Machine-washable viscoelastic foam and devices made therefrom

Abstract

A cushioning device containing a machine-washable polyurethane viscoelastic foam.

What is claimed is: 
     
         1 . A machine-washable cushioning device comprising a polyeurethane viscoelastic foam layer having thickness of 0.5-1.5 cm, wherein the viscoelastic foam has density of 1-3 lb/ft 3 , ILD rating of 3-12 lbs, recovery time of 3-7 seconds, and airflow of about 30 to 110. 
     
     
         2 . The cushioning device according to  claim 1 , wherein the device is one of a pillow, a pillow protector, a mattress pad, or a bed sheet. 
     
     
         3 . The cushioning device according to  claim 1 , further comprising a cover layer and a backing layer, wherein the polyeurethane viscoelastic foam layer is quilted between the cover layer and the backing layer. 
     
     
         4 . The cushioning device according to  claim 3 , wherein the quilting includes a circular or parallelogram pattern, and wherein the diameter or diagonal length of each circle or parallelogram is 1-4 inches. 
     
     
         5 . The cushioning device according to  claim 3 , further comprising a polyester padding layer between the cover layer and the backing layer. 
     
     
         6 . The cushioning device according to  claim 4 , wherein the cover layer is selected from the group consisting of cotton, polyester, lyocell, microfiber, and combinations thereof, and wherein the backing layer includes one of polypropylene and a polyester blend. 
     
     
         7 . The cushioning device according to  claim 1 , wherein the device is a pillow, and wherein the pillow is filled with a synthetic washable filler. 
     
     
         8 . The cushioning device according to  claim 8 , wherein the synthetic washable filler is selected from the group consisting of polyester, polyester ball fiber, microveneer, down, foam, and combinations thereof. 
     
     
         9 . The cushioning device according to  claim 1 , wherein the viscoelastic foam has an ILD rating of 7-9 lbs. 
     
     
         10 . A viscoelastic foam article having thickness of 0.5-1.5 cm, wherein the viscoelastic foam has density of 1-3 lb/ft 3 , ILD of 3-12 lbs, recovery time of 3-7 seconds, and airflow of about 30 to 110. 
     
     
         11 . A method of laundering a cushioning device, comprising:
 providing a cushioning device having a viscoelastic foam layer, wherein the viscoelastic foam layer has a thickness of 0.5-1.5 cm, a density of 1-3 lb/ft 3 , an ILD rating of 3-12 lbs, a recovery time of 3-7 seconds, and airflow of about 30 to 110;   washing the cushioning device in a washing machine for one cycle of the washing machine; and   drying the cushioning device in a dryer for one cycle of the dryer.   
     
     
         12 . The method of  claim 11 , wherein the one cycle of the dryer is a heat cycle. 
     
     
         13 . The method of  claim 11 , wherein the device is one of a pillow, a pillow protector, a mattress pad, or a bed sheet. 
     
     
         14 . The method of  claim 11 , wherein the cushioning device further comprises a cover layer and a backing layer, wherein the viscoelastic foam layer is quilted between the cover layer and the backing layer. 
     
     
         15 . The method of  claim 14 , wherein the quilting includes a circular or parallelogram pattern, and wherein the diameter or diagonal length of each circle or parallelogram is between 1 to 4 inches. 
     
     
         16 . The method of  claim 14 , wherein the cushioning device further comprises a polyester padding layer between the cover layer and the backing layer. 
     
     
         17 . The method of  claim 11 , wherein the cushioning device is loaded from a front side of the washing machine. 
     
     
         18 . The method of  claim 11 , wherein the cushioning device is loaded from a top side of the washing machine.