non-reticulated
visco-elastic foam (which can be immediately adjacent a user's body
upon the body support 602). Also, the passages 630 can be
particularly useful in providing ventilation and/or heat
dissipation for the bottom layer 614 of the body support 602.
[0078] FIG. 7 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 1-1B. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 1-1B.
Reference should be made to the description above in connection
with FIGS. 1-1B for additional information regarding the structure
and features, and possible alternatives to the structure and
features of the body support illustrated in FIG. 7 and described
below. Structure and features of the embodiment shown in FIG. 7
that correspond to structure and features of the embodiment of
FIGS. 1-1B are designated hereinafter in the 700 series of
reference numbers.
[0079] Like the body support 102 illustrated in FIGS. 1-1B, the
body support 702 illustrated in FIG. 7 comprises a top layer 710
comprising open-celled non-reticulated visco-elastic foam, beneath
which lies a bottom layer 712 comprising reticulated
non-visco-elastic foam. However, the bottom layer 712 further
comprises portions of flexible cellular polyurethane foam having a
relatively high resilience. In particular, the bottom layer 712 has
a first portion 732 comprising reticulated non-visco-elastic foam
having the same properties as described above with reference to the
bottom layer 112 of the body support 102 illustrated in FIG. 1, and
second and third portions 734, 736 comprising flexible cellular
polyurethane foam having the same properties as described above
with reference to the bottom layer 214 of the body support 202
illustrated in FIG. 2. Therefore, the second and third portions
734, 736 of the bottom layer 712 illustrated in FIG. 7 define side
borders of foam that is relatively stiff and supportive compared to
the conventional reticulated non-visco-elastic foam of the first
portion 732. Either or both of the second and third portions 734,
736 can have a width W that is at least about 1 cm and is no
greater than about 20 cm. In other embodiments, either or both of
the second and third portions 734, 736 can have a width W that is
at least about 3 cm and is no greater than about 15 cm. In still
other embodiments, either or both of the second and third portions
734, 736 can have a width W that is at least about 5 cm and is no
greater than about 10 cm.
[0080] The second and third portions 734, 736 of the bottom layer
712 can have any width desired, and therefore can be wider or
narrower than those illustrated in FIG. 7. Also, the second and
third portions 734, 736 can have substantially constant widths as
illustrated in FIG. 7, or can have widths that vary along the sides
738, 740 of the bottom layer 712. In addition, the second and third
portions 734, 736 need not necessarily run along the entire length
of the sides 738, 740 of the bottom layer 712 as shown in FIG. 7,
and can instead run along any portion of the sides 738, 740 of the
bottom layer 712 (e.g., only at the corners of the bottom layer
712, in two or more areas along either or both sides 738, 740 of
the bottom layer 712, and the like). In this regard, the second and
third portions 734, 736 need not necessarily be identical in width,
length, or shape. Also, in other embodiments, the bottom layer 712
has only one of the second and third portions 734, 736.
[0081] As described above, the bottom layer 712 illustrated in FIG.
7 has second and third portions 734, 736 of flexible cellular foam
having a relatively high resilience defining borders flanking a
first portion 732 of reticulated non-visco-elastic foam. In other
embodiments, the second and third portions 734, 736 of foam can
instead be located at the ends 742, 744 of the bottom layer 712
(e.g., at the head and foot of the body support 702 at least
partially defining a mattress, mattress topper, overlay, or futon),
respectively, and in such locations can take any of the forms and
shapes described above. In some embodiments, side and end borders
of the relatively high resilience flexible cellular foam can be
employed, thereby surrounding or at least partially surrounding the
first portion 732 of reticulated non-visco-elastic foam. Any
combination of borders and border locations of the relatively
highly resilient flexible cellular foam can be utilized as
desired.
[0082] By employing an underlying layer of reticulated
non-visco-elastic foam having the properties described above, the
first portion 732 of the bottom layer 712 can enhance ventilation
of the body support 702 and/or heat dissipation from the top layer
710. In some embodiments, some types of reticulated foam do not
provide a relatively high degree of support and resilience.
Although such a foam can be acceptable in many applications, in
some products, more supportive and resilient sides 738, 740 and/or
ends 742, 744 of the bottom layer 712 are desirable. For example, a
mattress having such sides 738, 740 and/or ends 742, 744 can better
support a user entering or exiting a resting location on the
mattress, and can better support a user sitting or leaning on an
edge of the mattress.
[0083] Also, the location of a border of relatively highly
resilient flexible cellular foam as described above can be selected
based upon the desired heat dissipating qualities of the body
support 702. For example, the borderless ends 742, 744 of the body
support 702 illustrated in FIG. 7 can enable increased ventilation
and/or heat dissipation from the first portion 732 of reticulated
non-visco-elastic foam in the bottom layer 712. Similarly, body
supports 702 having bordered ends 742, 744 of the relatively highly
resilient flexible cellular foam and borderless sides 738, 740 can
provide similar results. In those embodiments in which ventilation
and heat dissipation through the ends and/or sides of the first
portion 732 of reticulated non-visco-elastic foam is less important
than additional resilience and support in such locations, a border
of the relatively highly resilient flexible cellular foam can be
provided in such locations.
[0084] In still other embodiments of the present invention, the
bottom layer 712 of the body support 702 comprises two or more
regions of reticulated non-visco-elastic foam, each at least
partially surrounded by one or more borders of relatively highly
resilient and flexible cellular polyurethane foam. The reticulated
non-visco-elastic foam can have the properties described above with
reference to the bottom layer 112 of the body support 102
illustrated in FIG. 1, while the relatively highly resilient
flexible cellular foam of the border(s) can have the same
properties as described above with reference to the bottom layer
214 of the body support 202 illustrated in FIG. 2. In some
embodiments, the bottom layer 712 can have two or more regions
defining "islands" of reticulated non-visco-elastic foam surrounded
by one or more borders of relatively highly resilient flexible
cellular foam. In these and other embodiments, one or more of the
regions of reticulated non-visco-elastic foam can be open to one or
more sides or ends 738, 740, 742, 744 of the bottom layer 712
and/or can be connected to another of the regions of reticulated
non-visco-elastic foam.
[0085] In those embodiments in which the body support 702 has a
bottom layer 712 comprising one or more regions of reticulated
non-visco-elastic foam, the regions can be in any location or
locations across the bottom layer 712. For example, the regions of
reticulated non-visco-elastic foam can be located in areas of
greatest contact and/or pressure from a user lying upon the body
support 702, such as near the shoulders, back, and buttocks of a
user. Also, such regions of reticulated non-visco-elastic foam can
have any shape (such as rectangular, trapezoidal, triangular, or
other polygonal shapes, round, oval, or other rotund shapes,
irregular shapes, and the like), and can have any size desired.
[0086] FIG. 8 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 7. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 7. Reference
should be made to the description above in connection with FIG. 7
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 8 and described below. Structure and
features of the embodiment shown in FIG. 8 that correspond to
structure and features of the embodiment of FIG. 7 are designated
hereinafter in the 800 series of reference numbers.
[0087] Like the embodiment of the present invention illustrated in
FIG. 7, the body support 802 illustrated in FIG. 8 comprises a top
layer 810 comprising open-celled non-reticulated visco-elastic
foam, beneath which lies a bottom layer 812 comprising reticulated
non-visco-elastic foam and relatively highly resilient and flexible
cellular polyurethane foam. However, the first portion 832 of the
bottom layer 812 comprises flexible cellular polyurethane foam
having the same properties described above with reference to the
bottom layer 214 of the body support 202 illustrated in FIG. 2, and
the border 846 of the bottom layer 812 comprises reticulated
non-visco-elastic foam having the same properties described above
with reference to the bottom layer 112 of the body support 102
illustrated in FIG. 1. The border 846 can extend fully around the
first portion 832 of relatively highly resilient flexible cellular
foam as shown in FIG. 8, or can extend partially around the first
portion 832 of relatively highly resilient flexible cellular foam
(e.g., having portions flanking the first portion 832 as described
above with reference to the embodiment of FIG. 7, or having one or
more portions shaped and located in any of the manners described
above in connection with the illustrated embodiment of FIG. 7).
[0088] In short, the first portion 832 and border 846 illustrated
in FIG. 8 can have any of the shapes, positions, and arrangements
described above in connection with the embodiment of FIG. 7. Also,
the materials of the bottom layer region(s) and border(s) described
above in connection with FIG. 7 (i.e., two or more regions or
islands of material at least partially surrounded by one or more
borders) can be reversed, in which case the two or more regions or
islands of the relatively highly-resilient flexible cellular foam
can be at least partially surrounded by one or more borders of
reticulated non-visco-elastic foam.
[0089] By utilizing a border 846 of reticulated non-visco-elastic
foam partially or fully surrounding the first portion 832
comprising relatively highly-resilient flexible cellular foam in
the bottom layer 812, the body support 802 can have an enhanced
ability to provide ventilation of the body support 802 and/or to
dissipate heat from the first portion 832 and/or from the top layer
810. The peripheral location of the border 846 illustrated in FIG.
8 is desirable for performing this function, enabling heat to be
drawn from a central area of the top and bottom layers 810, 812
toward the edges of the body support 802, where heat can be more
readily dissipated from the body support 802.
[0090] FIG. 9 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 7. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 7. Reference
should be made to the description above in connection with FIG. 7
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 9 and described below. Structure and
features of the embodiment shown in FIG. 9 that correspond to
structure and features of the embodiment of FIG. 7 are designated
hereinafter in the 900 series of reference numbers.
[0091] Like the body support 702 illustrated in FIG. 7, the body
support 902 illustrated in FIG. 9 comprises a top layer 910
comprising open-celled non-reticulated visco-elastic foam, beneath
which lies a bottom layer 912 comprising a first portion 932
comprising reticulated non-visco-elastic foam flanked by second and
third portions 934, 936 comprising relatively highly resilient
flexible cellular foam. The first portion 932 can comprise
reticulated non-visco-elastic foam having the same properties
described above with reference to the bottom layer 112 of the body
support 102 illustrated in FIG. 1. The second and third portions
934, 936 can comprise relatively highly resilient flexible cellular
foam having the same properties described above with reference to
the bottom layer 214 of the body support 202 illustrated in FIG. 2.
Also, the portions 932, 934, 936 can have any of the shapes and
arrangements described above with reference to FIG. 7, such as a
border 946 of the relatively highly resilient flexible cellular
foam partially or entirely surrounding the reticulated
non-visco-elastic foam portion 932, borders of the relatively
highly resilient flexible cellular foam on any of the sides and
ends of the bottom layer 912, islands or other regions of the
reticulated non-visco-elastic foam at least partially surrounded by
the relatively highly resilient flexible cellular foam, and the
like.
[0092] If desired, the bottom surface 918 of the top layer 910
and/or the top surface 920 of the bottom layer 912 can have a
non-planar shape defining a plurality of passages 930 between the
top and bottom layers 910, 912. In the illustrated embodiment of
FIG. 9, for example, passages 930 are defined between a
substantially planar bottom surface 918 of the top layer 910 and a
non-planar top surface 920 of the bottom layer 912. The non-planar
shape of the top surface 920 of the bottom layer 912 can take any
of the forms described above in connection with the non-planar top
surface 420 of the bottom layer 412 illustrated in FIG. 4, and can
be defined by a plurality of protrusions 928 and/or a plurality of
apertures as also described above.
[0093] The passages 930 between the bottom surface 918 of the top
layer 910 and the top surface 920 of the bottom layer 912 can
provide enhanced ventilation and/or heat dissipation of the body
support 902. The passages 930 can be particularly useful in
reducing heat in regions of the body support 902. The passages 930
can supplement the ability of the reticulated non-visco-elastic
foam of the first portion 932 to dissipate heat between the second
and third portions 934, 936 of relatively highly resilient flexible
cellular foam and the top layer 910 of non-reticulated
visco-elastic foam.
[0094] Although the first portion 932 of the bottom layer 912
illustrated in FIG. 9 comprises reticulated non-visco-elastic foam,
and the second and third portions 934, 936 of the bottom layer 912
comprise a relatively highly resilient flexible cellular foam, the
material of the first portion 932 and the material of the second
and third portions 934, 936 can be reversed in other embodiments,
thereby providing a structure similar to those described above in
connection with the embodiment illustrated in FIG. 8. Accordingly,
the description above regarding the body support 802 illustrated in
FIG. 8 applies equally to such alternative embodiments of FIG.
9.
[0095] With continued reference to the illustrated embodiment of
FIG. 9, the first and second layers 910, 912 of the body support
902 can have a cover 948 comprising reticulated non-visco-elastic
foam. The reticulated non-visco-elastic foam of the cover 948 can
have the same properties as described above with reference to the
bottom layer 112 of the body support 102 illustrated in FIG. 1.
Also, the reticulated non-visco-elastic foam of the cover 948 can
cover any portion of the first and second layers 910, 912. For
example, the cover 948 illustrated in FIG. 9 covers substantially
the entire top surface 916 of the top layer 910. In other
embodiments, the cover 948 can also or instead cover any portion or
all of the sides and ends of the first and second layers 910, 912,
and/or can underlie any portion or all of the bottom surface 924 of
the bottom layer 912. In some embodiments, the cover 948
substantially entirely surrounds the first and second layers 910,
912.
[0096] The reticulated non-visco-elastic foam cover 948 can be
selected to provide a heightened degree of fire resistance to the
body support 902, and in some countries and/or localities can be
utilized to meet fire codes calling for such fire resistance.
Although other materials capable of meeting such fire code
requirements can be employed, the use of reticulated
non-visco-elastic foam can provide improved ventilation for the
surface(s) of the first and/or second layers 910, 912 covered by
the reticulated non-visco-elastic foam cover 948. As described
above, reticulated non-visco-elastic foam can reduce the amount of
heat in adjacent areas of a body support, based at least in part
upon the skeletal cellular structure of the reticulated foam.
Therefore, in some embodiments, the reticulated non-visco-elastic
foam cover 948 can provide a degree of fire resistance while also
dissipating heat from the adjacent first and/or second layers 910,
912 covered by the reticulated foam cover 948 in use of the body
support 902.
[0097] With continued reference to the embodiment of FIG. 9, the
visco-elastic nature of t h e top layer 910 can provide a
relatively comfortable substrate for a user's body, can at least
partially conform to the user's body to distribute force applied
thereby, and can be selected for responsiveness to a range of
temperatures generated by the body heat of a user. In some
embodiments, the reticulated foam cover 948 (if employed) has a
maximum thickness through which these properties can still be
exhibited. Although the desirable tactile feel of the visco-elastic
first layer 910 can be blocked in some embodiments by the
reticulated non-visco-elastic foam cover 948, the other desirable
properties of the visco-elastic material of the first layer 910 are
still experienced through a sufficiently thin reticulated
non-visco-elastic foam cover 948. In some embodiments, the
reticulated non-visco-elastic foam cover 948 has a maximum
thickness of about 1 cm. In other embodiments, the reticulated
non-visco-elastic foam cover 948 has a maximum thickness of about 2
cm. In still other embodiments, the reticulated non-visco-elastic
foam cover 948 has a maximum thickness of about 5 cm.
[0098] As also shown in FIG. 9, the top surface 916 of the top
layer 910 can have a non-planar shape defining a plurality of
passages 930 between the reticulated non-visco-elastic foam cover
948 and the top layer 910. In other embodiments, the passages 930
can be defined between a non-planar bottom surface 952 of the
reticulated non-visco-elastic foam cover 948 and a substantially
planar top surface 916 of the top layer 910 and/or between a
non-planar bottom surface 952 of the reticulated non-visco-elastic
foam cover 948 and a non-planar top surface 916 of the top layer
910. Enhanced user comfort, ventilation, and/or heat dissipation
can be achieved in some embodiments by such passages 930.
[0099] The non-planar shape of the top surface 916 illustrated in
FIG. 9 (and/or of the bottom surface 952 of the reticulated
non-visco-elastic foam cover 948) can take any of the forms
described above in connection with the non-planar top surface 420
of the bottom layer 412 illustrated in FIG. 4, and can be defined
by a plurality of protrusions 928 and/or a plurality of apertures
as also described above.
[0100] The passages 930 between the bottom surface 952 of the
reticulated non-visco-elastic foam cover 948 and the top surface
916 of the top layer 910 can provide a degree of ventilation and/or
enhanced heat dissipation for the body support 902. These passages
930 can be particularly useful in reducing heat in regions of the
body support 902. These passages 930 can also supplement the
ability of the reticulated non-visco-elastic foam of the cover 948
to dissipate heat between the cover 948 and the top layer 910.
[0101] The reticulated non-visco-elastic foam cover 948 illustrated
in FIG. 9 is utilized in conjunction with a top layer 910
comprising non-reticulated visco-elastic foam, and a bottom layer
912 comprising a first portion 932 of reticulated non-visco-elastic
foam flanked by second and third portions 934, 936 of relatively
highly resilient flexible cellular foam as described above.
However, it should be noted that the reticulated non-visco-elastic
foam cover 948 (and the alternative embodiments of the reticulated
non-visco-elastic foam cover 948 described above) can be utilized
to cover any or all surfaces of any of the body supports described
and/or illustrated herein.
