U.S. patent application number 14/242289 was filed with the patent office on 2015-10-01 for support cushions for providing ventilation.
This patent application is currently assigned to Dan-Foam ApS. The applicant listed for this patent is Dan-Foam ApS. Invention is credited to Kristina Skjoldemose Asklof, Rikke Lund Jorgensen, Asa Anna Marie Wendsjo Pedersen.
Application Number | 20150272354 14/242289 |
Document ID | / |
Family ID | 54188631 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150272354 |
Kind Code |
A1 |
Asklof; Kristina Skjoldemose ;
et al. |
October 1, 2015 |
SUPPORT CUSHIONS FOR PROVIDING VENTILATION
Abstract
A support cushion is provided that includes a core comprised of
a first flexible foam and a second flexible foam. Both the first
flexible foam and the second flexible foam include a reticulated
cellular structure, with the first flexible foam having a density
less than the second flexible foam. A sleeve is also included in
the support cushion and encapsulates the core.
Inventors: |
Asklof; Kristina Skjoldemose;
(Nyborg, DK) ; Jorgensen; Rikke Lund; (Odense NV,
DK) ; Pedersen; Asa Anna Marie Wendsjo; (Odense SV,
DK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dan-Foam ApS |
Aarup |
|
DK |
|
|
Assignee: |
Dan-Foam ApS
Aarup
DK
|
Family ID: |
54188631 |
Appl. No.: |
14/242289 |
Filed: |
April 1, 2014 |
Current U.S.
Class: |
5/636 ; 5/652.1;
5/655.9 |
Current CPC
Class: |
A47G 2009/1018 20130101;
A47G 9/109 20130101; A47C 7/746 20130101; A47C 7/18 20130101; A47G
9/1036 20130101; A47C 27/15 20130101 |
International
Class: |
A47G 9/10 20060101
A47G009/10; A47C 7/74 20060101 A47C007/74 |
Claims
1. A support cushion, comprising: a core comprised of a first
flexible foam including a reticulated cellular structure and a
second flexible foam including a reticulated cellular structure,
the first flexible foam having a density less than the second
flexible foam; and a sleeve encapsulating the core.
2. The support cushion of claim 1, wherein the first flexible foam,
the second flexible foam, or both is a visco-elastic foam.
3. The support cushion of claim 1, wherein the first flexible foam
has a density of about 45 kg/m.sup.3 to about 65 kg/m.sup.3, and
wherein the second flexible foam has a density of about 85
kg/m.sup.3.
4. The support cushion of claim 1, wherein the first flexible foam
has a hardness of about 30 N to about 60 N, and wherein the second
flexible foam has a hardness of about 60 N to about 90 N.
5. The support cushion of claim 1, wherein the first flexible foam
and the second flexible foam are comprised of a plurality of
visco-elastic foam fragments.
6. The support cushion of claim 1, wherein the core is a molded
foam core.
7. The support cushion of claim 1, wherein the sleeve is comprised
of a three-dimensional spacer material having an outer surface, an
inner surface, and a middle spacer layer.
8. The support cushion of claim 7, wherein the outer surface of the
sleeve defines a plurality of vents.
9. The support cushion of claim 1, wherein the first flexible foam,
the second flexible, the sleeve, or a combination thereof includes
an amount of phase change material.
10. The support cushion of claim 1, wherein the sleeve is comprised
of a flame retardant material.
11. The support cushion of claim 1, further comprising an outer
cover surrounding the sleeve.
12. The support cushion of claim 11, wherein the outer cover is
comprised of one or more textiles.
13. The support cushion of claim 11, wherein the outer cover
includes a first surface and a second surface opposite the first
surface, and wherein at least one of the first surface or the
second surface includes a central panel surrounded by a border, the
border defining a plurality of openings.
14. The support cushion of claim 13, wherein the central panel is
comprised of cotton and the border is comprised of polyester.
15. A pillow, comprising: a core comprised of a reticulated
visco-elastic foam; and a sleeve encapsulating the core, the sleeve
comprised of a three-dimensional spacer material having a top
surface, a bottom surface, and a middle spacer layer.
