Cover for a patient support

Abstract

A patient support is provided that includes a cover with flexible material formed of a fabric layer and a coating layer. The fabric layer and the coating layer may provide a configuration that is breathable, chemically durable, resistant to staining, resistant to being ripped, or resistant to delamination.

Description

COVER FOR A PATIENT SUPPORTTECHNICAL FIELD

[0001] The present disclosure relates to a patient support apparatus and more particularly a cover assembly for a patient support.BACKGROUND

[0002] The present disclosure relates to patient support apparatuses, such as beds, cots, stretchers, recliners, or the like. More specifically, the present disclosure relates to patient support apparatuses that include a patient support, such as a mattress. Such patient supports often utilize a cover in an effort to protect the interior components of the mattress. There are several issues common to these conventional covers: lack of breathability, lack of durability (e.g., delamination of layers in the cover), fluid intrusion and staining of the cover, and cross contamination between patients. Lack of breathability, for instance, at the patient interface may result in increased moisture accumulation thereby increasing potential for pressure injury development. As another example, fluid intrusion can often damage one or more layers of the cover.SUMMARY

[0003] In general, one innovative aspect of the subject matter described herein can be embodied in a patient support for a hospital bed, the patient support may include a pressure distribution layer operable to support a patient and distribute pressure with respect to the patient, and a cover adapted to be disposed between the pressure distribution layer and the patient. The cover may include a fabric layer with a first side and a second side and a coating layer coupled to the first side of the fabric layer. The fabric layer may be defined by yam provided in a weave or knit, and the coating layer may be bonded to the yam of the fabric layer or adhered to the fabric layer via a polycarbonate adhesive.

[0004] The foregoing and other aspects can each optionally include one or more of the following features, alone or in combination. In particular, one aspect includes all the following features in combination.

[0005] In some aspects, the coating layer may be thermally bonded to the yam of the fabric layer.

[0006] In some aspects, the coating layer may be directly bonded to the yam of the fabric layer via extrusion coating.

[0007] In some aspects, the yam may be formed by one of dry spun short stable, dry spun filament fibers, or melt spun filament.

[0008] In some aspects, the yam may be formed by a monofilament.

[0009] In some aspects, one or more fibers may form the yam.

[0010] In some aspects, at least one of a draw and a crimp may be applied to the one or more fibers.

[0011] In some aspects, the yam may be formed by spinning a plurality of the one or more fibers with an amount of twist corresponding to at least 2 twists per inch.

[0012] In some aspects, the amount of twist may provide both stretch and tensile strength to the cover.

[0013] In some aspects, the one or more fibers may be coated or provided with an additive.

[0014] In some aspects, the additive may correspond to a polymer additive that provides anti-microbial properties to the fabric.

[0015] In some aspects, the one or more fibers may be shaped non-symmetrically to provide substantial stain resistance between fibers and substantially prevent seepage and coagulation with respect to the fabric.

[0016] In some aspects, the one or more fibers may be shaped according to at least one of a bean shape, a dog-bone shape, and a trilobal shape.

[0017] In some aspects, the one or more fibers may include at least one of nylon, acrylic, and polypropylene.

[0018] In some aspects, the fabric may be formed by knitting the yam according to one of a warp knit, tricot knit, or raschel knit.

[0019] In some aspects, the yam may be knit with an amount of warps per inch that is greater than 24.

[0020] In some aspects, a knit structure of the fabric may provide moisture wicking and heat dissipation.

[0021] In some aspects, the coating layer may be a polyurethane coating layer that is laminated by an adhesive layer to the fabric layer.

[0022] In some aspects, the coating layer may be an extrusion coating that is melted onto the fabric layer.

[0023] In general, one innovative aspect of the subject matter described herein can be embodied in a cover for a patient support adapted to be disposed on a hospital bed. The cover may include a fabric layer with a first side and a second side. The fabric layer may be defined by a yam provided in a weave or knit. The cover may include a coating layer provided on the first side of the fabric layer, and the coating layer may be bonded to the yam of the fabric layer or adhered to the fabric layer via a polycarbonate adhesive.

[0024] The foregoing and other aspects can each optionally include one or more of the following features, alone or in combination. In particular, one aspect includes all the following features in combination.

[0025] In some aspects, the coating layer may be thermally bonded to the yam of the fabric layer.

[0026] In some aspects, the coating layer may be directly bonded to the yam of the fabric layer via extrusion coating.

[0027] In some aspects, the yam may be formed by one of dry spun short stable, dry spun filament fibers, or melt spun filament.

[0028] In some aspects, the yam may be formed by a monofilament.

[0029] In some aspects, one or more fibers may form the yam.

[0030] In some aspects, at least one of a draw and a crimp may be applied to the one or more fibers.

[0031] In some aspects, the yam may be formed by spinning a plurality of the one or more fibers with an amount of twist corresponding to at least 2 twists per inch.

