US20160128487A1 - Support Cushions Including Thermoelectric Elements and Air Conduits, and Methods for Controlling Surface Temperature of Same - Google Patents

Support Cushions Including Thermoelectric Elements and Air Conduits, and Methods for Controlling Surface Temperature of Same Download PDF

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Publication number
US20160128487A1
US20160128487A1 US14/899,244 US201414899244A US2016128487A1 US 20160128487 A1 US20160128487 A1 US 20160128487A1 US 201414899244 A US201414899244 A US 201414899244A US 2016128487 A1 US2016128487 A1 US 2016128487A1
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United States
Prior art keywords
base layer
layer
heat transfer
inlet
body supporting
Prior art date
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Abandoned
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US14/899,244
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English (en)
Inventor
Horace R. Eskridge, III
Tom Mikkelsen
Mario A.G. Nava
Samuel K. Pollock
Tarek Makansi
Leslie A. Burton
Norman L. Vaughn
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Tempur Pedic Management LLC
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Tempur Pedic Management LLC
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Priority to US14/899,244 priority Critical patent/US20160128487A1/en
Assigned to JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT reassignment JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT PATENT SECURITY AGREEMENT Assignors: SEALY TECHNOLOGY LLC, TEMPUR WORLD, LLC, TEMPUR-PEDIC MANAGEMENT, LLC
Publication of US20160128487A1 publication Critical patent/US20160128487A1/en
Assigned to SEALY TECHNOLOGY LLC, TEMPUR WORLD, LLC, TEMPUR-PEDIC MANAGEMENT, LLC reassignment SEALY TECHNOLOGY LLC RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C21/00—Attachments for beds, e.g. sheet holders or bed-cover holders; Ventilating, cooling or heating means in connection with bedsteads or mattresses
    • A47C21/04—Devices for ventilating, cooling or heating
    • A47C21/042—Devices for ventilating, cooling or heating for ventilating or cooling
    • A47C21/044—Devices for ventilating, cooling or heating for ventilating or cooling with active means, e.g. by using air blowers or liquid pumps
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C21/00—Attachments for beds, e.g. sheet holders or bed-cover holders; Ventilating, cooling or heating means in connection with bedsteads or mattresses
    • A47C21/04—Devices for ventilating, cooling or heating
    • A47C21/048—Devices for ventilating, cooling or heating for heating
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/001—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with several cushions, mattresses or the like, to be put together in one cover
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/62—Accessories for chairs
    • A47C7/72—Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like
    • A47C7/74—Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like for ventilation, heating or cooling
    • A47C7/742—Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like for ventilation, heating or cooling for ventilating or cooling
    • A47C7/744—Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like for ventilation, heating or cooling for ventilating or cooling with active means, e.g. by using air blowers or liquid pumps

Definitions

  • the present invention relates to support cushions and methods for controlling the surface temperature of support cushions.
  • the present invention relates to support cushions, such as mattress assemblies, that make use of thermoelectric elements and internal air conduits to selectively heat or cool the surfaces of the support cushions.
  • sleep deprivation can have significant negative impacts on longevity, productivity, and overall mental, emotional, and physical health.
  • Chronic sleep debt has been linked to weight gain and, more specifically, has been observed to not only affect the way the body processes and stores carbohydrates, but has also been observed to alter hormone levels that affect appetite.
  • sleep debt may result in irritability, impatience, inability to concentrate, and moodiness, which has led some researchers to suggest a link between sleep debt and worksite accidents, traffic incidents, and general afternoon inattentiveness.
  • the present invention includes support cushions and methods for controlling the surface temperature of support cushions.
  • the present invention includes support cushions, such as mattress assemblies, that make use of thermoelectric elements and internal air conduits to selectively heat or cool the surfaces of the support cushions.
  • the support cushions of the present invention allow a user to individualize their level of comfort, including sleep comfort, by controlling the temperature of the surface of the support cushions.
  • a support cushion in the form of a mattress assembly that includes a body supporting layer having a first surface and a second surface that is opposite the first surface.
  • the mattress assembly further includes a plurality of thermoelectric elements that are positioned and configured to selectively provide heating or cooling at the first surface of the body supporting layer.
  • the mattress assembly also includes a heat transfer layer and a base layer. The heat transfer layer is positioned adjacent to the second surface of the body supporting layer and is operably connected to the thermoelectric elements, while the base layer is positioned adjacent to the heat transfer layer opposite the body supporting layer.
  • the base layer defines an inlet conduit that is in fluid communication with the heat transfer layer, and an outlet conduit that is also in fluid communication with the heat transfer layer, but is spaced at a predetermined distance from the inlet conduit.
  • a fan that is operatively connected to the outlet conduit and, as described in further detail below, acts to draw an amount of air from the inlet conduit, through the heat transfer layer, and into the outlet conduit before dissipating the air away from the mattress assembly.
  • the body supporting layer is generally comprised of a flexible foam capable of suitably distributing pressure from a user's body, or portion thereof, across the body supporting layer.
  • the flexible foam is a visco-elastic foam that has a desired density and hardness, and allows pressure to be absorbed uniformly and distributed evenly across the body supporting layer of the mattress assembly.
  • the body supporting layer can be further covered by a comfort layer that is positioned atop the first surface of the body supporting layer to provide an additional level of comfort to the body of a user, or a portion thereof, resting on the mattress assembly.
  • Such a comfort layer in certain embodiments, is also comprised of a visco-elastic foam or other foam, but typically has a density less than that of the body supporting layer of the mattress assembly so as to provide a softer surface on which to rest and to also provide a sufficiently soft barrier between the body of a user and the thermoelectric elements of a mattress assembly, the position of which are described in further detail below.
  • thermoelectric elements of the mattress assembly are positioned in the mattress assembly and are configured to allow a user to control the temperature of the first (or upper) surface of the body supporting layer of the mattress assembly.
  • the thermoelectric elements are comprised of a plurality of Peltier elements that, upon flowing an amount of electrical current in a first direction through the Peltier elements, cool the first surface of the body supporting layer by drawing heat away from the first surface and toward the second surface of the body supporting layer.
  • the Peltier elements upon flowing an amount of electrical current in a second (e.g., opposite) direction through the Peltier elements, heat the first surface of the body supporting layer by drawing heat away from the second surface of the body supporting layer and toward the first surface of the body supporting portion.
  • the Peltier elements are arranged in a series, such that the Peltier elements are arranged one after another and are capable of providing heating or cooling across the entire surface of the body supporting layer or a desired portion thereof.
  • the Peltier elements are arranged in an array, such that a group of Peltier elements can be positioned on a desired area of the body supporting portion and used to selectively heat or cool an area of the body supporting portion that would be in contact with a particular portion of the body of a user that is prone to excessive heating or cooling (e.g., the torso or feet of a user, respectively).
  • the mattress assembly can include one or more removable portions that are comprised of an area of the body supporting layer and a corresponding area of the heat transfer layer, and that each house an array of Peltier elements.
  • the Peltier elements are comprised of discrete Peltier elements, are individually addressable, or both.
  • each Peltier element typically spans the width of the body supporting layer of the mattress assembly, such that a first side of each Peltier element is positioned above or adjacent to the first surface of the body supporting portion and the opposite side of each Peltier element is positioned below or adjacent to the second surface of the body supporting portion.
  • the body supporting layer typically defines a plurality of slots that each include a portion of the Peltier elements that are transmitting heat from one surface of the body supporting surface to the other.
  • the Peltier elements are positioned adjacent to the body supporting layer and are directly transferring heat from one surface of the body supporting layer, through the interior of the body supporting layer, and to the other surface of the body supporting layer.
  • thermoelectric elements are also operably connected to a heat transfer layer that is typically comprised of a porous flexible foam.
  • the heat transfer layer of the mattress assembly is comprised of a porous visco-elastic foam that encases at least a portion of the Peltier elements adjacent to or near the second surface of the body supporting layer.
  • the fan acts to create an air flow route whereby air enters the inlet conduit through an inlet, meets the less porous base layer, travels into the more porous heat transfer layer, picks up any heat generated by the Peltier elements, and then travels from the heat transfer layer into the outlet conduit before being dissipated away from the mattress assembly.
