GB2561927A

GB2561927A - Cushion support

Info

Publication number: GB2561927A
Application number: GB1711006.5A
Authority: GB
Inventors: John Saggers Michael
Original assignee: MJS HEALTHCARE Ltd
Current assignee: MJS HEALTHCARE Ltd
Priority date: 2017-07-07
Filing date: 2017-07-07
Publication date: 2018-10-31
Anticipated expiration: 2037-07-07
Also published as: GB201711006D0; GB2561927B

Abstract

A method of making a cushion support by compressing resilient members 6 betweenfirst 5 and second 7 sheet material portions and joining the sheet portions 5, 7 together around the periphery of the resilient members 6 whilst they are in a compressed state to form a cushion support cell. The first sheet portion 5 may have an inlet for fluid connection with a source of compressed air. The inlet may be obstructed by the opposed, second portion 7 when the resilient members are compressed, such that expansion of the resilient members 6 is at least partially constrained. Also disclosed is a tool 4 and apparatus for making a cushion support cell, where the tool is operable to join areas of the sheet portions and comprises depressions to receive the first sheet material.

Description

(71) Applicant(s):

MJS Healthcare Limited

310-312 Dallow Road, Luton, Bedfordshire, LU1 1TD, United Kingdom (56) Documents Cited:

GB 1279558 A WO 2016/094501 A1 US 6038722 A US 20110258782 A1

WO 2016/130103 A1 WO 2007/031774 A1 US 5303435 A (58) Field of Search:

(72) Inventor(s):

Michael John Saggers

INT CLA47C, B68G Other: EPODOC and WPI (74) Agent and/or Address for Service:

HGF Limited

Document Handling - HGF - (Birmingham),

City Walk, LEEDS, LS11 9DX, United Kingdom (54) Title ofthe Invention: Cushion support

Abstract Title: Method of making a cushion by compressing resilient members between first and second sheet portions (57) A method of making a cushion support by compressing resilient members 6 betweenfirst 5 and second 7 sheet material portions and joining the sheet portions 5, 7 together around the periphery ofthe resilient members 6 whilst they are in a compressed state to form a cushion support cell. The first sheet portion 5 may have an inlet for fluid connection with a source of compressed air. The inlet may be obstructed by the opposed, second portion 7 when the resilient members are compressed, such that expansion ofthe resilient members 6 is at least partially constrained. Also disclosed is a tool 4 and apparatus for making a cushion support cell, where the tool is operable to join areas of the sheet portions and comprises depressions to receive the first sheet material.

A

FIGURE 1

1/3

A

V

FIGURE 1

FIGURE 2

FIGURE 3

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313

CUSHION SUPPORT

This invention relates generally to cushion supports. More specifically, although not exclusively, this invention relates to methods and apparatus for making cushion supports for incorporation into support apparatus, such as mattresses and the like.

Cushion supports are useful in a wide variety of environments for increasing comfort of users and/or at least partially mitigating the physiological effects of pressure experienced on the bodies of those users. These physiological effects are particularly acute in hospitals and nursing homes, where patients that spend extensive periods in bed often suffer from painful injuries, such as pressure sores or ulcers.

The use of customised cushion supports for specific applications have increased significantly in recent years. For example, specialist mattresses incorporating customised cushion supports are used widely in hospitals to prevent and treat decubitus ulcers, or pressure sores. A primary cause of pressure sores is the inability of the patient to move so as to relieve pressure points.

These pressure points typically occur in the area of a bony protuberance which results in a cut-off of the blood flow in the skin and soft tissue adjacent to the protuberance when distortion of capillary blood vessels curtails blood flow. When the blood flow in the capillaries is blocked due to excessive external interface pressure, the cells in that area begin to die and may result in such wounds.

Mobile persons do not generally suffer from such wounds because they move continually, even when asleep. This movement prevents blood flow from being cut-off over extended periods of time.

A typical mattress for use in preventing and/or treating such wounds includes a profiled cushion support, such as a block of foam split into segments with varying stiffness. These varying stiffness regions control the distribution of pressure across the patient’s body. It is also known to provide a mattress having a plurality of individual cushion support cells arranged parallel to one another to provide support for a user. The cells normally extend across the width of a foam base or other support and are disposed in series along its length.

The mattress may also include a peripheral border for retaining the unitary cushion support or the series of support cells in place. Some or all of the cells may be filled with air and in some designs they are selectively inflatable. In the case of a unitary cushion support, one or more inflatable cells may be located beneath the cushion support. Generally, a cover encases and retains the unitary cushion support or the cells to prevent ingress of bodily fluids.

