US20250108945A1

US20250108945A1 - Body support and method of packing a body support

Info

Publication number: US20250108945A1
Application number: US18/478,263
Authority: US
Inventors: Jeffrey W. Wilkinson
Original assignee: WCW Inc
Current assignee: WCW Inc
Priority date: 2023-09-29
Filing date: 2023-09-29
Publication date: 2025-04-03
Also published as: WO2025072671A1

Abstract

A body support includes at least one self-inflating fluid cell. Each of the at least one self-inflating fluid cell contains a reforming element. The body support further includes 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.

Description

FIELD OF TECHNOLOGY

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.

BACKGROUND

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.

SUMMARY

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.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 depicts a schematic view of a body support according to one embodiment;

FIG. 2 depicts a perspective view of the body support of FIG. 1 according to one embodiment;

FIG. 3 depicts a schematic view of a further body support according to one embodiment;

FIG. 4 depicts a schematic view of a further body support according to one embodiment;

FIG. 5 depicts a schematic view of a further body support according to one embodiment;

FIG. 6 depicts a schematic view of a further body support according to one embodiment;

FIG. 7 depicts a schematic view of a still further body support according to one embodiment;

FIG. 8 depicts a partial cutaway view of an exemplary blow off valve according to one embodiment;

FIG. 9 depicts a perspective view of a body support located within a polymeric bag located between two surfaces of a compression seal machine according to one embodiment;

FIG. 10 depicts a perspective view of the body support of FIG. 8 after compression and sealing according to one embodiment;

FIG. 11 depicts a perspective view of the body support of FIGS. 8-9 after a rolling process according to one embodiment; and

FIG. 12 depicts a method of packing a body support according to one embodiment.

