Patent Application
20250108945
The subject matter disclosed herein relates generally to a body support, mattress, or other cushioning device that includes a valve system. More particularly, the subject matter relates to a method for packing a body support that allows for ease of compression and fluid volume removal for packaging and/or transportation.
In the medical field, body supports such as cushioning devices or mattresses including a plurality of fluid cells are often used to provide support for a patient. These fluid cell deploying cushioning devices may also be used in non-medical fields of use, including consumer bedding, hotels or the like. Such fluid cells may include a reforming element within, such as a form or other structure, in order to maintain shape, self-inflate and respond to pressure changes caused by a body resting or laying on the cushioning device or mattress. These systems typically intake fluid or air from the atmosphere and exhaust fluid into the atmosphere in order to achieve dynamic pressurization within the fluid cells. However, the fluid cells in these mattresses and cushioning devices are voluminous, making the structure of the mattress or cushioning devices very large and cumbersome for the purpose of transportation from a manufacturing site to a sales, distribution or ultimate deployment location such as a medical facility, hotel or customer home.
Thus, a body support such as a cushioning device or mattress having a valve system allowing for compression of the fluid cells for the purpose of packaging and/or transportation would be well received in the art.
According to a first described aspect, a body support is configured to support a weight up to a maximum weight limit. The body support comprises: at least one self-inflating fluid cell, each of the at least one self-inflating fluid cell containing a reforming element; a blow-off valve attached to the at least one self-inflating fluid cell or a manifold system interconnecting the at least one self-inflating fluid cells. The blow-off valve opens at a blow-off pressure that is higher than a maximum working pressure that occurs when the body support is supporting the maximum weight limit.
According to a second described aspect, a method of packing a body support configured to support a weight up to a maximum weight limit comprises: providing the body support, the body support including: at least one self-inflating fluid cell, each of the at least one self-inflating fluid cell containing a reforming element; a blow-off valve attached to the at least one self-inflating fluid cell or a manifold system interconnecting the at least one self-inflating fluid cell. The blow-off valve opens at a blow-off pressure that is higher than a maximum working pressure that occurs when the body support is supporting the maximum weight limit; compressing the body support with a compression machine to open the blow-off valve. The method further includes removing fluid through the blow-off valve from the at least one self-inflating fluid cell during the compressing.
According to a third described aspect, a body support comprises: at least one self-inflating fluid cell containing a reforming element, each of the at least one self-inflating fluid cell containing a reforming element; at least one pressure relief valve operably attached to the at least one self-inflating fluid cell or a manifold interconnecting the at least one self-inflating fluid cell, the at least one pressure relief valve configured to be controllable to allow for a maximum operable pressure level to be maintained within the at least one self-inflating fluid cell during body support use; and a blow-off valve attached to the at least one self-inflating fluid cell or the manifold system. The blow-off valve opens at a blow-off pressure that is higher than the maximum operable pressure level.
The subject matter disclosed herein is distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Embodiments described herein relate to a body support system having one or more fluid cells. The body support system may be, e.g., a mattress, cushion, pad or the like, and incorporates a novel blow-off valve system to aid in compression of the fluid cells for the purpose of packaging and/or transportation of the body support system. Various embodiments of body support systems are contemplated, including systems having one or more manifolds, operable pressure relief valves, self-inflating fluid cells, check valves, or the like. However, in any of these embodiments, it is contemplated herein that one or more blow off valves are additionally added to the fluidic system which opens at a blow-off pressure that is higher than a maximum working pressure that occurs when the body support is supporting the maximum weight limit. In other words, the blow off valve(s) are configured to be inoperable during usage of the body support system by a person sitting, laying or otherwise being supported by the body support system. Instead, the blow off valve will be configured to only activate and open at a high pressure created by a packing process, such as a machine compression process and/or a roll packing process or the like. The blow off valves, when activated and opened may be configured to expel air from the fluid cells of the body support system at a rapid rate to allow for fast packing and volume and/or mass removal of the body support system for the purposes of transportation.