In some designs, the cushion support cells include a foam cushion contained within an inflated or inflatable chamber. The chamber may be inflatable by the introduction of pressurised air therein or it may be hermetically sealed with a predetermined inflation pressure. In some cases, these foam cushions are similar in design to segments of the profiled foam in the aforementioned mattresses. Such cushion support cells may thereby provide support by way of both the foam cushion and an air cushion.

The applicant has observed that manufacturing such cushion cells has proven difficult, generally requiring multiple stages. For example, a tubular cell is manufactured from one or two sheets of material, e.g. polyurethane, with portions that are welded together. The foam is then inserted into the tubular cell and the end is welded closed to form a cell that is hermetically sealed. Where the mattress is configured for selective inflation and deflation, a pneumatic fitting is secured to a hole in the cell or a sheet portion at an appropriate stage in the process.

It would therefore be beneficial to provide a simpler and more effective process for the manufacture of such cushion supports.

Accordingly, a first aspect of the invention provides a method of making a cushion support or cushion support cell, the method comprising placing a resilient member between portions of a sheet material and joining the sheet portions together around at least part of the periphery of the resilient member to form a cushion support cell.

Thus, the invention involves less steps than known methods of making such cushion supports or cells. In the context of the present invention, the term “cushion support” refers to a support including one or more cells, which can but need not be for inclusion in a support apparatus such as a mattress or other support apparatus incorporating multiple components.

The method may comprise compressing the resilient member between the sheet portions. The method may comprise joining the sheet portions together around at least part of the periphery of the resilient member whilst it is in a compressed state to form the support or cell.

Another, more specific aspect of the invention provides a method of making a cushion support or cushion support cell, the method comprising compressing a resilient member between portions of a sheet material and joining the sheet portions together around at least part of the periphery of the resilient member whilst it is in a compressed state to form a cushion support cell.

Compressing and joining may occur at least partially concurrently. The method may comprise providing an inlet, e.g. through a first of the sheet portions. The inlet may be for fluid connection with a source of compressed air. The inlet may be obstructed, for example by an opposed or second of the sheet portions, e.g. when the resilient members are compressed therebetween. The inlet may be obstructed such that expansion of the resilient members is at least partially constrained. For example, obstruction of the inlet may create a vacuum, which may be caused by the resilience of, and/or the expansion force applied by, the resilient member to the sheet portions, e.g. when a compression force applied to the resilient member is released.

The method may comprise providing, installing, securing or otherwise associating a grommet or fluid connector to or with one of the sheet portions, e.g. the first sheet portion.

The fluid connector may be in communication with the inlet or with a hole in the sheet portion, e.g. to provide the inlet. The resilient members may be compressed against a tool, which may have a recess, e.g. for receiving the grommet or fluid connector.

Advantageously, the thus formed cushion support comprises a resilient member which is in a compressed or partially compressed condition or state. The cushion support therefore has a volume which is reduced with respect to prior art cushioning supports in which the resilient member is in its naturally expanded condition or state, which is advantageous for storage and transport.

The resilient member may comprise one or more resilient members. Placing or compressing the resilient member may comprise placing or compressing one or more resilient members. The method may comprise joining the sheet portions together around at least part of the periphery of the resilient member(s), for example both or all resilient members or each resilient member.

Another issue observed by the applicants with mattresses that incorporate individual cushion cells is that they can become twisted, displaced or otherwise misaligned relative to other cells during use, for example when a user mounts or dismounts the cushioning support or shifts their position. Although the cover and peripheral border prevent excessive displacement ofthe cells, they do not prevent all such displacement. Twisted, displaced or otherwise misaligned cells can alter the intended pressure distribution and/or may thereafter be uncomfortable or provide suboptimal support to the user. Realignment of the twisted, displaced or otherwise misaligned cell(s) commonly requires partial removal of the cover and manual rearrangement of the offending cell(s). In some cases, one or more correctly aligned cells must first be removed from the cushion cover in order to reach the offending cell(s). This requires the patient to be removed from the mattress, for example by a hoist sling, which is costly, time consuming and uncomfortable for the patient..

It is therefore a further non-exclusive aim ofthe invention to mitigate such issues.

The one or more resilient members may comprise a pair of resilient members. Placing or compressing the resilient member may comprise placing or compressing a pair of resilient members. The cushion support or cell may comprise a cushion support cell pair. The method may comprise a method of making a cushion support cell pair. The method may comprise joining the sheet portions together around at least part of the periphery of the pair of resilient members, for example both or all resilient members or each resilient member, e.g. thereby to form a joined cell pair.

Another aspect of the invention provides a method of making a cushion support or cushion support cell pair, the method comprising placing two or more, e.g. a pair of, resilient members between portions of a sheet material and joining the sheet portions together around at least part of the periphery of each resilient member, thereby to form a joined cushion support cell pair.