16. The pillow of claim 15, further comprising an outer cover
surrounding the sleeve.
17. The pillow of claim 15, further comprising an amount of phase
change material incorporated into the core, the sleeve, or
both.
18. The pillow of claim 17, wherein the reticulated visco-elastic
foam comprises a plurality of reticulated visco-elastic foam
fragments.
19. A pillow, comprising: a sleeve encapsulating a plurality of
reticulated visco-elastic foam fragments; and an outer cover having
a first surface and a second surface opposite the first surface, at
least one of the first surface or the second surface including a
central panel surrounded by a border, the border defining a
plurality of openings.
20. The pillow of claim 19, wherein the sleeve is comprised of a
three-dimensional spacer material having a top surface, a bottom
surface, and a middle spacer layer.
Description
TECHNICAL FIELD
[0001] The present invention relates to support cushions for
providing ventilation. In particular, the present invention relates
to support cushions, such as pillows, that make use of a core that
includes flexible foams having reticulated cellular structures and
densities configured to increase the air movement through the
support cushions.
BACKGROUND
[0002] As is generally the case with support cushions and, in
particular, with support cushions comprised of flexible foam or
other body-conforming materials, the effectiveness of the support
cushion in providing support to the body of a user is partly a
function of how well the flexible foam responds to the contour of
the particular user resting on the cushion. In this regard, support
cushions made from temperature-sensitive visco-elastic foam are
often particularly desirable as such support cushions are able to
change shape based, at least in part, upon the temperature of the
supported body part. That conformance of the cushion to the body of
a user, however, often causes more of the user's body to be in
contact with the body support cushion, and thus, less of the body
of the user is exposed to the ambient air around the cushion. The
reduction in the amount of the body of the user exposed to ambient
air, in turn, causes many users to find support cushions comprised
of visco-elastic foam to "sleep hot" and, occasionally, such users
will choose other types of support cushions, notwithstanding the
supportive benefits associated with visco-elastic foam and similar
types of body-conforming materials.
[0003] In an effort to remedy users' concerns of "sleeping hot" as
a result of the body-conforming qualities of their support
cushions, many support cushion manufacturers have incorporated
so-called "cooling" technologies into their products. For example,
many body-conforming support cushions now incorporate latent heat
storage units, such as phase change material, that absorb heat and
provide a cooling sensation when in contact with the body of a
user. Despite the inclusion of phase change material in such
support cushions, however, those support cushions still often fail
to sufficiently address the heat and humidity that becomes trapped
within the support cushions as a result of the lack of ventilation
through the support cushions.
SUMMARY
[0004] The present invention includes support cushions for
providing ventilation. In particular, the present invention
includes support cushions, such as pillows, that make use of a core
that includes flexible foams having reticulated cellular structures
and densities configured to increase the air movement through the
support cushions. Thus, the support cushions of the present
invention allow a user to obtain the supportive benefits of a
support cushion comprised of flexible foam, but without the
increases in heat and humidity that may occur as a result of the
body of a user, or a portion thereof, resting on the support
cushion.
[0005] In one exemplary embodiment of the present invention, a
support cushion is provided in the form of a pillow and includes a
sleeve encapsulating a core comprised of a first flexible foam and
a second flexible foam. Both the first flexible foam and the second
flexible foam include a reticulated cellular structure, with the
first flexible foam having a density less than that of the second
flexible foam, such that the pillow is configured to increase the
air flow through the pillow and reduce the heat and humidity that
may be present in the pillow as a result of a user resting on the
pillow.
[0006] The core of the support cushion generally has a shape
suitable for accommodating the body of a user. Further, the first
flexible foam and the second flexible foam comprising the core of
the support cushion are generally comprised of a flexible foam that
is capable of suitably distributing the pressure from a user's body
or portion thereof across the support cushions. In some
embodiments, the first flexible foam and the second flexible foam
are both comprised of a reticulated visco-elastic foam that has a
desired density and hardness and allows pressure to be distributed
uniformly across the support cushion, while still allowing for
increased air movement through the core. In this regard, in some
embodiments, the first flexible foam has a hardness of about 30 N
to about 60 N and the second flexible foam has a hardness of about
60 N to about 90 N. In some embodiments, the first flexible foam
has a density of about 45 kg/m.sup.3 to about 65 kg/m and the
second flexible foam has a density of about 85 kg/m.sup.3, such
that the core provides a sufficiently soft and supportive cushion,
while also including less dense material within the core of the
support cushion to increase the air flow through the support
cushion.
