Abstract:
The present invention relates to a cushion device for supporting a large animal such as a cow, a horse, a buffalo, a sheep, a goat, a pig and so forth. The cushioning device includes a top and bottom surface interconnected by a ‘drop stitch’ structure and a chamber. Contained within the chamber of the cushioning device is a filling material. The filling material includes a gaseous compound, a liquid or a mixture of a gaseous compound and a liquid. Additionally, the present invention also relates to the methods of transporting and installing the cushioning device. The device is shipped to the installation site absent the filling material. During installation a controlled mixture of dual phase fluids such as water and inert gas are disposed into the cushioning device, creating a gelatinous and gaseous filling material.

Description:
FIELD OF INVENTION 
       [0001]    The present invention relates to cushioning devices, specifically the present invention relates to a drop stitch fabric to form a mattress for providing comfort to large animals. The present invention relates also to the transportation, installation and automatic control of the cushioning device at a desired pressure. 
       BACKGROUND OF INVENTION 
       [0002]    Prior animal cushioning devices comprised of either a plurality of combined fabric chamber packed with comminuted rubber for example, U.S. Pat. No. 5,653,195 or utilizing a gelatinous material again housed within a plurality of chambers forming a mattress (WO2011/054091). While such mattresses do provide cushioning, the uneven surface generated by plurality of chambers fosters hygiene issues amongst the livestock as these mattresses can be challenging to clean. Furthermore, the resiliency of the cushioning with the age of the mattress does begin to taper off, thus limiting the longevity of the mattress. 
         [0003]    Another form of prior art is the inflatable kayak type boat U.S. Pat. No. 7,861,662 which utilizes the drop stitch structure to form a single floatation chamber. However the kayak of this prior art is solely pressurized with air, and not designed to resist the weight and forces imparted by large animals, as this term is defined below. 
         [0004]    Another form of prior art is the inflatable cushioning device with manifold system U.S. Pat. No. 6,826,795 which uses a manifold system for providing separately adjustable pressure zones within a single cushioning device for human patients. Nevertheless, this prior art is designed for use with a single human patient and not designed to withstand the weight and forces imparted by large animals. 
         [0005]    What is needed is a cushioning device that is capable of absorbing and withstanding the dynamic and static forces imposed by large animals, all the while maintaining or exceeding the level of comfort posed by existing products. What is also needed is a cushioning device that maintains resiliency with age, thus increasing the longevity of the device. What is also needed is to utilize a manifold system to enable customizing the firmness and softness of a plurality of cushioning devices for one animal up to several animals. 
       SUMMARY OF THE INVENTION 
       [0006]    One object of the present invention is to provide a cushioning device designed from a flat chamber, which may be a single flat chamber, capable of withstanding the forces imposed by large animals. 
         [0007]    In one embodiment, the invention relates to a cushioning device. The cushioning device, in one embodiment, includes a drop stitch structure and a chamber configured for receiving an amount of a filling material. 
         [0008]    In one embodiment of the present invention, the cushioning device further includes: (a) a top wall and (b) a bottom wall, the top and bottom surfaces being connected by the drop stitch structure. 
         [0009]    In another embodiment of the cushioning device of the present invention, the filling material includes a gaseous compound. 
         [0010]    In another embodiment of the cushioning device of the present invention, the filling material is a mixture of a gaseous compound and a liquid. 
         [0011]    In another embodiment of the cushioning device of the present invention, the liquid is a gelatinous material based on a super absorbent polymer. 
         [0012]    In another embodiment of the cushioning device of the present invention, the mixture comprises about 1-20% v/v % gaseous compound and about 80-99% v/v % gelatinous material. 
         [0013]    In another embodiment of the cushioning device of the present invention, the gaseous compound includes air, nitrogen, argon, or a combination thereof. 
         [0014]    In another embodiment of the cushioning device of the present invention, the amount of filling material within the chamber is sufficient to exert a positive pressure upon the chamber sufficiently beyond atmospheric pressure when there is no large animal on said cushioning device. 
         [0015]    In another embodiment of the cushioning device of the present invention, the pressure within the chamber ranges between about 0.1 PSI to about 12 PSI. 
         [0016]    In another embodiment of the cushioning device of the present invention, the pressure within the chamber ranges between about 2.1 PSI to about 14 PSI. 
         [0017]    In another embodiment of the cushioning device of the present invention, the cushioning device includes at least one valve having means of fluid communication with a site exterior to the chamber. 
         [0018]    In another embodiment of the cushioning device of the present invention, the means for communication with the site exterior to the chamber includes a check valve or a valve having a septum disposed within. 
         [0019]    In another embodiment of the cushioning device of the present invention, the cushioning device further includes at least one port connecting the chamber with an exterior of the cushioning device, and a cap for sealing the at least one port, the cap comprising (i) a main body, (ii) a connector extending from the main body, the connector designed for interfacing with the port of the cushioning device, and (iii) a septum disposed in the cap, the septum configured for receiving an inflation needle there through and into the chamber of the cushioning device. 
         [0020]    In another embodiment of the cushioning device of the present invention, the drop-stitch structure comprises two opposing base layers connected by a plurality of threads, and wherein the two opposing layers directly line the chamber of the cushioning device. 