The applicant has observed that use of joined support cell pairs within the mattress inhibits the aforementioned twisting, displacement and/or misalignment associated with individual cells. For the avoidance of doubt, the cushion support comprising a cushion support cell pair may include more than two cushion support cells or joined cushion support cells.

The method may comprise compressing the resilient members between the sheet portions. The method may comprise joining the sheet portions together around at least part of the periphery of each resilient member whilst they are in a compressed state, e.g. to form a joined cushion support cell pair.

Another, more specific aspect of the invention provides a method of making a cushion support or cushion support cell pair, the method comprising compressing two or more, e.g. a pair of, resilient members between portions of a sheet material and joining the sheet portions together around at least part of the periphery of each resilient member whilst they are in a compressed state, thereby to form a joined cushion support cell pair.

The method may comprise joining the sheet portions together between the resilient members. The join may comprise a common join between the cells. The join between the resilient members may be interrupted and/or may be configured to enable fluid communication between the cells or adjacent cells. The join between the resilient members may be continuous or uninterrupted and/or may be configured to isolate or hermetically isolate the cells from one another.

The method may comprise providing an inlet through the first sheet portion adjacent each of the resilient members. The inlets may include the aforementioned inlet and a further inlet. The method may comprise joining the sheet portions together between the resilient members and/or around at least part of their peripheries, for example to provide two or more, e.g. a pair of, isolated or hermetically isolated cushion support cells. Each of the cells may have a respective inlet.

The method may comprise placing the or each resilient member in a depression, e.g. the same or a respective depression, of a tool. The or each depression may be described, e.g. entirely or at least in part, by one or more joining elements. The joining element(s) may be operable to join the sheet portions.

The one or more resilient members may be compressed between opposed platens, for example opposed platens of a press or clamping device or machine. A first of the platens may carry the tool. In embodiments, the method involves the use of a pair of tools which are brought together to compress the resilient member(s) and/or to join the sheet portions.

The method may comprise placing the or a first sheet portion in or on the tool. The method may comprise placing the one or more resilient members on the first sheet portion. The method may comprise placing the or a second sheet portion on a second of the platens. The method may comprise moving the platens relative to one another, for example to compress the resilient member(s), e.g. between the sheet portions.

The method may comprise locating at least one or each sheet portion, for example the first sheet portion, in or on the tool. The sheet portion may be located in or on the tool using locating means. The locating means may at least partially surround at least one of the one or more joining elements, for example such that no excess material of the sheet portion is present beyond the joined portions.

The method may comprise joining the sheet portions about their peripheries such that substantially no excess sheet material, e.g. of either sheet portion, is present beyond the joined portions. Alternatively, the method may comprise removing excess material from one or both sheet portions.

In embodiments, joining the sheet portions together may comprise applying, e.g. via the joining elements, electromagnetic or thermal or ultrasonic energy, for example to fuse at least partially the sheet portions together. Joining may comprise high frequency welding.

Another aspect of the invention provides a cushion support, which may be obtainable by a method as described above.

Yet another aspect of the invention provides a cushion support or cushion support cell. The cushion support or cushion support cell may comprise a resilient member, which may be surrounded by, e.g. encased between, a pair of sheet portions joined together around at least part of the periphery of the resilient member to provide a cell. A first of the sheet portions may, but need not, have an inlet. The inlet may, but need not be obstructed by an opposed, second of the sheet portions, e.g. such that the resilient member is at least partially constrained in a compressed or partially compressed state.

The resilient member may comprise one or more, for example two or more, e.g. a pair of, resilient members. The one or more resilient members may be surrounded by, e.g. encased between, the joined sheet portions to provide one or more, e.g. respective, cells. The obstructed inlet may cause the or each resilient member to be at least partially constrained in a compressed or partially compressed state.

The cushion support or cushion support cell may comprise a grommet or fluid connector, which may be provided, installed or secured in, on or to or otherwise associated with the first sheet. The grommet or fluid connector may be in communication with the inlet or a hole in the sheet portion, for example to provide the inlet.

The grommet or fluid connector may comprises a multi-way fluid connector, for example a T-piece, which may enable fluid connection between the inlet and a pair of tubes. The resilient member may be profiled, or may comprise a profiled insert. The resilient member may comprise a foam material, for example a foam insert. The resilient member may comprise one or more projections or formations, e.g. thereon or therein.

