CN117042654A

CN117042654A - Integrated fan assembly for bed

Info

Publication number: CN117042654A
Application number: CN202280020659.6A
Authority: CN
Inventors: 科迪·李·卡施尼克; 韦德·丹尼尔·帕拉休斯基; 埃里克·罗斯; 亨特·韦恩·约翰逊; 弗莱彻·埃弗雷姆·卡尔森-桑切斯
Original assignee: Select Comfort Corp
Current assignee: Sleep Number Corp
Priority date: 2021-03-12
Filing date: 2022-03-11
Publication date: 2023-11-10
Also published as: KR20230155479A; AU2022233176A1; EP4291071A1; JP2024511324A; MX2023010691A; US20220287473A1; CA3211555A1; WO2022192700A1

Abstract

The mattress has a first layer with a first layer top and a first layer bottom and extending from a first edge to a second edge, a first side stay proximate the first edge, a second side stay proximate the second edge, an additional layer positioned below the first layer bottom between the first side stay and the second side stay, and a first air module positioned between at least one of the first side stay and the additional layer that creates an air flow. The first air module may draw air from the first layer and direct exhaust air between the first side stay and the second layer. The mattress may define a first channel between the first side stay and the second layer that may allow the flow of exhaust air. The second layer may define a layer recess at a side of the second layer adjacent the first side stay.

Description

Integrated fan assembly for bed

Cross Reference to Related Applications

The present application claims the benefit of U.S. provisional application Ser. No. 63/160,041 filed on 3/12 of 2021. The disclosure of the prior application is considered part of the disclosure of the present application (and is incorporated by reference herein).

Technical Field

This document relates to bed systems and, more particularly, to apparatus, systems and methods for cooling the temperature of a bed.

Background

Generally, a bed is a piece of furniture that is used for sleeping and relaxation. Many modern beds have a soft mattress on the bed frame. The mattress may include springs, foam (foam) material, and/or air chambers to support the weight of one or more users. Various features and systems have been used in connection with beds, including heating systems and cooling systems that regulate the temperature of the bed.

SUMMARY

Some embodiments described herein include a bed system having an integrated fan assembly for directing airflow in a mattress to regulate the temperature of the mattress (e.g., at or above a top surface of the mattress). The integrated fan assembly may also provide for adjusting the temperature of the internal components of the mattress. Being able to remove accumulated heat from the mattress may provide for a faster rate of more rapid heat reduction from the microclimate at the top of the mattress. Instead of being located on the outside of the mattress (e.g., attached to the outside surface of the mattress or to the bottom of the foundation supporting the mattress), the fan assembly may be enclosed in the mattress and operated to draw air into the fan assembly, thereby circulating air in the mattress and controlling the microclimate (e.g., temperature) at the top of the mattress. Alternatively, a fan assembly enclosed in the mattress may control the microclimate at the top surface of the mattress by removing and/or drawing air from the top surface of the mattress. As another example, the fan assembly may blow air across the bottom of the mattress, rather than just toward the head or foot end of the mattress. The bottom of the mattress may be made of a breathable material to allow air to flow through the bottom of the mattress. As yet another example, the fan assembly may blow air from the side of the mattress and/or through the side of the mattress. At least a portion of each side of the mattress may be made of a breathable material, and the fan assembly is positioned adjacent to at least a portion of the side of the mattress such that air from the fan assembly may pass through at least a portion of each side of the mattress. In addition, the mattress cover (or the portion of the mattress cover adjacent the fan assembly) that encloses the mattress may also be made of a breathable material to allow air to flow through the mattress cover to regulate the temperature of the top of the mattress.

In some embodiments, the fan assembly may be received in a foot brace of a brace (rail) structure of a mattress. The foot struts may have a thicker width than the head struts and/or the opposite side (e.g., left and right) struts of the strut structure. The thicker width of the foot braces can provide additional support to the brace structure so that the brace structure does not bend out of shape with the mattress when weight/movement is applied to the mattress. The thicker width of the foot braces may also allow the mattress to be used without one or more reinforcement strips (reinforcement strap). In addition, the thicker width of the foot stay may allow the fan assembly to be fully received into the recessed portion of the foot stay without compromising the support and structure of the mattress. The opposing side struts may have a thicker width than the head struts of the strut structure to provide additional support for the strut structure. Although the braces have different widths, the braces (e.g., head braces, foot braces, opposing side braces) may be sized to provide the same interior space for housing the interior components (e.g., air chamber, air distribution layer, and associated electronics) while providing the same exterior dimensions (e.g., standardized mattress dimensions such as king, queen, full, and twin bed (twin) dimensions). For example, the total width of the opposing struts (e.g., the total width of the foot and head struts, or the total width of the opposing side struts) may be similar or identical to the total width of equal sized struts in other strut structures of the same or similar mattress. Thus, the same components used in other mattresses may also be used with mattresses having struts of different sizes. For example, the air chambers of other mattresses may be placed in mattresses having differently sized braces because the total amount of space created by the brace structures in a mattress is the same as the total amount of space created by equally sized brace structures in other mattresses. The use of the same components for different mattresses may provide ease and efficiency in manufacturing, assembling, shipping, and maintaining the mattress.

The fan assembly may be oriented to generate an airflow in one or more directions to draw air from the top of the mattress. For example, the fan assembly may draw air from the top of the mattress and exhaust the exhaust air into the foot struts of the strut structure and/or toward the side struts (e.g., right side struts or left side struts) of the strut structure. The fan assembly may be fully received in the recessed portion of the foot stay. The foot braces and/or other braces in the brace structure may be made of foam or other materials that allow the exhaust air to pass through and eventually drain around the mattress.

In addition, the mattress may include a base pad (e.g., bottom layer) that is attached to the brace structure and encloses the components of the mattress within the base pad. The base pad may be split longitudinally down the midpoint of the base pad, creating two flaps (flaps) of the base pad that may be opened and closed. The edges of the base pad may be adhered to the side struts of the strut structure to facilitate opening and closing of the base pad flaps from the midpoint of the base pad. This configuration of the base pad may provide ease of access to the components of the mattress.

In some embodiments, the fan assembly may be received at the sides of the interior of the mattress and oriented to generate an airflow in one or more directions, which may be effective to draw air from the top of the mattress. The fan assembly may be arranged to draw air from the top of the mattress and to exhaust air along the sides of the interior of the mattress at the bottom of the mattress. For example, the fan assembly may be disposed (e.g., positioned) at a side or foot of the mattress interior. In another example, the fan assembly may be positioned at the head of the mattress interior. The air inlet of the fan assembly is oriented toward the top surface of the mattress and the air outlet of the fan assembly is oriented toward the head or foot end of the mattress such that the fan assembly can draw air from the top of the mattress and expel air along the sides of the mattress toward the head or foot end. In some embodiments, the fan assembly may be oriented such that the fan assembly may exhaust air toward one side of the mattress (e.g., the side on which the fan assembly is positioned (e.g., the foot side) or adjacent sides thereof (e.g., one or both of the lateral sides extending between the foot side and the head side)) and/or along the interior of the mattress. The fan assembly may include a tube defining an air inlet positioned adjacent one or more layers that may comprise the top of the mattress. The tube may extend vertically or horizontally along the sides of the mattress toward the bottom or sides of the mattress so that air being sucked up the top of the mattress may be routed (route) through the tube and vented at the sides or bottom of the mattress. The fan assembly may be positioned within a recess defined at one or more layers of the mattress (e.g., a brace structure at least partially defining a side of the mattress). Thus, the fan assembly may be integrated into the mattress without impeding one or more components of the mattress (e.g., the inflatable air chamber, the air chamber hose, and/or other components).

In some embodiments, the fan assembly is configured to exhibit a relatively small form factor that is suitable for being fully received within the mattress without interfering with other components (e.g., pneumatic and electrical elements) in the mattress. For example, the fan assembly may be configured in a compact housing and operated only to provide simple functions such as drawing ambient air into the housing and exhausting ambient air from the housing. In some embodiments, the fan assembly does not include other microclimate functions, such as heating air, cooling air, or the like, which would otherwise require a larger spacing in the housing, and thus increase the size of the fan assembly.

Particular embodiments described herein include a mattress comprising: a first layer having a first layer top and a first layer bottom; a head stay attached to the first layer bottom; a foot brace attached to the first layer bottom and defining a first recessed portion; and a first air module configured to generate an air flow between the first layer top and the first layer bottom, the first air module positioned in the first recessed portion of the foot stay.

In some implementations, the system can optionally include one or more of the following features. For example, the mattress may further include: a first side strut extending longitudinally and connecting the first edge of the head strut and the first edge of the foot strut; a second side brace opposite the first side brace, the second side brace extending longitudinally and connecting a second edge of the head brace with a second edge of the foot brace; and one or more additional layers positioned below the bottom of the first layer between the first side stay and the second side stay. The one or more additional layers may include a core (core) and a second layer positioned below the core and covering the core between the first side stay and the second side stay. The mattress may include a thermal layer attached to the bottom of the first layer. The thermal layer is (i) configured to extend longitudinally a first distance between the head strut and the foot strut, and (ii) offset a second distance relative to at least one of the first side strut and the second side strut. The thermal layer may be positioned closer to the foot struts of the mattress than to the head struts of the mattress. The mattress may include an air tube hose configured to fluidly connect the first air module to the thermal layer. The first air module is configured to draw air from the thermal layer through the air tube hose and expel the drawn air into the foot brace. The first air module is configured to draw air from the first layer and direct exhaust air into the foot struts and toward the first side struts of the mattress. The first air module is configured to draw air from the first layer and direct exhaust air into the foot struts and toward the second side struts of the mattress. The first air module is configured to draw air from the first layer and direct exhaust air into foot struts of the mattress. The first recess portion is configured to at least partially receive the first air module. The first air module may include: a housing defining an air inlet and an air outlet; and a fan assembly enclosed in the housing and configured to draw in air through the air inlet and supply exhaust air through the air outlet. The first air module may include an electrical cord electrically connected to the fan assembly and extending from the housing, the electrical cord configured to be electrically connected to a power source external to the mattress and to supply power to the fan assembly. The mattress may include: a second recessed portion defined in the foot stay proximate to the first recessed portion; and a second air module configured to generate an air flow and positioned within the second recessed portion of the foot brace. The second air module is configured to draw air from the first layer and direct the exhaust air in the foot stay in the same direction as the exhaust air directed by the first air module. The second air module is configured to draw air from the first layer and direct the exhaust air in the foot stay in a different direction than the exhaust air directed by the first air module. The first air module may define an air outlet configured to discharge air into the foot struts of the mattress. The first air module is configured to draw air from the first layer and direct exhaust air into the foot struts toward the interior of the mattress. The mattress may include a bottom layer positioned below the first layer. The bottom layer may extend from the head struts to the foot struts of the mattress. The bottom layer may include a first portion and a second portion extending laterally between the head stay and the foot stay along a predetermined axis of the bottom layer. The first and second portions of the bottom layer may be laminated to respective first and second side struts of the mattress. The first portion and the second portion are configured to open from a predetermined axis of the bottom layer to expose at least a portion of the first air module in the first layer of the mattress, the head strut, the foot strut, and the recessed portion of the foot strut. The bottom layer may include first and second openings in respective first and second portions of the bottom layer. The first opening and the second opening are configured to route electrical wires from at least the first air module along at least one side of the mattress.

Certain embodiments of the present disclosure provide a mattress comprising: a first foam layer having a top surface and an opposing bottom surface; an inflatable chamber positioned below the bottom surface of the first foam layer; a foam strut structure comprising a head portion, a foot portion, and first and second side portions, the foam strut structure extending from a perimeter of the first foam layer around a perimeter of the mattress and configured to enclose an inflatable chamber; a mattress bottom covering the inflatable chamber; and an air source configured to generate an air flow and positioned below the inflatable chamber, above the mattress bottom, and in the foot portion of the foam strut structure.

In some implementations, the system can optionally include one or more of the following features. For example, the air source is a first air module. The mattress may include a second foam layer positioned below the inflatable chamber and covering at least a portion of the inflatable chamber between the head portion, the foot portion, and the first and second side portions of the foam strut structure. The air source is configured to draw air from the second foam layer and direct exhaust air into the foot portion of the foam strut structure. The air source is configured to draw air from the first foam layer and direct exhaust air into the foot portion of the foam strut structure and toward the first side portion or the second side portion of the foam strut structure. The foot portion of the foam strut structure may define a first strut recess configured to receive an air source. The foot portion of the foam strut structure has a first width, the head portion of the foam strut structure has a second width, the first and second portions of the foam strut structure have a third width, and the first width may be greater than the second and third widths, and the second width may be less than the third width. The air source may include: a housing defining an air inlet and an air outlet; a fan assembly enclosed in the housing and configured to draw in air through the air inlet and supply exhaust air through the air outlet; one or more sensors configured to generate signals representative of at least one of temperature, humidity, and flame (flame); a controller included in the housing, the controller configured to control operation of the fan assembly and to receive signals from the one or more sensors; and an electrical wire electrically connected to the controller and the fan assembly. Electrical wires extend from the housing and are configured to electrically connect to a power source external to the mattress and supply power to the controller and fan assembly. The inflatable chamber may be a mattress core.

Particular embodiments described herein include a mattress having a first layer with a first layer top and a first layer bottom and extending from a first edge to a second edge, a first side stay proximate the first edge, a second side stay proximate the second edge, one or more additional layers positioned below the first layer bottom between the first side stay and the second side stay, and a first air module configured to generate an air flow and positioned between the first side stay and at least one of the one or more additional layers.

In some implementations, the system can optionally include one or more of the following features. For example, the one or more additional layers may include a core and a second layer positioned below the core and covering the core between the first side stay and the second side stay. The first air module may be configured to draw air from the first layer and direct exhaust air between the first side stay and the second layer. The mattress may define a first channel between the first side stay and the second layer, and the first channel may be configured to allow exhaust air to flow between the first side stay and the second layer. The second layer may define a layer recess at a side of the second layer that may be adjacent to the first side stay, and the layer recess may define a first channel between the first side stay and the second layer. The layer recess may extend at least partially along the length of the second layer.

As another example, the first air module may be configured to draw air from the first layer and direct exhaust air along the first side stay toward the foot side of the mattress. The first air module may be configured to draw air from the first layer and direct exhaust air along the first side stay toward the head side of the mattress. The first side stay may define a first stay recess portion that may be configured to at least partially receive the first air module. The mattress system may also include a first strap connected to the first side stay and the second side stay at a connection location such that the first strap may extend from the bottom of the first side stay to the bottom of the second side stay under the one or more additional layers.

As another example, the first air module may include a housing that may define an air inlet and an air outlet, and a fan assembly that may be enclosed in the housing and may be configured to draw in air through the air inlet and supply exhaust air through the air outlet. The first air module may include electrical wires that may be electrically connected to the fan assembly and extend from the housing, which may be configured to electrically connect to a power source external to the mattress and supply power to the fan assembly. The first layer, the first side stay, and the second side stay may comprise one or more foam materials. The one or more additional layers may include an inflatable air chamber. The first layer, the first side stay, and the second side stay may be part of an inverted foam box (foam tub), wherein the inverted foam box may further include a foot stay and a head stay.

As yet another example, the mattress system may include a second air module that may be configured to generate an air flow and be positioned between the second side stay and the one or more additional layers below the bottom of the first layer. The second air module may be configured to draw air from the first layer and direct the exhaust air in the same direction as the exhaust air that may be directed by the first air module. The second air module may be configured to draw air from the first layer and direct the exhaust air in a different direction than the exhaust air that may be directed by the first air module.

