초록 ▼

The invention modulates the air volume in foam cores of cushioning support devices and any other support apparatus using foam or similar materials. The foam core can be incrementally modulated to realize an infinite number of comfort levels as to softness and support firmness. The core consists of s

The invention modulates the air volume in foam cores of cushioning support devices and any other support apparatus using foam or similar materials. The foam core can be incrementally modulated to realize an infinite number of comfort levels as to softness and support firmness. The core consists of self-inflating open-cell flexible polyurethane foam and is completely sealed within an enclosure fitted over it, with one or more valves installed in the side walls which communicate with the outside air. Through the valves air is selectively withdrawn from the foam core, allowing the foam's density to increase. The invention uses relatively inexpensive foam, but through air volume modulation achieves a tactile feel of supreme softness for the user, without giving up the necessary firmness to support the body, as happens with very soft foam (bottoming-out or hammock-effect). When air is extracted from a self-inflating foam core, the surface of the core will soften uniformly while maintaining its support firmness. Contrary to this, when pressure is exerted on, for example, traditional coil spring core mattresses, their surface will harden. Integral part of the invention is a device using balanced springs in valve assemblies to avoid compression set, an irreversibly solid state of totally air-depleted foam.

대표청구항 ▼

1. A cushioning apparatus adapted to cushion objects placed on either surface of said apparatus, said apparatus including one or more pieces of open cell self-inflating flexible polyurethane foam to form a foam core, said foam core is covered by one or more hermetically sealed envelopes forming one