[0102] FIG. 10 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 3. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 3. Reference
should be made to the description above in connection with FIG. 3
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 10 and described below. Structure and
features of the embodiment shown in FIG. 10 that correspond to
structure and features of the embodiment of FIG. 3 are designated
hereinafter in the 1000 series of reference numbers.
[0103] Like the body support 302 illustrated in FIG. 3, the body
support 1002 illustrated in FIG. 10 comprises a first layer 1010
comprising open-celled non-reticulated visco-elastic foam, a second
layer 1012 comprising a relatively highly resilient flexible
cellular foam beneath the first layer 1010, and a third layer 1014
comprising reticulated non-visco-elastic foam beneath the second
layer 1012 of relatively highly resilient flexible cellular foam.
The properties of the non-reticulated visco-elastic foam in the
first layer 1010 and the reticulated non-visco-elastic foam in the
third layer 1014 are described above in connection with the top and
bottom layers 110, 112, respectively, in the illustrated embodiment
of FIGS. 1-1B. The properties of the relatively highly resilient
flexible cellular foam in the second layer 1012 are described above
in connection with the bottom layer 214 in the illustrated
embodiment of FIGS. 2 and 2A.
[0104] In the embodiment illustrated in FIG. 10, the
non-reticulated visco-elastic foam of the first layer 1010 can be
provided with a desired degree of support by the adjacent
underlying layer 1012 of relatively highly resilient flexible
cellular foam. As described above, the skeletal cellular structure
of the reticulated non-visco-elastic foam of the third layer 1014
can function to reduce heat in the second layer 1012 (and in some
embodiments, the first layer 1010 as well).
[0105] In some embodiments, the reticulated non-visco-elastic foam
of the third layer 1014 is less resilient and/or less supportive
than the foams that can be employed for the second layer 1012
(e.g., the relatively highly resilient flexible cellular foam
described above in connection with the illustrated embodiment of
FIGS. 2 and 2A). Although the second layer 1012 can be increased in
thickness to accommodate for the less resilient and/or less
supportive reticulated non-visco-elastic foam layer 1014, the
ability to dissipate heat (via the resulting relatively thinner
reticulated foam material) can be reduced. In some embodiments, a
fourth layer 1054 of relatively highly resilient flexible cellular
foam is located beneath the third layer 1014 of reticulated
non-visco-elastic foam, thereby providing additional support to the
first, second, and third layers 1010, 1012, 1014, and supplementing
the resilience and support provided by the second layer 1012. In
the illustrated embodiment of FIG. 10, the fourth layer 1054
comprises substantially the same relatively highly resilient
flexible cellular foam as the second layer 1012. However, in other
embodiments, the relatively highly resilient flexible cellular foam
of the fourth layer 1054 is different than that of the second layer
1012.
[0106] If desired, a fifth layer 1056 of reticulated
non-visco-elastic foam can lie beneath the fourth layer 1054,
thereby providing an increased capability to dissipate heat from
the body support 1002. In the illustrated embodiment of FIG. 10,
the fifth layer 1056 comprises substantially the same reticulated
non-visco-elastic foam as the third layer 1014. However, in other
embodiments, the reticulated non-visco-elastic foam of the fifth
layer 1056 is different than that of the third layer 1014. In this
regard, any number of alternating layers of relatively highly
resilient flexible cellular foam and reticulated non-visco-elastic
foam can lie beneath the first layer 1010 of non-reticulated
visco-elastic foam. Such body supports 1002 can therefore have a
desirable degree of resilience and support (from two or more layers
of relatively highly resilient flexible cellular foam) while still
retaining the desirable heat dissipative capabilities described
above (from two or more layers of reticulated non-visco-elastic
foam). In some embodiments, heat in one or more areas of the body
support 1002 can be transmitted through one or more layers of the
relatively highly resilient flexible cellular foam for dissipation
through the alternating layers of reticulated non-visco-elastic
foam.
[0107] FIG. 11 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 2 and 2A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 2 and 2A.
Reference should be made to the description above in connection
with FIGS. 2 and 2A for additional information regarding the
structure and features, and possible alternatives to the structure
and features of the body support illustrated in FIG. 11 and
described below. Structure and features of the embodiment shown in
FIG. 11 that correspond to structure and features of the embodiment
of FIGS. 2 and 2A are designated hereinafter in the 1100 series of
reference numbers.
[0108] Like the body support 202 illustrated in FIGS. 2 and 2A, the
body support 1102 illustrated in FIG. 11 comprises a first layer
1110 comprising open-celled non-reticulated visco-elastic foam, a
second layer 1112 comprising reticulated non-visco-elastic foam
beneath the first layer 1110, and a third layer 1114 comprising
relatively highly resilient flexible cellular foam beneath the
second layer 1112. The properties of the non-reticulated
visco-elastic foam in the first layer 1010 and the reticulated
non-visco-elastic foam in the second layer 1012 are described above
in connection with the top and bottom layers 110, 112,
respectively, in the illustrated embodiment of FIGS. 1-1B. The
properties of the relatively highly resilient flexible cellular
foam in the third layer 1014 are described above in connection with
the bottom layer 214 in the illustrated embodiment of FIGS. 2 and
2A.
[0109] In the embodiment illustrated in FIG. 11, the skeletal
cellular structure of the reticulated foam of the second layer 1112
can function to dissipate heat in the first layer 1110 of
non-reticulated visco-elastic foam, while the first and second
layers 1110, 1112 can be provided with a desirable degree of
support by the underlying layer 1114 of relatively highly resilient
flexible cellular foam. Compared to the second layer 1012 of body
support 1002 illustrated in FIG. 10, the second layer 1112 of
reticulated foam in the body support 1102 of FIG. 11 can provide an
increased amount of heat dissipation and/or ventilation, but with a
less resilient upper portion of the body support 1102 (in some
embodiments, and depending at least in part upon the thickness of
the first and second layers 1110, 1112). Therefore, the first three
layers 1010, 1012, 1014, 1110, 1112, 1114 of the body supports
1002, 1102 illustrated in FIGS. 10 and 11 can have different
qualities adapted for the comfort and taste of different users.
[0110] With continued reference to the illustrated embodiment of
FIG. 11, in some embodiments, the reticulated non-visco-elastic
foam of the second layer 1112 is less resilient and/or less
supportive than the foams that can be employed for the third layer
1114 (e.g., the relatively highly resilient flexible cellular foam
described above in connection with the illustrated embodiment of
FIGS. 2 and 2A). Although the third layer 1114 can be increased in
thickness to accommodate for the less resilient and/or less
supportive reticulated non-visco-elastic foam layer 1112, the
advantages relating to heat dissipation from the relatively thinner
reticulated foam material can be reduced. In some embodiments, a
fourth layer 1154 of reticulated non-visco-elastic foam is located
beneath the third layer 1114 of relatively highly resilient
flexible cellular foam, thereby providing an increased capability
to dissipate heat from the body support 1102. In the illustrated
embodiment of FIG. 11, the fourth layer 1154 comprises
substantially the same reticulated non-visco-elastic foam as the
second layer 1112. However, in other embodiments, the reticulated
non-visco-elastic foam of the fourth layer 1154 is different than
that of the second layer 1112.
[0111] In some embodiments, a fifth layer 1156 of relatively highly
resilient flexible cellular foam is located beneath the fourth
layer 1154 of reticulated non-visco-elastic foam, thereby providing
additional support to the first, second, third, and fourth layers
1110, 1112, 1114, and 1154, and supplementing the resilience and
support provided by the third layer 1014. In the illustrated
embodiment of FIG. 11, the fifth layer 1154 comprises substantially
the same relatively highly resilient flexible cellular foam as the
third layer 1114. However, in other embodiments, the relatively
highly resilient flexible cellular foam of the fifth layer 1154 is
different than that of the third layer 1112. As described above,
any number of alternating layers of relatively highly resilient
flexible cellular foam and reticulated non-visco-elastic foam can
lie beneath the first layer 1010 of non-reticulated visco-elastic
foam to provide a desired degree of resilience and support while
still retaining the ventilation and/or heat dissipative
capabilities also described above. In some embodiments, heat in one
or more areas of the body support 1102 can be transmitted through
one or more layers of the relatively highly resilient flexible
cellular foam for dissipation through the alternating layers of
reticulated non-visco-elastic foam.
[0112] FIGS. 12 and 12A illustrate another embodiment of a body
support according to the present invention. The body support 1202
illustrated in FIGS. 12 and 12A comprises two layers of material: a
top layer 1210 comprising reticulated visco-elastic foam and a
bottom layer 1212 comprising a cellular structure of polyurethane
foam.
[0113] Like the foam of the top layer 10 described above with
reference to the embodiment of the body support 102 illustrated in
FIGS. 1, 1A, and 1B (and utilized in the other embodiments
illustrated and/or described above in connection with FIGS. 1-11),
the reticulated foam of the top layer 1210 is a visco-elastic foam,
and therefore falls generally within the category of foams
otherwise known as "memory foams" or "low resilience foams".
However, the reticulated visco-elastic foam of the top layer 1210
has a structure that is significantly different than that of
non-reticulated visco-elastic foams (such as those described above
in connection with the embodiments of FIGS. 1-11), and can
therefore provide body supports with significantly different
properties as will now be described.
[0114] As shown in FIG. 12A, the reticulated visco-elastic foam of
the top layer 1210 is a cellular foam structure in which the cells
of the visco-elastic foam are essentially skeletal. Many (if not
substantially all) of the cell walls separating one cell from
another do not exist. In other words, the cells of the reticulated
visco-elastic foam are defined only by a plurality of supports or
"windows" and by no cell walls, substantially no cell walls, or by
a substantially reduced number of cell walls. In some embodiments,
the visco-elastic foam is considered "reticulated" if at least 50%
of the walls defining the cells of the visco-elastic foam do not
exist (i.e., have been removed or were never allowed to form during
the manufacturing process of the visco-elastic foam).
[0115] By virtue of the skeletal cellular structure of the
reticulated visco-elastic foam of the top layer 1210 illustrated in
FIGS. 12 and 12A, heat in the top layer 1210 can be transferred
away from the source of heat (e.g., a user's body), thereby helping
to prevent one or more areas of the top layer 1210 from reaching an
undesirably high temperature. Also, the reticulated structure of
the foam in the top layer 1210 enables significantly higher airflow
into, out of, and through the top layer 1210--a characteristic of
the top layer 1210 that can reduce heat in the top layer 1210. At
the same time, the visco-elastic nature of the foam in the top
layer 1210 provides desirable tactile contact and pressure
responsiveness for user comfort. In this regard, the reticulated
visco-elastic foam of some embodiments has a reduced hardness
level, thereby providing a relatively soft and comfortable surface
for a user's body. In conjunction with the slow recovery
characteristic of the reticulated visco-elastic material, the top
layer 1210 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 1210.
[0116] In some embodiments, the top layer 1210 of reticulated
visco-elastic foam has a hardness of at least about 20 N and no
greater than about 150 N for desirable softness and
pressure-responsive qualities. In other embodiments, a top layer
1210 having a hardness of at least about 30 N and no greater than
about 100 N is utilized for this purpose. In still other
embodiments, a top layer 1210 having a hardness of at least about
40 N and no greater than about 85 N is utilized.
[0117] The top layer 1210 can also have a density providing a
relatively high degree of material durability. The density of the
foam in the top layer 1210 can also impact other characteristics of
the foam, such as the manner in which the top layer 1210 responds
to pressure, and the feel of the foam. In some embodiments, the top
layer 1210 has a density of no less than about 30 kg/m.sup.3 and no
greater than about 175 kg/m.sup.3. In other embodiments, a top
layer 1210 having a density of at least about 50 kg/m.sup.3 and no
greater than about 130 kg/m.sup.3 is utilized. In still other
embodiments, a top layer 1210 having a density of at least about 60
kg/m.sup.3 and no greater than about 110 kg/m.sup.3 is
utilized.
[0118] The reticulated visco-elastic foam of the top layer 1210 can
be selected for responsiveness to any range of temperatures.
However, in some embodiments, a temperature responsiveness in a
range of a user's body temperatures (or in a range of temperatures
to which the body support 1202 is exposed by contact or proximity
to a user's body resting thereon) can provide significant
advantages. For example, a reticulated visco-elastic foam selected
for the top layer 1210 can be responsive to temperatures changes
(as defined above) above at least 0.degree. C. In some embodiments,
the reticulated visco-elastic foam selected for the top layer 1210
can be responsive to temperature changes within a range of at least
about 10.degree. C. In other embodiments, the reticulated
visco-elastic foam selected for the top layer 1210 can be
responsive to temperature changes within a range of at least about
15.degree. C.
[0119] As described above, the bottom layer 1212 of the body
support 1202 illustrated in FIGS. 12 and 12A comprises a cellular
structure of polyurethane foam. This layer of foam is a supportive
layer providing a relatively stiff but flexible and resilient
substrate upon which the top layer 1210 lies. The resiliently
deformable nature of the bottom layer 1212 can therefore provide a
degree of user comfort to the extent that the user's weight affects
the shape of the bottom layer 1212. The foam of the bottom layer
1212 can be relatively highly resilient, and in some embodiments
has a hardness of at least about 50 N and no greater than about 300
N for a desirable degree of support and comfort. In other
embodiments, a bottom layer 1212 having a hardness of at least
about 80 N and no greater than about 250 N is utilized for this
purpose. In still other embodiments, a bottom layer 1212 having a
hardness of at least about 90 N and no greater than about 180 N is
utilized.
[0120] Depending at least in part upon the thickness and material
properties of the top layer 1210, in some embodiments the bottom
layer 1212 can be exposed to substantial body heat from a user
resting upon the body support 1202. In such embodiments, the foam
of the bottom layer 1212 can be selected to be substantially
insensitive to temperature changes (as defined above) within a
range of between about 10.degree. C. to about 35.degree. C.,
thereby retaining the supportive properties desired for the bottom
layer 1212 throughout a range of body temperatures to which the
bottom layer 1212 may be exposed. In some embodiments, the bottom
layer 1212 can comprise foam that is substantially insensitive to
temperature changes within a range of between about 15.degree. C.
to about 30.degree. C. In still other embodiments, a bottom layer
1212 of foam that is substantially insensitive to temperature
changes within a range of between about 15.degree. C. to about
25.degree. C. can be used.
[0121] The reticulated visco-elastic foam layer 1210 atop the
bottom layer 1212 can provide an additional degree of ventilation
and/or heat dissipation on the top surface 1216 of the top layer
1210, can help dissipate heat within the body support 1202, and can
therefore help to reduce heat in one or more locations of the body
support 1202.
[0122] Like the top layer 1210 of the body support 1202, the bottom
layer 1212 can have a density providing a relatively high degree of
material durability. Also, the density of the foam in the bottom
layer 1212 can also impact other characteristics of the foam, such
as the manner in which the bottom layer 1212 responds to pressure,
and the feel of the foam. In some embodiments, the bottom layer
1212 has a density of no less than about 20 kg/m.sup.3 and no
greater than about 80 kg/m.sup.3. In other embodiments, a bottom
layer 1212 having a density of at least about 25 kg/m.sup.3 and no
greater than about 60 kg/m.sup.3 is utilized. In still other
embodiments, a bottom layer 1212 having a density of at least about
30 kg/m .sup.3 and no greater than about 40 kg/m.sup.3 is
utilized.
[0123] The body support 1202 illustrated in FIGS. 12 and 12A can
have a bottom layer 1212 that is at least as thick as the top layer
1210, thereby providing a significant degree of support for the top
layer 1210. In some embodiments, the bottom layer 1212 is at least
2 times as thick as the top layer 1210. In other embodiments, the
bottom layer 1212 is at least 3 times as thick as the top layer
1210.
[0124] The body support 1202 illustrated in FIGS. 12 and 12A is a
mattress, mattress topper, overlay, or futon, and is illustrated in
such form by way of example only. It will be appreciated that the
features of the body support 1202 described above are applicable to
any other type of body support having any size and shape.
[0125] FIG. 13 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 12 and 12A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 12 and
12A. Reference should be made to the description above in
connection with FIGS. 12 and 12A for additional information
regarding the structure and features, and possible alternatives to
the structure and features of the body support illustrated in FIG.
13 and described below. Structure and features of the embodiment
shown in FIG. 13 that correspond to structure and features of the
embodiment of FIGS. 12 and 12A are designated hereinafter in the
1300 series of reference numbers.
[0126] The body support 1302 illustrated in FIG. 13 has a top layer
1310 comprising reticulated visco-elastic foam and a bottom layer
1312 comprising reticulated non-visco-elastic foam. The reticulated
visco-elastic foam (including the material properties thereof) of
the top layer 1310 is described in greater detail above in
connection with the embodiments of FIGS. 12 and 12A. The
reticulated non-visco-elastic foam of the bottom layer 1312
comprises an essentially skeletal structure of cells in which many
(if not substantially all) of the cell walls separating one cell
from another do not exist. In other words, the cells are defined by
a plurality of supports or "windows" and by no cell walls,
substantially no cell walls, or by a substantially reduced number
of cell walls. In some embodiments, the foam is considered
"reticulated" if at least 50% of the walls defining the cells of
the foam do not exist (i.e., have been removed or were never
allowed to form during the manufacturing process of the foam). Due
at least in part to the skeletal cellular structure of the
reticulated non-visco-elastic foam in the bottom layer 1312, the
bottom layer 1312 can reduce heat in one or more areas of the top
layer 1310.