Referring now to the Figures,
The body support 10 includes at least one self-inflating fluid cell 12a, 12b, 12c, 12d, 12e, 12f, 12g, 12h for providing lifting support for a patient, user, sleeper or other person. While the body support 10 is shown including eight separate self-inflating fluid cells 12a, 12b, 12c, 12d, 12e, 12f, 12g, 12h, this is an exemplary embodiment. It is contemplated that the blow-off valve system and methods described herein may be applied to a body support having any number of fluid cells, including a single self-inflating fluid cell having a reforming element such as a foam structure contained therein. In a single self-inflating fluid cell embodiment one or more blow off valves may be directly attached to the single self-inflating fluid cell, or a fluid conduit extending therefrom. When more than one self-inflating fluid cell is deployed in a body support, the one or more blow off valves may be attached directly to the plurality of self-inflating fluid cells, or may be attached at one or more locations of a manifold interconnecting the plurality of self-inflating fluid cells, as shown in the embodiments in
As shown in
Each of the self-inflating fluid cells 12 may include an envelope and a reforming element located within the envelope. The envelope may be configured to contain fluid, such as air or the like. The envelope may be fluid-tight or air-tight in order to contain the fluid without leakage. The application of an external load may cause the envelope to deform into a compressed form. The reforming element may be a foam or other resilient material. In another example, the reforming element may be a coiled sprint or bellows made of a resilient material (such as forming a helical pattern). A coiled spring reforming element may be surrounded by a resilient material. A bellows reforming element may be formed from a pliable resilient material such as plastic and filled with a fluid such as air. Whatever the embodiment, the reforming element may provide a reforming force to the interior surface of the envelope of the self-inflating fluid cell.
The manifold system 20 of the body support 10 shown includes a first interconnected manifold 22a and a second interconnected manifold 22b. The first manifold 22a connects alternating self-inflating fluid cells 12a, 12c, 12e, 12g while the second manifold 22b connects alternating self-inflating fluid cells 12b, 12d, 12f, 12h. While there may be two groups of cells in the embodiment shown, it should be understood that any number of groups or zones of cells are contemplated, connected by one or more manifolds in any manner.
Each of the self-inflating fluid cells 12 includes a port 30. The port 30 may be a valve, connection, port or the like. In some embodiments, the port 30 for one or more of the self-inflating fluid cells 12 may be a T-valve or port. The port 30 may connect one or more fluidic tubes 32 extending between the alternating self-inflating fluid cells 12 of the manifold 22. The ports 30 may be configured to both intake fluid into an attached self-inflating fluid cell 12, or may configured to expel fluid from an attached fluid cell into the manifold system 20. While not shown, other embodiments contemplated may include multiple ports connected to each self-inflating fluid cell 12, such as one exhaust-only valve and one intake-only valve.
As shown, the first manifold 22a extends, at a first end 34 of the body support 10, to a first combination of valves. Similarly, the manifold 22b extends, at a second end 26 of the body support 10, to a second combination of valves. The first combination of valves connected at the first end 34 of the first manifold 22a includes a port 38 which is configured to split the manifold 22a into three separate pathways. The separate pathways may be fluidic pathways which are each split from the port 38. The fluidic pathways may be fluidic tubes, for example, which extend from the port 38 to respective valves.
A first pathway extends to a one-way intake check valve 40. This check valve 40 may be configured to intake fluid from a fluid reservoir. Preferably, the fluid included in the fluid reservoir(s) contemplated herein is air, however, any suitable fluid, e.g., water or nitrogen, can be used. The fluid reservoirs contemplated herein may comprise the same reservoir, and may comprise an ambient source of fluid such as atmospheric air. The fluid reservoirs may be the open atmosphere in a room in which the body support 10 resides.
