U.S. patent application number 13/141534 was filed with the patent office on 2011-11-24 for body support with non-planar top surface.
Invention is credited to Kristina Rasmussen.
Application Number | 20110283461 13/141534 |
Document ID | / |
Family ID | 42288113 |
Filed Date | 2011-11-24 |
United States Patent
Application |
20110283461 |
Kind Code |
A1 |
Rasmussen; Kristina |
November 24, 2011 |
BODY SUPPORT WITH NON-PLANAR TOP SURFACE
Abstract
A body support including a visco-elastic foam layer having a
length and a non-planar top surface with peaks and troughs that
define a horizontal distance between peaks and a vertical height
between a peak and a trough. The peaks and troughs of the
non-planar top surface form sinusoidal or domed waves. A density of
the foam at the peaks is substantially the same as the density of
the foam at the troughs. A ratio of the length to the distance is
from 10 to 50, optionally from 15 to 40. The ratio of length to
distance can be from 20 to 30 and optionally from 20 to 25.
Inventors: |
Rasmussen; Kristina;
(Nyborg, DK) |
Family ID: |
42288113 |
Appl. No.: |
13/141534 |
Filed: |
December 21, 2009 |
PCT Filed: |
December 21, 2009 |
PCT NO: |
PCT/US2009/069022 |
371 Date: |
June 22, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61140721 |
Dec 24, 2008 |
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61142777 |
Jan 6, 2009 |
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Current U.S.
Class: |
5/731 |
Current CPC
Class: |
A47C 27/146 20130101;
A47C 27/15 20130101; A47C 27/148 20130101 |
Class at
Publication: |
5/731 |
International
Class: |
A47C 27/14 20060101
A47C027/14 |
Claims
1. A body support comprising a foam layer having a substantially
planar bottom surface and a smooth, non-planar top surface with a
plurality of peaks and troughs that run in succession along an
entire length of the body support, wherein only two of the
plurality of peaks have an adjacent trough on each side thereof,
and wherein an additional two of the plurality of peaks have an
adjacent trough on only one side thereof.
2. A body support as defined in claim 1, wherein the foam comprises
visco-elastic foam.
3. A body support as defined in claim 1, wherein the peaks and
troughs of the non-planar top surface form sinusoidal waves.
4. A body support as defined in claim 1, wherein the peaks and
troughs of the non-planar top surface form domed waves.
5. A body support as defined in claim 1, wherein a density of the
foam at the peaks is substantially the same as the density of the
foam at the troughs.
6. (canceled)
7. (canceled)
8. (canceled)
9. A body support as defined in claim 1, wherein the peaks and
valleys define a horizontal distance between peaks and a vertical
height between a peak and a trough, and wherein a ratio of the
distance to the height is from 13 to 66.
10. (canceled)
11. (canceled)
12. (canceled)
13. (canceled)
14. A body support as defined in claim 9, wherein the ratio of the
distance to the height is from 20 to 52.
15. A body support as defined in claim 9, wherein the ratio of the
distance to the height is from 26 to 40.
16. A body support as defined in claim 9, wherein the ratio of the
distance to the height is from 26 to 33.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is hereby claimed to U.S. Provisional Patent App.
No. 61/140,721, filed Dec. 24, 2008, and U.S. Provisional Patent
App. No. 61/142,777, filed Jan. 6, 2009, the entire contents of
both of which are herein incorporated by reference.
BACKGROUND
[0002] Conventional body supports are found in a wide variety of
shapes and sizes, each of which is adapted for supporting one or
more body parts of a user. As used herein, the term "body support"
includes without limitation any deformable element or structure
adapted to support one or more parts of (or the entire body of) a
human or animal in one or more positions. Examples of body supports
include but are not limited to mattresses, pillows, and cushions of
any type, including those for use in beds, seats, and other
applications.
[0003] Body supports are often 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
firmness based at least in part upon the temperature of the body
part(s) supported thereon.
[0004] In addition to the increasing use of visco-elastic foams in
body supports, reticulated foams (both visco-elastic and
non-visco-elastic) have also gained in popularity. Reticulated
foams can provide added benefits of increased heat and moisture
transfer due in large part to the relatively porous nature of
reticulated foams. These characteristics are often highly desirable
in body support applications of all types.