[0127] In some embodiments, it is desirable that the bottom layer
1312 of reticulated non-visco-elastic foam be capable of providing
some degree of support that is substantially independent of
temperatures experienced by the top layer 1310 when supporting a
user's body (i.e., independent of a user's body heat). Therefore,
the bottom layer 1312 can comprise reticulated non-visco-elastic
foam that is substantially insensitive to temperature changes (as
defined above) within a range of between about 15.degree. C. and
about 30.degree. C. In some embodiments, the bottom layer 1312 can
comprise foam that is substantially insensitive to temperature
changes within a range of between about 15.degree. C. and about
25.degree. C.
[0128] By virtue of the skeletal cellular structure of the bottom
layer 1312 illustrated in FIGS. 13, heat in the top layer 1310 of
reticulated visco-elastic foam can be transferred away from the top
layer 1310 toward the bottom layer 1314 (in addition to lateral
transfer of heat within the top layer 1310 and transfer of heat
from exterior surfaces of the top layer 1310 by virtue of the
reticulated visco-elastic foam of the top layer 1310). Such heat
transfer can help to prevent the top layer 1310 from reaching an
undesirably high temperature. Also, the reticulated nature of the
foam in the bottom layer 1312 can enable significantly higher
airflow into, out of, and through the bottom layer 1312--a
characteristic of the bottom layer 1312 that can supplement the
ventilation provided by the reticulated visco-elastic foam of the
top layer 1310.
[0129] Like the top layer 1310, the bottom layer 1312 can have a
density providing a relatively high degree of material durability.
Also, the density of the foam in the bottom layer 1312 can also
impact other characteristics of the foam, such as the manner in
which the bottom layer 1312 responds to pressure, and the feel of
the foam. In some embodiments, the bottom layer 1312 has a density
of no less than about 20 kg/m.sup.3 and no greater than about 80
kg/m.sup.3. In other embodiments, a bottom layer 1312 having a
density of at least about 25 kg/m.sup.3 and no greater than about
60 kg/m.sup.3 is utilized. In still other embodiments, a bottom
layer 1312 having a density of at least about 30 kg/m.sup.3 and no
greater than about 40 kg/m.sup.3 is utilized.
[0130] Also, in some embodiments, the bottom layer 1312 has a
hardness of at least about 50 N and no greater than about 300 N. In
other embodiments, a bottom layer 1312 having a hardness of at
least about 80 N and no greater than about 250 N is utilized. In
still other embodiments, a bottom layer 1312 having a hardness of
at least about 90 N and no greater than about 180 N is
utilized.
[0131] The body support 1302 illustrated in FIGS. 1-1B can have a
bottom layer 1312 that is at least as thick as the top layer 1310,
thereby providing a significant ventilation and/or heat dissipation
layer that, in some embodiments, is relatively temperature
insensitive. In some embodiments, the bottom layer 1312 is at least
half as thick as the top layer 1310. In other embodiments, the
bottom layer 1312 is at least as thick as the top layer 1310. In
still other embodiments, the bottom layer 1312 is at least twice as
thick as the top layer 1310.
[0132] As described above with reference to the body support 1202
illustrated in FIGS. 12 and 12A, the reticulated visco-elastic foam
of the top layer 1310 can provide an increased amount of
ventilation for the top layer 1310, can help to dissipate heat
within the top layer 1310, and can provide desirable
body-conforming, softness, and pressure responsiveness for user
comfort. As also described above, in some embodiments, the
reticulated non-visco-elastic foam of the bottom layer 1312 can
provide additional ventilation and heat dissipation for the top
layer 1310. These features can be particularly beneficial for those
areas of the top layer 1310 that have been compressed or otherwise
modified in shape by a user's body. With respect to some
embodiments of the present invention, the temperature insensitivity
of the reticulated non-visco-elastic foam of the bottom layer 1312
can enable the bottom layer 1312 to resist form and shape change
resulting from body heat from the top layer 1310, while the
reticulated cellular structure of the bottom layer 1312 provides
desirable heat dissipation and ventilation properties for the top
layer 1310.
[0133] FIG. 14 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 13. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 13. Reference
should be made to the description above in connection with FIG. 13
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 14 and described below. Structure and
features of the embodiment shown in FIG. 14 that correspond to
structure and features of the embodiment of FIG. 13 are designated
hereinafter in the 1400 series of reference numbers.
[0134] Like the embodiment illustrated in FIG. 13, the body support
1402 illustrated in FIG. 14 has a top layer 1410 comprising
reticulated visco-elastic foam and an underlying layer 1412
comprising reticulated non-visco-elastic foam. In some embodiments,
the body support 1402 can therefore provide the desirable softness,
body-conforming, ventilation, and heat dissipative properties
described above. The body support 1402 illustrated in FIG. 14
further comprises a bottom layer 1414 beneath the layer of
reticulated non-visco-elastic foam 1412. Therefore, the layer 1412
of reticulated non-visco-elastic foam is a middle layer 1412
located between the top and bottom layers 1410, 1414 of the body
support 1402.
[0135] The bottom layer 1414 of the body support 1402 illustrated
in FIG. 14 comprises a cellular structure of flexible polyurethane
foam that is relatively highly resilient and supportive. This
relatively highly resilient flexible cellular foam is described in
greater detail above in connection with the embodiment of FIGS. 12
and 12A. In some embodiments, the bottom layer 1414 comprising the
relatively highly resilient flexible cellular foam is a supportive
layer providing a relatively stiff substrate upon which the top and
middle layers 1410, 1412 lie, and has a degree of deformability to
provide user comfort (to the extent that the user's weight affects
the shape of the bottom layer 1414). Therefore, the bottom layer
1414 can comprise a foam having a relatively high resilience
capable of providing significant support to the top and middle
layers 1410, 1412. The bottom layer 1414 can have a resilience
greater than that of the top and middle layers 1410, 1412.
[0136] The body support 1402 illustrated in FIG. 14 can have a
bottom layer 1414 that is at least as thick as the combination of
the top and middle layers 1410, 1412, thereby providing substantial
support for the top and middle layers 1410, 1412. In some
embodiments, the bottom layer 1414 is at least 0.22 times as thick
as the combination of the top and middle layers 1410, 1412. In
other embodiments, the bottom layer 1414 is at least 0.40 times as
thick as the combination of the top and middle layers 1410,
1412.
[0137] FIG. 15 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 14. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 14. Reference
should be made to the description above in connection with FIG. 14
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 15 and described below. Structure and
features of the embodiment shown in FIG. 15 that correspond to
structure and features of the embodiment of FIG. 14 are designated
hereinafter in the 1500 series of reference numbers.
[0138] Like the body support 1402 illustrated in FIG. 14, the body
support 1502 illustrated in FIG. 15 has a top layer 1510 comprising
reticulated visco-elastic foam, beneath which lies middle and
bottom layers 1512, 1514 of the body support 1502. However, the
materials of the middle and bottom layers 1512, 1514 are switched
compared to the body support 1402 illustrated in FIG. 14.
Accordingly, the middle layer 1512 of the body support 1502
illustrated in FIG. 15 comprises a relatively highly resilient
flexible cellular foam, and the bottom layer 1514 of the body
support 1502 comprises reticulated non-visco-elastic foam. The
relatively highly resilient flexible cellular foam and the
reticulated non-visco-elastic foam of the middle and bottom layers
1512, 1514, respectively, are described in greater detail above in
connection with the embodiment illustrated in FIG. 14
(incorporating information in connection with the embodiments
illustrated in FIGS. 12-13).
[0139] In the embodiment illustrated in FIG. 15, the reticulated
visco-elastic foam of the first layer 1510 can be provided with a
desired degree of support by the adjacent underlying layer of
relatively highly resilient flexible cellular foam, rather than by
a layer of such material underlying another intermediate layer as
shown in FIG. 14. Also with reference to FIG. 15, the middle layer
1512 can provide enhanced user support, depending at least in part
upon the thicknesses of the top and middle layers 1510, 1512. The
top layer 1510 of reticulated visco-elastic foam and the bottom
layer 1514 of reticulated non-visco-elastic foam can reduce heat in
the middle layer 1512, drawing heat from both sides of the middle
layer 1512 and/or providing enhanced ventilation of the body
support 1502 on both sides of the middle layer 1512 (due at least
in part to the reticulated cellular structure of the foam in the
top and bottom layers 1510, 1512).
[0140] The body support 1502 illustrated in FIG. 15 can have a
middle layer 1512 that is at least 0.33 times at least as thick as
the top layer 1510 to provide a desirable degree of support for the
top layer 1510. In some embodiments, the middle layer 1512 can be
at least half as thick as the top layer 1510 for this purpose. In
other embodiments, a middle layer 1512 that is at least as thick as
the top layer 1510 is used for this purpose.
[0141] With further reference to FIG. 15, the body support 1502 can
have a bottom layer 1514 that is at least 0.15 times as thick as
the combined thickness of the top and middle layers 1510, 1512 to
carry heat away from the middle layer 1512. In some embodiments,
the bottom layer 1514 can be at least 0.25 times as thick as the
combined thickness of the top and middle layers 1510, 1512 for this
purpose. In other embodiments, a bottom layer 1514 that is at least
0.36 times as thick as the combined thickness of the top and middle
layers 1510, 1512 is used for this purpose.
[0142] A body support 1602 according to another embodiment of the
present invention is illustrated in FIG. 16, and comprises two
layers of material: a top layer 1610 comprising reticulated
visco-elastic foam, and a bottom layer 1612 comprising open-celled
non-reticulated visco-elastic foam.
[0143] The reticulated visco-elastic foam in the top layer 1610
(including the material properties of the reticulated visco-elastic
foam) is described in greater detail above in connection with the
embodiments of FIGS. 12 and 12A. The open-celled non-reticulated
visco-elastic foam in the bottom layer 1612 falls generally within
the category of foams otherwise known as "memory foams" or "low
resilience foams".
[0144] In some embodiments, the bottom layer 1612 has a relatively
low hardness, providing a deformable and comfortable substrate
beneath the top layer 1610 of reticulated visco-elastic foam.
Depending at least in part upon the thickness of the top layer
1610, the bottom layer 1612 can conform to a user's body based upon
pressure exerted by the user's body, thereby supplementing the
ability of the top layer 1610 to distribute force applied by the
user's body upon the body support 1602. In some embodiments, the
bottom layer 1612 has a hardness of at least about 30 N and no
greater than about 175 N. In other embodiments, a bottom layer 1612
having a hardness of at least about 40 N and no greater than about
110 N is utilized. In still other embodiments, a bottom layer 1612
having a hardness of at least about 40 N and no greater than about
75 N is utilized.
[0145] The bottom layer 1612 can also have a density providing a
relatively high degree of material durability. Also, the density of
the foam in the bottom layer 1612 can impact other characteristics
of the foam, such as the manner in which the bottom layer 1612
responds to pressure, and the feel of the foam. In some
embodiments, the bottom layer 1612 has a density of no less than
about 30 kg/m.sup.3 and no greater than about 150 kg/m.sup.3. In
other embodiments, a bottom layer 1612 having a density of at least
about 40 kg/m.sup.3 and no greater than about 125 kg/m.sup.3 is
utilized. In still other embodiments, a bottom layer 1612 having a
density of at least about 60 kg/m.sup.3 and no greater than about
115 kg/m.sup.3 is utilized.
[0146] The non-reticulated visco-elastic material of the bottom
layer 1612 can be selected for responsiveness to any range of
temperatures. However, in some embodiments, a temperature
responsiveness in a range of a user's body temperatures (or in a
range of temperatures to which the bottom layer 1612 is exposed by
a user's body upon the body support 1602) can provide significant
advantages. In some embodiments, a non-reticulated visco-elastic
material selected for the bottom layer 1612 can be responsive to
temperature changes above at least 0.degree. C. In other
embodiments, the non-reticulated visco-elastic material selected
for the bottom layer 1612 can be responsive to temperature changes
within a range of at least about 10.degree. C. In still other
embodiments, the non-reticulated visco-elastic material selected
for the bottom layer 1612 can be responsive to temperature changes
within a range of at least about 15.degree. C.
[0147] In some embodiments, the top layer 1610 of reticulated
visco-elastic foam can reduce the amount of heat in the bottom
layer 1612 (due at least in part to the reticulated cellular
structure of the foam in the top layer 1612) while still providing
a relatively soft and comfortable surface of the body support 1602,
and the capability to conform to a user's body and/or distribute
pressure responsive to force from the user (by virtue of the
visco-elastic nature of the top layer 1610).
[0148] The body support 1602 illustrated in FIG. 16 can have a top
layer 1610 that is between 0.33 and 2 times the thickness of the
bottom layer 1612, thereby providing a significant degree of
ventilation and/or heat dissipation via the top layer 1610 and the
desirable body-conforming, pressure distribution, and comfort
characteristics of the bottom layer 1612. In some embodiments, the
body support 1602 has a top layer 1610 that is between 0.5 and 1.5
times the thickness of the bottom layer 1612 for these purposes. In
still other embodiments, the body support 1602 has a top layer 1610
that is about the same thickness of the bottom layer 1612 for these
purposes.
[0149] FIG. 17 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 16. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 16. Reference
should be made to the description above in connection with FIG. 16
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 17 and described below. Structure and
features of the embodiment shown in FIG. 17 that correspond to
structure and features of the embodiment of FIG. 16 are designated
hereinafter in the 1700 series of reference numbers.
[0150] Like the body support 1602 illustrated in FIG. 16, the body
support 1702 illustrated in FIG. 17 has a top layer 1710 comprising
reticulated visco-elastic foam and an underlying layer 1712
comprising open-celled non-reticulated visco-elastic foam. In some
embodiments, the body support 1702 can therefore provide the
desirable softness, body-conforming, ventilation, and heat transfer
properties described above in connection with the embodiment of
FIG. 16. The body support 1702 illustrated in FIG. 17 further
comprises a bottom layer 1714 beneath the layer of non-reticulated
visco-elastic foam 1712. Therefore, the layer 1712 of
non-reticulated visco-elastic foam is a middle layer 1712 located
between the top and bottom layers 1710, 1714 of the body support
1702.
[0151] The bottom layer 1714 of the body support 1702 illustrated
in FIG. 17 comprises reticulated non-visco-elastic foam. The
reticulated non-visco-elastic foam (and various possible properties
thereof) of the bottom layer 1714 is described in greater detail
above in connection with the embodiment of FIG. 13.
[0152] In some embodiments, the top layer 1710 of reticulated
visco-elastic foam and the bottom layer 1714 of reticulated
non-visco-elastic foam can reduce the amount of heat in the middle
layer 1712, drawing heat from both sides of the middle layer 1712
and/or providing enhanced ventilation of the body support 1702 on
both sides of the middle layer 1712 due at least in part to the
reticulated cellular structure of the foam in the top and bottom
layers 1710, 1714. In addition, the visco-elastic nature of the top
layer 1710 can still provide a relatively soft and comfortable
surface of the body support 1702, the ability to conform to a
user's body responsive to pressure from the user's body, and a
degree of pressure distribution for the user's body.
[0153] The body support 1702 illustrated in FIG. 17 can have a
bottom layer 1714 that is at least 0.17 times at least as thick as
the combined thickness of the top and middle layers 1710, 1712 to
provide a desirable degree of heat dissipation and ventilation from
the bottom of the middle layer 1712. In some embodiments, the
bottom layer 1714 can be at least 0.25 times as thick as the
combined thickness of the top and middle layers 1710, 1712 for
these purposes. In still other embodiments, a bottom layer 1714
that is at least 0.375 times as thick as the combined thickness of
the top and middle layers 1710, 1712 is used for these
purposes.
[0154] FIG. 18 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 16. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 16. Reference
should be made to the description above in connection with FIG. 16
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 18 and described below. Structure and
features of the embodiment shown in FIG. 18 that correspond to
structure and features of the embodiment of FIG. 16 are designated
hereinafter in the 1800 series of reference numbers.
[0155] Like the body support 1602 illustrated in FIG. 16, the body
support 1802 illustrated in FIG. 18 has a top layer 1810 comprising
reticulated visco-elastic foam and an underlying layer 1812
comprising open-celled non-reticulated visco-elastic foam. In some
embodiments, the body support 1802 can therefore provide the
desirable softness, body-conforming, ventilation, and heat transfer
properties described above in connection with the embodiment of
FIG. 16. The body support 1802 illustrated in FIG. 18 further
comprises a bottom layer 1814 beneath the layer of non-reticulated
visco-elastic foam 1812. Therefore, the layer 1812 of
non-reticulated visco-elastic foam is a middle layer 1812 located
between the top and bottom layers 1810, 1814 of the body support
1802.
[0156] The bottom layer 1814 of the body support 1802 illustrated
in FIG. 18 comprises a cellular structure of flexible polyurethane
foam that is relatively highly resilient and supportive. This
relatively highly resilient flexible cellular foam (and various
possible properties thereof) is described in greater detail above
in connection with the embodiment of FIGS. 12 and 12A.
