Note: Descriptions are shown in the official language in which they were submitted.
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SUPPORT CUSHIOl\TS
Technical Pield
The invention relates to cushions or cushioning devices
and specifically to a cushion or pillow which can be easily
shaped to conform to a body member for orthopedic support.
Background Art
Various cushioning devices or pillows have been devel-
oped whereby the shape of the pillow is designed to providesupport for a body member of the user. Typical examples of
such pillows or cushions can be found in U.S. Patent Nos.
5,513,462 (neck support): 3,574,397 (haad support);
4,324,012 and 4,535,495 (back support): and 4,031,578,
- 15 4,218,792, 4,320~543 and 4,550,459 (head and neck support).
To provide such support, these cushions were constructed and
designed to conform the shape of the body part to be
supported.
Conventional pillows are usually filled with a cushion-
ing material of cotton, feathers, sponge rubber, fiberfill,and/or foam. The sponge or foam fillers may be in the form
of chunks or particles. Such pillows can be manipulated to
conform to the shape of the body part to be suppoxted. If
the construction of the pillow is too sti~f, however, it
becomes difficult to conform the shape of the pillow ts the
body part. Conversely, if the pillow is too soft,
depressions are easily formed, and the proper support of the
body member is not achieved. Furthermore, the shaping
capabilities of such conventional pillows are rather
limited. Often, the filler simply packs into a dense mass
and loses it resiliency.
U.S. Patent No. 4,021,871 discloses an improvement on
the previous devices in that the internal cavity of the
cushion is filled with a layer of fibrous textile filler
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positioned in a particular manner to provide a cushion which
retains its shape more effectively and imparts improved
cushioning resistance.
None of these prior art cushioning devices is capable,
however, of being easily shaped to the desired configuration
to provide support, while retaining sufficient resilisncy to
maintain the desired shape until it is changed by the user.
Furthermore, if the pillow cannot be conformed the exact
shape needed for support, the user can feel displeasure,
discomfort, or pain.
Summary of the Invention
The present invention relates to a lightweight shapable
cushioning apparatus which is easily conformable to a
desired configuration for supporting an item comprising
exterior surface means of a material stretchable in two
directions forming a desired shape ~o~ the apparatus and
defining an internal cavity therein, and a plurality of
lightweight, resilient, solid, expanded thermoplastic
spheres substantially filling the internal cavity. The
spheres are capable of compression, deformation and three-
dimensional movement throughout the internal cavity to allow
shaping of the apparatus for support of an item. The
2 spheres are further capable of returning to their spherical
shape after the item to be supported is removed from the
apparatus. For certain apparatus, external prestressing
means may be used to control the shape of the apparatus.
The exterior surface means may be made of any natural
or synthetic fabric, preferably a stretch fabric of a
lightweight, stretchable synthetic material while the
spheres are preferably made of a thermoplastic or expanded
thermoplastic material.
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The exterior surface means of the apparatus may be
substantially spherical in shape, with the connecting means
passing through the center of the sphere, or in the shape of
a six-sided box whereby the connecting means connect opposed
sides of the box. Other configurations for the exterior
surface means may also ~e used.
An alternate embodiment ~f the invention relates to the
lightweight cushioning apparatus described above along with
means for adjusting the shape of the apparatus. One
adjusting means includes draw cord means extending through
the internal cavity. If desired, locking means can be
utilized with the draw cord means for retaining the adjusted
shape of the apparatus. Alternately a porkion of the
exterior surface means may be made of non-stretchable
material to assist in guiding the r~shaping during
adjustment, thus maintaining the shape of the apparatus.
A further embodiment of the invention relates tD a
lightweight cushioning apparatus described above which
further includes internal or external frame means for
forming a desired shape for the apparatus or for holding it
erect. It is also possible to include means for bending the
article about a predetermined curved or straight line for
folding or compressing the article. Such bending means may
include a plurality of tension cords aligned along the
predetermined line. Alternately, ~ seam or panel of non-
stretchable fabric can be used.
A further embodiment of the invention relates to a
lightweight cushioning apparatus comprising exterior surface
means forming a desired shape for the apparatus and defining
an internal cavity therein, a plurality of members
connecting substantially opposed portions of the surface
means through the internal cavity to maintain the surface
means under tension and attempt to draw together the opposed
portions of the surface means, and a plurality of expanded
thermoplastic spheres substantially filling the internal
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cavity to retain the exterior surface means in the desired
shape and provide resistance against the attempt of the
tension members to draw together the opposed portions of the
surface means.