  • a mattress assembly that includes: a base layer having a head portion and a foot portion; one or more inlet conduits that extend longitudinally through the base layer from the head portion; and one or more outlet conduits that extend longitudinally through the base layer from the foot portion and that are each operably connected to a fan.
  • a mattress assembly in some embodiments of the mattress assemblies of the present invention, includes a base layer having three inlet conduits extending longitudinally through the base layer from inlets positioned on the head end of the base layer, and two outlet conduits extending longitudinally through the base layer from outlets positioned on a foot end of the base layer. More specifically, in those embodiments, a first inlet conduit is positioned on a first side of the base layer, a second inlet conduit is positioned in a central portion of the base layer, and a third inlet conduit positioned in a second side of the base layer opposite the first inlet conduit.
  • a first outlet conduit is then positioned between the first inlet conduit and the second inlet conduit, and a second outlet conduit is positioned between the second inlet conduit and the third inlet conduit.
  • air is drawn into each of the inlet conduits, into a portion of the heat transfer layer positioned between a particular inlet conduit and the outlet conduit that is in closest proximity to that particular inlet conduit, and then into the outlet conduit before it is dissipated away from the mattress assembly.
  • the inlet conduits and the outlet conduits included in an exemplary base layer are in the form of evacuated or hollow channels that extend longitudinally through the base layer and allow a maximum amount of air to flow through the channels and the heat transfer layer of each mattress assembly.
  • a flexible foam insert having a porosity greater than that of the base layer can be included each inlet conduit and each outlet conduit of a base layer.
  • a base layer is provided where the inlet and outlet conduits are essentially filled with a flexible foam that provides an increased amount of support to the heat transfer layer, but yet still also allows for a sufficient amount of air to flow into the inlet conduits, into the heat transfer layer, and then into the outlet conduits to dissipate heat away from the thermoelectric elements and away from the mattress assembly.
  • a mattress assembly having: a first inlet conduit extending longitudinally through a first side of the base layer and including a flexible foam insert; a second inlet conduit extending longitudinally through a second side of the base layer opposite the first side and including a flexible foam insert; and an outlet conduit extending longitudinally through the base layer between the first inlet conduit and the second inlet conduit and including a flexible foam insert.
  • a fan operably connected to the outlet conduit, air is thus first drawn into the flexible foam inserts in each of the inlet conduits.
  • the air then travels from the inlet conduits in the first side and second side of the mattress assembly, through the heat transfer layer, and then into the flexible foam insert in the outlet conduit positioned in the central portion of the mattress assembly, where it is then dissipated away from the mattress assembly.
  • each of the one or more inlet conduits and outlet conduits are substantially rectangular areas that are positioned at the head end and the foot end of an exemplary mattress assembly, respectively, and that each include a flexible foam insert having a porosity greater than that of the base layer.
  • air upon activation of a fan operatively connected to the outlet conduit, air enters the flexible foam insert positioned in the inlet conduit, and then enters and travels along the length of the heat transfer layer before it enters and subsequently exits through the flexible foam insert positioned in the outlet conduit at the foot end of the mattress assembly.
  • the base layers of the mattress assemblies include inlet and outlet conduits that do not extend from a first end or second end of the base layer (e.g., from the head end or foot end of the mattress assembly).
  • the base layer defines one or more inlet conduits that extend from the bottom surface of the base layer to the heat transfer layer, and one or more outlet conduits that extend from the bottom surface of the base layer to the heat transfer layer and that are spaced at a predetermined distance from each of the one or more inlet conduits.
  • a mattress assembly comprising a first inlet conduit extending longitudinally through a first side of the base layer, a second inlet conduit extending longitudinally through a second side of the base layer opposite the first side, and an outlet conduit positioned between the first inlet conduit and the second inlet conduit.
  • first inlet conduit, the second inlet conduit, nor the outlet conduit extend from or contact the head end or the foot end of the base layer.
  • first inlet conduit, the second inlet conduit, and the outlet conduit each extend from the bottom surface of the base layer to the heat transfer layer, air flows from below the base layer, into the inlet conduits, and upwardly into and through the heat transfer layer before being drawn back down into the outlet conduit and away from the mattress assembly by virtue of a fan operatively connected to the outlet conduit.
  • a mattress assembly in another embodiment, includes at least two columnar voids as outlet conduits positioned on a first side of the base layer, a second side of the base layer, or both, and an elongated channel as an inlet conduit that extends longitudinally through the base layer (e.g., through a central portion of the base layer).
  • a mattress assembly in yet further embodiments, includes at least two columnar voids as outlet conduits positioned on a first side of the base layer, at least two columnar voids as outlet conduits positioned on a second side of the base layer opposite the first side, and at least two columnar voids as inlet conduits positioned in a central portion of the base layer.
  • a flexible foam insert is positioned in each of the inlet and outlet conduits and has a porosity greater than that of the base layer.
  • air is drawn into the flexible foam insert positioned in each of the inlet conduits, into and through the heat transfer layer, and into the flexible foam insert positioned in each of the outlet conduits upon activation of a fan operatively connected to each of the outlet conduits.
  • the porosity of the flexible foam inserts positioned in the inlet or outlet conduits is the same as or is at least comparable to the base layer.
  • a barrier layer is used to cover one or more portions of the base layer including, in some embodiments, a continuous side panel of the base layer, as well as top and/or bottom surface of the base layer.
  • each mattress assembly of the present invention further includes a power supply for supplying electrical current to the plurality of thermoelectric elements and the fan attached to each outlet conduit, and a controller for controlling the electrical current that is supplied to the plurality of thermoelectric elements and each fan.
  • a controller for controlling the electrical current that is supplied to the plurality of thermoelectric elements and each fan.
  • the controller is configured to automatically control the electrical current supplied to Peltier elements, such that the electrical current can be supplied to the Peltier elements in a particular direction to heat or cool the first surface of the body supporting portion when the first surface of the body supporting portion reaches a particular temperature.
  • the controller in some embodiments, is configured to allow the electrical current to be supplied to the Peltier elements for a predetermined time period, such as for an 8-hour sleeping period or for a length of time that corresponds to the time a user usually spends in a specific stage of the sleep cycle (e.g., REM sleep).
  • the mattress assemblies further include one or more features that are operably connected to the body supporting layer, the heat dissipating layer, or both of the mattress assembly and provide input to the controller.
  • Such features include, in some embodiments, pressure sensors that provide pressure feedback to the controller and allow the controller to automatically begin heating or cooling the mattress assembly when a user lies on the mattress or otherwise places an amount of pressure on the mattress assembly.
  • temperature sensors are included in an exemplary mattress assembly and provide temperature feedback to the controller to allow the controller to selectively heat or cool the first surface of the body supporting portion in response to received temperature feedback and to maintain a desired temperature.
  • Such desired temperature or pressure feedback settings are, in certain embodiments, directly inputted or adjusted at the controller itself or, in other embodiments, can be transmitted to the controller from a remote control that is also operably connected to the controller and allows a user to remotely adjust the first surface of the body supporting layer to a desired temperature.
  • each of the mattress assemblies of the present invention generally includes at least three layers, namely a body supporting layer, a heat transfer layer, and a base layer.
  • additional layers are incorporated into the mattress assemblies to provide an increased level of comfort, to provide additional support for the mattress assemblies, or both.
  • a foundation is included in the mattress assembly to provide support to the body supporting layer, the heat transfer layer, and/or the base layer.
  • the foundation can be used as a housing for the fans that are operatively connected to the outlet conduits of the mattress assemblies.
  • an exemplary support cushion can also be used as part of a method of controlling a surface temperature of a support cushion.
  • a method of controlling the surface temperature of a support cushion includes first providing a support cushion having a body supporting layer, a heat transfer layer, and a base layer positioned adjacent to the heat transfer layer opposite the body supporting layer and having a porosity less than that of the heat transfer layer.
  • the base layer further defines one or more inlet conduits in fluid communication with the heat transfer layer, and one or more outlet conduits in fluid communication with the heat transfer layer and spaced at a predetermined distance from each of the one or more inlet conduits.
  • a fan is also included in the mattress assembly utilized as part of the method and is operably connected to each of the one or more outlet conduits.