[0007] With further respect to the visco-elastic foam included in
the core of the support cushion, the visco-elastic foam comprising
the core can also have a structure configured to improve the air
movement through the support cushion. For example, in some
embodiments, the visco-elastic foam included in the core comprises
a plurality of visco-elastic foam fragments, such that the core is
not comprised of a single continuous piece of a first flexible foam
and a single continuous piece of a second visco-elastic foam, but
is instead comprised of a number of different fragments of
visco-elastic foam that allow air to more readily travel through
the core and, consequently, allow more heat and humidity to be
removed from the core and provide cooling to a user resting on the
support cushion. In some embodiments, to also take advantage of and
enhance the cooling capabilities of the support cushion, the first
flexible foam, the second flexible foam, the sleeve, or a
combination thereof can include an amount of phase change
material.
[0008] To further enhance the air movement through the support
cushion of the present invention, the sleeve encapsulating the core
is generally comprised of a three-dimensional spacer material
having an outer surface, an inner surface, and a middle spacer
layer. The middle spacer layer of the sleeve separates the outer
surface from the inner surface and allows the sleeve to have a high
air permeability that serves to further enhance the heat and
humidity removal from the support cushion. In some embodiments, to
also enhance the flow of air and the removal of heat and humidity
from the support cushion and, more particularly, through the sleeve
of the support cushion, the outer surface of the sleeve defines a
plurality of vents.
[0009] In addition to including a sleeve that provides the support
cushions of the present invention with enhanced air flow, the
support cushion can, in certain embodiments, include an outer cover
that surrounds the sleeve and is also configured to provide
enhanced air flow. For instance, in some embodiments, an outer
cover is included that has a first surface and a second surface
opposite the first surface, where at least one of the first surface
or second surface includes a central panel surrounded by a border
defining a plurality of openings to further allow air and any
associated heat and humidity to travel through and be removed from
the support cushion (i.e., through the core and sleeve and out of
the openings in the border). Such outer covers are typically
comprised of one or more textiles having a sufficient amount of
durability to protect the underlying sleeve and core of the support
cushion, but are also sufficiently breathable to allow air to flow
not only through the openings in the border, but also through the
central panels. For example, in some embodiments, the central panel
is comprised of cotton, and the border is comprised of
polyester.
[0010] Further features and advantages of the present invention
will become evident to those of ordinary skill in the art after a
study of the description, figures, and non-limiting examples in
this document.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of an exemplary support
cushion, in the form of a pillow, made in accordance with the
present invention and with a portion of the pillow removed to show
the core and the sleeve of the pillow;
[0012] FIG. 2 is a cross-sectional view of the exemplary support
cushion of FIG. 1 taken along line 2-2 of FIG. 1;
[0013] FIG. 3 is a perspective view of another exemplary support
cushion, in the form of a pillow, made in accordance with the
present invention and with a portion of the pillow removed to show
the core and the sleeve of the pillow;
[0014] FIG. 4 is a cross-sectional view of the exemplary support
cushion of FIG. 3 taken along line 4-4 of FIG. 3;
[0015] FIG. 5 is a cross-sectional view of exemplary support
cushions for use in a chair and made in accordance with the present
invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0016] The present invention includes support cushions for
providing ventilation. In particular, the present invention
includes support cushions, such as pillows, that make use of a core
that includes flexible foams having reticulated cellular structures
and densities configured to increase the air movement through the
support cushions. Thus, the support cushions of the present
invention allow a user to obtain the supportive benefits of a
support cushion comprised of flexible foam, but without the
increases in heat and humidity that may occur as a result of a user
resting on the support cushion.