The apparatus may also include means for connectiny and
prestressing substantially opposed portions of the exterior
surface means through the intlernal cavity. These connecting
means generally comprises a plurality of flexible tension
members, each spaced by a distance of between l and lO
inches, and preferably between 4 and 5 inches.
Advantageously, such tension members are made of a
stretchable synthetic fabric, thermoplastic, or elastomeric
material in the shape of ~trip, rod, bar, fiber or cord.
Brief Description of the Drawinqs
The nature, advantages, and various other additional
features of the invention will appear more fully upon con-
sideration of the illustrative embodiments now to be des-
cribed in detail in connection with the accompanying drawing
figur~s, wherein:
FIG. l is a front plan view of an orthopedic backrest
support cushion;
FIG. 2 is a top plan view of the support cushion of
FIG. l:
FIG. 3 is a rear plan view, partially in cross-
section, of the support cushion of FIG. l;
FIG. 4 is a side plan view, partially in cross-
section, of the support cushion of FIG. l:
FIG. 5 is a perspective view of a travel support
cushion in an elongated position;
FIG. 6 is a perspective view of the support cushion
of FIG. 5 in a compact position;
FIG. 7 is a perspective view of a maternity support
cushion;
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FIG. 8 is a side ~iew of a support cushion in
accordance with the teachings o~ the invention placed in a
support ring to ~orm a chair;
FIG. 9 i~ an em~odiment of a suppor~ cushion in the
form of a mattress;
FIG. 10 is a side view of the cushion o~ FIG. 9 in a
folded or chair con~igura~ion;
FIG. 11 is a side view of the cushion of FIG. lO
placed upon a support element;
FIG. 12 is a perspective view o~ another cushion
in accordance with the in~en~ion;
FIG. 13 is a perspective view of the cushion of
FIG. 12 with a side panel removed;
FIG. 14 is a perspective ~iew of a round cushion
according to the in~ention; and
FIG. 15 is a perspective view of a support cushion
utilizing external prestressing means.
Detailed DescriPtion of the Prefe~red Embodiments
Referring initially to FIGS. 1-4, there is illustrated
a support cushion 10 in the ~orm of a back rest for a chair
or automobile seat. The ~xterior covering 20 of the cushion
10 can be made of any of ~ variety of natural or ~ynthetic
cloth or fabric materials_ Prefer~bly, the covering 20 is
made o~ a synthetic, elastic or stretch fabric, whether
woven or knitted. It has been found that synthetic
polyester materials having good stretchability, preferably
in both the X and Y direckions (i.e., 2-way stxetch
matexials), with s~retch re~ention, washability and non-
allergenic properties are preferred. The optimum material
~or such pillows is availa~le from Dupont under the trad~
mark "Lycra Spandex". This ma~erial can be combined with
other fibers (cotton, nylon, etc.) to produce fabrics o~
varying weights and stret~h factors which could be selected
depending upon the desired end use for the cushion.
:
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FIG. 4 illustrates the cushion with a portion of the
side panel removed to detail the spherical plastic foam
spheres 30 and wire frame 40 which are located inside.
Tension members 50 are used to pre-stress opposed faces of
- 5 the exterior covering 20 while the spheres 30 prevent the
opposed faces the exterior ~overing from being drawn
together. Also, the frame 40 enables the cushion t~
initially conform to the desired shape, i.e., that of a seat
back for the cushion of FIGS. 1-4. Straps 60 are used to
mount cushion 10 upon a chair or automobile seat.
The wire frame 40 can also be made with graphite or
high strength plastic rods, and is used to provide sti~fness
to the pillow as well as to offset a certain degree of
manipulation of the pillow be~ond a p~rticular shape. Thus,
the pillow can be conformed to the support upon which it is
attached but the user will not be able to deform it to an
unusable or uncomfortable shape.
A wide variety of plastic or elastomeric foam particles
or pellets are available at present and any of the generally
known types are suitable for use in one embodiment of this
invention. Again, for the construction of a lightweight
pillow, the low density foamed materials, such as foamed or
expanded polyethylene, polypropylene, polystyrene and the
like, are preferred. All of the pellets used in this
invention, however, should be resilient, washable, and
capable of retaining their resiliency over an extended
period of use and time. The smaller size pellets generally
contribute to a soft cushion which can be easily manipulated
to conform to a particular or desired shape, while the
larger pellets produce a somewhat firmer cushion. Also, a
wide range of pellet sizes can be used in tha cushion
without departing from the invention.