The one or more resilient members may comprise two or more resilient members. The sheet portions may be joined together between the resilient members and/or around at least part of their peripheries, for example to provide two or more cells. The cushion support may comprise a further inlet, which may be through one of the sheet portions, e.g. the first or second sheet portion. Each inlet may be adjacent one of the resilient members. The sheet portions may be joined together between the resilient members and/or around at least part of their peripheries, for example to provide a pair of cells or cushion support cells or hermetically isolated cushion support cells, e.g. each having a respective inlet.

The cushion support may comprise a twin cell cushion support.

The material, stiffness and/or profile of at least two of the resilient members may be the same or different. The, at least one or each resilient member may include a concave or convex major surface, for example to alter the compressibility thereof along its length.

The sheet material may comprise any suitable material, but preferably includes a plastics material. The sheet material may comprise a polymer, such as a polyurethane or polyvinylchloride material. Alternatively, the sheet material may comprise a polyethylene terephthalate, ethylene-vinyl acetate, nylon, acrylonitrile butadiene styrene material or any other suitable material. The sheet material may comprise a thin or thick film, or a semi-rigid sheet. It will be appreciated that the sheet portions may be formed of the same sheet, for example which may be folded over, or separate sheets. Additionally or alternatively, each cell may be formed of a separate pair of sheets, for example wherein three or four sheets of material are used to provide a joined cell pair. However, for simplicity, it is generally, although not always, preferred to use one or two sheets to provide the multiple, joined or interconnected cells.

Another aspect of the invention provides a mattress comprising a plurality of cushion supports as described above.

The cushion supports and/or mattress may be inflatable, e.g. by the introduction of air. The cushion supports or mattress may be fluidly connected, e.g. via the inlet(s), to a source of pressurised air, such as a pump.

Another aspect of the invention provides a cushioning apparatus comprising a source of pressurised air, e.g. a pump, and one or more cushion supports and/or a mattress as described above, which may be fluidly connected to the source.

Another aspect of the invention provides a kit of parts for assembly into the cushion support or mattress or apparatus.

Another aspect of the invention provides a tool for making a cushion support. The tool may comprise one or more depressions, which may be described at least in part by one or more joining elements. The tool may be configured to receive in the or each depression a first portion of sheet material, for example with a resilient member thereon. The or each joining element may be operable, e.g. on compression of the resilient member by a second portion of sheet material, to join the sheet portions together around at least part of the periphery of the resilient member(s), for example whilst it is in a compressed state to form a cushion support cell.

The tool may comprise a recess, which may be in the or one of the depression(s), e.g. for receiving a grommet or fluid connector associated with one of the sheet portions. The or each joining element may comprise a welding element. The welding element may be suitable, configured or operable for applying electromagnetic or thermal energy to the sheet portions to join them together.

The tool may comprise a locating means, which may at least partially surround the one or more joining elements and/or which may be for locating the first sheet portion in or on the tool. The tool may comprise a resilient support, which may at least partially surround the one or more joining elements and/or may be for resiliently supporting a locating plate providing the locating means.

Another aspect of the invention provides an apparatus for making a cushion support. The apparatus may comprise a tool as described above and/or a press, e.g. for compressing one or more resilient members between a pair of sheet portions and/or against the tool.

For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the cushion support, cushion support cell, cushion support cell pair, mattress or apparatus may comprise any one or more features of the method relevant thereto and/or the method may comprise any one or more features or steps relevant to one or more features of thereof. Similarly, any aspect may include any feature that would be understood by the skilled person to result from or correspond to anything included in this disclosure is expressly envisaged. Indeed, within the scope of this application it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one aspect or embodiment of the invention are applicable to all aspects or embodiments, unless such features are incompatible.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is a schematic of an apparatus for making a twin cell cushion support in accordance with an embodiment of the invention;

Figure 2 is a perspective view of the tool of the apparatus of Figure 1;

Figure 3 is a perspective section view of the tool of Figure 2 with the inserts omitted;

Figure 4 is a perspective exploded view of the assembly of the sheets, resilient members and tool of Figures 2 and 3 in accordance with the method; and

Figure 5 is a perspective view illustrating a twin cell cushion support formed by the apparatus of Figure 1 as it is removed from the tool.

Referring now to Figure 1, there is shown an apparatus 1 for carrying out a method according to an embodiment of the invention. The apparatus 1 includes first and second platens 2, 3 and a tool 4 mounted on the lowermost platen 2. The platens 2, 3 are parallel, co-aligned and movable toward one another to apply a compressive force A to the tool 4 during the manufacturing process.

In accordance with the invention, a first sheet portion 5 is located in the tool 4 with a pair of resilient members 6 thereon and a second sheet portion 7 is secured to the uppermost platen 3. In use, the platens 2, 3 are operated to compress the resilient members 6 between the sheet portions 5, 7 and the tool 4 is operable to join areas of the sheet portions 5, 7 together in order to form a cushion support 8 (shown in a partially compressed state in Figure 5).

