(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2007/0246157 A1
`Oct. 25, 2007
`Mason et al.
`(43) Pub. Date:
`
`US 20070246157Al
`
`(54)
`
`PROCESS FOR PREPARING AN APPARATUS
`COMPRISING A GEL LAYER
`
`(75)
`
`Inventors:
`
`Matteo Mason, Limena (Padova)
`(IT); Massimo Losio, Asolo
`(Treviso) (IT)
`
`(60)
`
`(51)
`
`Related US. Application Data
`
`Provisional application No. 60/745,564, ?led on Apr.
`25, 2006.
`Publication Classi?cation
`
`Int. Cl.
`(2006.01)
`B29D 31/00
`(2006.01)
`B29C 44/04
`US. Cl. ....... .. 156/242; 264/299; 264/45.l; 264/511
`
`Correspondence Address:
`ALSTON & BIRD LLP
`BANK OF AMERICA PLAZA, 101 SOUTH
`TRYON STREET, SUITE 4000
`CHARLOTTE, NC 28280-4000
`
`(73)
`
`Assignee:
`
`TechnoGel GmbH & Co.
`
`(21)
`
`Appl. No.:
`
`11/739,280
`
`(22)
`
`Filed:
`
`Apr. 24, 2007
`
`ABSTRACT
`
`(52)
`(57)
`The invention provides a method for preparing a support
`apparatus comprising a gel layer and a second layer, such as
`a foam layer. In particular, the invention provides a method
`for preparing a mattress. The method generally comprises
`preparing a gel layer and affixing the gel layer to a second
`layer. In certain embodiments, Where a foam layer is used as
`the second layer, the foam layer may have a surface having
`a cavity formed therein for receiving the gel layer.
`
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`Patent Application Publication
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`Oct. 25, 2007 Sheet 1 0f 4
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`US 2007/0246157 A1
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`IPR2017-00351
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`Patent Application Publication
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`Oct. 25, 2007 Sheet 2 0f 4
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`US 2007/0246157 Al
`
`FIG. 2
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`Patent Application Publication
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`Oct. 25, 2007 Sheet 3 0f 4
`
`US 2007/0246157 Al
`
`.
`
`II]
`
`)f
`)GUSEJ
`‘)EQJEJEJEJEJEJEEM
`)EJIIJUC'GD
`‘Q
`)\
`
`“
`
`FIG. 3
`
`M5: 50
`
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`Patent Application Publication
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`Oct. 25, 2007 Sheet 4 0f 4
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`US 2007/0246157 A1
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`FIG. 4
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`US 2007/0246157 A1
`
`Oct. 25, 2007
`
`PROCESS FOR PREPARING AN APPARATUS
`COMPRISING A GEL LAYER
`
`CROSS-REFERENCE TO RELATED
`APPLICATION
`
`[0001] The present application claims priority to US.
`Provisional Patent Application No. 60/745,564, ?led Apr.
`25, 2006, the disclosure of Which is incorporated herein in
`its entirety.
`
`FIELD OF THE INVENTION
`
`[0002] The present invention is generally directed to meth
`ods of preparing apparatuses designed for bodily support. In
`particular, the invention is directed to methods of preparing
`apparatuses comprising a gel layer and an additional layer,
`such as a foam layer.
`
`BACKGROUND
`
`[0003] Multiple apparatuses are knoWn in the art for
`providing support to the body of a user. Such apparatuses
`generally comprise one or more layers of padding or cush
`ioning to provide functional support of the user’s body and
`to provide such support While also providing a level of
`comfort. Similarly, such apparatuses may also comprise
`mechanical supports, such as coil springs.
`[0004] Advances in the art are generally directed to appa
`ratuses that provide the functional support necessary in such
`apparatuses but also provide increased comfort or provide a
`decrease in the volume of materials necessary to provide the
`support. For example, US. Pat. No. 6,701,556 to Romano et
`al. discloses mattress or cushion structures designed to
`improve pressure distribution While reducing the overall
`thickness of the mattress or cushion. Further, US. Pat. No.
`6,804,848 to Rose discloses an air support sleep system
`having an upper mattress air posturiZing module and an
`adjustable air posturiZing sleep surface.