  • an electrical current is then supplied to each fan, such that each fan draws an amount of air into each of the inlet conduits, from the inlet conduits and through the heat transfer layer, and then into the outlet conduits to thereby control the surface temperature of the support cushion.
  • the support cushion further comprises a plurality of Peltier elements that are positioned and configured to selectively provide heating or cooling at the first surface of the body supporting layer.
  • an electrical current can also be supplied to the plurality of Peltier elements, such that when electrical current is supplied in a first direction, the surface temperature of the body supporting portion decreases, and such that when electrical current is supplied in a second direction, the surface temperature of the body supporting portion increases.
  • FIG. 1 is a perspective view of an exemplary support cushion, in the form of a mattress assembly, made in accordance with the present invention
  • FIG. 2 is a cross-sectional view of the exemplary mattress assembly of FIG. 1 taken along line 2 - 2 of FIG. 1 ;
  • FIG. 3 is a partial cross-sectional view of the exemplary mattress assembly of FIG. 1 also taken along line 2 - 2 of FIG. 1 ;
  • FIG. 4 is another cross-sectional view of the exemplary mattress assembly of FIG. 1 , but taken along line 4 - 4 of FIG. 1 ;
  • FIG. 5 is an exploded, perspective view of the exemplary mattress assembly of FIG. 1 ;
  • FIG. 6 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 7 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 8 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 9 is a cross-sectional view of the exemplary mattress assembly of FIG. 8 taken along line 9 - 9 of FIG. 8 ;
  • FIG. 10 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 11 is a cross-sectional view of the exemplary mattress assembly of FIG. 10 taken along line 11 - 11 of FIG. 10 ;
  • FIG. 12 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 13 is a cross-sectional view of the exemplary mattress assembly of FIG. 12 taken along line 13 - 13 of FIG. 12 ;
  • FIG. 14 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 15 is a cross-sectional view of the exemplary mattress assembly of FIG. 14 taken along line 15 - 15 of FIG. 14 ;
  • FIG. 16 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 17 is a cross-sectional view of the exemplary mattress assembly of FIG. 16 taken along line 17 - 17 of FIG. 16 ;
  • FIG. 18 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 19 is a cross-sectional view of the exemplary mattress assembly of FIG. 18 taken along line 19 - 19 of FIG. 18 ;
  • FIG. 20 is an exploded, perspective view of another exemplary mattress assembly made in accordance with the present invention.
  • FIG. 21 is a perspective view of a cover assembly for covering an exemplary mattress assembly of the present invention.
  • FIG. 22 is a cross-sectional view of an exemplary support cushion for use in a chair and made in accordance with the present invention.
  • FIG. 23 is a schematic diagram showing input into and output from an exemplary controller used in accordance with the present invention.
  • FIG. 24 is a perspective view of an exemplary remote control for controlling the surface temperature of a support cushion made in accordance with the present invention.
  • the present invention includes support cushions and methods for controlling the surface temperature of support cushions.
  • the present invention includes support cushions, such as mattress assemblies, that make use of thermoelectric elements and internal air conduits to selectively heat or cool the surfaces of the support cushions.
  • the support cushions of the present invention allow a user to individualize their level of comfort, including sleep comfort, by controlling the temperature of the surface of the support cushions.
  • a support cushion in the form of a mattress assembly 10 is provided that includes a body supporting layer 20 having a first surface 22 and a second surface 24 that is opposite the first surface 22 .
  • the mattress assembly 10 further includes a plurality of thermoelectric elements in the form of Peltier elements 30 that are positioned and configured to selectively provide heating or cooling at the first surface 22 of the body supporting layer 20 .
  • the mattress assembly also includes a heat transfer layer 40 and a base layer 50 .
  • the heat transfer layer 40 is positioned adjacent to the second surface 24 of the body supporting layer 20 and is operably connected to the thermoelectric elements 30 , while the base layer 50 is positioned adjacent to the heat transfer layer 40 opposite the body supporting layer 20 and is supported by a foundation 70 .
  • the base layer 50 defines three inlet conduits 52 a , 52 b , 52 c , each of which extend longitudinally from respective inlets 53 a , 53 b , 53 c positioned on the head end 56 of the base layer 50 .
  • Each of the inlet conduits 52 a , 52 b , 52 c are in fluid communication with the heat transfer layer 40 .
  • the base layer 50 further defines a first outlet conduit 54 a and a second outlet conduit 54 b , each of which extend longitudinally from respective outlets 55 a , 55 b positioned on the foot end 58 of the base layer 50 .
  • Each of the outlet conduits 54 a , 54 b are also in fluid communication with the heat transfer layer 40 , but are spaced at a predetermined distance from each of the inlet conduits 52 a , 52 b , 52 c . Further included in the mattress assembly 10 is a first fan 60 a that is operatively connected to the first outlet conduit 54 a , and a second fan 60 b that is operatively connected to the second outlet conduit 54 b .
  • each of the fans 60 a , 60 b act to draw an amount of air from the inlet conduits 52 a , 52 b , 52 c , through the heat transfer layer 40 , and into the respective outlet conduits 54 a , 54 b before dissipating the air away from the mattress assembly 10 .
  • the body supporting layer 20 of the mattress assembly 10 is generally comprised of a continuous layer of flexible foam for suitably distributing pressure from a user's body or portion thereof across the body supporting layer 20 .
  • flexible foams include, but are not limited to, latex foam, reticulated or non-reticulated visco-elastic foam (sometimes referred to as memory foam or low-resilience foam), reticulated or non-reticulated non-visco-elastic foam, polyurethane high-resilience foam, expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like.
  • the body supporting layer 20 is comprised of a visco-elastic foam that has a low resilience as well as a sufficient density and hardness, which allows pressure to be absorbed uniformly and distributed evenly across the body supporting layer 20 of the mattress assembly 10 .
  • a visco-elastic foam that has a low resilience as well as a sufficient density and hardness, which allows pressure to be absorbed uniformly and distributed evenly across the body supporting layer 20 of the mattress assembly 10 .
  • such visco-elastic foams have a hardness of at least about 10 N to no greater than about 80 N, as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the material at approximately room temperature (i.e., 21° C. to 23° C.), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard.
  • ISO International Organization of Standardization
  • the visco-elastic foam has a hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, or about 80 N to provide a desired degree of comfort and body-conforming qualities.
  • the visco-elastic foam described herein for use in the mattress assembly 10 can also have a density that assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability.
  • the density of the visco-elastic foam used in the body supporting layer 20 has a density of no less than about 30 kg/m 3 to no greater than about 150 kg/m 3 .
  • the density of the visco-elastic foam used in the body supporting layer 20 of the mattress assembly 10 is about 30 kg/m 3 , about 40 kg/m 3 , about 50 kg/m 3 , about 60 kg/m 3 , about 70 kg/m 3 , about 80 kg/m 3 , about 90 kg/m 3 , about 100 kg/m 3 , about 110 kg/m 3 , about 120 kg/m 3 , about 130 kg/m 3 , about 140 kg/m 3 , or about 150 kg/m 3 .
  • a visco-elastic foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it is appreciated that a visco-elastic foam having a desired density and hardness can readily be selected for a particular application or mattress assembly as desired. Additionally, it is appreciated that the body supporting layers of the mattress assemblies need not be comprised of a continuous layer of flexible foam at all, but can also take the form of more traditional mattresses, including spring-based mattresses, without departing from the spirit and scope of the subject matter described herein.
  • the body supporting layer 20 of the mattress assembly 10 is further covered by a comfort portion or layer 72 that is positioned atop the body supporting layer 20 and provides a level of comfort to a body of a user or a portion of thereof that is resting on the mattress assembly 10 .
  • the comfort layer 72 can also be comprised of a visco-elastic foam.
  • the comfort layer 72 typically has a density, hardness, or both that is less than that of the body supporting layer 20 of the mattress assembly 10 , such that the comfort layer 72 provides a softer surface on which to rest the body of a user or a portion thereof, while also providing a sufficiently soft barrier between the body of a user and the Peltier elements 30 of the mattress assembly 10 , as described in further detail below.