The resilient members 6 are in the form of elongate blocks having a profiled upper side formed with a plurality of projections or formations 60 in a manner that is known in the art. The sheet portions 5, 7 are pre-cut to the appropriate size required to form the cushion support 8 such that no excess material of the sheet portions 5, 7 is present beyond the joined portions. In this embodiment, the sheet portions 5, 7 are formed of a polyurethane or polyvinylchloride material and the resilient members 6 is formed of a polyurethane foam, but other suitable materials are envisaged without departing from the scope of the invention.

Turning now to Figures 2 and 3, the tool 4 includes two depressions 40 each having a periphery described by joining elements 41, 42 and a base described by an insert 43 received between the joining elements. The tool 4 also includes a base plate 44 on which the joining elements 41, 42 and insert 43 are mounted, a resilient support 45 surrounding the joining elements 41, 42 and a locating plate 46 mounted on the resilient support 45 and also surrounding the joining elements 41, 42. The resilient support 45 is formed of an elastomeric foam in this embodiment, but it will be appreciated that any suitable material may be used.

The joining elements 41, 42 are formed of series of thin aluminium bars in an upright orientation and joined together to form a relatively deep rectangular pocket 47. The joining elements 41, 42 include a peripheral joining element 41 describing the pocket 47 and an intermediate joining element 42 extending lengthwise along the centre ofthe rectangular pocket 47. The intermediate joining element 42 separates the rectangular pocket 47 into two substantially identical rectangular sub-pockets 47a, 47b. The joining elements 41, 42 in this embodiment are secured to the base plate 44 and connected to a source of high frequency electromagnetic energy (not shown) for welding the sheet portions 5, 7 together.

Each insert 43 is in the form of a thick rectangular plate of medium density fibre board in this embodiment, but these may be formed from any suitable material, preferably a nonelectrically conductive material. Each insert has a periphery that is slightly smaller than each of the sub-pockets 47a, 47b. Each insert 43 includes a pair of recesses 43a on its uppermost surface, one recess 43a being adjacent each end of the insert 43, for receiving a fluid connector 50 (shown in Figure 4) associated with the first sheet portion 5. Each insert 43 is received within one of the sub-pockets 47a, 47b to provide the base of one of the depressions 40.

The resilient support 45 is in the form of a resilient plastic foam material that is easily compressible on application of a force to the locating plate 46. The locating plate 46 is rectangular in plan with an aperture through its thickness, which is slightly larger than the periphery of the peripheral joining elements 41 such that it is able to slide therealong. The locating plate 46 is formed of a plastics material with a thickness selected such that its top surface 46a is slightly proud of the top of the peripheral joining elements 41 (shown more clearly in Figure 3).

As such, the locating plate 46 provides a peripheral locating wall 46b within which the first sheet portion 5 is receivable for location purposes. It will be appreciated that when the uppermost platen 3 contacts the locating plate 46, continued movement thereof compresses the resilient support 45, thereby enabling the second sheet portion 7 to come into contact with the first sheet portion 5 against the joining elements 41,42.

In use, the process begins with location of the second sheet portion 7 on the uppermost platen 3. This is done by placing the second sheet portion 7 in the tool 4 by locating it within the peripheral locating wall 46b provided by the locating plate 46 such that the periphery of the second sheet portion 7 rests on the peripheral joining element 41. Adhesive strips 70 are then secured to the uppermost platen 3 in predetermined regions above the tool 4.

The uppermost platen 3 is then lowered into contact with the locating plate 46 and forced against the locating plate 46 to compress the resilient support 45. Thus, the second sheet portion 7 is brought into contact with the adhesive strips 70, thereby securing the second sheet portion 7 to the uppermost platen 3. The uppermost platen 3 is then raised to enable the first sheet portion 5 and resilient members 6 onto the tool.

As shown more clearly in Figure 4, a T-piece 50 is secured, welded in this embodiment, to the lower major surface of the first sheet portion 5, adjacent one of its corners and in fluid communication with an inlet hole 51. Similarly, a further T-piece (not shown) is secured to the same major surface adjacent an opposite corner in fluid communication with a further inlet hole (not shown). The first sheet portion 5 is placed in the tool 4 by locating it within the peripheral locating wall 46b provided by the locating plate 46 such that its periphery rests on the peripheral joining element 41. As is clear from Figure 4, the recesses 43a in the inserts 43 receive the T-pieces 50 as the first sheet portion 5 is placed in the tool 4.