         [0021]    In another embodiment of the cushioning device of the present invention, the top and bottom walls include a fabric layer having a scrim. 
         [0022]    In another embodiment of the cushioning device of the present invention, the cushioning device further includes an abrasion resistant material adjacent to either or both the top and bottom walls. 
         [0023]    In another embodiment of the cushioning device of the present invention, the cushioning device is in communication with a filling material reservoir. 
         [0024]    In another embodiment of the cushioning device of the present invention, the cushioning device further includes a filling material reservoir, an intake valve and an exhaust valve, at least the intake vale being in communication with the filling material reservoir, the intake valve having an intake check valve configured for allowing filling material to flow into the cushioning device, while preventing the filling material from flowing out of the cushioning device, and the exhaust valve having an exhaust check valve configured for allowing filling material to flow out of the cushioning device, while preventing filling material from flowing back into the cushioning device. 
         [0025]    In another embodiment of the cushioning device of the present invention, the cushioning device is a large animal cushioning device. 
         [0026]    In another embodiment of the cushioning device of the present invention, the large animal includes a cow, a horse, a buffalo a goat and a pig. 
         [0027]    In another embodiment of the cushioning device of the present invention, the cushioning device when filled with the filling material is capable of withstanding an animal weighing more than about 400 Kg. 
         [0028]    In another embodiment of the cushioning device of the present invention, the cushioning device when filled with the filling material is capable of withstanding an animal weighing between about 400 Kg and about 1,200 Kg. 
         [0029]    In one embodiment, the present invention provides a system including (a) at least one cushioning device according to any of the previous embodiments, and (b) a filling material reservoir in connection with the at least one cushioning device. 
         [0030]    In one embodiment of the system of the present invention, each of the at least one cushioning device includes at least one intake valve, at least one exhaust valve, at least the intake vale being in communication with the filling material reservoir, the at least one intake valve having an intake check valve configured for allowing filling material to flow into the cushioning device, while preventing the filling material from flowing out of the cushioning device, and the at least one exhaust valve having an exhaust check valve configured for allowing filling material to flow out of the cushioning device, while preventing filling material from flowing back into the cushioning device. 
         [0031]    In another embodiment of the system of the present invention, the system is maintained at a desired pressure. 
         [0032]    In another embodiment of the system of the present invention, the cushioning device is a large animal cushioning device. 
         [0033]    In another embodiment of the system of the present invention, the large animal includes a cow, a horse, a buffalo a goat and a pig. 
         [0034]    In another embodiment of the system of the present invention, the cushioning device when filled with the filling material is capable of withstanding an animal weighing more than about 400 Kg. 
         [0035]    In yet another embodiment of the system of the present invention, the cushioning device when filled with the filling material is capable of withstanding an animal weighing between about 400 Kg and about 1,200 Kg. 
         [0036]    In one embodiment, the present invention provides for a method of installing cushioning device at a site. In one embodiment, the installation method includes: (a) providing a cushioning device having a drop stitch structure and a chamber configured for receiving a filling material, (b) delivering the cushioning device and an amount of a polymer capable of producing gel upon contact with a liquid to the site, and (c) mixing the polymer with a controlled mixture of the liquid to create the gel inside the chamber of the cushioning device. 
         [0037]    In one embodiment of the method, the cushioning device is delivered with the amount of polymer inside the chamber or outside the chamber. 
         [0038]    In another embodiment of the method, the method further comprises introducing a gas into the chamber. 
         [0039]    In one embodiment, the present invention provides for a kit comprising (a) a cushioning device of any of the above embodiments and (b) a filling material. 
         [0040]    In one embodiment of the kit, the filling material is provided inside the chamber. 
         [0041]    In another embodiment of the kit, the filling material is provided outside the chamber. 
         [0042]    In yet another embodiment of the kit, the kit further comprises an installation manual. 
         [0043]    In one embodiment of the kits of the present invention, the cushioning device is a large animal cushioning device. 
         [0044]    In one embodiment of the kit of the present invention, the large animal includes a cow, a horse, a buffalo a goat and a pig. 
         [0045]    In one embodiment of the kits of the present invention, the cushioning device when filled with the filling material is capable of withstanding an animal weighing more than about 400 Kg. 
         [0046]    In another embodiment of the kits of the present invention, the cushioning device when filled with the filling material is capable of withstanding an animal weighing between about 400 Kg and about 1,200 Kg. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0047]      FIG. 1  illustrates an isometric view of a cushioning device in accordance to one embodiment of the present invention. 
           [0048]      FIG. 2  A illustrates a top view of a cushioning device in accordance to one embodiment of the present invention.  FIG. 2  B is a cross section view of the cushioning device of  FIG. 2  A through A-A.  FIG. 2  C is a detailed view of  FIG. 2  B illustrating different layers in accordance with one embodiment of the present invention. 
           [0049]      FIG. 3  A illustrates a cross section of a cushioning device in accordance to one embodiment of the present invention showing a drop stitch structure. 
           [0050]      FIG. 3  B illustrates a cross section of a cushioning device in accordance to one embodiment of the present invention showing a drop stitch structure. 
