BLANKET OR PAD WITH HOLLOW FILLING PARTICLES

FIELD OF THE INVENTION

The present invention relates to a blanket or a pad with hollow filling particles. The invention also relates to a method of manufacturing the blanket or pads and the use of said blanket or pad.

The term blanket used herein is intended to include coverlets, comforters and therapy blankets and the term pad is intended to include cushions, pillows, mattresses and like supporting pads.

BACKGROUND OF THE INVENTION

A supporting pad filled with plastic beads is described in US Patent No. 3,459,179. Here, the pad comprises a soft case containing a filling of loose non-absorbent small solid plastic particles having rounded outlines. The size, nature and number of the particles are such as to permit free rolling of the particles over and among themselves in the case, so that the shape of the pad will all the time be adapted to the supported part of the body, while at the same time, the particles will, by their movement, exert a massaging action on the surface of this part. However, since all particles are spherical said massaging action will not be very efficient and as the filling particles are permitted to roll freely in the supporting pad, the particles tend to gather at the periphery of the supporting pad.

A therapy blanket filled with therapy balls is described in European Patent No. 0729340. Here, the blanket is square quilted with therapy balls use as filling particles. The filling particles are described as therapy balls, which in the usual understanding are round balls, and there is no mentioning that the filling particles could have other shapes than a ball.

Said blanket have the same drawbacks as described with the pad known from US 3,459,179.

Furthermore, as the filling particles normally are solid their will provide a very heavy blanket, if such particles are used in a blanket, and hollow round or ball shaped particles may be moving or rolling around when used in a blanket or pad - whereby the particles tend to be gathering at the periphery of the blanket or pad.

It is therefore a first aspect of the present invention to provide a blanket or pad having light-weight filling particles, which cannot move or roll around as easily as ball shaped particles, thereby making the blanket or pad more comfortable for the user.

It is a second aspect of the present invention to provide a blanket or pad which is inexpensive to manufacture, can be easily cleaned and which has a durable and reliable construction.

It is a third aspect according to the present invention to provide a blanket or pad where the filling particles are kept at the desired location during use of the blanket or pad.

SUMMARY OF THE INVENTION

These and further aspects are achieved according to the present invention as the blanket or pad comprises filling particles embedded in or surrounded by a cover, said filling particles including a number of hollow filling particles having a form with one or more outwardly curved surface parts and one or more inwardly curved surface parts, and wherein the particles are being dimensioned so that the maximum length is larger than the maximum height.

The outwardly and inwardly curved surface parts of the filling particles will ensure that a fixed or movable therapeutic and/or stimulating pressure is applied to a person's body during use of the pad or blanket. It is well known that massage not only improves a person's health by providing e.g. relaxation or improved sleep, but also provides specific physical benefits, such as relief of muscular aches and pains. Use of the blanket or pad according to the invention therefore ensures that these advantageously effects easily can be obtained e.g. during sleep or relaxation.

As the filling particles has a larger maximum length than maximum height it is ensured that the particles are held more safely at the desired location as the particles cannot move easily around each other. It must in this respect be understood that the particles are capable of mutual displacement in order for the pad or blanket to gradually form a custom impression that contours to the body of the user, however as the particles movement are restricted, the pad or blanket becomes especially efficient in stimulating e.g. the blood circulation and enhancing the massaging effect. This is due to the fact that the users body will need to apply more force/pressure to the blanket or pad before the filling particles can move and the pad or blanket will therefore be very effective in minimizing and/eliminating e.g. bedsores in patients laying more or less permanently in bed. Furthermore, in contrast to spherical filling particles, the filling particles used in the present invention will not tend to gather at the periphery of the blanket or pad and they will have an improved cohesion. This will also ensure that the user will experience a more comfortable pad or blanket than hitherto known.

In order to further ensure that the filling particles are located at the desired location and that their mutual movement is restricted in the pad or blanket it is preferred that part of, a major part of, or all of the hollow filling particles are

dimensioned so that the average length is larger than the average height as this will ensure that large pressure needs to be applied to the particles before they can move. This will also ensure that the particles will not be gathering at the blankets or pads periphery. Therefore, it is also preferred that part of, a major part of, or all of the hollow filling particles are dimensioned so that the maximum length is larger than the maximum width and/or so that the average length is larger than the average width. Also, it is preferred that part of, a major part of, or all of the hollow filling particles are dimensioned so that the maximum width is larger than the maximum height or so that the average width is larger than the average height.