[0157] In some embodiments, the bottom layer 1814 is a supportive
layer providing a relatively stiff substrate upon which the top and
middle layers 1810, 1812 lie, while still providing a degree of
deformability for user comfort (to the extent that the user's
weight affects the shape of the bottom layer 1814). Therefore, the
bottom layer 1814 can comprise a foam having a relatively high
resilience capable of providing significant support to the top and
middle layers 1810, 1812. Both of the top and middle layers 1810,
1812 can provide the desirable body-conforming and pressure
distribution features described above, while the top layer 1810 can
provide significant heat dissipation and ventilation for the body
support 1802 as also described above. In some embodiments, the
bottom layer 1814 has a resilience greater than that of the top and
middle layers 1810, 1812.
[0158] The body support 1802 illustrated in FIG. 18 can have a
bottom layer 1814 that is at least 0.17 times as thick as the
combined thickness of the top and middle layers 1810, 1812, thereby
providing substantial support for the top and middle layers 1810,
1812. In some embodiments, the bottom layer 1814 is at least 0.33
times as thick as the combined thickness of the top and middle
layers 1810, 1812. In other embodiments, the bottom layer 1814 is
at least half as thick as the combined thickness of the top and
middle layers 1810, 1812.
[0159] A body support 1902 according to another embodiment of the
present invention is illustrated in FIG. 19, and comprises two
layers of material: a top layer 1910 comprising open-celled
non-reticulated visco-elastic foam, and a bottom layer 1912
comprising reticulated visco-elastic foam. The non-reticulated
visco-elastic foam (and various possible properties thereof) is
described above in connection with the embodiment of FIG. 16. The
reticulated visco-elastic foam (and various possible properties
thereof) is described above in connection with the embodiment of
FIGS. 12 and 12A.
[0160] In some embodiments, heat received by the top layer 1910
(e.g., from a user resting upon the body support 1902) can be
dissipated by the reticulated visco-elastic foam of the bottom
layer 1912 due at least in part to the reticulated cellular
structure of the foam in the bottom layer 1912. In this body
support construction, the softness, body-conforming, and
pressure-distributing properties of the non-reticulated
visco-elastic foam are retained in the top layer 1910 (proximate
the body of a user) while the ventilating and heat-dissipative
properties of the bottom layer 1912 can help reduce heat in the top
layer 1910. The bottom layer 1912 can also provide softness, can at
least partially conform to a user's body responsive to pressure
from the user's body, and can distribute pressure of the user's
body by virtue of the visco-elastic nature of the bottom layer
1912.
[0161] The body support 1902 illustrated in FIG. 19 can have a
bottom layer 1912 that is at least 0.33 times the thickness of the
top layer 1910, thereby providing a significant degree of
ventilation and/or heat dissipation via the bottom layer 1912 and
the desirable body-conforming, pressure distribution, and comfort
properties of the top layer 1910. In some embodiments, the body
support 1902 has a bottom layer 1912 that is at least as thick as
the top layer 1910 for these purposes. In still other embodiments,
the body support 1902 has a bottom layer 1912 that is at least
twice as thick as the top layer 1910 for these purposes.
[0162] FIG. 20 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 19. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 19. Reference
should be made to the description above in connection with FIG. 19
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 20 and described below. Structure and
features of the embodiment shown in FIG. 20 that correspond to
structure and features of the embodiment of FIG. 19 are designated
hereinafter in the 2000 series of reference numbers.
[0163] Like the embodiment illustrated in FIG. 19, the body support
2002 illustrated in FIG. 20 has a top layer 2010 comprising
open-celled non-reticulated visco-elastic foam, and an underlying
layer 2012 comprising reticulated visco-elastic foam. In some
embodiments, the body support 2002 can therefore provide the
softness, body-conforming, and pressure-distributing
characteristics of the non-reticulated visco-elastic foam in the
top layer 2010 (proximate the body of a user) as described above,
and the ventilating and heat-dissipative properties of the
underlying layer 2012 for dissipating heat from the top layer 2010
as also described above. The underlying layer 2012 can also provide
softness of the body support 2002, can help to conform the body
support 2002 to the user's body, and can thereby distribute
pressure of the user's body by virtue of the visco-elastic property
of the underlying layer 2012.
[0164] The body support 2002 illustrated in FIG. 20 further
comprises a bottom layer 2014 beneath the layer of reticulated
visco-elastic foam 2012. Therefore, the layer 2012 of reticulated
visco-elastic foam is a middle layer 2012 located between the top
and bottom layers 2010, 2014 of the body support 2002.
[0165] The bottom layer 2014 of the body support 2002 illustrated
in FIG. 20 comprises open-celled non-reticulated visco-elastic
foam. The non-reticulated visco-elastic foam (and various possible
properties thereof) of the bottom layer 2014 is described above
with reference to the top layer 2010 of the body support 2002.
Also, the non-reticulated visco-elastic foam of the bottom layer
2014 can have substantially the same or different properties than
the non-reticulated visco-elastic foam of the top layer 2010, while
still falling within the material property ranges of the
non-reticulated visco-elastic foam described above. In some
embodiments, top and bottom layers 2010, 2014 of non-reticulated
visco-elastic foam can be utilized in products that can be oriented
with either layer 2010, 2014 facing generally toward a user's body
(e.g., a mattress that can be flipped on either side). Also or
alternatively, the non-reticulated visco-elastic foam of the bottom
layer 2014 can supplement the body-conforming and
pressure-distributing capabilities of the top and middle layers
2010, 2012 described above.
[0166] The body support 2002 illustrated in FIG. 20 is also an
example of the manner in which a layer of non-reticulated
visco-elastic foam can be replaced by two layers of non-reticulated
visco-elastic foam flanking a layer of reticulated visco-elastic
foam for ventilation and heat dissipation.
[0167] FIG. 21 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 19. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 19. Reference
should be made to the description above in connection with FIG. 19
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 21 and described below. Structure and
features of the embodiment shown in FIG. 21 that correspond to
structure and features of the embodiment of FIG. 19 are designated
hereinafter in the 2100 series of reference numbers.
[0168] Like the embodiment illustrated in FIG. 19, the body support
2102 illustrated in FIG. 21 has a top layer 2110 comprising
open-celled non-reticulated visco-elastic foam, and an underlying
layer 2112 comprising reticulated visco-elastic foam. In some
embodiments, the body support 2102 can therefore provide the
softness, body-conforming, and pressure-distributing
characteristics of the non-reticulated visco-elastic foam in the
top layer 2110 (proximate the body of a user) as described above,
and the ventilating and heat-dissipative properties of the
underlying layer 2112 for reducing heat in the top layer 2110 as
also described above. The underlying layer 2112 can also provide
softness for the body support 2002, can help to conform the body
support 2102 to the user's body, and can thereby distribute
pressure of the user's body by virtue of the visco-elastic property
of the underlying layer 2112.
[0169] The body support 2102 illustrated in FIG. 21 further
comprises a bottom layer 2114 beneath the layer of reticulated
visco-elastic foam 2112. Therefore, the layer 2112 of reticulated
visco-elastic foam is a middle layer 2112 located between the top
and bottom layers 2110, 2114 of the body support 2102.
[0170] The bottom layer 2114 of the body support 2102 illustrated
in FIG. 21 comprises reticulated non-visco-elastic foam. The
reticulated non-visco-elastic foam (and various possible properties
thereof) of the bottom layer 2114 is described in greater detail
above in connection with the embodiment of FIG. 13.
[0171] In some embodiments, the middle layer 2112 of reticulated
visco-elastic foam can reduce heat in the top layer 2110 as
described above. However, some types of reticulated visco-elastic
foam that can be utilized in the middle layer 2112 do not provide a
high degree of support for the body support 2102. While this may be
acceptable and/or desirable in some applications (e.g., in pillows,
futons, and the like), in some embodiments additional support is
desired. The reticulated non-visco-elastic foam of the bottom layer
2114 can provide such additional support, while still providing the
ventilation and/or heat dissipation properties described earlier in
connection with the embodiment of FIG. 13. A bottom layer 2114 of
reticulated non-visco-elastic foam can be utilized for other
reasons as well, including without limitation to provide a layer of
material that is less responsive or substantially non-responsive to
a user's body temperature (described in greater detail above in
connection with the embodiment of FIG. 13), while still providing
the ventilation and/or heat dissipation properties also described
above.
[0172] The body support 2102 illustrated in FIG. 21 can have a
bottom layer 2114 that is at least as thick as the combined
thicknesses of the top and middle layers 2110, 2112, thereby
providing substantial support, ventilation, and heat dissipation
for the top and middle layers 2110, 2112. In some embodiments, the
bottom layer 2114 is at least 0.17 times as thick as the combined
thickness of the top and middle layers 2110, 2112. In other
embodiments, the bottom layer 2114 is at least 0.375 times as thick
as the combined thickness of the top and middle layers 2110,
2112.
[0173] FIG. 22 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 19. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 19. Reference
should be made to the description above in connection with FIG. 19
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 22 and described below. Structure and
features of the embodiment shown in FIG. 22 that correspond to
structure and features of the embodiment of FIG. 19 are designated
hereinafter in the 2200 series of reference numbers.
[0174] Like the embodiment illustrated in FIG. 19, the body support
2202 illustrated in FIG. 22 has a top layer 2210 comprising
open-celled non-reticulated visco-elastic foam, and an underlying
layer 2212 comprising reticulated visco-elastic foam. In some
embodiments, the body support 2202 can therefore provide the
softness, body-conforming, and pressure-distributing
characteristics of the non-reticulated visco-elastic foam in the
top layer 2210 (proximate the body of a user) as described above,
and the ventilating and heat-dissipative properties of the
underlying layer 2212 for reducing heat in the top layer 2210 as
also described above. The underlying layer 2212 can also provide
softness to the body support 2202, can help to conform the body
support 2202 to the user's body, and can thereby distribute
pressure of the user's body by virtue of the visco-elastic property
of the underlying layer 2212.
[0175] The body support 2202 illustrated in FIG. 22 further
comprises a bottom layer 2214 beneath the layer of reticulated
visco-elastic foam 2212. Therefore, the layer 2212 of reticulated
visco-elastic foam is a middle layer 2212 located between the top
and bottom layers 2210, 2214 of the body support 2202.
[0176] The bottom layer 2214 of the body support 2202 illustrated
in FIG. 22 comprises a cellular structure of flexible polyurethane
foam that is relatively highly resilient and supportive. The bottom
layer 2214 can therefore provide a relatively stiff substrate upon
which the top and middle layers 2210, 2212 lie, thereby providing
support for the top and middle layers 2210, 2212. Also, the
flexibility of the bottom layer 2214 can provide a degree of
deformability for user comfort (to the extent that the user's
weight affects the shape of the bottom layer 2214), while the top
and middle layers 2210, 2212 provide the desirable body-conforming
and pressure distribution features described above, and while the
middle layer 2212 provides significant heat dissipation and
ventilation for the body support 2202. In some embodiments, the
bottom layer 2214 has a resilience greater than that of the top and
middle layers 2210, 2212.
[0177] The body support 2202 illustrated in FIG. 22 can have a
bottom layer 2214 that is at least as thick as the combined
thicknesses of the top and middle layers 2210, 2212, thereby
providing substantial support for the top and middle layers 2210,
2212. In some embodiments, the bottom layer 2214 is at least 0.17
times as thick as the combined thicknesses of the top and middle
layers 2210, 2212. Also, in some embodiments, the bottom layer 2214
is at least half as thick as the combined thicknesses of the top
and middle layers 2210, 2212.
[0178] FIG. 23 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 12 and 12A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 12 and
12A. Reference should be made to the description above in
connection with FIGS. 12 and 12A for additional information
regarding the structure and features, and possible alternatives to
the structure and features of the body support illustrated in FIG.
23 and described below. Structure and features of the embodiment
shown in FIG. 23 that correspond to structure and features of the
embodiment of FIGS. 12 and 12A are designated hereinafter in the
2300 series of reference numbers.
[0179] Like the body support 1202 illustrated in FIGS. 12 and 12A,
the body support 2302 illustrated in FIG. 23 has a top layer 2310
comprising reticulated visco-elastic foam, beneath which lies a
bottom layer 2312 comprising a cellular structure of relatively
resilient flexible polyurethane material. The reticulated
visco-elastic foam and the relatively highly resilient flexible
cellular foam of the top and bottom layers 2310, 2312,
respectively, are described in greater detail above in connection
with the embodiment illustrated in FIGS. 12 and 12A.
[0180] The top surface 2320 of the bottom layer 2312 of the body
support 2302 has a non-planar shape beneath the substantially
planar bottom surface 2318 of the top layer 2310. The non-planar
shape of the top surface 2320 can take any of the forms described
above in connection with the non-planar top surface 420 of the
bottom layer 412 in the body support 402 illustrated in FIG. 4, and
can be defined by a plurality of protrusions 2328 and/or a
plurality of apertures (not shown) as also described above.
Passages 2330 between the substantially planar bottom surface 2318
of the top layer 2310 and the non-planar top surface 2320 of the
bottom layer 2312 can provide a degree of ventilation and enhanced
heat dissipation of the body support 2302. In other embodiments,
such passages 2330 can be defined between a non-planar bottom
surface 2318 of the top layer 2310 and a substantially planar top
surface 2320 of the bottom layer 2312, or between a non-planar
bottom surface 2318 of the top layer 2310 and a non-planar top
surface 2320 of the bottom layer 2312, wherein the non-planar
surface(s) can be defined in any of the manners described above in
connection with the illustrated embodiment of FIG. 4.
[0181] Passages 2330 running between the top and bottom layers
2310, 2312 illustrated in FIG. 23 can supplement the ventilation
and/or heat dissipative capabilities of the top layer 2310 of
reticulated visco-elastic foam, and can reduce heat in the bottom
layer 2312 of relatively highly resilient flexible cellular foam.
In this regard, the skeletal structure of the cells in the top
layer 2310 of reticulated visco-elastic foam can enable heat to be
transferred from the top layer 2310 to and through the passages
2330.
[0182] FIG. 24 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 14. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 14. Reference
should be made to the description above in connection with FIG. 14
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 24 and described below. Structure and
features of the embodiment shown in FIG. 24 that correspond to
structure and features of the embodiment of FIG. 14 are designated
hereinafter in the 2400 series of reference numbers.
[0183] As described in greater detail above with regard to the body
support 1402 illustrated in FIG. 14, the body support 2402
illustrated in FIG. 24 comprises a top layer 2410 comprising
reticulated visco-elastic foam, a middle layer 2412 comprising
reticulated non-visco-elastic foam, and a bottom layer 2414
comprising a cellular structure of relatively resilient flexible
polyurethane material. The reticulated visco-elastic foam and the
relatively highly resilient flexible cellular foam of the top and
bottom layers 2410, 2414, respectively, are described in greater
detail above in connection with the embodiment illustrated in FIGS.
12 and 12A. The reticulated non-visco-elastic foam of the middle
layer 2412 is described in greater detail above in connection with
the embodiment illustrated in FIG. 13.
[0184] The top surface 2424 of the bottom layer 2414 has a
non-planar shape beneath the substantially planar bottom surface
2422 of the middle layer 2412. The non-planar shape of the top
surface 2424 can take any of the forms described above in
connection with the non-planar top surface 420 of the bottom layer
412 in the body support 402 illustrated in FIG. 4, and can be
defined by a plurality of protrusions 2428 and/or a plurality of
apertures (not shown) as also described above. Passages 2430
between the substantially planar bottom surface 2422 of the middle
layer 2412 and the non-planar top surface 2424 of the bottom layer
2414 can provide a degree of ventilation and enhanced heat
dissipation of the body support 2402 (e.g., moving heat from the
middle layer 2412, and in some cases from both the middle and top
layers 2412, 2410). In other embodiments, such passages 2430 can be
defined between a non-planar bottom surface 2422 of the middle
layer 2412 and a substantially planar top surface 2424 of the
bottom layer 2414, or between a non-planar bottom surface 2422 of
the middle layer 2412 and a non-planar top surface 2424 of the
bottom layer 2414, wherein the non-planar surface(s) can be defined
in any of the manners described above in connection with the
illustrated embodiment of FIG. 4.
[0185] Passages 2430 running between the middle and bottom layers
2412, 2414 illustrated in FIG. 24 can provide the body support 2402
with increased capacity to dissipate heat from the middle layer
2412 of reticulated non-visco-elastic foam, which can receive a
user's body heat from the top layer 2410 of reticulated
visco-elastic foam. The skeletal structure of the cells in the top
and middle layers 2410, 2412 can enable heat to be transferred from
the top and middle layers 2410, 2412 to and through the passages
2430. Although heat transfer in lateral directions (i.e., toward
the edges of the body support 2402) still occurs in the top and
middle layers 2410, 2412 of reticulated visco-elastic and
reticulated non-visco-elastic foam based at least in part upon the
cell structure of such foams, the passages 2430 can enhance this
heat transfer.
[0186] FIG. 25 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 21. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 21. Reference
should be made to the description above in connection with FIG. 21
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 25 and described below. Structure and
features of the embodiment shown in FIG. 25 that correspond to
structure and features of the embodiment of FIG. 21 are designated
hereinafter in the 2500 series of reference numbers.