A second pathway extends to a pressure relief valve 42. The pressure relief valve 42 may be set to open at a particular predetermined pressure within the first manifold 22a in order to thereafter allow fluid from within the first manifold 22a to escape from the body support 10 system into the fluid reservoir (ambient air, etc). The pressure relief valve 42 may further be a controllable or adjustable pressure relief valve. The pressure relief valve 42 may control the maximum pressure level of the fluid in the first manifold 22a and in each of the alternating self-inflating fluid cells 12a, 12c, 12e, 12g. A rotatable knob or other adjusting mechanism on the pressure relief valve 42 allows a user to adjust the regulated maximum pressure level. Different selected maximum allowable pressures in the self-inflating fluid cells 12a, 12c, 12e, 12g allow the body support 10 to accommodate patients of different weights. Also, the setting of different maximum allowable pressures in the self-inflating fluid cells 12a, 12c, 12e, 12g allows different degrees of conformation between the patient and the surface of each envelope. The maximum pressure is preferably set to ensure that the interface pressure under the entire contact surface of the patient is below the pressure that may cause tissue damage. The body support 10 of the present invention allows a user in the field to adjustably set the maximum pressure level in each self-inflating fluid cells 12a, 12c, 12e, 12g. The maximum pressure is preferably above about 6 inches of water but is optimally in the range of about 8 to 12 inches of water, for example. Other ranges may also be used, depending on operational requirements, user preferences, etc.
A third pathway extends to a blow off valve 44. The blow off valve may thus be attached to at least one of the plurality of self-inflating fluid cells 12a, 12c, 12e, 12g or the manifold system. The blow-off valve 44 may be configured to open at a blow-off pressure (i.e. cracking pressure) that is higher than a maximum working pressure that occurs when the body support 10 is supporting the maximum weight limit. The blow-off valve 44 is located in the first manifold 22a and/or in the manifold system 20 such that fluid from the plurality of self-inflating fluid cells 12a, 12c, 12e, 12g does not flow through the pressure relief valve 42 when the fluid leaves the body support 10 from the blow-off valve 44. The blow-off valve 44 may be structured to provide a higher volume flow rate of airflow when opened than a volume flow rate of the pressure relief valve 42 at the same pressure level. For example, the volume flow rate of the blow-off valve 44 may be at least three times the volume flow rate of the pressure relief valve 42 at the same pressure level. Alternatively, the volume flow rate of the blow off valve 44 may be twice the volume flow rate of the pressure relief valve 42 at the same pressure level. However, any volume flow rate is contemplated, such as three times, four times, five times or the like. The cracking pressure of the blow off valve 44 may be greater than 10 psi, for example. In various embodiments, the cracking pressure of the blow off valve 44 may be 15, 20, 25, 35, 50 or 74 psi, or any pressure therebetween. In some embodiments, the blow off valve 44 may have a cracking pressure of the blow-off valve is adjustable. The blow-off valve 44 may be configured to be permanently deactivated after at least one opening sequence.
Similar to the first manifold 22a, the second manifold 22b extends, at a second end 36 of the body support 10, to the second combination of valves. Like the first combination of valves connected to the first manifold 22a, the second combination of valves connected at the second end 36 of the second manifold 22b includes a port 48 which is configured to split the second manifold 22b into three separate pathways. A first pathway extends to a one-way intake check valve 50. The check valve 50 may be configured to intake fluid from a fluid reservoir (such as the ambient air, atmosphere, etc.).
A second pathway extends to a pressure relief valve 52. The pressure relief valve 52 may be set to open at a particular predetermined pressure within the second manifold 22b in order to thereafter allow fluid from within the second manifold 22b to escape from the body support 10 system into the fluid reservoir (ambient air, etc). The pressure relief valve 52 may further be a controllable or adjustable pressure relief valve. The pressure relief valve 52 may control the maximum pressure level of the fluid in the first manifold 22b and in each of the alternating self-inflating fluid cells 12b, 12d, 12f, 12h. A rotatable knob or other adjusting mechanism on the pressure relief valve 52 allows a user to adjust the regulated maximum pressure level. The pressure relief valve 52 may be the same or similar to the pressure relief valve 42. Thus, different selected maximum allowable pressures in the self-inflating fluid cells 12b, 12d, 12f, 12h allow the body support 10 to accommodate patients of different weights.