As another example, the mattress may define a second channel between the second side stay and the second layer, and the second channel may be configured to direct exhaust air between the second side stay and the second layer. The second layer may define a layer recess at a side of the second layer that may be adjacent to the second side stay, the layer recess defining a second channel between the second side stay and the second layer. The second air module may be configured to draw air from the second layer and may direct exhaust air through a second channel between the second side stay and the second layer. The first strut recessed may be offset relative to the first tube, which may be configured to inflate the first air chamber of the one or more additional layers.

Particular embodiments described herein may also include a mattress comprising; a first foam layer having a top surface and an opposing bottom surface; an inflatable chamber positioned below the bottom surface of the first foam layer; a foam strut structure including a strut top, a strut bottom, a strut inner side, and a strut outer side, the foam strut structure extending from a perimeter of the first foam layer and configured to enclose an inflatable chamber; a mattress bottom covering the inflatable chamber; and an air source that can generate an air flow and is positioned below the inflatable chamber, above the mattress bottom and inside and adjacent to the inside of the brace.

In some implementations, the system can optionally include one or more of the following features. For example, the air source may be a first air module. The mattress may also include a second foam layer positioned below the inflatable chamber and covering the inflatable chamber between the interior side of the stay and the exterior side of the stay. The air source may be configured to draw air from the second foam layer and direct exhaust air between the inside of the struts and the second foam layer. The mattress may define a first channel between the interior side of the struts and the second foam layer, and the first channel may be configured to direct exhaust air between one side of the foam strut structure and the second foam layer. The second foam layer may define a layer recess at a side of the second foam layer that may be adjacent to the strut inner side, and the layer recess may define a first channel between the strut inner side and the second layer. The layer recess may extend at least partially along the length of the second foam layer. The air source may be configured to draw air from the first foam layer and direct the exhaust air toward the foot side of the mattress. The air source may be configured to draw air from the first foam layer and direct the exhaust air toward the head side of the mattress. The strut inner side may define a first strut recess, which may be configured to at least partially receive an air source.

As another example, the mattress system may further include a first strap that may be connected to the strut inner side and the strut outer side at a connection location such that the first strap may extend from a bottom of the strut inner side to a bottom of the strut outer side below the inflatable chamber. The air source may include: a housing, which may define an air inlet and an air outlet; and a fan assembly enclosed in the housing and configured to draw in air through the air inlet and supply exhaust air through the air outlet. The air source may include electrical wires that may be electrically connected to the fan assembly and extend from the housing, which may be configured to electrically connect to a power source external to the mattress and supply power to the fan assembly.

As another example, the first foam layer, the inside of the brace, the outside of the brace, the top of the brace, and the bottom of the brace may comprise one or more foam materials. The inflatable chamber may be a mattress core. The first foam layer, the strut inner side and the strut outer side may be part of an inverted foam box body, wherein the inverted foam box body may further comprise a foot strut and a head strut. The mattress may also include a second air source that may be configured to generate an air flow and may be positioned below the inflatable chamber, above the mattress bottom, and inside and adjacent to the outside of the brace. The air source may be configured to draw air from the first foam layer and direct exhaust air in a first direction, and the second air source may be configured to draw air from the first foam layer and direct exhaust air in a second direction. The first direction may be the same as the second direction. The first direction may be different from the second direction. The layer recess may extend from a medial axis of the second layer and may taper toward a first corner (corner) of the second layer. The layer recess may also extend from a medial axis of the second layer and may taper toward a second corner of the second layer, wherein the second corner may be opposite the first corner along the same side of the second layer. The first corner may be adjacent a head portion of the mattress and the second corner may be adjacent a foot portion of the mattress.

As yet another example, the first side stay may be attached to the first layer bottom at a first edge of the first layer, and the second side stay may be attached to the first layer bottom at a second edge of the first layer. The mattress may define a first flow path configured for airflow generated by the first air module, the first flow path being defined by a side surface of the first side stay and a corresponding side surface of the at least one additional layer. The at least one additional layer may be a bottom layer covering the core between the first side stay and the second side stay. The mattress may also include a mattress cover including a top panel, a bottom panel, and opposing side panels, wherein the first flow path may also be defined by a bottom surface of the core and a top surface of the bottom panel of the mattress cover. The core may include an air chamber.

As another example, the width of the first flow path between the side surface of the first side strut and the corresponding side surface of the bottom layer may vary in the longitudinal direction along the first side strut. The corresponding side surface of the bottom layer may include a tapered surface, which may be angled relative to a side surface of the first side stay (which may face the corresponding side surface of the bottom layer). The width of the first flow path may decrease from the location where the first air module is positioned toward the head side of the mattress or the foot side of the mattress. The width of the first flow path may vary along the entire length of the bottom layer. The first flow path may extend to a corner of the bottom layer. The first flow path may extend vertically along at least a portion of a side of the mattress. The first flow path may be defined along at least one foam layer between the mattress top and the mattress bottom. The mattress top may include a mattress cover and the mattress bottom may include a bottom layer.

As another example, the first air module may include an air tube, which may define an air inlet that is exposed toward the first layer and configured to draw air from the first layer. The first air module may define an air outlet that may be configured to exhaust air toward a channel defined between the first side stay and at least one of the one or more additional layers. The first air module may be configured to draw air from the first layer and direct exhaust air from the side of the mattress toward the first side stay. The first air module may be configured to draw air from the first layer and direct exhaust air toward the interior of the mattress.

The devices, systems, and techniques described herein can provide one or more of the following advantages. First, some embodiments described herein provide a harmonious arrangement of components of a mattress (non-obtrusive arrangement) with the surroundings. The fan assembly may be small and integrated into the recessed portion of the brace structure of the mattress. The fan assembly may not be located outside of the mattress system. Thus, the fan assembly may be hidden from view. Because the fan assembly is positioned and enclosed within a recessed portion of the interior of the mattress, the fan assembly may also not impede the configuration and/or operation of other components of the mattress. For example, the positioning of the fan assembly may not create protrusions in any layer of the mattress or create an uneven surface of the mattress. Thus, a user lying on top of the mattress may not notice that the fan assembly is positioned within the mattress. As another example, the positioning of the fan assembly may not interfere with the positioning and operation of other components (e.g., hoses, cables, housing components, ports, and/or air chambers). The fan assembly located within the recessed portion may be offset relative to the central axis of the mattress or another portion of the mattress in which the hose and/or port has been integrated into the mattress. The hoses and/or ports may be configured to provide air flow to one or more inflatable air chambers in the core of the mattress. The fan assembly may be positioned proximate to the hoses and/or ports so as not to interfere with the configuration and operation of the hoses and/or ports. This offset positioning may be advantageous when manufacturing mattresses. This is because the configuration of the conventional hoses and/or ports does not have to be modified to accommodate the fan assembly, which is also integrated into the mattress during mattress production. Instead of changing the configuration of any existing components of the mattress, the recessed portions in the brace arrangement may simply be offset relative to the existing components, and the fan assembly may be positioned within the recessed portions. The fan assembly may still be operable to provide an air flow to cool the temperature of the mattress regardless of the placement or orientation of the fan assembly in the brace construction.

Second, some embodiments described herein provide for less expensive production and maintenance of mattresses and/or integrated fan assemblies. For example, the fan assembly may not need to be coupled or connected to the base. Thus, if the fan assembly requires maintenance, the fan assembly may be accessed only from the mattress. Servicing may not require access to the foundation supporting the mattress. Furthermore, as described above, integrating the fan assembly into the mattress during mattress production may be a simple and less expensive process. For example, the integrated fan assembly may be less expensive because the integration may only require defining recessed portions in one or more components of the mattress (e.g., the brace structure and/or bottom layer of the mattress). Once the recessed portion is defined, the fan assembly may be secured within the recessed portion. As another example, integration may be a simple process in that the recessed portion may be defined in the mattress based on where other components (e.g., hoses, air chamber ports, etc.) are conventionally positioned in the mattress. The location of the recessed portion does not affect the ability of the fan assembly to direct airflow to one or more portions of the mattress. Thus, integrating the fan assembly into any portion of the mattress along the brace structure may be a simple, quick, and easier manufacturing process while accommodating the integration of additional mattress components. Furthermore, when the bed is installed on the customer site, no additional procedure is required to assemble the fan assembly to a designated location outside the mattress (e.g., the bottom of the foundation supporting the mattress). Furthermore, a mattress that completely encloses the fan assembly need not provide a dedicated feature to fluidly connect the fan assembly to the mattress.

Third, some embodiments described herein may provide for continued operation of existing, conventional, and/or other components of a mattress. For example, offsetting the recessed portion and the fan assembly disposed within the recessed portion may provide for continuous and unobstructed operation of the air plenum hose and/or port. Thus, the air chambers of the mattress may be inflated and/or deflated using known or conventional techniques, while the fan assembly may provide a non-interfering air flow through and around the components of the mattress system. As another example, the wires of the fan assembly may be routed out of the mattress such that the wires do not interfere with the components of the mattress or foundation. Thus, the mattress may be placed on any type of foundation. The electrical wires of the fan assembly may not need to run through or be configured to any component within the chassis (such as the control module). This configuration not only provides for continued operation of the existing components of the mattress and foundation, but also provides for easier and less expensive production and maintenance of the mattress and/or fan assembly therein.

Fourth, some embodiments described herein may provide for directing a target air flow from a top surface of a mattress. This direction of air flow is beneficial in lowering or reducing the temperature of the top surface of the mattress. The air flow may be directed toward and into a fan assembly at or adjacent the top of the mattress and discharged at the bottom of the mattress in a predetermined direction so that air at the top of the mattress may be drawn out without being circulated or distributed through or around other components of the mattress that would impede efficient air circulation from/toward the top of the mattress. Thus, the temperature of the top surface of the mattress may be reduced or lowered more effectively and/or more rapidly.

Alternatively, a fan assembly may be used to provide a target air flow through and around components of the mattress (e.g., the air plenum and the various layers) toward the top of the mattress. Although the air directed through these components may provide a cooling effect, the cooling effect may be minimal because these components may be made of a non-breathable or less breathable material (e.g., foam). With the disclosed fan assembly, air may be directed along the air channels created by the recessed portions such that the air flows more directly to the top surface of the mattress and around one or more layers (e.g., non-breathable layers) or components of the mattress. Thus, the temperature of the mattress top surface may be reduced or lowered more effectively and/or more rapidly. With the disclosed fan assembly, some air may still be directed through one or more layers (e.g., non-breathable layers) or components of the mattress to provide additional cooling effects, thereby reducing the overall temperature of the mattress. By providing layers and/or components around the mattress and airflow through those layers and/or components, the fan assembly may more effectively and more quickly cool or reduce the temperature of the mattress.

Fifth, some embodiments described herein provide for an airflow that is directed in any orientation of the fan assembly. Thus, the air flow drawn from the top of the mattress may be directed into one or more different areas or portions of the mattress, allowing air to effectively vent from the mattress. For example, the fan assembly may be oriented in a recessed portion of the brace structure to discharge the aspirated air toward the side or head portion of the mattress. The vented air may then be directed toward the sides or head portion of the mattress through the channel created by the recessed portion. The channels created by the recessed portions along the sides of the mattress provide an air evacuation path that minimizes resistance and exits the mattress. In some embodiments, the air flow may additionally provide a cooling effect in this region of the mattress. As another example, the fan assembly may be oriented toward the foot portion or another side portion of the mattress such that the air flow may be directed toward the foot portion of the mattress through the channel created by the recessed portion. The channels created by the recessed portions along the foot or side of the mattress provide an air evacuation path that minimizes resistance and exits the mattress. In some embodiments, this may additionally provide a cooling effect for the foot portion of the mattress. Air may flow through the channels defined by the recessed portions of the strut structures to provide a more direct cooling effect on the top surface of the mattress. Air may also flow through one or more layers and/or components of the mattress by being exhausted from air outlets of the fan assembly, wherein the air outlets are directed toward the layers and/or components of the mattress. Such a configuration may be advantageous in reducing the amount of time it takes to reduce the overall temperature of the mattress. In some embodiments, the recessed portions and associated channels may be symmetrically sized and/or configured such that the fan assembly may be oriented in any desired direction (e.g., toward either side portion of the mattress, the head portion or the foot portion of the mattress) to provide airflow in the desired direction.

Seventh, some embodiments described herein may provide a small and compact fan assembly. As noted above, the fan assembly may have a simple and small configuration so as not to interfere with the operation and configuration of other components of the mattress. Further, because the fan assembly may be used to provide cooling options to portions of the mattress, while no other options are available (e.g., heating and cooling), the fan assembly may be smaller and simpler than an assembly that provides heating and cooling. The fan assembly may have a simple configuration in that the fan assembly may circulate ambient air to naturally reduce the temperature at the top of the mattress. The fan assembly may not require additional components to generate the conditioned air and then provide the conditioned air to the portion of the mattress. This simple arrangement provides a smaller size which makes integration of the fan assembly into the brace structure of the mattress easier and harmonious with the surroundings. Furthermore, this simple configuration also makes maintenance or repair of the fan assembly simpler.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

Brief Description of Drawings

FIG. 1 illustrates an example bed system with an integrated fan assembly as described herein.

Fig. 2 is a bottom perspective view of the mattress system, showing the mattress system inverted.

FIG. 3 is a partially exploded view of the mattress system of FIG. 2, showing the top layer, middle layer, example air plenum assembly, and integrated fan assembly.

Fig. 4 shows a bottom perspective view of the mattress system of fig. 2 with a set of reinforcing strips removed and an integrated fan assembly in place.

Fig. 5 is a perspective view of an integrated fan assembly.

Figure 6 shows a concave view of the air flow through the mattress system.

Fig. 7 shows a side cross-sectional view of air flow through the mattress system of fig. 6.

Fig. 8 is a bottom view of an example mattress system with integrated fan assemblies.

Fig. 9 is another bottom view of the example mattress system of fig. 8 with an integrated fan assembly.

Fig. 10 is another bottom view of the example mattress system of fig. 8 with an integrated fan assembly.

Fig. 11 is a bottom view of another example mattress system with an integrated fan assembly.

Fig. 12 is a bottom view of another example mattress system with integrated fan assemblies.

Fig. 13A is a perspective view of an integrated fan assembly in a mattress system.

Fig. 13B is a top view of an integrated fan assembly in the mattress system of fig. 13A.

Fig. 13C is a side perspective view of an integrated fan assembly in the mattress system of fig. 13A.

FIG. 14 illustrates an example bed system for providing a high quality sleep experience with an example local bed system.

Fig. 15 illustrates another fan assembly integrated into another example mattress system.

Fig. 16 is a bottom perspective view of the mattress system of fig. 15, showing the mattress system inverted.

Fig. 17 is a partially exploded view of the mattress system of fig. 16.

Fig. 18 shows a bottom perspective view of the mattress system of fig. 16.

Fig. 19 is a perspective view of the integrated fan assembly of fig. 15.

Fig. 20 shows a concave view of the airflow through the mattress system of fig. 16.

Fig. 21 shows a side cross-sectional view of air flow through the mattress system of fig. 20.

Fig. 22 is a bottom view of an example mattress system with the integrated fan assembly of fig. 15.

Fig. 23 is another bottom view of the example mattress system of fig. 22 with integrated fan assemblies.

Fig. 24A-24B illustrate bottom views of the bottom layer of an example mattress system having the integrated fan assembly of fig. 15.

Detailed description of illustrative embodiments

This document relates generally to a bed system having an integrated fan assembly for directing airflow around and/or in a mattress to regulate the temperature of the mattress.

FIG. 1 illustrates an example bed system 100 having an integrated fan assembly 110 as described herein. In this example, the bed system 100 includes a mattress 101 and a foundation 103, and the mattress 101 and foundation 103 may be configured the same or similar to the mattresses and foundations described herein. The mattress 101 may have a mattress core configured to support a user resting on the mattress 101. In some embodiments, the mattress core may have one or more inflatable air chambers. Furthermore, in other embodiments, mattress 101 may be configured as a climate control mattress.