[0187] As described in greater detail above with regard to the body
support 2102 illustrated in FIG. 21, the body support 2502
illustrated in FIG. 25 comprises a top layer 2510 comprising
open-celled non-reticulated visco-elastic foam, a middle layer 2512
comprising reticulated visco-elastic foam, and a bottom layer 2514
comprising reticulated non-visco-elastic foam.
[0188] The top surface 2520 of the middle layer 2512 has a
non-planar shape beneath the substantially planar bottom surface
2518 of the top layer 2510. The non-planar shape of the top surface
2520 of the middle layer 2512 can take any of the forms described
above in connection with the non-planar top surface 420 of the
bottom layer 412 in the body support 402 illustrated in FIG. 4, and
can be defined by a plurality of protrusions 2528 and/or a
plurality of apertures (not shown) as also described above.
Passages 2530 between the substantially planar bottom surface 2518
of the top layer 2510 and the non-planar top surface 2520 of the
middle layer 2512 can provide a degree of ventilation and enhanced
heat dissipation of the body support 2502. In some embodiments, the
passages 2530 can be defined between a non-planar bottom surface
2518 of the top layer 2510 and a substantially planar top surface
2520 of the middle layer 2512, or between a non-planar bottom
surface 2518 of the top layer 2510 and a non-planar top surface
2520 of the middle layer 2512, wherein the non-planar surface(s)
can be defined in any of the manners described above in connection
with the illustrated embodiment of FIG. 4.
[0189] The passages 2530 between the top and middle layers 2510,
2512 described above can be particularly useful in reducing heat in
regions of the body support 2502. The passages 2530 can supplement
the ventilation and/or heat dissipative capabilities of the middle
and bottom layers 2512, 2514 of reticulated visco-elastic foam and
reticulated non-visco-elastic foam, and can reduce heat in the top
layer 2510 of non-reticulated visco-elastic foam. In addition, the
skeletal structure of the cells in the middle and bottom layers
2512, 2514 can enable heat to be transferred from the top layer
2510 to and through the cells of the middle and bottom layers 2512,
2514.
[0190] FIG. 26 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 22. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 22. Reference
should be made to the description above in connection with FIG. 22
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 26 and described below. Structure and
features of the embodiment shown in FIG. 26 that correspond to
structure and features of the embodiment of FIG. 22 are designated
hereinafter in the 2600 series of reference numbers.
[0191] As described in greater detail above with regard to the body
support 2202 illustrated in FIG. 22, the body support 2602
illustrated in FIG. 5 comprises a top layer 2610 comprising
open-celled non-reticulated visco-elastic foam, a middle layer 2612
comprising reticulated visco-elastic foam, and a bottom layer 2614
comprising flexible cellular polyurethane foam having a relatively
high resilience. However, the top surface 2624 of the bottom layer
2614 has a non-planar shape beneath the substantially planar bottom
surface 2622 of the middle layer 2612. The non-planar shape of the
top surface 2624 can take any of the forms described above in
connection with the non-planar top surface 420 of the bottom layer
412 in the body support 402 illustrated in FIG. 4, and can be
defined by a plurality of protrusions 2628 and/or a plurality of
apertures (not shown) as also described above. Passages 2630 can be
defined between the substantially planar bottom surface 2622 of the
middle layer 2612 and the non-planar top surface 2624 of the bottom
layer 2614. In other embodiments, such passages 2630 can be defined
between a non-planar bottom surface 2622 of the middle layer 2612
and a substantially planar top surface 2624 of the bottom layer
2614, or between a non-planar bottom surface 2622 of the middle
layer 2612 and a non-planar top surface 2624 of the bottom layer
2614, wherein the non-planar surface(s) can be defined in any of
the manners described above in connection with the illustrated
embodiment of FIG. 4.
[0192] Passages 2630 running between the middle and bottom layers
2612, 2614 illustrated in FIG. 26 can provide a degree of
ventilation and enhanced heat dissipation of the body support 2602
(e.g., in which heat can move from the middle layer 2612 toward the
passages 2630, and in some cases from both the middle and top
layers 2612, 2610 toward the passages 2630). The skeletal structure
of the cells in the middle layer 2612 can enable heat to be
transferred from the top layer 2610 to and through the passages
2630. Although heat transfer in lateral directions. (i.e., toward
the edges of the body support 2602) still occurs in the middle
layer 2612 of reticulated visco-elastic foam based at least in part
upon the cell structure of the reticulated visco-elastic foam, the
passages 2630 can enhance this heat transfer.
[0193] FIG. 27 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 17. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 17. Reference
should be made to the description above in connection with FIG. 17
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 27 and described below. Structure and
features of the embodiment shown in FIG. 27 that correspond to
structure and features of the embodiment of FIG. 17 are designated
hereinafter in the 2700 series of reference numbers.
[0194] As described in greater detail above with regard to the body
support 1702 illustrated in FIG. 17, the body support 2702
illustrated in FIG. 25 comprises a top layer 2710 comprising
reticulated visco-elastic foam, a middle layer 2712 comprising
open-celled non-reticulated visco-elastic foam, and a bottom layer
2714 comprising reticulated non-visco-elastic foam.
[0195] The top surface 2720 of the middle layer 2712 has a
non-planar shape beneath the substantially planar bottom surface
2718 of the top layer 2710. The non-planar shape of the top surface
2720 can take any of the forms described above in connection with
the non-planar top surface 420 of the bottom layer 412 in the body
support 402 illustrated in FIG. 4, and can be defined by a
plurality of protrusions 2728 and/or a plurality of apertures (not
shown) as also described above. Passages 2730 can be defined
between the substantially planar bottom surface 2718 of the top
layer 2710 and the non-planar top surface 2720 of the middle layer
2712. In some embodiments, the passages 2730 can be defined between
a non-planar bottom surface 2718 of the top layer 2710 and a
substantially planar top surface 2720 of the middle layer 2712, or
between a non-planar bottom surface 2718 of the top layer 2710 and
a non-planar top surface 2720 of the middle layer 2712, wherein the
non-planar surface(s) can be defined in any of the manners
described above in connection with the illustrated embodiment of
FIG. 4.
[0196] Passages 2730 running between the top and middle layers
2710, 2712 illustrated in FIG. 27 can provide the body support 2702
with a degree of ventilation and/or with an increased capacity to
dissipate heat from the middle layer 2712 of non-reticulated
visco-elastic foam, which can receive a user's body heat from the
top layer 2710 of reticulated visco-elastic foam. In some
applications, heat can be transferred through the skeletal
structure of cells in the top layer 2710 and then through the
passages 2730 between the top and middle layers 2710, 2712.
[0197] FIG. 28 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 18. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 18. Reference
should be made to the description above in connection with FIG. 18
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 28 and described below. Structure and
features of the embodiment shown in FIG. 28 that correspond to
structure and features of the embodiment of FIG. 18 are designated
hereinafter in the 2800 series of reference numbers.
[0198] As described in greater detail above with regard to the body
support 1802 illustrated in FIG. 18, the body support 2802
illustrated in FIG. 28 comprises a top layer 2810 comprising
reticulated visco-elastic foam, a middle layer 2812 comprising
open-celled non-reticulated visco-elastic foam, and a bottom layer
2814 comprising flexible cellular polyurethane foam having a
relatively high resilience.
[0199] The top surface 2824 of the bottom layer 2814 has a
non-planar shape beneath the substantially planar bottom surface
2822 of the middle layer 2812. The non-planar shape of the top
surface 2824 can take any of the forms described above in
connection with the non-planar top surface 420 of the bottom layer
412 in the body support 402 illustrated in FIG. 4, and can be
defined by a plurality of protrusions 2828 and/or a plurality of
apertures (not shown) as also described above. Passages 2830 can be
defined between the substantially planar bottom surface 2822 of the
middle layer 2812 and the non-planar top surface 2824 of the bottom
layer 2814. In other embodiments, such passages 2830 can be defined
between a non-planar bottom surface 2822 of the middle layer 2812
and a substantially planar top surface 2824 of the bottom layer
2814, or between a non-planar bottom surface 2822 of the middle
layer 2812 and a non-planar top surface 2824 of the bottom layer
2814, wherein the non-planar surface(s) can be defined in any of
the manners described above in connection with the illustrated
embodiment of FIG. 4.
[0200] Passages 2830 running between the middle and bottom layers
2812, 2814 illustrated in FIG. 28 can provide the body support 2802
with a degree of ventilation and/or increased capacity to dissipate
heat from the middle layer 2812 of non-reticulated visco-elastic
foam, which can receive a user's body heat through the top layer
2810 of reticulated visco-elastic foam. In particular, the passages
2830 running beneath the middle layer 2812 of non-reticulated
visco-elastic foam can enable heat to be transferred from the
middle layer 2812 through the passages 2830.
[0201] FIG. 29 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIGS. 12 and 12A. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIGS. 12 and
12A. Reference should be made to the description above in
connection with FIGS. 12 and 12A for additional information
regarding the structure and features, and possible alternatives to
the structure and features of the body support illustrated in FIG.
29 and described below. Structure and features of the embodiment
shown in FIG. 29 that correspond to structure and features of the
embodiment of FIGS. 12 and 12A are designated hereinafter in the
2900 series of reference numbers.
[0202] Like the body support 1202 illustrated in FIGS. 12 and 12A,
the body support 2902 illustrated in FIG. 29 has a top layer 2910
comprising reticulated visco-elastic foam, beneath which lies a
bottom layer 2912 comprising flexible cellular polyurethane foam
having a relatively high resilience. The reticulated visco-elastic
foam and the relatively highly resilient flexible cellular foam of
the top and bottom layers 2910, 2912, respectively, are described
in greater detail above in connection with the embodiment
illustrated in FIGS. 12 and 12A.
[0203] With continued reference to the body support 2902
illustrated in FIG. 29, the top and bottom layers 2910, 2912 of the
body support 2902 can have a cover 2948 comprising reticulated
non-visco-elastic foam. The reticulated non-visco-elastic foam of
the cover 2948 can have the same properties as described above with
reference to the bottom layer 1312 of the body support 1302
illustrated in FIG. 13. Also, the reticulated non-visco-elastic
foam of the cover 2948 can cover any portion of the top and bottom
layers 2910, 2912 desired. For example, the cover 2948 illustrated
in FIG. 29 covers substantially the entire top surface 2916 of the
top layer 2910. In other embodiments, the cover 2948 can also or
instead cover any portion or all of the sides and ends of the top
and/or bottom layers 2910, 2912, and/or can underlie any portion or
all of the bottom surface 2924 of the bottom layer 2912. In some
embodiments, the cover 2948 substantially entirely surrounds the
top and bottom layers 2910, 2912.
[0204] The reticulated non-visco-elastic foam cover 2948 can be
selected to provide a heightened degree of fire resistance to the
body support 2902, and in some countries and/or localities can be
utilized to meet fire codes calling for such fire resistance.
Although other materials capable of meeting such fire code
requirements can be utilized, the use of reticulated
non-visco-elastic foam can provide improved ventilation for the
surface(s) of the first and/or second layers 2910, 2912 covered by
the reticulated non-visco-elastic foam cover 2948. As described
above, reticulated non-visco-elastic foam can reduce the amount of
heat (e.g., from a user's body heat) in adjacent areas of a body
support, based at least in part upon the skeletal cellular
structure of the reticulated non-visco-elastic foam. Therefore, the
foam cover 2948 can provide enhanced fire resistance while also
serving to ventilate the body support 2902 and/or dissipate heat
from the adjacent first and/or second layers 2910, 2912 covered by
the reticulated non-visco-elastic foam cover 2948. Also, the
reticulated non-visco-elastic foam of the cover 2948 can be
utilized to provide a layer of material that is less responsive or
substantially non-responsive to a user's body temperature
(described in greater detail above in connection with the
embodiment of FIG. 13), while still providing the ventilation
and/or heat dissipation properties also described above.
[0205] The reticulated visco-elastic material of the top layer 2910
can provide a relatively comfortable substrate for a user's body,
can at least partially conform to the user's body (to distribute
force applied by the user's body upon the reticulated visco-elastic
material of the top layer 2910), and can be selected for
responsiveness to a range of temperatures generated by body heat of
a user. In some embodiments, the reticulated non-visco-elastic foam
cover 2948 (if employed) has a maximum thickness through which
these properties are still exhibited. Although the desirable
tactile feel of the reticulated visco-elastic first layer 2910 is
blocked in some embodiments by the reticulated non-visco-elastic
foam cover 2948, the other desirable properties of the reticulated
visco-elastic material of the first layer 2910 can still be
experienced through a sufficiently thin reticulated
non-visco-elastic foam cover 2948. In some embodiments, the
reticulated non-visco-elastic foam cover 2948 has a maximum
thickness of about 1 cm. In other embodiments, the reticulated
non-visco-elastic foam cover 2948 has a maximum thickness of about
2 cm. In still other embodiments, the reticulated non-visco-elastic
foam cover 2948 has a maximum thickness of about 5 cm.
[0206] FIG. 30 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 29. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 29. Reference
should be made to the description above in connection with FIG. 29
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 30 and described below. Structure and
features of the embodiment shown in FIG. 30 that correspond to
structure and features of the embodiment of FIG. 29 are designated
hereinafter in the 3000 series of reference numbers.
[0207] Like the body support 2902 illustrated in FIG. 29, the body
support 3002 illustrated in FIG. 30 has a top layer 3010 comprising
reticulated visco-elastic foam, a bottom layer 3012 comprising
flexible cellular polyurethane foam having a relatively high
resilience, and a cover 3048 comprising reticulated
non-visco-elastic foam. The reticulated visco-elastic foam and the
relatively highly resilient flexible cellular foam of the top and
bottom layers 3010, 3012, respectively, are described in greater
detail above in connection with the embodiment illustrated in FIGS.
12 and 12A. The reticulated non-visco-elastic foam of the cover
3048 is described in greater detail above in connection with the
embodiment illustrated in FIG. 13.
[0208] The reticulated non-visco-elastic foam cover 3048 of the
body support 3002 illustrated in FIG. 30 can be selected to provide
a heightened degree of fire resistance for the body support 3002,
and can also function to dissipate heat (e.g., received from a
user's body) from the adjacent first and/or second layers 3010,
3012 covered by the reticulated non-visco-elastic foam cover 3048.
In this regard, the reticulated non-visco-elastic foam of the cover
3048 can be utilized to provide a layer of material that is less
responsive or is substantially non-responsive to a user's body
temperature (described in greater detail above in connection with
the embodiment of FIG. 13), while still providing the ventilation
and/or heat dissipation properties also described above.
[0209] The top surface 3020 of the bottom layer 3012 of the body
support 3002 has a non-planar shape beneath the substantially
planar bottom surface 3018 of the top layer 3010. The non-planar
shape of the top surface 3020 can take any of the forms described
above in connection with the non-planar top surface 420 of the
bottom layer 412 in the body support 402 illustrated in FIG. 4, and
can be defined by a plurality of protrusions 3028 and/or a
plurality of apertures (not shown) as also described above.
Passages 3030 can be defined between the substantially planar
bottom surface 3018 of the top layer 3010 and the non-planar top
surface 3020 of the bottom layer 3012. In other embodiments, such
passages 3030 can be defined between a non-planar bottom surface
3018 of the top layer 3010 and a substantially planar top surface
3020 of the bottom layer 3012, or between a non-planar bottom
surface 3018 of the top layer 3010 and a non-planar top surface
3020 of the bottom layer 3012, wherein the non-planar surface(s)
can be defined in any of the manners described above in connection
with the illustrated embodiment of FIG. 4.
[0210] Passages 3030 running between the top and bottom layers
3010, 3012 illustrated in FIG. 30 can supplement the ventilation
and/or heat dissipative capabilities of the top layer 3010 of
reticulated visco-elastic foam, and can prevent or reduce heat in
the bottom layer 3012 of relatively highly resilient flexible
cellular foam. In this regard, the skeletal structure of the
reticulated visco-elastic foam cells in the top layer 3010 can
enable heat to be transferred from the top layer 3010 to and
through the passages 3030.
[0211] FIG. 31 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 21. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 21. Reference
should be made to the description above in connection with FIG. 21
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 31 and described below. Structure and
features of the embodiment shown in FIG. 31 that correspond to
structure and features of the embodiment of FIG. 21 are designated
hereinafter in the 3100 series of reference numbers.
[0212] Like the body support 2102 illustrated in FIG. 21, the body
support 3102 illustrated in FIG. 31 comprises a top layer 3110 of
open-celled non-reticulated visco-elastic foam, a middle layer 3112
comprising reticulated visco-elastic foam, and a bottom layer 3114
comprising reticulated non-visco-elastic foam. However, the top
layer 3110 further comprises portions of reticulated visco-elastic
foam that can have the same or different properties as the
reticulated visco-elastic foam in the middle layer 3112. The
non-reticulated visco-elastic foam of the top layer 3110 is
described in greater detail above in connection with the embodiment
illustrated in FIG. 16. The reticulated visco-elastic foam of the
top and middle layers 3110, 3112 is described in greater detail
above in connection with the embodiment illustrated in FIGS. 12 and
12A. The reticulated non-visco-elastic foam of the bottom layer
3114 is described in greater detail above in connection with the
embodiment illustrated in FIG. 13.
