Reticulated material body support and method

Abstract

A body support comprising a top layer of flexible visco-elastic material having an exposed convoluted top surface is disclosed. The flexible visco-elastic material can have a reticulated or non-reticulated cellular structure. In some embodiments, one or more other layers of the body support comprises reticulated visco-elastic foam, and can have at least one material property responsive to temperatures in the range of a user's body heat. In these and other embodiments, one or more of the other layers of flexible material comprises non-visco-elastic foam, and can be combined in a body support with one or more layers of visco-elastic foam. The body support can include one or more layers of other material types, including one or more layers of high-resilience polyurethane foam.

1 . A support cushion, comprising: 
 a first layer comprising visco-elastic foam having an exposed top surface; and    a bottom surface opposite the top surface and separated from the top surface by a distance defining a thickness of the support cushion;    wherein at least a portion of the exposed top surface of the top layer has a convoluted shape.    
   
   
       2 . The support cushion as claimed in  claim 1 , further comprising a cover at least partially covering the exposed top surface of the first layer.  
   
   
       3 . The support cushion as claimed in  claim 1 , wherein the first layer comprises a plurality of cells defining a reticulated cellular structure, the cells of the reticulated cellular structure comprising a skeletal plurality of supports through which substantially open cell walls establish fluid communication between an interior of the cell and interiors of adjacent cells.  
   
   
       4 . The support cushion as claimed in  claim 3 , wherein the first layer comprises foam having a density no less than about 30 kg/m 3  and no greater than about 175 kg/m 3 , and a hardness of no less than about 20 N and no greater than about 150 N at 40% indentation force defection measured at about 22 degrees Celsius, the layer of flexible foam comprising visco-elastic foam having at least one material property responsive to a temperature change in a range of 10-30° C.  
   
   
       5 . The support cushion as claimed in  claim 4 , wherein the first layer comprises foam having a density no less than about 50 kg/m 3  and no greater than about 130 kg/m 3 .  
   
   
       6 . The support cushion as claimed in  claim 4 , wherein the first layer comprises foam has a density no less than about 60 kg/m 3  and no greater than about 110 kg/m 3 .  
   
   
       7 . The support cushion as claimed in  claim 1 , further comprising a second layer of polyurethane foam located beneath the first layer, the second layer of polyurethane foam having a hardness of at least about 50 N.  
   
   
       8 . The support cushion as claimed in  claim 1 , further comprising a second layer of polyurethane foam located beneath the first layer, the second layer of polyurethane foam having a hardness of at least about 80 N.  
   
   
       9 . The support cushion as claimed in  claim 1 , further comprising a second layer of flexible foam supporting the first layer, the second layer of flexible foam having a plurality of cells defining a reticulated cellular structure and having a temperature change responsiveness of no greater than 10% change in hardness within a temperature range of 10-30 degrees Celsius.  
   
   
       10 . The support cushion as claimed in  claim 9 , wherein the first layer comprises visco-elastic foam having a non-reticulated visco-elastic cellular structure having 
 a density no less than about 30 kg/m 3  and no greater than about 150 kg/M 3 ;    a hardness of no less than about 30 N and no greater than about 175 N at 40% indentation force defection measured at about 22 degrees Celsius; and    at least one material property responsive to a temperature change in a range of 10-30° C.