As depicted, mattress 101 may include a top layer 102, a brace structure 106, a bottom layer 108, and an air chamber. The integrated fan assembly 110 depicted and described herein may be attached to or configured to a portion of the strut structure 106. For example, the fan assembly 110 may be disposed (e.g., positioned) on opposite left and right sides of the strut structure 106. As described herein, the fan assembly 110 may be received in a recessed portion of each of the opposite left and right sides of the strut structure 106. Thus, the fan assembly 110 may not interfere with other components of the mattress 101 (e.g., the bottom layer 108, the air plenum, and/or the top layer 102). As shown in fig. 1, the fan assembly 110 may also be mounted to an air tube hose 111. The fan assembly 110 may be connected to the air tube hose 111 using one or more different fastening devices (e.g., snaps, zippers, adhesives, and/or buttons). For example, as shown in fig. 1, the fan assembly 110 may be snap-fit to the top opening of the air tube hose 111. As described herein, air tube hose 111 may extend from an air flow insert pad 122 in mattress 101. In some embodiments, at least a portion of hose 111 may be made of a silicon material and configured to fit around an air opening (e.g., air inlet 710 in fig. 5) of fan assembly 110. As shown, the fan assembly 110 mounted to the air tube hose 111 may be positioned closer to the head side or foot side of the mattress 101. The fan assembly 110 and hose 111 may be offset relative to the midpoint of the mattress 101.

The fan assembly 110 may be configured to cool the top surface of the mattress 101 by, for example, drawing air from the top of the mattress and venting air at the bottom of the mattress. Additionally or alternatively, the fan assembly 110 may be configured to circulate ambient or conditioned air (e.g., heated or cooled air) around or through one or more components in the mattress 101 to control the microclimate (e.g., raise or lower temperature or humidity) at the top surface of the mattress 101.

In other words, the mattress 101 may include a first layer (e.g., top layer 102) having a first layer top (e.g., top surface) and a first layer bottom (e.g., bottom surface) and extending from a first edge to a second edge. Mattress 101 may also include a first side brace attached to the bottom of the first layer proximate the first edge and a second side brace attached to the bottom of the first layer proximate the second edge (e.g., opposite left and right sides of brace construction 106). A core (e.g., an inflatable air chamber) may be positioned below the first layer bottom between the first side struts and the second side struts. A first air module (e.g., fan assembly 110, air conditioning module) may also be included in mattress 101 and configured to generate an air flow. The first air module may be disposed between the first side stay and the core below the first tier bottom. A second layer (e.g., bottom layer 108) may also be disposed below the core and cover the core between the first side struts and the second side struts. The first air module may be configured to draw air from the first layer and direct exhaust air between the first side stay and the second layer. The first air module may also be configured to draw air from the first layer and direct exhaust air toward the head side of the mattress 101 and/or the foot side of the mattress 101.

In other embodiments, the first air module may be configured to direct exhaust air toward the interior of the mattress 101. One or more of the interior components (e.g., layers) of the mattress 101 may be made of a breathable material that allows exhaust air to circulate through the mattress 101. Channels may also be integrated into one or more of the interior components such that the exhaust air may be routed toward the middle portion of the mattress 101 and away from the first air module. In other embodiments, the first air module may be configured to direct exhaust air toward a base supporting the bottom of the mattress 101. For example, the first air module may draw air from the top surface of the mattress 101 and push the air out of an opening defined at the base supporting the bottom of the mattress 101. In other embodiments, the first air module may be configured to direct exhaust air out of the sides of the mattress 101 (e.g., direct exhaust air through the side braces 234, 236 and through the mattress cover 140 of the mattress 101). For example, the exhaust air may be directed toward the side struts. A portion of each side stay may be made of a breathable material through which exhaust air may pass. Alternatively or additionally, the side stay may also have a hole or opening integrated in the side stay and close to the first air module. Thus, the exhaust air may be routed through holes or openings. As described further below, the first air module may be mounted to a first tube configured to allow air flow to inflate the air chamber of the core. The first air module and the first tube may be positioned offset relative to a midpoint of the mattress 101. In other embodiments, the first air module may be positioned offset relative to the first tube.

In addition, the mattress 101 includes a cover 140, the cover 140 having a top surface, a bottom surface, and side surfaces configured to at least partially cover the top layer 102, the brace structure 106, the bottom layer 108, the air chamber 104, and the fan assembly 110. In some embodiments, the fan assembly 110 may be configured to draw air into the mattress 101 from the top of the mattress 101, through the mattress cover 140, through the top layer 102, into the inlet of the fan assembly 110, out the outlet of the fan assembly 110, and out the mattress cover 140 or some other outlet to the space outside of the mattress 1010. In some embodiments, the fan assembly may be configured to blow air from the fan assembly 110, through the top layer 102, and out through the mattress cover 140 to a location at the top of the mattress 101. Thus, the temperature of the top surface of mattress 101 may be cooled more quickly and efficiently.

One or more of the top layer 102, brace structure 106, and bottom layer 108 may be made of a foam material. Alternatively or additionally, the top layer 102 may be surface treated with one or more gel materials having different heat capacities to provide extended cooling through the mattress when the bed is in a cooling air supply mode. In some embodiments, one or more gel materials may be incorporated into the top layer 102 by surface infusion. Furthermore, in some embodiments, the top layer 102 and the strut structure 106 may be part of an inverted foam box-like body. The inverted foam box body may include foot braces and head braces in addition to the first side braces and the second side braces.

Fig. 2 is a bottom perspective view of the mattress system 200, showing the mattress system 200 inverted. Mattress system 200 may be a mattress (e.g., with reference to mattress 101 in fig. 1) as depicted and described throughout this disclosure. The mattress system 200 may include a top layer (e.g., a first layer) 202, a middle layer (e.g., a second layer) 204, a brace structure 206, and a bottom layer (e.g., a third layer) 208. Mattress system 200 also has a top surface 212 (e.g., the top surface of top layer 202). The intermediate layer 204 may include one or more air flow insert pads 122 (shown in fig. 1).

In some embodiments, the top layer 202, middle layer 204, and bottom layer 208 are disposed sequentially from top to bottom of the mattress system 200. The brace arrangement 206 is disposed about the perimeter of the mattress system 200 and is configured to at least partially enclose an air chamber assembly or mattress core. For example, the air chamber assembly may include one or more inflatable air chambers (e.g., see fig. 3). As shown in fig. 2, the bottom layer 208 may be configured to be at least partially surrounded by the strut structure 206. The bottom layer 208 may be configured to enclose a space 211 (e.g., see fig. 3) defined by the strut structure 206. In other embodiments, the bottom layer 208 may be disposed over the strut structure 206.

Mattress system 200 may also include a fan assembly 110, as described throughout this disclosure (e.g., with reference to fig. 1). As depicted, the mattress system 200 may have two fan assemblies 110 disposed in opposite left and right sides of the brace structure 206 and configured and operable to control the microclimate of two independent zones (left and right sides) at the top of the mattress. In some embodiments, the fan assembly 110 may be disposed in the head side of the strut structure 206 and/or the foot side of the strut structure 206. In other embodiments, mattress system 200 may have fewer or more integrated fan assemblies.

Fig. 3 is a partially exploded view of the mattress system 200 of fig. 2, showing the top layer 202, middle layer 204, example air plenum assembly 220, and integrated fan assembly 110. The top layer 202 may have a top surface 212 on which the user's body may rest directly or indirectly through a mattress cover and/or one or more additional layers disposed on the top surface. The middle layer 204 may be disposed opposite the top surface 212 of the top layer 202. The middle layer 204 may be attached to the top layer 202 in various ways. The middle layer 204 may be glued to the top layer 202, for example, or attached to the top layer 202 using fasteners, such as hook and loop fasteners (e.g., ) Zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners.

Further, mattress system 200 may include an air chamber assembly 220. In the illustrated example, the air chamber assembly 220 includes a pair of air chambers 222 disposed between the top layer 202 and the bottom layer 208. The air chamber 222 may be an inflatable air chamber. The depicted air chamber assembly 220 may be used with extra-large or large-sized mattresses 200. Other mattresses, such as double bed size and full size mattresses, may have an air chamber assembly containing only one air chamber. In still other examples (not depicted), the air chamber assembly may simply be a non-inflatable or air filled mattress core.

The air chamber 222 may be arranged to be surrounded by the strut structure 206. The air chamber assembly 220 may also include a pump system configured to inflate and/or deflate the air chamber 222. The pump system may be disposed external to the mattress and fluidly connected to the air chamber 222 via a fluid delivery component. For example, mattress 200 also includes an air chamber hose 226 connected to air chamber 222 for inflating or deflating air chamber 222. For example, one end of the air chamber hose 226 may be connected to the air chamber 222 to be in fluid communication with the interior of the air chamber 222, and the other end of the air chamber hose 226 may be fluidly connected to a pump system. In the illustrated embodiment, the air chamber hose 226 is routed to be located at a lateral position of the mattress system 200 at a medial axis of the mattress system 200. In alternative embodiments, the air chamber hose 226 may be routed at a different location of the mattress system 200, such as at the head or foot of the mattress system 200, or at other suitable locations of the mattress system 200.

As depicted, the strut structure 206 may be disposed on the middle layer 204, or on the top layer 202 without a middle layer, to define a space 211 for at least partially receiving the air chamber assembly 220. The bottom layer 208 may be at least partially disposed within the space 211 to at least partially cover the space 211 and the air chamber assembly 220 within the space 211. The space 211 may be a single monolithic solid layer. The space 211 may be made of the same or different material as the top layer 202, middle layer 204, and/or brace structure 206.

The mattress system 200 may also include an air flow insert pad 122 (e.g., a thermal insert), which air flow insert pad 122 may be included in the mattress 200 and configured to circulate ambient or conditioned air through the mattress 200 under a user in a resting state. The airflow insert 122 may be positioned below the top layer 202. In some embodiments, the intermediate layer 204 defines a cutout region or recess to receive the airflow insert 122 therein. The airflow insert 122 may include a material that is more breathable than the top layer 202, middle layer 204, and/or other adjacent layers, thereby facilitating airflow through the airflow insert 122 rather than through the adjacent layers of the airflow insert 122 (e.g., the top layer 202 and middle layer 204). In the example shown, the mattress includes two air flow insert pads 122. Other embodiments of mattresses may include a single air flow insert pad or more than two air flow insert pads. The air flow insert pad 122 may be disposed at various locations in the mattress 200. In the illustrated example, the air flow insert pad 122 is disposed between the head and foot of the mattress 200 (e.g., in the middle of the mattress). The pad 122 may also be positioned closer to the head of the mattress 200 or the foot of the mattress 200 to optimize positioning without relying on the passage of base holes. In some embodiments, the pad 122 may be laminated in place using an adhesive. The pad 122 may also be held in place using one or more other attachment devices (e.g., hook and loop fasteners and/or zippers).

The fan assembly 110 may be connected to the air duct hose 111 or mounted on the air duct hose 111. The fan assembly 110 may also be at least partially disposed in the strut structure 206. As depicted, the fan assembly 110 is offset relative to a medial axis of the mattress system 200. The medial axis may extend along a center between the head end and the foot end of the mattress. The fan assembly 110 may be positioned closer to the head side of the strut structure 206 or the foot side of the strut structure 206. Positioning the fan assembly 110 closer to the head side of the brace structure 206 may facilitate venting or providing more airflow to the head portion of the top surface 212 of the mattress system 200 than to other portions of the mattress system. Positioning the fan assembly 110 closer to the foot side of the brace structure 206 may facilitate providing or exhausting more airflow to the foot portion of the top surface 212 of the mattress system 200 than to other portions of the mattress system. Offsetting the fan assembly 110 relative to the medial axis of the mattress system 200 may be beneficial in that the fan assembly 110 does not interfere with the configuration and operation of the air plenum hose 111 located at or about the medial axis of the mattress system 200. Further, the fan assembly 110 may be positioned in the brace structure 206 relative to the air plenum hose 111 based on the location where the air plenum hose 111 is disposed in the mattress system 200 (e.g., if the hose 111 is positioned closer to the head portion of the mattress system 200, the fan assembly 110 may be positioned at a medial axis of the mattress system 200 or any other suitable location). In some embodiments where mattress system 200 does not have air chamber assembly 220, fan assembly 110 may be positioned at a medial axis of mattress system 200.

The top layer 202, middle layer 204, brace construction 206, and bottom layer 208 may be made of a variety of materials. For example, at least one of the top layer 202, the middle layer 204, the brace construction 206, and the bottom layer 208 may be made of foam, which may be closed cell foam, open cell foam, or a combination thereof. Further, the top layer 202, middle layer 204, and/or strut structure 206 may form a foam box-like body in which the air chamber assembly 220 is housed. Other materials, such as one or more coil springs, air chambers, spacer materials, and/or other suitable materials, may be used for at least one of the top layer 202, the middle layer 204, the strut structure 206, and the bottom layer 208.

Fig. 4 shows a bottom perspective view of the mattress system 200 of fig. 2 with a set of reinforcement bands 250A-250B removed and the integrated fan assembly 110 in place. Reinforcement strips 250A-250B may be used to hold mattress system 200 in place and prevent mattress system 200 from bending outward during use. For example, straps 250A-250B may be used to hold bottom layer 208 (e.g., see fig. 2-3) in place within brace structure 206 and over one or more components of mattress system 200 (e.g., air chamber assembly 220 disposed within space 211 in fig. 3). Thus, one or more components may be retained within the mattress system 200 when the mattress system 200 is flipped over and positioned on top of a foundation or other mattress support system.

In some embodiments, mattress system 200 may be configured to include various types of cores, such as one or more inflatable air chambers, foam, and/or spring assemblies, which may be received in the space defined by brace arrangements 206 in the same or similar manner as described herein.

The strut structure 206 may include a foot strut 230, a head strut 232, and opposed side struts 234, 236 extending between the foot strut 230 and the head strut 232. In some embodiments, the strut structure 206 may be made of one or more foam materials. In this example, a brace structure 206 is attached to the intermediate layer 204. The strut structure 206 has a top strut side, a bottom strut side, a strut inner side, and a strut outer side. In other words, each of the foot brace 230, the head brace 232, and the opposing side braces 234, 236 has a top brace side, a bottom brace side, a brace inner side, and a brace outer side. In the example shown, the top strut side may be attached to the middle layer 204, while the bottom strut side opposite the top strut side is exposed and defines the perimeter of the strut structure 206 in the view of fig. 4. The strut inner side faces the interior of the mattress and the strut outer side opposite the strut inner side faces outwardly and defines a side exterior of the mattress.

When attached to the middle layer 204, the brace structure 206 may also be engaged with the air chamber assembly 220 or attached to the air chamber assembly 220, the air chamber assembly 220 being positioned in the space 211 of the mattress and abutting the middle layer 204. For example, the foot brace 230 is attached to the bottom of the middle layer 204 at (or near) the foot edge of the middle layer 204, and the head brace 232 is attached to the bottom of the middle layer 204 at (or near) the head edge of the middle layer 204 (opposite the foot edge of the middle layer 204). Side braces 234, 236 are attached to the bottom of middle layer 204 at (or near) opposite sides of middle layer 204. The strut structure 206 also forms an inverted foam box-like body with the layers (e.g., the middle layer 204 and/or the top layer 202). For example, the strut structure 206 defines a space 211 for receiving a mattress core or air chamber assembly 220 (e.g., one or more inflatable air chambers, foam, and/or spring assemblies (e.g., see fig. 3)). In embodiments where the middle layer 204 is not provided, the brace arrangements 206 may be attached to the top layer 202 in a similar manner.