`[0005] While the apparatuses commonly used for bodily
`support may provide functional support, they yet fail to
`provide a level of comfort useful for facilitating restfulness
`or sleep, or for providing a greatest relief of pressure for the
`body parts in contact With the support surface. Gel materials
`are generally knoWn to provide good physical comfort and
`pressure relief. Further, gels are also knoWn to exhibit a
`relatively high thermal conductivity. Accordingly, gels, such
`as polyurethane gels, are generally regarded as having a
`“cool” feel to the body, as body heat is perceptibly moved
`aWay from the body When in contact With the gel.
`[0006] In light of the desirable properties afforded by gel
`materials, it is not surprising that demand for support
`apparatuses comprising gels continues to increase. HoWever,
`there has heretofore yet not been provided a method for
`preparing support apparatuses comprising a gel layer in a
`manner that is both cost effective and e?icient.
`[0007] Accordingly, there still remains a need in the ?eld
`for methods of preparing apparatuses useful for bodily
`support that comprise a gel layer. Such methods are provided
`by the present invention.
`
`SUMMARY OF THE INVENTION
`[0008] The present invention provides various methods
`for preparing a support apparatus, such as a mattress. The
`apparatus prepared according to the invention generally
`comprises a gel layer. In further embodiments, the apparatus
`
`comprises a gel layer in combination With a foam layer. The
`inventive methods provide for preparation of a variety of
`support apparatuses and ?nd particular use in the preparation
`of mattresses.
`[0009] In one embodiment, the invention is directed to a
`method for preparing a support apparatus, such as a mat
`tress, that comprises a gel layer and a cover layer. The
`method generally comprises the folloWing steps: providing
`a mold; inserting a gel material into the mold to form the gel
`layer; and affixing a cover layer to the gel layer. In a
`particular embodiment, the mold comprises a vacuum-assist
`mold. In further embodiments, the method can further
`comprise the step of placing a release layer in the mold prior
`to the step of inserting the gel material into the mold.
`[0010] According to another embodiment, the method of
`the invention for preparing a support apparatus comprises
`the folloWing steps: providing a ?rst foam layer comprising
`a foam piece having a surface With one or more cavities
`formed therein; inserting a gel material into the one or more
`cavities in the surface of the foam piece; and at least partially
`curing the gel material to form one or more gel layers. This
`method of the invention is particularly characterized in that
`the foam layer of the support apparatus can function not only
`as a layer of the apparatus but also as the mold for the gel
`material. Further, the cavities in the foam can be prepared to
`be of a siZe, shape, and distribution such that a Wide variety
`of apparatus gel/foam combinations can be prepared accord
`ing to desired speci?cations and uses.
`[0011] According to yet another embodiment, the method
`of the invention for preparing a support apparatus comprises
`the folloWing steps: providing a mold useful for molding one
`or both of a gel material and a foam material; placing a
`release layer in the mold; inserting a gel material into a
`portion of the mold adapted for receiving a gel material; at
`least partially curing the gel material to form a gel layer;
`inserting a foam material into a portion of the mold adapted
`for receiving a foam material; and curing the foam material
`to form a foam layer. Optionally, the step of curing the gel
`material can be carried out simultaneously With the step of
`curing the foam material, thereby forming both the gel layer
`and the foam layer simultaneously and, further optionally,
`chemically bonding the gel layer and the foam layer during
`the simultaneous curing step. In further embodiments, the
`method can further comprise the step of placing a release
`layer in the mold prior to the step of inserting the gel
`material into the mold.
`[0012] In still another embodiment, the invention provides
`another method for preparing a support apparatus compris
`ing a foam layer and a gel layer. According to this embodi
`ment, the method comprises the folloWing steps: providing
`a ?rst foam layer comprising a foam piece With a surface that
`is at least partially convoluted; and applying a gel material
`to the convoluted surface of the foam layer to form a gel
`layer attached to the foam layer. In further embodiments, the
`method can comprise the step of affixing a cover layer to the
`apparatus. In a speci?c embodiment, the cover layer can
`comprise a second foam layer.