1. A cushioning apparatus adapted to cushion objects placed on either surface of said apparatus, said apparatus including one or more pieces of open cell self-inflating flexible polyurethane foam to form a foam core, said foam core is covered by one or more hermetically sealed envelopes forming one or more autonomous airtight chambers, means for controlling and modulating the principal characteristics of said open cell self-inflating flexible polyurethane foam, said means comprising means for removing some air uniformly from within said open foam cells to change the softness and support ratio within the foam core, said means for removing said air from said foam core including one or more valves installed in said chamber walls that are removably connected to a vacuum pump by way of a hose;said apparatus including one or more foam pieces combined to form one or more foam cores, said cores may have different factory preset density and IFD ratings and further combined into autonomous airtight chambers within said apparatus. 2. The apparatus for claim 1 wherein said means for removing some air results in altering the cellular density of said foam core.3. The apparatus of claim 2, wherein said means for removing some air results in increasing the cellular density of said foam core.4. The apparatus of claim 1, wherein said foam core can an IFD value within a range of 22 to 50 in its original factory pre-set configuration and a progressively decreasing value when some air is removed from said core.5. The apparatus of claim 1, wherein said foam core has a density within a range of 1.2 to 2.5 pounds per cubic foot in its original, factory pre-set configuration, and a progressively increasing density when some air is removed from said foam core, without adding weight to the overall apparatus.6. The apparatus of claim 5, wherein the foam core exhibits a diminishing density and an increasing IFD value when allowed to self-inflate from a collapsed state.7. The apparatus of claim 1, wherein said foam core has a thickness of at least four inches in a fully self-inflated state to be able to fully achieve the characteristics of said modulation.8. The apparatus of claim 1, including means for distancing said valve in said chamber from any adjacent materials that may obstruct airflow.9. The apparatus of claim 8, wherein said means for distancing is air-permeable and contiguous with said foam material within the chamber.10. The apparatus of claim 8 in which said means for distancing includes a cylindrical extension element connected communicably and extending axially laterally to said valve and having an air permeable opening for keeping said foam core and said envelope at a distance from said valve to prevent said core and envelope from occluding said valve.11. The apparatus of claim 1, including one or more foam pieces, combined to form one or more foam cores, said cores may have identical factory pre-set density and IFD ratings and are further combined into autonomous airtight chambers within said apparatus.12. The apparatus of claim 11 wherein each of said autonomous airtight chambers has one or more valves located in a wall of each of said chambers with an air permeable distancing element interconnected to said valves.13. The apparatus of claim 1, wherein each of said autonomous airtight chambers has one or more valves located in a wall of each of said chambers with an air-permeable distancing element interconnected to said valves.14. The apparatus of claim 1, whereby a partially deflated foam core contained within an autonomous airtight chamber, having a closed valve, recovers slowly when a weight placed upon said chamber is removed, thereby exhibiting the principal characteristics of visco-elastic foam.15. The apparatus of claim 14, whereby further deflation of a partially deflated foam core contained within an autonomous airtight chamber, having a closed valve, exhibits no upward recovery thereby exhibiting less upward pressure than visco-elastic foam.16. The apparatus of claim 1, wherein the self-inflating foam core adjusts to pressure points only locally without creating a hammock. effect.17. The apparatus of claim 1, wherein each of said autonomous airtight chambers may be permanently attached to each other to form a sectional mattress.18. The apparatus of claim 1, wherein each of said autonomous airtight chambers may be removably connected to each other at the exterior edges of said chamber.19. The apparatus of claim 1, wherein each of said autonomous airtight chambers when combined into a mattress or support apparatus, may be used on either side before modulation is commenced.20. A cushioning apparatus adapted to cushion objects placed on either surface of said apparatus, said apparatus including one or more pieces of open cell self-inflating flexible polyurethane foam to form a foam core, said foam core is covered by one or more hermetically sealed envelopes forming one or more autonomous airtight chambers, means for controlling and modulating the principle characteristics of said open cell self-inflating flexible polyurethane foam, said means comprising means for removing some air uniformly from within said open foam cells to change the softness and support ratio within the foam core, said means for removing said air from said foam core including one or more valves installed in said chamber walls that are removably connected to a vacuum pump by way of a hose; and a pressure-balanced closure spring located in said valve.21. The apparatus of claim 20, including a means for opening and closing said valve and said closure spring.22. The apparatus of claim 21, including means for opening said valve by a hose, which is permanently attached to said valve but removably connected to said vacuum pump.23. The apparatus of claim 20, including a closure force of said spring which equals the re-inflating force of said foam core when said foam core is in a partially inflated state so that no more air can enter said foam core.24. The apparatus of claim 20, wherein said pressure-balanced closure force of said spring is within a range of 2 lb. to 6.0 lb.25. A cushioning apparatus adapted to cushion objects placed on either surface of said apparatus, said apparatus including one or more pieces of open cell self-inflating flexible polyurethane foam to form a foam core, said foam core is covered by one or more hermetically sealed envelopes forming one or more autonomous airtight chambers, means for controlling and modulating the principle characteristics of said open cell self-inflating flexible polyurethane foam, said means comprising means for removing some air uniformly from within said open foam cells to change the softness and support ratio within the foam core, said means for removing said air from said foam core including one or more valves installed in said chamber walls that are removably connected to a vacuum pump by way of a hose; and a pressure-balanced closure spring located in said valve, said spring including a closure force which opposes a re-inflating force of the foam core, said opposing force being weaker than the re-inflating force of said foam core in its collapsed state, whereby some air can re-enter said foam core to avoid the risk of compression set inherent in a totally collapsed foam, collapsed over a certain period of time.26. A cushioning apparatus adapted to cushion objects placed on either surface of said apparatus, said apparatus including one or more pieces of open cell self-inflating flexible polyurethane foam to form a foam core, said foam core is covered by one or more hermetically sealed envelopes forming one or more autonomous airtight chambers, means for controlling and modulating the principle characteristics of said open cell self-inflating flexible polyurethane foam, said means comprising means for removing some air uniformly from within said open foam cells to change the softness and support ratio within the foam core, said means for removing said air from said foam core including one or more valves installed in said chamber walls that are removably connected to a vacuum pump by way of a hose; and further including means for distancing said valve in said chamber from any adjacent materials that may obstruct airflow, said means for distancing being air-permeable and contiguous with said foam material within said chamber.27. The apparatus of claim 26, wherein said air-permeable distancing element is communicably attached to said valve at a point which is opposite to said foam material.28. The apparatus of claim 27, wherein said air-permeable distancing element acts as a means to increase inflation and deflation speed as well as the air quantity to and from the apparatus and into a vacuum pump.29. A cushioning apparatus adapted to cushion objects placed on either surface of said apparatus, said apparatus including one or more pieces of open cell self-inflating flexible polyurethane foam to form a foam core, said foam core is covered by one or more hermetically sealed envelopes forming one or more autonomous airtight chambers, means for controlling and modulating the principle characteristics of said open cell self-inflating flexible polyurethane foam, said means comprising means for removing some air uniformly from within said open foam cells to change the softness and support ratio within the foam core, said means for removing said air from said foam core Including one or more valves installed an said chamber walls that are removably connected to a vacuum pump by way of a hose; and further including means for distancing said valve in said chamber from any adjacent materials that may obstruct airflow, said means for distancing including a cylindrical extension element connected communicably and extending axially laterally to said valve and having an air-permeable opening for keeping said foam core and said envelope at a distance from said valve to prevent said core and envelope from occluding said valve.