GB2567163A - Support appliance - Google Patents

Abstract

A support device 1 having a padded structure for supporting a person and a thermally conductive flexible metallic sheet 2 extending to multiple regions thereof. The sheet 2 is positioned to receive thermal energy from a user and conduct heat to the multiple regions. The metal sheet 2 may be copper, a foil, or woven wires and may have perforations. Heat can be distributed between multiple users or to a user’s feet. The sheet 2 may be a composite of thermally connected parts. The sheet may have multiple polygonal regions 3, 4 thermally connected by pathways 5. There may be a region acting as a heat sink to dissipate heat away from a user, being thermally disconnectable from other regions of the sheet 2 and located on a sidewall of the device 1. The device 1 may be a mattress, a mattress topper or a blanket for a chair. Also provided is a method of manufacturing a support device of providing a thermally conductive flexible metallic sheet as a layer in a mattress or composite sheet and having a cover.

Description

Support Appliance

This invention relates to support appliances such as mattresses, mattress coverings, chair coverings or the like, as may be used to support a person in a lying or sitting position. More particularly, it relates to such support appliances that seek to control or influence the temperature of the person being supported.

Beds typically comprise of a mattress and sheets, along with a covering duvet or further sheets or blankets The mattresses tend to be thermally insulated to prevent the occupant of the bed from getting cold from downwardly directed heat loss. The degree of insulation will vary dependent upon the mattress type and quality, and also whether it is being used in a hot or colder climate. A person sleeping in the bed generally lies on a sheet covering the mattress, with sheets, blankets or duvets covering them. This can provide good thermal insulation, keeping the person warm even in a cold room. However, sometimes it can keep a person too warm, particularly on warm nights.

Mattresses exist that have cooling networks, such as a network of water pipes running through them. However, such mattresses require a power source to pump the cooling liquid - typically water - around the network. There is also a risk of leakage.

It is a common complaint, particularly among older people, that they have difficulty in keeping their feet warm when in bed. Heated blankets can be used to alleviate this, but these require a source of power (and hence money) to run, and also may end up overheating the occupant. Also, if they have cold feet but their torso is warm, then a heated blanket will tend to overheat them.

It is an object of the present invention to provide an alternative means for thermally regulating a person using a mattress, or mattress covering or the like.

According to the present invention there is provided a support appliance comprising a padded structure for supporting a person, wherein the appliance has a thermally conductive flexible metallic sheet positioned to have thermal communication with a user of the appliance, and wherein the thermally conductive metallic flexible sheet extends to different regions of the appliance to conduct heat to different parts thereof.

Embodiments ofthe invention therefore provide a support appliance that is able to distribute body heat of an individual to places other than where it is generated. For example, when the appliance is a mattress or mattress cover, it can take heat from one part of the body, and help to move it to other parts or to different regions. In contrast to this, a regular mattress tends to keep heat in places where it is generated, due to the thermally insulating nature of the materials used.

The metallic flexible sheet advantageously sits under a soft cloth material, such as cotton or the like, where it is removed from direct contact with a person using the product, but which is close enough to the person to take heat produced by the body.

Advantageously, the thermally conductive flexible sheet comprises a metal foil such as a thin metal sheet, or woven material made from metal wires. Such materials are flexible, and so do not have significant impact on the comfort of the appliance, whilst also having a good thermal conductivity.

Preferably the metal is copper. This is relatively inexpensive whilst having excellent thermal properties. Copper also has useful anti-microbial properties, and thus its presence in the appliance, close to the surface, helps to maintain a healthy environment where the appliance is used. Other materials may be used, such as aluminium, or other metals (including metal alloys or metallic composite materials) as would be appreciated by a normally skilled person.

Advantageously, the flexible metallic sheet has perforations or gaps that allow moisture to pass through. A woven material will tend to have such gaps inherently due to the nature of the material, but such gaps may be formed or otherwise arranged to exist if the weave is particularly tight. A foil, or other generally homogeneous material may have perforations or holes cut, pressed or otherwise formed therein to allow moisture to pass. This allows the product to breathe, as a user sweats, as is the case with e.g. common mattresses, and so helps to prevent an uncomfortable built up of damp on or near the mattress surface.