`[0013] According to the various methods of the invention,
`the gel material used in the gel layer can be any gel material
`that, in a cured form, is non-toxic to a potential user and that
`provides bene?cial and comfortable physical properties. In
`particular, the gel material may comprise a gel having
`speci?c physical properties identi?ed as providing increased
`support pressure and relief to a user, and also providing a
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`user With an increased perception of comfort (i.e., a good
`“feel”). Further, in the support apparatuses prepared accord
`ing to the inventive methods, the gel layer can be the
`outermost layer of the apparatus, therefore being in direct
`contact With the user. According to further embodiments, the
`apparatus can also comprise a covering overlying the gel
`layer. Preferably, the covering layer is not of structure or
`thickness to substantially reduce or mask the comfort and
`support provided by the gel layer. Non-limiting examples of
`coverings encompassed by the invention include a textile
`layer, a ?lm layer, a coating layer, and a foam layer.
`[0014] In addition to the gel and foam layers described in
`the illustrative embodiments noted above, the methods of
`the invention further encompass preparation of support
`apparatuses comprising one or more additional support
`layers. These additional support layers can include any type
`of support material generally knoWn in the art of bodily
`support apparatuses, particularly in the art of mattresses and
`seating apparatuses. For example, the one or more additional
`support layers may include one or more of the folloWing: a
`foam layer; a spring layer; a textile layer; a gas layer, a Wood
`layer, a metal layer, and a plastic layer. Accordingly, the
`apparatus prepared according to the methods of the inven
`tion ?nds use in a Wide variety of supports. For example, an
`apparatus prepared according to the invention could be used
`for supporting the entire body or only a portion of the body.
`As such, the apparatus ?nds use in home settings, such as
`bedding or seating, in o?ice settings, such as chair seats,
`chair back rests, chair arm rests, keyboard Wrist rests, and
`the like, in transportation, such as car seats or other interior
`components, medical settings, such as bedding, Wheelchairs,
`and clothing, particularly footWear, as Well as other settings
`Wherein comfort or pressure relief are to be maximiZed. In
`one particular embodiment, the method of the invention is
`used in the preparation of a mattress. Non-limiting examples
`of further support apparatuses prepared according to the
`methods of the invention include seating apparatuses, pil
`loWs, mattress toppers, footWear cushions (or insoles), arm
`pads, and Wrist pads.
`[0015] According to another embodiment, the gel layer, in
`addition to the gel, may further comprise a content of one or
`more ?llers. Such ?llers are particularly useful in modifying
`the thermal conductivity of the gel used in the gel layer. As
`previously noted, gels are typically characteriZed by a “cool”
`feel, in part arising from the thermal conductivity of the gel
`in that it transports heat aWay from a Warmer object in
`contact With the gel, such as the body of a user. The ?llers
`used in the gel layer are preferentially capable of reducing
`the thermal conductivity of the gel, thereby alloWing the gel
`to exhibit a feel to a user that is less “cool”.
`[0016] Various types of ?ller can be used With the methods
`of the invention. The ?ller material should generally be
`non-reactive With the gel, or With possible derivatives of the
`gel or the precursors thereof (e.g., isocyanates and polyols in
`the case of polyurethane gels). Preferably, the ?ller is a
`material capable of bene?cially affecting one or more physi
`cal characteristics of the gel including, but not limited to, the
`thermal conductivity of the gel. In one particular embodi
`ment of the invention, the ?ller material is selected from the
`group consisting of cork pieces, cork ?our, Wood pieces,
`Wood chips, foam ?akes, textile ?bers, textile pieces, par
`
`af?ns, holloW spheres, synthetic microspheres, mineral par
`ticles, glass beads, gasses, active agents, nanoparticles, and
`mixtures thereof.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0017] Having thus described the invention in general
`terms, reference Will noW be made to the accompanying
`draWings, Which are not necessarily draWn to scale, and
`Wherein:
`[0018] FIG. 1 is a perspective vieW of a vacuum-assist
`mold illustrating a mattress formed therein having a gel
`layer and a foam layer, said layers being partially cut aWay
`to reveal the underlying detail;
`[0019] FIG. 2 is perspective vieW of a support apparatus
`prepared according to one embodiment of the invention
`comprising a cavity foam layer, Wherein the cavities are
`?lled With a gel layer;
`[0020] FIG. 3 is a perspective of another support apparatus
`prepared according to one embodiment of the invention
`comprising a cavity foam layer, Wherein the cavities are
`?lled With a gel layer; and
`[0021] FIG. 4 is a cross-sectional vieW of a support
`apparatus prepared according to one embodiment of the
`invention comprising a foam layer having a convoluted
`surface covered With a gel layer.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`[0022] The present invention Will be described more fully
`hereinafter in connection With preferred embodiments of the
`invention Which are given so that the present disclosure Will
`be thorough and complete and Will fully convey the scope of
`the invention to those skilled in the art. HoWever, it is to be
`understood that this invention may be embodied in many
`different forms and should not be construed as being limited
`to the speci?c embodiments described herein. Although
`speci?c terms are used in the folloWing description, these
`terms are merely for purposes of illustration and are not
`intended to de?ne or limit the scope of the invention. Like
`numbers refer to like elements throughout. As used in this
`speci?cation and the claims, the singular forms “a,” “an,”
`and “the” include plural referents unless the context clearly
`dictates otherwise.