The first reinforcing strip 250A may be connected to the opposing side braces 234, 236 so as to extend under the mattress core or air chamber assembly 220 between the bottoms of the side braces 234, 236. For example, one end of the first strap 250A may be connected to a first connection point 242A located on the bottom of a first side brace (e.g., side brace 234) and the other end of the first strap 250A may be connected to a second connection point 240A located on the bottom of a second side brace (e.g., side brace 236). The first strap 250A may be attached to the opposing side struts 234, 236 at predetermined connection locations 240A, 242A. Thus, the first strap 250A may extend from the bottom of the first side stay to the bottom of the second side stay below the core. Similarly, a second strap 250B may be connected to the opposing side braces 234, 236 so as to extend under the mattress core or air chamber assembly 220 between the bottoms of the side braces 234, 236. For example, one end of the second strap 250B may be connected to a third connection point 242B located on the bottom of the first side stay (e.g., side stay 234), and the other end of the second strap 250B may be connected to a fourth connection point 240B located on the bottom of the second side stay (e.g., side stay 236). The second strap 250B may be attached to the opposing side braces 234, 236 at predetermined connection locations 240B, 242B.

One or more fastening elements 238 may be used to attach the straps 250A-250B to the strut structure 206. The fastening element 238 may be of various types. For example, the fastening element 238 comprises an adhesive tape. Alternatively, or in addition, the fastening elements 238 may be hook and loop fasteners (e.g.,) Zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners. The fastening elements 238 may be applied at the connection locations 240A-240B and/or 242A-242B or at desired locations (e.g., ends) of the straps 250A-250B such that such desired locations of the straps 250A-250B are attached to the connection points 240A-240B and/or 242A-242B of the strut structure 206. For example, adhesive tape may be applied between the connection locations 240A-240B and 242A-242B of the strut structure 206 and the ends of the bands 250A-250B.

The reinforcement strips 250A-250B may be used with pieces (e.g., fastening elements 238) of hook material (e.g., 3M hook material) having an adhesive backing. Hook material may be placed along the bottom sides of the perimeter side braces 234 and 236. In some embodiments, the reinforcement strips 250A-250B may include a scrim material (scrim material) and are attached to the hooked material and extend from one side of the mattress system 200 to the other. The straps 250A-250B may be removable to allow other components (e.g., air chambers, layers, etc.) to be assembled without interference. The straps 250A-250B may be adjustable to accommodate stretching or changing over time, variable tolerances of the foam box and its cover, or general aesthetic preference effects. The strips 250A-250B may also have widths of different dimensions, such as widths in the range between about 1 inch and about 7 inches.

In some embodiments, the first strap 250A and the second strap 250B are positioned in a longitudinally intermediate section of the mattress system 200. The first belt 250A may extend in parallel with the second belt 250B and spaced a predetermined distance from the second belt 250B.

Other configurations of the belts 250A-250B are also possible. In some embodiments, the bands 250A-250B may be arranged to cross each other. For example, a first strap 250A and a second strap 250B are connected to the opposing side braces 234, 236 to extend under the mattress core or air chamber assembly 220 between the bottoms of the side braces 234, 236. The first strap 250A may be arranged to cross the second strap 250B by connecting one end of the first strap 250A to one of the side braces 234, 236 between the head brace 232 and the second strap 250B and connecting the other end of the first strap 250A to the other of the side braces 234, 236 between the foot brace 230 and the second strap 250B.

In other configurations, one or more of the straps 250A-250B may extend to one or both of the foot stay 230 and the head stay 232. In one example, one or more of the straps 250A-250B may extend from the foot stay 230 to the head stay 232 instead of extending between the opposing side stays 234, 236. In another example, in addition to having one or more straps 250A-250B extending between opposing side braces 234 and 236, one or more of the straps 250A-250B may also extend from the foot brace 230 to the head brace 232. In still other configurations, fewer or additional reinforcing strips may be included in mattress system 200.

As depicted, the fan assembly 110 may be at least partially disposed in the strut structure 206. The straps 250A-250B may be attached to the brace structure 206 on opposite sides of the fan assembly 110, thereby reinforcing or retaining the brace structure 206 at or around the fan assembly 110. For example, in the illustrated example, the fan assembly 110 is disposed in the opposing side braces 234, 236, and the first strap 250A and/or the second strap 250B are connected to the opposing side braces 234, 236 and proximate to the fan assembly 110. The brace arrangement 206 may also include one or more recessed portions proximate to the connection points of the fan assembly 110 and/or straps 250A-250B to receive other components of the mattress system 200 (e.g., air channels, air chamber hoses, wires, etc.). In alternative embodiments, mattress system 200 does not include belts 250A-250B and their associated elements.

Other configurations of the fan assembly 110 are possible. For example, the fan assembly 110 may be positioned closer to the foot stay 230 and/or closer to the head stay 232. Fan assembly 110 may also be positioned outside of connection locations 240A-240B and 242A-242B. In other words, the fan reinforcement bands 250A-250B need not be positioned around the fan assembly 110. In some embodiments, mattress system 200 may not include reinforcement bands 250A-250B, as further depicted and described with reference to FIG. 18.

Fig. 5 is a perspective view of integrated fan assembly 110. As depicted, the fan assembly 110 includes an outer housing 700, the outer housing 700 configured to receive a fan and electronics that can control the operation of the fan. The fan assembly 110 may include an air tube 708 (e.g., plenum), the air tube 708 being fluidly connected to the housing 700 and configured for airflow into or out of the housing 700. The housing 700 and air tube 708 may define an air inlet and an air outlet. In embodiments where the fan assembly 110 operates to draw air, the air tube 708 defines an air inlet 710 and the housing 700 defines an air outlet 702. In embodiments where the fan assembly 110 operates to blow air, the air inlet 710 of the air tube 708 serves as an air outlet, and the air outlet 702 of the housing 700 serves as an air inlet.

The air inlet 710 of the air tube 708 is positioned toward the top of the mattress, effectively drawing air from the top of the mattress. As described herein, the air outlet 702 of the housing 700 is oriented toward the foot side or the head side of the mattress at the bottom of the mattress. For example, the housing 700 may be positioned between a bottom layer (e.g., bottom layer 208) and a corresponding side brace (e.g., one of the side braces 234, 236) of a mattress, and the air outlet 702 oriented toward a channel defined between the bottom layer and the corresponding side brace (i.e., a side surface of the bottom layer and a side surface of the side brace facing the side surface of the bottom layer), as shown and described with reference to fig. 2-3.

In some embodiments, the air tube 708 of the fan assembly 110 may also serve as a base portion of the fan assembly 110. For example, the air tube 708 may be attached to the brace structure of the mattress using one or more fastening elements (e.g., screws, bolts, adhesive, etc.). In some embodiments, the air tube 708 is configured to mate with recessed portions (e.g., recessed portions 306, 406, 506) defined at the strut structure. The air tube 708 may be received into and fit within the recessed portion with or without additional fastening elements (e.g., screws, bolts, adhesive, etc.). Further, when manufacturing a mattress, the fan assembly 110 may be integrated into or attached to the mattress during production. In some embodiments, the air tube 708 (along with the housing 700) may be removed from the mattress when the fan assembly 110 requires maintenance and/or replacement. Thus, fastening the air duct 708 to the strut structure may provide for easier maintenance of the fan assembly 110.

Fig. 6 illustrates a cross-sectional view of the mattress system 200, taken along the cross-sectional line shown in fig. 8. Fig. 6 illustrates an example airflow 800 (e.g., exhaust air) through the mattress system 200. As depicted, mattress 200 includes mattress cover 140, top layer 202, middle layer 204, brace structure 206, air chambers 222, optional air flow layer 223, air flow insert pad 122 (e.g., a thermal insert), and bottom layer 208 (e.g., see fig. 1-3). The air flow insert 122 may be sewn together or attached together as one piece (one piece). The view of fig. 6 depicts the opposite side struts 234 and 236 of the strut structure 206. The fan assembly 110 is positioned within opposite side struts 234 and 236 of the strut structure 206. In some embodiments, the optional air flow layer 223 may be positioned flush with the middle layer 204 and configured to promote circulation and distribution of air toward the top layer 202 and from the top layer 202. The airflow layer 223 may include a material that provides a higher airflow rate than the middle layer 204 and/or the top layer 202. The air flow layer 223 may facilitate and direct the air flow 800 from the top of the mattress into the air duct 708 of the fan assembly 110.

The fan assembly 110 is positioned such that the air tube 708 is fluidly connected to the air tube hose 111, the air tube hose 111 is fluidly connected to the air flow layer 223 in the middle layer 204, and such that the air opening of the housing 700 (e.g., the air outlet 702 shown and described in fig. 5) is oriented toward the head portion or the foot portion of the mattress 200. As depicted in fig. 6, the air flow 800 is directed from the top of the mattress through the air tube hose 111 into the air tube 708 of the fan assembly 110 and is routed into the housing 700 of the fan assembly 110. The air flow 800 may also flow through one or more layers of the mattress 200 to provide air circulation at the top layer 202. In addition, the air flow 800 may be directed through the middle layer 204, the air flow layer 223, and/or the top layer 202 of the mattress 200. Thus, the fan assembly 110 may cause the airflow 800 at the top surface of the mattress cover 140 to reduce or moderate the temperature of the mattress 200.

Fig. 7 shows a side cross-sectional view of the mattress 200, taken along the cross-sectional line shown in fig. 8. Fig. 7 depicts an airflow 800 drawn into the fan assembly 110, and also depicts exhaust air 801 from the fan assembly 110. This side cross-sectional view of the mattress 200 depicts a longer side, such as a left side or a right side, of the mattress 200. Mattress 200 includes a brace structure 206 having a head brace 232, a foot brace 230, and one side brace 234. In addition, the fan assembly 110 is disposed in the side braces 234 of the brace structure 206 closer to the head braces 232 or the head portion of the mattress 200. As depicted, the fan assembly 110 is offset relative to the medial axis of the mattress 200. In the example shown, the fan assembly 110 is oriented toward the head stay 232. Accordingly, the air flow 801 is discharged from the fan assembly 110 toward the head portion of the mattress 200, thereby lowering the temperature of the top surface of the mattress 200. Alternatively, fan assembly 110 is oriented toward foot brace 230.

As described herein, the exhaust air 801 may be directed through channels or recessed portions (e.g., channels or recessed portions 308, 408, 508, 604) defined between sides of the bottom layer 208 and adjacent side struts of a strut structure (e.g., strut structure 206). The channels or recessed portions may extend toward the head portion or the foot portion of the mattress 200. This provides for more direct and efficient evacuation of air from the fan assembly 110, thereby rapidly lowering the temperature of the top surface of the mattress 200. In addition, the air flow 800 may be drawn from the top surface of the mattress 200 through the air flow insert pad 122 (e.g., a thermal insert), the air flow 800 may be collected at the air flow insert pad 122, and then directed into the air duct 708 and the fan assembly 110 through the air duct hose 111.

Fig. 8 is a bottom view of an example mattress system 300 with an integrated fan assembly 110. As depicted, the mattress system 300 is flipped up and down such that the top surface of the mattress system 300 is facing down. The depicted mattress system 300 has a brace structure 302 and a bottom layer 304, as described throughout the present disclosure (e.g., with reference to the brace structure 206 and bottom layer 208 in fig. 2). Mattress system 300 may have one or more additional components described herein, such as a top layer, middle layer, and/or air chamber assembly. Further, in some embodiments, as depicted with reference to fig. 4, the bottom layer 304 disposed inside the strut structure 302 may be retained or held in place using one or more reinforcing strips.

The spacer structure 302 has a recessed portion 306. Recessed portion 306 is configured to receive fan assembly 110. In other words, the first side brace (e.g., left or right side brace of brace structure 302) may define a first brace recess (e.g., recess 306) configured to at least partially receive the first air module (e.g., fan assembly 110). The recessed portion 306 may be any suitable size to fit the size of the fan assembly 110. Accordingly, the fan assembly 110 may be disposed inside the brace structure 302 such that the fan assembly 110 does not interfere with one or more other components of the mattress system 300. Further, as depicted, the recessed portion 306 may be offset relative to the medial axis 310 of the mattress system 300. Such a configuration may also be beneficial in preventing placement of the fan assembly 110 from interfering with one or more other components of the mattress system 300 disposed at or about the medial axis 310. The medial axis 310 may be an axis that extends between opposing side braces and bisects the mattress system 300. Alternatively, the intermediate axis 310 may be offset relative to an axis that bisects the mattress system 300.

Recessed portion 306 may have a predetermined width W1 adapted to receive at least a portion of fan assembly 110. The predetermined width W1 may be large enough to maintain adequate airflow and space for mounting the fan assembly 110, while also being a minimum size to minimize discomfort that may occur due to too wide an opening. Otherwise, a user lying on top of the mattress system 300 may feel the opening too large, thereby reducing comfort. For example, the width W1 may be 9.5 inches. This width may advantageously provide adequate air flow without compromising the comfort of the mattress system 300 to the user. In other embodiments, the width W1 of the recessed portion 306 may be in the range of 4 inches to 10 inches. Other ranges of width W1 are also possible for various configurations of the mattress.

In addition, the bottom layer 304 may have a recessed portion 308. The recessed portion 308 may have various dimensions (width, length, and depth). In some embodiments, the width W2 of the recessed portion 308 may be less than 1 inch. In other example embodiments, the width W2 may range from 1 inch to 6 inches. In some embodiments, as shown in fig. 8, a length L2 of the recessed portion 308 may extend between the opposing head strut portion 314 and foot strut portion 316. As shown in fig. 8, the length L2 of the recessed portion 308 may extend the entire distance between the opposing head strut portion 314 and foot strut portion 316. The size of the distance L2 of the recessed portion 308 may vary depending on the size of the mattress system 300. In other embodiments, the length L2 of the recessed portion 308 may be less than the distance between the opposing head strut portion 314 and foot strut portion 316, as described in further detail with reference to fig. 12. Various other sizes of recessed portions 308 may be implemented (e.g., with reference to fig. 9-12). The various dimensions of the recessed portion 308 may advantageously ensure that the bottom layer 304 remains centered in the mattress system 300 without shifting to one side of the system 300 and without eliminating or compromising the airflow 312A-312B through the recessed portion 308. For example, the bottom layer 304 may have recessed portions 308 positioned at the head portion 314 and/or the foot portion 316 of the mattress system 300. Further, instead of having recessed portions 308, the bottom layer 304 may be made of a breathable material to allow air to flow directly through the bottom layer 304, as described herein.

Recessed portion 308 may be configured to facilitate or direct airflow 312A-312B (e.g., exhaust air) from fan assembly 110. For example, the recessed portion 308 may create one or more different flow paths to direct the exhaust air from the fan assembly 110. The first flow path may be defined by a side surface of a first side strut (e.g., side strut 302) and a corresponding side surface of at least one additional layer (e.g., bottom layer 304). The bottom layer 304 may cover the core between the first side stay and the second side stay 302. Mattress 300 may also include a mattress cover having a top panel, a bottom panel, and opposing side panels. The first flow path may also be defined by a bottom surface of the core and a top surface of the floor of the mattress cover. In some embodiments, the core may include an air chamber. The width of the first flow path between the side surface of the first side strut 302 and the corresponding side surface of the bottom layer 304 may vary in the longitudinal direction along the first side strut. The corresponding side surface of the bottom layer 304 may include a tapered surface 305, the tapered surface 305 being angled relative to the side surface 303 of the first side stay 302 facing the corresponding side surface of the bottom layer 304. The width of the first flow path may decrease from the location where the fan assembly 110 is positioned toward the head side of the mattress 300 or the foot side of the mattress 300. The width of the first flow path may also vary along the entire length of the bottom layer 304. The first flow path may extend to a corner of the bottom layer 304. The first flow path may also extend vertically along at least a portion of the sides of the mattress 300. The first flow path may be defined at least through the air duct 708 of the fan assembly 110. The first flow path may be defined along at least one foam layer between the mattress top and the mattress bottom. The mattress top may include a mattress cover and the mattress bottom may include a bottom layer.