           [0051]      FIG. 4  is a perspective view of a cushioning device for large animals in accordance to one embodiment of the present invention illustrating a cushioning device installed. 
           [0052]      FIG. 5  A is a perspective view of a system of cushioning devices for large animals in accordance to another embodiment of the present invention. 
           [0053]      FIG. 5  B is a detail view of the area indicated by dashed rectangle “a” of  FIG. 5  A. 
           [0054]      FIG. 6  is a perspective view illustrating the layers of a wall of a cushioning device for large animals in accordance with one embodiment of the present invention. 
           [0055]      FIG. 7  is an isometric top view of one corner of an inflatable mattress, showing one valve cap with septum in accordance to one embodiment of the present invention shown above the filling port on the inflatable mattress. 
           [0056]      FIG. 8  is an isometric top view of one corner of an inflatable mattress, showing one valve cap with septum in accordance to one embodiment of the present invention installed on the inflatable mattress 
           [0057]      FIG. 9  is an isometric top view of an inflatable mattress including two valve caps with septa in accordance to one embodiment of the present invention. 
           [0058]      FIG. 10  is an isometric exploded perspective view from the top of a valve cap with septum in accordance to one embodiment of the present invention. 
           [0059]      FIG. 11  is an isometric exploded perspective view from the bottom of a valve cap with septum in accordance to one embodiment of the present invention. 
           [0060]      FIG. 12  is an isometric perspective view from the bottom of a valve cap and a grommet with septum in accordance with one embodiment of the present invention. 
           [0061]      FIG. 13  is an isometric top view of one corner of an inflatable mattress showing one valve cap with septum installed on the inflatable mattress, with a syringe of filling fluid shown in position ready to be inserted into the valve cap with septum in accordance to one embodiment of the present invention. 
           [0062]      FIG. 14  is an isometric top view of one corner of an inflatable mattress showing a valve cap with septum installed on the inflatable mattress, with a syringe of filing fluid shown inserted through the septum of the valve cap in accordance to one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0063]    Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Also, unless indicated otherwise, except within the claims, the use of “or” includes “and” and vice-versa. Non-limiting terms are not to be construed as limiting unless expressly stated or the context clearly indicates otherwise (for example “including”, “having” and “comprising” typically indicate “including without limitation”). Singular forms including in the claims such as “a”, “an” and “the” include the plural reference unless expressly stated otherwise. All publications cited herein, as well as the priority document, are incorporated by reference in their entirety. 
         [0064]    “Inflatable”, as used in this document, means inflation with a suitable filling material. The filling material includes any suitable fluid or combination of fluids. Suitable fluids include gaseous compounds and/or liquids, including gels. 
         [0065]    “Large animals” refer to livestock species such as cattle, buffalos, horses, sheep, goats, and pigs. The term “large animal” excludes pets, such as dogs and cats regardless of their size and weight. 
         [0066]    The invention will be explained in details by referring to the figures. 
         [0067]    The Cushioning Device 
         [0068]    The present invention relates to a cushioning device that may be filled with a gaseous compound or a mixture of gaseous compound and a liquid. In one embodiment, the cushioning device of the present invention includes a drop stitch structure and a chamber configured for receiving an amount of the filling material capable of withstanding a large animal. As such, the present invention relates also to a large animal cushioning device. 
         [0069]    The cushioning device of the present invention may take an overall configuration which may be the same, or has similarities to, a mattress. As such, the cushioning device of the present invention may also be referred to in this document as a mattress. With reference to  FIG. 1 , reference numeral  100  denotes generally a cushioning device, which may comprise of an inflatable bladder capable of withstanding a large animal, such as cow or buffalo. A cow/bull may weigh between about 900 pounds and about 3,000 pounds. A buffalo may weigh between about 2100 pounds and about 2600 pounds. Accordingly, the cushioning device of the present invention may be capable of withstanding animals having a weight between about 900 pounds and about 2,600 pounds (between about 400 Kg to about 1,200 Kg). The cushioning device  100  of the present invention may comprise a top or first wall  120 , and a bottom or second wall  130 . The top and bottom walls  120 ,  130  may form a chamber. The chamber may be configured to receive a filling material for filling the chamber of the cushioning device  100 . The cushioning device may also include filling/retrieving means such as a port  110  for disposing or retrieving a filling material into/from the chamber. 
         [0070]    To form the chamber, the top and bottom walls  120 ,  130  may be connected at their peripheral ends throughout the periphery of the cushioning device  100  to form a peripheral structure. It may be necessary to seal the chamber to prevent the filling material from leaking out of the cushioning device. In this case, the top and bottom surfaces  120 ,  130  may be connected directly at their peripheral end by sealed end seams in order to create the sealed chamber (see in  FIG. 7  end seams  701 ). Alternatively, the top and bottom surfaces may be connected at their peripheral ends to side walls  140 , for example by sealed end seams. 
