Abstract:
A cushion for supporting an infant on a support surface includes a reticulated foam pad having a base surface and an upper surface that extends upwardly therefrom, the pad being fluid permeable. The cushion also includes a covering surrounding the pad that includes an upper layer constructed, at least partially, from a breathable polyester sandwich fabric confronting the upper surface whereby fluid introduced onto the covering permeates through the covering and through the pad to the support surface. The reticulated foam has a porosity of between 5 and 20 pores per cubic inch, thereby being sufficiently resilient to support the infant above the support surface and sufficiently permeable to allow fluid to move through the pad.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to sleep aids and, more particularly, to cushions, sleep positioners, and bedding systems that include reticulated foam pads and breathable polyester coverings. 
       BACKGROUND 
       [0002]    According to the American Academy of Pediatrics, sudden infant death syndrome (SIDS) is the sudden unexplained death of an infant under one year of age. SIDS is sometimes referred to as crib death and strikes nearly 5,000 babies in the United States every year. While much research has been conducted to understand what causes SIDS, there are no clear answers. However, the American Academy of Pediatrics recommends, among other things, that a baby should be put to sleep on his or her back. One theory that has been proposed to explain SIDS is that small infants with little or no control over their heads may, while face down, smother themselves on their own bedding. With that in mind the academy also recommends that babies sleep on a firm mattress or other firm surface and without overly soft or fluffy blankets, pillows, or toys, as an infant may be smothered by these items. 
         [0003]    Infant sleep positioners have been developed in an effort to reduce the risk of SIDS. One example is the INFANT SUPPORT SYSTEM described in U.S. Pat. No. 6,877,176 issued Apr. 12, 2005 to Houghteling. This infant sleep positioner includes a cushion for supporting an infant and includes positioning support members for maintaining the infant in a safe sleeping position. Houghteling provides a head panel made of a material that enhances the breathability for an infant, since the head panel serves as the general location for the infant&#39;s head. Thus, the enhanced breathability of the head panel may provide some help in the event an infant is incorrectly placed on the cushion by providing an air permeable buffer between the infant and the underlying foam pad of the cushion. 
         [0004]    The underlying foam pad in many types of sleep positioners has historically been formed of regular closed or open cell foam. Closed cell foam is comprised of cell membranes that are completely closed. Open cell foam, on the other hand, is typically comprised of both open and closed cell membranes with varying degrees of air and liquid permeability. In both cases the air and liquid permeability characteristics of these types of foams is less than ideal when one considers the need for a cushion with improved breathability. Closed cell foam is particularly unsuited for this application because the closed cell membranes provide very low air permeability. While open cell foam has somewhat better air permeability characteristics, it has the disadvantage of allowing liquids to pass through the open cell membranes and become trapped in other partially closed cell membranes. 
         [0005]    While it is believed that current products may be helpful in reducing the instances of SIDS by maintaining an infant in a safe sleeping position, there is still room for improvement in the area of sleep aids and in particular infant sleep positioners and cushions. It is believed, for instance that the breathability features of infant sleep positioners can be enhanced to further reduce cases of SIDS. Furthermore, it is believed that infant sleep positioners can be improved with respect to their ability to maintain a dry environment for an infant as well as their ability to be easily cleaned. Accordingly, there is a need for cushions, sleep positioners, and bedding systems that have enhanced breathability and/or cleanability. 
       SUMMARY 
       [0006]    Provided herein is a cushion generally comprised of the combination of a fluid permeable reticulated foam pad having a base and an upper surface along with a layer of breathable polyester sandwich fabric covering at least a portion of the upper surface. Preferably the foam pad is resilient and is sized as a standard crib pad. 
         [0007]    In one embodiment a cushion for supporting an infant on a support surface includes a reticulated foam pad having a base surface and an upper surface that extends upwardly therefrom, the pad being fluid permeable. The cushion also includes a covering surrounding the pad that includes an upper layer constructed, at least partially, from a breathable polyester sandwich fabric confronting the upper surface whereby fluid introduced onto the covering permeates through the covering and through the pad to the support surface. The reticulated foam has a porosity of between 5 and 20 pores per cubic inch, thereby being sufficiently resilient to support the infant above the support surface and sufficiently permeable to allow fluid to move through the pad. 