Recessed portion 308 may also be angled (e.g., tapered) to better direct and exhaust air streams 312A-312B toward either head portion 314 or foot portion 316 of mattress system 300. As depicted in fig. 8, the recessed portion 308 of the bottom layer 304 is symmetrical with respect to a medial axis 310 of the mattress system 300. Thus, when the bottom layer 304 is assembled to other portions of the mattress system 300 (e.g., when disposed in the brace structure 302), how the bottom layer 304 is oriented or oriented is not important. In other words, the symmetrical concave portion 308 of the bottom layer 304 allows the bottom layer 304 to be easily assembled to other portions of the mattress system 200 because the bottom layer 304 provides the same configuration of the mattress system 200 regardless of the orientation of the bottom layer 304 attached to the rest of the mattress system 200. In one example, the angle a of the tapered recess 308 relative to the intermediate axis 310 may be in the range of 60 degrees to 85 degrees. Another example of angle a may be in the range of 65 degrees to 80 degrees. Another example of angle a may be in the range of 70 degrees to 75 degrees. Other ranges of angle a are also possible.

In one example, the fan assembly 110 in the mattress system 300 is oriented toward the head portion 314 of the mattress system 300. In another example, fan assembly 110 may also be oriented toward foot portion 316 of mattress system 300. The symmetrical concave portion 308 provides uniform airflow in any direction in which the fan assembly 110 is oriented, whether the fan assembly 110 is oriented toward the head portion 314 or the foot portion 316.

Recessed portion 308 creates an air duct or passageway for air streams 312A-312B to exit fan assembly 110.

For example, mattress 300 may define a first channel (e.g., recessed portion 308) between a first side strut (e.g., strut structure 302) and a second layer (e.g., a layer above bottom layer 304, such as an inflatable air chamber). The first channel is configured to allow airflow between the first side stay and the second layer. The second layer may also define a layer recess (e.g., recess 308) that defines a first channel between the first side stay and the second layer. The layer recess may extend at least partially along the length of the second layer.

Directing the air streams 312A-312B around the components of the mattress system 300 (e.g., along the edges or sides of the components) may provide a more efficient cooling effect on the top surface of the mattress system 300. For example, the airflows 312A-312B facilitate air aspiration from the top of the mattress through the fan assembly 110, thereby creating a more efficient cooling effect at the top of the mattress.

Recessed portions 306 and/or 308 may prevent fan assembly 110 from interfering with one or more other components integrated into mattress system 300. For example, wires and/or air plenum hoses may be provided along the sides of the bottom layer 304 and/or the brace structure 302. Placing fan assembly 110 in recessed portions 306 and/or 308 may keep fan assembly 110 separate from these additional components and prevent interference with the configuration or operation of these components.

In some embodiments, mattress system 300 may have fewer or additional fan assemblies 110. For example, mattress system 300 may have one fan assembly 110 along the longer sides of brace construction 302. In another example, bed system 300 may have one fan assembly 110 along either head portion 314 or foot portion 316. As yet another example, the mattress system 300 may have two fan assemblies 110 on each longer side of the brace arrangement 302. In yet another example, mattress system 300 may have fan assemblies 110 disposed on a longer side of brace structure 302 and each of head portion 314 and foot portion 316. As described herein, each fan assembly 110 may be oriented in any direction when disposed in recessed portions 306 and 308.

Fig. 9 is another bottom view of the example mattress system 300 of fig. 8 with integrated fan assembly 110. In contrast to fig. 8, fig. 9 depicts air flows 312A-312B (e.g., exhaust air) directed toward foot portion 316 of mattress system 300. Accordingly, fan assembly 110 is disposed and oriented toward foot portion 316 of mattress system 300. In this example, the fan assembly 110 is disposed on the left side of the central axis 310 such that the fan assembly 110 is disposed closer to the head portion 314 than the bottom portion 316. Alternatively, fan assembly 110 may be disposed to the right of intermediate axis 310 such that fan assembly 110 is disposed closer to foot portion 316 than to head portion 314 and thus increases the airflow toward foot portion 316 as compared to the airflow toward head portion 314.

The recessed portion 308 of the bottom layer 304 is symmetrical and proportional along the length of the mattress system 300. Thus, the orientation of the bottom layer 304 is not critical when assembled with other portions of the mattress system 300, thereby improving ease of assembly and maintenance of the mattress system 300. The air streams 312A-312B may be directed along the channels created by the recessed portions 308 such that air may flow along the sides of the components of the mattress system 300 and cool the top surface of the mattress system 300.

Similar to the recessed portion of fig. 8, the recessed portion 306 may have a predetermined width W3 adapted to receive at least a portion of the fan assembly 110. The width W3 of the recessed portion 306 may be in the range of 2 inches to 10 inches. In other embodiments, the width W3 of the recessed portion 306 may be in the range of 3 inches to 9 inches. In other embodiments, the width W3 of the recessed portion 306 may be in the range of 4 inches to 8 inches. Further, the recessed portion 308 may have various dimensions (width, length, and depth). In some embodiments, the width W4 of the recessed portion 308 may be less than 1 inch. In other embodiments, the width W4 may be in the range of 1 inch to 6 inches. In other embodiments, the width W4 of the recessed portion 308 may be in the range of 2 inches to 5 inches. In other embodiments, the width W4 of the recessed portion 308 may be in the range of 3 inches to 4 inches. In some embodiments, as shown in fig. 8, a length L3 of the recessed portion 308 may extend between the opposing head strut portion 314 and foot strut portion 316. The length L3 of the recessed portion 308 may extend the entire distance between the opposing head and foot strut portions 314, 316. As described above, the size of the distance L3 of the recessed portion 308 may vary depending on the size of the mattress system 300.

Fig. 10 is another bottom view of the example mattress system 300 of fig. 8 with integrated fan assembly 110. In contrast to fig. 8 and 9, fig. 10 depicts airflows 312A-312B traveling in different or opposite directions (e.g., exhaust air). For example, air flow 312A is directed toward head portion 314 of mattress system 300. Air flow 312B is directed toward foot portion 316 of mattress system 300. Directing air toward both the head portion 314 and the foot portion 316 of the mattress system 300 may facilitate cooling or reducing the temperature of two different regions at the top surface of the mattress system 300 at different rates. Directing air toward both the head portion 314 and the foot portion 316 of the mattress system 300 may also be advantageous to allow the use of a common fan assembly 110, whether the fan assembly is positioned to the right or left of the mattress system 300. Regardless of the orientation of the fan assembly, the air streams 312A-312B may be directed along the channels created by the recessed portions 308 such that air may flow along the sides of the components of the mattress system 300 and cool the top surface of the mattress system 300.

Similar to the recessed portion of fig. 8-9, the recessed portion 306 may have a predetermined width W5 adapted to receive at least a portion of the fan assembly 110. Further, the recessed portion 308 may have various dimensions (width, length, and depth). For example, the recessed portion 308 may have a width W6, as described with reference to fig. 8-9. In some embodiments, as shown in fig. 8-9, a length L4 of the recessed portion 308 may extend between the opposing head strut portion 314 and foot strut portion 316.

Fig. 11 is a bottom view of another example mattress system 400 with integrated fan assembly 110. Mattress system 400 may be similar to mattress system 300 depicted and described with reference to fig. 8-10. For example, the mattress system 400 is flipped up and down such that the top surface of the mattress system 400 is facing downward. As described throughout this disclosure, the depicted mattress system 400 has a brace structure 402 and a bottom layer 404. The bottom layer 404 disposed inside the brace bar structure 402 may be retained or held in place using one or more reinforcing strips, as described with reference to fig. 4. For example, reinforcing strips may be placed across the medial axis 410 of the mattress system 400 so as to be connected to opposite longer sides of the brace construction 402.

The spacer structure 402 has a recessed portion 406 as described with reference to fig. 8-10. The fan assembly 110 is at least partially disposed in the recessed portion 406 of the strut structure 402. As depicted, recessed portion 406 is offset relative to a medial axis 410 of mattress system 400. Such a configuration may be advantageous to prevent placement of the fan assembly 110 from interfering with one or more other components of the mattress system 400.

In addition, the bottom layer 404 has recessed portions 408 to facilitate or direct air flows 412A-412B (e.g., exhaust air) from the fan assembly 110. The recessed portion 408 may also be angled to better direct the airflow 412A-412B. In contrast to the recessed portion 308 in fig. 8-10, the recessed portion 408 in fig. 11 begins at the medial axis 410 of the mattress system 400 and tapers toward the head portion 414 of the mattress system 400. In other embodiments, the recessed portion 408 may taper from the central axis 410 and toward the foot portion 416 of the mattress system 400.

The configuration of recessed portion 408 in fig. 4 provides that fan assembly 110 is oriented toward head portion 414 of mattress system 400. Accordingly, the air streams 412A-412B may be directed toward one or more layers of the mattress system 400 and proximate the head portion 414 of the mattress system 400. This configuration may facilitate venting and directing air toward the head portion 414 of the mattress system 400. In other embodiments where recess 408 is disposed toward foot portion 416, fan assembly 110 may be oriented toward foot portion 416 such that air streams 412A-412B are exhausted and directed toward foot portion 416 of mattress system 400.

The configuration of recessed portions 406 and/or 408 also facilitates preventing fan assembly 110 from interfering with one or more other components integrated into mattress system 400. For example, wires and/or air plenum hoses may be disposed along the sides of the bottom layer 404 and/or the strut structure 402, such as at the intermediate axis 410. Placing the fan assembly 110 in the recessed portions 406 and/or 408 may keep the fan assembly 110 separate from these additional components and prevent interference with the configuration or operation of these components.

Similar to the recessed portion of fig. 8-10, the recessed portion 406 may have a predetermined width W7 adapted to receive at least a portion of the fan assembly 110. The width W7 of the recessed portion 406 may be in the range of 2 inches to 10 inches. One or more other ranges may be used for the width W7. In addition, the recessed portion 408 may have various dimensions (width, length, and depth). In some embodiments, the width W8 of the recessed portion 408 may be less than 1 inch. In other embodiments, the width W8 may be in the range of 1 inch to 6 inches. One or more other ranges may be used for the width W8. In some embodiments, a length L5 of the recessed portion 408 may extend between the head portion 414 and the intermediate axis 410. In other embodiments, length L5 may extend between foot portion 416 and medial axis 410. The size of the distance L5 of the recessed portion 408 may vary depending on the size of the mattress system 400.

Fig. 12 is a bottom view of another example mattress system 500 with integrated fan assembly 110. Mattress system 500 may be similar to mattress systems 300 and 400 depicted and described with reference to fig. 8-11. For example, the mattress system 500 is flipped up and down such that the top surface of the mattress system 500 is facing downward. The depicted mattress system 500 has a brace structure 502 and a bottom layer 504, as described throughout this disclosure. The bottom layer 504 disposed inside the brace structure 502 may be retained or held in place using one or more reinforcing strips, as described with reference to fig. 4. For example, reinforcement strips may be placed across the central axis 510 of the mattress system 500, connecting to opposite longer sides of the brace structure 502.

The brace bar structure 502 has a recessed portion 506 as described with reference to fig. 8-11. The fan assembly 110 is disposed in the recessed portion 506 of the strut structure 502. As depicted, the recessed portion 506 is offset relative to a medial axis 510 of the mattress system 500. Such a configuration may be advantageous to prevent placement of the fan assembly 110 from interfering with one or more other components of the mattress system 500 disposed at or about the central axis 510 of the mattress system 500.

In addition, the bottom layer 504 has recessed portions 508 to facilitate or direct air flows 512A-512B (e.g., exhaust air) from the fan assembly 110. The recessed portion 508 may also be angled or tapered to better direct the air flows 512A-512B. As with the recessed portion 308 of fig. 8-11, the recessed portion 508 of fig. 12 is symmetrical with respect to the medial axis 510 of the mattress 500. The recessed portion 508 tapers symmetrically from the central axis 510 to corners of the head portion 514 and corners of the foot portion 516 of the mattress system 500. The width of the concave portion 508 (e.g., with reference to the width W10) is also narrower than the concave portion 308 in fig. 8 to 11. The width of recessed portions 508 and 308 may vary based on the configuration of the mattress system. In some embodiments, a greater width may enable better air flow, thereby more effectively and/or more quickly circulating air throughout mattress 500. In some embodiments, the smaller width may maintain the comfort of the user on mattress 500. The smaller width may also maintain the surface stability of mattress 500.

As depicted in fig. 12, air flows 512A-512B (e.g., exhaust air) are directed through channels of recessed portion 508 toward a head portion 514 of mattress system 500. In other embodiments, one or more of the air flows 512A-512B may be directed through the channel of the recessed portion 508 toward the foot portion 516 of the mattress system 500. Because recessed portion 508 is symmetrical with respect to medial axis 510, fan assembly 110 may be oriented in either direction toward head portion 514 or foot portion 516 of mattress system 500 without compromising the effectiveness of cooling the top surface of mattress system 500. Furthermore, the symmetrical concave portion 508 of the bottom layer 504 allows the bottom layer 504 to be easily assembled to other portions of the mattress system 500 because the bottom layer 504 provides the same configuration of mattress system 500 regardless of the orientation of the bottom layer 504 attached to the rest of the mattress system 500. In one example, the angle B of the tapered recess 508 relative to the intermediate axis 510 may be in the range of 60 degrees to 85 degrees. Another example of angle B may be in the range of 50 degrees to 65 degrees. Other ranges of angle B are also possible.

Furthermore, as described throughout this disclosure, the configuration of recessed portions 506 and/or 508 facilitates preventing fan assembly 110 from interfering with one or more other components integrated within mattress system 500. For example, wires and/or air plenum hoses may be disposed along the sides of the bottom layer 504 and/or the brace structure 502, such as at the intermediate axis 510. Placing fan assembly 110 in recessed portions 506 and/or 508 may keep fan assembly 110 separate from these additional components and prevent interference with the configuration or operation of these components.

Similarly and as described with reference to the recessed portion of fig. 8-11, recessed portion 506 may have a predetermined width W9 adapted to receive at least a portion of fan assembly 110. The recessed portion 508 may also have various dimensions (width, length, and depth), such as a width W10 of the recessed portion 508 and a length L6 that may extend between the opposing head and foot strut portions 514, 516.

Fig. 13A is a perspective view of integrated fan assembly 110 in mattress system 600. As depicted, the fan assembly 110 is placed within the recessed portion 601 of the strut structure 206/positioned within the recessed portion 601. The positioning of the fan assembly 110 within the recess 601 is advantageous because it keeps the fan assembly 110 hidden from view. In addition, this configuration prevents the fan assembly 110 from impeding access to other components of the mattress system 600 or operation of other components of the mattress system 600.

The recessed portion 601 is offset relative to a medial axis 602 of the mattress system 600. This configuration is advantageous because it allows existing ports in mattress system 600 to function properly. For example, the recessed portion 601 may not interfere with the function or placement of the ports for inflating and deflating the inflatable air chambers of the mattress system 600.

The fan assembly 110 protrudes from the recessed portion 601 and into a recessed portion 604 of the bottom layer 208 of the mattress system 600. As depicted, the recessed portion 604 is angled such that the recessed portion 604 has a greater width nearer to the medial axis 602 and a smaller or narrower width nearer to the corners of the strut structure 206. For example, as depicted in fig. 13A, the fan assembly 110 is positioned such that the air flow 606 (e.g., exhaust air) is directed toward the foot end of the mattress 600. In other embodiments, the fan assembly 110 may be positioned such that the airflow 606 is directed toward the head end of the mattress 600.

