Beds – Support for users body or part thereof – Removable support specially adapted for seating
Reexamination Certificate
2001-03-23
2003-09-02
Santos, Robert G. (Department: 3673)
Beds
Support for users body or part thereof
Removable support specially adapted for seating
C005S653000, C005S655400
Reexamination Certificate
active
06611980
ABSTRACT:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to custom-molded cushions, and is particularly well-adapted to custom-molded seating cushions designed for use with seated mobility systems such as wheelchairs.
2. Description of Related Art
Seated mobility platforms, wheelchairs and other seated mobility systems (hereinafter “wheelchairs”) provide a means of movement, positioning and postural support for persons with physical disabilities or deformities. These persons remain seated in or on the wheelchair, often in a fixed position, throughout most of their daily activities. Proper seating and positioning in the wheelchair is necessary to prevent pressure sores, to increase comfort and sitting tolerance, and to improve circulation, range of motion, respiratory function and digestion, all of which allow the user to achieve a higher degree of function and interaction with his or her environment.
Mass-produced wheelchair cushions, including inflatable cushions, jell pads and layered foam pads, are well known. Although mass-produced cushions are inexpensive and provide adequate support and positioning for some individuals, other persons require a padding system including contoured and form-fitting cushions. To such end, various types of custom-contoured wheelchair cushions, and methods for making such cushions, have been employed in an effort to form a seat that is “molded” to the shape of the portion of the user that contacts the wheelchair seat, i.e., the user's “seating surface.”
For example, U.S. Pat. No. 4,615,856 discloses forming an impression of the user's seating surface on a bead-filled bag and removing air from the bag to fix the impression. A positive mold of the individual's impression is made from the bag, and is utilized to mold a customized seat cushion. In a similar method, the shape of the bead-filled bag is scanned into a computer which then cuts a cushion of the same shape out of a foam block. Although these methods are capable of creating fairly accurate and usable seating, the methods are labor intensive, take a considerable amount of time to complete and are expensive.
Another method for producing custom-contoured cushions is the foam-in-place method. In the foam-in-place method, a low density, high foaming two-part foam is mixed and poured into a flexible enclosure. As the foam begins expanding, the bag is placed on a simulator chair frame and the user is then positioned on the bag. The foam quickly expands around the user and cures with an imprint of the user on the cushion surface. The foam cushion is then covered with a suitable material to protect it from contaminants and moisture. The resultant cushion is very soft, but does not provide a great deal of support to the user.
Although the foam-in-place method can produce a cushion with a fairly accurate contoured surface, the speed at which the material foams and cures makes it difficult to mold the foam properly around the user. Further, the user can easily “bottom out” by displacing the uncured foam under the ischium, where it is needed most. Unfortunately, attempts to mold the foam around the user and work the foam under the ischium can cause tiny bubbles in the expanding foam to collapse, resulting in hard spots within the cushion. Poor mixing of the foam can also create inconsistent texture and density within the cushion, which can be uncomfortable to the user and cause pressure sores. Further, the expanding foam often leaks out of the bag creating a mess on the user, the cushion, the technician and the simulator chair.
Another method of customizing a cushion involves hand carving different densities of foam into pads of various shapes, which are then upholstered by traditional methods. Such customized cushions can be expensive to install and maintain and are generally less accurate than other customized cushions. The inaccuracy can result in pressure points that create soreness and discomfort for the user. Further, the external hardware required to position the pads is unsightly and, more importantly, may limit the user's range of motion.
Although these known custom-contoured cushions are suitable for their intended purpose, a need remains for an inexpensive, easy to manufacture custom-contoured seat cushion that provides the comfort and support required by the intended user.
Thus, an object of the present invention is to provide a custom-contoured seat cushion that accurately conforms to the shape of the intended user's seating surface and provides postural support to the user.
It is a further object of the present invention to provide such a custom-contoured cushion that is resilient and fairly soft.
Another object of the invention is to provide a method of making such a cushion that can be completed in one to two days.
It is yet another object of the invention to provide a custom-contoured cushion that has a uniform texture and density.
It is another object of the invention to provide an aesthetically pleasing custom-contoured cushion.
Yet another object of the present invention is to provide a high quality, low maintenance and durable cushion that is aesthetically pleasing.
SUMMARY OF THE INVENTION
The present invention is directed to a custom-contoured cushion for use as a seat bottom, seat back, headrest or other type of cushion for a wheelchair, or other seating device. The novel custom-contoured cushion is comprised of a stretchable bag having an opening that is in a closed position when the cushion is in use. The bag is filled with soft and non-absorbent pellets adhered together by and/or embedded within an elastomeric polymerizable adhesive, preferably a two-part low-foaming polyurethane adhesive. The pellets are sufficiently soft and resilient to provide a comfortable and durable cushion and are non-absorbent, so as not to absorb the adhesive, which could create inconsistencies in the texture and density of the cushion. In a preferred embodiment the cushion has been molded to conform to the shape of an object. Preferably, the cushion has been custom-molded to conform to the shape of the seating surface of an intended user.
The cushion may optionally include a baseboard to add structure and support to the cushion. Additional structure and support can be provided by generally L-shaped support guides, affixed along opposing edges of the baseboard. In one embodiment, the support guides are tall enough to obviate the need for separate modular hip and lateral support pads that are often added to wheelchairs. The baseboard and/or support guides may be affixed around the outside of the custom-contoured cushion or positioned within the cushion bag. In either embodiment, conventional wheelchair hardware may be mounted onto the baseboard to facilitate installation of the cushion onto the wheelchair or other support structure.
In an alternative embodiment, the cushion of the present invention does not contain an adhesive to adhere the pellets together. In such embodiment, the pellets are able to move relative to each other within the bag after construction is completed. Each time the user sits on the cushion, the pellets will deform to conform to the shape of the user's seating surface. The user may purchase such a cushion “off the shelf” and use it with an existing chair for added comfort. Such “off the shelf” cushions will preferably be formed in appropriate dimensions to be used in standard sized chairs as can readily be calculated by one of skill in the art.
The custom-contoured cushion is preferably formed by custom molding. In a preferred custom molding process, a seating technician first measuring the user to determine the general dimensions required for the finished cushion. A bag conforming to such general dimensions is provided or constructed out of a suitable stretchable fabric. The bag is constructed with an opening through which the pellets, baseboard and support guides may be inserted. If a baseboard is to be included within the cushion, holes are dri
Santos Robert G.
Stinson Morrison & Hecker LLP
Wempe Patrick L.
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