DETAILED DESCRIPTION

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, FIG. 1 depicts a schematic view of a body support 10 according to one embodiment, while FIG. 2 depicts a perspective view of the body support 10 of FIG. 1 according to one embodiment. The body support 10 may be used in combination with any support device that includes compressible and reformable support or fluid cells. The body support 10 may be a support system where self-adjusting dynamic pressure is required. For example, the support device may include a mattress, sofa, seat, etc. The body support 10 includes a plurality of self-inflating fluid cells 12, a sleeve apparatus 14 (shown in FIG. 2 ), a jacket 16 (shown in FIG. 2 ) and a topper cushion 18 (shown in FIG. 2 ).
The body support 10 includes at least one self-inflating fluid cell 12 a, 12 b, 12 c, 12 d, 12 e, 12 f, 12 g, 12 h 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 12 a, 12 b, 12 c, 12 d, 12 e, 12 f, 12 g, 12 h, 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 FIGS. 1-7 .
As shown in FIG. 1 , a manifold system 20 is provided with the body support 10. The manifold system 20 contains valves, tubing and/or ports that fluidically interconnect various self-inflating fluid cells 12 of the body support 10. As illustrated in FIG. 2 , the body support 10 includes two end walls 24, 26, and two side walls 28, 30. The end walls 24, 26, and the side walls 28, 30 can be formed from a resilient material such as foam or rubber. The topper cushion 20 rests on top of the jacket 18 and provides further cushioning to a body. The topper cushion 20 can be composed of any resilient material, for example, foam, down feathers, an inflatable air cushion, etc.
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 22 a and a second interconnected manifold 22 b. The first manifold 22 a connects alternating self-inflating fluid cells 12 a, 12 c, 12 e, 12 g while the second manifold 22 b connects alternating self-inflating fluid cells 12 b, 12 d, 12 f, 12 h. 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 22 a extends, at a first end 34 of the body support 10, to a first combination of valves. Similarly, the manifold 22 b 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 22 a includes a port 38 which is configured to split the manifold 22 a 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 22 a in order to thereafter allow fluid from within the first manifold 22 a 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 22 a and in each of the alternating self-inflating fluid cells 12 a, 12 c, 12 e, 12 g. 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 12 a, 12 c, 12 e, 12 g 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 12 a, 12 c, 12 e, 12 g 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 12 a, 12 c, 12 e, 12 g. 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 12 a, 12 c, 12 e, 12 g 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 22 a and/or in the manifold system 20 such that fluid from the plurality of self-inflating fluid cells 12 a, 12 c, 12 e, 12 g 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 22 a, the second manifold 22 b 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 22 a, the second combination of valves connected at the second end 36 of the second manifold 22 b includes a port 48 which is configured to split the second manifold 22 b 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 22 b in order to thereafter allow fluid from within the second manifold 22 b 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 22 b and in each of the alternating self-inflating fluid cells 12 b, 12 d, 12 f, 12 h. 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 12 b, 12 d, 12 f, 12 h 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 12 b, 12 d, 12 f, 12 h 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 22 b and/or in the manifold system 20 such that fluid from the plurality of self-inflating fluid cells 12 b, 12 d, 12 f, 12 h 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.
FIG. 3 depicts a schematic view of a further body support 100 according to one embodiment. The body support system 100 may be the same or similar to the body support system 10 shown in FIG. 1-2 , but includes additional blow off valves 156, 158, 162, 166 connected to the manifold system 122. Thus, the body support 100 includes eight self-inflating fluid cells 112 a, 112 b, 112 c, 112 d, 112 e, 112 f, 112 g, 112 h interconnected by the manifold system 122. Each self-inflating fluid cell 112 includes a port 130 (like the ports 30 of the body support 10) connecting the cell to the manifold system 122. The manifold system includes two separate manifold portions, a first manifold 122 a, and a second manifold 122 b, each connecting the self-inflating fluid cells 112 in an alternating scheme. At a first end 134 of the body support 100 is a first port 138 that is connected to the first manifold 122 a which splits the fluidic system into three pathways: a first extending to an intake check valve 140 (like the check valve 40), the second extending to a pressure relief valve 142 (like the pressure relief valve 42), and the third extending to a blow off valve 144 (like the blow off valve 44). At a second end 136 of the body support 100 is a second port 148 that is connected to the second manifold 122 b which splits the fluidic system into three pathways: a first extending to an intake check valve 150 (like the check valve 50), the second extending to a pressure relief valve 152 (like the pressure relief valve 52), and the third extending to a blow off valve 154 (like the blow off valve 54).
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 122 a, and the blow off valves 156, 166 are connected to, and provide additional blow-off capacity for, the second manifold 122 b. The blow off valves 156, 158, 162, 166 are each connected to respective ports 130, 160. The embodiment shown in FIG. 3 depicts that any number of blow off valves can be connected to the manifold systems contemplated by body supports herein. The blow-off valves may be connected at various locations along a given manifold system or portions thereof. Additional blow-off valves may increase the speed of fluidic expelling during compression of the body support system 100 for the purposes of packing and/or transportation.
FIG. 4 depicts a schematic view of a further body support 200 according to one embodiment. Unlike the body supports 10, 100, the body support 200 is shown including only four self-inflating fluid cells 212 a, 212 b, 212 c, 212 d. While the cells in the body supports 10, 100 may be horizontally aligned to form a mattress, the self-inflating fluid cells 212 a, 212 b, 212 c, 212 d may be vertically aligned, and run from a head end to a foot end of the body support 200 or mattress. Thus, the embodiment shown is indicative of the fact that the principles of the invention described herein may be applicable to any number of fluid cells aligned or disposed in any configuration. Further, unlike the body supports 10, 100, the body support 200 includes a blow off valve 244 directly attached to each of the self-inflating fluid cells 212 a, 212 b, 212 c, 212 d. A manifold 222 is shown interconnecting ports 230 for each of the self-inflating fluid cells 212 a, 212 b, 212 c, 212 d. The manifold 222 is shown extending to a port 238 which splits into two fluidic pathways. A first pathway extends to an intake check valve 240 (the same as or similar to the intake check valves 40, 140 described herein above), while a second pathway extends to a pressure relief valve 242 (the same as or similar to the pressure relief valves 142, 42 described herein above). Thus, no blow-off valve is connected to the manifold in the body support 200, but rather at least one blow-off valve is directly connected to each of the self-inflating fluid cells 212 a, 212 b, 212 c, 212 d. Furthermore, the embodiment shown displays that a single manifold 222 is contemplated, rather than an embodiment with alternating fluid cells (as shown in FIGS. 1-3 ). Thus, in operation, all of the self-inflating fluid cells 212 a, 212 b, 212 c, 212 d of the body support 200 may be configured to equalize to the same pressure when supporting a patient, person, sleeper or the like.