Fig. 13B is a top view of the integrated fan assembly 110 in the mattress system 600 of fig. 13A. The fan assembly 110 includes an electrical cord 608. Wires 608 may connect fan assembly 110 to a power source in mattress system 600. The electrical wires 608 may also provide a connection for the fan assembly 110 to a power source external to the mattress system 600. Thus, the wires 608 may supply power to the fan assembly 110. As depicted in fig. 13B, the wire 608 may be positioned within the recessed portion 601 of the strut structure 206. Thus, the wire 608 may be held in place in the absence of view. Such placement of the wires 608 may also be advantageous because it may not obstruct other components of the mattress system 600, such as the bottom layer 208, the fan assembly 110 itself, and/or other layers of the mattress system 600 as depicted and described herein. In some embodiments, the fan assembly 110 may be placed within a housing having a fan guard (fan guard), a Printed Circuit Board (PCB) to help control the fan assembly 110, and an indicator light. As described herein, the wires 608 may be organized inside the housing and routed out.

Fig. 13C is a side perspective view of the integrated fan assembly 110 in the mattress system 600 of fig. 13A. The fan assembly 110 is positioned within recessed portions 601 on opposite sides (e.g., left and right sides) of the strut structure 206. Both sides of the bottom layer 208 may also have symmetrical recessed portions 604 to facilitate airflow in any direction in which the fan assembly is oriented. In addition, the fan assembly 110 is offset relative to the medial axis 602 such that additional components of the mattress system 600 (e.g., air chamber ports) may still function as they would normally. For example, placement of the fan assembly 110 offset relative to the medial axis 602 does not require reconfiguration or movement of the inflatable air chamber ports positioned at the medial axis 602 of the mattress system 600. In some embodiments where mattress system 600 does not include an air chamber port or inflatable air chamber, fan assembly 110 may be positioned at a medial axis 602 of mattress system 600.

Fig. 14 illustrates an example bed system 900 for providing a high quality sleep experience through an example local bed system 901. The local bed system 901 may include a bed 902 and a bed control system 910, the bed control system 910 being used in conjunction with the bed 902 and configured to control one or more user comfort features of the bed 902. The local bed system 901 may be any of the bed systems described throughout this disclosure.

The bed 902 may include a mattress 904 and a foundation 906. In some embodiments, mattress 904 may be an air mattress having an inflatable air chamber and a controller for controlling inflation of the inflatable air chamber, as described herein. In other embodiments, mattress 904 does not include an air chamber. For example, mattress 904 may include foam and/or springs in place of or in addition to the inflatable air chambers. Mattress 904 may be sized and shaped as a double mattress, a full mattress, a large mattress, a king mattress, a California king mattress, a split king mattress, a partially split mattress (e.g., a mattress split at the head and/or foot ends and joined in between), and/or other mattresses suitable for use. A base 906 is positioned under the mattress 904 to support the mattress 904. In some embodiments, the base 906 may be an adjustable base having one or more articulatable regions, for example, for raising the base 906 and the head and feet of the mattress 904. In other embodiments, the base 906 may be a fixed base.

The bed 902 may be configured to provide microclimate control of the mattress 904. In some embodiments, the bed 902 may be configured to provide a cooling function, as described herein. For example, the bed 902 may include a fan assembly 905 (e.g., with reference to the fan assembly 110 described throughout the present disclosure), and the fan assembly 905 may be included in the mattress 904. The fan assembly 905 may be configured to circulate ambient air through the mattress 904, thereby lowering the top surface temperature of the mattress 904.

Additionally or alternatively, the bed 902 provides a foot warming function. For example, the bed 902 may include a foot warming device 920 disposed on the mattress 904 or incorporated into the mattress 904 at the foot side of the bed 902. Foot warming device 920 may be disposed on top of mattress 904, included in mattress 904, or disposed elsewhere in bed 902, and/or disposed in other configurations. In some embodiments, foot warming device 920 may include an electronic heating element. In other embodiments, foot warming device 920 may include an air circulation element through which heated air circulates. Other configurations are also possible.

Additionally or alternatively, the bed 902 may include an air flow insert pad 922, which air flow insert pad 922 may be included in the mattress 904 and configured to circulate ambient or conditioned air through the mattress under a user in a resting state. The air flow insert 922 may be disposed at various locations in the mattress 904. In the illustrated example, an air flow insert pad 922 is disposed between the head and foot of mattress 904 (e.g., in the middle of mattress 904).

The bed control system 910 operates to control features available to the bed 902. In some embodiments, bed control system 910 includes a bed articulation system 912, an air chamber control system 914, a foot warming control system 916, an air flow insert pad control system 918, and a fan control system 919.

The bed hinge system 912 operates to hinge the base 906 and/or the mattress 904. For example, the bed hinge system 912 may adjust one or more hingeable sections of the base 906 to raise the base 906 and/or the head and feet of the mattress 904. The bed hinge system 912 can include a controller and an actuator (e.g., a motor) operatively coupled to the hingeable section of the base 906 by the controller such that the section of the base 906 is automatically adjusted to a desired position. Alternatively or additionally, the articulatable region of the base 906 may be manually adjusted.

An air chamber control system 914 operates to control the air chambers of mattress 904. The air chamber control system 914 may include a controller and an actuator (e.g., a pump) operated by the controller and fluidly connected to the air chamber. The actuator is controlled to inflate or deflate the air chamber to provide and maintain a desired pressure in the air chamber to provide a desired stiffness of the air chamber.

Foot warming control system 916 operates to control foot warming device 920 disposed in mattress 904. The foot-warming control system 916 may include a controller configured to activate the heating element of the foot-warming device 920 and maintain a desired temperature of the heating element.

An air flow insert pad control system 918 operates to control an air flow insert pad 922 disposed in mattress 904. The air flow insert pad control system 918 may include an air controller configured to flow ambient or conditioned air into or out of the air flow insert pad 922 such that the top layer of the mattress above or adjacent to the air flow insert pad 922 has a desired temperature and/or humidity. The air flow insertion pad control system 918 may determine the air flow based on one or more temperature and/or humidity sensor readings at the top layer of the mattress 904 and/or the user's body.

The fan control system 919 operates to control the fan assembly 905. The fan control system 919 may include an air controller configured to cause ambient air to be expelled from the fan assembly 905 so that the top layer of the mattress may reach a desired cooling temperature and/or humidity level. The fan control system 919 may determine airflow based on one or more temperature and/or humidity sensor readings at the top layer of the mattress 904 and/or the user's body. In other embodiments, the fan control system 919 may operate the fan assembly 905 by drawing ambient air into the fan assembly 905 to circulate air through the mattress.

In some embodiments, the bed hinge system 912, the air chamber control system 914, the foot warming control system 916, the air flow insertion pad control system 918, and the fan control system 919 may be configured and operated independently. In other embodiments, some or all of the bed hinge system 912, the air plenum control system 914, the foot warm control system 916, the air flow insert pad control system 918, and the fan control system 919 are at least partially combined such that the systems share at least a portion of their components, such as actuators (e.g., motors, pumps, etc.) and/or controllers (e.g., control circuits, processors, memories, network interfaces, etc.).

The bed control system 910 may be accessed by a user via one or more control devices 930 (e.g., a bedside controller 932 and a mobile computing device 934). The bedside controller 932 is wired or wirelessly connected to the bed control system 910 to enable a user to at least partially control the bed control system 910. The bedside controller 932 includes input devices (e.g., keyboards, buttons, switches, etc.) for receiving user inputs that control various settings of the bed control system 910 (e.g., articulation position, temperature settings, air chamber pressure settings, etc.). The bedside controller 932 may also include output devices (e.g., displays, speakers, etc.) for outputting the status and condition of the bed control system 910 as well as other information useful to the user, such as articulation position, temperature settings, air chamber pressure settings, sleep analysis results, etc. The same or similar functionality may be implemented with a mobile computing device 934 (e.g., a mobile device running a dedicated software application). For example, the user may control various settings of the bed control system 910 (such as articulation position, temperature settings, air chamber pressure settings, etc.) using the mobile device as an input device, and further use the mobile device as an output device to view the status and condition of the bed control system 910 as well as other useful information (such as articulation position, temperature settings, air chamber pressure settings, sleep analysis results, etc.).

Still referring to fig. 14, the system 900 may include a server system 940 connected to the local bed system 901 and configured to provide one or more services associated with the bed 902. The server system 940 may be connected to the local bed system 901 (such as the bed 902, the bed control system 910, and/or the control device 930) via a network 942. The server system 940 may be in various forms, such as a local server system with one or more computing devices dedicated to one or more beds, or a cloud server. Network 942 is an electronic communications network that facilitates communications between local bed system 901 and server system 940. An electronic communication network is a group of computing devices and links between computing devices. Computing devices in a network use links to enable communication between computing devices in the network. Network 942 may include routers, switches, mobile access points, bridges, hubs, intrusion detection devices, storage devices, stand-alone server devices, blade server devices, sensors, desktop computers, firewall devices, laptop computers, handheld computers, mobile phones, and other types of computing devices. In various embodiments, network 942 includes various types of links. For example, the network 942 includes wired and/or wireless links. Further, in various embodiments, the network 942 is implemented on various scales. For example, network 942 may be implemented as one or more Local Area Networks (LANs), metropolitan area networks, subnets, wide area networks (such as the internet), or may be implemented at another scale.

In some implementations, the server system 940 may provide a bed data service that may be used in a data processing system associated with the local bed system 901. The server system 940 may be configured to collect sensor data and sleep data from a particular bed and, when generating the sensor data and sleep data, match the sensor data and sleep data to one or more users using the bed. The sensor data and sleep data and matching data may be stored in a database as bed data 950. The bed data 950 may include user identification data that may be used to identify a user of the bed. The user may include a client, owner, or other user registered with the server system 940 or another service. Each user may have, for example, a unique identifier, user credentials, contact information, billing information, demographic information, or any other technically suitable information. The bed data 950 may include management data that may be used to identify data related to a bed or other product associated with the data processing system. For example, the beds may include products that are sold or registered with a system associated with the server system 940. Each bed may have, for example, a unique identifier, model and/or serial number, sales information, geographic information, shipping information, a list of associated sensors and control peripherals, and the like. In addition, one or more indices stored in the bed data 950 may identify users associated with the beds. For example, the index may record sales of a user's bed, a user sleeping in the bed, and so on.

The bed data 950 may include sensor data that records raw or compressed sensor data recorded by the bed through an associated data processing system. For example, the data processing system of the bed may have a temperature sensor, a humidity sensor, a pressure sensor, and a light sensor. Readings from the sensors, either in raw form or in a format generated from raw data of the sensors (e.g., sleep metrics), may be communicated by the data processing system of the bed to the server system 940 for storage in the bed data 950. Additionally, one or more indices stored by server system 940 can identify a user and/or bed associated with the sensor data. In some implementations, the server system 940 can use any of its available data to generate advanced sleep data. Advanced sleep data includes sleep metrics and other data generated from sensor readings.

For example, advanced sleep data may include sensed mattress surface temperature values and/or sensed mattress surface humidity values. Using these values, server system 940 may determine the amount of ambient air and/or conditioned air to be delivered through mattress 904 to maintain an optimal or desired temperature of mattress 904 (e.g., the desired temperature may be determined by a user, by server system 940, and/or by any of the other systems described with reference to fig. 14). The server system 940 may also determine/estimate the body temperature of the user based on the sensed mattress surface temperature values and/or humidity values. One or more of these calculations may be performed locally on the data processing system of the bed. However, performing such calculations in server system 940 may be advantageous because the calculations may be computationally complex or require a large amount of storage space or processor power not available on the data processing system of the bed. This may help allow the bed system to operate with a relatively simple controller and still be part of a system that performs relatively complex tasks and calculations.

The sensed temperature values and/or airflow adjustment determinations may also be transmitted to the bedside controller 932 and/or the mobile computing device 934. Based on these values and the airflow adjustment determinations, the user may selectively moderate, adjust, and/or alter the airflow or desired temperature through mattress 904.

Additionally or alternatively, server system 940 may provide sleep data services that may be used in data processing systems that may be associated with local bed system 901. In this example, server system 940 is configured to record data related to the user's sleep experience and store the data as sleep data 952. Sleep data 952 may include pressure sensor data related to the configuration and operation of pressure sensors in the bed. For example, the pressure sensor data may include an identifier of the type of sensor in a particular bed, their settings, calibration data, and so forth. Sleep data 952 may include pressure-based sleep data that may be calculated based on raw pressure sensor data and that represents sleep metrics that are particularly associated with the pressure sensor data. For example, the presence, movement, weight change, heart rate, and respiration rate of the user may be determined from raw pressure sensor data. Additionally, one or more indices stored by server system 940 may identify a user associated with pressure sensors, raw pressure sensor data, and/or pressure-based sleep data. Sleep data 952 may include pressureless sleep data that may be calculated based on other data sources and represent sleep metrics obtained from those other data sources. For example, user-entered preferences, light sensor readings, and acoustic sensor readings may all be used to track the sleep data 952. Additionally, one or more indices stored by the server system 940 may identify users associated with other sensors and/or non-pressure sleep data 952.

Additionally or alternatively, server system 940 may provide user account services that may be used in a data processing system associated with local bed system 901. For example, server system 940 may record a list of users and identify other data related to those users and store those data as user account data 954. User account data 954 relates to users of beds having associated data processing systems. For example, the user may include a client, owner, or other user registered with the server system 940 or another service. Each user may have, for example, a unique identifier, user credentials, demographic information, or any other technically suitable information. User account data 954 may include engagement data (engagement data) that may be used to track user interactions with manufacturers, suppliers, and/or administrators of the bed and/or cloud services. The engagement data may include communications (e.g., emails, service calls), data from sales (e.g., sales receipts, configuration logs), and social network interactions. The user account data 954 may include usage history data related to user interactions with one or more applications and/or remote controls of the bed. For example, the monitoring and configuration application may be allocated to run on, for example, control device 930. The application may record and report user interactions for storage. Additionally, one or more indexes stored by the server system 940 may identify the user associated with each log entry.

Additionally or alternatively, server system 940 may provide an environmental service that may be used in a data processing system associated with local bed system 901. For example, the server system 940 may record data related to the user's home environment and store such data as environment data 956. Environmental data 956 may be obtained using one or more sensors mounted in or around the bed. Such sensors may be of various types capable of detecting environmental variables, such as light sensors, noise sensors, vibration sensors, thermostats, and the like. The environmental data 956 may include historical readings or reports from these sensors. For example, light sensors are used to collect data indicating the frequency and duration of instances of increased illumination as the user sleeps.

Fig. 15 illustrates another fan assembly 1110 integrated into another example mattress system 1500. Mattress system 1500 may be part of bed system 100 described with reference to fig. 1. For example, the components 1106, 1122, and 1110 may replace the components 106, 110, and 122 in the mattress 101 of fig. 1. Mattress system 1500 may be similarly configured as other examples of mattress systems described herein. Further, the fan assembly 1110 may be similarly configured as other examples of fan assemblies described herein. More specifically, mattress system 1500 may include top layer 102, brace structure 1106, bottom layer 108, and an air chamber. In this example, the integrated fan assembly 1110 may be disposed (e.g., positioned) at the foot end of the strut structure 1106. As described herein, the fan assembly 1110 may be received in a recess of the foot end of the brace structure 1106. Thus, the fan assembly 1110 may not interfere with other components of the mattress system 1500, such as the bottom layer 108, the air plenum, and/or the top layer 102. The fan assembly 1110 may also be mounted to the air tube hose 111 (e.g., fig. 16). As described herein, air tube hose 111 may extend from an air flow insert pad 1122 in mattress system 1500. In some embodiments, at least a portion of hose 111 may be made of a silicon material and configured to fit around an air opening (e.g., air inlet 1710 in fig. 19) of fan assembly 1110. The fan assembly 1110 may then draw air from the airflow insert pad 1122 and expel the drawn air into the foot end of the strut structure 1106.

