Support apparatus with gel layer

Abstract

The invention provides a support apparatus comprising a gel layer. In one embodiment, the gel layer is overlying one or more additional support layers. The gel layer comprises a gel, such as a polyurethane gel, and optionally comprises one or more fillers, which can be a natural or synthetic material. The support apparatus includes apparatuses, such as mattresses, chairs and other furniture, and cushions.

1 . An apparatus for supporting at least a portion of the body thereon, said apparatus comprising a gel layer overlying one or more additional support layers, wherein said gel layer comprises a gel having a hardness in the range of about 0.5 kPa to about 50 kPa.  
   
   
       2 . The apparatus according to  claim 1 , wherein said gel exhibits a hysteresis of about 15% to about 80%.  
   
   
       3 . The apparatus according to  claim 2 , wherein said gel exhibits a hysteresis of about 25% to about 60%.  
   
   
       4 . The apparatus according to  claim 1 , wherein said gel has a hardness in the range of about 1.5 kPa to about 30 kPa.  
   
   
       5 . The apparatus according to  claim 1 , wherein said one or more additional support layers is selected from the group consisting of a foam layer, a spring layer, a textile layer, a gas layer, a wood layer, a metal layer, a plastic layer, and combinations thereof.  
   
   
       6 . The apparatus according to  claim 1 , further comprising a covering overlying said gel layer.  
   
   
       7 . The apparatus according to  claim 6 , wherein said covering is selected from the group consisting of a textile layer, a film layer, a coating layer, and a foam layer.  
   
   
       8 . The apparatus according to  claim 1 , wherein said apparatus is selected from the group consisting of a mattress, a seating apparatus, a pillow, a mattress topper, a footwear cushion, an arm pad, and a wrist rest.  
   
   
       9 . The apparatus according to  claim 1 , wherein there are no additional support layers positioned above said gel layer.  
   
   
       10 . The apparatus according to claims  1 , wherein said gel layer comprises a polyurethane gel.  
   
   
       11 . The apparatus according to  claim 1 , wherein said apparatus is a mattress comprising a gel layer overlying a foam layer, wherein said gel layer comprises a polyurethane gel having a hardness in the range of about 0.5 kPa to about 50 kPa and exhibiting a hysteresis of about 15% to about 80%.  
   
   
       12 . The apparatus according to  claim 1 , wherein said gel hardness is measured according to the method of ISO 3386-1.  
   
   
       13 . The apparatus according to  claim 1 , wherein said hardness represents the force deflection of a 5 cm×5 cm×2.5 cm sample of said gel at 40% compression.  
   
   
       14 . The apparatus according to  claim 1 , wherein said gel layer is integrally attached to at least one of said one or more additional support layers.  
   
   
       15 . The apparatus according to  claim 1 , wherein said one or more additional support layers comprises a foam layer.  
   
   
       16 . The apparatus according to  claim 15 , wherein said foam is convoluted foam.  
   
   
       17 . The apparatus according to  claim 15 , wherein said foam comprises one or more cavities for receiving said gel layer.  
   
   
       18 . The apparatus according to  claim 15 , wherein said gel layer and said foam layer are chemically bonded together.  
   
   
       19 . The apparatus according to  claim 15 , wherein said foam layer has a thickness of at least about 5 cm, said apparatus further comprises at least one covering overlying said gel layer, said covering being selected from the group consisting of textile layer, a film layer, a coating layer, and a foam layer, and wherein said at least one covering has a thickness of less than about 5 cm.  
   
   
       20 . The apparatus according to  claim 1 , wherein said apparatus is a mattress topper comprising a gel layer overlying a foam layer, wherein said gel layer comprises a polyurethane gel having a hardness in the range of about 0.5 kPa to about 50 kPa and exhibiting a hysteresis of about 15% to about 80%, and wherein said foam layer has a thickness of less than about 5 cm.  
   
   
       21 . The apparatus according to  claim 1 , wherein said gel comprises a content of one or more fillers.  
   
   
       22 . The apparatus according to  claim 21 , wherein said one or more fillers are selected from the group consisting of cork pieces, cork flour, wood pieces, wood chips, foam flakes, textile fibers, textile pieces, paraffins, hollow spheres, synthetic microspheres, mineral particles, glass beads, gasses, active agents, nanoparticles, and mixtures thereof.  
   
   
       23 . The apparatus according to  claim 21 , wherein said gel filled with said one or more fillers has a thermal conductivity of less than about 0.20 W·m −1 ·°K −1 .  
   
   
       24 . The apparatus according to  claim 23 , wherein said gel filled with said one or more fillers has a thermal conductivity of less than about 0.10 W·m −1 ·°K −1 .  
   
   
       25 . The apparatus according to  claim 23 , wherein said one or more fillers comprise about 5% to about 95% of said gel, on a volume basis.  
   
   
       26 . An apparatus for supporting at least a portion of the body thereon, said apparatus comprising a filled gel layer overlying one or more additional support layers.  
   
   
       27 . The apparatus according to  claim 26 , wherein said filled gel layer comprises one or more fillers selected from the group consisting of cork pieces, cork flour, wood pieces, wood chips, foam flakes, textile fibers, textile pieces, paraffins, hollow spheres, synthetic microspheres, mineral particles, glass beads, gasses, active agents, nanoparticles, and mixtures thereof.  
   