[0032] In some aspects, the amount of twist may provide both stretch and tensile strength to the cover.

[0033] In some aspects, the one or more fibers may be coated or provided with an additive.

[0034] In some aspects, the additive may correspond to a polymer additive that provides anti-microbial properties to the fabric.

[0035] In some aspects, one or more fibers may be shaped non-symmetrically to provide substantial stain resistance between fibers and substantially prevent seepage and coagulation with respect to the fabric.

[0036] In some aspects, the one or more fibers may be shaped according to at least one of a bean shape, a dog-bone shape, and a trilobal shape.

[0037] In some aspects, the one or more fibers may include at least one of nylon, acrylic, and polypropylene.

[0038] In some aspects, the fabric may be formed by knitting the yam according to one of a warp knit, tricot knit, or raschel knit.

[0039] In some aspects, the yam may be knit with an amount of warps per inch that is greater than 24.

[0040] In some aspects, a knit structure of the fabric may provide moisture wicking and heat dissipation.

[0041] In some aspects, the coating layer may be a lamination coating provided between the fabric layer and a polyurethane coating layer.

[0042] In some aspects, the coating layer may be an extrusion coating that melted onto the fabric layer.

[0043] In some aspects, the patient support for a hospital bed may include a pressure distribution layer operable to support a patient and distribute pressure with respect to a patient; and a cover according to one or more aspects described herein. The cover may be disposed between the pressure distribution layer and the patient.

[0044] In some aspects, the hospital bed may include a patient support, a frame including a deck surface that supports the patient support, and a barrier mounted to the frame.

[0045] Before the embodiments and aspects of the disclosure are explained in detail, it is to be understood that the disclosure is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure may be implemented in various other embodiments and aspects and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments and aspects. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting one or more embodiments or aspects to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of an embodiment or aspect anyadditional steps or components that might be combined with or into the enumerated steps or components.BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Fig. 1 shows a patient support apparatus according to one aspect.

[0047] Fig. 2 shows a patient support according to one aspect.

[0048] Fig. 3 shows the patient support of Fig. 2 without a cover.

[0049] Fig. 4 shows a flexible material according to one aspect.

[0050] Fig. 5 shows a flexible material according to one aspect.

[0051] Fig. 6 shows a fabric layer according to one aspect.

[0052] Fig. 7 shows a fabric layer according to one aspect.

[0053] Fig. 8 shows yam according to one aspect.

[0054] Fig. 9 shows a trilobal-shaped fiber.

[0055] Fig. 10 shows a lima bean-shaped fiber.

[0056] Fig. 11 shows a dog bone-shaped fiber.

[0057] Fig. 12 shows a straight fiber and a crimped fiber according to one aspect.DETAILED DESCRIPTION

[0058] A patient support apparatus in accordance with one aspect is depicted in Fig. 1 and generally designated 100. The patient support apparatus 100 includes a frame 120 and a patient support 112 for supporting a patient (not shown). The patient support 112, such as a mattress, may be disposed on a deck surface of a deck 130 for comfortably supporting the patient. It is to be understood that the patient support 112 may be implemented without a mattress or with numerous alternatives for the mattress, such as cushions. For instance, the mattress may be an air mattress according to one or more aspects described herein.

[0059] The patient support 112 in one aspect may include a cover 150 with flexible material 180 formed of a fabric layer 182 and a coating layer 186. The fabric layer 182 and the coating layer 186 may provide a configuration that is breathable, chemically durable, resistantto staining, resistant to being ripped (particularly along the warp of the fabric layer 182), or resistant to delamination, or a combination thereof. As described herein, the fabric layer 182 may be formed of a yam 200 in either a knit or woven configuration, in a manner that defines spacing or openings O. The size of the openings O according to one aspect may be reduced by increasing the ends per inch or the warps per inch, respectively for woven or knit configurations.

[0060] The flexible material 180 in one aspect, as described herein, may include a fabric layer 182 that includes fiber in the form of at least one of polyester, nylon, acrylic, and polypropylene — although the present disclosure is not limited to any particular form of fiber for the fabric layer 182. The fiber of the fabric layer 182 may be processed to yield yam 200 that can be melt spun short staple, dry sponge short staple, melt spun filament, or dry spun filament fibers. It is to be understood that the present disclosure is not limited to any particular type of yam configuration or processing technique. It is noted that although several fibers are described herein as being available to produce the yam 200 according to a variety of configurations and processing techniques, optionally, yam 200 formed of dry spun filament fibers may exclude polypropylene fibers. The fabric layer 182 may be produced, as described herein, by weaving or knitting the yam 200. Example types of knitting include single jersey knitting, warp knitting, tricot knitting, and raschel knitting. The present disclosure shows a plain weave configuration in Fig. 7, with the fabric layer designated 182’ — but it is to be understood that any type of weave configuration may be utilized.