  • the mattress assembly 10 includes a body supporting layer 20 that is comprised of visco-elastic foam with a density of about 80 kg/m 3 and a hardness of about 13 N, while the comfort layer 72 is comprised of a visco-elastic foam with a density of about 35 kg/m 3 and a hardness of about 10 N.
  • the flexible foam material utilized for the body supporting layer 20 generally has a composition different than that of the heat transfer layer 40 of the mattress assembly 10 , as is described in further detail below, but it is additionally contemplated that an exemplary body supporting layer can be further comprised of one or more different or additional layers having various densities and hardnesses.
  • an exemplary body supporting layer can be further comprised of one or more different or additional layers having various densities and hardnesses.
  • a layer of high-resilience polyurethane foam can be secured to the second surface of a layer of low-resilience visco-elastic foam used in a body supporting portion.
  • Such multi-layered body supporting portions are described, for example, in U.S. Pat. Nos. 7,469,437; 7,507,468; 8,025,964; and 8,034,445, as well as in U.S. Patent Application Publication No. 2011/0252562, each of which is incorporated herein by this reference.
  • thermoelectric elements included in the support cushions of the present invention various thermoelectric elements can be incorporated into a support cushion and used to heat or cool a surface of an exemplary support cushion, including resistive heaters that convert electrical energy to heat, as well as other thermoelectric elements.
  • the thermoelectric elements are Peltier elements 30 that are positioned in the mattress assembly 10 and are configured to allow a user to control the temperature of the first surface 22 of the body supporting layer 20 of the mattress assembly 10 , which can then change the temperature of the comfort layer 72 of the mattress assembly 10 by virtue of the proximity of the first surface 22 of the body supporting layer 20 to the comfort layer 72 .
  • the Peltier elements 30 which may also be referred to as Peltier devices, Peltier heaters or heat pumps, solid-state refrigerators or thermoelectric heat pumps, are solid-state active heat pumps which transfer heat from one side of body supporting layer 20 of the mattress assembly 10 to the other side of the body supporting layer 20 by flowing an amount of electrical current through the Peltier elements 30 to produce a Peltier effect or, in other words, the presence of heat at an electrified junction of two different metals.
  • the junctions of two different metals are in the form of a n-type semiconductor or element 32 and a p-type semiconductor or element 34 .
  • a Peltier effect is created whereby electrons in the n-type elements 32 move in the opposite direction of the current and holes in the p-type element 34 move in the direction of current, such that both remove heat from the first surface 22 of the body supporting layer 20 of the mattress assembly 10 toward the second surface 24 of the body supporting layer 20 .
  • the Peltier elements 30 upon flowing an amount of electrical current in a second (e.g., opposite) direction through the Peltier elements 30 and the n-type elements 32 and p-type elements 34 , the Peltier effect can be reversed, and the Peltier elements 30 can be used to heat the first surface 22 of the body supporting layer 20 by drawing heat away from the second surface 24 of the body supporting layer 20 and toward the first surface 22 of the body supporting layer 20 .
  • the Peltier effect including the types of Peltier elements that may be included in support cushion to create such an effect, see, e.g., U.S. Patent Application Publication Nos. 2012/0198616 and 2012/0060885, each of which is incorporated herein by this reference in their entirety.
  • the Peltier elements 30 substantially span the width of the body supporting layer 20 of the mattress assembly 10 such that an upper portion 31 of each of the Peltier elements 30 is positioned above and adjacent to the first surface 22 of the body supporting layer 20 , and the metallic interconnects 33 of the Peltier elements 30 are positioned below and adjacent to the second surface 24 of the body supporting layer 20 .
  • the body supporting layer 20 typically includes slots to allow a portion of the Peltier elements 30 , including the n-type elements 32 and the p-type elements 34 to be positioned in and pass through the body supporting layer 20 and allow heat to be transferred from one surface of the body supporting layer 20 to the other.
  • the Peltier elements 30 are positioned adjacent to the body supporting layer 20 and direct transfer heat from one surface of the body supporting layer 20 and through the body supporting layer 20 to the other surface of the body supporting layer 20 and into the heat transfer layer 40 .
  • each of the arrays 35 a , 35 b , 35 c , 35 d are included in removable portions 12 a , 12 b , 16 a , 16 b of the mattress assembly 10 that are each comprised of a portion of the body supporting layer 20 and a corresponding portion of the heat transfer layer 40 , and that allow a user to easily remove the Peltier elements 30 from the mattress assembly 10 as desired (e.g., to service or replace the Peltier elements 30 ).
  • the arrays 35 a , 35 b , 35 c , 35 d of Peltier elements 30 are individually addressable such that it is possible to cool the arrays 35 a , 35 b that would be in contact with the torso or head of a user lying in a supine or prone position, while heating the arrays 35 c , 35 d that would be in proximity to the feet of a user lying in a supine or prone position.
  • individual rows or columns of the Peltier elements 30 in the arrays 35 a , 35 b , 35 c , 35 d can also be individually addressable such that more specific portions of the first surface 22 of the body supporting layer 20 can be selectively heated and cooled to allow a particular portion of a user's body to be heated or cooled, or to allow only the Peltier elements 30 that are in closest contact with the body of a user to be selectively heated or cooled (e.g., when a user is lying on their side).
  • Peltier elements used in the mattress assemblies of the present invention can be provided in the form of discrete Peltier elements that are not connected to one another in a series, so as to provide an even greater amount of control over the heating and cooling of the first surface of a body supporting layer.
  • the Peltier elements 30 are also operably connected to the heat transfer layer 40 of the mattress assembly 10 .
  • the heat transfer layer 40 of the mattress assembly 10 is comprised of a substantially uniform layer of a porous visco-elastic foam that is secured to and covers the entirety of the second surface 24 of the body supporting layer 20 .
  • the porous visco-elastic foam of the heat transfer layer 40 also encases the metallic interconnects 33 of the Peltier elements 30 near the second surface 24 of the body supporting layer 20 .
  • the porous visco-elastic foam of the heat transfer layer 40 in addition to providing structural support for the Peltier elements 30 and the overlying body supporting layer 20 , provides an open environment into which the heat generated by the Peltier elements 30 can be transferred, such as by the flow of air across the Peltier elements 30 and through the open environment provided by the porous visco-elastic foam of the heat transfer layer 40 , as described in further detail below.
  • porous visco-elastic foam included in the heat transfer layer 40 of the mattress assembly need not be comprised of a visco-elastic foam, but that any number of porous flexible foams can be used to produce a heat transfer layer having a porosity sufficient to allow for the heat generated by the Peltier elements to dissipate within.
  • porous flexible foam (visco-elastic or otherwise) is used herein to generally refer to flexible foam having a cellular foam structure in which at least a portion of the cells of the foam are essentially skeletal.
  • the cells of the foam are each defined by a plurality of apertured windows surrounded by cell struts, where the cell windows of the porous foam can be entirely absent (leaving only the cell struts) or substantially missing.
  • the foam is considered “porous” if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts).
  • Such structures can be created by destruction or other removal of cell window material, by chemical or mechanical means, or by preventing the complete formation of cell windows during the manufacturing process of the foam.
  • the term “porous” can thus be used interchangeably with the term “reticulated” when referring to flexible foam.
  • porous foam by virtue of its open cellular structure, has characteristics that are well suited for use in the heat transfer layer 40 of the mattress assembly 10 , including the enhanced ability to permit fluid movement through the porous foam and, consequently, the ability to provide enhanced air movement into, through, and away from the heat transfer layer 40 of the mattress assembly 10 .
  • the heat that is transferred to the heat transfer layer 40 by the Peltier elements 30 as part of the cooling of the first surface 22 of the body supporting layer 20 is allowed to easily disperse throughout the porous visco-elastic foam of the heat transfer layer 40 .
  • the heat transfer layer 40 Upon transferring heat into the open environment of the heat transfer layer 40 , the heat can then easily be transferred out of the heat transfer layer 40 by conveying an amount of air through the porous visco-elastic foam of the heat transfer layer 40 .
  • the heat transfer layer 40 and, in particular, the porous visco-elastic foam of the heat transfer layer 40 has a pore size of about 10 pores per inch (ppi) to allow a sufficient amount of air to move into, through, and away from the heat transfer layer 40 .