`[0023] The present invention provides methods for pre
`paring an apparatus useful for bodily support, particularly
`support that, in addition to being functional, also provides
`increased comfort and pressure point relief for a user. The
`methods of the invention generally comprise providing a
`mold having one or more portions adapted for receiving a
`gel material, inserting a gel material into the mold, and
`curing the gel material to form a gel layer. Optionally, a
`foam layer may be added to the gel layer. In certain
`embodiments, the mold comprises a foam layer having a
`surface With one or more cavities adapted for receiving the
`gel material.
`[0024] The gel material used in the methods of the inven
`tion can comprise any gel material that is stable, non-toxic,
`and generally knoWn to provide a cushioning effect while
`maintaining a degree of structural stability and support. In
`particular, the gel can comprise any gel material having a
`hardness and elasticity that are Within a preferred range, as
`more fully described herein.
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`[0025] Polyurethane gels are particularly useful according
`to the invention. Further, other gels that are resistant to
`hardening over time, have limited expandability, and are
`resistant to substance degradation (e.g., from migration of
`volatile agents, such as plasticizers) could also be useful as
`the gel material in the present invention. Preferably, the gels
`used according to the invention are also shock absorbent and
`resistant to vibration.
`[0026] Polyurethanes are generally understood to be the
`product of the chemical reaction betWeen a polyisocyanate
`compound and a polyfunctional alcohol (i.e., a polyol). One
`example of a general reaction scheme for preparing a
`polyurethane compound is shoWn beloW:
`
`wherein R1 and R2 can be various organic groups including,
`but not limited to, straight or branched chain or cyclic alkyl,
`alkenyl, or alkynyl groups, as Well as various aryl groups. Of
`course, the above scheme is provided only as an example of
`the preparation of the polyurethane compounds useful
`according to the invention and is not intended to be limiting
`thereof. Additional examples of polyurethane gels that may
`be useful in the methods of the invention are disclosed in
`US. Pat. No. 6,191,216, United States Published Patent
`Application No. 2004/0058163 (application Ser. No. 10/618,
`558) and United States Published Patent Application No.
`2004/0102573 (application Ser. No. 10/656,778), Which are
`incorporated herein by reference. Examples of other types of
`gels useful according to the invention are disclosed in US.
`Pat. No. 4,404,296, US. Pat. No. 4,456,642, and United
`States Published Patent Application No. 2005/0186436 (ap
`plication Ser. No. 11/058,339), Which are incorporated
`herein by reference.
`[0027] Gels, such as polyurethane gels, are generally
`recognized as imparting a balanced pressure distribution.
`Unlike standard padding materials, Which react to an applied
`pressure, such as a user sitting or lying of the padding, by
`deforming along only the axis of the applied pressure (i.e.,
`the axis perpendicular to the plane of the padding), gels tend
`to exhibit tri-dimensional deformation properties. In other
`Words, the gel reacts to the applied pressure by deforming
`along three axes: the X and Y axes in the plane of the gel
`surface, as Well as the Z axis that lies perpendicular to the
`plane of the gel surface. This leads to an even distribution of
`the exerted pressure, Which lessens the pressure felt by the
`user at the pressure points. Accordingly, in addition to
`providing added comfort, the gel provides health advan
`tages, such as increased blood circulation, encouragement of
`correct posture, and alleviation of pressure concentration,
`Which can lead to serious conditions, such as bed sores, or
`other types of ulcerations.