[0005] Although the number and types of body supports constructed
with one or more layers of foam continue to increase, including one
or more layers of foam comprising visco-elastic foam and/or
reticulated foam, 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.
[0006] 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 continue to be
welcome additions to the art.
SUMMARY OF THE INVENTION
[0007] Some embodiments of the present invention provide a body
support having a layer of foam material adapted for use as the
upper-most surface of the body support and having a top surface and
a bottom surface, wherein the top surface of the body support is a
non-planar surface defined at least in part by a series of waves
extending across at least part of the length or width of the body
support and having dimensions selected to visually communicate
softness of the body support and/or to simulate a billowy user body
support surface. In some embodiments, the body support includes
visco-elastic foam and/or comprises reticulated foam. The body
support can itself have two or more layers, the top layer of which
has the non-planar surface. Also, the body support can be adapted
for use alone or in combination with one or more underlying body
support layers, any of which can include foam of any type (e.g.,
visco-elastic or non-visco-elastic, reticulated or non-reticulated,
and the like), and which can be permanently or releasably attached
to the body support, or which can support the body support without
being attached thereto.
[0008] Some embodiments of the invention provide a body support
including a visco-elastic or other foam layer having a length and a
non-planar top surface with peaks and troughs that define a
horizontal distance between peaks and a vertical height between a
peak and a trough. The peaks and troughs of the non-planar top
surface form sinusoidal or domed waves. A density of the foam at
the peaks is substantially the same as the density of the foam at
the troughs. A ratio of the length to the distance can be from 10
to 50, optionally from 15 to 40. The ratio of length to distance
can be from 20 to 30 and optionally from 20 to 25.
[0009] Some embodiments of the invention provide a body support
including a visco-elastic or other foam layer having a length and a
non-planar top surface with peaks and troughs that define a
horizontal distance between peaks and a vertical height between a
peak and a trough. The peaks and troughs of the non-planar top
surface form sinusoidal or domed waves. A ratio of the distance to
the height is from 13 to 66 or optionally from 20 to 52. The ratio
of the distance to the height can be from 26 to 40 and can
optionally be from 26 to 33. A density of the foam at the peaks is
substantially the same as the density of the foam at the
troughs.
[0010] 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
[0011] FIG. 1 is a perspective view of a body support according to
an embodiment of the present invention.
[0012] FIG. 2 is a perspective view of a body support according to
another embodiment of the present invention.
[0013] FIG. 3 is a side view of a portion of the body support of
FIG. 2.
DETAILED DESCRIPTION
[0014] 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, 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 unless otherwise specified. The term
"first" does not necessarily refer to the top most layer, rather,
it refers to the first of a plurality, without indicating a
particular location or position. Similarly, the terms "top" and
"bottom" are used for the purpose of description and are not
intended to indicate or imply relative importance, significance,
unless otherwise specified. The term "top" does not necessarily
refer to the top most layer, and "bottom" does not necessarily
refer to the bottom most layer.
[0015] 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.
[0016] Body supports 10 according to two different embodiments of
the present invention are illustrated schematically in FIGS. 1-3.
Both illustrated body supports 10, 10A are defined by one or more
layers of foam material adapted to be used alone (e.g., on a floor,
frame, or other structure) or upon another body support (e.g., a
mattress). In both applications, the body supports 10, 10A define
the top layer(s) of a body support upon which a user lies.
Accordingly, each of the body supports 10, 10A can itself define a
mattress (e.g., a futon), can be part of a mattress (i.e., define
the uppermost layer(s) or pillow top of a mattress that has one or
more underlying layers), or can define a mattress topper or overlay
intended either for releasable attachment to an existing mattress
or for resting upon an existing mattress without being attached
thereto, depending upon the manner in which the body support 10,
10A is used. However, it will be appreciated that the features of
the body supports 10, 10A described and/or illustrated herein are
applicable to any other type of body support having any size and
shape. Accordingly, as used herein, the term "body support" is
intended to refer to any and all of such structures, unless
otherwise specified.
[0017] The body support 10 illustrated in FIG. 1 includes a top
surface 12 positioned to face and support a user thereon, and a
bottom surface 14 adapted to either rest directly upon a floor
surface, frame, foundation, or other rigid support, or upon another
body support or portion of a body support. In the illustrated
embodiments of FIGS. 1-3, the top surface 12, 12A is substantially
non-planar and the bottom surface 14 is substantially planar. In
other non-illustrated embodiments, either or both of the top and
bottom surfaces 12, 14 can include one or more convolutions or
other non-planar shapes.