  • the size of the pores present in the foam of an exemplary heat transfer layer can readily be adjusted as needed to convey a particular amount of air through an exemplary heat transfer layer and/or through a particular mattress assembly without departing from the spirit and scope of the subject matter described herein.
  • the base layer 50 defines three separate, hollow inlet conduits 52 a , 52 b , 52 c that are spaced apart from one another and extend longitudinally from the head end 56 of the base layer 50 .
  • the base layer 50 further defines two separate, hollow outlet conduits 54 a , 54 b that extend longitudinally from the foot end 58 of the base layer 50 , with the first outlet conduit 54 a being positioned between the first inlet conduit 52 a and the second inlet conduit 52 b , and the second outlet conduit 54 b being positioned between the second inlet conduit 52 b and the third inlet conduit 52 c .
  • Each of the inlet conduits 52 a , 52 b , 52 c and each of the outlet conduits 54 a , 54 h span the width of the base layer 50 and extend from the bottom surface 59 of the base layer 50 to the bottom surface 44 of the heat transfer layer 40 .
  • each the inlet conduits 52 a , 52 b , 52 c and the outlet conduits 54 a , 54 b of the base layer 50 are in fluid communication with the heat transfer layer 40 .
  • the base layer 50 is also generally comprised of a flexible foam.
  • the base layer 50 is comprised of a standard polyurethane foam.
  • the polyurethane foam used in the base layer 50 has a porosity that is less than that found in the porous visco-elastic foam of the heat transfer layer 40 positioned immediately above the base layer 50 .
  • the first fan 60 a operably connected to the first outlet conduit 54 a when the first fan 60 a operably connected to the first outlet conduit 54 a is activated and the second fan 60 b operably connected to the second outlet conduit 54 b is activated, the first fan 60 a and the second fan 60 b do not directly draw air into the inlet conduits 52 a , 52 b , 52 c , through the base layer 50 , and then into the outlet conduits 54 a , 54 b and away from the mattress assembly 10 .
  • the fans 60 a , 60 b act to create an air flow route whereby air is drawn into the inlet conduits 52 a , 52 b , 52 c through the respective inlets 53 a , 53 b , 53 c , meets the less porous base layer 50 , is drawn into the more porous heat transfer layer 40 and picks up any heat generated by the Peltier elements 30 and dissipated into the heat transfer layer 40 , and then travels from the heat transfer layer 40 into the outlet conduits 54 a , 54 b before being dissipated away from the mattress assembly 10 by the first fan 60 a and the second fan 60 b.
  • the base layer 50 and the heat transfer layer 40 are generally secured to one another.
  • Various means of securing one layer of material to another can be used in this regard, including tape, hook and loop fasteners, conventional fasteners, stitches, and the like.
  • the base layer 50 , the heat transfer layer 40 , the body supporting layer 20 , and the comfort layer 72 are bonded together by an adhesive or cohesive bonding material to create a substantially continuous assembly where the comfort layer 72 and the body supporting layer 20 and are fully adhered to one another, the body supporting layer 20 and the heat transfer layer 40 are fully adhered to one another, and the heat transfer layer 40 and the base layer 50 are fully adhered to one another.
  • adhesive bonding materials include, for example, environmentally-friendly, water based adhesives, like SABA AQUABOND RSD, a two-component water-based adhesive product produced by SABA DINXPERLO BV, B-7090 AA, Dinxperlo, Belgium.
  • the mattress assembly 10 further includes a power supply 90 for supplying electrical current to the Peltier elements 30 and the fans 60 a , 60 b , as well as a controller 92 for controlling the electrical current that is supplied to the plurality of Peltier elements 30 and the fans 60 a , 60 b .
  • the controller 92 can be configured to automatically control the electrical current supplied to Peltier elements 30 , such that electrical current can be supplied to the Peltier elements 30 to heat or cool the first surface 22 of the body supporting layer 20 when the first surface 22 of the body supporting layer 20 reaches a particular temperature, such as after a user has been lying on the body supporting layer 20 for an extended period of time.
  • the controller 92 can also be configured to allow the electrical current to be supplied to the Peltier elements 30 for a predetermined time period, such as for an 8-hour sleeping period.
  • the controller 92 can further be operably connected to a device that monitors sleep rhythms, such as, for example, the ZEO SLEEP MANAGERTM manufactured by ZEO, Newton, Mass., such that the controller 92 can be configured to provide electrical current to the Peltier elements 30 upon receiving input that the user lying on the mattress assembly 10 has entered a particular stage of the sleep cycle (e.g., REM sleep).
  • a device that monitors sleep rhythms such as, for example, the ZEO SLEEP MANAGERTM manufactured by ZEO, Newton, Mass.
  • the controller 92 of the mattress assembly 10 further allows the direction of the electrical current being supplied to the Peltier elements 30 to be controlled.
  • the controller 92 can be used to not only alter the direction of the electrical current being supplied to the Peltier elements 30 in order to either selectively heat or cool the first surface 22 of the body supporting layer 20 of the mattress assembly 10 , but can further be configured to dissipate heat away from the heat transfer layer 40 of the mattress assembly 10 after an extended period of cooling the first surface 22 of the body supporting layer 20 . For instance, after an overnight period of cooling the first surface 22 of the body supporting layer 20 , a significant amount of heat will have been transferred to the heat transfer layer 40 of the mattress assembly 10 .
  • the direction of the electrical current being supplied to the Peltier elements 30 can be reversed, and the heat in the heat transfer layer 40 can be transferred from the heat transfer layer 40 to the first surface 22 of the body supporting layer 20 and released into the surrounding atmosphere.
  • exemplary mattress assemblies can further include one or more features that are operably connected to the body supporting layers, the heat transfer layers, or both and provide input to the controllers.
  • the mattress assembly 10 includes pressure sensors 94 a , 94 b that provide pressure feedback to the controller 92 in response to a user resting upon the first surface 22 of the body supporting layer 20 to thereby allow the controller 92 to automatically begin providing electrical current and heating or cooling the mattress assembly 10 as soon as the user lies on the mattress assembly 10 or otherwise places an amount of pressure on the mattress assembly 10 .
  • temperature sensors 96 a , 96 b are further included in the mattress assembly 10 and provide temperature feedback to the controller 92 to thereby allow the controller 92 to selectively heat or cool the first surface of the mattress assembly 10 in response to the received temperature feedback and to thereby maintain a desired temperature at the first surface 22 of the body supporting layer 20 .
  • desired temperature or pressure feedback settings are, in certain embodiments, directly inputted or adjusted at the controller 92 itself or, in other embodiments, are transmitted to the controller 92 from a remote control 97 that includes temperature control buttons 98 and fan control buttons 99 , as shown in FIG. 24 , and that is also operably connected to the controller 92 such that the Peltier elements 30 and fans 60 a , 60 b of the mattress assembly 10 can be operated remotely.
  • the first fan 60 a is generally secured to the first outlet 55 a and the second fan 60 b is generally secured to the second outlet 55 b at the foot end 58 of the base layer.
  • each of the fans 60 a , 60 b can also be housed within the outlet conduits 54 a , 54 b themselves or within specialized assemblies to conceal the fans 60 a , 60 b within the mattress assembly 10 itself and/or to reduce the amount of noise generated by the fans.
  • any number of types of fans as well as any number of other means for drawing an amount of air through an exemplary mattress assembly of the present invention, including air pumps and the like, can be used in accordance with the present invention.
  • Such fans include, for example, a Delta Electronics Fan Model No. P/N VFB070B3A1-DC54 manufactured and distributed by Delta Electronics, Inc. (Taipei City, Taiwan).
  • a “twin” size mattress assembly 110 in another embodiment of the present invention that makes use of separate, hollow inlet and outlet conduits, includes a comfort layer 172 , a body supporting layer 120 having a first surface 122 and a second surface 124 that is opposite the first surface 122 , a heat transfer layer 140 , a base layer 150 comprised of a material having porosity greater than that of the heat transfer layer 140 , and a foundation 170 .