[0061] The coating layer 186 in one aspect may correspond to an extrusion coating of polyurethane or polyether. It is to be understood, however, that the material utilized in the extrusion coating may vary from application to application and is not limited to polyurethane or polyether. The coating layer 186 in one aspect may be bonded to the yam 200 of the fabric layer 182, such as the coating layer 186 described herein in conjunction with Fig. 4.

[0062] The coating layer 186 in one aspect may be laminated to the fabric layer 182 via an adhesive layer 189. This configuration is depicted in Fig. 5, with the flexible material designated 180’. The coating layer 186 may correspond to a polyurethane coating, and the adhesive layer 189 may correspond to a polycarbonate adhesive, a PVC adhesive, or any other type of adhesive. The flexible material 180’ may be similar to the flexible material 180 described herein, with the exception of including the adhesive layer 189. One or more aspects of the flexible material 180 may be incorporated into or provided by the flexible material 180’.

[0063] The flexible material 180 may provide a more breathable surface via changes in the fundamentals of the fabric (fiber type, yam construction, fabric construction). For instance, by changing the fabric through the type of polymer used, the manufacturing process for the yam, and the type of knit / weaving structure, better moisture wicking and heat dissipation properties may be provided.

[0064] In one aspect, a polymer additive may be added at the fiber level in order to create a rechargeable anti-microbial surface that is recharged each time it is cleaned. The additive may be able to kill bacteria including C. diff.

[0065] In one aspect, by utilizing a coating method and / or adhesive, the possibility for delamination may be reduced despite repeated cleaning cycles in the hospital.

[0066] In one aspect, increasing the amount of twist in a yam structure may increase the amount of stretch and the tensile strength in the cover.

[0067] Changing the fabric structure according to one aspect may improve the amount of allowed stretch and remove the issue of tearing over conventional cover configurations.

[0068] In one aspect, the fibers of the flexible material may be constructed with a non- cylindrical shape that increases the resistance for staining between the fibers.

[0069] In one aspect, the yam and fabric construction may provide a tighter weave to prevent bodily fluids from seeping through and coagulating.

[0070] In one aspect, as described herein, the patient support apparatus 100 may include a pump assembly (not shown) operable to control supply of fluid to the patient support 112.

[0071] Although the particular form of patient support apparatus 100 illustrated in Fig.1 is a bed adapted for use in a hospital or other medical setting, it is to be understood that the patient support apparatus 100 may be a cot, a stretcher, a gurney, a recliner, an operating room table, or a residential bed or any other structure capable of supporting a patient, whether stationary or mobile and / or whether used in a medical or residential setting.

[0072] In one aspect, the patient support apparatus 100 may include a plurality of wheels 122 supporting the frame 120. The wheels 122 may allow the patient support apparatus 100 to be easily moved along a surface (i.e., the floor). Alternatively, the patient support apparatus 100 may be implemented without wheels 122, such that the patient support apparatus 100 is relatively stationary. When implemented with wheels 122, the patient support apparatus 100 may include a brake 125 for immobilizing at least one of the wheels, including configurations where the brake immobilizes all of the wheels 122.

[0073] The patient support 112 of the patient support apparatus 100 may provide a patient support surface 118 and may be supported on the deck surface of the deck 130, which in turn is supported on the frame 120. One or more components of the patient support 112 may provide a pressure distribution layer operable to support a patient and distribute pressure with respect to the patient. Such internal components may include but are not limited to cushioning assemblies of the patient support, such as bladders 163, foam 162, and gel layers 164.

[0074] The term “patient support” is used broadly herein and may refer to the whole mattress or cushion that supports a patient thereon or may refer to a portion of the mattress or cushion, such as a topper or an overlay, or to a separate device that can be used with a mattress or cushion, for example such as a pad to be placed on top of a mattress to provide treatment toa patient, such as low air loss, to move a patient, or to change the characteristic of the mattress or cushion, such as described below.

[0075] The deck 130 may have one or more articulatable deck sections, including a back deck section (“Fowler”), a seat deck section, and a thigh deck section, which together with the frame 120 are supported on a wheeled base 123 by a lift assembly 127.

[0076] In one aspect, the patient support apparatus 100 may include one or more barriers, such as a footboard 148, a headboard 146 proximal a head end 144, and a plurality of side rails 114. One of the side rails 114 proximal to the footboard 148 in Fig. 1 is shown in a lowered position in which ingress into, and egress out of, the patient support apparatus 100 is not obstructed by the lowered side rail 114. Each side rail 114 may be configured so it can be individually moved between a lowered position and a raised position. The side rails 114 may be moved to one or more intermediate positions as well.