The resilient members 6 are then placed on the first sheet portion 5 centrally over a respective depression 40 such that one of the T-pieces 50 is adjacent each resilient member 6, but at opposite ends thereof. The uppermost platen 3 is then lowered to bring the second sheet portion 7 into contact with the top of the resilient members 6 and a compressive force A is applied thereto to compress the resilient members 6. Movement of the uppermost platen 3 is continued until it comes into contact with the locating plate 46 and is forced against the locating plate 46 to compress the resilient support 45 until regions of the second sheet portion 7 come into contact with the first sheet portion 5.

More specifically, the periphery and a central region of the second sheet portion 7 are forced against corresponding regions ofthe first sheet portion 5. These regions correspond to the peripheral and intermediate joining elements 41, 42. In addition, the recesses 43a of the inserts 43 locate the T-pieces 50 such that the inlet holes 51 is brought into contact with facing surfaces of the second sheet portion 7 when the peripheral and central regions of the sheet portions 5, 7 are brought into contact.

The joining elements 41, 42 are then activated to apply high frequency electromagnetic energy to the sheet portions 5, 7, thereby welding them together and forming the cushion support 8. As a result, the sheet portions 5, 7 are welded about their periphery and across their centre between the resilient members 6. The welds are uninterrupted and, as such, describe two hermetically isolated cells 80. The uppermost platen 3 is then raised to separate it from the tool 4 and relieve the compression applied to the resilient members 6.

However, as the inlet holes 51 are in contact with the facing surface of the second sheet portion 7, air is prevented from entering the cells 80. As such, expansion of the resilient members 6 creates a relative vacuum (i.e. a pressure within the cells 80 that is less than atmospheric pressure), inhibiting separation of the sheet portions 5, 7 and as a result constraining expansion of the resilient members 6. Thus, the resilient members 6 are retained in a partially compressed state by the sheet portions 5, 7.

The cushion support 8 so formed, which is a twin cell 80 cushion support 8 in this embodiment, is illustrated in Figure 5 in its partially compressed state. This state has been found to be particularly beneficial for storage and transportation, since the cushion support 8 requires less storage space. In this embodiment, the cushion support 8 is approximately one third of its size in a fully expanded state. It will be appreciated, however, that various features, such as the depth of the depressions 40, may be varied to reduce further the size of the cushion support 8 in the partially compressed state.

When the cushion support 8 is to be inflated, pressurised air is applied to the T-pieces 50 to unseat the second sheet portion 7 from the inlet holes 51, thereby enabling the resilient members 6 to expand. It is also envisaged that covers or plugs (not shown) may be inserted in or on the exposed inlets of the T-piece 50 to prevent inadvertent unseating of the second sheet portion 7 from the inlet holes 51 during storage and transportation. It is also envisaged that the cushion support 8 may be returned to its partially compressed state by compressing the resilient members 6, evacuating air from the cells 80 and forcing the second sheet portion 7 into contact with the inlet holes 51.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, the cushion support 8 may include a single cell 80 or three or more cells 80. One or both of the inlet holes 51 may be omitted, for example to provide a hermetically sealed cell with no inlet. Additionally or alternatively, one or both of the T-pieces 50 may be omitted or replaced with any other suitable fitting or grommet. The T-pieces 50 (or any other suitable connectors or grommets) may be connected to the cushion support 8 subsequent to the welding operation. Additionally or alternatively, the inlet hole 51 of the first sheet portion 5 io may be sized and/or configured to enable the T-piece 50 or other fluid connector to be pushed or pressed therein or therethrough.

The second sheet portion 7 may be secured to the uppermost platen 3 using alternative means, such as static electricity or any other suitable mechanical fixing. Alternatively, the sheet portion 7 may be placed on the resilient members 6 directly prior to movement of the uppermost platen 3. The process need not involve a press with platens 2, 3. The joining elements 41, 42 may take any suitable form, which may but need not be configured to weld the sheets 5, 7 together. For example, the joining elements 41, 42 may be operable to weld the sheets 5, 7 using a different technique, for example not involving high frequency or electromagnetic energy. The joining elements 41, 42 may comprise thermal or ultrasonic welding elements or any other type of welding elements. The joining elements 41, 42 may comprise inductive and/or resistive heating elements. In some embodiments, the joining elements 41,42 may be operable to join the sheets 5, 7 together mechanically.

The locating plate 46 may be omitted or replaced with any other suitable locating means. It is envisaged that the apparatus 1 may include a pair of tools 4 or a plate or other member or device, which may or may not cooperate with or be movably connected to the tool 4. The plate or other member or device and/or the tool 4 may incorporate a locating means, such as one or more guides or abutments, e.g. for locating the plate or other member or device relative to the tool 4. Additionally or alternatively, the plate or other member or device and/or the tool 4 may comprise a locating means that is configured or operable to locating the second sheet portion 7 relative to the first sheet portion 5 and/or relative to the tool 4 and/or relative to the resilient members 6.