[0018] The body support 10 includes a layer of foam material
defining the uppermost (non-planar) surface of the body support 10,
and can have one or more additional layers (not shown) immediately
beneath the layer of foam. In this regard, the body support 10 can
be manufactured of any type of foam, including without limitation
visco-elastic and non-visco-elastic foam, reticulated and
non-reticulated foam, polyurethane foam, latex foam, any expanded
polymer (e.g., expanded ethylene vinyl acetate, polypropylene,
polystyrene, or polyethylene), and the like. If the body support 10
is defined by two or more layers of material, the layer(s) beneath
this uppermost layer can also be manufactured of any type of foam
(including those mentioned above), any other type of body support
material, and any combination of these materials. In some
embodiments, the resulting body support of two or more layers can
be a single integral unit permanently attached together in any
conventional manner (e.g., by adhesive or cohesive bonding
material, by being bonded together during formation of the layers,
by stitches extending at least partially through the layers, or in
any other suitable manner).
[0019] By way of example only, the foam of the body supports 10,
10A shown in FIGS. 1-3 is non-reticulated visco-elastic foam,
sometimes referred to as "memory foam" or "low resilience foam". As
mentioned above, in other embodiments, the foam of the body support
10, 10A can comprise reticulated visco-elastic foam, or reticulated
or non-reticulated non-visco-elastic foam. Reticulated foam
(visco-elastic or otherwise) is a cellular foam structure in which
the cells of the foam are essentially skeletal. In other words, the
cells of the reticulated foam are each defined by a plurality of
apertured windows surrounded by cell struts. The cell windows of
reticulated foam can be entirely gone (leaving only the cell
struts) or substantially gone. In some embodiments, the foam is
considered "reticulated" if at least 50% of the windows of the
cells are missing (i.e., windows having apertures therethrough, or
windows that are completely missing and therefore leaving only the
cell struts). Such structures can be created by destruction or
other removal of cell window material, or preventing the complete
formation of cell windows during the manufacturing process of the
foam.
[0020] The visco-elastic nature of the foam material of the body
supports 10, 10A illustrated in FIGS. 1-3 can provide a relatively
soft and comfortable substrate for a user's body or body portion
(hereinafter referred to simply as "body" for ease of description).
Also, by its nature, the visco-elastic foam body supports 10, 10A
at least partially conforms to the user's body to distribute force
applied thereby. By virtue of the low-resiliency and
pressure-distributing characteristics of visco-elastic foam, the
non-planar surface of the illustrated visco-elastic body supports
10, 10A (described in greater detail below) will not result in
discomfort to a user, as the non-planar surface will conform to the
user's body with minimal to no resistance. Accordingly, the top
surface 12, 12A of the visco-elastic body support 10, 10A can be
made non-planar to perform the functions described below while not
sacrificing the function of properly supporting the user.
[0021] In some embodiments, the visco-elastic foam of the body
support 10, 10A 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, the visco-elastic foam of the body
support 10, 10A has a hardness of at least about 40 N and no
greater than about 110 N for this purpose. In still other
embodiments, the visco-elastic foam of the body support 10, 10A has
a hardness of at least about 40 N and no greater than about 75 N.
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
centimeters (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.
[0022] The visco-elastic foam of each illustrated body support 10,
10A can also have a density providing a relatively high degree of
material durability. The density of the visco-elastic foam of each
illustrated body support 10, 10A can also impact other
characteristics of the foam, such as the manner in which the body
support 10, 10A responds to pressure and the feel of the foam. In
some embodiments, the foam of the body support 10, 10A is
visco-elastic, and 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, this body support foam has a density of at least about
40 kg/m.sup.3 and no greater than about 130 kg/m.sup.3. In still
other embodiments, this body support foam has a density of at least
about 55 kg/m.sup.3 and no greater than about 115 kg/m.sup.3.
[0023] With continued reference to the visco-elastic foam body
supports 10, 10A illustrated in FIGS. 1-3, the visco-elastic foam
of the body supports 10, 10A 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 10, 10A 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 body support 10, 10A can be responsive to
temperature changes above at least about 10.degree. C. In other
embodiments, the visco-elastic foam selected for the body supports
10, 10A can be responsive to temperature changes within a range of
at least about 15.degree. C. As used herein, 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.
