MXPA06004247A - Pillow top for a cushion - Google Patents

Abstract

A cushion having an elastic core and a pillow top layer or portion. The elastic core can have one or more layers of foam to provide varying degrees of cushioning and support. The pillow top layer is positioned adjacent to the elastic core and includes a plurality of strips. Any number of strips can form the pillow top layer. The strips can all have the same density or the density can vary among the strips to provide comfort zones. The pillow top layer can be connected to the elastic core in a variety of ways, such as through the use of a common cover or separate covers joined together.

Description

UPPER PILLOW FOR A CUSHION FIELD OF THE INVENTION The present invention relates generally to cushions, and more particularly to cushions that include bed mattresses, chair cushions, back cushions and any other cushion to support a body in part or in its entirety.

BACKGROUND OF THE INVENTION A typical cushion uses elastic foam material to properly distribute body pressure over a relatively large surface area of the body that is being supported by the cushion, such as a person lying on a mattress, a person sitting on a sofa , or an animal that rests on a veterinary surgical table. When used in combination with some type of less elastic cover layer, the underlying layer of elastic foam on the cushion counteracts the depressed portions deeper in the top layer in order to provide increased counter pressure against the body. To achieve a reasonably limited cushion thickness, the underlying layer is normally disposed in the form of a highly foam layer elastic or a spring base with mechanical springs to provide adequate support to the user. Some conventional cushions have an "upper pillow" surface or layer on top of or instead of the less elastic cover layer. In the mattress industry, conventional upper pillow layers have been formed by inserting soft elastic fillers into an annex that is interconnected with an upper surface of a mattress core. Normally, when an inner spring coil mattress core is employed, the construction of the upper pillow serves essentially to dampen the inner spring coils and to allow a more independent and unrestricted articulation which results in a forming capacity and improved interface pressure, thereby providing overall comfort levels for a mattress user.

BRIEF DESCRIPTION OF THE INVENTION Some embodiments of the present invention relate to a support cushion including an elastic core having a first surface, a second surface, a thickness defined by the first surface and the second surface, and an upper pillow surface having a plurality of foam bands adjacent to the first surface of the elastic core.

Other embodiments refer to a pillow top layer for a support cushion that includes an elastic core having a length and a width. The top layer of the pillow includes a plurality of foam strips having a length, a width and a thickness. The width of each foam band is substantially the same as the width of the elastic core and greater than the length of each foam band. The plurality of foam bands are placed side by side in such a manner that the combined length of the plurality of bands is substantially the same as the length of the elastic core. Still other embodiments relate to a support cushion having an elastic core and an upper pillow portion adjacent to the core. The upper portion of the pillow includes a plurality of foam strips placed side by side and separated by a different material than the foam strips to form a non-continuous layer adjacent to the core.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, similar reference numerals indicate similar parts: Figure 1 illustrates a perspective view of a cushion representing the aspects of the present invention; Figure 2 is a top view of the cushion illustrated in the Figure Figure 3 is a side view of the cushion illustrated in Figure 1; and Figure 4 is a cross section of the cushion illustrated in Figure 2, taken along line 4-4 of Figure 2. Before explaining the embodiments of the present invention in detail, it should be understood that the present invention is not limited in its application to the details of construction and arrangements of components set forth in the following description or illustrated in the drawings. The present invention has the capacity of other modalities and of being practiced or performed in various ways. It should also be understood that the words and terminology used in the present invention are intended to be descriptive and should not be construed as limiting the present invention.