[0077] It is to be understood that the patient support apparatus 100 may be modified from what is shown to include one or more components adapted to allow the user to extend the width of the deck 130, thereby allowing the patient support apparatus 100 to accommodate patients of varying sizes. For example, the width of the deck 130 may be adjusted, between a first width, a second or intermediate width, and a third or expanded width. The first width may be, for example, a 36 inch width, the second intermediate width may be, for example a 42 inch width, and the third expanded width may be, for example, a 48 inch width, although these widths may be varied.

[0078] Referring to Figs. 2-3, the patient support 112 is shown in further detail with a cover 150 in Fig. 2 and without the cover 150 in Fig. 3.

[0079] The patient support 112 may be integrated into an underlying mattress (and hence form a part of the mattress) or be placed on the mattress. The mattress itself may include a variety of different cushioning assemblies, e.g., an assembly or assemblies formed from foam 162, foam 162 in combination with bladders 163, foam 162 in combination with one or moregel layers 164, or foam 162 in combination with bladders 163 and one or more gel layers 164, and may include a control system incorporated into the patient support apparatus 100 or underlying cushioning components and contained, for example, proximal to the foot end 142 of the patient support apparatus 100 in a control housing, such as disclosed in U.S. Patent Nos. 5,542,136; 5,325,551; 7,406,736; 8,910,334; 8,911,387; 9,468,307; and 9,820,904, which are commonly owned by Stryker Corporation of Kalamazoo, Michigan, and are incorporated by reference in their entireties herein.

[0080] Another example bladder cushioning assembly as well as a pneumatic control system is disclosed in commonly assigned U.S. patent application serial numbers 61 / 696,819, which is the provisional application to U.S Non-Provisional Application No. 13 / 836,813, now Patent No. 9,468,307, and 61 / 697,010, which is the provisional application to U.S NonProvisional Application No. 14 / 019,353, now Patent No. 9,420,895, entitled INFLATABLE MATTRESS AND CONTROL METHODS and PATIENT SUPPORT, respectively, both of which were filed on September 5, 2012, which are hereby incorporated herein by reference in their entireties. Yet another example bladder cushioning assembly and pneumatic control system is disclosed in U.S. patent application serial number 63 / 359,227 , entitled PATIENT SUPPORT APPARATUS WITH PATIENT SUPPORT SURFACES THEREFORE, filed July 8, 2022.

[0081] The patient support 112, in one aspect, may include a low air loss system operable to receive air from a pneumatic system. For example, the low air loss system may include perforated tubing positioned between some of the bladders 163 or other portions of the patient support 112 so as to direct air flow across or between the bladders 163 or the other portions, which air flow would facilitate the removal of moisture from the patient’s skin. Further, tubing or tube extensions or perforated bladders may be provided to extend up between the support bladders 163 to direct air close to the support surface. Alternately, air loss conduits may be formed in the bladder layer, for example, the base sheet between the support bladders163. In one aspect, the low air loss system may be incorporated into a cover for the patient support 112, where the cover receives air from the pneumatic system to remove moisture from the patient resting on the patient support 112. Such a cover may include a moisture permeable layer and a spacer material that supports an air space in the cover under the patient’s weight to facilitate removal of moisture from the patient via directing air through the air space.

[0082] Additional to or alternative to the patient support 112 including bladders 163 and / or a low-air-loss system that provides cushioning for the patient support 112, one or more turning bladders on each side of the patient support 112 may be inflated to provide patient turning capabilities (e.g., turn therapy). Turn bladders may be located under bladders and / or other cushioning aspects of the patient support 112 and may be inflated by the pneumatic system. In use, the turning bladders may be used for turning one side of the patient support 112 while the other remains generally stationary — though it should be understood that the bladders on the stationary side may have their pressure reduced to reduce their inflation to allow the person to immerse deeper into the surface while being turned to reduce the chances of a patient fall during turning. The turning bladders may be full length bladders that may extend substantially the full length of the patient support 112 or may be segmented. Further, the segment turning bladders may be independently inflated or deflated to allow access to a portion of a patient’s body while being turned, or to effect a rolling turning effect, or just to turn a portion of the patient’s body. For examples of optional controls for and examples of suitable turning bladders, reference is made to U.S. application Ser. No. 12 / 234,818, filed Sep. 22, 2008, now U.S. Pat. No. 8,296,887, entitled RESILIENT MATERIAL / AIR BLADDER SYSTEM; and U.S. application Ser. No. 11 / 891,451, filed Aug. 10, 2007, entitled TURNASSIST WITH ACCESS AREAS, which are incorporated herein by reference in their entireties.