         [0071]    Along the periphery of the cushioning device, additional layers may be used to couple the top and bottom surfaces. This configuration is shown in  FIG. 2  for clarity.  FIG. 2  illustrates a cushioning device  200  having a top wall  220  and a bottom wall  230  and a periphery or side wall  201 . Also shown is a port  210 .  FIG. 2  C details a cross section of the cushioning device  200  (for convenience only,  FIG. 2  C does not illustrate the drop stitch structure, which is illustrated in  FIG. 3A  and  FIG. 3B ). Item  201  designates a periphery having a layer which may be comprised of polyvinylchloride (PVC) which may include a scrim, which may be a nylon scrim. Items  220  and  230  designate the top and bottom walls of a mattress  200 . The top and bottom walls  220 ,  230  may include an outer layer, which may be made of PVC, with scrim. Item  242  designates a portion of the periphery in which the scrim PVC  201  overlaps with the top or bottom surfaces  220 ,  230  forming the peripheral structure  242 . The peripheral structure  242  may be provided with an additional layer  202 , which may be made of a PVC without a scrim. Item  202  may serve to provide an additional liquid tight seal where Items  201  and  230  may be bound together. Item  202  may also serve to provide an additional means of transmitting the shear forces experienced in the joint between items  201  and  230 . 
         [0072]    The basic structure of the cushioning device of the present invention includes a drop stitch structure.  FIG. 3  A illustrates, in one embodiment, the top wall  320  and the bottom wall  330  interconnected by fabric stitching  370  to form a drop stitch structure  350  of the cushioning device of the present invention. 
         [0073]    As shown in  FIG. 3  A, the “drop stitch fabric” generally shown as  350  includes two opposing base layers  352  and  354 , with a core section  356  positioned between (and connected to) the base layers  352  and  354 . This core section  356  may include a plurality of individual threads or cords  370  which have upper and lower end portions which connect to, respectively, the upper and lower layers  352  and  354 . Threads  370  may be made of any suitable material, such as nylon. 
         [0074]    Each of the top wall and the bottom wall of the cushioning device of the present invention may be made of one layer or of at least one layer. As such the bottom and top walls may be made of 1, 2, 3, 4, 5 or more layers.  FIG. 3  A illustrates a top wall  320  and a bottom wall  330  including four layers each. With reference to  FIG. 3  A, the layers of the walls will now be described in order from the chamber  310  to the exterior surface of the cushioning device  300 . In the embodiment shown in  FIG. 3 , the top and bottom walls  320 ,  330  may include two opposing base layers  352 ,  354  lining or covering the chamber  310 . The opposing base layers  352 ,  354  may be connected by a drop stitch structure  350 . The base layers  352 ,  354  may be a cloth or fabric made of nylon, ballistic nylon or similar materials, and they may serve to provide strength and durability to the cushioning device, as well as enable shape retention. The base layers  352 ,  354  may in turn be lined by a scrim layer, as shown in  FIG. 3 . The scrim layer may include two sheet layers having a scrim sheet in between. The scrim layer may, for example, be made of PVC sheets  383   a,b,    385   a,b  having a nylon scrim  387 ,  389 . The scrim layer may serve to provide a fluid tight seal, durability and resistance to degradation in harsh environments such as animal urine or feces. The base cloth  352 ,  354 , and scrim layer may be laminated together. 
         [0075]      FIG. 3  B shows another embodiment of a cushioning device having a drop-stitch structure. In this embodiment, the top and bottom walls include five layers each  82 ,  83 ,  84 ,  85 ,  86 . Layers  82  may be based layers joined by a plurality of individual threads or cords  87 . 
         [0076]      FIG. 6  illustrates the different layers forming a wall of the cushioning device of the present invention: the base layer  610  that covers or line the chamber of the cushioning device and forms part of the drop-stitch structure, and the scrim layer  620 . The base fabric layer  610  may be a polypropylene fabric layer. The scrim layer  620  may include two PVC sheets  622 ,  626  and a scrim sheet  624 , which may be made of, but not limited to, nylon, ballistic nylon, nylon 6, polyester, or similar fabric like materials in between the two PVC sheets  622 ,  626 . 
         [0077]    As illustrated in  FIG. 4 , the cushioning device  400  of the present invention may be placed over a deck  410 , such as a concrete deck. A protective, abrasion resistant sheet  412  may be used to line the deck  410 , and adjacent to the bottom surface of the mattress  400 . Protective sheet  412  may be a suitable polypropylene fabric. An abrasion resistant cover sheet  414  may be used adjacent to the top surface of the cushioning device  400 . The abrasion resistant cover sheet  414  may be made of polypropylene or a suitable rubber material. One or more coupling means  417 ,  419  may be used to maintain the cushioning device  400  substantially immobilized on the deck. Item  419  may take the form of a plastic arch/barrier. Item  417  may take the form of a plastic strip. 
         [0078]    The cushioning device of the present invention may be inflated utilizing a filling station in fluid communication with one or more ports on the cushioning device enabling the introduction of the filling material in/from the chamber. In one embodiment, the filling station may dispose a liquid, a gaseous compound or a mixture of the aforementioned filling materials into the chamber of the cushioning device. Subsequent to the cushioning device being sufficiently inflated it may be manually disposed on the deck. According to another embodiment of the invention, the cushioning device may subsequently be covered with a protective sheet  414 . One or more coupling means,  417 ,  419  may be used to maintain the protective sheet and cushioning device substantially immobilized on the deck  410 . 
