BODY SUPPORT ASSEMBLY

Abstract

Body support assembly (1) having a top surface (2) and a spaced away bottom surface (3) defining a cushion volume (4) and defining side walls (5). The air permeability of the top surface (2) is higher than the air permeability of the bottom surface (3). The cushion volume (4) comprises an upper cushion zone (7) and a lower cushion zone (8) and separated by a separation sheet (9). The upper cushion zone (7) and the lower cushion zone (8) comprise of a compressible material (10) which is permeable for air in all directions. The cushion volume (4) further comprises a flow path for air comprising an air inlet (6) in the bottom surface (3), air displacement means (20), a heat exchanger (21), a flow path through the compressible material of the lower cushion zone (8), through openings in the separation sheet (9) and through the compressible material (10) of the upper cushion zone (7) and multiple air outlets as present in the top surface (2).

Claims

1. A body support assembly (1) having an air permeable top surface (2) for supporting a human body and a spaced away bottom surface (3) defining a cushion volume (4) and defining side walls (5), wherein the air permeability of the top surface (2) is higher than the air permeability of the bottom surface (3) and higher than the air permeability of the side walls (5), wherein the air permeable top surface (2) has multiple air outlets (2a) and wherein the cushion volume (4) comprises, an upper cushion zone (7) nearest to the top surface (2) and a lower cushion zone (8) and separated by a separation sheet (9) provided with openings (9a), wherein the upper cushion zone (7) and the lower cushion zone (8) comprise of a compressible material (10) which is permeable for air in all directions and a flow path for air comprising an air inlet (6) in the bottom surface (3), air displacement means (20), a heat exchanger (21), a flow path through the compressible material (10) of the lower cushion zone (8), through the openings in the separation sheet (9) and through the compressible material (10) of the upper cushion zone (7) and multiple air outlets as present in the top surface (2).

2. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2, as measured by ASTM D737.

3. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, and wherein the compressible material (10) is a three-dimensional random loop bonded structure of a thermoplastic resin.

4. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), and wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11).

5. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), and wherein the metal springs comprise Bonnell springs (11) or equivalents thereof.

6. The body support assembly according to claim 1, wherein the air permeability of the separation sheet (9) is lower than the air permeability of the top surface (2), and wherein the separation sheet (9) is a sheet of a woven spacer fabric (non-woven).

7. (canceled)

8. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), wherein the compressible material (10) in the upper cushion volume (7) comprises the material of claim 2 or 3 and wherein the compressible material (10) in the lower cushion volume (8) are metal springs (11), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an airtight cover layer (14,33), wherein the top surface (2) and the part or all of the side walls (5) is comprised of a textile cover layer (18,31), and wherein the air permeability of the textile cover layer (18,31) is higher than the air permeability of the airtight cover layer (14,33).

9. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), wherein the compressible material (10) in the upper cushion volume (7) comprises the material of claim 2 or 3 and wherein the compressible material (10) in the lower cushion volume (8) are metal springs (11), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an airtight cover layer (14,33), wherein the top surface (2) and the part or all of the side walls (5) is comprised of a textile cover layer (18,31) and wherein the air permeability of the textile cover layer (18,31) is higher than the air permeability of the airtight cover layer (14,33), and wherein the upper end (36) of the air-tight cover layer (14,33) is folded inwards and attached to the upper end (37) of the separation sheet (9) leaving most of the upper end of the separation sheet (9) not covered by said air tight cover layer (14,33).

10. The body support assembly according to claim 8, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), wherein the compressible material (10) in the upper cushion volume (7) comprises the material of claim 2 or 3 and wherein the compressible material (10) in the lower cushion volume (8) are metal springs (11), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an airtight cover layer (14,33), wherein the top surface (2) and the part or all of the side walls (5) is comprised of a textile cover layer (18,31) and wherein the air permeability of the textile cover layer (18,31) is higher than the air permeability of the airtight cover layer (14,33), wherein the textile cover layer (31) further fully covers part (35) of the side walls (5) at the elevation of the lower cushion zone (8) and the layer (30) of the material which is permeable for air in all directions, and wherein the air tight cover layer (14,33) is comprised of a single sheet and the textile cover layer (18,31) is comprised of at least two detachably connected parts of sheet of textile.