[0083] With respect to Fig. 3, the patient support 112, to provide cushioning and immersion for the patient, may include one or more cushioning layers for supporting a patient’sbody. Optionally, the patient support 112 includes a cushioning system formed from a plurality of cushioning layers that are configured to be mechanically interconnected (at least about or along one axis) so that the layers work together at least in one or more directions. In Fig. 3, the patient support 112 includes a bladder layer with a plurality of bladders 163, which provide support to the patient’s thighs, seat, back, and head, and an optional gel layer 164, for example, which provides support to the patient’s heels. The bladder layer and gel layer may be supported by a foam crib 165, which together may form a cushioning system for the patient support 112. The foam crib 165 tends to keep the softer cushion layers of the bladders and gel in place while also providing a firmer rail along both sides of the patient support 112. Optionally, the bladders 163 of the bladder layer, the gel layer 164 and / or the foam crib 165 each have surfaces or structures that interconnect them together at least in one direction so that the bladders 163, the gel layer 164, and the foam crib 165 may work in unison in one degree or another. Additionally, the side rails of the foam crib 165, which form bolsters, may be raised or angled upwardly relative to the top surface of the bladder layer, over at least a portion of the bladder layer, to form a cradle so that when the patient is lying on the bladder and gel layers, the foam crib 165 may cradle the patient and further provide lateral support to the patient to reduce the risk of the patient rolling or falling from the patient support even when the side rails are lowered. For further details of optional bladder layers, gel layers, and foam cribs, and, for example, how they may be mechanically connected, reference is made to U.S. Patent 9,420,895, entitled PATIENT SUPORT, filed September 5, 2013, to Lafleche et al. — the disclosure of which is incorporated by reference herein in its entirety.

[0084] With respect to Fig. 2, the cover 150 may be formed from a flexible material 180, which may provide a high breathability rate to facilitate moisture management. The cover 150 may include an upper cover portion 152 and a lower cover portion 156 that are joined together by a zipper 154, which allows access to the various components inside the patient support 112. The upper cover portion 152 includes an upper side, which may be formed froma separate panel, and upper side portions that extend downwardly from the upper side and optionally are formed from separate panels that are joined with the upper panel, for example by welding, stitching, or the like. Similarly, the lower cover portion 156 includes a lower side, which may be formed from a separate lower panel, and lower side portions that extend upwardly from the lower side and optionally are formed from separate panels that are joined with the lower panel, for example by welding, stitching, or the like. In one aspect, the upper side of the cover 150 may be configured to follow the surface topology of the underlying cushion or cushioning system to provide a smooth surface, which can facilitate cleaning.

[0085] The flexible material 180 of the cover 150 is shown in further detail in one aspect in Fig. 4. The flexible material 180 may form one or more panels of the cover 150.

[0086] The flexible material 180 in Fig. 4 may include a fabric layer 182 with a first side 181 and a second side 183. The flexible material 180 may also include a coating layer 186 with a first side 185 and a second side 187. The coating layer 186 may be provided on the first side 181 of the fabric layer 182. The coating layer 186 and / or the process of applying the coating layer 186 may be configured to substantially prevent delamination of the flexible material 180 after multiple cleaning cycles in a hospital environment.

[0087] The coating layer 186 in one aspect may be provided on the fabric layer 182 via an extrusion coating method that includes melting the coating onto the fabric layer 182. This extrusion coating methodology may facilitate bonding the coating layer 186 directly to the yam of the fabric layer 182. The extrusion coating process may involve thermally bonding the coating layer 186 to the yam of the fabric layer 182.

[0088] In one aspect, depicted in Fig. 5, the coating layer 186 may be coupled to the yam 200 of the fabric layer 182 via an adhesive layer 189. The adhesive layer 189 may include a polycarbonate adhesive that facilitates bonding the coating layer 186 to the yam 200 of the fabric layer 182. In one aspect, the coating layer 186 is a polyurethane coating that is laminated to the fabric layer 182 via the adhesive layer 189.

[0089] In one aspect, the fabric layer 182 may be defined by yam 200 provided in a weave or knit, and the coating layer 186 may be bonded to the yam of the fabric layer 182. The coating layer 186 may be directly bonded to the yam 200 of the fabric layer 182.

[0090] The yam 200 of the fabric layer 182 may vary from application to application. As an example, the yam may be formed of dry spun short stable, dry spun filament fibers, or melt spun filament. As another example, the yam may be formed of a monofilament. The present disclosure is not limited to these examples — the yam may be formed of any one or more types of materials in any configuration.

[0091] In one aspect, one or more fibers may form the yam 200 of the fabric layer 182. An example strand of yam 200 including a plurality of fibers designated A and B is shown in Fig. 8. The fibers A, B are spun or twisted together to form the yam 200. The number of twists per inch (TPI) can be determined by counting the bumps 1, 2, 3, 4, 5, 6 . . . on the strand over a one-inch distance. The amount of twist or TPI for the yam 200 may facilitate proving both stretchiness and tensile strength to the fabric layer 182 and therefore to the cover 150. The TPI for the yam 200 and the process for forming the yam 200 may depend on which type of fibers are utilized (e.g., polyester, acrylic, polypropylene, etc.) and which spinning form is used, such as dry spinning, wet spinning, air jet, melt spinning, rotor spinning, and dispersion spinning.