DETAILED DESCRIPTION OF THE INVENTION Figure 1 illustrates one embodiment of the present invention. This cushion 10 has an elastic core 14 and an upper layer of pillow or portion 18. A cover 22 (or one or more portions thereof) surrounds the elastic core 14 and the upper portion of pillow 18. In some embodiments, the core elastic 14 and the upper portion of pillow 18 are each surrounded by individual covers that are coupled together, although in other embodiments, the two portions 14, 18 are surrounded by a single cover. The elastic core 14 of some embodiments may have any conventional construction or construction similar to the cushions described in the following Patents and related applications: Patent Application E.U.A. No. 10 / 379,889 filed March 5, 2003, the U.S. Patent. No. 6,602,579, and the U.S. Patent. No. 6,159,574, which are assigned in a common manner and are incorporated in the present description as a reference. For example, the elastic core of some embodiments may have a plurality of springs covered with filler or foam. Other exemplary embodiments of the elastic core 14 may have one or more layers of foam, such as viscoelastic foam, polyurethane foam, HR foam, or other foams commonly used in the industry. In order to be convenient, the cushioning material of the elastic core will be referred to as foam through the detailed description. Therefore, although the term foam will be used, it should be understood that other conventional fillers may also be used. Figure 4 shows a cross section of the elastic core 14 having three layers of foam: a bottom layer, a middle layer and an upper layer, as illustrated. Although any number of layers can be used and many different types of materials can be used in each layer, the particular embodiment of the elastic core illustrated in Figure 4 will be set forth. The bottom layer of the illustrated elastic core consists of highly elastic polyurethane foam. Preferably, this layer has a density of twenty to seventy kilograms per cubic meter and a hardness of between one hundred ten to one hundred sestees Newtons at 40% deviation Margin of force (IFD). The polished bottom layer has a density of about thirty-five kilograms per cubic meter and a hardness of about one hundred forty Newtons to 40% of IFD. The bottom layer can also have a thickness between about five to fifteen centimeters. However, in the illustrated construction, the thickness of the bottom layer is approximately eleven centimeters. The surfaces of this layer can be flat or folded (for example, truncated cones extending to the next layer above). The bottom layer is placed adjacent to the middle layer. In some embodiments, t layers are joined together. In this particular embodiment, the middle layer is identical to the bottom surface. However, in other embodiments, t two surfaces may be different (ie have different thicknesses, materials, densities and hardnesses). The two layers can be held together by any conventional clamping technique, such as melting, bonding and any other suitable mechanical or chemical joint. The top layer of foam inside the core has a thickness between approximately five centimeters and nine centimeters, although more preferably about seven centimeters. The upper layer is placed adjacent to the middle layer. Preferably, the upper layer is attached to the middle layer by melting or gluing together or with any other suitable mechanical or chemical mutual bond between the layers. The top layer is made of a viscoelastic foam material with suitable density and hardness, such as the material marketed under the name of TEMPUR®. In some modalities, this layer has a density of between fifty-five and one hundred ten kilograms per cubic meter. Preferably, this layer has a density of eighty-five kilograms per cubic meter. This layer may also have a hardness of between about fifty and eighty Newtons. Preferably, the hardness is from sixty Newtons to 40% DFI. The terms "top layer", "middle layer" and "bottom layer" are intended to describe the position of the individual layers in relation to each other based on the illustration. Accordingly, the terms will not be construed as meaning that the bottom layer is the layer that always resides beneath the top layer in relation to an up and down orientation. Instead, this means a layer that resides on the opposite side of the cushion in relation to the user's body. Similarly, the upper layer is a layer that resides on the closest side of the cushion in relation to the wearer's body. If the cushion, for example, is mounted on a backrest, then the underlying layer, the top layer and the top layer, if they are provided, they will be oriented towards the sides and not downwards and upwards, respectively. Also, the term body should not be interpreted solely as the entire body of the user. The body can be any part of the body such as a head if the cushion is used as a pillow, the buttocks if the cushion is used as a seat, or the back if the cushion is used as a backrest. However, the cushion can also support the whole body if the cushion is used as a mattress. The elastic core has a length Lc, a width Wc and a thickness Tc. In some embodiments, the length Lc is greater than the width Wc. For example, most mattresses have a length that is greater than the width. However, this does not prevent the width Wc from being the same as or greater than the length Lc. The elastic core 14 can have a variety of thicknesses Tc depending on the materials comprising the elastic core 14, the number of layers within the elastic core 14, the desired feel and the like. As mentioned and illustrated above in Figures 1 to 4, the foam of the elastic core is contained within a cover. Specifically, the cover 22a, illustrated in these Figures, covers only the elastic foam core 14 that protects the foam from other shock absorbing materials of the elastic core. The cover 22a generally has approximately the same dimensions as the elastic foam core. Depending on the desired characteristics of the cushion 10, the cover 22a can be made slightly larger or smaller than the size of the elastic foam core. For example, in some embodiments, the cover is designed to fit snugly over the elastic foam core to provide a feeling of firmness. In other embodiments, the cover is not as tight to provide a softer feel. The cover 22a of some embodiments is made of cloth material. The cover may be at least partially elastic to allow a body on the cushion 10 to sink therein. The cover can be secured to the elastic foam core 14 in a conventional manner. For example, the cover 22a may have a slide fastener (not shown) located along the peripheral edge or along one or more sides to allow the cover 22a to be removed, washed and / or replaced. The upper portion of the pillow 18 of the illustrated mattress 10 comprises a plurality of foam strips 26 contained within individual covers 22b or sleeves. The foam strips 26, each having a length Ls, a width Ws and a thickness TS) which for convenience move in the same direction as the length Lc, the width Wc and the thickness Tc of the elastic core 14, respectively. The total width Ws of the layer of foam strips 26 and the combined