The flexible metallic sheet may cover substantially the whole of an area ofthe appliance. Alternatively, and preferably, it may only cover one or more selected regions. The regions may be tailored to coincide with the expected body length and general position adopted by a typical user

The flexible metallic sheet may advantageously be shaped, to coincide with the general mass distribution of a user, or with different positions a user is likely to adopt. Thus for example it may comprise a plurality of main regions, such as a larger region where the torso is expected to lie, and a smaller region where the feet are expected to lie, with the main regions being connected by connecting parts such as strips or bands of the metallic flexible sheet to allow heat to conduct between them. The strips may in some embodiments be narrower than the main regions, or may in some embodiments be of the same width. Thus body heat from a torso may be readily conducted down to where the feet are. The regions may in some embodiments be chosen to be symmetrical so that similar thermal performance is obtained whether the appliance is used in a first orientation, or in a second, e.g. 180° rotated orientation. Thus e.g. on a mattress, it enables the mattress to be turned around at intervals to even out wear upon it. The main regions may be formed as squares, rectangles or other polygons, e.g. generally chosen to match the general form of a body lying or sitting on the regions. Other forms will be readily apparent, such as a single rectangular strip running at least a portion of the mattress or covering, or one or more ellipses or generally elliptical or circular regions.

The flexible metallic sheet may be formed from a single piece of material, e.g. from a single piece of foil or woven metallic strands,, or may be formed from a plurality of pieces that are joined together in a manner that allows heat to transfer by conduction readily between them. They may be, for example, welded, soldered, clipped, pressed, folded, glued, screwed or otherwise attached together. Advantageously, a thermally conductive compound, such as a heat-sink compound, may be used in some embodiments when sheets of conductive material are attached together.

Where the appliance is designed for more than one user, such as a double-size mattress, then the flexible metallic sheet may in some embodiments be arranged to extend from a region normally occupied by a single user into a region normally occupied by a second user. Thus, the metallic sheet may bridge between regions occupied by multiple users. In this way, the heat from one person may, through conduction through the metallic sheet, be shared with a second person.

Some embodiments of the invention therefore facilitate the distribution of body heat around a bed or chair etc., to provide a more uniform thermal distribution throughout the appliance, e.g. to help keep extremities warm or to share heat between multiple people. Some embodiments may, alternatively, or as well, be arranged to take body heat and to dissipate it away from the user(s) of the appliance. To this end, some embodiments may have a dissipative region of the flexible sheet adapted to dissipate heat away from a body area of a user. Such a dissipative region may be located, for example, on one or more sidewalls such as, in a mattress or the like, an end of the appliance, where the appliance is a mattress, Thus the dissipative region acts as a heat sink, that dissipates heat into the atmosphere or otherwise away from the occupant.

Such a dissipative region may be mainly of use e.g. in the summer months when it can get too hot in a bed. It may not be desirable to have such a dissipative means present throughout the year, in environments where the winters are cold. Thus some embodiments may have a dissipative region that is disconnectable from the remaining part of the flexible sheet, such that, in a disconnected state, there is little or no conduction of heat between it and the remaining part of the flexible sheet. It may be arranged e.g. to detachably clip or otherwise attach on to the remaining part of the flexible sheet. The dissipative region may be arranged to remain in-place within the appliance when in the disconnected state, if, for example, it is formed as an integral part of the appliance. Alternatively, the dissipative region may be completely detachable from the appliance, so that it may be stowed away when not in use.

The support appliance may be a mattress, such as is commonly found on a bed. Alternatively, it may be a mattress cover, that in use sits upon a regular mattress, and has a flexible metallic thermally conductive sheet formed as a part of it. Advantageously, such a mattress cover has the conductive sheet located below a cloth covering, which provides a traditional feel to a user. Thus, the mattress cover may take the form of a composite sheet.

Advantageously the thermally conductive flexible sheet is attached to a neighbouring layer, to prevent it from moving around, out of place, over time, or folding up upon itself. It may be, for example, stitched or glued in place, or held by another suitable means.

The support appliance may form an element of a chair, such as a medical chair, an orthopaedic chair or the like, and is particular suited to use where such a chair is occupied by a user for a significant amount of time. It may also take the form of a composite (i.e. multiple-layered) sheet or blanket that may be fitted or laid onto a regular chair. It may be used, for example, to help maintain body heat in a user’s extremities, or, with the aid of a dissipative region, to keep the occupant cool, as required.