[0017] Referring first to FIGS. 1 and 2, in one exemplary
embodiment of the present invention, a support cushion is provided
in the form of a pillow 10 that includes an outer cover 40 and a
sleeve 30 that encapsulates a core 20 comprised of a first flexible
foam 22 and a second flexible foam 24. In the pillow 10, although
the first flexible foam 22 and the second flexible foam 124 are
shown in FIGS. 1-2 as separate from one another for purposes of
clarity, the first flexible foam 22 and the second flexible foam
124 are typically included in the pillow 10 as a loose filling that
allows air to readily move through the pillow 10. Additionally, the
first flexible foam 22 typically has a density less than that of
the second flexible foam 24, such that the pillow 10 is further
configured to increase the air flow through the pillow 10 and to
reduce the heat and humidity that may be present in the pillow 10
as a result of the body of a user, or a portion thereof, resting on
the pillow 10, as described in further detail below.
[0018] Both the first flexible foam 22 and the second flexible foam
24 included in the core 20 of the pillow 10 are generally comprised
of flexible foam that is capable of suitably distributing the
pressure from a user's body or portion thereof across the pillow
10. Such flexible foams include, but are not limited to, latex
foam, reticulated or non-reticulated visco-elastic foam (sometimes
referred to as memory foam or low-resilience foam), reticulated or
non-reticulated non-visco-elastic foam, polyurethane
high-resilience foam, expanded polymer foams (e.g., expanded
ethylene vinyl acetate, polypropylene, polystyrene, or
polyethylene), and the like. In the embodiment shown in FIGS. 1 and
2, both the first flexible foam 22 and the second flexible foam 24
comprising the core 20 of the pillow 10 are comprised of
reticulated visco-elastic foam fragments or, in other words, both
the first flexible foam 22 and second flexible foam 24 are
visco-elastic foam fragments having a reticulated cellular
structure.
[0019] Reticulated foam (visco-elastic or otherwise) is a cellular
foam structure in which the cells of the foam are essentially
skeletal. In such a structure, the cells of the reticulated foam
are each defined by a plurality of apertured windows surrounded by
cell struts, where the cell windows of reticulated foam can be
entirely absent (leaving only the cell struts) or substantially
missing. In some embodiments, the reticulated visco-elastic foam
fragments comprising the first flexible foam 22 and the reticulated
visco-elastic foam fragments comprising the second flexible foam 24
are 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, by chemical or mechanical
means, or by preventing the complete formation of cell windows
during the manufacturing process of the foam.
[0020] Regardless of the manufacturing process used to produce the
reticulated visco-elastic foam fragments, the reticulated
visco-elastic foam fragments comprising the first flexible foam 22
and the reticulated visco-elastic foam fragments comprising the
second flexible foam 24, by virtue of their reticulated cellular
structure, have characteristics that are well-suited for use in the
core 20 of the pillow 10, including the enhanced ability to permit
fluid movement through the reticulated visco-elastic foam fragments
and, consequently, the ability to provide enhanced air movement
throughout the core 20 and allow for the removal of heat and/or
humidity from the core 20 of the pillow 10 to provide a user with a
cooling sensation.
[0021] Generally, such reticulated visco-elastic foam fragments
have a hardness of at least about 10 N to no greater than about 80
N, as measured by exerting pressure from a plate against a sample
of the material to a compression of at least 40% of an original
thickness of the material at approximately room temperature (i.e.,
21.degree. C. to 23.degree. C.), where the 40% compression is held
for a set period of time as established by the International
Organization of Standardization (ISO) 2439 hardness measuring
standard. In some embodiments, the reticulated visco-elastic foam
fragments comprising the first flexible foam 22 and the reticulated
visco-elastic foam fragments comprising the second flexible foam 24
each have a hardness of about 10 N, about 20 N, about 30 N, about
40 N, about 50 N, about 60 N, about 70 N, or about 80 N to provide
a desired degree of comfort and body-conforming qualities. In some
embodiments, the reticulated visco-elastic foam fragments
comprising the first flexible foam 22 have a hardness of about 30 N
to about 60 N, while the reticulated visco-elastic foam fragments
comprising the second flexible foam 24 have a hardness about 60 N
to about 90 N.