         [0079]    The cushioning device of the present invention may include one or more means for disposing and retrieving the filling material in/from the chamber. In one embodiment, a standard port may be provided on the cushioning device to permit entry and exit of the filling material to/from the chamber (see for example item  110  of  FIG. 1 ). In one embodiment, the port may be comprised of an inlet or intake port and an outlet or exhaust port. A single port may be used to enable the inflation and/or installation of the cushioning device of the present invention with the filling materials.  FIG. 5  A illustrates an exhaust valve  510  and an intake valve  512  which may be included in each mattress  501 ,  502 . In one embodiment, the one or more ports for disposing and retrieving the filling material may be in fluid communication with a powered or non-powered reservoir including but not limited to a pressurized fluid reservoir, gas compressor or fluid pump. The cushioning device may be inflated by providing a means of fluid communication to the aforementioned reservoir through the implementation of a fluid conduit.  FIG. 5  A illustrates a fluid conduit, trunk line  514  which may communicate a fluid reservoir with a plurality of cushioning devices. 
         [0080]      FIG. 5  B illustrates detail of dashed rectangle a, in which the exhaust port check valve  510 , the inlet port check valve  512 , the trunk line  514  to reservoir, and drop stitch mattress  501 . Item  515  illustrates a spacer wedge. 
         [0081]    The Filling Material 
         [0082]    In the present invention the filling materials may include one fluid, or a mixture of fluids having different viscosities or being in different physical states. As such, in one embodiment, the filling material may include or consist of a gaseous compound, including a mixture of gases. In other embodiments the filling material may be a mixture of a gaseous compound such as air, and substances in liquid state, such as water and gelatinous materials. 
         [0083]    The gaseous compound may be an inert gas. Examples of gases that may be used to fill the cushioning device of the present invention include air, nitrogen and argon. Other gases may also be used. 
         [0084]    The liquid may include a gelatinous filling material. The gelatinous material may be provided as a compound, preferably substantially dry or powder form that creates a gel when in contact with a liquid solution such as water. Examples of such a compound for creating the gelatinous material may include a polymer such as a superabsorbent polymer (SAP). SAP is commonly used in the hygiene industry, particularly in the manufacture of diapers to absorb body fluids. As such, a preferred material for providing a gelatinous filling material may be in the form of a powder or granules made up of SAP, and the powder or granules may be interspersed throughout the chamber. An example may be the sodium polyacrylate AP95 OS produced by Evonik Stockhousenr®. 
         [0085]    When SAP is in contact with a liquid, such as water, it creates a gel that can last as a gelatinous material for many years when inside a sealed chamber. 
         [0086]    SAP that may be used in the present invention include absorbent polymers that absorb liquids and are commonly used in the manufacture of sanitary articles. SAP that may be used in the present invention include polymers that absorb over 50 times, more preferably over 75 times, even more preferably over 100 times, its weight in water. Non-limiting examples of SAP that may be used according to the present invention include sodium polyacrylate, sodium polyacrylamide, and potassium polyacrylamide. The 
         [0087]    The high viscosity of the gelatinous filling material that may be included within the chamber of the cushioning device may create impact absorption to absorb energy peaks. Also, the conformability of the gel may help reduce the pressure points on joints or extremities of the large animal, which may result, in the case of cows, in an increase in the milk production. 
         [0088]    If a mixture of gas and gelatinous material are used to fill the chamber, the cushioning device may include about 1-20% v/v % gas and 80-99% v/v % gelatinous material, and any possible range of gas to gelatinous material therein between. 
         [0089]    System 
         [0090]    In another embodiment, the present invention relates to a system for providing comfort to large animals. The system may include (a) at least one cushioning device of the present invention, and (b) a source of filling material in connection with the at least one cushioning device. 
         [0091]    The system, in another embodiment, may include: (a) one or more cushioning devices, each cushioning device including a chamber configured for receiving a filling material, and (b) a source of filling material in connection with the one or more of cushioning devices. In one aspect, the one or more cushioning device may include a drop stitch structure. In another embodiment, the cushioning device is a large animal cushioning device. 
         [0092]    The one or more cushioning devices may be interconnected to one or more reservoirs of filling material that enables the adjusting or maintaining pressure once the mattresses are installed; the adjustment may be based on animal attributes (health, weight) or compensating for the stretching/aging of the mattress. The system may include a trunk line connecting the one or more cushioning devices to a source of filling material, such as a gas reservoir. The mattresses and connections in the system may be maintained at a desired pressure. If a mattress in the system falls below the pressure at which the system is set, then, because of pressure differential, the system automatically (i.e. without the input of an operator) fills the mattress, thereby bringing the pressure back to the system&#39;s pressure. 
         [0093]    In one particular embodiment, the system may include a plurality of cushioning devices of the present invention and the source of filling material. 