[0213] With continued reference to the illustrated embodiment of
FIG. 31, the top layer 3110 has three portions 3132 comprising
reticulated visco-elastic foam, each of which are surrounded by
other portions 3146 of the top layer 3110 comprising the
non-reticulated visco-elastic foam. In some embodiments, one or
more of the three portions 3132 comprising reticulated
visco-elastic foam can be disposed a distance from adjacent edges
of the top layer 3110 by at least about 10 cm and by no greater
than about 20 cm. In other embodiments, this distance can be at
least about 10 cm and no greater than about 15 cm. It should be
noted that this distance can be the same or different at different
locations about any of the three portions 3132 comprising
reticulated visco-elastic foam, and can be larger or smaller than
that illustrated in FIG. 31.
[0214] Each of the three portions 3132 comprising reticulated
visco-elastic foam described above can have any shape desired, such
as rectangular (see FIG. 31), trapezoidal, triangular, and other
polygonal shapes, round, oval, and other rotund shapes, hourglass,
star, irregular, and other shapes. Also, the three portions 3132
comprising reticulated visco-elastic foam can have the same shape
(see FIG. 31) or can have different shapes, and can have the same
size (see FIG. 31) or can have different sizes.
[0215] The three portions 3132 comprising reticulated visco-elastic
foam can be located in any positions in the top layer 3110. By way
of example only, the three portions 3132 illustrated in FIG. 31 are
located proximate areas of the body support 3102 where an adult
user's head, buttocks, and lower legs would be located when the
user is in a supine position on the body support 3102. In other
embodiments, the top layer 3110 can have one or more portions 3132
of reticulated visco-elastic foam located in any other position in
the top layer 3110, such as two portions 3132 of reticulated
visco-elastic foam located proximate the head and buttocks of a
user, a single portion 3132 of reticulated visco-elastic foam
located proximate the head and/or shoulders of a user, four
portions 3132 of reticulated visco-elastic foam located proximate
the head, back, buttocks, and legs of a user, and the like. In some
embodiments, the reticulated visco-elastic foam portion(s) 3132 are
located proximate areas that correspond to those areas of a user's
body on the body support 3102 that experience the highest pressure
when the user is lying on the body support 3102 in an orientation
substantially aligned with the length L of the body support
3102.
[0216] The three portions 3132 comprising reticulated visco-elastic
foam in the illustrated embodiment of FIG. 31 are each surrounded
by the non-reticulated visco-elastic foam of the top layer 3110.
However, in other embodiments, one or more sides of one or more of
the portions 3132 are open to a side or end of the top layer 3110,
or are otherwise not separated from a side or end of the top layer
3110 by the non-reticulated visco-elastic foam.
[0217] With continued reference to the illustrated embodiment of
FIG. 31, the non-reticulated visco-elastic foam in the top layer
3110 can provide the desirable softness, body-conforming, and
pressure-distributing features described above in connection with
the illustrated embodiment of FIG. 21. The portions 3132 of the top
layer 3110 comprising reticulated visco-elastic foam can provide a
significant degree of ventilation and/or heat dissipation for areas
of the top layer 3110 adjacent the user's body that could
experience the greatest pressure and heat from the user's body.
These capabilities can supplement the ventilation and/or heat
dissipation provided by the reticulated visco-elastic and
reticulated non-visco-elastic foams of the middle and bottom layers
3112, 3114 described above in connection with the embodiment of
FIG. 21. Also, the visco-elastic properties of these portions 3132
can still provide a relatively high degree of softness,
body-conforming, and pressure-distribution for the user's body.
[0218] The top layer 3110 illustrated in FIG. 31 comprises three
portions 3132 comprising reticulated visco-elastic foam surrounded
by other portions 3146 comprising non-reticulated visco-elastic
foam. In other embodiments, the materials of these portions 3132,
3146 can be reversed, such that one or more portions comprising
non-reticulated visco-elastic foam are at least partially
surrounded by other portions comprising reticulated visco-elastic
foam. In such embodiments, the softness, body-conforming, and
pressure-distributing features of the "islands" comprising
non-reticulated visco-elastic foam can be located proximate those
areas of a user's body that could experience the greatest pressure
and heat from the user's body. The surrounding portions comprising
reticulated visco-elastic foam can also provide a degree of
softness, body-conforming, and pressure-distribution while also
functioning to prevent or reduce heat in the top layer 3110 by
virtue of the skeletal structure of the reticulated visco-elastic
foam.
[0219] FIG. 32 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 13. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 13. Reference
should be made to the description above in connection with FIG. 13
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 32 and described below. Structure and
features of the embodiment shown in FIG. 32 that correspond to
structure and features of the embodiment of FIG. 13 are designated
hereinafter in the 3200 series of reference numbers.
[0220] Like the body support 1302 illustrated in FIG. 13, the body
support 3202 illustrated in FIG. 32 comprises a top layer 3210
comprising reticulated visco-elastic foam and a bottom layer 3212
comprising reticulated non-visco-elastic foam. However, the top
layer 3210 further comprises portions of open-celled
non-reticulated visco-elastic foam. The reticulated visco-elastic
foam of the top layer 3210 is described in greater detail above in
connection with the embodiment illustrated in FIGS. 12 and 12A. The
non-reticulated visco-elastic foam of the top layer 3210 is
described in greater detail above in connection with the embodiment
illustrated in FIG. 16. The reticulated non-visco-elastic foam of
the bottom layer 3212 is described in greater detail above in
connection with the embodiment illustrated in FIG. 13.
[0221] With continued reference to the illustrated embodiment of
FIG. 32, the top layer 3210 has three portions 3232 comprising
non-reticulated visco-elastic foam, each of which is surrounded by
other portions 3246 of the top layer 3210 comprising the
reticulated visco-elastic foam. The three portions 3232 comprising
non-reticulated visco-elastic foam illustrated in FIG. 32 are each
substantially rectangular, are spaced from one another along the
length of the top layer 3210, and are spaced from the edges of the
top layer 3210. However, the three portions 3232 can have any other
shape and size as described above in connection with the
illustrated embodiment of FIG. 31. Also, the top layer 3210 can
have any number of such portions 3232 located in any of the manners
described above in connection with the illustrated embodiment of
FIG. 31.
[0222] With continued reference to the illustrated embodiment of
FIG. 32, the non-reticulated visco-elastic foam in the three
portions 3232 of the top layer 3110 can provide in such areas the
desirable softness, body-conforming, and pressure-distributing
features described above in connection with the illustrated
embodiment of FIG. 16. The surrounding portions 3246 of the top
layer 3210 comprising reticulated visco-elastic foam can provide
significant ventilation and/or heat dissipation to the three
portions 3232 adjacent the user's body, and can draw heat from
internal areas of the top layer 3210 toward the edges of the top
layer 3210. Such ventilation and/or heat dissipation can supplement
the ventilation and/or heat dissipation provided by the reticulated
non-visco-elastic foam of the bottom layer 3212 described above in
connection with the embodiment of FIG. 13. Also, the visco-elastic
properties of the surrounding portions 3246 can still provide a
relatively high degree of softness, body-conforming, and
pressure-distribution for the user's body.
[0223] FIG. 33 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 31. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 31. Reference
should be made to the description above in connection with FIG. 31
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 33 and described below. Structure and
features of the embodiment shown in FIG. 33 that correspond to
structure and features of the embodiment of FIG. 31 are designated
hereinafter in the 3300 series of reference numbers.
[0224] Like the body support 3102 illustrated in FIG. 31, the body
support 3302 illustrated in FIG. 33 comprises a top layer 3310
having a combination of open-celled non-reticulated visco-elastic
foam (portion 3346) and reticulated visco-elastic foam (portion
3332). However, the body support 3302 illustrated in FIG. 33 has a
bottom layer 3312 comprising flexible cellular polyurethane foam
having a relatively high resilience, rather than the layers of
reticulated visco-elastic and reticulated non-visco-elastic foam in
the embodiment of FIG. 31. The non-reticulated visco-elastic foam
of the top layer 3310 is described in greater detail above in
connection with the embodiment illustrated in FIG. 16. The
reticulated visco-elastic foam of the top layer 3310 is described
in greater detail above in connection with the embodiment
illustrated in FIGS. 12 and 12A. The relatively highly resilient
flexible cellular foam of the bottom layer 3312 is also described
in greater detail above in connection with the embodiment
illustrated in FIGS. 12 and 12A.
[0225] The top layer 3310 illustrated in FIG. 33 includes a border
3346 comprising the non-reticulated visco-elastic foam, which
extends fully around a portion 3332 of the top layer 3310
comprising the reticulated visco-elastic foam. The border 3346 can
extend fully around the portion 3332 comprising the reticulated
visco-elastic foam as shown in FIG. 33, or can extend partially
about the portion 3332 comprising the reticulated visco-elastic
foam (e.g., having portions flanking the first portion 3332 as
described above with reference to the bottom layer 712 of the
embodiment of FIG. 7, or having one or more portions shaped and
located in any of the manners described above in connection with
the bottom layer 712 in the illustrated embodiment of FIG. 7). In
short, any number of portions 3332 comprising the reticulated
visco-elastic foam and any number of borders 3346 comprising the
non-reticulated visco-elastic foam can have any of the shapes,
positions, and arrangements described above in connection with the
bottom layer 712 in the illustrated embodiment of FIG. 7.
[0226] With continued reference to the illustrated embodiment of
FIG. 33, the non-reticulated visco-elastic foam in the top layer
3310 can provide the desirable softness, body-conforming, and
pressure-distributing features described above (in connection with
the illustrated embodiment of FIG. 19) along the periphery of the
top layer 3310, such as in locations where a user enters or exits
the body support (e.g., in mattress applications). The portion 3332
of the top layer 3310 comprising reticulated visco-elastic foam can
provide ventilation and/or heat dissipation for an interior area of
the top layer 3310 upon which a user will most likely rest for a
prolonged period of time, and to which a user's body heat would
most likely be transferred. The ventilation and heat dissipative
properties of the reticulated visco-elastic foam in the top layer
3310 can also reduce heat in the underlying layer of relatively
highly resilient flexible cellular foam (which can be used to
provide additional support, and a relatively stiff but flexible and
resilient substrate beneath the top layer 3310).
[0227] As described above, the top layer 3310 illustrated in FIG.
33 includes an interior portion 3332 comprising reticulated
visco-elastic foam surrounded by other portions 3346 comprising
non-reticulated visco-elastic foam. In other embodiments, the
materials of these portions 3332, 3346 can be reversed, such that
one or more portions comprising non-reticulated visco-elastic foam
are at least partially surrounded by one or more other portions
comprising reticulated visco-elastic foam. Such alternative
embodiments and their features and characteristics are described in
greater detail above in connection with the illustrated embodiment
of FIG. 31.
[0228] FIG. 34 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 31. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 31. Reference
should be made to the description above in connection with FIG. 31
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 34 and described below. Structure and
features of the embodiment shown in FIG. 34 that correspond to
structure and features of the embodiment of FIG. 31 are designated
hereinafter in the 3400 series of reference numbers.
[0229] Like the body support 3102 illustrated in FIG. 31, the body
support 3402 illustrated in FIG. 34 comprises a top layer 3410
having a combination of open-celled non-reticulated visco-elastic
foam (portion 3432) and reticulated visco-elastic foam (portions
3434, 3436), and a middle layer 3412 comprising reticulated
visco-elastic foam. However, the body support 3402 illustrated in
FIG. 34 has a bottom layer 3414 comprising flexible cellular
polyurethane foam having a relatively high resilience, rather than
a layer of reticulated non-visco-elastic foam (as in the embodiment
of FIG. 31). The non-reticulated visco-elastic foam of the top
layer 3410 is described in greater detail above in connection with
the embodiment illustrated in FIG. 16. The reticulated
visco-elastic foam of the top and middle layers 3410, 3412 is
described in greater detail above in connection with the embodiment
illustrated in FIGS. 12 and 12A. The relatively highly resilient
flexible cellular foam of the bottom layer 3414 is also described
in greater detail above in connection with the embodiment
illustrated in FIGS. 12 and 12A.
[0230] The portions 3434, 3436 of reticulated visco-elastic foam
illustrated in FIG. 34 define side borders of the top layer 3410,
and can have any of the shapes, sizes, and locations described
above with reference to the second and third portions 734, 736 of
the bottom layer 712 illustrated in FIG. 7. The non-reticulated
visco-elastic foam portion 3432 of the top layer 3410 can provide
the desirable softness, body-conforming, and pressure-distributing
features described above in connection with the illustrated
embodiment of FIG. 16. The portions 3434, 3436 of reticulated
visco-elastic foam of the top layer 3410 can provide a degree of
ventilation and/or heat dissipation for the interior portion 3432
adjacent the user's body, and can draw heat from internal areas of
the top layer 3410 toward the sides and ends of the top layer 3410.
Such ventilation and/or heat dissipation can supplement the
ventilation and/or heat dissipation provided by the reticulated
visco-elastic foam of the middle layer 3412. Also, the
visco-elastic properties of the portions 3434, 3436 of reticulated
visco-elastic foam can still provide a relatively high degree of
softness, body-conforming, and pressure-distribution for the user's
body at the sides of the top layer 3410 (e.g., in locations where a
user may enter or exit the body support 3420, such as in mattress
applications).
[0231] The ventilation and heat dissipative properties of the
reticulated visco-elastic foam in the portions 3434, 3436 of the
top layer 3310 and in the middle layer 3412 can also reduce heat in
the bottom layer 3414 of relatively highly resilient flexible
cellular foam (which can be used to provide additional support, and
a relatively stiff but flexible and resilient substrate upon which
the top and middle layers 3410, 3412 lie).
[0232] As described above, the top layer 3410 illustrated in FIG.
34 includes an interior portion 3432 comprising non-reticulated
visco-elastic foam flanked by portions 3434, 3436 comprising
reticulated visco-elastic foam. In other embodiments, the materials
of these portions 3432 and 3434, 3436 can be reversed. Such
alternative embodiments can therefore include a portion of
reticulated visco-elastic foam flanked by and providing ventilation
and/or heat dissipation to adjacent portions of non-reticulated
visco-elastic foam.
[0233] One or more of the layers of material in each of the body
support embodiments described above can comprise material in slab
or block form. For example, each of the illustrated layers of
material in FIGS. 1-34 is illustrated as a sheet of foam. In this
regard, any or all of such layers in any of the embodiments can
each be defined by a single, continuous, and unbroken sheet of
material. Alternatively, one or more of such layers can be defined
by two or more pieces of material coupled in any suitable manner,
such as by adhesive or cohesive bonding material, double-sided
tape, stitching, hot-melting, conventional fasteners, by being
molded together in one or more manufacturing processes, or in any
other suitable manner. Such pieces of material can have any shape
and size desired, such as blocks, strips, pads, or balls, pieces
having polygonal, curvilinear, irregular, or other shapes, and the
like. Also, such pieces of material can be identical to or
different from one another in shape and/or size.
[0234] In some embodiments, one or more of the layers of material
in any of the body support embodiments described above and
illustrated in FIGS. 1-34 comprise pieces of material that are not
coupled together. For example, any one or more of such layers can
include loose pieces of material having any shape and size as
described above, wherein the pieces are partially or entirely
enclosed and contained within one or more layers of material. In
such embodiments, the enclosing layer(s) of material can comprise
synthetic and/or natural fabric, cloth, or other sheet material. In
some embodiments, the enclosing layer(s) can have one or more seams
attached by adhesive or cohesive bonding material, double-sided
tape, stitching, hot-melting, conventional fasteners (e.g.,
zippers, buttons, clasps, laces, hook and loop fastener material,
hook and eye sets, tied ribbons, strings, cords, or other similar
elements, and the like), by being molded together in one or more
manufacturing processes, or in any other suitable manner. One or
more of such enclosing layers can also partially or entirely
enclose and contain layers comprising pieces of material coupled
together as described above.
[0235] An example of a body support 3502 comprising pieces of
material within one or more enclosing layers is illustrated in FIG.
35. The body support 3502 illustrated in FIG. 35 is in the shape of
a pillow, although it should be noted that the body support 3502
can take any other shape and have any other size for any other body
support application (e.g., mattresses, mattress toppers, overlays,
futons, seat cushions, seat backs, neck pillows, leg spacer
pillows, eye masks, and any other shape and size suitable for
supporting or cushioning any part or all of a human or animal
body).
[0236] The body support 3502 illustrated in FIG. 35 comprises
filler material 3558 surrounded by an enclosing layer of material
3560. The filler material 3558 illustrated in FIG. 35 includes
separate pieces of material that are not coupled together, although
in other embodiments some or all of the pieces can be coupled to
adjacent pieces (such as separate pieces coupled together in one or
more manufacturing processes as described above). In some
embodiments, the filler material 3558 comprises a plurality of
pieces of non-reticulated visco-elastic foam having any of the
material properties described above in connection with the material
of top layer 110 in the illustrated body support 102 of FIG. 1. The
body supports 3502 of these embodiments can therefore provide
significant softness and can conform to a user's body, and in some
cases can provide a greater degree of body support deformability
due to the multiple-piece construction of the body support 3502.
Such deformability can be desirable in many applications, such as
in pillows and cushions adapted to support portions of a user's
body, by way of example only. Also, the temperature sensitivity of
body supports 3502 having non-reticulated visco-elastic filler
material 3558 can enable the body support to better adapt to a
user's body (as described in greater detail above in connection
with the non-reticulated visco-elastic material utilized in the
embodiment of FIGS. 1-1B), thereby distributing pressure and
increasing user comfort.