         [0008]    An improvement is contemplated for a cushion that supports an infant upon a support surface. Such a cushion includes a pad having a lower surface adapted to confront the support surface and an upper surface opposite the lower surface and oriented at an acute angle from a first end portion to a second end portion such that the upper surface inclines upwardly relative to the support surface along an axis extending between the first and second end portions. The pad has a width extending transversely of the axis. A top panel is disposed on at least a portion of the upper surface of the pad. The improvement is comprised of the pad being constructed from fluid permeable reticulated foam and the top panel being comprised of polyester sandwich fabric. 
         [0009]    In another embodiment, a formable sleep positioner includes an outer covering comprising a breathable polyester sandwich fabric. An inner pad is formed, at least partially, of reticulated foam and received in the outer covering. The inner pad includes an upper surface, a bottom surface, and a forming member embedded in the pad between the upper surface and the bottom surfaces. The forming member is manually conformable into a formed state so that side portions of the positioner flare upwardly to form a trough-shaped channel for placing an infant. The positioner also includes a head portion selectively conformable to change the elevation of the infant&#39;s head. The outer covering and inner pad of the head portion may be in close confronting relation to one another. 
         [0010]    A bedding system for supporting an infant in a dry environment is also provided herein. The bedding system includes a mattress, such as a crib mattress, having a lower surface and an upper surface defining a support surface. A cushion is supported upon the support surface, the cushion includes a reticulated foam pad having a base surface and an upper surface, the pad has a porosity that allows fluid permeation through the pad. An absorbent layer is interposed between the support surface and the cushion that is operative to collect fluid permeating through the pad. A barrier layer may be interposed between the support surface and the absorbent layer. 
         [0011]    The foregoing and other features, utilities, and advantages of the invention will be apparent from the following more particular description of the embodiments of the invention as illustrated in the accompanying drawings, in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0012]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and together with the description, serve to explain the principles thereof. Like items in the drawings are referred to using the same numerical reference. 
           [0013]      FIG. 1  is a perspective view of a sleep aid according to a first exemplary embodiment in the form of a cushion, partially cutaway to show its interior construction; 
           [0014]      FIG. 2  is a perspective view of a sleep aid according to a second exemplary embodiment in the form of an infant sleep positioner, with a portion of the top panel peeled back to expose the interior; 
           [0015]      FIG. 3  is a perspective view of a positioning support member shown in  FIG. 2  with a portion of its covering peeled back to expose the interior; 
           [0016]      FIG. 4  is a partial cross-sectional side view in elevation of the support cushion taken about line  4 - 4  in  FIG. 2 ; 
           [0017]      FIG. 5  is a perspective view of a sleep aid according to a third exemplary embodiment in the form of a formable infant sleep positioner; 
           [0018]      FIG. 6  is a perspective view of a sleep aid according to a fourth exemplary embodiment in the form of an infant sleep positioner; 
           [0019]      FIG. 7  is a partial cross-sectional side view in elevation of a sleep aid according to a fifth exemplary embodiment in the form of a bedding system; and 
           [0020]      FIG. 8  is a partially exploded side-view in elevation of a sleep aid according to a sixth exemplary embodiment in the form of a bedding system. 
       
    
    
     DETAILED DESCRIPTION  
       [0021]    The detailed description with reference to the accompanying drawings describe the exemplary embodiments of sleep aids in the form of cushions, sleep positioners, and bedding systems that have enhanced breathability and/or cleanability. 
         [0022]    Referring first to  FIG. 1 , a sleep aid, according to a first exemplary embodiment, in the form of cushion  10  is introduced. Cushion  10 , preferably, includes a fluid permeable reticulated foam pad  40  surrounded by an outer covering  20 . Outer covering  20  includes top panel  22 , lower panel  26 , and surrounding sidewall  24  extending therebetween. Top panel  22  and lower panel  26  may be stitched, or otherwise joined, about their respective peripheries to sidewall  24 . Covering  20  may be joined entirely around pad  40  or include an opening for insertion and removal of pad  40 . The opening may include a suitable closure, such as a zipper or cooperative hook and loop materials, for example. While cushion  10  is illustrated in this example with a surrounding covering, outer covering  20  could be comprised of top panel  22  alone. 