`[0028] The gel materials used in the methods of the
`invention may particularly be characterized by the speci?c
`physical properties they exhibit. For example, tWo physical
`properties speci?cally useful in characterizing the gel mate
`rial are hardness and elasticity. Optimization of these tWo
`properties exhibited by the gels alloWs for preparation of a
`
`gel layer (and ultimately an overall apparatus) providing
`both objective and subjective comfort and support. In other
`Words, gels according to the invention having a certain
`degree of hardness and a certain degree of elasticity provide
`therapeutic bene?ts (i.e., objective comfort), as previously
`described, but also provide a user With a good “feel” (i.e.,
`subjective comfort). The ability to provide both objective
`and subjective comfort is particularly useful because a
`support apparatus designed to provide therapeutic bene?t to
`a user may not alWays feel good to the user. Conversely,
`What feels good to a user may not alWays provide therapeutic
`bene?t to the user. HoWever, gel materials used in the
`methods of the present invention having a hardness and
`elasticity Within the presently speci?ed ranges provide both
`objective and subjective comfort.
`[0029] A person skilled in the relevant arts Would be
`expected to seek out material having a good perceived
`comfort for use in preparing a support apparatus. For
`example, such a skilled person Would be expected to choose
`a material having a hardness providing subjective comfort to
`the user. HoWever, only according to the present invention
`has it been found that merely optimizing a single material
`property, such as hardness, to provide a good feel to a user
`is insuf?cient to provide a support apparatus that provides
`both subjective and objective comfort for a user.
`[0030] Based upon knoWn technology, a skilled person
`may prepare an apparatus to have a physical property Within
`a certain range of values. The present invention reveals,
`however, that such range can change When the underlying
`material is further optimized in relation to other values
`necessary to provide both subjective and objective comfort
`to a user. Accordingly, the values for the physical properties
`described herein have been established through testing and
`evaluation to balance off-setting nature of various gel physi
`cal properties and arrive at a desired gel formulation that
`provides a good feel to the user but also provides therapeutic
`bene?t. This is a distinct advantage over the art in that
`changing a single physical property may lead to a support
`apparatus that is comfortable to one user but uncomfortable
`to another user and fails to provide therapeutic bene?t to
`either user. The gel used in the present invention, hoWever,
`is the culmination of rigorous testing to provide a gel
`material having hardness and hysteresis values that give the
`gel a good feel to a variety of users While also providing
`therapeutic bene?t. As such, the range of values provided
`herein provide for a gel material having properties and
`e?fects that are unexpected in light of the knoW art and that
`provide distinct bene?ts not provided by gel materials
`having hardness and hysteresis values outside of the dis
`closed ranges.
`[0031] Preferably, the gel material is characterized by
`having a loW degree of hardness, such hardness being
`measurable as the force de?ection of the gel at a speci?c
`compression. Gel hardness can be measured according to
`any knoWn method, and a gel useful according to the
`invention can be identi?ed as having a hardness in a speci
`?ed range. One method particularly useful according to the
`invention for measuring gel hardness is the testing method
`ISO 3386-1 (year 1986 version), as designated by the
`International Organization for Standardization (ISO).
`[0032] According to ISO 3386-1, a method is provided for
`the calculation of the compression stress value of various
`materials. The compression stress/strain characteristic is a
`measure of the load-bearing properties of the material, and
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`the testing method provides tWo formulas for calculating the
`compression force de?ection in kilopascals (kPa), Which
`provides a measured hardness of the material.
`[0033] Speci?cally, under the ISO 3386-1 standard, a gel
`according to the invention can be measured for a hardness
`determination through a compression load de?ection test. In
`particular, a 5 cm><5 cm><2.5 cm gel sample is subjected to
`a compressive force, With a 70% maximum compression,
`and gel hardness is measured as the stress applied to the gel
`(in kPa) at 40% compression. Such testing Would typically
`be performed after the gel material has been alloWed to cure
`(i.e., formation of a gel layer).