The fan assembly 1110 may be similar (e.g., in function) to the fan assembly 110 described throughout this disclosure. For example, the fan assembly 1110 may be configured to draw or suck air from the mattress system 1500. In other examples, the fan assembly 1110 may also be configured to push air into the mattress system 1500 (e.g., ambient air or cooling/conditioning air), which facilitates cooling the top surface of the mattress system 1500. In still other examples, the fan assembly 1110 may be configured to push heated air into the mattress system 1500 to heat a top surface of the mattress system 1500. Thus, the fan assembly 1110 may be arranged to draw air into the mattress system 1500 and circulate air in the mattress system 1500, thereby helping to control the microclimate at the top surface of the mattress 1500.

Fig. 16 is a bottom perspective view of a mattress system 1600, showing the mattress system 1600 inverted. Mattress system 1600 may be mattress system 1500 depicted and described with respect to fig. 15. Mattress system 1600 may also include some similar or identical components to mattress system 200 depicted and described in fig. 2. For example, the mattress system 1600 may include a top layer (e.g., a first layer) 202, a middle layer (e.g., a second layer) 204, and a bottom layer (e.g., a third layer) 208, which are not shown in fig. 16. The middle layer 204 may include an air flow insert pad 1122 as shown in fig. 15. The air flow insert pads 1122 may each extend a length from the foot end 1207 of the strut structure 1206 toward the head end 1209 of the strut structure 1206. The air flow insert pad 1122 may be inserted a distance from the foot end 1207 of the strut structure 1206 and from the respective right and left sides of the strut structure 1206.

The bottom layer (e.g., bottom layer 108 as shown in fig. 15) may cover the entire bottom of mattress system 1600, from one brace edge to another brace edge (e.g., from the head end edge to the foot end edge of brace structure 1206, and from the right side edge to the left side edge of brace structure 1206). In some embodiments, the bottom layer may also cover the brace structure. In other embodiments, the bottom layer is inserted into the space defined (enclosed) by the brace structure.

As shown in fig. 15, the mattress system 1600 may also include a brace arrangement 1206. The strut structure 1206 is disposed about the perimeter of the mattress system 1600 and is configured to at least partially enclose an air chamber assembly or mattress core. For example, the air chamber assembly may include one or more inflatable air chambers (e.g., see fig. 17). The foot end 1207 of the strut structure 1206 may have a width that is wider than the head end 1209 of the strut structure 1206 opposite the foot end and the left and right sides of the strut structure 1206. In some embodiments, the combined width of the foot end 1207 and the head end 1209 of the strut structure 1206 is the same as the combined width of the foot end 230 and the head end 232 of the mattress 200 (fig. 4). Foot end 1207 may be wider to accommodate placement of fan assembly 1110 in foot end 1207. As described with reference to fig. 15, the fan assembly 1110 may be disposed within the foot end 1207 of the strut structure 1206 and configured to draw air from the airflow insert pad 1122 through the air tube hose 111 and out along the interior of the strut structure 1206 (e.g., along the foot end 1207 of the strut structure 1206). For example, the foot end 1207 defines a cavity 1306, the cavity 1306 configured to receive a fan assembly 1110. Referring also to fig. 19, the cavity 1306 is configured to fully receive the outer housing 1700 of the fan assembly 1110. The cavity 1306 is open to the interior of the mattress such that the air tube 1708 of the fan assembly 1110 extends through the cavity 1306. An air inlet 1710 at the end of the air tube 1708 is exposed outside of the cavity 1306 in the foot end 1207 and is configured to be coupled to the air tube hose 111. The fan assembly 1110 may be positioned at the foot end 1207 of the strut structure 1206 to prevent the fan assembly 1110 from protruding from the mattress system 1600 due to the connection to the air tube hose 111. In addition, fan assembly 1110 is positioned farther from the head of the user of mattress system 1600 such that fan assembly 1110 is quieter in operation. Thus, sound from the fan assembly 1110 does not disturb the user's sleep.

As depicted, the mattress system 1600 may have two fan assemblies 1110 disposed in the foot ends 1207 of the strut structure 1206 and configured and operable to control the microclimate of two independent zones (left and right) at the top of the mattress system 1500. In still other embodiments, mattress system 1500 may have fewer or more integrated fan assemblies.

Fig. 17 is a partially exploded view of the mattress system 1600 of fig. 16, showing the top layer 202, middle layer 204, example air plenum 222, and integrated fan assembly 1110. The air chamber 222 may be arranged to be surrounded by a strut structure 1206.

As depicted, the strut structure 1206 may be disposed on the middle layer 204, or on the top layer 202 without a middle layer, to define a space 211 for at least partially receiving the air chamber 222. As described with reference to fig. 16, the bottom layer 208 may be disposed within the space 211 to cover the entire space 211 and the air chamber 222 within the space 211.

The mattress system 1600 may also include an air flow insert pad 1122 (e.g., a thermal insert), and the air flow insert pad 1122 may be positioned below the top layer 202. In some embodiments, the intermediate layer 204 may define a cutout region or recess to receive the airflow insert pad 1122 therein. The airflow insert pad 1122 may be similar to the airflow insert pad 122 described throughout this disclosure. In the example shown, the air flow insert pad 1122 is disposed between the head and foot of the mattress 1600, partially along the length of the mattress 1600 from the head to the foot. The pad 1122 is disposed closer to the foot of the mattress 1600 than to the head of the mattress 1600 to optimize positioning without reliance on the passage of base holes. For example, the fan assembly may be embedded in foam as described herein. The fan assembly is operable to draw air from the top of the mattress and is designed with sufficient power to expel air from the strut structure of the mattress. This design allows the mattress assembly to be independent of a single foundation and can be used with any type of foundation. In one embodiment, a portion of the brace structure may be thickened to accept the primary structural integrity of the fan assembly and foam mattress assembly. In some embodiments, the fan assembly is placed in the foot of the bed (e.g., in the foot brace of the mattress) and the air chamber is displaced upward toward the head of the bed, thereby reducing the thickness of the head brace. Additional benefits may be provided by placing the fan assembly in the foot stay rather than the head stay. For example, the sound of the fan is farther from the head, reducing the perceived sound level. The air chamber is displaced to a more comfortable and sensitive area of the body (core, head) instead of the feet. Furthermore, where the fan assembly is a cooling only module, the fan assembly may have a relatively small form factor so as to fit within the confines of the mattress.

The airflow insert pad 1122 may be attached to a surface of the space 211 using one or more attachment mechanisms. For example, each corner of the airflow insert pad 1122 may include a hook or loop configured to mate with a corresponding loop or hook on the space 211. Such hook and loop fasteners may provide easy and secure attachment of the airflow insert pad 1122 in the space 211. One or more other attachment mechanisms may be used, including but not limited to adhesives. In other examples, the airflow insert pad 1122 may be interference fit into or received within a cutout region or recess in the intermediate layer 204 without an attachment mechanism. In some embodiments, the airflow insert pad 1122 may be positioned flush with the middle layer 204.

The fan assembly 1110 may be connected to the air tube hose 111 or mounted on the air tube hose 111. As described with reference to fig. 15-16, the fan assembly 1110 may also be at least partially disposed in the strut structure 1206 (at the foot end). In some embodiments, intermediate layer 1122 defines a cut-out region or recess configured to receive air tube hose 111. The air tube hose 111 may be received in the cutout region or recess to be flush with the intermediate layer 1122.

Fig. 18 shows a bottom perspective view of the mattress system 1600 of fig. 16. Unlike the mattress system 200 depicted and described in fig. 4, the mattress system 1600 depicted and described in fig. 18 does not include reinforcing strips (e.g., reinforcing strips 250A-250B in fig. 4). Instead, the foot struts 1230 of strut structure 1206 are thicker than the head struts 1232 and the opposing side struts 234 and 236. Thicker foot braces 1230 may provide additional support for the brace structure 1206 to maintain the shape of the mattress system 1600. Thicker foot braces 1230 may also provide additional support for maintaining the fan assembly 1110 in place such that the brace structure 1206 does not bend and/or the fan assembly 1110 does not protrude from the overall shape of the mattress system 1600. By thickening foot struts 1230, the width of head struts 1232 and opposing side struts 234 and 236 can be adjusted so that existing air chamber assemblies can be positioned in mattress system 1600. For example, the head struts 1232 may be thinned/thinner in width. Accordingly, the air chamber assembly may not have to be sized and/or shaped to fit within the space (e.g., space 211 in fig. 17) defined by the foot 1230, head 1232 and opposing side 234 and 236 struts of strut structure 1206 and defined between the foot 1230, head 1232 and opposing side 234 and 236 struts of strut structure 1206. For example, the air chamber assembly 220 depicted in fig. 3 may be used with both mattress system 200 and mattress system 1600 even if the strut structures 206 of mattress system 200 have struts of the same width and the strut structures 1206 of mattress system 1600 have struts of different widths. In one example, the width of the foot stay may range between 4 inches and 7 inches, and the width of the head stay may range between 1 inch and 4 inches, such that the total width of the foot stay and head stay may be around 8 inches. In this example, each side stay may be maintained at a width of 4 inches.

In some embodiments, the foot struts 1230 may have a maximum width, the head struts 1232 may have a minimum width, and the opposing side struts 324 and 236 may have the same width that is less than the width of the foot struts 1230 and greater than the width of the head struts 1232. As described above, the strut structure 1206 may be sized so as to still allow an existing air chamber assembly to be positioned in the mattress system 1600 without having to be replaced with an air chamber assembly of a different size. In some embodiments, the width of the opposing side braces 234 and 236 may be increased to provide additional support and maintain the brace structure 1206 in the shape of the mattress system 1600.

Fig. 19 is a perspective view of the integrated fan assembly 1110 of fig. 15. As depicted, the fan assembly 1110 includes an outer housing 1700, the outer housing 1700 configured to receive a fan and electronics that can control the operation of the fan. The fan may be positioned in the outer housing 1700. The electronics may include a printed circuit board positioned proximate to the fan and/or near the air outlet 1702 of the fan assembly 1110. The electronics may be connected (e.g., wired and/or wirelessly) to a controller of a bed system (e.g., bed system 100 of fig. 1) and may be configured to control operation of the fan assembly 1110. In some implementations, the electronics may include one or more sensors for measuring temperature, humidity, and/or smoke detection in the fan assembly 1110 and/or near the fan assembly 1110 when positioned in the mattress system 1500 and/or 1600.

The fan assembly 1110 may include an air tube 1708 (e.g., an air delivery channel), the air tube 1708 being fluidly connected to the housing 1700 and configured for airflow into or out of the housing 1700. The housing 1700 and air tube 1708 may define an air inlet and an air outlet. For example, with the fan assembly 110 operating to draw air, the air tube 1708 defines an air inlet 1710 and the housing 1700 defines an air outlet 1702. In an embodiment in which the fan assembly 1110 operates to blow air, the air inlet 1710 of the air tube 1708 serves as an air outlet, and the air outlet 1702 of the housing 1700 serves as an air inlet. One or more components of the fan assembly 1110 depicted and described in fig. 19 may be similar to one or more components of the fan assembly 110 depicted and described in fig. 5.

Fig. 20 illustrates a cross-sectional view of the air flow through the mattress system 1600 of fig. 16, the cross-sectional view taken along the cross-sectional line shown in fig. 22. Fig. 20 illustrates an example airflow 1800 (e.g., exhaust air) through a mattress system 1600. Mattress system 1600 may be similar to mattress system 200 depicted and described with reference to fig. 6. The view of fig. 20 depicts the head and foot struts 1232, 1230 of the strut structure 1206. As described throughout fig. 15-19, the fan assembly 1110 is positioned within the foot struts 1230 of the strut structure 1206.

As shown in fig. 20, an air flow 1800 is directed from the top surface of the mattress system 1600, through the air flow insert pad 1122, and into the fan assembly 1110 via the air tube 1708. The airflow 1800 may then be routed into the housing 1700 of the fan assembly 1110. In some embodiments, the air flow 1800 may also flow through one or more layers of the mattress 1600 to provide air circulation at the top layer 202. By circulating the air flow 1800, the fan assembly 1110 may reduce or moderate the temperature of the mattress 1600 at the top surface of the ticking 140.

Fig. 21 illustrates a side cross-sectional view of the mattress system 1600, taken along the cross-sectional line shown in fig. 22. Fig. 21 depicts an airflow 1800 drawn into the fan assembly 1110, and also depicts exhaust air 1801 from the fan assembly 1110. This side cross-sectional view of the mattress 1600 depicts the shorter foot side of the mattress 1600. Mattress 1600 includes a strut structure 1206 having side struts 234 and 236. The fan assembly 1110 is disposed in a foot strut 1230 (not shown) of the strut structure 1206. In the example shown, the fan assembly 1110 is oriented toward the side struts 234 of the strut structure 1206. Accordingly, air flow 1801 is discharged from fan assembly 1110 toward the same side portion of mattress 1600, thereby lowering the temperature of the top surface of mattress 1600. Alternatively, the fan assembly 1110 may be oriented toward the side struts 236 of the strut structure 1206.

As shown in fig. 21, the fan assembly 1110 may exhaust the air flow 1801 in the same direction. In some embodiments, the fan assembly 1110 may exhaust the air flow 1801 in a different direction (e.g., the fan assembly 1110 of the closest side strut 234 may exhaust the air flow 1801 toward the side strut 234, while the fan assembly 1110 of the closest side strut 236 may exhaust the air flow 1801 toward the opposite side strut 236). As described throughout this disclosure, regardless of the orientation/direction of the fan assembly 1110, the air flow 1801 may be directed into the strut structure 1206 and/or around the strut structure 1206 to effectively adjust the microclimate of the top surface of the mattress 1600.

Fig. 22 is a bottom view of an example mattress system 1600 having the integrated fan assembly 1110 of fig. 15. As depicted, the mattress system 1600 is flipped up and down such that the top surface of the mattress system 1600 is facing down. The depicted mattress system 1600 has a brace structure 1302 and a bottom layer 304, as described throughout this disclosure (e.g., with reference to the brace structure 1206 in fig. 16 and the bottom layer 208 in fig. 2). In some embodiments, as described with reference to fig. 24A-24B, the mattress system 1600 may have an underlayer 1900.

Fig. 23 is another bottom view of the example mattress system 1600 of fig. 22 with integrated fan assembly 1110. In fig. 23, the bottom layer 304 is removed to show details of the strut structure 1302. The stay structure 1302 has a recessed portion 1306. Recessed portion 1306 is configured to receive fan assembly 1110. Foot brace 1304 may include recessed portions 1306, recessed portions 1306 configured to at least partially receive each of fan assemblies 1110. The recessed portion 1306 may be any suitable size to fit the size of the fan assembly 1110. Thus, the fan assembly 1110 may be disposed inside the brace structure 1302 such that the fan assembly 1110 does not interfere with one or more other components of the mattress system 1600. This configuration also facilitates preventing placement of fan assembly 1110 from interfering with one or more other components of mattress system 1600 that are disposed at or about a medial axis of mattress system 1600 (e.g., medial axis 310 described with reference to fig. 8-10).

Recessed portion 1306 may have a predetermined width W1 adapted to receive at least a portion of fan assembly 1110. The predetermined width W1 may be large enough to maintain adequate airflow and space for mounting the fan assembly 1110 while also being minimal in size to minimize discomfort that may occur due to too wide an opening. The width W1 may depend on the length of the thermic module. For example, the width W1 may be greater than the length of the thermal module (e.g., 1 inch or more). In some embodiments where the length of the thermic module is 8.5 inches, the width W1 may be 9.5 inches or greater.