Preferably the filling particles will have a size and weight that will ensure that when the blanket according to the invention is placed over the person, said blanket will in itself have the necessary weight and dimensions to providing the massaging effect from the filling particles. Therefore it is preferred that the filling particles have an average weight between 2.0 to 9.0 g, preferably between the 4.0 and 7.0 g more preferably around 5.5 g, as the inventors surprisingly have found that these weights provides a gentle yet very efficient massaging effect. A person lying on a pad according to the invention will in itself provide sufficient weight to the filling particles of the pad thereby obtaining the massaging effect .

In order to keep the weight of the filling particles in the above areas the wall thickness of the filling particles can preferably be in the range of 0,5 - 3 mm, such as in the range of 1 - 1,6 mm such as around 1,3 mm.

Immobilised patients e.g. after surgery will often contaminate the blanket and/or pad with different bodily fluids and in a preferred embodiment according to the present invention a part

of, a major part of, or all of the hollow filling particles are closed particles as this will ensure that the particles has no cavities capable of storing e.g. contaminants. This will further ensure that the pad and/or blanket according to the invention easily can be cleaned e.g. by placing the pad or blanket in the washing machine and subsequent efficiently dried as no water can get trapped inside the closed filling particles .

In principal the filling particles can have any given shape as long as the particles have at least one inwardly and at least one outwardly curved surface part in order to provide the desired massaging effect and the restrictive movement of the particles. The particles can therefore within the scope of the present invention be identical or different from each other, and in a preferred embodiment the particles shape resembles naturally occurring chestnuts as the heterogeneity and diversity of chestnuts have been shown to provide an especially comfortable blanket or pad with improved cohesion of the particles. Accordingly to one or more embodiments of the invention, part of, a major part of or all of the hollow filling particles may have at least two outwardly curved surface parts. The present invention also covers one or more embodiments, wherein part of, a major part of, or all of the hollow filling particles have a form with one or more inwardly curved surface parts. Here, part of, a major part of, or all of the hollow filling particles may have at least two inwardly curved surface parts. It is within one or more embodiments of the invention that part of, a major part of, or all of the hollow filling particles have at least two inwardly curved surface parts and at least two outwardly curved surface parts. It is also within one or more embodiments of the invention that part of, a major part of, or all of the hollow filling particles have an upper surface with one or more outwardly curved surface parts and/or a lower surface with one or more outwardly curved surface parts.

In order to prevent the particles from being a chocking hazard to small children, it is preferred that the maximum or average length of the hollow filling particles is in the range of 40-60 mm, such as in the range of 45-55 mm. It is also preferred that the maximum or average width of the hollow filling particles is in the range of 20-40 mm, such as in the range of 25-35 mm. Also, it is preferred that maximum or average height of the hollow filling particles is in the range of 20-35 mm, such as in the range of 25-30 mm. Using the above sizes ensures that the filling particles will have a size and shape that cannot become lodged in the airway of children and obstruct the child's breathing.

According to one or more embodiments of the invention, part of, a major part of, or all of the hollow filling particles are made of a non-allergenic material, preferably a plastic such as polypropylene. Said material is not only inexpensive, easy to prepare providing strong and durable filling particles but polypropylen is also approved for being used with foodstuff and is therefore non-allergenic. However other similar materials well known for the person skilled in the art can also be used in the present invention. When the filling particles are made of a plastic, the filling particles can easily be cleaned and since the material are naturally dry said material will minimizes the presence of dust mites and other allergens in the blanket or pad.

The filling particles can preferably be coated with a shock absorbing material, e.g. a silicone, in order to ensure that the impact between the respective filling particles is silent thereby providing a more comfortable blanket or pad.

It is within one or more embodiments of the invention that about 50 to 90%, preferably between about 60 and 80%, of the area of an unfolded and expanded blanket or pad is covered by a

single layer of filling particles, as this will ensure that the pad or blanket provides both the desired massaging effect and a soft and warm blanket or pad. The degree of insulation, and thus warmth, provided by e.g. a blanket is a function of the amount of air trapped within its outer covering. The above filling degree results in an insulating blanket or pads which not only is comfortable to use but also inexpensive to manufacture .