         [0023]    Foam pad  40  is preferably a reticulated foam material. Reticulated foam is a particular foam structure that may be formed by one of at least two methods described below. Conventional foam is formed of thousands, if not millions, of plastic bubbles called cells. These cells intersect with each other creating a lattice or framework of interconnecting ligaments with window membranes extending therebetween. Reticulation involves removing the window membranes from between the ligaments leaving only the framework. The resulting foam structure is a framework having completely open cells. This type of foam has a high degree of breathability and permeability. In other words, air and fluids may flow easily through the foam structure. The foam&#39;s permeability is of course affected by the number of cells in a given volume, known as porosity, which is generally measured in pores per cubic inch (PPI). The porosity of the foam can range from about 5 to 100 PPI. In this embodiment, the preferred range of porosity for the reticulated foam is between about 5 and 20 PPI. Reticulated foam may be made of various materials such as polyether polyurethanes and polyester, for example. One example of a suitable reticulated foam material is available from Foamasters located in China and marketed under the part number NF264040. This foam has a density of 23-25 kh/m 3 , a hardness of 7.5-9.5, and a porosity of 11.55. 
         [0024]    One method of creating reticulated foam is a thermal process known as zapping. Zapping involves placing a selected quantity of closed cell foam in a chamber that is evacuated of air and subsequently filled with an explosive gas mixture. The gas is ignited and the resulting explosion passes through the foam melting the window membranes and leaving the framework structure intact. Zapping results in smooth, clean, and polished ligaments. Another method of reticulation is a chemical process known as quenching. In quenching, a quantity of conventional foam is exposed to a caustic bath that attacks and dissolves the window membranes of the foam thereby leaving only the framework of interconnected ligaments. 
         [0025]    With continuing reference to  FIG. 1 , top panel  22  is preferably a 100% polyester sandwich fabric. The sandwich fabric includes an upper layer  32  and a lower layer  34  both comprising a polyester construction. The remainder of covering  20  (i.e. bottom panel  26  and sidewall  24 ) may be formed of another suitable material such as a tri-layer polyester construction, which includes an outer layer that is 100% polyester tricot, a bottom layer that is 100% polyester fine mesh, and an intermediate layer that is 100% polyester fiber. Alternatively, the remainder of the cover could be formed of a fabric that is 50% cotton and 50% polyester, for example. 
         [0026]    As is discussed in co-pending U.S. patent application Ser. No. 12/014,645 entitled SLEEP AID ALONG WITH METHOD INCORPORATING SAME, which was filed Jan. 15, 2008, the disclosure of which is hereby incorporated by reference in its entirety, utilizing such a breathable fabric casing in conjunction with a reticulated foam pad allows bodily fluids to pass through cushion  10 , which helps to provide a dry support surface for an individual, such as an infant, to lie on. Cleaning reticulated foam is also much easier because fluids do not absorb into the pad, given the nature of the interconnected ligament framework. It has been found that when reticulated foam is used in conjunction with a 100% polyester sandwich fabric, or other similar material, there is an additional advantage of breathability which can help prevent suffocation. Accordingly, one of the aspects of the teachings herein is the provision of a sleep aid which exhibits one or a combination of the characteristics of breathability to help reduce the risk of suffocation, fluid absorption, and relatively fast drying, as compared to other sleep aid products. The ordinarily skilled artisan will appreciate that various articles of manufacture having suitable configurations could be designed to accomplish such objectives including, but not limited to, pads, blankets, mats, positioning members, sleep positioners for individuals such as infants, support systems, and bedding systems for infants and other individuals. The additional embodiments that follow are examples of such articles of manufacture that may fall into one or more of the above listed categories. 
         [0027]      FIG. 2  illustrates a sleep aid according to a second exemplary embodiment in the form of infant sleep positioner  205 . Sleep positioner  205  is sized and adapted for use with an infant  5  and broadly comprises a support, shown here to be in the form of wedge-shaped cushion  210 , and a pair of wedge shaped positioning members  215 . This support system is constructed similarly to the INFANT SUPPORT SYSTEM discussed in U.S. Pat. No. 6,877,176 issued Apr. 12, 2005 to Houghteling, the disclosure of which is hereby incorporated by reference in its entirety. 
         [0028]    The infant sleep positioner&#39;s cushion  210  is generally constructed of an outer covering  220 , which receives a resilient reticulated foam pad  240  in a close-fitted relationship. Outer covering  220  can be constructed of various panel sections including a head panel  223  and foot panel  225 , which have respective confronting edges and are stitched or otherwise joined (permanently or releasably) together. Head and foot panels  223  and  225 , thus, form a continuous, two-piece top panel  222  which may be joined to a surrounding sidewall  224 , which is in turn joined to bottom panel  226 . Wedge shaped positioning members  215  (see  FIG. 3 ) each include a wedge shaped reticulated foam pad  230 . Surrounding reticulated foam pad  230  is casing  237 , which is preferably formed of a 100% polyester sandwich fabric. 