   
       28 . The apparatus according to  claim 26 , wherein said one or more fillers comprises particulate matter have an average diameter of about 0.05 mm to about 15 mm.  
   
   
       29 . The apparatus according to  claim 26 , wherein said filled gel exhibits a thermal conductivity that is less than the thermal conductivity of the gel without said one or more fillers.  
   
   
       30 . The apparatus according to  claim 26 , wherein said filled gel has a thermal conductivity of less than about 0.20 W·m −1 ·°K −1 .  
   
   
       31 . The apparatus according to  claim 30 , wherein said filled gel has a thermal conductivity of less than about 0.10 W·m −1 ·°K −1 .  
   
   
       32 . The apparatus according to  claim 26 , wherein said one or more fillers comprise about 5% to about 95% of said gel, on a volume basis.  
   
   
       33 . The apparatus according to  claim 32 , wherein said one or more fillers comprises about 20% to about 90% of said gel, on a volume basis.  
   
   
       34 . The apparatus according to  claim 26 , wherein said filled gel layer comprises a gel having a hardness in the range of about 0.5 KPa to about 50 KPa.  
   
   
       35 . The apparatus according to  claim 26 , wherein said filled gel layer comprises a gel exhibiting a hysteresis of about 15% to about 80%.  
   
   
       36 . The apparatus according to  claim 26 , wherein said one or more additional support layers is selected from the group consisting of a foam layer, a spring layer, a textile layer, a gas layer, a wood layer, a metal layer, a plastic layer, and combinations thereof.  
   
   
       37 . The apparatus according to  claim 26 , further comprising a covering overlying said filled gel layer.  
   
   
       38 . The apparatus according to  claim 37 , wherein said covering is selected from the group consisting of a textile layer, a film layer, a coating layer, and a foam layer.  
   
   
       39 . The apparatus according to  claim 26 , wherein said apparatus is selected from the group consisting of a mattress, a seating apparatus, a pillow, a mattress topper, a footwear cushion, an arm pad, and a wrist rest.  
   
   
       40 . A mattress comprising a gel layer overlying a foam layer, wherein said gel layer comprises a gel having a hardness in the range of about 0.5 kPa to about 50 kPa measured according to the method of ISO 3386-1.  
   
   
       41 . The mattress according to  claim 40 , wherein said gel exhibits a hysteresis of about 15% to about 80%.  
   
   
       42 . The mattress according to  claim 40 , further comprising one or more spring layers.  
   
   
       43 . The mattress according to  claim 40 , further comprising a covering overlying said gel layer.  
   
   
       44 . A mattress comprising a gel layer overlying a spring layer, wherein said gel layer comprises a gel having a hardness in the range of about 0.5 kPa to about 50 kPa measured according to the method of ISO 3386-1.  
   
   
       45 . The mattress according to  claim 44 , wherein said gel exhibits a hysteresis of about 15% to about 80%.  
   
   
       46 . The mattress according to  claim 44 , further comprising one or more foam layers.  
   
   
       47 . The mattress according to  claim 44 , further comprising a covering overlying said gel layer.  
   
   
       48 . A mattress topper comprising a gel layer overlying a foam layer, wherein said gel layer comprises a gel having a hardness in the range of about 0.5 kPa to about 50 kPa measured according to the method of ISO 3386-1, and wherein said foam layer has a thickness of less than about 5 cm.  
   
   
       49 . The mattress topper according to  claim 48 , wherein said gel exhibits a hysteresis of about 15% to about 80%.  
   
   
       50 . The mattress topper according to  claim 48 , further comprising a covering overlying said gel layer.  
   
   
       51 . A pillow comprising a gel layer overlying a foam layer, wherein said gel layer comprises a gel having a hardness in the range of about 0.5 kPa to about 50 kPa measured according to the method of ISO 3386-1.  
   
   
       52 . The pillow according to  claim 51 , wherein said gel exhibits a hysteresis of about 15% to about 80%.  
   
   
       53 . The pillow according to  claim 51 , further comprising a covering overlying said gel layer.  
   
   
       54 . An apparatus for supporting at least a portion of a body thereon, said apparatus comprising a gel layer comprising a gel having a hardness in the range of about 0.5 kPa to about 50 kPa measured according to the method of ISO 3386-1 and exhibiting a hysteresis of about 15% to about 80%.  
   
   
       55 . The apparatus according to  claim 54 , further comprising one or more additional support layers underlying said gel layer.  
   
   
       56 . The apparatus according to  claim 54 , further comprising a covering overlying said gel layer.  
   
   
       57 . The apparatus according to  claim 54 , wherein said apparatus is selected from the group consisting of a mattress, a mattress topper, and a pillow.  
   
   
       58 . The apparatus according to  claim 54 , wherein said gel layer further comprises one or more fillers selected from the group consisting of cork pieces, cork flour, wood pieces, wood chips, foam flakes, textile fibers, textile pieces, paraffins, hollow spheres, synthetic microspheres, mineral particles, glass beads, gasses, active agents, nanoparticles, and mixtures thereof.