[0022] The reticulated visco-elastic foam fragments comprising the
first flexible foam 22 and the reticulated visco-elastic foam
fragments comprising the second flexible foam 24 can also have a
density that assists in providing not only a desired degree of
comfort and body-conforming qualities, as well as an increased
degree of material durability, but that also assists in
facilitating the movement of air through the core 20 of the pillow
10 by virtue of the inclusion of less dense visco-elastic foam
fragments as compared to the density of traditional visco-elastic
foam pillows. In some embodiments, in the core 20 of the pillow 10,
the density of the reticulated visco-elastic foam fragments
comprising the first flexible foam 22 and the density of the
reticulated visco-elastic foam fragments comprising the second
flexible foam 24 have a density of no less than about 30 kg/m.sup.3
to no greater than about 150 kg/m.sup.3. In some embodiments, the
density of the visco-elastic foam used in the core 20 of the pillow
10 is about 30 kg/m.sup.3, about 40 kg/m.sup.3, about 50
kg/m.sup.3, about 60 kg/m.sup.3, about 70 kg/m.sup.3, about 80
kg/m.sup.3, about 90 kg/m.sup.3, about 100 kg/m.sup.3, about 110
kg/m.sup.3, about 120 kg/m.sup.3, about 130 kg/m.sup.3, about 140
kg/m.sup.3, or about 150 kg/m.sup.3. In one preferred embodiment,
the first flexible foam 22 has a density of about 45 kg/m.sup.3 to
about 65 kg/m.sup.3 and the second flexible foam 24 has a density
of about 85 kg/m.sup.3, such that the core 20 provides a
sufficiently soft and supportive cushion, while also including less
dense material within the core 20 of the pillow 10 that allows air
to more readily flow through the pillow 10.
[0023] Of course, the selection of a reticulated visco-elastic foam
having a particular density will affect other characteristics of
the foam, including its hardness, the manner in which the foam
responds to pressure, and the overall feel of the foam, but it is
appreciated that a reticulated visco-elastic foam having a desired
density and hardness can readily be selected and included in an
amount suitable for a particular application or support cushion as
desired. For instance, in some embodiments, the first flexible foam
22 included in the core 20 of the pillow 10 has a hardness of about
37 N to about 55 N and a density of about 45 kg/m.sup.3, while the
second flexible foam has a hardness of about 68 N to about 88 N and
a density of about 85 kg/m.sup.3 to provide the pillow 10 with a
softer feel. As another example, in some embodiments, the first
flexible foam 22 included in the core 20 of the pillow 10 has a
hardness of about 37 N to about 55 N and a density of about 65
kg/m.sup.3, while the second flexible foam 24 has a hardness of
about 68 N to about 88 N and a density of about 85 kg/m.sup.3 to
provide the pillow 10 with a medium feel (i.e., not too soft and
not too firm). As yet another example, in some embodiments, the
first flexible foam 22 included in the core 20 of the pillow 10
again has a hardness of about 37 N to about 55 N and a density of
about 65 kg/m.sup.3, and the second flexible foam 24 again has a
hardness of about 68 N to about 88 N and a density of about 85
kg/m.sup.3, but the first flexible foam 22 is included in the core
20 of the pillow 10 in an increased amount relative to the amount
included in a "medium feel" pillow to thereby provide the pillow 10
with a firm feel.
[0024] Referring still to FIGS. 1-2, to further enhance the air
movement through the pillow 10, the sleeve 30 encapsulating the
core 20 is comprised of a three-dimensional spacer material having
an outer surface 32, an inner surface 34, and a middle spacer layer
36. The middle spacer layer 36 is generally a woven layer that
connects the outer surface 32 to the inner surface 34, but that
also sufficiently separates the outer surface 32 from the inner
surface 34 and allows the sleeve 30 to have a high air
permeability. To further enhance the flow of air and the removal of
heat and humidity from the pillow 10 and, more particularly,
through the sleeve 30 of the pillow 10, the outer surface 32 of the
sleeve 30 also defines a plurality of vents 38 (FIG. 1) that allow
air and any associated heat and humidity to be transferred from the
core 20 of the pillow 10 and through sleeve 30. Additionally, in
the pillow 10, the sleeve 30 also incorporates a flame-retardant
material, such that a flame-retardant barrier surrounds the core 20
of the pillow 10.