[0237] With continued reference to the illustrated embodiment of
FIG. 35, the pieces of non-reticulated visco-elastic foam in the
filler material 3558 can be produced by shredding or cutting
non-reticulated visco-elastic foam, whether in virgin, recycled, or
scrap form. Alternatively, the pieces of non-reticulated
visco-elastic foam can be produced by molding the individual pieces
or in any other manner.
[0238] As described above, the pieces of non-reticulated
visco-elastic foam in the filler material 3558 can have any size
and shape desired. However, in some embodiments, these pieces have
an average largest dimension of no greater than about 4 cm and/or
no less than about 0.3 cm. In other embodiments, the pieces have an
average largest dimension of no greater than about 2 cm and/or no
less than about 0.6 cm. In still other embodiments, the pieces have
an average largest dimension of about 1.3 cm.
[0239] The filler material 3558 of the body support 3502
illustrated in FIG. 35 can be varied to change the characteristics
and/or cost of the body support 3502. For example, substantially
all of the filler material 3558 can comprise unconnected pieces of
non-reticulated visco-elastic foam as described above, or can
comprise a combination of such pieces and pieces of another
material (e.g., cotton, synthetic or organic fiber material,
feathers, another type of foam material, polystyrene balls, and the
like). In this regard, the filler material 3558 of the body support
3502 can comprise no less than about 20% non-reticulated
visco-elastic foam pieces in some embodiments. In other
embodiments, the filler material 3558 of the body support 3502
comprises no less than about 30% non-reticulated visco-elastic foam
pieces. In still other embodiments, the filler material 3558 of the
body support 3502 comprises no less than about 50% non-reticulated
visco-elastic foam pieces. The density and other characteristics of
the other material (if any) in the filler material 3558 can help to
define the density and other characteristics of the filler material
3558.
[0240] As described above, the filler material 3558 in the
illustrated embodiment of FIG. 35 is surrounded by an enclosing
layer of material 3560, which can have one or more seams coupled
together as described in greater detail above. In some embodiments,
the enclosing layer 3560 comprises reticulated non-visco-elastic
foam having any of the material properties described above in
connection with the material of the bottom layer 112 in the
illustrated body support 102 of FIG. 1. The enclosing layer 3560
can have any thickness desired. In some embodiments, the enclosing
layer 3560 of reticulated non-visco-elastic foam has a thickness of
no less than about 5 mm and/or no greater than about 20 mm.
Relatively lightweight body supports in some embodiments can have a
thickness of no greater than about 7 mm, while relatively heavy
weight body supports in some embodiments can have a thickness of no
less than about 13 mm.
[0241] With continued reference to the body support 3502
illustrated in FIG. 35, the enclosing layer 3560 of
non-visco-elastic foam can provide a significant degree of
ventilation and/or heat dissipation for the body support 3502, and
can prevent or reduce heat in the filler material 3558 of the body
support 3502.
[0242] In some embodiments, the enclosing layer 3560 of the body
support 3502 is partially or entirely covered with one or more
reinforcing fabric layers (not shown), which in some embodiments
can act as an anchor for stitches or other fastening elements
securing portions of the enclosing layer 3560 together (e.g., at
seams of the enclosing layer 3560), thereby reducing the
opportunity for stitches or other fastening elements to rip or tear
through the enclosing layer 3560. If employed, the reinforcing
fabric layer(s) can comprise cotton, polyester, a cotton/polyester
blend, wool, or any other fabric material.
[0243] A cover 3562 can at least partially surround the enclosing
layer 3560 and filler material 3558 of the body support 3502, can
be removable from the rest of the body support 3502, and in some
embodiments can conform to the shape of the body support 3502. The
cover 3562 can comprise any fabric material, such as a cotton,
polyester, cotton/polyester blend, wool, and the like. Also, the
cover 3562 can have one or more closure devices 3564, such as one
or more zippers (see FIG. 35), snaps, buttons, clasps, laces,
pieces of hook and loop fastener material, hook and eye sets,
overlapping flaps, tied ribbons, strings, cords, or other similar
elements, and the like, in order to retain the enclosing layer 3560
and filler material 3558 within the cover 3562.
[0244] As described above, the enclosing layer 3560 of the body
support 3502 illustrated in FIG. 35 comprises reticulated
non-visco-elastic foam, which can provide any of the features also
described above. In other embodiments, all or part of the enclosing
layer 3560 can comprise reticulated visco-elastic foam having any
of the enclosing layer thicknesses described above, and having any
of the material properties described above in connection with the
material of the top layer 1210 in the illustrated body support 1202
of FIG. 12. An enclosing layer 3560 comprising reticulated
visco-elastic material can have an improved ability to conform to a
user's body while still providing a significant degree of
ventilation and/or heat dissipation for the body support 3502, and
can prevent or reduce heat in the filler material 3558 of the body
support 3502. In this regard, such an enclosing layer 3560 can be
temperature-sensitive to a user's body heat, thereby better
enabling the enclosing layer 3560 to perform the body-conforming
function described above.
[0245] As described above, the illustrated body support 3502 can
comprise non-reticulated visco-elastic filler material 3558 at
least partially surrounded by one or more enclosing layers 3560 of
reticulated visco-elastic or reticulated non-visco-elastic foam as
described above. In alternative embodiments, the filler material
3558 can instead or also include a plurality of unconnected
reticulated non-visco-elastic foam pieces having any of the size
and shape properties described above with reference to the
non-reticulated visco-elastic foam filler material 3558 illustrated
in FIG. 35. Such reticulated non-visco-elastic foam pieces can be
produced in any of the manners described above in connection with
the non-reticulated visco-elastic foam filler material 3558
illustrated in FIG. 35, can define any part of the filler material
3558 of the body support 3502 in combination with any of the other
filler materials as also described above, or can define all of the
filler material 3558 of the body support 3502. Also, such
reticulated non-visco-elastic foam pieces can have any of the
material properties described above in connection with the material
of the bottom layer 112 in the illustrated body support 102 of FIG.
1.
[0246] The construction of a body support 3502 with filler material
3558 comprising pieces of reticulated non-visco-elastic foam within
an enclosing layer 3560 of reticulated visco-elastic or reticulated
non-visco-elastic foam as described above can provide a relatively
high degree of ventilation in and through the filler material 3558
as well as the enclosing layer 3560. This construction can also
enable heat to be rapidly dissipated from the body support 3502,
thereby preventing or reducing heat in areas of the body support
3502. In those applications in which the temperature-sensitive,
body-conforming, and pressure distribution properties of
visco-elastic foam are desired on or immediately adjacent the
exterior of the body support 3502, the enclosing layer 3560 can
comprise reticulated visco-elastic foam. Alternatively, if such
features are instead desired only in the interior of the body
support 3502 (e.g., to provide an exterior that is less subject to
change, such as resulting from a user's body heat), the enclosing
layer 3560 can comprise reticulated non-visco-elastic foam.
[0247] In other embodiments of the present invention, the body
support illustrated in FIG. 35 can comprise one or more enclosing
layers 3560 of reticulated visco-elastic or reticulated
non-visco-elastic foam (as described above) at least partially
surrounding filler material comprising a plurality of unconnected
reticulated visco-elastic foam pieces. The reticulated
visco-elastic foam pieces can have any of the size and shape
properties described above with reference to the non-reticulated
visco-elastic foam filler material 3558 illustrated in FIG. 35.
Such reticulated visco-elastic foam pieces can be produced in any
of the manners described above in connection with the
non-reticulated visco-elastic foam filler material 3558 illustrated
in FIG. 35, can define any part of the filler material 3558 of the
body support 3502 in combination with any of the other filler
materials as also described above, or can define all of the filler
material 3558 of the body support 3502. Also, such reticulated
visco-elastic foam pieces can have any of the material properties
described above in connection with the material of the top layer
1210 in the illustrated body support 1202 of FIG. 12.
[0248] The construction of a body support 3502 with filler material
3558 comprising pieces of reticulated visco-elastic foam within an
enclosing layer 3560 of reticulated visco-elastic or reticulated
non-visco-elastic foam as described above can provide a relatively
high degree of ventilation in and through the filler material 3558
as well as the enclosing layer 3560, while still providing the
desirable temperature-sensitivity, body-conforming, and pressure
distribution properties of the visco-elastic filler material (and
visco-elastic enclosing layer, if used) as described in greater
detail above in connection with the body support 1202 of FIGS. 12
and 12A. This construction can also enable heat to be rapidly
dissipated from the body support 3502, thereby preventing or
reducing heat in areas of the body support 3502. As described
above, in those applications in which the temperature-sensitive,
body-conforming, and pressure distribution properties of
visco-elastic foam are desired on or immediately adjacent the
exterior of the body support 3502, the enclosing layer 3560 can
comprise reticulated visco-elastic foam. Alternatively, if such
features are instead desired only in the interior of the body
support 3502 (e.g., to provide an exterior that is less subject to
change, such as resulting from a user's body heat), the enclosing
layer 3560 can comprise reticulated non-visco-elastic foam.
[0249] In still other embodiments of the present invention, the
reticulated visco-elastic or reticulated non-visco-elastic
enclosing layer 3560 of the body support 3502 illustrated in FIG.
35 and described above can be replaced by a non-reticulated
visco-elastic enclosing layer 3560 at least partially enclosing
pieces of unconnected reticulated visco-elastic or reticulated
non-visco-elastic foam (also described above). The non-reticulated
visco-elastic enclosing layer 3560 can have any of the enclosing
layer thicknesses described above, and can have any of the material
properties described above in connection with the material of the
top layer 110 in the illustrated body support 102 of FIG. 1. A
non-reticulated visco-elastic enclosing layer 3560 can provide a
high degree of softness and user comfort, while also providing the
desirable temperature-sensitivity, body-conforming, and pressure
distribution properties described above in connection with the
material of the top layer 110 in the illustrated body support 102
of FIG. 1. The pieces of reticulated visco-elastic or reticulated
non-visco-elastic foam within such an enclosing layer 3560 can help
to dissipate heat within the body support 3502, thereby reducing
heat in one or more areas of the body support 3502.
[0250] FIG. 36 illustrates another embodiment of a body support
according to the present invention. This embodiment employs much of
the same structure and has many of the same properties as the
embodiments of the body support described above in connection with
FIG. 35. Accordingly, the following description focuses primarily
upon the structure and features that are different than the
embodiments described above in connection with FIG. 35. Reference
should be made to the description above in connection with FIG. 35
for additional information regarding the structure and features,
and possible alternatives to the structure and features of the body
support illustrated in FIG. 36 and described below. Structure and
features of the embodiment shown in FIG. 36 that correspond to
structure and features of the embodiment of FIG. 35 are designated
hereinafter in the 3600 series of reference numbers.
[0251] Like the body support embodiments described above in
connection with the body support 3502 illustrated in FIG. 35, the
body support 3602 illustrated in FIG. 36 comprises filler material
3658 surrounded by an enclosing layer of material 3660. However,
the body support 3602 can also include a pocket 3666 of additional
filler material 3668 comprising pieces of reticulated visco-elastic
material. In the illustrated embodiment of FIG. 36, these pieces of
material are unconnected, can be produced in any of the manners
described above in connection with the embodiment of FIG. 35, and
can have any of the material properties, shapes, and sizes also
described above in connection with the embodiment of FIG. 35. In
other embodiments, some or all of the pieces of reticulated
visco-elastic material are connected to one another.
[0252] The pocket 3666 of additional filler material 3668 can be at
least partially defined by fabric or other sheet material within
which the reticulated visco-elastic pieces are located. In this
regard, the pocket 3666 can have any of the forms described above
with reference to the enclosing layer of material 3560 of FIG. 35,
and can be connected to the enclosing layer of material 3660 in any
of the manners described above with reference to the construction
of seams in the embodiment of FIG. 35. In other embodiments, the
material at least partially defining the pocket 3666 is not
connected to any other potion of the body support 3602, although is
still contained within the enclosing layer of material 3660.
[0253] Using the body support construction illustrated in FIG. 36,
the pieces of reticulated visco-elastic filler material 3668 can be
kept from mixing with the surrounding filler material 3658
contained within the enclosing layer 3660 of the body support 3602.
Such a construction can be desirable in those embodiments in which
the surrounding filler material 3658 is different than the filler
material 3668 within the pocket 3666, such as when the surrounding
filler material 3658 comprises non-reticulated visco-elastic foam
pieces or reticulated non-visco elastic foam pieces. In some of
these examples, the surrounding filler material 3658 can still
provide the desirable softness, body-conforming, and pressure
distribution features within the body support 3602, while the
reticulated visco-elastic foam pieces within the pocket 3666
provide a region within the body support 3602 capable of providing
ventilation between different internal areas of the body support
3602 and/or dissipating heat within the body support 3602. These
functions can be performed regardless of whether the enclosing
layer 3660 comprises non-reticulated visco-elastic material,
reticulated visco-elastic material, or reticulated
non-visco-elastic material (all of which can be utilized in the
enclosing layer 3660, as described above).
[0254] The reticulated visco-elastic filler material 3668 within
the pocket 3666 of the body support 3602 illustrated in FIG. 36 can
function to provide ventilation and/or to dissipate heat within the
body support 3602 (as just described) while still being responsive
to a user's body heat, and while still providing the
body-conforming and pressure distribution functions by virtue of
the visco-elastic nature of the filler material 3668. In other
embodiments, the filler material 3668 within the pocket 3666 can
instead comprise connected or unconnected reticulated
non-visco-elastic foam pieces. Such pieces can be produced in any
of the manners described above in connection with the embodiment of
FIG. 35, and can have any of the material properties, shapes, and
sizes also described above in connection with the embodiment of
FIG. 35. By employing non-reticulated visco-elastic foam for the
pieces of filler material 3668 within the pocket 3666, the
stiffness of the body support 3602 can be less sensitive to a
user's body heat while still performing the ventilating and/or heat
dissipating function described above.
[0255] Another embodiment of a body support according to the
present invention is illustrated in FIGS. 37 and 38. The body
support 3702 illustrated in FIGS. 37 and 38 is a pillow having a
contoured shape. However, the body support 3702 can have any other
pillow shape desired. The body support 3702 can comprise a single
piece of reticulated visco-elastic foam manufactured by molding or
in any other suitable manner. In other embodiments, the body
support 3702 can be defined by two or more pieces of reticulated
visco-elastic foam connected in any of the manners described above
with reference to multi-piece foam layer construction. The
reticulated visco-elastic foam of the body support 3702 can have
any of the material properties described above in connection with
the material of the top layer 1210 in the illustrated body support
1202 of FIG. 12.
[0256] The body support 3702 illustrated in FIGS. 37 and 38 can
provide support for a user while still conforming to a user's body
(e.g., head and neck) based upon the visco-elastic nature of the
body support material. Accordingly, the reticulated visco-elastic
material of the body support 3702 can distribute pressure from the
user's body across the surface of the body support 3702, thereby
potentially reducing stress upon the user's neck and/or reducing
pressure upon the user's face or other area of the user's head in
contact with the body support 3702. In those embodiments in which
the reticulated visco-elastic foam is temperature-sensitive as
described above, the shape of the body support 3702 can also be
adapted to the user based upon the user's body heat. Also, the
reticulated visco-elastic material of the body support 3702 can
provide an increased amount of ventilation and/or heat dissipation
based upon the skeletal cellular structure of the foam, thereby
reducing heat in the body support 3702.
[0257] FIGS. 39 and 40 illustrate another embodiment of a body
support according to the present invention. This embodiment employs
much of the same structure and has many of the same properties as
the embodiments of the body support described above in connection
with FIG. 16. Accordingly, the following description focuses
primarily upon the structure and features that are different than
the embodiments described above in connection with FIG. 16.
Reference should be made to the description above in connection
with FIG. 16 for additional information regarding the structure and
features, and possible alternatives to the structure and features
of the body support illustrated in FIGS. 39 and 40 and described
below. Structure and features of the embodiment shown in FIGS. 39
and 40 that correspond to structure and features of the embodiment
of FIG. 16 are designated hereinafter in the 3900 series of
reference numbers.
[0258] As described above, the various body supports of the present
invention can have any shape and size desired for any body support
application, including without limitation body supports used for
mattress, mattress topper, overlay, futon, head pillow, seat
cushion, seat back, neck pillow, leg spacer pillow, eye mask, and
other applications upon which any part or all of a human or animal
body is supported or cushioned. The body support 3902 illustrated
in FIGS. 39 and 40 is an example of how a body support illustrated
herein in the form of a mattress, mattress topper, overlay, or
futon (e.g., see FIG. 16) can take the form of a pillow or other
body support (e.g., see FIGS. 39 and 40). Like the body support
1602 illustrated in FIG. 16, the body support 3902 illustrated in
FIGS. 39 and 40 has a first layer 3910 of reticulated visco-elastic
foam and a second layer 3912 of non-reticulated visco-elastic foam.
However, the first layer 3910 of reticulated visco-elastic foam
illustrated in FIGS. 39 and 40 encloses the second layer 3912 of
non-reticulated visco-elastic foam. In other embodiments, the first
layer 3910 can cover any portion of the second layer 3912, such as
only the top 3916 and sides 3670 of the second layer 3912, only the
top 3916 of the second layer 3912, and the like.