  • the mattress assembly 110 further includes a plurality of Peltier elements 130 that are arranged in a first array 135 a in a first removable insert 112 positioned in a central region 114 of the mattress assembly 110 and in a second array 135 b in a second removable insert 116 positioned in a lower region 118 of the mattress assembly 110 .
  • the base layer 150 of the “twin” size mattress assembly 110 does not include a series of three inlet conduits and two outlet conduits.
  • the base layer 150 only includes a single inlet conduit 152 extending longitudinally through the base layer 150 from an inlet 153 positioned on a head end 156 of the base layer 150 , and a single outlet conduit 154 extending longitudinally through the base layer 150 from an outlet 155 positioned on a foot end 158 of the base layer 150 . Additionally, by virtue of only including the single outlet conduit 154 in the base layer 150 , the mattress assembly 110 only includes a single fan 160 operably connected to the outlet conduit 154 .
  • the fan 160 when the fan 160 is activated, via a power supply 190 and controller 192 connected to the fan 160 and Peltier elements 130 , the fan 160 draws air into the single inlet conduit 152 , up through the heat transfer layer 140 , and then into the single outlet conduit 154 before exiting through the outlet 155 .
  • the base layer 150 also includes a filter 195 that covers the inlet 153 , such that only filtered air is allowed to pass into the inlet conduit 152 through the inlet 153 and the inlet conduit 152 is kept free of particulates such as smoke, dust, dirt, pollen, mold, bacteria, hair, or insects that may otherwise collect in the interior of the mattress 10 and limit air flow.
  • filters including, but not limited to, charcoal filters for removing chemicals and/or unpleasant odors can be readily incorporated into an exemplary mattress of the present invention without departing from the spirit and scope of the subject matter described herein.
  • a mattress assembly 210 is provided that also includes a comfort layer 272 , a body supporting layer 220 having a first surface 222 and a second surface 224 that is opposite the first surface 224 , a heat transfer layer 240 , a base layer 250 comprised of a material having porosity less than that of the heat transfer layer 240 , and a foundation 270 .
  • the mattress assembly 210 further includes a plurality of Peltier elements 230 that are arranged in separate arrays 235 a , 235 b , 235 c , 235 d included in removable portions 212 a , 212 b , 212 c , 212 d of the mattress assembly 210 . Additionally, defined by the base layer 250 of the mattress assembly 210 , are three separate inlet conduits 252 a , 252 b , 252 c that are spaced apart from one another and that extend longitudinally from inlets 253 ; 253 b , 253 c at the head end 256 of the base layer 250 .
  • the base layer 250 further defines two separate outlet conduits 254 a , 254 b that extend longitudinally from particular outlets 255 a , 255 b at the foot end 258 of the base layer 250 , with the first outlet conduit 254 a operably connected to a first fan 260 a and positioned between the first inlet conduit 252 a and the second inlet conduit 252 b , and with the second outlet conduit 254 b operably connected to a second fan 260 b and positioned between the second inlet conduit 252 b and the third inlet conduit 252 c.
  • the mattress assembly 210 includes a porous foam insert 280 a , 280 b , 280 c positioned in each of the inlet conduits 252 a , 252 b , 252 c and a porous foam insert 282 a , 282 b positioned in each of the outlet conduits 254 ; 254 b .
  • Each of the porous foam inserts 280 ; 280 b , 280 c positioned in the inlet conduits 252 a , 252 b , 252 c and each of the porous foam inserts 282 a , 282 b positioned in the outlet conduits 254 a , 254 b have a porosity greater than that of the flexible foam comprising the base layer 250 .
  • the porous foam inserts 280 a , 280 b , 280 c in the inlet conduits 252 a , 252 b , 252 c and the porous foam inserts 282 a , 282 b in the outlet conduits 254 a , 254 b
  • the porous foam inserts 280 a , 280 b , 280 c , 282 a , 282 b allow a greater amount of support to be provided to the heat transfer layer 240 , but yet still allow for a sufficient amount of air to be drawn into the inlet conduits 252 a , 252 b , 252 c , into the heat transfer layer 240 , and then into the outlet conduits 254 a , 254 b to dissipate heat away from the Peltier elements 230 in the heat transfer layer 240 and away from the mattress assembly 210 .
  • the fans 260 a , 260 b when the fans 260 a , 260 b are activated via a power supply 290 and a controller 292 connected to the fans 260 a , 260 b and Peltier elements 230 , the fans 260 a , 260 b draw air through the porous foam inserts 280 a , 280 b , 280 c in the inlet conduits 252 a , 252 b , 252 c , through the heat transfer layer 240 , and then into the porous foam inserts 282 a , 282 b in the outlet conduits 254 a , 254 b before exiting the mattress assembly 210 through the outlets 255 a , 255 b at the foot end 258 of the base layer 250 .
  • the inlet and outlet conduits can be positioned in discrete areas of a base layer of an exemplary mattress assembly rather than extending longitudinally through a substantial portion of the base layer.
  • a mattress assembly 310 in another exemplary embodiment, includes a comfort layer 372 , a body supporting layer 320 having a first surface 322 and a second surface 324 that is opposite the first surface 324 , a plurality of Peltier elements 30 , a heat transfer layer 340 , a base layer 350 comprised of a material having porosity less than that of the heat transfer layer 140 , and a foundation 370 .
  • the mattress assembly 310 further includes a first inlet conduit 352 a and a second inlet conduit 352 b , as well as a first outlet conduit 354 a operably connected to a first fan 360 a and a second outlet conduit 354 b operably connected to a second fan 360 b .
  • the first inlet conduit 352 a and the first outlet conduit 354 a are positioned on a first side 362 of the base layer 350
  • the second inlet conduit 352 b and second outlet conduit 354 b are positioned on a second side 364 of the base layer 350 opposite the first side 362 .
  • each of the inlet conduits 352 a , 352 b and each of the outlet conduits 354 a , 354 b do not extend longitudinally through a substantially portion of the base layer 350 .
  • each of the inlet conduits 352 a , 352 b and each of the outlet conduits 354 a , 354 b are substantially rectangular areas that are positioned at the head end 356 and at the foot end 358 of the mattress assembly 310 , respectively, and that each include a porous foam insert 380 a , 380 b , 382 a , 382 b having a porosity greater than that of the base layer 350 .
  • the base layers of the mattress assemblies can include inlet and outlet conduits that do not extend from a head end or foot end of the base layer, but instead extend only from a bottom surface of the base layer.
  • a mattress assembly 410 that, similar to the other embodiments described herein, includes a comfort layer 472 , a body supporting layer 420 having a first surface 422 and a second surface 424 that is opposite the first surface 422 , a plurality of Peltier elements 430 , a heat transfer layer 440 , and a base layer 450 comprised of a flexible foam having porosity less than that of the heat transfer layer 440 .
  • the mattress assembly 410 further includes a first inlet conduit 452 a extending longitudinally through a first side 462 of the base layer 450 , a second inlet conduit 452 b extending longitudinally through a central portion 466 of the base layer 450 , a third inlet conduit 452 c also extending longitudinally through the central portion 466 of the base layer and spaced apart from the second inlet conduit 452 b , and a fourth inlet conduit 452 d extending longitudinally though a second side 464 of the base layer 450 opposite the first side 462 .
  • first outlet conduit 454 a extending longitudinally through the base layer 450 and positioned between the first inlet conduit 452 a and the second inlet conduit 452 b
  • second outlet conduit 454 b extending longitudinally through the base layer 450 and positioned between the third inlet conduit 452 c and fourth inlet conduit 452 d .
  • Porous foam inserts 480 a , 480 b , 480 c , 480 d are positioned in each of the inlet conduits 452 a , 452 b , 452 c , 452 d
  • porous foam inserts 482 a , 482 b are also positioned in each of the outlet conduits 454 a , 454 b .
  • neither the inlet conduits 452 a , 452 b , 452 c , 452 d , nor the outlet conduits 454 a , 454 b extend from or contact the head end 456 or the foot end 458 of the base layer 450 .
  • each of the inlet conduits 452 a , 452 b , 452 c , 452 d and each of the outlet conduits 454 a , 454 b in addition to extending longitudinally through the base layer, span the thickness of the base layer 450 and extend from the bottom surface 459 of the base layer 450 to the heat transfer layer 440 .