         [0094]    Shown in  FIG. 5  A and in  FIG. 5  B is a system  500  of a plurality of drop-stitch, large animal cushioning devices of the present invention  501 ,  502 . The cushioning devices  501 ,  502  may be placed on top of a deck  505  lined with a protective layer  506 , which may be made of PVC. The cushioning devices  501 ,  502  may be covered by a cover  504  which may be made of PVC or a suitable rubber material. For illustration purposes only, a portion of the rubber cover  504  is cut-out to show cushioning devices  501 ,  502 , but it should be understood that the system may include  2 ,  3 ,  4  or more cushioning devices. 
         [0095]    The cushioning devices  501 ,  502  may include intake valves  512 , and exhaust valves  510 . Each intake valve  512  includes an intake check valve configured for allowing filling fluid to flow into the cushioning device  501 ,  502 , while preventing the fluid from flowing out of the cushioning device  501 ,  502 . Each exhaust valve  510  includes an exhaust check valve configured for allowing filling fluid to flow out of the cushioning device  501 ,  502 , while preventing fluid from flowing back into the cushioning device  501 ,  502 . Each exhaust valve may be connected to an exhaust conduit included in a trunk line  514 . Each intake valve  512  may be preferably connected to an intake conduit included in the trunk line  514 . 
         [0096]    Through extension of the trunk line  514  each intake valve  512  is in communication, such as fluid communication, with a powered or non-powered fluid reservoir including but not limited to a pressurized fluid reservoir, gas compressor or fluid pump (not shown). The exhaust valve through extension of the trunk line  514  may be in fluid communication with a pressurized fluid reservoir, or atmosphere through the implementation of a pressure regulator (not shown). Generally, the fluid included in the supply and exhaust reservoir is a gaseous compound, however, a liquid such as water, or a mixture of gas and liquid may also be suitable. 
         [0097]    The weight of a body such as a cow resting, or standing, or the impact of a cow in transition from the resting to standing position and vice versa may deform the chamber of a cushioning device. Thus the pressure of the fluid within each chamber increases as the volume of the chamber decreases under deformation. As the pressure of the fluid increases, the fluid in the affected cushioning device(s) flows out of the chamber through a corresponding exhaust valve and into the pressure regulated trunk line and reservoir. The aforementioned sequence of events occurs such that the entire system remains substantially close to or at equilibrium, thereby maintaining the desired level of comfort throughout the entire spectrum of events imposed by animal occupancy. 
         [0098]    Valve Cap with Septum 
         [0099]    The present invention, in another embodiment, additionally provides means for the re-pressurization of an inflatable bladder such as the cushioning device of the present invention subsequent to installation of the inflatable mattress. In one embodiment, the re-pressurization may be achieved through the incorporation of a septum or check valve or equivalent within the valve cap that facilitates fluid communication with regions exterior to the chamber of the inflatable bladder. 
         [0100]    The present invention also provides for a cap with septum for use in an inflatable bladder such as gas, liquid or both liquid and gas filled mattresses where it may be desired to re-pressurize the bladder by adding relatively small amounts of fluid, such as gas, liquid or a mixture of gas and liquid. In one embodiment of the present invention there is provided a cap for sealing a filling port of an inflatable bladder having a chamber, the cap comprising (i) a main body, (ii) a connector extending from the main body, the connector designed for interfacing with the filling port of the inflatable bladder, and (iii) a septum disposed in the cap such that an inflation member, such as a needle, can be inserted through the septum and into the chamber of the cushioning device. 
         [0101]    With reference to  FIGS. 7 to 11 , the cap  10  of the present invention may include a main body  12  with a top wall  14  and a bottom wall  16 . Bottom wall  16  may include a gasket  13  for better sealing the filling port. Extending from the bottom wall  16  there is a connector or throat  18  configured for engagement to or interfacing with a filling port  2  of an inflatable bladder  1  and having a free bottom wall  19 . The connector  18  may include external threads  17  that may match threads  3  in the filling port. Alternative to the threads, the connector may include one or more ribs or rings made of a flexible material like rubber, for frictionally engaging the filling port. The cap  10  includes a channel  20 , which may be centrally located, that extends from an opening  22  on the top wall  14  through the main body  12 , through connector  18 , and ending in an aperture  24  on the bottom wall  19  of the throat  18 . The two opposing openings  22 ,  24  may be arranged substantially co-axially on axially opposite ends of the channel  20 . Opening  24  may be smaller in diameter, including slightly smaller, than opening  22 . The side walls  25  of channel  20  may be threaded. 
         [0102]    The septum  30  may be configured for essentially fitting inside channel  20 . Within the channel  20 , septum  30  may sit on the inside surface of throat&#39;s  18  bottom wall  19  thereby covering opening  24 . The septum may be frictionally engaging the side walls of the throat. Septa may be made from silicone, rubber, or other similar materials. The trait that these materials have is that when a needle is pushed through them, the septum seals around the needle during insertion, and then when removed, the needle hole closes back up and seals again. 