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

1. A method of making a cushion support comprising compressing one or more resilient members between portions of a sheet material and joining the sheet portions together

5 around at least part of the periphery of the resilient member(s) whilst it is in a compressed state to form a cushion support cell.

2. Method according to claim 1 comprising providing an inlet through a first of the sheet portions for fluid connection with a source of compressed air.

3. Method according to claim 2, wherein the inlet is obstructed by an opposed, second of the sheet portions when the resilient members are compressed therebetween such that expansion of the resilient members is at least partially constrained.

15

4. Method according to claim 2 or claim 3 comprising securing a grommet or fluid connector to the first sheet portion in communication with a hole therein to provide the inlet.

5. Method according to claim 4, wherein the resilient members are compressed against

20 a tool having a recess for receiving the grommet or fluid connector.

6. Method according to any one of claims 2 to 5, wherein the one or more resilient members comprises two or more resilient members, the method comprising joining the sheet portions together around at least part of the periphery of each resilient

25 member whilst they are in a compressed state, thereby forming a joined cushion support cell pair.

7. Method according to claim 6 comprising providing a further inlet through the first sheet portion such that each inlet is adjacent one of the resilient members and joining the

30 sheet portions together between the resilient members and around at least part of their peripheries to provide a pair of hermetically isolated cushion support cells each having a respective inlet.

8. Method according to any preceding claim comprising placing the or each resilient member in a depression of a tool which is described at least in part by one or more joining elements operable to join the sheet portions.

9. Method according to claim 8, wherein the one or more resilient members are compressed between opposed platens a first of which carries the tool.

10. Method according to claim 9 comprising placing the or a first sheet portion in or on the tool, placing the one or more resilient members on the first sheet portion, placing the or a second sheet portion on a second of the platens and moving the platens relative to one another in order to compress the resilient member(s) between the sheet portions.

11. Method according to claim 10 comprising locating the first sheet portion in or on the tool using locating means at least partially surrounding the one or more joining elements such that no excess material of the first sheet portion is present beyond the joined portions.

12. Method according to any one of claims 8 to 11, wherein joining the sheet portions together comprises applying via the joining elements electromagnetic, thermal or ultrasonic energy to fuse at least partially the sheet portions together.

13. Method according to any preceding claim comprising joining the sheet portions about their peripheries such that substantially no excess sheet material is present beyond the joined portions.

14. Method according to any one of claims 1 to 12 comprising removing excess material from one or both sheet portions.

15. A cushion support obtainable by a method according to any preceding claim.

16. A cushion support comprising one or more resilient members encased between a pair of sheet portions joined together around at least part of the periphery of the resilient member(s) to provide one or more cells, wherein a first of the sheet portions has an inlet which is obstructed by an opposed, second of the sheet portions such that the or each resilient member is at least partially constrained in a compressed or partially compressed state.

17. Cushion support according to claim 16 comprising a grommet or fluid connector secured to the first sheet in communication with a hole therein to provide the inlet.

18. Cushion support according to claim 17, wherein the grommet or fluid connector comprises a T-piece enabling fluid connection between the inlet and a pair of tubes.

19. Cushion support according to any one of claims 16 to 18, wherein the resilient member comprises a profiled foam insert with one or more projections or formations.

20. Cushion support according to any one of claims 16 to 19, wherein the one or more resilient members comprises two or more resilient members and the sheet portions are joined together between the resilient members and around at least part of their peripheries to provide two or more cells.

21. A mattress comprising a plurality of cushion supports according to any one of claims 13 to 20.

Intellectual

Property

Office

Application No: GB 1711006.5 Examiner: Ms Rachel Evans

21. Cushion support according to claim 20 comprising a further inlet through the first sheet portion, wherein each inlet is adjacent one of the resilient members and the sheet portions are joined together between the resilient members and around at least part of their peripheries to provide a pair of hermetically isolated cushion support cells each having a respective inlet.

22. Cushion support according to claim 20 or claim 21, wherein the material, stiffness and/or profile of at least two of the resilient members is different.

23. Cushion support according to any one of claims 15 to 22, wherein the or each resilient member includes a concave major surface.

24. A mattress comprising a plurality of cushion supports according to any one of claims 15 to 23.

25. A tool for making a cushion support cell, the tool comprising one or more depressions described at least in part by one or more joining elements, wherein the tool is configured to receive in the or each depression a first portion of sheet material with a resilient member thereon and, on compression ofthe resilient member by a second portion of sheet material, the or each joining element is operable to join the sheet portions together around at least part of the periphery of the resilient member(s) whilst it is in a compressed or partially compressed state to form the cushion support cell.