  • the mattress assembly 410 further includes a foundation 470 positioned adjacent to the bottom surface 459 of the base layer 450 .
  • the foundation 470 includes a plurality of grates 471 positioned below and having a shape corresponding to the inlet conduits 452 a , 452 b , 452 c , 452 d and the outlet conduits 454 a , 454 b of the base layer 450 .
  • the foundation 470 further houses a first fan 460 a positioned below and operably connected to the first outlet conduit 454 a and a second fan 460 b positioned below and operably connected to the second outlet conduit 454 b .
  • a first fan 460 a and the second fan 460 b are positioned below the first outlet conduit 454 a and the second outlet conduit 454 b .
  • air is drawn from below the base layer 450 , through the grates 471 , into the inlet conduits 452 a , 452 b , 452 c , 452 d , and then upwardly into and through the heat transfer layer 440 before being drawn back down into the first outlet conduit 454 a and the second outlet conduit 454 b and away from the mattress assembly 410 , as indicated by the arrows in FIG. 11 .
  • a mattress assembly 510 is provided that includes another exemplary arrangement of inlet conduits 552 a , 552 b , 552 c , 552 d and outlet conduits 554 a , 554 b . Similar to the exemplary mattress assembly 410 shown in FIGS.
  • the mattress assembly 510 includes a comfort layer 572 , a body supporting layer 520 having a first surface 522 and a second surface 524 that is opposite the first surface 522 , a plurality of Peltier elements 530 , a heat transfer layer 540 , a base layer 550 , and a foundation 570 housing a first fan 560 a and a second fan 560 b that are each positioned below one of the outlet conduits 554 a , 554 b .
  • the foundation 570 also similarly includes a number of grates 571 corresponding to the position and shape of the inlet conduits 552 a , 552 b , 552 c , 552 d and outlet conduits 554 a , 554 b .
  • the inlet conduits 552 a , 552 b , 552 c , 552 d do not extend longitudinally through a substantial length of the base layer 550 .
  • the inlet conduits 552 a , 552 b , 552 c , 552 d defined by the base layer 550 of the mattress assembly 510 are in the form of columnar voids that extend from the bottom surface 559 of the base layer 550 to the heat transfer layer 540 .
  • the base layer 550 includes a first row of three inlet conduits 552 a in the form of columnar voids that are spaced apart from one another in a first side 562 of the base layer 550 , a second row of three inlet conduits 552 b in the form of columnar voids that are spaced apart from one another in a central portion 566 of the base layer 550 , a third row of three inlet conduits 552 c in the form of columnar voids that are spaced apart from one another and from the second row of inlet conduits 552 b in the central portion 566 of the base layer 550 , and a fourth row of three inlet conduits 552 d in the form of columnar voids that are spaced apart from one another in a second side 564 of the base layer 550 .
  • a first outlet conduit 554 a then extends longitudinally though the base layer 550 between the first row of inlet conduits 552 a and the second row of inlet conduits 552 b
  • a second outlet conduit 554 b extends longitudinally though the base layer 550 between the third row of inlet conduits 552 c and the fourth row of inlet conduits 552 d
  • Porous foam inserts 580 a , 580 b , 580 c , 580 d are further positioned in each of the inlet conduits 552 a , 552 b , 552 c , 552 d , respectively.
  • a porous foam insert 582 a is positioned in the first outlet conduit 554 a and a porous foam insert 582 b is positioned in the second outlet conduit 554 b .
  • air is drawn from below the base layer 550 , into porous foam inserts 580 a , 580 b , 580 c , 580 d positioned in the inlet conduits 552 a , 552 b , 552 c , 552 d , and then upwardly into and through the heat transfer layer 540 before being drawn back down into the porous foam insert 582 a positioned in the first outlet conduit 554 a and the porous foam insert positioned in the second outlet conduit 554 b and away from the mattress assembly 510 , as indicated by the arrows in FIG. 13 .
  • the base layer 550 of the mattress 510 is not comprised of a flexible foam having a porosity greater than that of the heat transfer layer 540 , so as to direct an amount of air through the row of inlet conduits 452 a , 452 b , 452 c , 452 d and into the heat transfer layer 540 .
  • the base layer 550 is also comprised of a porous foam.
  • the mattress assembly 510 further includes a barrier layer 584 that is positioned over the exposed exterior surfaces of the base layer 550 and the heat transfer layer 540 (i.e., the continuous side walls of the base layer 550 and the heat transfer layer 540 , and the bottom surface 559 of the base layer 550 ), as well as between the base layer 550 and the heat transfer layer 540 .
  • a barrier layer 584 that is positioned over the exposed exterior surfaces of the base layer 550 and the heat transfer layer 540 (i.e., the continuous side walls of the base layer 550 and the heat transfer layer 540 , and the bottom surface 559 of the base layer 550 ), as well as between the base layer 550 and the heat transfer layer 540 .
  • the barrier layer 584 can be comprised of a number of different materials, such as plastics, textiles, and the like, but, in all cases, functions as an substantially air tight layer that directs air being drawn through the base layer 550 and the heat transfer layer 540 by the fans 560 a , 560 b through the rows of inlet conduits 552 a , 552 b , 552 c , 552 d , into the heat transfer layer 540 , and then into the first outlet conduit 554 a and the second outlet conduit 554 b.
  • a mattress assembly 610 that includes yet another arrangement of inlet conduits 652 and outlet conduits 654 a , 654 b .
  • the mattress assembly 610 includes a comfort layer 672 , a body supporting layer 620 having a first surface 622 and a second surface 624 that is opposite the first surface 622 , a plurality of Peltier elements 630 , a heat transfer layer 640 , a base layer 650 comprised of a flexible foam having a porosity less than that of the heat transfer layer 640 , and a foundation 670 including a number of grates 671 corresponding to the position and shape of the inlet conduits 652 and outlet conduits 654 a , 654 b .
  • the foundation 670 further houses four separate fans (of which only a first fan 660 a and a second fan 660 b are shown in FIG. 15 ) that are angled to direct air away from the mattress assembly 610 and that are connected to a controller 692 and a power supply 690 .
  • Porous foam inserts 680 are also included in each of the inlet conduits 652 and porous foam inserts 682 a , 682 b are also included in each of the outlet conduits 654 a , 654 b , respectively, of the mattress assembly 610 .
  • the inlet conduits 652 are included in a central portion 666 of the base layer 650
  • a first row of the outlet conduits 654 a is included on a first side 662 of the base layer 650
  • a second row of outlet conduits 654 b are included on a second side 664 of the mattress assembly 610 .
  • the air when air is drawn into the mattress assembly 610 , the air first enters the porous foam inserts 680 positioned in the inlet conduits 652 in the central portion 666 of the mattress assembly 610 , then flows through the heat layer transfer layer 640 to both the first side 662 of the base layer 650 and the second side 664 of the base layer 650 before exiting through the porous foam inserts 682 a , 682 b in the outlet conduits 682 a , 682 b , as shown best in FIG. 15 .
  • a mattress assembly 710 is provided that includes a comfort layer 772 , a body supporting layer 720 having a first surface 722 and a second surface 724 that is opposite the first surface 722 , a plurality of Peltier elements 730 , a heat transfer layer 740 , a base layer 750 , and a foundation 770 including a number of shaped grates 771 .
  • the foundation 770 also houses four separate fans, of which only a first fan 760 a and a second fan 760 b are shown in FIG. 17 .
  • the mattress assembly 710 further includes a first row of outlet conduits 754 a positioned on a first side 762 of the base layer 750 and including porous foam inserts 782 a , and a second row of outlet conduits 754 b positioned on a second side 764 of the base layer 750 and including porous foam inserts 782 b .
  • the inlet conduit 752 is in the form of a porous foam area 780 positioned in a central portion 766 of the base layer 750 and extending longitudinally from the head end 756 of the base layer 750 to the foot end 758 of the base layer 750 .
  • the base layer 750 is comprised of a porous foam and a barrier layer 784 is again positioned over the exterior surfaces of the base layer 750 and the heat transfer layer 740 , as well as between the base layer 750 and the heat transfer layer 740 .