[0092] The length of the plurality of fibers that form the yam 200 (e.g. , the staple fibers) may vary from application to application. Based on this length, the TPI of the yam 200 may be varied. For example, if short staple is used with a length of between 1 and 3 inches, additional twist may be utilized for the yam 200 to leave fewer gaps and to be more resistant to staining. Additional twists in this configuration may also enhance thermal properties and allow for greater heat dissipation. It is noted that, in the case of filament fibers (e.g., monofilament), no twist may be utilized to form the yam 200.

[0093] In one aspect, the one or more fibers of the yam 200 may be coated with an additive, which may enhance properties of the yam 200, such as antimicrobial properties. Forexample, the coating of the one or more fibers of the yam 200 may correspond to a polymer additive that provides antimicrobial properties. The coating may be applied to the fibers prior to formation of the yam 200 and / or to the yam 200 itself. The additive in one aspect may be rechargeable with respect to its properties so as by cleaning the cover 150 and recharging the additive to provide antimicrobial properties. In one aspect, the additive may be able to kill or substantially disable bacteria including C diff.

[0094] In one aspect, draw may be applied to one or more fibers of the yam 200 after spinning. Optionally, draw may be performed after the spinning of a filament. For instance, the as-spun filament on a drum or bobbin may be passed through a feed roll at one set velocity and then through one or multiple take-up wheels at increasing speeds to lengthen the filament proportionate to the draw ratio. The draw ratio may be defined as the ratio of feed velocity to take-up velocity.

[0095] The draw process may be used to align the polymer chains of the as-spun filament allowing for an increase in crystallinity to occur, which can increase the strength of the filament and decrease the elongation (stretch).

[0096] There are multiple potential environments for the drawing process including: at air temperature, in a hot air chamber, on contact with a hot plate or drums, or in liquid baths that may also contain plasticizers and / or other agents.

[0097] Drawing can increase filament length 20-8000% relative to an initial length. In one aspect, optionally, drawing can be utilized in the process of manufacturing the filament / fiber with a minimum draw of 20%. It is to be understood that the minimum amount of draw may be larger or smaller, depending on the application.

[0098] In one aspect, crimp may be applied in the process of producing one or more fibers of the yam 200. Crimp is an optional step that may be completed after the spinning of a filament. Crimping may follow the optional drawing process. Crimp can be applied to a filament / fiber to add waviness to increase elongation. Crimp may also aid in decreasing gapsbetween filament / fiber, thus potentially decreasing liquid permeation. Crimp applied to a fiber according to one aspect is shown in Fig. 12, next to a straight fiber for purposes of discussion.

[0099] Crimp may be measured either in crimps per unit length or as a percentage (shown in the below equation):,1“lo Crimp(% = — - — x 100, io where l0= length of the crimped fiber, and I = length of the straightened fiber.

[0100] In one aspect, optionally, crimp can be utilized in the process of manufacturing the yam 200 with a minimum of 1 crimp per inch or 1% crimp. It is to be understood that the minimum amount of crimp may be larger or smaller, depending on the application.

[0101] In one aspect, the yam 200 may be configured to be resistant to moisture absorption, such as being resistant to swelling in response to exposure to moisture. A variety of processes and / or structural aspects of the yam 200 and / or the fibers of the yam 200 may be utilized to yield such properties. For instance, as described herein, greater twist with respect to the yam 200 may be utilized to enhance resistance to moisture absorption. As another example, providing one or more fibers of the yam 200 that are asymmetrical or non-symmetrical in shape may enhance resistance to moisture absorption. In yet another example, the fibers of the yam 200 may be filament fibers with a structure that does not absorb moisture. The filament fiber may be a bi-component fiber in one aspect with an interior base polymer core and an outside anti-microbial sheath, which may be resistant to moisture absorption.

[0102] In one aspect, the one or more fibers of the yam 200 may have a cross-section that is shaped in a non-symmetrical (e.g., asymmetrical) manner. Example non-symmetrical fibers are depicted in Figs. 9-11 and include a trilobal shape, a Lima bean shape, and a dog bone shape. It is to be understood that the present disclosure is not limited to these specific shapes and that any type of non-symmetrical shape may be provided with respect to the cross section of one or more fibers of the yam 200. The non-symmetrical shape or asymmetrical shape of the one or more fibers of the vam 200 may facilitate providing substantial stainresistance between the one or more fibers and substantially prevent seepage and coagulation with respect to the fabric layer 182.