11. (canceled)

12. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), wherein the compressible material (10) in the upper cushion volume (7) comprises the material of claim 2 or 3 and wherein the compressible material (10) in the lower cushion volume (8) are metal springs (11), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an airtight cover layer (14,33), wherein the top surface (2) and the part or all of the side walls (5) is comprised of a textile cover layer (18,31) and wherein the air permeability of the textile cover layer (18,31) is higher than the air permeability of the airtight cover layer (14,33) and wherein between the bottom surface (3) is comprised of an interior layer of felt (14a) and an exterior layer of the air tight cover layer (14,33).

13. The body support assembly according to claim 1, wherein a layer (30) of a material which is permeable for air in all directions is connected to the bottom surface (3) of the body support assembly, and wherein the layer (30) is a sheet of a warp knitted spacer fabric.

14. (canceled)

15. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), wherein the compressible material (10) in the upper cushion volume (7) comprises the material of claim 2 or 3 and wherein the compressible material (10) in the lower cushion volume (8) are metal springs (11), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an airtight cover layer (14,33), wherein the top surface (2) and the part or all of the side walls (5) is comprised of a textile cover layer (18,31) and wherein the air permeability of the textile cover layer (18,31) is higher than the air permeability of the airtight cover layer (14,33) and wherein the layer (30) of a material which is permeable for air in all directions extends upwards as upward part (30a) as positioned between the air tight cover layer (33) and the textile cover layer (31).

16. (canceled)

17. The body support assembly according to claim 1, wherein the heat exchanger (21) is a Positive Temperature Coefficient (PTC) Air Heater.

18. The body support assembly according to claim 1, wherein the air displacement means (20) is a tangential fan.

19. (canceled)

20. The body support assembly according to claim 1, wherein the compressible material (10) which is permeable for air in all directions has an air permeability of greater than 10 cm.sup.3/s/cm.sup.2 as measured by ASTM D737, wherein the upper cushion volume (7) comprises the compressible material (10), wherein the compressible material (10) in the lower cushion volume (8) comprises metal springs (11), wherein the compressible material (10) in the upper cushion volume (7) comprises the material of claim 2 or 3 and wherein the compressible material (10) in the lower cushion volume (8) are metal springs (11), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an airtight cover layer (14,33), wherein the top surface (2) and the part or all of the side walls (5) is comprised of a textile cover layer (18,31) and wherein the air permeability of the textile cover layer (18,31) is higher than the air permeability of the airtight cover layer (14,33), wherein between the bottom surface (3) is comprised of an interior layer of felt (14a) and an exterior layer of the air tight cover layer (14,33), and wherein the air inlet (6) in the bottom surface (3) comprises an opening (25) in the interior layer of felt (14a) and in the exterior layer of the air tight cover layer (14,33), a frame (26) connected to the lower end of the opening (25) and connected to a matching frame positioned above the opening (25), thereby sandwiching a strip of the interior layer of felt (14a) and the exterior layer of the air tight cover layer (14,33) at the opening (25) and wherein the connected frames provide for an opening (6) for the air inlet and wherein the matching frame (27) is the support for the heat exchanger (21).

21. A method to heat a body support assembly of claim 1 having a top surface for supporting a human body and a spaced away bottom surface defining a cushion volume and defining side walls, wherein the cushion volume comprises, an upper cushion zone nearest to the top surface and a lower cushion zone and separated by a separation sheet, wherein the upper cushion zone and the lower cushion zone comprise of a compressible material which is permeable for air in all directions, and wherein ambient air flows in a flow path via an air inlet, air displacement means, a heat exchanger, a flow path through the compressible material of the lower cushion zone, through openings in the separation sheet, through the compressible material of the upper cushion zone and through the top surface.

22. (canceled)

23. (canceled)

24. (canceled)

25. A bed comprising a body support assembly according to claim 1 and a mattress support.

26. (canceled)

27. The body support assembly (1) according to claim 1, having a top surface (2) for supporting a human body and a spaced away bottom surface (3) defining a cushion volume (4) and defining side walls (5), wherein the cushion volume (4) comprises an upper cushion zone (7) nearest to the top surface (2) comprising of a compressible material (10) and a lower cushion zone (8) comprising of Bonnell springs (11) as present between the bottom surface (3) and a separation sheet (9), wherein the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of a single sheet of an air tight layer (14,33) and wherein the top surface (2) and the part of the side walls (5) is comprised of a textile cover layer (18), wherein the upper end (15) of the air tight layer (14,33) is folded inwards and attached to the upper end (16) of the separation sheet (9) and wherein the lower end of the textile cover layer (18) extends to the bottom surface (3) and is folded inwards thereby covering the side walls (5) comprised of the air tight layer (14,33) and covering part or all of the bottom surface (3) comprised of the air tight layer (14,33).