[0259] The visco-elastic material of the second layer 3912 can
provide the same desirable softness and body-conforming features
described above in connection with the illustrated embodiment of
FIGS. 1-1B. The first layer 3910 of reticulated visco-elastic foam
can provide ventilation for the second layer 3912 of
non-reticulated visco-elastic foam, and/or can dissipate heat from
the second layer 3912 (due at least in part to the skeletal
cellular structure of the foam of the first layer 3912), while
still providing a relatively soft and comfortable surface of the
body support 3902 and a degree of body-conforming and pressure
distribution for the user's body by virtue of the visco-elastic
nature of the first layer 3910. Also, the reticulated cellular
structure of the first layer 3912 can provide improved ventilation
at the surface of the body support 3902--a feature that can be
desirable for applications in which a user's face, head, or other
body portion is in close proximity to or in contact with the first
layer 3910.
[0260] In other embodiments, the first layer 3910 of the body
support 3902 illustrated in FIGS. 39 and 40 comprises reticulated
non-visco-elastic foam (rather than reticulated visco-elastic
foam). In such embodiments, the reticulated non-visco-elastic foam
of the first layer 3910 can provide a degree of support while still
retaining the heat-dissipative and/or ventilating properties
described above due to the reticulated cellular structure of the
first layer 3910. A body support 3902 having such a construction
can also have significant softness and body conforming properties,
based at least in part upon the non-reticulated visco-elastic foam
in the second layer 3912.
[0261] In still other embodiments, the materials of the first and
second layers 3910, 3912 described above can be reversed, in which
case the first layer 3910 can comprise non-reticulated
visco-elastic foam, and the second layer 3912 can comprise
reticulated visco-elastic foam or reticulated non-visco-elastic
foam. In such alternative embodiments, heat can be dissipated from
the first layer 3910 by the reticulated visco-elastic or
reticulated non-visco-elastic foam of the second layer 3912 (due at
least in part to the skeletal cellular structure of the foam of the
second layer 3912). In this structure, the softness,
body-conforming, and pressure-distributing properties of the
non-reticulated visco-elastic foam are retained in the first layer
3910 (proximate the body of a user) while the ventilating and/or
heat-dissipative properties of the second layer 3912 can prevent or
reduce heat in the first layer 3910. In those applications in which
greater support independent of the user's body heat is desired, the
second layer 3912 can comprise reticulated non-visco-elastic foam.
In those applications in which temperature-sensitivity, greater
softness, and increased body-conforming and pressure distribution
is desired, the second layer 3912 can comprise reticulated
visco-elastic foam.
[0262] FIGS. 41 and 42 illustrate another embodiment of a body
support according to the present invention. This embodiment employs
much of the same structure and has many of the same properties as
the embodiments of the body support described above in connection
with FIGS. 39 and 40. Accordingly, the following description
focuses primarily upon the structure and features that are
different than the embodiments described above in connection with
FIGS. 39 and 40. Reference should be made to the description above
in connection with FIGS. 39 and 40 for additional information
regarding the structure and features, and possible alternatives to
the structure and features of the body support illustrated in FIGS.
41 and 42 and described below. Structure and features of the
embodiment shown in FIGS. 41 and 42 that correspond to structure
and features of the embodiment of FIGS. 39 and 40 are designated
hereinafter in the 4100 series of reference numbers.
[0263] Like the body support 3902 illustrated in FIGS. 39 and 40,
the body support 4102 illustrated in FIGS. 41 and 42 has a first
layer 4110 of reticulated visco-elastic foam and a second layer
4112 of non-reticulated visco-elastic foam. The second layer 4112
can be partially or fully enclosed within the material of the first
layer 4110, and can have any shape and size desired. By way of
example only, the second layer 4112 illustrated in FIG. 42 is
substantially block-shaped, and is relatively thick and
elongated.
[0264] The body support 4102 can be manufactured in any manner
desired. In some embodiments, the body support 4102 is manufactured
by molding the first layer 4110 of reticulated visco-elastic foam
over the second layer 4112 of non-reticulated visco-elastic foam.
In such embodiments, the second layer 4112 can be an insert within
the mold about which the reticulated visco-elastic foam of the
first layer 4110 is formed. It will be appreciated that other
manners of manufacturing the body support 4102 with an insert
comprising non-reticulated visco-elastic foam are possible, and
fall within the spirit and scope of the present invention.
[0265] In other embodiments, the first layer 4110 in the body
support 4102 illustrated in FIGS. 41 and 42 comprises reticulated
non-visco-elastic foam (rather than reticulated visco-elastic
foam). In such embodiments, the body support 4102 can be
manufactured in any of the manners just described. Further
description of the properties of such a body support construction
are provided above in connection with the embodiment of FIGS. 39
and 40.
[0266] In still other embodiments, the materials of the first and
second layers 4110, 4112 described above can be reversed, in which
case the first layer 4110 can comprise non-reticulated
visco-elastic or reticulated non-visco-elastic foam, and the second
layer 4112 can comprise reticulated visco-elastic foam. Further
description of the properties of such a body support construction
are provided above in connection with the embodiment of FIGS. 39
and 40.
[0267] In those embodiments of the present invention disclosed
herein having one or more layers of material, any layer can itself
be defined by one or more "sub-layers" of the same type of material
(e.g., open-celled non-reticulated visco-elastic foam, reticulated
visco-elastic foam, reticulated non-visco-elastic foam, flexible
cellular polyurethane foam having a relatively high resilience). In
this regard, any of the layers can be defined by any number of such
sub-layers. Also, the sub-layers in each layer can have the same or
different thickness, and can have any of the layer shapes, surface
profiles, or other features described and illustrated herein.
[0268] By way of example only, the body support 4302 illustrated in
FIG. 43 has the same layers arranged in the same order as the body
support 2202 illustrated in FIG. 22. However, the top layer 4310 of
open-celled non-reticulated visco-elastic foam illustrated in FIG.
43 comprises two sub-layers 4310a, 4310b of open-celled
non-reticulated visco-elastic foam. Similarly, any of the other
layers 4312, 4314 can instead or also comprise two or more
sub-layers of material (i.e., two or more sub-layers of reticulated
visco-elastic foam in the middle layer 4312, two or more sub-layers
of relatively highly resilient flexible cellular foam in the bottom
layer 4314, and the like).
[0269] In those embodiments having one or more layers defined by
two or more sub-layers of the same type of material (as just
described), the sub-layers can have the same or substantially the
same material properties. However, this need not necessarily be the
case. In this regard, the sub-layers can have different densities,
hardnesses, temperature responsiveness or insensitivity, and other
material properties while still falling within the ranges of such
properties disclosed herein. With reference again to the body
support 4302 illustrated in FIG. 43 by way of example only, the top
sub-layer 4310a of non-reticulated visco-elastic foam has a greater
density and lower hardness than that of the bottom sub-layer 4310b
of non-reticulated visco-elastic foam. For example, in some
embodiments, the top sub-layer 4310a of non-reticulated
visco-elastic foam can have a density of about 110 kg/m.sup.3, and
a hardness of no less than about 40 N and/or no greater than about
50 N, while the bottom sub-layer 4310b of non-reticulated
visco-elastic foam can have a density of no less than about 85
kg/m.sup.3, and a hardness of no less than about 50 N and/or no
greater than about 65 N. In this manner, a relatively soft (and, in
some cases, relatively expensive) visco-elastic body support
material can be utilized in a location where user sensitivity can
be most demanding, while the cost of the top layer 4310 can be
reduced by utilizing less expensive visco-elastic foam in the
bottom sub-layer 4310b and/or while the support of the top layer
4310 can be increased by utilizing a firmer bottom sub-layer
4310b.
[0270] It will be appreciated that a first sub-layer in any layer
of any body support disclosed herein can have a higher or lower
density, hardness, temperature responsiveness, temperature
insensitivity, or other material property than an underlying second
sub-layer. In this regard, such differences in material properties
can exist in sub-layers of non-reticulated visco-elastic foam and
reticulated non-visco-elastic foam; and reticulated visco-elastic
foam and relatively highly resilient flexible cellular foam, the
properties of which are described above with reference to the
embodiments of FIGS. 1-1B and 2-2A, respectively. In many cases,
the material properties of the sub-layers can impact the cost of
the layer and/or the manner in which the layer (and body support)
responds to pressure, deformation, and other environmental
conditions.
[0271] Any of the body supports disclosed herein can have one or
more covers at least partially enclosing one or more of the body
support layers. Each cover can fully or partially enclose a single
layer of the body support, or two or more layers of the body
support, as desired. Also, each cover can cover any or all surfaces
of one or more layers, such as the top of a layer, the top and
sides of a layer, one or more sides of a layer or adjacent layers,
and the like. With reference again to the illustrated embodiment of
FIG. 43 by way of example only, the illustrated body support 4302
comprises two covers: a first cover 4372 enclosing the top and
middle layers 4310, 4312 of the body support 4302 and a second
cover 4374 enclosing the bottom layer 4314 of the body support
4302. Also with reference to the embodiment of FIG. 43, the second
cover 4374 can cover portions of the body support foundation 4376
(described in greater detail below).
[0272] The covers 4372, 4374 can comprise any sheet material
desired, including without limitation any synthetic and/or natural
fabric or cloth material, such as cotton, polyester, a
cotton/polyester blend, wool, visco-elastic or non-visco-elastic
foam sheeting, and the like, and can be made of the same or
different materials. In some embodiments, each cover 4372, 4374 can
have one or more seams. Depending at least in part upon the type of
cover material utilized, the seams can be attached by adhesive or
cohesive bonding material, double-sided tape, stitching,
hot-melting, conventional fasteners (e.g., zippers, buttons,
clasps, laces, hook and loop fastener material, hook and eye sets,
tied ribbons, strings, cords, or other similar elements, and the
like), by being molded together in one or more manufacturing
processes, or in any other suitable manner.
[0273] The covers 4372, 4374 can be secured permanently to and/or
about the layers 4312, 4314, 4316 which the covers 4372, 4374 at
least partially enclose. In some embodiments, the covers 4372, 4374
are removable from such layers 4312, 4314, 4316, such as by being
shaped to slip onto and off of the layers, by one or more
releasable fasteners (e.g., zippers, buttons, clasps, laces, hook
and loop fastener material pieces, hook and eye sets, tied ribbons,
strings, cords, or other similar elements), and the like. Any such
fasteners can be positioned to releasably secure at least one
portion of a cover 4372, 4374 to another portion of the same or
different cover 4372, 4374 and/or to an adjacent layer 4312, 4314,
4316. For example, the top cover 4372 illustrated in FIG. 43 can
have a zippered slot (not shown) through which the top and middle
layers 4310, 4312 of the body support 4302 can be moved to install
and remove the top cover 4372.
[0274] With continued reference to the illustrated embodiment of
FIG. 43, the body support 4302 in some embodiments of the present
invention can be supported upon a foundation 4376 in an elevated
position with respect to a floor surface. The foundation 4376 can
take any form suitable for supporting the weight of the body
support 4302 under normal or heavy loading. For example, the
foundation 4376 can be constructed of beams, poles, tubes, planks,
plates, blocks, and any combination thereof made of steel, iron,
aluminum, and other metals, plastic, fiberglass and other synthetic
materials, wood, refractory materials, and any combination thereof.
For example, the foundation 4376 in the illustrated embodiment of
FIG. 43 comprises a wood frame 4380 to which are attached legs 4382
for supporting the frame 4380 over a floor surface. Other
foundation constructions and materials are possible, and fall
within the spirit and scope of the present invention.
[0275] In some embodiments of the present invention, one or more
bottom-most layers of any of the body supports disclosed herein can
be separate from the other layers of the body support, and can be
attached to a body support foundation (such as any of the body
support foundation embodiments described above in connection with
the embodiment of FIG. 43). In some embodiments, the bottom-most
layer(s) can be permanently coupled to the body support foundation,
such as by adhesive or cohesive bonding material, stitching (e.g.,
into a fabric or other sheet material covering of the foundation),
double-sided tape, conventional fasteners, and the like.
Alternatively, the bottom-most layer(s) can be releasably coupled
to the body support foundation, such as by one or more zippers,
straps, buttons, clasps, laces, pieces of hook and loop fastener
material, hook and eye sets, tied ribbons, strings, cords, or other
similar elements on the bottom-most layer(s) and/or on the
foundation. In still other embodiments, the bottom-most layer(s)
can be coupled to the body support by a cover (described above),
such as by coupling the cover of the bottom-most layer(s) to the
foundation (e.g., by staples, tacks nails, brads, rivets, and other
conventional fasteners) or by permanently or releasably coupling
the cover to the foundation in any of the manners described above
with reference to connections between the bottom-most layer(s) and
the foundation.
[0276] For example, the bottom cover 4374 of the embodiment
illustrated in FIG. 43 can be permanently secured by nails or
staples to the foundation 4376. The bottom cover 4374 can enclose
any or all of the bottom layer 4314 of relatively highly resilient
flexible cellular foam, and can enclose any part or all of the
foundation 4376 (although in some embodiments, the bottom cover
4374 covers substantially none of the foundation 4376).
[0277] By utilizing a body support construction in which one or
more of the layers of the body support are separate from one or
more other layers of the body support (i.e., are shipped separately
from, are releasably connected to, and/or are not connected to such
other layer(s)), a body support and foundation assembly can be
provided that can be easier and/or less expensive to ship, move,
and assemble. In some embodiments, it is not practical or
economical to manufacture and ship thicker body supports based at
least in part upon the weight and size of such supports. An option
is to provide the thicker body supports in two or more separate
pieces. However, the purchase and shipment of separate body support
pieces (in addition to a separate foundation) is not always
attractive to manufacturers, distributors, or purchasers. By
permanently or releasably coupling one or more layers of the body
support to the foundation, a relatively thick body support can
still be provided while avoiding the disadvantages of two or more
separate body support pieces in addition to a foundation. Also,
such a body support and foundation construction can enable the
manufacture and shipment of still thicker body supports that would
otherwise be too bulky or heavy to move.
[0278] It will be appreciated that the above description of the
covers 4372, 4374 applies equally to other covers utilized to at
least partially enclose any one or more layers in any of the other
body support embodiments disclosed herein. It will also be
appreciated that the above description of the foundation 4376
applies equally to the support of any of the other body support
embodiments disclosed herein.
[0279] The embodiments described above and illustrated in the
figures are presented by way of example only and are not intended
as a limitation upon the concepts and principles of the present
invention. As such, it will be appreciated by one having ordinary
skill in the art that various changes in the elements and their
configuration and arrangement are possible without departing from
the spirit and scope of the present invention as set forth in the
appended claims.
[0280] For example, the reticulated and non-reticulated
visco-elastic foam utilized in the various embodiments of the
present invention described and illustrated herein can be made from
a polyurethane foam. However, it should be noted that any other
visco-elastic polymer material exhibiting similar properties (e.g.,
thermally-responsive properties) can instead be used as
desired.
[0281] Also, several of the body support embodiments disclosed
herein utilize one or more non-planar surface shapes in order to
define passages through which air can move and/or to increase the
ability of heat to dissipate within the body support. Although the
locations of such non-planar surfaces as described above in the
various embodiments can provide significant performance advantages
for the body supports, such non-planar surface shapes can be
utilized between any two adjacent layers in any of the body support
embodiments disclosed herein. Further details of such non-planar
surface shapes are provided above in connection with the
illustrated embodiment of FIG. 4.
[0282] It should be noted that the various body supports described
and illustrated herein can be utilized alone or in combination with
one or more other layers of material. Such additional layers of
material can comprise any of the foam materials described herein
(or other materials, as desired), can be located beneath and
support the disclosed body support, and can be permanently or
releasably coupled to the disclosed body support.
[0283] As described in greater detail above, some embodiments of
the present invention have a relatively thin cover of reticulated
non-visco-elastic foam covering one or more surfaces of one or more
layers of the body support (e.g., see the embodiments of FIGS. 9,
29, and 30). The reticulated non-visco-elastic foam cover can be
selected to provide a heightened degree of fire resistance to the
body support, can be utilized in some countries and/or localities
to meet fire codes calling for such fire resistance, and can
provide improved ventilation and/or heat dissipation for surfaces
of one or more adjacent body support layers based at least in part
upon the skeletal cellular structure of the reticulated
non-visco-elastic foam. Although the reticulated foam covers
described above comprise non-visco-elastic foam, it will be
appreciated that such reticulated foam covers can instead comprise
visco-elastic foam. Also, the reticulated foam covers in the
embodiments of FIGS. 9, 29, and 30 are disclosed by way of example,
it being understood that reticulated visco-elastic or reticulated
non-visco-elastic foam covers can cover any exterior surface of any
of the layers in any of the other body support embodiments
disclosed herein.
[0284] A number of the body support embodiments disclosed herein
employ one or more layers of material having different types of
material in different areas of the same layer (e.g., see the
embodiments of FIGS. 7-9 and 31-34). It should be noted that such
layers can be utilized in other body supports having different
underlying and/or overlying layers while still performing some or
all of their functions described above. Such alternate body
supports and fall within the spirit and scope of the present
invention.
* * * * *