[0025] In addition to including the sleeve 30 in the pillow 10 to
provide for enhanced air flow, the outer cover 40 that surrounds
the sleeve 30 is also configured to provide enhanced air flow
through the pillow 10. As shown best in FIG. 1, in the pillow 10,
the outer cover 40 includes a first surface 42 and a second surface
43 that is opposite the first surface 42. Included on both the
first surface 42 and the second surface 43, only one of which is
fully shown in FIG. 1, is a central panel 44 surrounded by a border
45 that defines a plurality of openings 46. By including such a
border 45 in the outer cover 40 of the pillow 10, the pillow 10 is
further configured to allow air and any associated heat and
humidity in the pillow 10 and, more specifically, in the core 20 of
the pillow 10 to travel through the openings 46 and be removed from
the pillow 10. Such an outer cover 40 is typically comprised of one
or more textiles having a sufficient amount of durability to
protect the underlying sleeve 30 and core 20 of the pillow 10, but
is also sufficiently breathable to allow air to flow through both
the openings 46 in the border 45 and the remainder of the outer
cover 40 (e.g., through the central panel 44). For example, in the
embodiment shown in FIG. 1, the central panel 44 of the outer cover
40 is comprised of one-hundred percent cotton while the border 45
is comprised of a polyester to allow for an a sufficient amount of
breathability. However, it is further contemplated that numerous
other textiles, including silk, textiles having a lower percentage
of cotton, and cotton/polyester blends can also be readily used to
produce a sufficient outer cover.
[0026] Referring now to FIGS. 3-4, in another exemplary embodiment
of the present invention, a support cushion is provided in the form
of a pillow 110 that includes a core 120 comprised of a first
amount of reticulated visco-elastic foam fragments 122 and second
amount of reticulated visco-elastic foam fragments 124, a sleeve
130, and an outer cover 140. Like the pillow 10 shown in FIGS. 1
and 2, the sleeve 130 of the pillow 110 is comprised of a
three-dimensional spacer material having an outer surface 132
defining a plurality of vents 138, an inner surface 134, and a
middle spacer layer 136 that separates the outer surface 132 from
the inner surface 134. Likewise, the outer cover 140 of the pillow
also includes a first surface 142 having a central panel 144
surrounded by a border 145 that defines a plurality of openings
146. Unlike the pillow shown in FIGS. 1 and 2, however, the pillow
110 has a curved profile that acts to align the head, neck and
shoulders of a user lying on the pillow 10. Additionally, in the
pillow 110, while the first amount of reticulated visco-elastic
foam fragments 122 typically has a density that is less than the
second amount of visco-elastic foam fragments 124 included in the
pillow 110, the second amount of visco-elastic foam fragments 124
included in the pillow 110 as well as the sleeve 130 also includes
an amount of phase change material, as indicated by the stippling
in FIGS. 3-4 to enhance the cooling sensation that is provided to
the body of a user, or a portion thereof, resting on the pillow
110. In this regard, the phase change material is not only
generally positioned and configured to place the body of the user,
or a portion thereof, resting on the pillow 110 in close proximity
to the phase change material, but is also positioned to absorb heat
in the core 120 of the pillow 110.
[0027] The phase change material that is incorporated into the
second amount of visco-elastic foam fragments 124 and the sleeve
130 of the pillow 110 is typically comprised of microspheres that
include substances having a high heat of fusion and that store or
release heat as the substances oscillate between solid and liquid
form (i.e., phase change materials). As the phase change material
included in the second amount of visco-elastic foam fragments 124
and the sleeve 130 changes from solid to liquid form (i.e., melts)
as the result of heat generated by a user lying on the pillow 110,
the phase change material thus continually absorbs heat and
provides a cooling effect to the user until all of the phase change
material has been transformed from a solid to a liquid form.
