Body support modified with viscous gel and method of manufacturing a body support using the same

Abstract

A body support cushion, such as a mattress, mattress topper or overlay, or pillow, is comprised of a layer of flexible foam and further has a volume of gelatinous material, e.g., elastomer gel, applied to a surface thereof. The gelatinous material alters a physical property, such as firmness or feel, of the layer of flexible foam. The gelatinous material can be applied in a number of ways including, but not limited to a spray application whereupon the spray force can be used to control how much gelatinous material penetrates into the layer of foam. The foam layer may be comprised of reticulated or non-reticulated foam. The foam layer may also be comprised of viscoelastic or non-viscoelastic foam.

I claim: 
     
         1 . A body support cushion, comprising:
 a layer of flexible polyurethane foam having an upper surface defining a top surface of the body support cushion and a lower surface opposite the upper surface;   a gelatinous layer formed in the layer of flexible polyurethane foam and altering a physical property of the polyurethane foam.   
     
     
         2 . The body support cushion of  claim 1  wherein the gelatinous layer is spray-applied to the upper surface. 
     
     
         3 . The body support cushion of  claim 1  wherein the gelatinous layer substantially covers the upper surface. 
     
     
         4 . The body support cushion of  claim 3  wherein the gelatinous layer entirely covers the upper surface. 
     
     
         5 . The body support cushion of  claim 1  wherein the gelatinous layer is comprised of a single layer of gel elastomer that is flowable prior to setting and that assumes a deformable and elastic shape when set. 
     
     
         6 . The body support cushion of  claim 1  wherein the gelatinous layer is comprised of a single layer of polyurethane gel having a hardness of no greater than 90 Shore OOO and no less than about 10 Shore OOO at an ambient temperature between 21-23 degrees Celsius. 
     
     
         7 . The body support cushion of  claim 6  wherein the polyurethane gel has a density of no less than about 100 kg/m 3  and no greater than about 1500 kg/m 3  at a temperature between 0 degrees Celsius and 100 degrees Celsius. 
     
     
         8 . The body support cushion of  claim 6  where the single layer of polyurethane gel permeates the upper surface of the first layer of polyurethane foam to a depth of no less than 1 mm and no more than 5 mm. 
     
     
         9 . The body support cushion of  claim 1  wherein the layer of polyurethane foam is comprised of viscoelastic foam. 
     
     
         10 . The body support cushion of  claim 9  wherein the viscoelastic foam is reticulated viscoelastic foam. 
     
     
         11 . The body support cushion of  claim 9  wherein the viscoelastic foam is temperature-sensitive viscoelastic foam. 
     
     
         12 . The body support cushion of  claim 1  wherein the gelatinous layer alters a feel of the top surface of the layer of flexible polyurethane foam. 
     
     
         13 . The body support cushion of  claim 12  wherein the gelatinous layer increases a firmness of the top surface of the layer of flexible polyurethane foam. 
     
     
         14 . The body support cushion of  claim 12  wherein the gelatinous layer decreases a firmness of the top surface of the layer of flexible polyurethane foam. 
     
     
         15 . A mattress comprising:
 first and second layers of foam arranged in a stacked arrangement with an upper surface of the first layer of foam defining a top surface of the mattress; and   elastomer gel applied to at least one of the first and second layers of foam, and wherein the elastomer gel is flowable during application and penetrates into the at least one layer of foam to a depth of at least 1.0 mm.   
     
     
         16 . The mattress of  claim 15  further comprising a third layer of foam that provides support for the first and second layers of foam, and wherein the third layer of foam has an upper surface containing elastomer gel. 
     
     
         17 . The mattress of  claim 15  wherein the first and second layers is each viscoelastic foam. 
     
     
         18 . The mattress of  claim 17  wherein at least of the first and second layers is reticulated viscoelastic foam. 
     
     
         19 . The mattress of  claim 15  wherein the elastomer gel includes phase change material dispersed therein. 
     
     
         20 . A mattress comprising:
 first and second layers of foam arranged in a stacked arrangement with the first layer of foam defining an uppermost foam layer of the mattress;   viscous gel dispersed in at least one of the first and second layers; and   phase change material dispersed in at least one of the first and second layers.