The present invention also covers embodiments, wherein the blanket or pad is quilted. Here, the blanket or pad may comprise a number of boxes or quilts for holding the filling particles. The invention covers an embodiment, wherein the number of boxes or quilts is in the range of 30-60, such as 48 as the inventors have shown that blankets or pads comprising said number provides an especially comfortable blanket or pad. However, the number of boxes or quilts may vary depending on the use.

According to an embodiment of the invention, the blanket may comprise at least one rows, where said at least one row has a number of boxes for holding the filling particles. Here, each row may have a longitudinally extending channel, e.g. at one side or in the middle, for inserting of a filling tube. Each box further comprises one opening placed along said channel and in communication with said channel for filling each box individually. This construction will also ensure that the filling particles are placed in separate compartments that keeps the filling particles evenly distributed across the entire area of the blanket or pad.

This design also ensures that it is possible to adjust the distribution of the filling particles in the pad or blanket unevenly. As an example can be mentioned that the filling particles can be concentrated e.g. at the blankets periphery, with a reduced amount of filling particles in the central

region. This distribution of filling particles will provide sufficient thermal insulation for the person covered by the blanket. The reason for this is that the heat generated by the user's body and accumulated under the central region of the comforter cannot dissipate through the comforter's outside periphery as the heaver periphery will prevent warm air from escaping and cooler air from entering under the comforter. Furthermore, since the central region of blankets typically covers a major portion of the user's body, it is design to accommodate the user's movements.

The quilted blanket or pad by be manufactured using any kind of conventional technique e.g. by using the baffle box technique where a baffle i.e. an internal fabric wall, separates the top and bottom layers of fabric in a checkered pattern thereby constructing the quilt. Baffle box construction also adds strength to the fabric, via the internal walls, and is designed to maximize the blankets loft and fluffiness while also holding the filling particles in place. The use of the baffle technique further increase the available area for the filling particles, thereby maximize the comfort range, besides eliminating cold spots .

According to a preferred embodiment of the invention, the baffle, cover and the filling particles are dimensioned so that only a single layer of filling particles can be placed at each box and the height of the blanket or pad, i.e. the height of the baffle can therefore preferably be in the range of 25-40 mm, such as in the range of 25-35 mm, such as around 30 mm.

As an alternative technique the box stitch (also called sewn through) technique can be used. A box stitch blanket or pad is also sewn in a checkered pattern; but rather than using small strips of material to separate the top and bottom cover, the top and bottom cover are sewn together forming boxes. Boxes

serve the same purpose as baffle boxes: they keep the filling particles evenly spread out across the entire blanket or pad.

The invention further comprises a specific cover for the blanket or pad and a method of filling said cover.

Normally quilted blankets or pads are filled during the manufacturing process through openings in the baffles. However, these openings allow some migration of filling from one box to the next in use, which results in the disadvantage of a generally permanent shifting of the filling particles, since restoration of the particles to its original location after migration is quite difficult with a typical partially open baffle structure.

Thus in a preferred embodiment according to the present invention each box comprises a trap and/or valve configured to be opened by the filling tube when the filling particles is placed in the box and when the tube is removed the trap and/or valve closes, ensuring that each box is individually sealed to prevent any shifting of the filling particles.

The trap and/or valve is preferably made a simple elongated opening/slit made in the baffle adjacent to the box or of two overlapping baffle strips not sew together during manufacture of the cover. The trap and/or valve can be placed in any convenient location of said baffle construction.

Such covers further has the advantage that they can be manufactured at a first location and the filling of the covering with the filling particles can be performed at a second location, thereby keeping expenses for e.g. storage and transportation at a minimum.

For the pads of the invention, an anti-skid covering or layer may be provided at the lower, outer surface of the pad. If the

covering is made of a soft covering this will further increase patient comfort and enhances cleanliness. The present invention also covers a pad, which comprises a single box only for holding the filling particles.

The invention will be explained in greater detail below, describing only exemplary embodiments of the blanket or pad with reference to the drawing, in which

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows a prior art hollow ball shaped filling particle,

Fig. 2 shows a first embodiment of a hollow filling particle according to the present invention,

Figs. 3a-3c show a second embodiment of a hollow filling particle according to the present invention,

Figs. 4a, 4b show a third embodiment of a hollow filling particle according to the present invention,

Figs. 5a-5c show a forth embodiment of a hollow filling particle according to the present invention,

Fig. 6 shows a blanket according to the present invention and illustrates a method of filling the blanket with the hollow filling particles,

Fig. 7 shows a first embodiment of a pad according to the present invention and a method of filling the pad with the hollow filling particles,

Fig. 8 shows a second embodiment of a pad according to the present invention and a method of filling the pad with the hollow filling particles,

Fig. 9a shows a valve for use in filling the blanket or pad according to the invention, the valve is shown in a filling position, and

Fig. 9b shows the valve in fig. 9a in the closed position.