[0028] The phase change material is incorporated into the second
amount of visco-elastic foam fragments 124 and the sleeve 130 by
infusing and coating the second amount of visco-elastic foam
fragments 124 and the sleeve 130 with the microspheres of phase
change material. However, it is, of course, contemplated that the
phase change material need not be infused into and/or used to coat
both the second amount of visco-elastic foam fragments 124 and the
sleeve 130 to provide a sufficient amount of cooling to the body of
a user lying on the pillow 110, but can also be infused into and/or
used to coat only the second amount of visco-elastic foam fragments
124, only the sleeve 130, or other portions or combinations of
portions of the pillow 110 without departing from the spirit and
scope of the subject matter described herein.
[0029] Regardless of the particular configuration of the phase
change material in the pillow 110, the reticulated visco-elastic
foam fragments that comprise first flexible foam 122 and the second
flexible foam 124 in the core 120 of the pillow 110 are generally
secured to one another and molded to create a molded or integrated
foam core and to prevent the visco-elastic fragments comprising the
first flexible foam 122 and the visco-elastic foam fragments
comprising the second flexible foam 124 from moving during use.
Various means of securing flexible foam materials to another can be
used in this regard, including tape, hook and loop fasteners,
conventional fasteners, stitches, and the like. In the particular
embodiment shown in FIGS. 3-4, although the visco-elastic fragments
comprising the first flexible foam 122 and the visco-elastic foam
fragments comprising the second flexible foam 124 are shown as
separate from one another for purposes of clarity, the
visco-elastic fragments comprising the first flexible foam 122 and
the visco-elastic foam fragments comprising the second flexible
foam 124 are bonded together by an adhesive or cohesive bonding
material to create a substantially continuous assembly where the
visco-elastic fragments comprising the first flexible foam 122 and
the visco-elastic foam fragments comprising the second flexible
foam 124 are fully adhered to one another. Such adhesive bonding
materials include, for example, environmentally-friendly, water
based adhesives, like SABA AQUABOND RSD, a two-component
water-based adhesive product produced by SABA DINXPERLO BV, B-7090
AA, Dinxperlo, Belgium.
[0030] As yet another refinement to the present invention, although
the support cushions shown in FIGS. 1-4 are in the form of pillows
10, 110 and are dimensionally sized to support the head of a user,
it is contemplated that the features described herein are equally
applicable to mattresses, seat cushions, seat backs, neck pillows,
leg spacer pillows, mattress toppers, overlays, and the like. As
such, the phrase "support cushion" is used herein to refer to any
and all such objects having any size and shape, and that are
capable of or are generally used to support the body of a user or a
portion thereof. For example, as shown in FIG. 5, support cushions
made in accordance with the present invention are incorporated into
a seat 212 and back 214 of a desk chair 210. Each support cushion
of the desk chair 210 includes a core 220 comprised of a first
amount of reticulated visco-elastic foam fragments 222 and a second
amount of reticulated visco-elastic foam fragments 224, with the
first amount of visco-elastic foam fragments 222 having a density
less than the second amount of visco-elastic foam fragments 224 to
provide for enhanced air movement through the seat 212 and back 214
of the desk chair 210. The support cushions of the desk chair 210
further include and a sleeve 230 comprised of a three-dimensional
spacer material and, similar to the pillows of the present
invention, each support cushion of the desk chair 210 also includes
an outer cover 240 configured to enhance the movement of air and
the removal of heat and humidity from the support cushions of the
desk chair 210.
[0031] One of ordinary skill in the art will recognize that
additional embodiments or implementations are possible without
departing from the teachings of the present invention or the scope
of the claims which follow. This detailed description, and
particularly the specific details of the exemplary embodiments and
implementations disclosed herein, is given primarily for clarity of
understanding, and no unnecessary limitations are to be understood
therefrom, for modifications will become obvious to those skilled
in the art upon reading this disclosure and may be made without
departing from the spirit or scope of the claimed invention.
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