length The of all the individual foam strips are approximately equal to the width Wc and the length Lc of the elastic core 14, respectively. In some embodiments, however, the width Ws and the combined lengths of the Foam bands 26 may be slightly longer or slightly shorter than the respective measurement of the elastic core 14. For example, it is not uncommon for a pillow top surface to extend slightly over the edge of the elastic core 14. Therefore, in said location, Ws width and length The of the foam bands 26 may be slightly larger than the respective measurement in the elastic core 14. In some embodiments, the widths of each band may be less than the width of the core. In such embodiments, two or more bands may be used in such a manner that the total width of the top layer of the pillow is approximately equal to the total width of the core. The illustrated embodiment has five foam bands of equal length each having a length Ls that is less than its width. This arrangement places the seam between each band in an orientation that goes from one side of the cushion to the other. Although the bands can go in the other direction (from top to bottom), polished direction is the preferred orientation for a mattress. This allows the top surface of the pillow to be separated into different zones of softness and damping. These zones can be sized to correspond with the typical locations of certain characteristics of the human body. For example, a different area may be used for the lower part of the legs, the upper part of the legs, the hip, the lower back, the middle back, the upper back, the head and the neck. Also, moving the seam perpendicular to the direction in which a person could normally Rest on the mattress, there is less likelihood that a person will rest inside a seam. However, the seam can be moved along the length of the cushion 10 in some embodiments. Although the illustrated modality only shows five bands 26, other modalities may have more or fewer bands. For example, some modalities can have only three bands, while other modalities can have as many bands as twenty. Preferably, the top layer of the pillow 18 has between four and eight bands. Although the bands 26 are polished having equal lengths Ls, the length Ls of each foam band 26 does not have to be the same. Instead, the length may vary depending on the location of the band 26 on the cushion. For example, if the cushion is a mattress, the bands may have different lengths corresponding to the desired size of each area of the mattress. For example, an average person's hip will usually be located within a previously determined area on the mattress and needs to sink into the mattress rather than the back to properly align the spine. Accordingly, an area having a selected length and smoothness can be placed in this area. Adjacent areas may have different widths and / or densities to properly align the back and legs with the hips. The feeling of the upper surface of the pillow can be designed specifically based among other things on the types of materials used, the density and hardness of the material used, as well as the thickness of the material used. The bands 26 can have a thickness Ts greater than about one centimeter. However, preferably the bands 26 have a thickness Ts that is less than about ten centimeters. Generally, the cushion feels softer and plush with a thinner foam layer. However, in addition to a certain thickness, the layer may become too damped and a person may not have sufficient support or may feel trapped in the foam. Therefore, in some embodiments, the thickness Ts is between two centimeters and seven centimeters. However, in other embodiments, the thickness is between four and six centimeters. The foam bands 26 can be made of substantially any material. However, in some preferred embodiments, the foam webs are made of viscoelastic foam. As mentioned above, the viscoelastic foam in the elastic core 14 can also be used. The viscoelastic foam assumes the shape - in a somewhat "reluctant" way - of the shape of the body that is being supported by the viscoelastic foam. After assuming body shape, the viscoelastic foam returns in a "reluctant" form corresponding to its original shape when the body pressure is removed. A general definition of a viscoelastic foam can be determined from the following scenario: a rigid object, such as a steel ball, is dropped vertically down from a height of 1 m on a flat surface of the visco-elastic foam resulting in a rebound of the rigid object of less than 10%, ie a bounce of less than 10 cm upwards from the flat surface of the visco-elastic foam. The viscoelastic foam, in this way, exerts only a modest elastic counterpressure against that surface for which it is charged, and precisely for this reason, the body will thus be allowed to sink relatively deep inside the cushion in such a way that it distributes its general backpressure over a large area of the body, with a relatively uniform and relatively low back pressure per unit area of the body's supported area. When used in cushions, the viscoelastic foam especially is intended to relieve or counteract ulcerations, such as eschar (decubitus) that occurs from high pressure points when resting on a mattress for long periods of time. These high pressure points can be generated by a layer of highly elastic foam or the base of springs with mechanical springs that support the weight of the body. Accordingly, it is desirable to limit the poor pressure distribution of the highly elastic foam used in a typical cushion. The way in which the top layer of the pillow feels is not only determined based on the thickness, but also depends on the density and hardness of the foam. In some embodiments, the density of the foam bands 26 may be greater than fifty-five kilograms per cubic meter. In other modalities, the density may be less than one hundred ten kilograms per cubic meter. Preferably, the density is between seventy and one hundred kilograms per cubic meter. More preferably, the density is between eighty and ninety kilograms per cubic meter. More preferably, the density is about 85 kilograms per cubic meter. In some embodiments, the density is not the same in each band 26. The hardness of the foam bands 26 may be greater than twenty-five Newtons in some embodiments. In other embodiments, the foam band 26 may have a hardness of less than sixty-five Newtons. Preferably, the hardness is between thirty Newtons and sixty Newtons. More preferably, the bands 26 have a hardness of between forty Newtons and fifty-five Newtons. More preferably, the bands have a hardness of about fifty Newtons. The hardness of each band does not have to be constant. Instead, the bands may have a varying hardness to provide different comfort zones. Preferably, the hardness is measured at 40% DFI. As illustrated in Figure 4, each band 26 is contained within a cover sleeve 22b. The sleeve separates each adjacent band from the other and provides a superior pillow appearance. The sleeves may completely contain each side of each foam band 26 (which includes the top and bottom) or the sleeves may be designed to surround only a portion of each band 26.