DETAILED DESCRIPTION OF THE INVENTION

Fig. 1 shows a prior art hollow, and round ball shaped filling particle. Such filling particles may also be named therapy balls.

In the following the blanket is considered to consist of the cover and the terms are therefore interchangeable, however within the scope of protection the blanket may also comprise features, such as alternative insulating parts.

According to the present invention there is provided a blanket and/or a pad having a number of hollow filling particles with one or more outwardly and inwardly curved surface parts, which filling particles are dimensioned so that the maximum length is larger than the maximum height.

Thus, at least a part of the filling particles used for a blanket or pad according to the present invention will not be solid or round or ball shaped, and it should be understood that a number of different embodiments of filling particles can be formed while fulfilling such requirements. Different forms of hollow filling particles, which fulfil these requirements, are illustrated in Figs. 2-5.

Fig. 2 shows a first embodiment of a hollow filling particle 1 according to the present invention having both outwardly 2 and inwardly 3 curved surface parts The filling particles may be symmetric around the z-axis, where the particle of Fig. 2 is

higher/thicker at the edge than in the middle, thereby resulting in both outwardly 2 and inwardly 3 curved surface parts .

The outwardly 2 and inwardly 3 curved surface parts of the filling particles 1 will ensure that a fixed or movable therapeutic and/or stimulating pressure is applied to a person's body during use of the pad or blanket thereby providing e.g. relaxation, improved sleep, and relief of muscular aches and pains.

As the filling particles 1 has a larger length than height it is ensured that the particles 1 are held more safely at the desired location as the movement of the particles 1 are restricted compared to the prior art balls as shown in fig. 1.

Figs. 3a-3c show a second embodiment of a hollow filling particle I ¹ according to the present invention. Fig. 3a is a sectional view in the x-z plane, Fig. 3b is a sectional view in the y-z plane, and Fig. 3c is a sectional view in the x-y plane. The particle 1' of Fig. 3 is thicker at the edges than in the middle in the x-z plane, while the particle 1' has substantially the same thickness in the y-z plane. Thus, the particle of Fig. 3 has both outwardly 2' and inwardly 3' curved surface parts. The particle of Fig. 3 may be mirrored in the x- z plane and also in the y-z plane.

Figs. 4a, 4b show a third embodiment of a hollow filling particle \' ' according to the present invention. Fig. 4a is a sectional view in both the x-z plane and the y-z plane, and Fig. 4b is a sectional view in the x-y plane. The particle of Fig. 4 is thicker at the edges that at the middle in both the x-z plane and the y-z plane. Thus, the particle of Fig. 4 has both outwardly 2'' and inwardly 3'' curved surface parts. The particle of Fig. 4 may be mirrored in the x-z plane and also in the y-z plane.

Figs. 5a-5c show a forth embodiment of a hollow filling particle \' ' ' according to the present invention. Fig. 6a is a sectional view in the x-z plane, Fig. 6b is a sectional view in the y-z plane, and Fig. 6c is a sectional view in the x-y plane. The particle of Fig. 6 is non-symmetric with both outwardly 2' ' ' and inwardly 3''' curved surface parts.

It is preferred that hollow filling particles of Figs. 2-5 have a size and a dimension in order to prevent the filling particles 1, 1', 1'', I' ¹ ' to become lodged in the airway of e.g. children and obstructing the breathing and the particles therefore preferably have the maximum or average length is in the range of 40-60 mm, such as in the range of 45-55 mm. According to an embodiment the maximum or average length is about 50 mm. It is also preferred that the maximum or average width of the hollow filling particles is in the range of 20-40 mm, such as in the range of 25-35 mm. According to an embodiment the maximum width is about 35 mm. It is further preferred that the maximum or average height of the hollow filling particles is in the range of 20-35 mm, such as in the range of 25-30 mm. According to an embodiment the maximum height is around 30 mm.