Thus, the support appliance may, but need not, comprise of a rigid mechanical structure for supporting a person. It may act as a support in the sense of comprising a surface region upon which a person may lie or sit, that may benefit from a rigid support structure from some other item.

According to a second aspect of the present invention there is provided a method of manufacturing a support appliance comprising the steps of:

a) taking a partially manufactured mattress or composite sheet;

b) Adding to it one or more thermally conductive flexible metallic sheets in a layered fashion;

c) providing at least one cloth covering over the thermally conductive flexible sheet of a thickness that allows thermal communication between it and a user.

The method advantageously further includes the step of fastening the thermally conductive flexible sheet to a neighbouring layer.

Embodiments of the invention are further described hereinafter, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 diagrammatically illustrates an embodiment ofthe invention, comprising a single mattress in plan view with a thermally conductive metallic flexible sheet embedded therein;

Figure 2 diagrammatically illustrates a further embodiment ofthe invention, comprising a single mattress in plan view with an alternative form of a thermally conductive metallic flexible sheet embedded therein;

Figure 3 diagrammatically illustrates three further embodiments of the invention as may be employed in a double mattress, shown in plan view;

Figure 4 shows a layered structure of a part of a mattress, with a thermally conductive metallic layer forming a part of the structure;

Figure 5 diagrammatically illustrates a further embodiment of the invention comprising a mattress that utilizes a dissipative region; and

Figure 6 diagrammatically illustrates a further embodiment comprising an underblanket with a metallic layer sandwiched between a lower insulating layer and an upper cloth layer.

As shown in Figure 1, a single mattress 1 has embedded therein a flexible, thermally conductive sheet 2 made from a single sheet of copper foil. The mattress 1 is a sprung mattress with a layered arrangement of cushioning and insulation (not shown) that sits atop a set of springs. Within the layered arrangement is located the flexible conductive sheet 2 The conductive sheet 2 is positioned beneath a cloth mattress cover and a thin foam layer (not shown). A thicker, thermally insulating layer is positioned beneath the copper foil 2. The mattress cover and thin foam layer provide a comfortable feel to a user, whilst also allowing body heat to be transferred to the copper foil 2 from someone lying on the mattress.

The copper foil is arranged to have a first main region 3 located to sit beneath the torso of a user of the mattress. A second main region 4 of the copper foil is positioned where the feet of a user would normally rest when the mattress is in use. The first 3 and second 4 main regions are connected by a wide foil band 5, that acts to transfer heat, by means of conduction, between the regions 3, 4.

In use, the mattress will generally be covered by a thin sheet, and an occupant will lie upon this thin sheet. Body heat from the occupant will conduct through the relatively thin layers between themselves and the first main region 3 of the copper foil 2 The copper foil is an excellent conductor of heat and thus the heat within the copper foil in the main region 2 will tend to spread along the connecting band 5 to the second main region 4, where the occupant’s feet will generally be. Thus, the body heat from the occupant is effectively spread, by conduction, towards their feet. Note that that copper foil will not be visible to a normal user of the mattress - it is indicated as shown for clarity, and the copper foil (or, dependent upon the embodiment, other metallic, thermally conductive layer) sits underneath an upper covering on the mattress. This is also the case in general with the remaining embodiments disclosed, except where stated.

Figure 2 shows a further embodiment of the invention, with a mattress 10 having embedded therein a metallic conductive sheet 11. The conductive sheet 11 is formed from a copper weave, comprising thin copper wires woven into a sheet material. The conductive sheet is again arranged to sit within an upper layer of the mattress 10, so that it is physically close to the surface, and thus able to readily absorb and provide heat distribution to an occupant in similar fashion to that as described in relation to Figure 1. The layout of the copper weave again has first and second main regions, 12, 13, this time connected by a pair of connecting bands 14, 15. This has a wider lateral spread of the conductive sheet, as may be suitable for example with a larger person, although it will be appreciated that the patterning or arrangement of the conductive sheet can differ for this embodiment, as indeed it can for the other embodiments shown herein. The inherent nature of the copper weave material allows moisture to pass through it, so preventing the build-up of sweat on or near the surface of the mattress.