[0024] As discussed above, either body support 10, 10A can be
constructed of reticulated foam (visco-elastic or otherwise),
rather than the non-reticulated visco-elastic foam just described.
In such embodiments, airflow characteristics of the reticulated
foam can be significantly different, as can the material
characteristics of the reticulated foam. More detail regarding the
features and characteristics (e.g., hardness, density, and
temperature sensitivity) of reticulated foam used in some
embodiments of the present invention is presented below.
[0025] By virtue of the skeletal cellular structure of reticulated
foam, body supports 10, 10A comprising such foam are able to
transfer heat away from a source of heat (e.g., a user's body) on
the body support 10, 10A, thereby helping to prevent one or more
areas of the body support 10, 10A from reaching an undesirably high
temperature. Also, the reticulated structure of the foam enables
significantly higher airflow into, out of, and through the body
support 10, 10A--a characteristic of the body support 10, 10A that
can reduce heat in the body support. Furthermore, the reticulated
structure of the foam can function as a wick, drawing moisture from
an exterior area of the body support 10, 10A (e.g., adjacent the
user's body thereon) to locations away from the user's body,
thereby increasing user comfort. At the same time, in those
embodiments in which the body support 10, 10A comprises reticulated
visco-elastic foam, the visco-elastic nature of the foam provides
desirable tactile contact and pressure responsiveness for user
comfort. In this regard, reticulated visco-elastic foam of some
embodiments can have 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 body support 10, 10A can
also at least partially conform to the user's body, thereby
distributing the force applied by the user's body upon the body
support 10, 10A.
[0026] In some embodiments, the body support 10, 10A 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 body support
10, 10A 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 body support 10, 10A having a hardness of at least
about 40 N and no greater than about 85 N is utilized.
[0027] Body supports 10, 10A manufactured from reticulated
visco-elastic foam can also have a density providing a relatively
high degree of material durability. The density of the reticulated
visco-elastic foam can also impact other characteristics of the
foam, such as the manner in which the body support 10, 10A responds
to pressure, and the feel of the foam. In some embodiments, the
reticulated visco-elastic foam of the body support 10, 10A 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, the reticulated
visco-elastic foam of the body support 10, 10A has a density of at
least about 45 kg/m.sup.3 and no greater than about 130 kg/m.sup.3.
In still other embodiments, the reticulated visco-elastic foam of
the body support 10, 10A has a density of at least about 50
kg/m.sup.3 and no greater than about 120 kg/m.sup.3.
[0028] In those body support embodiments in which the body support
10, 10A is manufactured from reticulated visco-elastic foam, the
reticulated visco-elastic foam can be selected for responsiveness
(as defined above) to any range of temperatures, including those
described above.
[0029] As shown in FIGS. 1-3, the top surface 12, 12A of both body
supports 10, 10A is non-planar, and includes a plurality of peaks
16, 16A and troughs 18, 18A defining a wave-shaped top surface 12,
12A of the body support 10, 10A. In some embodiments, the peaks 16,
16A and troughs 18, 18A are regularly spaced along the body support
10, 10A. However, in other embodiments, the peaks 16, 16A and
troughs 18, 18A are irregularly spaced.
[0030] The peaks 16, 16A and troughs 18, 18A of the body supports
10, 10A can be defined by a number of different wave shapes,
including the domed waves shown in FIG. 1 and the sinusoidal waves
shown in FIGS. 2 and 3. In both examples, the wave shape of the
body supports 10, 10A is selected to visually communicate softness
of the body support 10, 10A and/or to simulate a billowy user body
support 10, 10A, both of which are desirable attributes for many
users. Other wave shapes are capable of performing the same
functions, and fall within the spirit and scope of the present
invention.
[0031] The following description is presented in connection with
the embodiment of FIGS. 2 and 3, it being understood, however, that
this description applies equally to the embodiment of FIG. 1.
Factors that can be important to visually communicate softness of
the body support 10A and/or to simulate a billowy user body support
10A can include the distance D between adjacent peaks 16A in a body
support 10A, the height of the peaks 16A (measured from trough 18A
to peak 16A, or the difference between H2 and H1 in FIG. 3), and
the ratio of these values (e.g., D:(H2-H1)). In some embodiments,
the distance D between adjacent peaks 16A is no less than about 260
mm and is no greater than about 660 mm to perform the visual
communication and simulation functions described above. In other
embodiments, this distance D is no less than about 400 mm and is no
greater than about 520 mm to perform these functions.
