Support System for a Reclining or Sitting Body

Abstract

A support system including polyurethane layers having different indentation load deflection characteristics and a plurality of zones to vary the level of support in different regions of a reclining or sitting body.

What is claimed is: 
     
         1 . A support system for a reclining body, comprising:
 a hexahedron comprising,   
       an upper layer comprising a first synthetic foam, said upper layer comprising a first side, a second side, a first end and a second end, a top surface and a bottom surface, said upper layer further comprising at least a first zone, a second zone, and a third zone, said first zone extending from the first end of said upper layer towards the second zone, said second zone positioned between the first zone and the third zone, said third zone extending from said second end towards said second zone of said upper layer, the top surface of said upper layer being substantially planar, the bottom surface of said upper layer comprising a plurality of ridges paralleling a plurality of valleys, each ridge and valley extending from said first side of said upper layer to said second side of said upper layer, and,
 a lower layer comprising a second synthetic foam different from the first synthetic foam of said upper layer, said lower layer paralleling said upper layer and comprising a first side, a second side, a first end and a second end, a top surface and a bottom surface, said lower layer further comprising at least a first zone, a second zone, and a third zone, said first zone extending from the first end of said lower layer towards the second zone, said second zone positioned between the first zone and the third zone, said third zone extending from said second end towards said second zone of said lower layer, the bottom surface of said lower layer being substantially planar, the top surface of said lower layer comprising a plurality of ridges paralleling a plurality of valleys each ridge and valley extending from said first side of said lower layer to said second side of said lower layer, 
 said zones of said upper layer align with said zones of said lower layer, wherein said plurality of ridges in said top surface of said lower layer interface with said plurality of valleys of said bottom surface of said upper layer, said plurality of valleys in said top surface of said lower layer interface with said plurality of ridges in said bottom surface of said upper layer, and 
 wherein the bottom surface of said upper layer interdigitates with said top surface of said lower layer whereby such combination of said upper layer and said lower layer form said support system. 
 
     
     
         2 . The support system of  claim 1  wherein said plurality of ridges and said plurality of valleys positioned in said first zone of said upper layer and said plurality of ridges and valleys positioned in said first zone of said lower layer are different in number than the plurality of ridges and valleys in said second zone of said upper layer and in said second zone of said lower layer. 
     
     
         3 . The support system of  claim 2  wherein said plurality of ridges and said plurality of valleys in said second zone of said upper layer and said plurality of ridges and valleys positioned in said second zone of said lower layer are different in number than said plurality of ridges and valleys in said third zone of said upper layer and in said third zone of said lower layer. 
     
     
         4 . The support system of  claim 1  wherein said upper layer comprises a polyurethane material comprising an indention load deflection and said lower layer comprises a material comprising an indention load deflection wherein said indentation load deflection of said lower layer is higher than the indention load deflection of the polyurethane material of said upper layer. 
     
     
         5 . The support system of  claim 1  wherein one or more of said plurality of ridges comprise a radius in cross-section. 
     
     
         6 . The support system of  claim 1  wherein one or more of said plurality of ridges comprise an apex comprising an acute angle in cross-section. 
     
     
         7 . The support system of  claim 1  wherein one or more of said plurality of ridges comprise an apex comprising an obtuse angle in cross-section. 
     
     
         8 . The support system of  claim 1 . wherein the thickness of one of the lower or upper layer is one to seven times as thick as the other layer. 
     
     
         9 . The support system of  claim 1  wherein the depth of said valleys in said lower layer is in a range of about 0.5 inches to about 24 inches. 
     
     
         10 . The support system of  claim 1  wherein the depth. of said valleys in said upper layer comprises 0.5 inches to 24 inches. 
     
     
         11 . The support system of  claim 1  wherein said upper layer comprises a polyurethane foam comprising one indentation load deflection and said lower layer comprises a polyurethane foam comprising another indentation load deflection. 
     
     
         12 . The support system of  claim 1  wherein of said a synthetic foam from one of said upper layer or said lower layer is selected from the group consisting of polyurethane foam, polyurethane gel foam, and viscoelastic polyurethane foam and the other of said upper layer or lower layer comprises a material having a different indentation load deflection than the other layer. 
     
     
         13 . The support system of  claim 1  wherein a base layer is positioned adjacent to and parallel to said bottom surface of said lower layer, 
     
     
         14 . The support system of  claim 1  wherein a surface layer is positioned adjacent to and parallel to said top surface of said upper layer. 
     
     
         15 . The support system of  claim 1  wherein a surface layer is positioned adjacent to and parallel to said top surface of said upper layer and a base layer is positioned adjacent to and parallel to said bottom surface of said lower layer.