26. Tool according to claim 25 comprising a recess in the or one of the depression(s) for receiving a grommet or fluid connector associated with one of the sheet portions.

27. Tool according to claim 25 or claim 26, wherein the or each joining element comprises io welding element for applying electromagnetic, thermal or ultrasonic energy to the sheet portions to join them together.

28. Tool according to any one of claims 25 to 27 comprising a locating means at least partially surrounding the one or more joining elements for locating the first sheet

15 portion in or on the tool.

29. Tool according to claim 28 comprising a resilient support at least partially surrounding the one or more joining elements for resiliently supporting a locating plate providing the locating means.

30. An apparatus for making a cushion support comprising a tool according to any one of claims 25 to 29 and a press for compressing one or more resilient members between a pair of sheet portions and against the tool.

Amendments to the Claims have been filed as follows:CLAIMS

1. A method of making a cushion support comprising compressing a resilient member between portions of sheet material, obstructing an inlet through a first of the sheet

5 portions by an opposed, second of the sheet portions when the resilient member is compressed therebetween and joining the sheet portions together around at least part of the periphery of the resilient member whilst in a compressed state to form a cushion support cell, wherein expansion of the resilient member is at least partially constrained by the obstructed inlet.

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2. Method according to claim 1 comprising securing a grommet or fluid connector to the first sheet portion in communication with a hole therein to provide the inlet.

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Method according to claim 2, wherein the resilient member is compressed against a tool having a recess for receiving the grommet or fluid connector.

Method according to any preceding claim comprising compressing two or more resilient members between portions of sheet material and joining the sheet portions together around at least part of the periphery of each resilient member whilst they are in a compressed state, thereby forming a joined cushion support cell pair.

5. Method according to claim 4 comprising providing a further inlet through the first sheet portion such that each inlet is adjacent one of the resilient members and joining the sheet portions together between the resilient members and around at least part of

25 their peripheries to provide a pair of hermetically isolated cushion support cells each having a respective inlet.

6. Method according to any preceding claim comprising placing the or each resilient member in a depression of a tool which is described at least in part by one or more

30 joining elements operable to join the sheet portions.

7. Method according to claim 6, wherein the or each resilient member is compressed between opposed platens a first of which carries the tool.

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8. Method according to claim 7 comprising placing the first sheet portion in or on the tool, placing the resilient member(s) on the first sheet portion, placing the second sheet portion on a second of the platens and moving the platens relative to one another in order to compress the resilient member(s) between the sheet portions.

9. Method according to claim 8 comprising locating the first sheet portion in or on the tool using locating means at least partially surrounding the one or more joining elements such that no excess material of the first sheet portion is present beyond the joined portions.

10. Method according to any one of claims 6 to 9, wherein joining the sheet portions together comprises applying via the joining elements electromagnetic, thermal or ultrasonic energy to fuse at least partially the sheet portions together.

11. Method according to any preceding claim comprising joining the sheet portions about their peripheries such that substantially no excess sheet material is present beyond the joined portions.

12. Method according to any preceding claim comprising removing excess material from one or both sheet portions.

13. A cushion support comprising one or more resilient members encased between a pair of sheet portions joined together around at least part of the periphery of the resilient

25 member(s) to provide one or more cells, wherein a first of the sheet portions has an inlet which is obstructed by an opposed, second of the sheet portions such that the or each resilient member is at least partially constrained in a compressed or partially compressed state.

30 14. Cushion support according to claim 13 comprising a grommet or fluid connector secured to the first sheet in communication with a hole therein to provide the inlet.

15. Cushion support according to claim 14, wherein the grommet or fluid connector comprises a T-piece enabling fluid connection between the inlet and a pair of tubes.

16. Cushion support according to any one of claims 13 to 15, wherein the or each resilient member comprises a profiled foam insert with one or more projections or formations.

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17. Cushion support according to any one of claims 13 to 16, wherein the one or more resilient members comprises two or more resilient members and the sheet portions are joined together between the resilient members and around at least part of their peripheries to provide two or more cells.

18. Cushion support according to claim 17 comprising a further inlet through the first sheet portion, wherein each inlet is adjacent one of the resilient members and the sheet portions are joined together between the resilient members and around at least part of their peripheries to provide a pair of hermetically isolated cushion support cells each having a respective inlet.

19. Cushion support according to claim 17 or claim 18, wherein the material, stiffness and/or profile of at least two of the resilient members is different.

20. Cushion support according to any one of claims 13 to 19, wherein the or each resilient member includes a concave major surface.