[0032] Also, in some embodiments, the peak height (H2-H1) is no
less than about 10 mm to perform the visual communication and
simulation functions described above. In other embodiments, this
peak height is no less than about 20 mm to perform these
functions.
[0033] A ratio of the distance D to the peak height (H2-H1) is from
13 to 66 or optionally from 20 to 52. The ratio of the distance to
the height can be from 26 to 40 and can optionally be from 26 to
33.
[0034] As indicated above, in some embodiments, the distance D
between adjacent peaks 16A may vary such that the distance D is
different along one portion of the body support 10A when compared
to the distance D along another portion of the body support 10A.
This may be especially advantageous if the body support 10A is
configured to support bodies exerting different pressures at
different locations on the body support 10A. Similarly, in some
embodiments, the peak height (H2-H1) may vary along the body
support 10A such that the peak height (H2-H1) along one portion of
the body support 10A is different when compared to the peak height
(H2-H1) along another portion of the body support 10A.
[0035] As described above, the top surface 12, 12A of the body
supports 10, 10A are configured to visually communicate softness
and to simulate a billowy body support 10, 10A. As also described
above, this is accomplished by shaping the top surface 12, 12A to
have peaks 16, 16A and troughs 18, 18A. This shaping can be
performed by directly forming the foam of the body support 10
(rather than, for example, by using quilting techniques), such as
by cutting a slab of foam to have the peaks 16, 16A and troughs 18,
18A, by molding foam to have such peaks 16, 16A and troughs 18,
18A, and by other manufacturing methods. In some embodiments, the
density of the foam at the peaks 16, 16A and the density of the
foam at the troughs 18, 18A is substantially similar, and in some
embodiments is identical.
[0036] The plurality of peaks 16, 16A and troughs 18, 18A in the
illustrated embodiments of FIGS. 1-3 extend across the width of the
body supports 10, 10A, and run in succession along the length of
the body supports 10, 10A. In other embodiments, the non-planar
surface can be formed from a plurality, and in some cases a
pattern, of such projections extending orthogonally with respect to
the direction shown in FIGS. 1-3 (i.e., peaks 16, 16A and troughs
18, 18A extending along the length of the body support 10, 10A, and
running in succession along the width of the body support 10, 10A).
Still other directions in which the peaks 16, 16A and troughs 18,
18A can run are possible, and fall within the spirit and scope of
the present invention.
[0037] In the illustrated embodiments of FIGS. 1-3, the non-planar
top surface 12, 12A of each body support 10, 10A is uniform across
the width and length of the body support 10, 10A. However, in other
embodiments, the non-planar top surface 12, 12A may not extend
fully across the length and/or width of the body support 10, 10A.
Also, the non-planar top surface 12, 12A may not be uniform across
the full width and length of the body support 10, 10A, but can
instead also include a combination of peaks, troughs, waves, bumps,
and/or other projections and recesses extending across the whole
width and length, or alternatively across only a portion of the
width and/or length of the body support 10, 10A. Accordingly, there
may be one or more portions of the top surface of the body support
10, 10A which are planar.
[0038] With continued reference to the illustrated embodiments of
FIGS. 1-3, the top surfaces 12, 12A of both embodiments are shown
as having five peaks 16 and four troughs 18. However, in other
embodiments, these top surfaces can have less or more than five
peaks and four troughs. For example, some mattress-type body
supports according to the present invention utilize no fewer than
two peaks and no greater than ten peaks across the length L of the
body support 10. In other mattress-type body support embodiments,
no fewer than four peaks and no greater than six peaks are used
across the length L of the body support 10. In still other
mattress-type body support embodiments, no fewer than four peaks
and no greater than five peaks are used across the length L of the
body support 10. In some desirable embodiments, the mattress-type
body support 10 has four peaks used to convey the visual impression
of proper user support in particular areas of the body support 10
(e.g., head, back, buttocks, and legs).
[0039] A ratio of the length L of the body support 10 to the
distance D between adjacent peaks 16A can be from 10 to 50,
optionally from 15 to 40. The ratio of length to distance can be
from 20 to 30 and optionally from 20 to 25.
[0040] 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.
* * * * *