         [0103]    A plugging device, such as a plug  40 , may be used to retain the septum  30  in place within cavity  20  and covering opening  24 . Plug  40  may include a top wall  42 , a bottom wall  44  and side walls  46 . Side walls  46  may include threads  47  matching the threads of the side walls  25  of throat  18 . Instead of threads, side walls of the plug may include one or more ribs or rings that would frictionally engage with the side walls of the cap&#39;s cavity. Plug  40  may include a hole  45 , which may be centrally located, having two openings  41 ,  43  that may be arranged substantially co-axially on the axially opposite top and bottom walls  42 ,  44  of the plug  40  respectively. Opening  41  may be designed to receive the head of bit of a screwdriver or other devices such as a hex key. 
         [0104]    Referring to  FIG. 12 , another embodiment of the cap with septum of present invention is illustrated. When referring elements of the cap, the same reference numbers of  FIGS. 7-11  will be used for convenience. In this embodiment, the septum  62  may be provided in a grommet  61  that may be inserted into the aperture  24  located on the bottom wall  19  of connector  18  of the cap  10 . Grommet  61  may include an external flange  66  and an internal flange  68 . The external flange  66  and the internal flange  68  define a groove  69  there in between. The internal flange  68  may include a surface  65  designed for easier insertion of the grommet through the aperture  24 . For example, surface  65  may be tapered. When inserted, the internal flange  68  becomes disposed in the interior of channel  20  of cap  10 , while the external flange may remain adjacent to the bottom wall  19  of the cap  10 . The groove  69  is adapted to receive a lip  64  of the aperture  24  disposed on the bottom wall  19  and may establish a seal between the grommet and the lip of the aperture  24 . The groove  69  and flanges  66 ,  68  may have a contour which is complementary to the shape of the aperture  24 . That is, the shape of grommet  61  may be designed to fit any specific aperture opening or shape such as circular, square, rectangular, etc. by changing the contours of the internal and external flanges. An improvement of the grommet of the present invention is that it includes a septum  62 . Septum  62  may be disposed within the external flange  66 . The grommet of the present invention may be made of any suitable material, preferably from a resilient or elastomeric material such as polyurethane. 
         [0105]    With reference to  FIGS. 13 and 14 , hole  45  may be designed to allow a needle  52  go through it and be inserted through the septum and into the filling port  2  of the inflatable bladder  1 . 
         [0106]    The inflation needle should be a non-coring needle. This means that the needle can spread open the septum, but will not puncture a hole in it. The inflation needle may be connected to a source of filling material.  FIGS. 13 and 14  illustrate an inflation needle  52  connected to a syringe  50  having a filling material. The inflation needle may alternatively be connected directly to a hose or pump to push the filling material into the inflatable bladder. 
         [0107]    In assembling the cap of the present invention, the septum may be positioned within the channel of the cap, preferably sitting on the bottom wall of the cap&#39;s connector and covering the connector&#39;s bottom wall&#39;s opening. When a plug is used to retain the septum in place, the septum may be inserted through the opening on the top wall of the main body first and then the plug is inserted in the cavity, for example manually or using a screw driver, a hex key or any other suitable device, to keep the septum in place. 
         [0108]    The cap of the present invention may be used to seal an inflatable bladder such as an inflatable mattress, by connecting the connector or throat of the cap into a filling port of the inflatable mattress. With reference to  FIGS. 13 and 14  if the mattress needs more internal pressure, in operation, a suitable needle  52  connected to a syringe  50  or to other device containing a filling material, may be inserted into the plug&#39;s  40  hole  45 , through the septum within the cavity and into the filling port  2  of the inflatable bladder  1 . The filling material may then be pushed into the inflatable bladder  1 , as illustrated in  FIG. 14 , until a desired internal pressure is attained. The needle  52  may then be retrieved from the plug&#39;s  40  hole  45 . 
         [0109]    The cap of the present invention may be used for filling relatively small amount of filling fluids or gas into an inflatable bladder, such as the cushioning device of the present invention, through the septum with a suitable member such as a needle. The advantage is that it will be much simpler and faster to add relatively small amounts of filling material to the inflatable bladder if the inflatable bladder were to become soft, for example, because of the material stretching, which may often occur in the case of inflatable mattresses for large animals due to the weight of the large animals. 
         [0110]    The cap with septum of the present invention provides an easy way to add fluid or gas the cushioning device of the present invention or to any other inflatable bladder. Adding filling fluid or air through the septum allows to leave the inflatable bladder closed, which saves time. 
         [0111]    Delivery and Installation of the Cushioning Device 
         [0112]    In one embodiment, the present invention provides for a kit comprising (a) a cushioning device according to one embodiment of the present invention and (b) a compound capable of creating a gelatinous filling material when in contact with a liquid solution such as water. The kit may also comprise instructions on how to install and/or care for the cushioning device. The kit may also comprise a cover for covering said cushioning device. The kit may also comprise a layer of protection for under the said cushioning device. The kit may also include a fluid reservoir and/or trunk line mentioned above. 
