WO2016171692A1 - Support cushions and methods for active ventilation of same - Google Patents

Support cushions and methods for active ventilation of same Download PDF

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Publication number
WO2016171692A1
WO2016171692A1 PCT/US2015/027262 US2015027262W WO2016171692A1 WO 2016171692 A1 WO2016171692 A1 WO 2016171692A1 US 2015027262 W US2015027262 W US 2015027262W WO 2016171692 A1 WO2016171692 A1 WO 2016171692A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
base layer
body supporting
support cushion
lower base
Prior art date
Application number
PCT/US2015/027262
Other languages
French (fr)
Inventor
Paul E. GRIESE
Daniel S. Powell
Leslie A. BURTON
Mario A.G. NAVA
Original Assignee
Tempur-Pedic Management, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tempur-Pedic Management, Llc filed Critical Tempur-Pedic Management, Llc
Priority to AU2015392446A priority Critical patent/AU2015392446A1/en
Priority to CN201580079015.4A priority patent/CN107529895A/en
Priority to PCT/US2015/027262 priority patent/WO2016171692A1/en
Priority to EP19180957.3A priority patent/EP3560389A1/en
Priority to EP15890095.1A priority patent/EP3285618B1/en
Priority to US15/568,368 priority patent/US20180098637A1/en
Publication of WO2016171692A1 publication Critical patent/WO2016171692A1/en
Priority to HK18107171.6A priority patent/HK1247537A1/en

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Classifications

    • 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, 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
    • 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
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers

Definitions

  • the present invention relates to support cushions and methods for actively ventilating support cushions.
  • the present invention relates to support cushions, such as mattress assemblies, that make use of a Fan located within the support cushion to draw and amount of air through and aw ay from the support cushion.
  • 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 w ay 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 inaitemiveness.
  • sleep disorders have been linked to hypertension, increased stress hormone levels, and irregular heartbeat, and additional research has recently suggested that a lack of sleep can affect immune function, resulting in increased susceptibility to illness and disease, e.g.. cancer.
  • researchers have now suggested that sleep debt costs the United States $63 billion annual ly in lost productivity due to these various effects. Accordingly, a support cushion that improves sleep comfort and lowers individual sleep debt would be both highly desirable and beneficial.
  • the present invention relates to support cushions and methods for actively ventilating support cushions.
  • the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw and amount of air through and away from the support cushion.
  • the support cushions of the present invention allow a user to increase his or her level of comfort, including steep comfort, by actively ventilating the support cushions.
  • a support cushion in the form of a mattress assembly includes a body supporting layer having a first surface and a second surface.
  • the body supporting layer of the mattress assembly includes a first porous foam insert that is positioned in a first side of the body supporting layer, and a second porous foam insert that is positioned in a second side of the body supporting layer opposite the first porous foam insert.
  • Both the first porous foam insert and the second porous foam insert are generally sized to support a torso of a user lying on the mattress assembly.
  • the first porous foam insert and the second porous foam insert are not only- configured to support the torso of a user lying on the mattress assembly, but are also configured to assist in dissipating any heat generated by the torso of a user lying on the mattress assembly away front the body supporting layer and the remainder of the mattress assembly.
  • the body supporting layer of the mattress assembly is covered by a comfort portion or layer that is positioned atop the body supporting layer.
  • the comfort layer defines a first plurality of channels and a second plurality of channels that extend through the comfort layer and that are positioned over the first porous foam insert and the second porous foam insert, respectively, of the body supporting layer.
  • the channels of the comfort layer place the first porous foam insert and the second porous foam insert in fluid communication with not only the comfort layer, but also with the environment surrounding the mattress assembly and/or the body of a user lying on the mattress assembly.
  • the comfort layer In addition to placing the first porous loan) insert and the second porous foam insert in communication with the surrounding environment, however, the comfort layer also functions to provide a level of comfort to a body of a user or a portion of thereof that is resting on the mattress assembly.
  • an upper base layer that is positioned adjacent to the second surface of the body supporting layer.
  • the upper base layer defines a first plurality of air conduits and a second plurality of air conduits that extend through the upper base layer and that are positioned below the first porous foam insert and the second porous foam insert, respectively, of the body supporting layer.
  • a lower base layer is also included in the exemplary mattress assembly and is positioned adjacent to the upper base layer opposite the body supporting layer.
  • the lower base layer defines a first cavity and a second cavity, w hich both extend through the lower base layer.
  • the first cavity of the lower base layer houses a fan assembly and is positioned belovv and is in fluid communication with the first plurality of air conduits in the upper base layer .
  • the second cavity houses a separate fan assembly and is positioned below and is in fluid communication w ith the second plurality of air conduits .
  • the fan assemblies draw air through the channels in the comfort layer, through the porous foam inserts in the body supporting layer, through air conduits in the upper base layer, and then through the fan assemblies and the low er base layer, where it is then exhausted air into a bottom layer of the mattress assembly that is positioned adjacent to the lower base layer opposite the upper base layer.
  • each of the fan assemblies includes a fan that is mounted in a housing sized to fit within one of the cavities defined by the lower base layer and to be fricttonally held in position within the cavities even when the mattress assembly is moved, tipped, or otherwise adjusted.
  • the fan assemblies each furthe r include a sleeve that is positioned between each of the housings and the respective cavities and that is comprised of a material w hich promotes friction between the cavities and the respective housings.
  • an exemplary mattress assembly also includes a power supply for supplying electrical current to the fan assemblies and a controller for controlling the electrical current supplied to the fan assemblies from the power supply.
  • an exemplary mattress assembly can further include several features that are operably connected to the body supporting layer and provide input to the controller.
  • an exemplary mattress assembly includes temperature sensors that are operably connected to porous foam inserts included in the body supporting layer and that provide temperature feedback to the controller to thereby not only allow the controller to selectively prov ide power to the fan assemblies and adjust how quickly or how much air is moved through the mattress assembly in response to the received temperature feedback, but to also maintain a desired temperature at the first surface of the body supporting layer.
  • pressure sensors are also operably connected to the body supporting layer and provide pressure feedback to the controller in response to a user resting upon or adjacent to the first surface of the body supporting layer.
  • a method for actively ventilating a support cushion includes first providing a support of the present invention. Power, in the form of electrical current, is then supplied to the fans in the support cushion, such that the fan draw s air from the first surface of the body supporting layer, through upper ba.se layer and lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion to thereby actively ventilate the support cushion and dissipate any heat away from the body supporting lay er of the support cushion.