[0103] The type of the one or more fibers provided in the yam 200 may vary from application to application. Example types of the one or more fibers include without limitation nylon, acrylic, and polypropylene. The yam 200 may be formed of more than one type of fiber, such as both nylon and polypropylene fibers. It is also to be understood that the fabric layer 182 may be formed of more than one type of yam 200.

[0104] The fabric layer 182, as described herein, may be formed of the yam 200 provided in a knit or weave configuration. A knit configuration in one aspect is depicted in Fig.6, with the yam 200 arranged in a single jersey knit configuration to form a portion of the fabric layer 182. The fabric layer is not limited to any particular style or type of knitting configuration. Additional examples of knit configurations include warp knit, tricot knit, and raschel knit arrangements. The knit or weave configuration may enhance stretch and provide resistance to tearing. For instance, double jersey knit configurations can be prone to ripping straight down, whereas single jersey knit, warp, tricot, or other knit configurations described herein may be less prone to such ripping.

[0105] In one aspect, the flexible material 180 may be provided in a woven configuration. Stretch with respect to a woven configuration, while maintaining stain resistance, may be achieved via the type of yam 200 utilized. For instance, the yam 200 in one aspect may be stretchable, allowing the woven form of the flexible material 180 to stretch. It is noted that such a stretchable yam 200 may be utilized in the knit configuration as well and is not limited to the woven configuration.

[0106] Various knit and woven configurations of the flexible material 180 described herein may provide enhanced moisture wicking and heat dissipation properties. For instance, with respect to the flexible material 180, 180’ shown in Figs. 4 and 5, openings O defined by the spacing between strands of yam 200 in the knit or weave configuration may affect moisturewicking and heat dissipation properties. For instance, the tighter the weave or knit the smaller the openings O, yielding greater moisture wicking, greater heat dissipation, and resistance to staining.

[0107] In one aspect, as described herein, the yam 200 of the flexible material 180, 180’ may have more twist that enhances moisture wicking, heat dissipation, and stained resistance. The greater twist of the yam 200 may decrease the size of the openings O of the flexible material 180, 180’.

[0108] In Fig. 6, the distance between warps in the knit arrangement is designated W. By decreasing the warp distance W, the warps per inch (WPI) may be increased. In one aspect, the WPI for the fabric layer 182 may be 24 or greater. This WPI may facilitate providing moisture wicking and heat dissipation with respect to the cover 150.

[0109] A weave configuration of the fabric layer 182’ in one aspect is depicted in Fig.7, with the warp and weft provided in a plain weaving pattern. The fabric layer 182’ may be similar to the fabric layer 182 described herein, with the exception of being formed by weaving the yam 200 instead of knitting the yam 200. One or more aspects of the fabric layer 182 described herein may be incorporated into or provided by the fabric layer 182’.

[0110] The pattern of the weave may vary from application to application. It can be seen that the number of ends per inch (EPI) is a function of the distance between the warp yam 200. In one aspect, the EPI for the fabric layer 182 may be 16 or greater. This EPI may facilitate providing moisture wicking and heat dissipation with respect to the cover 150.

[0111] In one aspect, as described in U.S. Non-provisional Ser. No. 14 / 019,353 filed September 5, 2013, entitled PATIENT SUPPORT, which is incorporated by reference herein in its entirety, the cover 150 may optionally enclose one or more blowers or fans for circulating air through the support, as part of a low air loss system. Therefore, the cover 150 may incorporate one or more open mesh panels to allow air to be drawn into or blown out of the cover 150.

[0112] The cover 150 in one aspect may facilitate enhancement of features on the patient support 100, such as low air loss (LAL). The cover 150 in one aspect may aid in preventing hospital acquired pressure injuries.

[0113] Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing embodiments and aspects of the present disclosure based on the orientation of the embodiments and aspects shown in the illustrations. The use of directional terms should not be interpreted to limit embodiments or aspects to any specific orientation(s).

[0114] The above description is that of current embodiments and aspects of the disclosure. Various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments or aspects of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments or aspects. For example, and without limitation, any individual element(s) of the described embodiments or aspects may be replaced by alternative elements that provide substantially similar fimctionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the fiiture, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments and aspects include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present disclosure is not limited to only those embodiments or aspects that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the”or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

[0115] While several forms have been shown and described, other changes and modifications will be appreciated by those skilled in the relevant art. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes, and are not intended to limit the scope of the disclosure which is defined by the claims which follow as interpreted under the principles of patent law including the doctrine of equivalents.

Claims

CLAIMS1. A patient support for a hospital bed, the patient support comprising: a pressure distribution layer operable to support a patient and distribute pressure with respect to the patient; and a cover adapted to be disposed between the pressure distribution layer and the patient, the cover including a fabric layer with a first side and a second side and a coating layer coupled to the first side of the fabric layer, the fabric layer defined by yam provided in a weave or knit, the coating layer being bonded to the yam of the fabric layer or adhered to the fabric layer via a polycarbonate adhesive.