FIG. 5 depicts a schematic view of a further body support 300 according to one embodiment. Like the body support 200, the body support 300 includes four self-inflating fluid cells 312 a, 312 b, 312 c, 312 d. The body support 300 may be the same or similar to the body support 200. However, the body support 300 includes a manifold 322 shown interconnecting ports 330 for each of the self-inflating fluid cells 312 a, 312 b, 312 c, 312 d. The manifold 322 is shown extending to a port 338 which splits into three fluidic pathways. A first pathway extends to an intake check valve 240 (the same as or similar to the intake check valves 40, 140 described herein above), while a second pathway extends to a pressure relief valve 242 (the same as or similar to the pressure relief valves 142, 42 described herein above), while a third pathway extends to a blow-off valve 344. Thus, in the embodiment shown, a single manifold system 322 includes a single blow-off valve is connected to the manifold 322 in the body support 300, instead of being directly connected to each of the self-inflating fluid cells 312 a, 312 b, 312 c, 312 d.
FIG. 6 depicts a schematic view of a further body support 400 according to one embodiment. The body support 400 shows another example of the arrangement of self-inflating fluid cells 412. In this embodiment, the self-inflating fluid cells 412 may be interconnected in a similar manner to the body supports described hereinabove—thus, the self-inflating fluid cells 412 may be connected by one or more manifolds 422 (while the specific connections to each of the cells 412 is not shown). The one or more manifolds 422 may provide the body support 400 with self-inflating, self-adjusting, zone pressure control (in the case of multiple manifold zones).
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.
FIG. 7 depicts a schematic view of a still further body support 500 according to one embodiment. The body support 500 includes a plurality of self-inflating fluid cells 512 a, 512 b, 512 c, 512 d, 512 e, 512 f, 512 g, 512 h interconnected by a plurality of manifold portions 520, 522, 524. Unlike the embodiments shown in FIGS. 1-5 , the body support 500 includes an intake manifold 520, and two separate exhaust manifolds 522, 524. Thus, instead of a single two-way port, as described above with previous embodiments, each of the self-inflating fluid cells 512 includes a separate exhaust valve 530 and intake valve 531. The intake valves 531 of each of the plurality of self-inflating fluid cells 512 is connected to the intake manifold 520 which extends to a port 560 which splits into an intake check valve 550 and a blow-off valve 544. The exhaust valves 530 of each of the self-inflating fluid cells 512 are interconnected by the manifolds 522, 524, which extend to at least one pressure relief valve 552 (which may be the same or similar to the pressure relief valves described herein above). The body support 500 includes a plurality of blow off valves 544 each connected to a port 560 which extends from various portions of the manifolds 520, 522, 524.
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.
FIG. 8 depicts a partial cutaway view of an exemplary blow-off valve 600 according to one embodiment. The blow-off valve 600 includes an outer body structure 610 or housing which may be connectable to a fluidic system (i.e. to a tubular structure of fluidic system). Within the body structure 610 is a poppet guide 612, a compression spring 610, and a stem structure 614. The poppet guide 612, when exposed to pressure, may be configured to compress the compression spring 610. The poppet guide 612 may thereby move the stem structure 614 in order to crack or break open the blow-off valve 600. Various possible cracking pressures are contemplated. Further various flow-rates are contemplated.
FIG. 9 depicts a perspective view of a body support 700 located within a polymeric bag 710 located between two surfaces 712, 714 of a compression seal machine 716 according to one embodiment. The body support 700 represents any of the body supports 10, 100, 200, 300, 400, 500 described hereinabove, or any variations contemplated herein. The polymeric bag 710 may be a sealable bag which is configured to seal the body support 700 once compressed. In operation, the two surfaces 712, 714 of a compression seal machine 716 compress the body support 700 and thereafter seal the polymeric bag 710 in order to maintain the body support 700 in the compressed state after compression. During the compression, the internal pressure of the body support 700 is raised much higher than a maximum working pressure which the body support 700 would experience when supporting a body, patient, person or the like. This machine-created high pressure causes the one or more blow-off valves of the body support 700 to open and expel fluid from the body support 700 at a rapid rate, allowing faster and more efficient compression. Once this compression process is complete, the one or more blow-off valves may thereafter be configured to be inoperable for the rest of the use-life of the body support 700. It is contemplated that the blow-off valves may be permanently deactivated after this compression, or may simply be rated with a high enough cracking pressure that would never be reached during usage of the body support 700 to support a person or body.
FIG. 10 depicts a perspective view of the body support 700 of FIG. 9 after compression and sealing according to one embodiment. As shown, the body support 700 in this state is extremely compressed and may have a significantly reduced volume, weight and the like with the fluid removed therefrom. The body support 700 may be retained in this reduced volume and weight state through the sealing of the polymeric bag 710.
FIG. 11 depicts a perspective view of the body support 700 of FIGS. 9-10 after a rolling process according to one embodiment. In this state, body support 700 is rolled into an easily packable and transportable shape. During or after the roll packing process, the body support 700 may be tied or otherwise secured by a rope, string, cord, or other line, or the like to prevent unrolling. Once in the rolled state, the body support 700 may be ready for loading and/or transportation. In some embodiments, a rolling process may not be necessary if the body support 700 is simply configured to be stacked in its compressed but pre-rolled state for transportation.
FIG. 12 depicts a method 800 of packing a body support, such as one or more of the body supports 10, 100, 200, 300, 400, 500, 700 described herein above, according to one embodiment. The method 800 may include a first step 810 of providing a body support, such as any of the body supports 10, 100, 200, 300, 400, 500, 700 described herein above, including any of the structure and features described, including one or more blow-off valves attached to one or more self-inflating fluid cells. The method 800 may include a second step 820 of enveloping the body support with a polymeric bag. The method 800 includes a third step 830 of compressing the body support with a compression machine to open the blow-off valve of the body support. The method 800 includes a fourth step 840 of removing fluid through the blow-off valve from the plurality of self-inflating fluid cells during the compressing. The method 800 may include an optional step of permanently deactivating operability of the blow-off valve after the compressing. After compression of the body support, the method 800 may include a next step 860 of sealing the polymeric covering material such that the body support remains enveloped within the polymeric covering material in an air-tight manner. The method 800 includes a step 870 of rolling the body support with a roll packing process after the compressing. This may include a step of securing the body support in a rolled position after the rolling. Finally, the method 800 includes a step 880 of packing the body support in a transportation vehicle after the securing.
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.