In some embodiments, recessed portions 1306 may be arranged in one or more different configurations to facilitate or direct airflow (e.g., exhaust air) from fan assembly 1110. As shown in fig. 23, recessed portion 1306 may be arranged such that fan assembly 1110 may direct air toward the same side strut of strut structure 1302. As another example, the recessed portions 1306 may be arranged in opposite directions such that the two fan assemblies 1110 direct air toward opposite side struts of the strut structure 1302. In some embodiments, each recessed portion 1306 may be arranged in an opposing configuration such that the fan assembly 1110 on the right side of the mattress system 1600 may direct air toward the right side brace of the brace structure 1302 and the fan assembly 1110 on the left side of the mattress system 1600 may direct air toward the left side brace of the brace structure 1302. In some embodiments, each recessed portion 1306 may be arranged toward each other such that two fan assemblies 1110 direct air inwardly toward a midpoint of foot stay 1304 of stay structure 1302. In still other embodiments, at least one of the recessed portions 1306 may be disposed inwardly toward a midpoint of the foot stay 1304 of the stay structure 1302. Further, in some embodiments, an air tube of the fan assembly 1110 (e.g., air tube 1708 in fig. 19) may extend out from the foot strut 1304 of the strut structure 1302.

Fig. 24A-24B illustrate bottom views of an underlayer 1900 of an example mattress system 1901 having the integrated fan assembly of fig. 15. Mattress system 1901 may be the same as or similar to mattress systems 1500 and 1600. In some embodiments, the bottom layer 1900 may be part of the mattress system 200 described herein.

24A-24B, a bottom layer 1900 (e.g., a base pad) may cover the entire bottom of the mattress system 1901, the mattress system 1901 including a top layer (e.g., a first layer, such as layer 202) 1902, an intermediate layer (e.g., a second layer, such as layer 204) 1904, and a brace structure 1906 (e.g., brace structures 206 and/or 1206). The bottom layer 1900 may be made of a material having some air permeability to provide sufficient air flow rate to regulate the microclimate at the top surface of the mattress system 1901. The fan assemblies described herein (e.g., fan assembly 110 and fan assembly 1110) may also route the airflow through the entire mattress system 1901 sufficiently to overcome features of the bottom layer 1900 that might otherwise interfere with the ability to adjust the microclimate and achieve the desired cooling at the top surface of the mattress system 1901. The foot of the bed is configured to have sufficient ventilation to vent air through the foot struts without any ventilation of the base. Thus, for example, the bottom layer 1900 can be made of various types of materials (e.g., gas impermeable materials, materials having minimal gas permeability, etc.). In some embodiments, the bottom layer is made to have little ventilation so that air leaves the vertical surface at the foot of the bed. Further, the fan assemblies described herein may route the airflow sufficiently through/around the strut structure 1906 and the bottom layer 1900 without requiring the exhaust openings (e.g., recessed portions 1306) to extend out of the strut structure 1906 and into the surrounding environment.

Still referring to fig. 24A-24B, the bottom layer 1900 may be formed from multiple pieces. For example, the bottom layer 1900 may be divided longitudinally down the midpoint of the bottom layer 1900 to have a first tab 1900A and a second tab 1900B, respectively. Each of the flaps 1900A and 1900B may be individually unfolded/folded back from the midpoint of the mattress system 1901 to access the components of the mattress system 1901 described throughout this disclosure. Such a configuration may be advantageous to allow the mattress system 1901 to be opened to assemble, maintain, and/or repair/replace one or more components of the mattress system 1901. Each of the flaps 1900A and 1900B can also be attached (e.g., laminated, adhered) to a respective side stay of the stay structure 1906. In some embodiments, the flaps are attached to the struts using foam lamination. For example, for lamination to the head and foot braces, glue (e.g., 3-4 inches) would be present along the glue path created by the side braces. This allows the head/foot braces to have a partial lamination with the base pad. Flaps 1900A and 1900B of bottom layer 1900 may not be laminated or otherwise attached to the head and foot struts of strut structure 1906 to ensure that flaps 1900A and 1900B may be opened or closed individually.

In some embodiments, the bottom layer 1900 can also include openings 1908A and 1908B (e.g., cuts, cavity ports, etc.) on the respective flaps 1900A and 1900B. Openings 1908A and 1908B may be positioned toward a midpoint of mattress system 1901 (e.g., buttocks (hip) of the bed). In some embodiments, openings 1908A and 1908B may be offset some predetermined distance relative to the midpoint of mattress system 1901. Further, openings 1908A and 1908B may be positioned where air tube hoses may be attached to the air chambers of mattress system 1901, such that all or some of the wires/cables may be maintained together in a centralized location and routed therefrom to the power supply and/or controller for mattress system 1901 and/or the bed system. Accordingly, openings 1908A and 1908B may be configured to receive wires/cables routed to and from components in bed system 1901 (e.g., fan assemblies, air plenums, etc.). For example, wires/cables connected to the outer housing of the fan assembly may be routed (e.g., wired in a harness or not bundled) from the foot brace of the brace structure 1906 to a midpoint of the mattress system 1901 (e.g., the buttocks of the bed) along one of the foot brace and the side brace of the brace structure 1906.

As an illustrative example, the wires may be routed along the foot brace to a position where the flaps 1900B are folded back from the respective side braces of the brace structure 1906. One or more wire management loops (wire management loop) may be used to secure the wires along one or more portions of the brace structure 1906. The loop may prevent the wires from moving out of their intended position within the mattress system 1901 when the mattress system 1901 is transported (e.g., to the user's home), when the user sits on the edge of the mattress system 1901, and/or when the mattress system 1901 is lifted off the base/foundation of the bed system. The loops may be secured to the respective side struts of strut structure 1906 (and/or portions of the foot struts of strut structure 1906) using an adhesive (e.g., a foam gel between the bottom layer 1900 and the respective side struts of strut structure 1906) and/or hook and loop fasteners (e.g., micro hooks adhered to the respective side struts and fabric attached to the micro hooks). One or more other attachment mechanisms may also be used to attach the wire management loop to the mattress system 1901.

One or more wire management loops may be attached to each side of mattress system 1901. For example, the ring may be configured at a corner of the strut structure 1906 where the foot strut means the right side strut of the strut structure 1906 (and where the foot strut meets the left side strut). Such a location may be advantageous to ensure that the wires do not shift or move toward the center of the mattress system 1901, thereby interfering with other components in the mattress system 1901. Further, such a location may be advantageous to ensure that stresses experienced on the fan assembly due to use and/or movement of the mattress system 1901 may be relieved. One or more additional wire management loops may be placed along the length of the side struts up to the respective openings 1908A or 1908B. In some embodiments, a wire management loop may not be used. Alternatively, the wires may be directly attached to the mattress system 1901 with adhesive, hook and loop fasteners, and/or one or more other types of attachment mechanisms.

The wires may then be tucked between the respective side struts of the strut structure 1906 and the flaps 1900B of the bottom layer 1900 up to the respective openings 1908B. The wires may then be routed through the respective openings 1908B. Thus, the wires may be incorporated and maintained in one location, thereby providing an aesthetically pleasing appearance, and also providing convenience to the user and/or technician of the mattress system 1901 when setting up and maintaining the mattress system 1901. In other words, when the mattress system 1901 is manufactured and before the mattress system 1901 is shipped to a user, electrical wires from the fan assembly may be routed along the side struts of the strut structure 1906 and out through the respective openings 1908A and 1908B. Maintaining the wires in one location may be advantageous to ensure that the mattress system 1901 is easily located in the user's home. The shipping technician or user may not need to connect wires between/among one or more components of the mattress system 1901. Instead, the wires may already be connected to the components and thus remain in a concentrated position (e.g., at openings 1908A and 1908B). The wires may also be maintained at openings 1908A and 1908B when mattress system 1901 is used in a user's home, such that the wires do not protrude from the cover of mattress system 1901 or otherwise interfere with the comfort of the user of mattress system 1901 or the aesthetic appearance of mattress system 1901.

The features of the integrated fan assembly described herein may be applied to various types of mattress systems. In some embodiments, the fan assemblies described herein may be integrated into a mattress without an air chamber. For example, the fan assembly may be integrated into a mattress that includes a spring assembly, foam material, or any suitable support material without an inflatable air chamber. The fan assembly may be installed within such a mattress in the same or similar manner as described herein (e.g., by at least partially inserting the fan assembly into a cutout region of a brace structure). In other embodiments, the fan assembly may be mounted to any suitable location within the mattress other than the brace structure of the mattress. In some cases, the mattress system may not include a brace arrangement. Instead, the mattress system may include materials that form the main components of the mattress, such as springs, foam, or another support material. In such mattress systems, the fan assembly (e.g., fan assembly 110 and/or fan assembly 1110) may be integrated into or otherwise received in a recessed portion of the material of the mattress system. For example, the mattress system may be composed of foam material. The recessed portion (e.g., opening) may be cut into the foot end of the foam material of the mattress system near the edge of the foot end. The fan assembly may then be placed in the recess (e.g., opening) to provide a mattress system with similar or identical functionality to the fan assembly described herein. As another example, the mattress system may be comprised of springs. A recessed portion may be formed near the foot end of the mattress system in which a fan assembly may be placed to provide the mattress system with similar or identical functionality to the fan assembly described throughout this disclosure. One or more other configurations and/or placements of the fan assembly may be used to incorporate the fan assembly into a mattress system that does not include a brace structure and/or an air plenum.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of the disclosed technology or of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of particular disclosed technology. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment, either in part or in whole. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described above as acting in certain combinations and/or even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations may be described in a particular order, this should not be construed as requiring that the operations be performed in a particular order or sequence, or that all operations be performed, to achieve desirable results. Specific embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims.

Claims

1. A mattress, comprising:

a first layer having a first layer top and a first layer bottom;

a head stay attached to the first layer bottom;

a foot brace attached to the first layer bottom and defining a first recessed portion; and

a first air module configured to generate an air flow between the first layer top and the first layer bottom, the first air module positioned in the first recessed portion of the foot stay.

2. The mattress of claim 1, further comprising:

a first side strut extending longitudinally and connecting a first edge of the head strut with a first edge of the foot strut;

a second side strut opposite the first side strut, the second side strut extending longitudinally and connecting a second edge of the head strut with a second edge of the foot strut; and

one or more additional layers positioned below the first layer bottom between the first side stay and the second side stay, wherein the one or more additional layers comprise:

A core, and

a second layer positioned below the core and covering the core between the first side struts and the second side struts.

3. The mattress of claim 2, further comprising a thermal layer attached to the first layer bottom, wherein the thermal layer is (i) configured to extend longitudinally a first distance between the head strut and the foot strut, and (ii) offset a second distance relative to at least one of the first side strut and the second side strut.

4. A mattress according to claim 3 wherein the thermal layer is positioned closer to the foot struts of the mattress than the head struts of the mattress.

5. The mattress of claim 3, further comprising an air tube hose configured to fluidly connect the first air module to the thermal layer.

6. The mattress of claim 5, wherein the first air module is configured to draw air from the thermal layer through the air tube hose and expel the drawn air into the foot brace.

7. The mattress of claim 2, wherein the first air module is configured to draw air from the first layer and direct exhaust air into the foot struts and toward the first side struts of the mattress.

8. The mattress of claim 2, wherein the first air module is configured to draw air from the first layer and direct exhaust air into the foot struts and toward the second side struts of the mattress.

9. The mattress of claim 1, wherein the first air module is configured to draw air from the first layer and direct exhaust air into the foot struts of the mattress.

10. The mattress of claim 1, wherein the first recessed portion is configured to at least partially receive the first air module.

11. The mattress of claim 1, wherein the first air module comprises:

a housing defining an air inlet and an air outlet; and

a fan assembly enclosed in the housing and configured to draw in air through the air inlet and supply exhaust air through the air outlet.

12. The mattress of claim 11, wherein the first air module comprises:

an electrical cord electrically connected to the fan assembly and extending from the housing, the electrical cord configured to be electrically connected to a power source external to the mattress and to supply power to the fan assembly.

13. The mattress of claim 1, further comprising:

a second recessed portion defined in the foot brace adjacent to the first recessed portion; and

a second air module configured to generate an air flow and positioned within the second recessed portion of the foot stay.

14. The mattress of claim 13, wherein the second air module is configured to draw air from the first layer and direct exhaust air in the foot struts in the same direction as exhaust air directed by the first air module.

15. The mattress of claim 13, wherein the second air module is configured to draw air from the first layer and direct exhaust air in the foot struts in a different direction than exhaust air directed by the first air module.

16. The mattress of claim 1, wherein the first air module defines an air outlet configured to vent air into the foot struts of the mattress.

17. The mattress of claim 1, wherein the first air module is configured to draw air from the first layer and direct exhaust air into the foot struts toward an interior of the mattress.

18. The mattress of claim 1, further comprising a bottom layer positioned below the first layer, wherein the bottom layer extends from the head strut of the mattress to the foot strut of the mattress, the bottom layer including a first portion and a second portion extending laterally between the head strut and the foot strut along a predetermined axis of the bottom layer.

19. The mattress of claim 18, wherein the first and second portions of the bottom layer are laminated to respective first and second side struts of the mattress, and the first and second portions are configured to open from the predetermined axis of the bottom layer to expose at least a portion of the first air module in the first layer, the head struts, the foot struts, and the recessed portions of the foot struts of the mattress.

20. The mattress of claim 18, wherein the bottom layer includes first and second openings in respective first and second portions of the bottom layer, the first and second openings configured to route electrical wires from at least the first air module along at least one side of the mattress.

21. A mattress, comprising:

a first foam layer having a top surface and an opposing bottom surface;

an inflatable chamber positioned below the bottom surface of the first foam layer;

a foam strut structure comprising a head portion, a foot portion, and first and second side portions, the foam strut structure extending from a perimeter of the first foam layer around a perimeter of the mattress and configured to enclose the inflatable chamber;

a mattress bottom covering the inflatable chamber, and

an air source configured to generate an air flow and positioned below the inflatable chamber, above the mattress bottom, and in the foot portion of the foam strut structure.

22. The mattress of claim 21, wherein the air source is a first air module.

23. The mattress of claim 22, further comprising:

a second foam layer positioned below the inflatable chamber and covering at least a portion of the inflatable chamber between the head portion, the foot portion, and the first and second side portions of the foam strut structure,

Wherein the air source is configured to draw air from the second foam layer and direct exhaust air into the foot portion of the foam strut structure.

24. The mattress of claim 21, wherein the air source is configured to draw air from the first foam layer and direct exhaust air into the foot portion of the foam strut structure and toward the first side portion or the second side portion of the foam strut structure.

25. The mattress of claim 21, wherein the foot portion of the foam strut structure defines a first strut recess configured to receive the air source.

26. The mattress of claim 21, wherein:

the foot portion of the foam strut structure has a first width,

the head portion of the foam strut structure has a second width,

the first and second portions of the foam strut structure have a third width, and

the first width is greater than the second width and the third width, and the second width is less than the third width.

27. The mattress of claim 21, wherein the air source comprises:

a housing defining an air inlet and an air outlet;

a fan assembly enclosed in the housing and configured to draw in air through the air inlet and supply exhaust air through the air outlet;

one or more sensors configured to generate signals representative of at least one of temperature, humidity, and flame;

a controller included in the housing, the controller configured to control operation of the fan assembly and to receive signals from the one or more sensors; and

an electrical cord electrically connected to the controller and the fan assembly, wherein the electrical cord extends from the housing and is configured to electrically connect to a power source external to the mattress and supply power to the controller and the fan assembly.

28. The mattress of claim 21, wherein the inflatable chamber is a mattress core.