         [0113]    In another embodiment, the present invention also provides for methods of transporting, delivering, distributing or shipping a cushioning device of the present invention to a site, such as a stall in a farm or a distributor of the cushioning device. These methods may be particularly useful to keep the shipping volumes and weights to a minimum. When the filling material includes a mixture of gelatinous compound and gas, one such method of transporting a cushioning device to a site may comprise delivering to the site the cushioning device with an amount of a compound capable of creating the gelatinous material when in contact with a liquid already disposed within the chamber. The amount of compound to be used would depend at least on the compound being used, and the dimensions of the chamber. For example, the dimensions may create a chamber that can hold approximately 100 litres of water, and a certain SAP can absorb a ratio of 1:100 by weight. In this case, the amount of SAP needed may be about 1 kg. The cushioning device with the compound disposed in the chamber may, for example, be packaged in a container for transportation to the site. At the installation site an amount of the liquid may be introduced into the chamber thereby creating the gel within the chamber and, when a mixture is used, an amount of a gas and installing the cushioning device at the site. 
         [0114]    Alternatively, the cushioning device and an amount of the compound capable of creating the gelatinous material upon contact with a liquid may be delivered separately to the site (i.e. the compound is not disposed within the chamber). The cushioning device and the amount of compound may, for example, be packaged in a container for transportation to the site. The compound may be provided, for example, in a plastic bag. The amount of compound to be delivered may depend, as provided before, at least on the compound being used and the dimensions of the chamber. At the remote site the compound may be disposed within the chamber and the chamber may then be filled with an amount of liquid to create the gelatinous filling material within the cushioning device. A gaseous compound may also be introduced within the chamber. 
         [0115]    When filling the cushioning device, a balance between the comfort of the large animal such as a cow or a horse, and the clean-ability of the surface of the cushioning device may be maintained. Clean-ability affects the work input for the farmer and the hygiene for the cow. Both comfort and hygiene can affect the milk production levels of a cow. 
         [0116]    The inventors discovered that a preferable balance between comfort and clean-ability may be achieved when the chamber of the cushioning device has a positive pressure, that is a positively past the atmospheric pressure. This pressure within the chamber may range from about 0.1 psi to about 12 psi when there is no large animal on the cushioning device. This positive pressure may ensure that, for example, when there is not a cow on the cushioning device, the cushioning device of the invention may remain in the fully inflated form without any indentations or low spots in the walls. When there are no indentations or low spots, the mattress may be easier to clean and the liquid matter may drain properly. However, within this range of positive pressure, since the large animals are heavy, they may still be capable of indenting the mattress, which is critical for animal comfort. 
         [0117]    Depending on the material being used to manufacture the cushioning device, such as a mattress, there may be some elastic and some permanent stretch in the material. In a preferred configuration, reinforced PVC may be used with internal glue and threads for the construction. This leads to a mattress having a relatively small amount of permanent stretch after it is first used. Thus, in order to maintain the positive pressure (as described above), the mattress may need an extra preload during installation. The preload may vary depending on the material of the mattress, but for the preferred configuration, the preload may be about 2 psi. Thus the installation pressure in the cushioning device may be between about 2.1 psi and about 14 psi. It is expected that this preload installation pressure may drop to a desired final pressure during the first month of use of the cushioning device. 
         [0118]    To achieve the right pressure within the cushioning device of the present invention, an installer may use a manual valve with a pressure gauge to achieve the right pressure. Gas may be included to achieve the desired pressure. The pressure may also be automatically regulated using the manifold system previously described. 
         [0119]    Advantages 
         [0120]    Advantages of independent (i.e. not in fluid communication) cushioning devices (gas only or hybrid gas/gel) of the present invention include: inclusion of gas, such as air, further aids in impact absorption when animal gets up and down in comparison to existing cushioning device or mattress systems; simplified installation procedure as compared to similar mattresses or cushioning devices; adds to the longevity of the mattress; compensates for stretching of PVC; added compensation for temperature fluctuations; drop-stitch structure makes mattress cushioning devices of the present invention substantially or completely flat which helps keep it clean; i.e. more hygienic for the animal; low transportation costs, because fluid may be added at installation site. 
         [0121]    Advantages of cushioning devices with manifold system—could be just gas or Hybrid (gel/gas), include: improved impact absorption which may benefit health of the animal; variable pressure settings for comfort customization depending on animal attributes (weight, health); uniform pressure throughout all cushioning devices in the system, which are in fluid communication; continued comfort compensation as the cushioning device ages and stretches; drop-stitch structure makes mattress or cushioning device substantially or completely flat which helps keep it clean; i.e. more hygienic for the animal, and less labour intensive to clean; lightweight at installation (air), good ergonomics for installation technicians; enables compensation for temperature variations within filling fluid; mat size can be for 1 or more animals e.g. 1 to 5 or more animals; decreasing amount failure areas; and further simplifying installation. 
         [0122]    Other unique attributes of the cushioning devices and systems of the present invention include: drop stitch has never been used in mattress system, including mattresses for large animals; provides unique substantially or completely flat surface for animal; uses a combination of fluids and gases to achieve cushioning effect; the device may remain in fluid communication with exterior regions, such as an air reservoir through at least one inlet and maybe one exhaust line; polypropylene fabric layers for extra protection against abrasion during usage. 
         [0123]    The above disclosure generally describes the present invention. Changes in form and substitution of equivalents are contemplated as circumstances may suggest or render expedient. Although specific terms have been employed herein, such terms are intended in a descriptive sense and not for purposes of limitation. It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.