`[0034] A gel material useful in the methods of the inven
`tion has a loW measurable hardness. Preferentially, the gel
`has a measurable hardness that is less than 90 kPa, more
`preferably less than 80 kPa, still more preferably less than 70
`kPa, and most preferably less than 60 kPa. In one embodi
`ment, the gel used in the invention has a measurable
`hardness in the range of about 0.5 kPa to about 50 kPa.
`According to further embodiments, the gel has a hardness in
`the range of about 1 kPa to about 40 kPa, about 1.5 kPa to
`about 30 kPa, or about 2 kPa to about 25 kPa.
`[0035] The gel material used in the methods of the inven
`tion is further characterized by having a measurable elas
`ticity that is Within a speci?ed range. In solid mechanics, a
`material is understood to behave elastically if it changes
`shape due to an applied load, and When the load is removed,
`the material recovers its original shape. The elasticity of a
`material is inversely proportional to its sti?‘ness.
`[0036] One method for evaluating the elasticity of a gel for
`use according to the invention is through determination of
`the hysteresis exhibited by the gel. Hysteresis is a property
`of systems (usually physical systems) that do not instantly
`folloW the forces applied to them, but react sloWly, or do not
`return completely to their original state. Hysteresis, then,
`can be evaluated as the ability of a material, such as a gel,
`to return to its original shape after removal of a force on the
`gel.
`[0037] In one method for determining hysteresis, a force is
`applied to a gel, Which leads to compression of the gel. The
`de?ection of the force by the gel at 70% compression is
`measured, and the external force is removed, alloWing the
`gel to decompress. The de?ection of the gel under no
`compression (i.e., after removal of the force) is then mea
`sured. The hysteresis of the gel (evaluated as a percentage)
`is the difference betWeen the tWo force values at the de?ned
`de?ections. Accordingly, a gel exhibiting a loW hysteresis
`percentage Would be expected to be highly elastic, in other
`Words, have a rapid and signi?cantly complete return to its
`original shape. A gel exhibiting a high hysteresis percentage
`Would be expected to be less elastic, in other Words have a
`more delayed and less complete return to its original shape.
`Again, according to the invention, such testing Would typi
`cally be performed on a gel layer after the gel material has
`been alloWed a su?icient time to cure or mature.
`[0038] Preferably, the gel materials used in the inventive
`methods exhibit an elasticity (or percentage hysteresis) that
`is not temperature dependent. In particular, it is preferable
`for the gel material to have an elasticity that lacks tempera
`ture dependence Within a range of temperatures that is Well
`tolerated by potential users (e. g., temperatures in climacetic
`conditions Wherein a support apparatus incorporating the gel
`may be used). Even more particularly, the absence of tem
`perature dependence is Within a range of temperatures
`
`commonly found in dWellings (such as betWeen about 500 F.
`and about 110° F.). In one embodiment, the gel used in the
`invention has a measurable hysteresis in the range of about
`15% to about 80%. According to further embodiments, the
`gel has a hysteresis in the range of about 20% to about 70%,
`about 25% to about 60%, or about 30% to about 50%.
`[0039] Gel materials are generally understood to have a
`relatively high thermal conductivity. High thermal conduc
`tivity can be a desirable gel property, such as in a Warm
`environment Where a cooling effect Would be Welcomed. In
`other situations, hoWever, it may be more desirable to have
`a loWer thermal conductivity in order to conserve heat near
`the body of the user. Advantageously, the gel materials used
`in the methods of the present invention can have a deter
`minable thermal conductivity.
`[0040] Thermal conductivity (7»), Which is generally
`reported in terms of Watts per meter per degree Kelvin
`(W-m'l ~° K_l), relates to the ability of a material to transmit
`heat under ?xed conditions. The loWer the value of 7», the
`better insulator the material Will be. Conversely, the higher
`the value of 7», the better heat conductor the material Will be.