         [0029]    The construction of cushion  210  may be better appreciated with reference to  FIG. 4 , which is a partial cross-section of cushion  210  shown in  FIG. 2 . As described above with respect to the first embodiment, foam pad  240  is preferably comprised of reticulated foam. Head panel  223  is a 100% polyester or sandwich fabric comprising upper layer  232 , lower layer  234 , and intermediate layer  235  interposed therebetween. Foot panel  225  may be formed of a tricot material as described above. The combination of a 100% polyester sandwich fabric  223  with the reticulated foam pad  240  allows air to flow into and out of cushion  210  as represented by arrow F A . The ordinarily skilled artisan will appreciate that this characteristic of cushion  210  could help prevent an infant from suffocating if inadvertently coming to rest in a face down position on the cushion. 
         [0030]      FIG. 5  is a sleep aid according to a third exemplary embodiment, in the form of a formable sleep positioner  310 . Formable sleep positioner  310  is constructed similarly to the formable sleep positioner discussed in co-pending U.S. patent application Ser. No. 12/013,382 entitled FORMABLE SLEEP POSITIONER ALONG WITH METHOD FOR ADJUSTING THE SAME, which was filed Jan. 11, 2008, the disclosure of which is hereby incorporated by reference in its entirety. Sleep positioner  310  comprises an inner pad  340  that is at least partially formed from reticulated foam and is received in outer covering  320 . Outer covering  320  is comprised of breathable polyester sandwich fabric and includes zipper  321 , or other suitable closure mechanism or construction, which provides a closable opening for insertion of pad  340  therein. Inner pad  340  corresponds to the inner pad  128  as discussed in the incorporated disclosure. As described more fully in the incorporated disclosure, a forming member may be embedded in the pad between the upper and lower panels. Positioner  310  also includes head portion  323  which is covered with breathable polyester sandwich fabric and is conformable to change the elevation of the infant&#39;s head as desired. 
         [0031]      FIG. 6  is an illustration of a sleep aid, according to a fourth exemplary embodiment, in the form of an infant positioner  410 . Infant positioner  410  may be constructed similarly to the infant positioner discussed in U.S. Pat. No. 7,213,281 entitled INFANT SAFETY SYSTEM, which was issued May 8, 2007 to Hahn et al, the disclosure of which is hereby incorporated by reference in its entirety. In this embodiment, sleep positioner  410  includes a reticulated foam pad  440 , which corresponds to positioner  10  from the incorporated disclosure. Foam pad  440  may be covered, at least partially, by breathable polyester sandwich fabric panel  423 . 
         [0032]      FIG. 7  represents a sleep aid, according to a fifth exemplary embodiment, in the form of a bedding system  505  shown in partial cross-section. Bedding system  505  comprises a mattress  530  including a lower surface  534  and an upper or support surface  532 . In this case mattress  530  could be a typical crib mattress with standard dimensions of approximately 52×27×6 inches. Cushion  510  is supported by support surface  532 . Here again, cushion  510  includes a reticulated foam pad  540  and breathable polyester sandwich fabric  523  as described above. An absorbent layer  525  may be interposed between support surface  532  and cushion  510 . Also, a barrier or waterproof layer  521  may be interposed between cushion  510  and mattress  530 . Because the polyester sandwich fabric material  523  and reticulated foam  540  are fluid permeable, liquid introduced onto layer  523  is allowed to permeate through the layer and through pad  540 , as represented by arrow F L , to be collected by absorbent layer  525 . Optional barrier layer  521  protects mattress  530  from any fluids that may permeate through all of the layers. 
         [0033]      FIG. 8  represents a sleep aid, according to a sixth exemplary embodiment, in the form of a bedding system  605  installed in a typical crib frame  601 . Bedding system  605  is shown partially exploded and the crib frame is shown with one end of the frame&#39;s rungs removed for clarity. Bedding system  605  comprises a mattress  630  that is supported by frame cross-members  603 . Crib sheet  627  is disposed between mattress  630  and cushion  610 . Crib sheet  627  has an upper absorbent layer  625  and a lower barrier layer  621 . Crib sheet  627  is secured to at least the corner posts  607  with loops  613 . Cushion  610  may be constructed substantially as described above with respect to cushion  10 . 
         [0034]    Accordingly, the present invention has been described with some degree of particularity directed to the exemplary embodiments of the present invention. It should be appreciated, though, that the present invention is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the exemplary embodiments of the present invention without departing from the inventive concepts contained herein.