The preferred pellets for use in constructing the
lightweight cushions of the present invention include any
foam or expanded plastic materials in the form of spheres.
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The size range for such spheres is not essential to the use
of the support cushion. However, it is preferred that a
majority of the spheres used in the apparatus have diameters
between l/64 and l/2 inch; most preferably between l/32 and
l/4 inch. Preferred materials would again included expanded
thermoplastic foams, with expanded polystyrene foam spheres
being the most advantageous from the standpoint of light
weight. When the pillow is filled with particles of
substantially uniform diameters on the order of l/4 inch or
greater, a relatively firm cushion is provided. For softer
and more easily shapable cushions, it is preferred to use
spheres having diameters in the range between l/4 and l/8
inch or smaller. Particle sizes having a diameter above l/2
inch are generally selected for very large cushions or
mattresses which in turn may be necessary for supporting the
user's entire body, or for larger objects, such as animals.
Again, as noted above, different size pellets may be used to
obtain cushions having the desired softness or firmness for
the particular application, and commercially available
spheres usually include a variety of different diameters.
Expanded or foamed thermoplastics are preferred due to
their springiness, resiliency, and ultra-light weight. If
spheres of these materials are compressed, they will
substantially return to their original shape after the com-
pressive force has been removed. Thus, the spheres contrib-
ute to the invention in that they are easily capable of
movement or deformation to allow shaping of the cushion. If
they are deformed, these spheres do return to their original
configuration reasonably well after the item to be supported
is removed from the pillow. This also enables the cushion
to be easily shaped, since the spheres can easily be moved
through the internal cavity without interference from the
tension elements or draw-cord. In addition, the use of such
expanded thermoplastics in conjunction with lightweight
covering materials enables an extremely ultra lightweight
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overall cushion to be provided. For example, a 14" x 10" x
10" box-like cushion containing expanded polystyrene spheres
having diameters between 1/8 and 1/4 inch with a Lycra
Spandex fiber blend of ~0.8% cotton, 35.4% Lycra, and 23.8
nylon as the outer surface material and with ~ycra Spandex
tension members would weigh approximately 1~-1/2 ounces.
This is a significant improvement in weight c~mpared to the
much heavier pillows of the prior art.
As is evident from FIGS. 1 and 3, the opposed exterior
surfaces 20 of the cushion 10 are pre-stressed by connecting
thereto a plurality of tension members 50 in the form of
elastic cord or other similar flexible connectors. Such
flexible connectors can be in the form of fiber, tube, rod,
bar, strip or the like: the only requirement being that
they have a flexible or elastic nature which when at rest
can be extended or stretched and which when stretched
attempts to return to its rest position. When the user
attempts to conform the cushion to a particular shape to
comfortably fit the shape of the user's back, the elastic
tension members 50 are allowed to expand and contract, thus
facilitating the shaping of the cushion 10 and also
maintaining the cushion in the desired shape until it is
later changed to a different shape by the user.
A preferred material for these tension members is also
the Lycra Spandex material referred to above. Similar
materials having the ability to stretch and contract
numerous times, while also being washable without losing its
flexibility over time/ can also be used. Various
thermoplastics or elastomeric materials, including natural
or synthetic latexes, are suitable for these tension
members. Generally, while the solid or hollow diameter tube
or rod is preferred, it is also possible to use rectangular
or sguare cross-sectional hollow or solid bar materials or
even fabric of various widths. When fabric is used, the
width of the material would generally be on the order of
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about l/4 to l/2 inch. Larger width material may be used
for larger sized cushions or where additional tension force
is required, provided that the movement of the thermoplastic
spheres is not substantially restricted.
The tension members are generally spaced on 4 to 5 inch
centers across the exterior ~;urface 20 of the cushion lO.
The pattern of a spaced elastic cord attachment positions
can be s~uare, diamond shapecl, centered or of~-centered.
The 4 to 5 inch spacing is not critical and again would be
determined by the size of the cushion. Tension member
spacings smaller than about l inch generally provide an
excessive number of such members, whereas spacing of greater
than lO inch~s is usually insufficient to prestress the
opposed surfaces, particularly in larger size cushions.
