Body support modified with viscous gel and method of manufacturing a body support using the same

Abstract

A body support cushion, such as a mattress, mattress topper or overlay, or pillow, is comprised of a layer of flexible foam and further has a volume of gelatinous material, e.g., elastomer gel, applied to a surface thereof. The gelatinous material alters a physical property, such as firmness or feel, of the layer of flexible foam. The gelatinous material can be applied in a number of ways including, but not limited to a spray application whereupon the spray force can be used to control how much gelatinous material penetrates into the layer of foam. The foam layer may be comprised of reticulated or non-reticulated foam. The foam layer may also be comprised of viscoelastic or non-viscoelastic foam.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of U.S. Ser. No. 61 / 535,045, filed Sep. 15, 2011, the disclosure of which is incorporated herein in its entirety.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 ...

AI Technical Summary

Benefits of technology

[0008]Some embodiments of the present invention provide a method of producing a body support including the steps of directing one or more nozzles toward a surface of a layer of reticulated or non-reticulated viscoelastic foam, spraying a viscous gel from the nozzle(s) upon the surface of the layer of v

Problems solved by technology

Polyurethane foam inherently has characteristics that define design limitations for manufacturers of body supports desiring to use the foam for particular applications.

Although the number and types of body supports constructed with one or more layers of foam continue to increase, including those having one or more layers of

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