It is preferred that the hollow filling particles used for the blanket or pad of the invention are made of plastic material such as polypropylene, and that the wall thickness is in the range of 0,5 - 3 mm, such as in the range of 1 - 1,6 mm such as around 1 , 3 mm.

Fig. 6 shows a quilted blanket 4 according to the present invention. The blanket comprises six rows 5 each of which is divided into eight boxes 6, making a total of forty-eight boxes 6 for holding the filling particles 1. Each row 5 has a longitudinally extending channel 7 at one side, and each box is via an opening (not shown) open along this channel.

In order to fill the boxes 6 with particles 1, a pipe 8 is conducted through each channel until the last box 6a of a row is reach. Thereafter the filling particles 1 are fed through the pipe 8 in the direction of the arrow A whereby the last box 6a is filled with particles 1. This situation is shown in fig. 6. The particles 1 can be blown into the boxes 6 by any conventional means, e.g. blowing or stuffing the particles into the boxes 6.

After the first box 6a is filled with filling particles 1 the pipe 8 is withdrawn into the next box 6b in order to fill said box 6b with particles 1, and the process is continued until all the different boxes 6 are filled to the desired degree. Thereafter the tube 8 is removed from the blanket 4 and the opening 9 in said blanket 4 is closed e.g. by sewing the opening together.

It is preferred that the cover of the blanket 4 is dimensioned so that each box 6 may hold a single layer only of the filling particles 1. Thus the blanket 4, when filled with particles 1, may have a height in the range of 25-40 mm, such as around 30 or 35 mm. The length of the blanket may be around 200- 220 cm and the width may be around 140 cm if the blanket is for used by an adult, however said blanket may be smaller if e.g. used by a child or larger if desired.

Fig. 7 shows a first embodiment of a pad 10 according to the present invention and illustrates a method of filling the pad 10 with hollow filling particles 1.

The pad comprises a single box 11 having an opening 12 for inserting of the filling pipe 8 and the filling particles 1 are fed through the pipe 8 in the direction of the arrow A whereby the box 11 is filled with particles 1. This situation is illustrated in fig. 7. After the box 11 is filled with filling

particles 1 the pipe 8 is withdrawn and the opening 12 is closed as describe under fig. 6.

Fig. 8 shows a second embodiment of a pad 10' according to the present invention and a method of filling the pad 10' with the hollow filling particles 1. The pad 10' has single row 13 with three boxes 14 for holding the filling particles 1. The filling particles 1 are fed through the pipe 8 placed in a channel 7 in the direction of the arrow A in a similar way as described under fig. 6. The pad 10' may have a length of 120 cm, a width of 50 cm, and a height in the range of 30-40 mm, such as around 30 mm. Also here, the pad 10' may comprise a single layer only of the particles 1.

Fig. 9a schematically shows one box 6 in the quilted blanket 4 shown in fig. 6. The blanket 4 is made of two substantially identical rectangular pieces of fabric. Each piece of fabric includes a number of internal cross baffle pieces 16 and internal length baffle pieces 17 separating the top and bottom layers of fabric in a checkered pattern thereby constructing the quilted blanket 4. The fabrics and baffle pieces are sew together using a conventional baffle sewing technique however in order to ensure that the filling particles 1 can be filled in the individual boxes 6 in a row 5, a channel 7 is establish along one side of a row 5 by skipping a length B of the sewing process in the cross direction.

Furthermore, as the top and bottom layers of fabric 16 are identical each internal baffle section will preferably consist of two pieces of fabric 17a, 17b. As best seen in fig. 9b a section 18 of the internal length baffle piece 17b are not sewn together leaving an opening 19 into the box 6b in which the filling pipe 8 can be inserted as shown in fig. 9a.

Thereafter the filling particles 1 can easily be fed through the pipe 8 into the box 6. The particles 1 can be added to the

box 6 by any conventional means, e.g. blowing or stuffing the particles through the pipe 8. After the filling particles 1 have been placed in the box 6 the pipe 8 is removed from the box 6b and the opening 19, and the fabric in section 18 will return to the original form as illustrated in fig. 9b, efficiently ensuring that the filling particles cannot escape from the box 6b. Section 18 can therefore be regarded as a trap or a one-way valve for filling the particle 1 in the blanket 4.

It should be understood that various modifications may be made to the above-described embodiments and it is desired to include all such modifications and functional equivalents as fall within the scope of the accompanying claims.