Pressure adjustable foam support apparatus

#This invention relates to a pressure adjustable foam support apparatus and to a method of producing a body supporting structure with adjustable levels of density and firmness (IFD) simulating those of viscoelastic foam or latex foam.

#Recently, high density viscoelastic foam has been used in mattresses, mattress toppers and support pads. This material, which was originally developed for NASA, exhibits a slow recovery time after an external pressure is applied to it. Viscoelastic foam products are intended to conform with the contours of the user's body and provide improved comfort and support. Unfortunately, conventional viscoelastic foam presents a number of disadvantages. Due to its high density (typically in excess of 3 lbs/ft3), this material is quite bulky and heavy. A standard viscoelastic pad typically weighs approximately 3-4 times as much as a comparably sized standard, low density polyurethane foam pad. This makes the high density foam quite difficult and inconvenient to handle, transport and maneuver. The viscoelastic product is also considerably more expensive, about 3-5 times more expensive at the manufacturing level than low density polyurethane foam. Furthermore, conventional viscoelastic foam is not pressure adjustable to meet the individual user's needs, since it's cell structure is so tight that it is difficult to deflate, self-inflate, or pass air through the cells. Moreover, if air is vacuumed from a visco foam core, this foam will typically densify rapidly, and become uncomfortably hard.

#Various self-inflating and pressure adjustable foam mattresses have been developed. See for example, Lea et al., U.S. Pat. No. 3,872,525, Nissen, U.S. Pat. No. 5,023,133, Bridgens, U.K. Patent No. 984,604 and my previous U.S. Pat. No. 6,038,722. To date, these devices have been particularly designed for outdoor and recreational use. None of the self-inflating mattresses or cushions are suitable for use in conventional indoor, bedroom or healthcare applications. For example, the Lea product is very thin and employed primarily as a camping mat. It is difficult to successfully adjust the pressure in the Lea mattress or to provide for desired levels of comfort because of the relative thinness of the item. If a user is lays upon the Lea mattress with the valve open, the foam cushion fully deflates almost immediately because the mat is very thin (i.e. 2″-3″). It is very difficult, if not impossible, to adjust the pressure and comfort level in either this or the other known products. A user lying on a mat of this type is simply unable to accomplish this. In fact, to date, self-inflating polyurethane foam mattresses have been utilized in only a fully inflated or fully deflated condition. Intermediate air pressure adjustment has not been exhibited in any of these devices. Nor has pressure adjustment been exhibited to date in any indoor foam mattress, mattress topper or healthcare mattress.

#Other objects, features and advantages will occur from the following description of preferred embodiments and the accompanying drawings, in which:

#FIG. 1 is a perspective, partly schematic view of a pressure adjustable foam support apparatus according to this invention;

#FIG. 2 is a perspective, partly cut away view of a representative air passageway, baffle and foam core of the support apparatus;

#There is shown in FIG. 1 a pressure adjustable foam support apparatus 10 comprising a body supporting component 12 that is releasably and adjustably interengaged with a conventional vacuum pump 13. Body supporting component 12 may comprise a mattress, mat, pad, cushion or virtually any other type of body supporting item. Component 12 is suitable for supporting humans as well as animals. Apparatus 10 is particularly adapted for indoor use although it may be used in a wide variety of indoor and outdoor applications. For example, the body supporting component 12 may be used in conjunction with a piece of furniture or it may serve as a floatation device for a pool.

#Component 12 may have assorted sizes and shapes. For example, component 12 may be rectangular as shown. Alternatively, it may include various non-rectangular configurations. The support component may have a size and thickness such that is suitable for use as a mattress, mattress topper, sofa bed, hospital mattress or mat or chair cushion, an exercise mat or a pet cushion. Representative dimensions for the body supporting component, when it is used as a mattress, are as follows:

#Twin:74″ in length x 39.6″ in width x 7″ thickness