Figure 3 shows three embodiments of the invention as may be used in a double mattress. Figure 3a shows an embodiment comprising a double mattress 20 that has two separate but otherwise identical thermally conductive sheets 21, 22 formed therein. Each conductive sheet sits beneath a cloth mattress cover, and above an insulating material, as described above. The conductive sheets are arranged into main regions as before, with three main regions, 23, 24, 25 (as indicated on the right hand sheet) being shown. The thermal performance of each of the sheets is identical. A first main region 23 sits beneath where the torso of a user of the bed will generally be positioned. Heat emanating from the person’s torso will be absorbed by the region 23, and will conduct, as previously described, to the other main regions 24, 25, to provide the warmth to the person’s extremities, e.g. their feet. Thus, each occupant of the bed distributes their body heat around themselves.

Figure 3b shows a double mattress with an alternative arrangement for a conductive sheet. Here, a mattress 30 has a single conductive sheet 31 that is shared between regions occupied by both users of the mattress. The conductive sheet is divided up into main regions, e.g. 32, 33, 34 as before, connected by connecting bands, e.g. 35, 36. As well as having connecting bands e.g. 35 that connect main regions occupied by a single user, it has connecting bands e.g. 36 that connect to the regions occupied by the other user. Thus, in this embodiment, body heat is shared between users.

Figure 3c shows a third arrangement as may be employed in a double mattress. In this embodiment, a double mattress 40 has a single metallic copper sheet 41 that is divided up into regions as would be normally occupied by two users of the mattress. Each side of the mattress has a first main region e.g. 42 or 46 positioned to absorb heat from a user’s torso, and head (if no pillow is being used) and a second main region e.g. 45 located where the feet normally lie. Connecting band 43 provides a thermal connection between the first and second main regions as would be covered by a first occupant,, and a connecting band 44 connects the first main region to a second main region 45 as would be occupied by a second user. Thus, body heat from the first user goes towards heating up the extremities of the second user, but does not go (in such significant amounts) to heating up the torso of a second user. Likewise, the body heat from the second user goes towards heating the extremities of the first user, but not so much in heating the torso of the first user. Thus the embodiment is more suited to occupants who do not wish to have their torsos heated by the other occupant, but do wish to have their legs and feet heated.

Figure 4 shows a close-up of a part of a mattress, with two upper layers partially peeled back to reveal a metallic foil layer as per an embodiment of the invention. A corner of a mattress 50 is shown. A base 51 contains a set of metal springs that act as a primary physical support for a user. On top of the springs lies a padded, thermally insulating layer 52. A copper foil 53 sits on top of that, which acts to spread localized heat, e.g. from a torso of a user, through to different regions of the mattress, as previously described. A set of perforation 54 can be seen going through the foil. These perforations allow moisture to pass through the foil, to prevent a build-up on or near the surface of the mattress due to sweat etc. The foil is 0.5mm thick, and is fastened to the layer 52 by stitching through some of the perforations. Other embodiments may use an adhesive or other fastening means. A further thin padding layer 55 sits on top of the foil layer, and a mattress outer covering 56 is on top of that. The arrangement allows a body to lie close enough to the thermally conductive layer 53 to allow the transfer of heat therebetween.

Figure 5 shows an embodiment of the invention incorporating a thermally dissipative region, designed to dissipate heat away from the body of a user of the appliance. A part of a mattress 60 is shown, having a top surface 61, and a side 62. Indicated at 63 is a metallic thermal conductor, such as has been disclosed above. The side 62 of the mattress has located thereon, under an outer covering, a copper band 64, wrapping partially around the side of the mattress. A copper weave material 65 is attached to the conductor 63 and curls around from the top of the mattress to the side, where it is attached to the copper band by means of a clip 66. The clip extends along the length of the material 65 to provide good thermal transfer between the two, and The clip is accessible by a user of the mattress, and allows the copper weave to be detached and tucked away from the copper band 64, or reattached as desired. The clip secures the weave material firmly against the band 64. Embodiments may use e.g. a spring clip, or a ribbon cable-like arrangement etc., or some other means, that preferably results in a connection that doesn’t protrude unduly from the side of the mattress.