These members may be parallel or they may cross each other
at an angle, depending on the size (i.e. shape, length,
width and/or depth) of the cushion. The arrangement and
spacing of the tension members (or tufts) is determined by
the specific support needs. Those skilled in the axt can
best determine the preferred arrangement of these members to
obtain the results desired.
When the tension cords are attached, they are stretched
and pulled relatively taut so that the outer surfaces of the
pillow are maintained under tension in a pre-stressed
condition. This is shown in the FIGS. as an indentation in
the surface of the exterior cover. Although each point of
attachment (i.e., indentation) normally utilizes a single
tension member, it may be desirable to use two or more
smaller size tension members at each indentation. This is
particularly useful in large pillows where single tension
members would have to be relatively large. The filling of
the pillow with the expanded thermoplastic spheres thus
enables the cushion to maintain its normal exterior shape
(i.e. round, square, rectangular, wedge etc~).
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FIGS. S and 6 illustra~e additional embodiments of
support cushions according to the invention. There, an
elongated pillow 70 having exterior surface means 20
containing A plurality of the thermoplastic spheres are
used. A draw cord 80 and an appropriately located locking
nut 90 are used to form either a thin elongated pillow, with
the locking nut at a retracted position as shown in FIG. 5,
or short, stubby pillow, with the locking nut compressing
the pillow as shown in FIG. 6. The draw cord 80 is attached
to one end of the pillow 70, passes through the internal
cavity, and exits the opposite side of the pillow through
the surface means 20. In other embodiments of the invention
using a draw cord, such as shown in FIG. 8, the draw cord 80
can pass through the surface means in multiple locations.
The light weight and shapeability of the cushion 70 in
conjunction with the draw cord 80, enables a wide range of
shapes and "hardness" (or compactness) of the spheres to
suit the desire of the user.
Also, exterior prestressing means (not shown), again in
2~ the form of tension cord but this time wrapped around the
circumference of exterior surface 20, can be used to help
hold the pillow in the shape formed by the user. The
desired configuration of the particular pillow to be
manufactured will determine whether such exterior
prestressing means are necessary, with elongated pillows not
having a draw cord generally requiring the additional
prestressing means as shown in FIG. 15.
Referring now to FIG. 7 there is illustrated a support
cushion lO0 formed of exterior surface means llO of the type
described above and also having a plurality of tension cords
shown as indentations 120. The shape of the pillow lO0 is
further defined by use of non-stretch fabric 130 for a
portion of the exterior surface means. In certain
situations, the use of the non-stretchable fabric 130
enables the tension cords 120 to be eliminated or only
necessary on certain faces, while more versatile pillows can
be made by using a combination of the non-stretchable fabric
130 and tension cords 120. Preferred non-stretchable
fabrics for the panel 130 include cotton, suede, denim,
nylon, corduroy, and the like. ~urthermore, draw cord and
locking means as disclosed in FIGS. 5 and 6 can be used to
provide further shapeability and forming configurations of
the pillow 100. Instead of non-stretchable fabric, non-
stretchable or surgical tape can be used to maintain a
desired shape for the pillow.
FIG. 8 shows a seating apparatus 150 comprised of a
support element 160 and a cushion 170. As shown in FIG. 8,
both draw cord 180, locking means 190, and tension cords 200
are used to assist in the shaping of the cushion 170 with
the support element 160 assisting in the possible
configurations attainable by the apparatus. Support xing
160, preferably made of metal or plastic, is used to hold
the cushion in a predetermined manner so that it can be used
as a footstool~ chair, hassock or the like. The shape of
the cushion 150 can be ~aried by the use of the draw cord
180 as well by manipulation of the tension cords 200 by
compression from the user.
Other cushion supports are shown in FISS. 8 and 11.
This allows a certain degree of shaping of the cushions
within the original support so that the user can experience
the desire degree of comfort while not manipulating the
cushion to an unuseable configuration.
FI&. 9 shows a support cushion in the form of a
mattress 210 having a plurality of tension cords 220 which
are aligned along the width of the mat~ress space in rows or
arrays. In order to accommodate ~olding of mattress into
segments, certain rows of tension cords are aligned so that
a hinge will be created. This can be achieved by closely
spacing the cords so that the cushion can be b2nt along the
row of cords. Thus, these tension cords 220 create a crease
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line or seam line along the mattress where it may be bent.