2. The patient support of claim 1 wherein the coating layer is thermally bonded to the yam of the fabric layer.

3. The patient support of claim 2 wherein the coating layer is directly bonded to the yam of the fabric layer via extrusion coating.

4. The patient support of claim 1 wherein the yam is formed by one of dry spun short stable, dry spun filament fibers, or melt spun filament.

5. The patient support of claim 1 wherein the yam is formed by a monofilament.

6. The patient support of claim 1 wherein one or more fibers form the yam.

7. The patient support of claim 6 wherein the yam is formed by spinning a plurality of the one or more fibers with an amount of twist corresponding to at least 2 twists per inch.

8. The patient support of claim 7 wherein the amount of twist provides both stretch and tensile strength to the cover.

9. The patient support of claim 6 wherein the one or more fibers are coated or provided with an additive.

10. The patient support of claim 9 wherein the additive corresponds to a polymer additive that provides anti-microbial properties to the fabric layer.

11. The patient support of claim 6 wherein the one or more fibers are shaped non- symmetrically to provide substantial stain resistance between fibers and substantially prevent seepage and coagulation with respect to the fabric layer.

12. The patient support of claim 11 wherein the one or more fibers are shaped according to at least one of a bean shape, a dog-bone shape, and a trilobal shape.

13. The patient support of claim 6 wherein the one or more fibers include at least one of nylon, acrylic, and polypropylene.

14. The patient support of claim 6 wherein at least one of a draw and a crimp is applied to the one or more fibers.

15. The patient support of claim 1 wherein the fabric layer is formed by knitting the yam according to one of a warp knit, tricot knit, or raschel knit.

16. The patient support of claim 15 wherein the yam is knit with an amount of warps per inch that is greater than 24.

17. The patient support of claim 15 wherein a knit structure of the fabric layer provides moisture wicking and heat dissipation.

18. The patient support of claim 1 wherein the coating layer is a polyurethane coating layer that is laminated by an adhesive layer to the fabric layer.

19. The patient support of claim 1 wherein the coating layer is an extrusion coating that is melted onto the fabric layer.

20. A cover for a patient support adapted to be disposed on a hospital bed, the cover comprising: a fabric layer with a first side and a second side, the fabric layer defined by a yam provided in a weave or knit; and a coating layer provided on the first side of the fabric layer, the coating layer being bonded to the yam of the fabric layer or adhered to the fabric layer via a polycarbonate adhesive.

21. The cover of claim 20 wherein the coating layer is thermally bonded to the yam of the fabric layer.

22. The cover of claim 21 wherein the coating layer is directly bonded to the yam of the fabric layer.

23. The cover of claim 20 wherein the yam is formed by one of dry spun short stable, dry spun filament fibers, or melt spun filament.

24. The cover of claim 20 wherein the yam is formed by a monofilament.

25. The cover of claim 20 wherein one or more fibers form the yam.

26. The cover of claim 25 wherein at least one of a draw and a crimp is applied to the one or more fibers.

27. The cover of claim 25 wherein the yam is formed by spinning a plurality of the one or more fibers with an amount of twist corresponding to at least 2 twists per inch.

28. The cover of claim 27 wherein the amount of twist provides both stretch and tensile strength to the cover.

29. The cover of claim 25 wherein the one or more fibers are coated or provided with an additive.

30. The cover of claim 29 wherein the additive corresponds to a polymer additive that provides anti-microbial properties to the fabric layer.

31. The cover of claim 25 wherein the one or more fibers are shaped non-symmetrically to provide substantial stain resistance between fibers and substantially prevent seepage and coagulation with respect to the fabric layer.

32. The cover of claim 31 wherein the one or more fibers are shaped according to at least one of a bean shape, a dog-bone shape, and a trilobal shape.

33. The cover of claim 25 wherein the one or more fibers include at least one of nylon, acrylic, and polypropylene.

34. The cover of claim 20 wherein the fabric layer is formed by knitting the yam according to one of a warp knit, tricot knit, or raschel knit.

35. The cover of claim 34 wherein the yam is knit with an amount of warps per inch that is greater than 24.

36. The cover of claim 35 wherein a knit structure of the fabric layer provides moisture wicking and heat dissipation.

37. The cover of claim 20 wherein the coating layer is a lamination coating provided between the fabric layer and a polyurethane coating layer.

38. The cover of claim 20 wherein the coating layer is an extrusion coating that melted onto the fabric layer.

39. A patient support for a hospital bed, said patient support comprising: a pressure distribution layer operable to support a patient and distribute pressure with respect to a patient; and a cover according to claim 20, the cover disposed between the pressure distribution layer and the patient.

0. A hospital bed comprising: a patient support according to claim 39; a frame including a deck surface that supports the patient support; and a barrier mounted to the frame.

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