In the attached state, any heat energy in the thermal conductor 63 is able to flow through the copper weave 66 to the dissipative metallic band 64. As this is located away from a user of the mattress, it will act as a heat sink to remove heat energy from the person, and hence cool them down. When the clip 66 is in a detached state, the band 64 is thermally disconnected from the thermal conductor 63, and will thus not provide this cooling action. The clip therefore provides a summer I winter functionality, for when the clip is attached or detached respectively.

Although the embodiments above have been described with relation to a mattress, it will be appreciated that the invention may also be applied to other cushioning arrangements. For example, shown in Figure 6 is a large padded blanket, that is intended to be placed e.g. on top of a standard mattress, or on a chair such as a reclining chair with a foot rest, and then to be sat upon. The blanket 70 is a layered structure comprising a padded underlayer 71, and a thinner top layer 72. A thermally conductive metallic layer 74 that is patterned in shape to covers some of the total area of the blanket is sandwiched between the underlayer and top layer. The metallic layer 73 is perforated with small holes e.g. 74 to allow moisture to permeate through, as described in relation to other embodiments. The blanket allows the benefits of the invention to be achieved using standard mattresses, or suitable chairs etc.

The thicknesses of the metallic thermally conductive layers as described in the above embodiments may typically range from around 0.3mm to 1mm where a foil is used, but may go thicker where the flexibility requirements of the support appliance are lesser, such as in hard mattresses. Metallic weave materials are naturally more flexible, and so may range in thickness between around 0.5mm up to a 3 or 4mm thick. It will be appreciated that these thicknesses are merely preferred thicknesses, and so some embodiments may have other material thicknesses dependent upon their desired properties.

Other embodiments and arrangements of the invention will be apparent to the normally skilled person, and lie within the scope of the invention.

The functions described herein as provided by individual components could, where appropriate, be provided by a combination of components instead. Similarly, functions described as provided by a combination of components could, where appropriate, be provided by a single component.

Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims (17)

1. A support appliance comprising a padded structure for supporting a person, wherein the appliance has a thermally conductive flexible metallic sheet positioned to have thermal communication with a user of the appliance, and wherein the thermally conductive flexible sheet extends to different regions of the appliance to conduct heat to different parts thereof.

2. A support appliance as claimed in claim 1 wherein the thermally conductive flexible metallic sheet is a metal foil or woven metal wire sheet.

3. A support appliance as claimed in claim 1 or claim 2 wherein the metal is copper.

4. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet has perforations or gaps that allow moisture to pass therethrough.

5. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet extends along a region covering an expected body length or general position adopted by a user.

6. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet is a composite sheet comprising of a plurality of separate individual parts connected together to allow thermal conduction therebetween.

7. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet comprises a plurality of main regions, each comprising polygonal shapes, with connecting parts that provide thermal conductivity between the main regions.

8. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet extends to a region in which a second occupant is expected to be.

9. A support appliance as claimed in any of the above claims wherein the appliance further has a dissipating region of the thermally conductive flexible sheet adapted to dissipate heat away from a body area of a user.

10. A support appliance as claimed in claim 9 wherein the dissipative region is adapted to be thermally disconnectable from the remaining part of the thermally conductive flexible sheet.

11. A support appliance as claimed in claim 9 or claim 10 wherein the dissipative region is located on a sidewall of the appliance.

12. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet is located beneath an outer covering of the appliance.

13. A support appliance as claimed in any of the above claims wherein the appliance is a mattress.

14. A support appliance as claimed in any of claims 1 to 12 wherein the appliance is a composite sheet or blanket adapted to sit on top of a mattress or chair.

15. A support appliance as claimed in any of the above claims wherein the thermally conductive flexible sheet is attached to a neighbouring layer using stitching or adhesive.

16. A method of manufacturing a support appliance comprising the steps of:

a) taking a partially manufactured mattress or composite sheet;

b) Adding to it one or more thermally conductive flexible metallic sheets in a layered fashion;

c) providing at least one cloth covering over the thermally conductive flexible sheet of a thickness that allows thermal communication between it and a user.

17. A method as claimed in claim 16 additionally comprising the step of fastening the thermally conductive flexible sheet to a neighbouring layer.