A folded and bent mattress is shown in FIG. 10. Also, the
crease lines or hinges enable other portions of the mattress
to easily conform to the shape of a supporting object such
as a frame 220 shown in FIG. ll. While an array o~ tension
cords 220 as shown in FIGS. 9-11 has been found suitable for
making this fold line or crease line, it is also possible to
sew non-stretchable panels or seams through the material
from the top to bottom to achie~e the same effect. As in
the other FIGS., the surface ~D~ the mattress is pre~erably
of a stretchable fabric and i~s maintained a tension by
filling the mattress with a plurality of thermoplastic
spheres also as described above. Again, this mattress can
be shaped to conformed to the outline of the user or the
item to be supported.
FIGS. 12-15 illustrate additional embodiments of
support cushions according to the invention. The tension
members are used to pre-stress opposed faces of the exterior
covering 260 while the spheres 270 prevent the opposed faces
the exterior covering from being drawn together. In FIGS.
12 and 13, a support cushion 250 in the form of a six sided
substantially rectangular box, with exterior covering 260,
plastic spheres 270, and tension members 280, is shown.
These tension members 280 produce indentations 290 in the
surface covering, and pre-stress said surface covering while
the spheres 270 prevent the f~ce~ o~ the covering ~rom being
drawn together. FIG. 14 shows a spherical pillow 300 having
exterior surface means 260 and a plurality of indentations
290. The tension members ~not shown, but see Fig. 13)
connecting these indentations all pass approximately through
the center of the sphere. In addition to use as a pillow or
cushion, the spherical shape is useful as a ball or play
object. Of course, other shapes or configurations can be
used to form toys or other play objects.
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FIG. 15 shows a cylindrical pillow 310 with exterior
surface 260 and indentations 290. According to a further
aspect of the invention, exterior prestressing means 320,
again in the form of tension cord but this time wrapped
around the circumference of exterior surface 260, help hold
the pillow in the shape formed by the user. The desired
configuration of the particular pillcw to be manufactured
will determine whether such exterior prestressing means are
necessary, with elongaged pillows generally requiring this
additional prestressing feature.
In order to use the cushion, one merely compresses the
exterior surface areas to conform the cushion to the shape
of the object or body member to be supported (i.e. arm,
elbow, leg, shoulder, etc.). The pellets or spheres easily
move around each other as the tension members contract, thus
enabling the cushion to be easily and quickly formed to the
desired shape. In the event the cushion is extremely
compressed in certain areas, such as it exposed to a heavy
load, the expanded thermoplastic spheres are capable of
being compressed to accommodate the load. Upon removal of
the load, the pellets or spheres return to their original
spherical shape, although the cushion itself will not return
to its original configuration. Should a different
configuration or shape be desired for the cushion, the user
must again compress or shape the cushion to the desired new
configuration.
As one skilled in the art can realize, the present
invention is ideally suited for arthritis sufferers,
patients recovering from surgery, those suffering from
backache, pain or discomfort caused by difficult
pregnancies, temporary sprains, sports injuries, broken
bones, or the like. One of the advantages of the cushions
of this invention is that they can be adjusted to the
precise shape for maximum comfort and support of the body
member. Therefore, the user is able to completely relax
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while the hody member is supported and this facilitates
resting and sleeping much easier than if the body member
were rested or being supported upon a conventional pillow or
cushion that could not be shaped to exactly meet the user's
need.
The si~e of the overall cushion is not critical to the
invention. Sizes can vary from relatively small (i.e. that
sufficient for supporting a head, hand or foot), to very
large which, for example, ~an be used in place of a bed
mattress for support of the entire body of ~he user.
Although practically any shape can be used, the following
have been ~ound to be particularly usefulo wedge, tube or
cylinder, truncated pyramid, sphere, eggshape, box (six-
sided - rectangular or square), and triangular. As noted
above, the extreme light weight of the preferred embodiments
enable the cushion to be easily handled, moved or shaped by
the user.
While it is apparent that the invention herein dis-
closed is well calculated to fulfill the ~bjects above
stated, it will be appreciated that numerous embodiments and
modifications may be devised by thos~ skilled in the art,
and it is intended that the appended claims cover all such
modifications and embodiments as fall within the true spiri$
and scope of the present invention.