For example, the sleeves can surround the four sides and the top of each band without covering the bottom. Additionally, the adjacent sleeves may be connected to each other in some embodiments. Therefore, a common seam or edge along the length of the cushion can be established to connect the cover 22b to the cover 22a of the elastic core 14. However, in some embodiments, each band 26 and cover 22b around the band, can be individually bonded to the core 14 or the cover 22a on the core 14. The upper cover of the pillow 22b can be attached to the cover 22a using any suitable fastener such as a slide fastener, adhesive, belts or even the sewing the top cover of the pillow 22b to the cover 22a. A zipper fastener or other removable fastener may be preferable in some situations where a person may wish to remove the cover to wash or replace it. In still other embodiments, the covers 22a and 22b can be combined into a single cover 22 (which can be removed or not). For example, the complete cushion 10 (core and bands) may be surrounded with a cover material and the upper surface of the cover may be fired to the core along the seam of the upper bands of the pillow. In such a situation, the strips 26 can be placed adjacent to the core 14. More specifically, the strips 26 can be secured directly to the core 14. In other embodiments, the foam strips 26 can also be surrounded on the inside of the sleeves. cover 22 and subsequently the cover 22 can be placed on the elastic foam core 14. In still other embodiments, the cover can be formed with channels of material. The foam bands 26 could be placed in the channels and subsequently the elastic foam core can be placed inside the cover. In some embodiments, it may be desirable to place a material having a low coefficient of friction, such as a polypropylene anti-cut material between the foam bands and / or the elastic core to allow some sliding movement of the relative bands 26 between yes. Additionally, the cover 22, 22b may be somewhat elastic, so that the user can sink into the cushion and allow the cushion 10 to conform to the user's shape, thereby releasing the interface pressure. The embodiments described and illustrated above in Figures 1 to 4 are presented by way of example only and are not intended to be limiting of the concepts and principles of the present invention. Therefore, a person ordinarily skilled in the art will appreciate that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention. For example, some embodiments of the present invention have been described with reference to specific types of foam, such as highly elastic foam and viscoelastic foam, as well as specific dimensions, densities and hardnesses. However, the type of foam, the dimensions of the foams and the combinations of the foams can be different, without departing from the scope of protection. Variations and modifications of the above embodiments are within the scope of the present invention. It should be understood that the present invention described and defined in the present disclosure extends to all alternative combinations of two or more individual features mentioned or evident from the text and / or drawings. For example, various alternatives for the features and elements determined are described with reference to the specific embodiments of the present invention. With the exception of characteristics, elements and forms of operation that are mutually exclusive of or inconsistent with each modality described above, it should be noted that the described characteristics, elements and alternative operation forms that refer to a particular modality can be applied to the other modalities. All of these different combinations constitute various alternative aspects of the present invention. The various features of the present invention are set forth in the following Claims.