A third pathway extends to a blow off valve 54. The blow off valve may thus be attached to at least one of the plurality of self-inflating fluid cells 12b, 12d, 12f, 12h or the manifold system. The blow-off valve 54 may be configured to open at a blow-off pressure that is higher than a maximum working pressure that occurs when the body support 10 is supporting the maximum weight limit. The blow-off valve 54 is located in the first manifold 22b and/or in the manifold system 20 such that fluid from the plurality of self-inflating fluid cells 12b, 12d, 12f, 12h does not flow through the pressure relief valve 52 when the fluid leaves the body support 10 from the blow-off valve 54. The blow-off valve 54 may be structured to provide a higher volume flow rate of airflow when opened than a volume flow rate of the pressure relief valve 52 at the same pressure level. For example, the volume flow rate of the blow-off valve 54 may be at least three times the volume flow rate of the pressure relief valve 52 at the same pressure level. Alternatively, the volume flow rate of the blow off valve 54 may be twice the volume flow rate of the pressure relief valve 52 at the same pressure level. However, any volume flow rate is contemplated, such as three times, four times, five times or the like. The cracking pressure of the blow off valve 54 may be greater than 10 psi, for example. In various embodiments, the cracking pressure of the blow off valve 54 may be 15, 20, 25, 35, 50 or 74 psi, or any pressure therebetween. The blow off valve 54 may have the same cracking pressure as the blow off valve 44. In some embodiments, the blow off valve 54 may have a cracking pressure of the blow-off valve is adjustable. The blow-off valve 54 may be configured to be permanently deactivated after at least one opening sequence.
Unlike the body support 10, the body support 100 includes the additional blow off valves 156, 158, 162, 166 each connected to the manifold 122. In particular, the blow off valves 158, 162 are connected to, and provide additional blowoff capacity for, the first manifold 122a, and the blow off valves 156, 166 are connected to, and provide additional blow-off capacity for, the second manifold 122b. The blow off valves 156, 158, 162, 166 are each connected to respective ports 130, 160. The embodiment shown in
In one example, each of the self-inflating fluid cells 412 of the body support 400 may be a structural helical bellow, having a helical pattern in its outer construct. This may allow each of the plurality of self-inflating fluid cells to collapse when loaded with force which is greater than the sum of the force of pressure inside the self-inflating fluid cell and the reforming force of the self-inflating fluid cell and inherently expand when the load is reduced.
The fluid cells 412 may have a single helical pattern or a double helical pattern on the outer construct. However, the fluid cell 412, like the previously described fluid cells 12, 112, 212, 312, may also be any fluid cell which has a spring bias which effects the reformation of the fluid cell such that the fluid cell collapses when loaded with a load having a force which is greater than the sum of the forces within the fluid cell, including the pressure of the fluid inside the fluid cell multiplied by the area of the fluid cell supporting the load, plus the reforming force of the fluid cell, and may further reform when the load is reduced to a load having a force which is less than the sum of the forces within the fluid cell and the reforming force of the fluid cell. In other words, once the fluid cell 412 is compressed with the weight of a person or article, the fluid cell 412 exerts a reforming force so as to reform when the weight is reduced. The application of an external load on the fluid cell 412 causes the fluid cell 412 to deform into a compressed form. The fluid cell 412 provides a reforming force which causes the fluid cell 412 to return to its original form when the external load is removed from the fluid cell 412 such that the fluid cell is self-inflating. The fluid cells described herein may work in the same manner.
The manifold 422 is shown extending to a port 438 which splits into three fluidic pathways. A first pathway extends to an intake check valve 440 (the same as or similar to the intake check valves 40, 140, 240, 340 described herein above), while a second pathway extends to a pressure relief valve 442 (the same as or similar to the pressure relief valves 42, 142, 242, 342 described herein above), while a third pathway extends to a blow-off valve 444. While the embodiment shown includes a single manifold system 422 which includes a single blow-off valve 44, it should be understood that any number of manifold portions and blow-off valve connections are contemplated.
Unlike the previous embodiments, the body support 500 includes an additional alternating pressure system 570 for providing alternating supply pressure to a plurality of zones. The alternating pressure system 570 can include any means for supplying fluid under pressure including a pump, compressor, etc. Also, included in the alternating pressure system 570 is any means such as a valve (not shown) for periodically switching the pressurized fluid between manifolds 522, 524. The alternating pressure system 570 includes a computerized control system 572 that is programmed to supply alternating pressures to a plurality of self-inflating fluid cells 512 in any sequence that is desired by the user. Thus, the embodiments described herein may include equipping any configuration of a powered body support system with one or more blow-off valves.
Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” and their derivatives are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or combination of terms. The terms “first” and “second” are used to distinguish elements and are not used to denote a particular order.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