28. The body support assembly according to claim 27, wherein the compressible material (10) is a three-dimensional random loop bonded structure of a thermoplastic resin.

29. The body support assembly according to claim 28, wherein the separation sheet (9) is made of natural fibres, wherein the separation sheet (9) is a sheet of a warp knitted spacer fabric, and wherein the textile cover layer (18) covers the entire bottom surface (3) and is comprised of at least two detachably connected parts of a sheet of textile.

30. (canceled)

31. (canceled)

Description

[0063] The invention will be illustrated making use of the following FIGS. 1-10.

[0064] FIG. 1 shows a body support assembly (1) according to the invention in a 3D presentation as seen from above. The assembly (1) has a top surface (2) for supporting a human body and a spaced away bottom surface (3) defining a cushion volume (4) and defining side walls (5). The air permeable top surface (2) has multiple air outlets (2a). The air permeability of the top surface (2) is higher than the air permeability of the bottom surface (3) and higher than the average air permeability of the side walls (5).

[0065] FIG. 2 shows the body support assembly (1) of FIG. 1 as seen from below showing an air inlet (6).

[0066] FIG. 3 shows the cross-sectional view AA′ of FIG. 1 of the body support assembly (1). In this Figure an upper cushion zone (7) nearest to the top surface (2) and a lower cushion zone (8) and separated by a separation sheet (9) made of coconut fibres is shown. The sheet of coconut fibres is provided with multiple openings (9a) to allow air to pass from the lower cushion zone (8) to the upper cushion zone (7). The upper cushion zone (7) comprises of Breathair® as the compressible material (10). The lower cushion zone is comprised of Bonnell springs (11). In this figure the bottom surface (3) and the part (13) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of a single sheet (14) of a tightly woven polyester tent sheet. The upper end (15) of the tent sheet is folded inwards and attached to the upper end (16) of the coconut separation sheet (8). Attachment may by for example by means of an adhesive. The folding of the single sheet may be performed using well known Origami folding techniques. As shown a large part of the coconut separation sheet (8) is not fully covered by the tent sheet (14) leaving enough area through which air can flow from the lower cushion zone (8) to the upper cushion zone (7). A layer of felt (14a) is present as part of the bottom end (3) to provide support for the Bonnell springs (11) and provide a support to fix the heat exchanger (21) as shown in FIGS. 4, 5 and 6.

[0067] FIG. 3 also shows the top surface (2) and the part (17) of the side walls (5) is comprised of a single sheet of a textile layer (18), for example a 3D knitted ventilating textile. The lower end (19) of the textile layer (18) extends to the bottom surface (3) and is folded inwards thereby covering the entire side walls (5) and the tent sheet covered part (13) of the side walls (5) at the elevation of the lower cushion zone (8). The lower end (19) is attached to the tent sheet (14) by for example by a hook and loop type connection, such as for example a Velcro type connection. The folding of the single sheet may be performed using well known Origami folding techniques. The textile layer (18) thereby holds together the upper (7) and lower (8) cushion zone. By removing the textile layer (18) it is possible to simply remove the compressible material (10) of the upper cushion zone after which new compressible material (10) may be provided. In this manner the tent sheet encapsulated lower cushion zone (8) can be reused in combination with a new upper cushion zone. The single sheet of a textile layer is thus detachably wrapped around the cushion volume. When detached from the cushion zone the sheet of textile layer is suitably a flat sheet which is not sewed into a three-dimensional shape. This enables easier cleaning of the sheet and a simpler manufacture of the textile sheet itself.

[0068] FIG. 4 shows the cross-sectional view BB′ of FIG. 2 of the body support assembly (1). In addition to the elements shown in FIG. 3 an air inlet (6), a fan (20) and a heat exchanger (21) is schematically shown. Further a heated air outlet (22) in fluid communication with the lower cushion zone (8) is present through which heated air flows from the heat exchanger (21) to the lower cushion zone (8). The dimensions and properties of the coconut fibre separation sheet are so chosen that air flowing to the upper cushion zone is evenly distributed. A suitable coconut fibre separation sheet may have a thickness of between 1 and 2 cm. The height of the lower cushion zone (8) may be between 8 and 15 cm. The height of the upper cushion zone (7) may be between 4 and 8 cm. The distance between top surface (2) bottom surface (3) may be between 14 and 25 cm.