`[0041] Foam, a typical cushion material for support appa
`ratuses, is knoWn to be a material exhibiting good insulating
`properties. For example, molded foam, such as used for seat
`cushions, typically has a 7» value of about 0.04 W~m_l~o K_l,
`and foam used in construction and building materials typi
`cally has a 7» value of about 0.022 W~m_l~o K_l. When a
`highly insulating material, such as foam, is used in a support
`apparatus for human use, the heat generated by the human
`body, at ?rst contact With the foam, is immediately trans
`ferred to the contact surface of the foam. With time, the
`transferred heat ?nds a high resistance to movement through
`the foam for dissipation. The energy (heat) produced con
`tinuously by the human body generates an increase in
`temperature because the foam is unable to absorb the energy
`and transport it aWay from the contact area quickly enough.
`In other Words, While the initial Warmth maintained by the
`contact With the foam may be of a comfortable level, an
`eventual heat build-up leads to discomfort for the user.
`[0042] Polyurethane gels, and similar gels as described
`herein, exhibit different thermal properties and can generally
`be considered good conductors of heat compared to foam.
`For example, a polyurethane gel can have a 7» value of about
`0.20 W~m_l~o K“1 or greater. Polyurethane gels also typi
`cally have a greater density than foam. For example, poly
`urethane gel can typically have a density in the range of
`about 600 to about 1,100 Kg/m3, While expanded foam for
`seat cushions can generally range from about 30 to about 85
`Kg/m3. Further, polyurethane gels commonly have a high
`thermal capacity. This combination of increased ability to
`transport heat through the material, higher material mass per
`unit area, and high amount of energy needed to increase the
`material temperature makes a signi?cant difference on the
`type of exchange of heat from the user to the gel over time.
`[0043] The heat exchange capacity of the gel materials
`used in the methods of the invention therefore further
`contributes to the good “feel” users desire and appreciate in
`a support apparatus, such as a mattress, pilloW, seating
`apparatus, or the like, Which may be prepared according to
`the invention. Accordingly, the presence of the gel layer
`alloWs for increased comfort not only because of the pres
`sure distribution qualities of the gel but also because of the
`thermal conductivity of the gel and the corresponding ability
`to move heat aWay from the body and therefore circumvent
`
`IPR2017-00351
`Fredman EX1012 Page 9
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`US 2007/0246157 Al
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`Oct. 25, 2007
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`the eventual heat buildup associated With many support
`apparatuses that can lead to discomfort.
`[0044] Bene?cially, gels useful according to the invention
`can have their 7» values altered through addition of one or
`more ?llers. Filled gels are useful according to the invention
`because they can be used in a support apparatus to provide
`increased comfort and pressure distribution, as previously
`noted, While also having a loWer thermal conductivity to
`lessen the movement of heat aWay from the body of the user.
`Such lowering of the 7» value of the gel reduces the “cool
`ness” of the gel. This can also increase the subjective
`comfort of the support apparatus for users Who desire a
`feeling of Warmth.
`[0045] Accordingly, in one embodiment of the invention,
`the gel material used in the methods of the invention further
`comprises one or more ?llers. The ?ller material can be any
`material capable of admixture With the gel and that is
`effective for altering the 7» value of the gel. In a speci?c
`embodiment, the ?ller material is effective for loWering the
`7» value of the gel to at least a value indicative of a thermal
`conductivity Wherein a perception of coolness of the gel is
`reduced. In yet another embodiment, the ?ller material is
`effective for loWering the 7» value of the gel such that there
`is a perception of Warmth from the gel. Accordingly, various
`types of materials ranging from solids to liquids may be used
`as ?ller for the gel used in the gel layer according to the
`invention.
`[0046] In one embodiment of the invention, the ?ller
`comprises a solid material. Preferentially, the solid material
`comprises a particulate material. The average siZe of the
`particulate can vary depending upon the apparatus in Which
`the ?lled gel is to be used and can also vary depending upon
`the 7» value desired in the ?lled gel. In one embodiment, the
`?ller can comprise coarse particles. In another embodiment,
`the ?ller can comprise ?ne particles (i.e., poWders). In yet
`another embodiment, the ?ller can comprise nanoparticles.
`In a particular embodiment of the invention, the ?ller
`material comprises particulates having an average diameter
`of about 0.05 mm to about 15 mm. In another embodiment,
`the particulates have an average diameter of about 0.10 mm
`to about 10 mm, about 0.10 mm to about 5 mm, or about
`0.10 to about 1 mm.
`[0047] In another embodiment of the