Claims

I claim:

1. A body support configured to support a weight up to a maximum weight limit, the body support comprising:

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, wherein 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.

2. The body support of claim 1, wherein the at least one self-inflating fluid cells is a plurality of self-inflating fluid cells, wherein the body support further comprises a manifold system including an exhaust conduit interconnecting the plurality of self-inflating fluid cells.

3. The body support of claim 2, further comprising at least one pressure relief valve operably attached to the exhaust conduit, the at least one pressure relief valve configured to be controllable to allow for a maximum operable pressure level to be maintained within the plurality of self-inflating fluid cells during body support use.

4. The body support of claim 3, wherein the blow-off valve is located in the manifold such that fluid from the plurality of self-inflating fluid cells does not flow through the at least one pressure relief valve when the fluid leaves the body support from the blow-off valve.

5. The body support of claim 3, wherein the blow-off valve is structured to provide a higher volume flow rate of airflow when opened than a volume flow rate of the at least one pressure relief valve at the same pressure level.

6. The body support of claim 5, wherein the volume flow rate of the blow-off valve is at least three times the volume flow rate of the at least one pressure relief valve at the same pressure level.

7. The body support of claim 1, wherein the blow-off valve is a first blow-off valve attached at a first end of the manifold, the body support further comprising a second blow-off valve attached at a second end of the manifold, wherein the second blow-off valve opens at the blow-off pressure.

8. The body support of claim 2, further comprising a respective blow-off valve attached directly to each of the plurality of self-inflating fluid cells, wherein the blow-off valve is a first blow-off valve of the respective blow-off valves and is attached directly to a first of the plurality of self-inflating fluid cells.

9. The body support of claim 2, wherein the plurality of fluid include a plurality of groups of self-inflating fluid cells, each of the plurality of groups of self-inflating fluid cells including a separate manifold portion.

10. The body support of claim 1, wherein the reforming element comprises a resilient foam material.

11. The body support of claim 2, wherein the reforming element comprises a helical pattern on an outer construct of each of the plurality of self-inflating fluid cells such that each of the plurality of self-inflating fluid cells 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.

12. The body support of claim 1, wherein the blow-off pressure of the blow-off valve is adjustable.

13. The body support of claim 1, wherein the blow-off valve is configured to be permanently deactivated after at least one opening sequence.

14. A method of packing a body support configured to support a weight up to a maximum weight limit comprising:

providing the body support, the body support including:

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, wherein 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; and

removing fluid through the blow-off valve from the at least one self-inflating fluid cell during the compressing.

15. The method of claim 14, wherein the at least one self-inflating fluid cell is a plurality of fluid cells, wherein the body support further includes a manifold system including an exhaust conduit interconnecting the plurality of self-inflating fluid cells.

16. The method of claim 15, wherein the body support further comprises at least one pressure relief valve operably attached to the exhaust conduit, the at least one pressure relief valve configured to be controllable to allow for a maximum operable pressure level to be maintained within the plurality of self-inflating fluid cells during body support use.

17. The method of claim 14, further comprising enveloping the body support with a polymeric bag before the compressing.

18. The method of claim 17, further comprising sealing the polymeric covering material such that the body support remains enveloped within the polymeric covering material in an air-tight manner.

19. The method of claim 18, further comprising rolling the body support with a roll packing process after the compressing.

20. The method of claim 19, further comprising securing the body support in a rolled position after the rolling.

21. The method of claim 20, further comprising packing the body support in a transportation vehicle after the securing.

22. The method of claim 19, further comprising permanently deactivating operability of the blow-off valve after the compressing.

23. A body support comprising:

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, wherein the blow-off valve opens at a blow-off pressure that is higher than the maximum operable pressure level.