[0069] FIGS. 5 and 6 show the fan (20)-heat exchanger (21) combination in more detail. The various elements are shown in an exploded view in FIG. 5. In FIG. 6 a cross section of the fan (20)-heat exchanger combination (21) is shown. The heat exchanger and fan are placed in a box like casing (24). Heat exchanger (21) is provided with electric-resistance heating coils (23) as placed in heated air outlet (22). The air inlet (6) in the bottom surface (3) comprises an opening (25) in interior layer of felt (14a) and in the exterior layer of the air tight cover layer (14). To this opening (25) a frame (26) is connected to the lower end of the felt bottom surface (3) and a matching frame (27) is positioned above the felt bottom surface. The two frames (26,27) are connected by means of multiple connectors (28), for example plug (28a) and lock rings (28b), thereby sandwiching a strip of felt layer at the opening (6). The two frames (26,27) as present in opening (25) form air inlet (6). In this opening (6) an air filter (29) is positioned as shown in FIG. 6. The matching frame (27) serves as support for the box like casing (24). The fan (20) is a tangential fan.

[0070] FIG. 7 shows a cut open body support assembly of FIGS. 3 and 4.

[0071] FIG. 8 shows the cross-sectional view of a body support assembly similar to FIG. 4. The common reference numbers have the same meaning as in FIG. 4. In FIG. 8 a layer (30) of a polyester warp knitted spacer fabric is present at the lower end (3) of the body support assembly (1). This layer is connected or held in place by a textile cover (31), made of a 0.5 cm thick layer of a polyester 3Mesh Smart Spacer Fabric which is permeable for air.

[0072] The layer (31) may be prepared from a single material, or may comprises two or more different materials with slightly different air permeability, e.g. polyester wadding combined with a 3Mesh spacer fabric. This combination allows for an easier bending and fit at corners and bends.

[0073] This textile cover layer (31) covers the upper end of the top surface (2), the side walls (5) of the body support assembly and the lower end (32) of the layer (30) warp knitted spacer fabric. The textile cover layer (31) is made of two detachable parts which are connected by a zipper (31a). A layer of felt (14a) is present as part of the bottom end (3) to provide support for the Bonnell springs (11) and provide a support to fix the heat exchanger (21) as shown in FIGS. 4, 5 and 6.

[0074] The separation sheet is a layer (34) of polyester warp knitted spaces fabric. This layer (34) redistributes air and further prevents the Breathair® material to be partially compressed into the openings of the Bonnell springs (11). The bottom surface (3) and the part (35) of the side walls (5) at the elevation of the lower cushion zone (8) is comprised of an air tight cover layer (33) made of a tightly woven polyester tent sheet having a thickness of about 1.5 mm. The upper end (36) of layer (34) is folded inwards and attached to the upper end (37) of layer (34) leaving an opening (38) for air to flow from the lower cushion zone (8) to the upper cushion zone (7). Upper end (36) may be connected to the upper end (37) by any means, such as sewing. Preferably such connection is detachable by for example using hooks or strips of hook and loop fasteners. For illustration purposes the height of the upper cushion zone may be 5 cm, the thickness of the separation sheet (34) may be 2 cm, the height of the lower cushion zone may be 15 cm and the thickness of layer (30) may be 2.5 to 3 cm.

[0075] The composition, e.g. the Breathair® compressible material (10), the layer (34), layer (30), sheet (31) and sheet (33) of the illustrated body support assembly in FIG. 8 may be chosen to be mainly composed of, and made of polyester, thereby resulting in a body support assembly that is more easily recyclable.

[0076] When an assembly of FIG. 8 is positioned on a box spring matrass support (39), or a similarly air impervious support as shown in FIG. 9 air will enter layer (30) as indicated by arrows (40) and leave the assembly (1) as indicated by arrows (41). Layer 30 preferably has a thickness in the range of from 10 to 40 mm, preferably of from 20 to 30 mm. This thickness, combined with the high air permeability, was found to permit to provide the fan with sufficient air inflow. FIG. 10 shows a body support assembly on a box spring support (39) as in FIG. 9 except that layer (30) extends upwards as upward layer part (30a) at the elevation of the lower cushion zone (8). Upward layer part (30a) hereby covers all 4 side wall parts thereby covering part of the air tight cover layer (33). The textile cover layer (31) remains the outer layer at the side walls (5). Air can enter the layer (30) also via the upward layer part (30a) as indicated by arrows (40) and flow to inlet (6) because layer (30) and upward part layer (30a) are fluidly connected, suitably made from a single piece of material. This design is advantageous because air will have more opportunities to flow to air inlet (6). This is especially advantageous when body support assemblies are positioned next to each other or next to a wall.