  • a barrier layer 784 is again positioned over the exterior surfaces of the base layer 750 and the heat transfer layer 740 , as well as between the base layer 750 and the heat transfer layer 740 .
  • FIGS. 18-19 as an alternative to the mattress assembly 710 shown in FIGS. 16-17 , another exemplary mattress assembly 810 is provided that similarly includes a comfort layer 872 , a body supporting layer 820 , a plurality of Peltier elements 830 , a heat transfer layer 840 , a base layer 850 , and a foundation 870 including a number of grates 871 and housing four separate fans, of which only a first fan 860 a and a second fan 860 b are shown in FIG. 19 .
  • the mattress assembly 810 also includes a first row of outlet conduits 854 a positioned on a first side 862 of the base layer 850 and including porous foam inserts 882 a , and a second row of outlet conduits 852 b positioned on a second side 864 of the base layer 850 and including porous foam inserts 882 b . Further included in the mattress assembly 810 is an inlet conduit 852 in the form of a porous foam area 880 extending longitudinally in a central portion 866 of the base layer 850 .
  • the base layer 850 is not comprised of a porous foam, but is instead comprised a standard flexible foam (e.g., a polyurethane foam) having a porosity less than that of the heat transfer layer 840 .
  • a barrier layer 884 is only used to surround the exterior surfaces of the base layer 850 and the heat transfer layer 840 , and is not positioned between the base layer 850 and the heat transfer layer 840 .
  • each of the mattress assemblies 10 , 110 , 210 , 310 , 410 , 510 , 610 , 710 , 810 shown in FIGS. 1-19 include a plurality of Peltier elements 30 , 130 , 230 , 330 , 430 , 530 , 630 , 730 , 830
  • the present invention is further inclusive of mattress assemblies that do not make use of a plurality of Peltier elements to selectively cool the body supporting layer of a mattress assembly. For example, as shown in FIG.
  • a mattress assembly 910 in an additional exemplary embodiment of the present invention, includes a body supporting layer 920 , a heat transfer layer 940 comprised of a porous flexible foam, and a base layer 950 comprised of a flexible foam having a porosity less than that of the porous flexible foam of the heat transfer layer 940 .
  • the mattress assembly 910 also includes three inlet conduits 952 a , 952 b , 952 c and two outlet conduits 954 a , 954 b defined by the base layer 950 .
  • a pair of fans 960 a , 960 b operably connected to a power supply 990 and a controller 992 , with one of the fans 960 a , 960 b operatively connected to each of the two outlet conduits 954 a , 954 b .
  • no Peltier elements are used to selectively cool the body supporting layer 920 of the mattress assembly.
  • the body supporting layer 920 is cooled by activating each of the fans 960 a , 960 b to draw an amount of air into the inlet conduits 952 a , 952 b , 952 c , through the heat transfer layer 940 where the air picks up heat absorbed by the adjacent body supporting layer 920 , and then into the outlet conduits 954 a , 954 b before being dissipated away from the mattress assembly 910 .
  • one or more covers can also be included and used to cover the mattress assemblies described herein.
  • a cover in the form of a fire sock can be first used to initially surround an exemplary mattress assembly.
  • an outer fabric cover such as a cover comprised of 100% cotton or another soft and breathable textile, can be used to cover the fire sock.
  • a cover assembly 2010 for an exemplary mattress assembly can be utilized that includes a first cover 2020 having a top panel 2022 , a bottom panel 2024 , and a continuous side panel 2030 .
  • the continuous side panel 2030 of the first cover 2020 can be characterized as including a head panel 2032 , a foot panel 2034 , and two opposing side panels 2036 , 2038 that, with the top panel 2022 and bottom panel 2024 , collectively define a cavity for enclosing a mattress assembly of the present invention.
  • the first cover 2020 further includes a brand tag 2062 extending vertically along a portion of the foot panel 2034 .
  • the cover assembly 2010 further includes a second cover 2040 having a top surface 2042 and a bottom surface 2044 , with the second cover 2040 also defining a perimeter 2046 .
  • the second cover 2040 of the cover assembly 2010 is generally positioned over the top panel 2022 of the first cover 2020 and is dimensionally-sized to cover at least the top panel 2022 of the first cover 2020 , the area of which is indicated by the hatching that is shown in FIG. 21 and that designates a blue color for the top panel 2022 of the first cover 2020 .
  • the second cover 2040 is dimensionally-sized to cover the top panel 2022 , the upper halves 2037 , 2039 of each opposing side panel 2036 , 2038 , an upper edge 2035 of the foot panel 2034 , and an upper edge 2033 of the head panel 2032 .
  • the second cover 2040 is thus configured to cover and protect the portions of the underlying first cover 2020 and, consequently, the portions of any mattress underlying the first cover 2020 , that would be exposed to excessive wear and would be at an increased risk of becoming stained or damaged, namely the top panel 2022 , the upper halves 2037 , 2039 of each opposing side panel 2036 , 2038 , the upper edge 2035 of the foot panel 2034 , and the upper edge 2033 of the head panel 2032 .
  • the second cover 2040 causes the upper halves 2037 , 2039 of each opposing side panel 2036 , 2038 to assume a more rounded configuration upon attachment of the second cover 2040 to the first cover 2020 via a zipper 2050 .
  • numerous other sizes and configurations for the second cover 2040 can also be readily selected as desired and can be incorporated into a particular cover assembly to prevent damage or staining to a mattress or to alter the appearance of an a mattress without departing from the spirit and scope of the subject matter described herein.
  • the support cushions shown in FIGS. 1-21 are in the form of mattress assemblies 10 , 110 , 210 , 310 , 410 , 510 , 610 , 710 , 810 , 910 , and are dimensionally sized to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to head pillows, seat cushions, seat backs, neck pillows, leg spacer pillows, mattress topers, overlays, and the like.
  • the phrase “support cushion” is used herein to refer to any and all such objects having any size or shape, and that are capable of or are generally used to support the body of a user or a portion thereof.
  • a support cushion made in accordance with the present invention is incorporated into the seat 1011 of a desk chair 1010 .
  • Each support cushion of the desk chair 1010 includes: a comfort layer 1072 ; a body supporting layer 1020 ; a plurality of Peltier elements 1030 ; a heat transfer layer 1040 comprised of a porous visco-elastic foam; a base layer 1050 comprised of a flexible foam having a porosity less than that of the visco-elastic foam included in the heat transfer layer 1040 ; and a fan 1060 operably connected to a power supply 990 and a controller 992 .
  • the base layer 1050 of the seat 1011 also defines a first inlet conduit 1052 a and a second inlet conduit 1052 b that each include a porous foam insert 1080 a , 1080 b , as well as an outlet conduit 1054 that includes a porous foam insert 1082 and that is operatively connected to the fan 1060 .
  • the fan 1060 draws an amount of air through the porous foam inserts 1080 a , 1080 b in the inlet conduits 1052 a , 1052 b , through the heat transfer layer 1040 , and then into the porous foam insert 1082 positioned in the outlet conduit 1054 , to thereby assist in the selective heating and cooling of the seat 1011 of the desk chair 1010 .
  • a method of controlling the surface temperature of a support cushion includes first providing a support cushion of the present invention. Electrical current is then supplied to each fan such that each fan draws an amount of air into each inlet conduit, through the heat transfer layer, and into each outlet conduit.
  • electrical current can also be supplied to the plurality of Peltier elements, such that when the electrical current is supplied in a first direction, the surface temperature of the body supporting portion decreases, but when electrical current is supplied in a second direction, the surface temperature of the body supporting portion increases.
  • the amount of electrical current supplied to the Peltier elements can be controlled.
  • the surface temperature of the support cushion is controlled by first receiving feedback from a temperature sensor or pressure sensor positioned in the body supporting portion of the support cushions, and then supplying electrical current to the fan, the plurality of Peltier elements, or both based on the feedback received from the temperature sensor, the pressure sensor, or both.

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  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
US14/899,244 2013-06-18 2014-06-17 Support Cushions Including Thermoelectric Elements and Air Conduits, and Methods for Controlling Surface Temperature of Same Abandoned US20160128487A1 (en)

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EP3010377A1 (en) 2016-04-27
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JP2016522068A (ja) 2016-07-28
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