Support cushions including a support insert surrounded by foam rails for directing air flow, methods for controlling surface temperature of same, and methods for manufacturing same

A support cushion, comprising:

• a body supporting layer having a first surface and a second surface opposite the first surface;
• an air distribution layer positioned adjacent to the first surface of the body supporting layer, the air distribution layer including a base plate and foam rails positioned at least around a perimeter of the base plate to define a cavity, and the air distribution layer further including a support insert positioned within the cavity;
• and
• a fan operably connected to the air distribution layer, the fan for providing air flow into the cavity of the air distribution layer such that the air flow is directed through the support insert and into and through the body supporting layer,
• wherein the foam rails are comprised of a substantially air impermeable foam and the support insert is substantially air permeable such that air provided into the cavity of the air distribution layer spreads through the support insert before flowing into and through the body supporting layer.

A method of manufacturing a support cushion, comprising the steps of:

• providing an air distribution layer defining a cavity on a top of the air distribution layer, the cavity having a bottom surface and side surface;
• positioning a support insert within the cavity on the bottom surface of the cavity with the side surface of the cavity surrounding the support insert such that only an upper side of the support insert opposite from the bottom surface of the cavity is left exposed;
• and
• positioning a body supporting layer over the top of the air distribution layer, the body supporting layer having a first surface and second surface opposite the first surface and defining a plurality of channels extending from the first surface to the second surface, the plurality of channels substantially aligned with the cavity of the air distribution layer;
• wherein the side surface of the cavity of the air distribution layer is comprised of a substantially air impermeable foam and the support insert is substantially air permeable, such that air provided into the cavity of the air distribution layer spreads through the support insert before flowing into and through the body supporting layer.