Claims (28)

NOVELTY OF THE INVENTION CLAIMS

1. - A support cushion comprising: an elastic core having a first surface, a second surface, and a thickness defined by the first surface and the second surface; a first cover portion that substantially covers the elastic core in its entirety; an upper pillow surface adjacent to the first surface of the elastic core, the upper surface of the pillow includes a plurality of foam bands; and a second cover portion covering at least partially the upper pillow surface, the second cover portion attached to at least one of the first cover potion and the elastic core.

2. The support cushion according to claim 1, further characterized in that the strips are placed side by side to substantially cover the first surface of the elastic core.

3. The support cushion according to claim 1, further characterized in that the plurality of bands includes between four and eight bands.

4. The support cushion according to claim 1, further characterized in that the bands are separated by a material.

5. - The support cushion according to claim 1, further characterized in that at least one of the first and second cover portions separates the core bands.

6. The support cushion according to claim 5, further characterized in that the second cover portion includes a plurality of sleeves, wherein each sleeve houses at least partially one of the bands.

7. The support cushion according to claim 1, further characterized in that the bands are separated from each other by the second cover portion.

8. The support cushion according to claim 1, further characterized in that the bands are viscoelastic foam strips.

9. The support cushion according to claim 1, further characterized in that the lengths of the bands are the same.

10. The support cushion according to claim 1, further characterized in that the bands include different hardnesses.

11. The support cushion according to claim 1, further characterized in that the bands have a thickness of between two and seven centimeters.

12. The support cushion according to claim 1, further characterized in that the elastic core has a greater hardness than the bands.

13. - An upper pillow layer for a support cushion having an elastic core, the elastic core has a length and a width wherein the length is greater than the width, the upper layer of the pillow comprises: a plurality of foam bands having a length, a width and a thickness, wherein the width of each foam band is substantially the same as the width of the elastic core and greater than the length of each foam band, wherein the adjacent bands have substantially oriented sides substantially flat placed side by side to define a structure substantially without holes, wherein the combined length of the plurality of bands is substantially the same as the length of the elastic core; and where the bands are separated from each other by a layer of material.

14. The pillow top layer according to claim 13, further characterized in that it additionally comprises a cover covering the elastic core.

15. The pillow upper layer according to claim 14, further characterized in that the cover includes a plurality of sleeves, wherein each sleeve houses at least partially one of the bands.

16.- The top layer of pillow in accordance with the Claim 13, further characterized in that the bands are viscoelastic foam strips.

17. - The pillow upper layer according to claim 13, further characterized in that the bands include between four and eight bands.

18. The pillow upper layer according to claim 13, further characterized in that the lengths of the bands are the same.

19. The pillow top layer according to claim 13, further characterized in that the bands have different thicknesses.

20.- The top layer of pillow in accordance with the Claim 13, further characterized in that the webs have a thickness of between two and seven centimeters.

21. The pillow upper layer according to claim 13, further characterized in that the elastic core has a greater hardness than the bands.

22. A support cushion comprising: an elastic core; and an upper pillow portion adjacent to the core, wherein the upper pillow portion comprises a plurality of foam strips placed side by side and separated from each other only by a material to form a non-continuous layer but without holes in the upper part of the elastic core, wherein the adjacent bands have parallel oriented lateral surfaces.

23. - The support cushion according to claim 22, further characterized in that the material separates the core strips.

24. The support cushion according to claim 22, further characterized in that the material defines a plurality of sleeves, wherein each sleeve houses one of the plurality of bands.

25. The support cushion according to claim 22, further characterized in that the material defines between four and eight sleeves.

26. The support cushion according to claim 1, further characterized in that the second cover portion is releasably attached to the first cover portion.

27. The support cushion according to claim 1, further characterized in that the first and second cover portions are part of the same cover.

28. An upper pillow layer for a support cushion having an elastic core, the upper cushion layer comprising: a first elongated foam portion having first and second opposite sides; a second elongated foam portion extending substantially parallel to the first elongated foam portion and having opposite third and fourth sides, wherein the second side of the first elongated foam portion is parallel and adjacent to the third side of the first portion of elongated foam, the first and second elongated foam portions collectively define a substantially flat and contiguous upper surface of the upper pillow layer; and one cover covering the first and second elongated foam portions and separating the second side of the first elongated foam portion from the third side of the second elongated foam portion, wherein the cover and the first and second elongated foam portions define a structure substantially without holes.