  • Power in the form of electrical current
  • FIG. 1 is a perspective v iew of an exemplary support cushion, in the form of a mattress assembly, made in accordance with the present invention:
  • FIG. 2 is an exploded, perspective v iew of the exemplary mattress assembly of FIG. 1 :
  • FIG. 3 is a cross-sectional view of the exemplary mattress assembly of T IG. 1 taken along line 3-3 of FIG. 1 :
  • FIG. 4 is an exploded perspective view of a fan assembly included in die exemplary mattress assembly of FIG. 1 : and
  • FIG. 5 is a cross-sectional view of another exemplary support cushion, in the form of another mattress assembly, made in accordance w ith the present invention and showing the mattress assembly having an adjustable foundation.
  • the present invention relates to support cushions and methods for actively ventilating support cushions.
  • the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw an amount of air through and away from the support cushion.
  • the support cushions of the present invention allow a user to increase his or her level of comfort, including sleep comfort, by actively ventilating 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. which is generally an upper surface of the body supporting layer 20. and a second surface 24. w hich is opposite the first surface 22 and is generally the lower surface of the body supporting layer 20.
  • the body supporting layer 20 of the mattress assembly 10 includes a first porous foam insert 26a positioned in a first side 28 of the body supporting layer 20. and a second porous foam insert 26b that is positioned in a second side 29 of the body supporting layer 20 opposite the first porous foam insert 26a.
  • Both the first porous foam insert 26a and the second porous foam insert 26b are generally sized to support a torso of a user lying on the mattress assembly '
  • the first porous foam insert 26a and the second porous foam insert 26b are not only configured to support the torso of a user lying on the mattress assembly 10. but the first porous foam insert 26a and the second porous foam insert 26b are also configured to assist in dissipating any heat generated by the torso of a user lying on the mattress assembly 10 away from the body supporting layer 20 and the remainder of the mattress assembly 10, as described in further detail below.
  • 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-resi lience foam ), reticulated or non-retieutaled non-visco-eiastic loam, polyurethane high-resilience foam, expanded polymer foams (e.g.. expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like.
  • FIGS. 1 -4 expanded polymer foams (e.g. expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like.
  • the bods .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 hod ⁇ ' 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 hod ⁇ ' 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.. 2 ! ⁇ C to 23 f> 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 viseo- 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 prov ide 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' to no greater than about 1 50 kg/m ⁇
  • the density of the visco-elastic foam used in the body supporting layer 20 of the mattress assembly 10 is about 30 kg m 1 . about 40 kg/m ', about 50 kg m ⁇ about 60 kg/m ⁇ about 70 kg/m- ⁇ about 80 kg/m ⁇ about 90 kg/m ⁇ about 100 kg/m- 5 .
  • a visco-elastic foam having a particular density n il! 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 ibam 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 porous foam inserts 26a. 26b are also comprised of a viseo-elasttc foam, but are generally comprised of a viscoelasiic foam having a porosity greater than the viseo-elastie foam included in the body supporting layer 20 to allow air to enter the porous foam inserts 26a, 26b more readily than the remainder of the body supporting layer 20.
  • the porous foam inserts 26a, 26b need not be comprised of a viseo-elastie foam at all.
  • porous foam or “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. In other words, at least a portion of the cells of the foam are each def ined 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.. w indows hav ing apertures therethrough, or w indows that are completely missing and therefore leaving only the cell struts ).
  • Such structures can be created by destruction or other removal of ceil window material, by chemical or mechanical means, or by preventing the complete formation of celt window s during the manufacturing process of the foam.
  • the term "porous'' can thus be used interchangeably w ith the term "reticulated' ' when referring to flexible foam.
  • the body supporting layer 20 of the mattress assembly 10 is further covered by a comfort portion or layer 62 (hat is positioned atop the body supporting layer 20.
  • the comfort layer 62 defines a first plurality of channels 66a and a second plurality of channels 66b that extend through the comfort layer 62 and that are positioned over the first porous foam insert 26a and the second porous foam insert 26b. respectively.
  • the channels 66a, 66b of the comfort layer 62 place the first porous foam insert 26a and the second porous foam insert 26b in fluid communication w ith not only the comfort layer 62.
  • the comfort layer 62 also functions to provide 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 62 can also be comprised of a visco-elastie foam, but 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 62 provides a softer surface on which to rest the body of a user.
  • the mattress assembly 10 includes a body supporting layer 20 that is comprised of visco-elastie foam with a density of about 80 kg/m ;i and a hardness of about 13 N, while the comfort layer is comprised of a visco-elastic foam with a density of about 35 kg/nr and a hardness of about 10 N.
  • the upper base layer 30 defines a first plurality of air conduits 32a and a second plurality of air conduits 32b that extend through the upper base layer 30 and that are positioned below the first porous foam insert 26a and the second porous foam insert 26b, respectively, of the body supporting layer 20,
  • first plurality of air conduits 32a and the second plurality of air conduits 32b are thus placed in direct fluid communication with the first porous foam insert 26b and the second porous foam insert 26b, and create a pathway for air to flow from the body supporting layer 20 and through the upper base layer 30, the importance of which is also described in further detail below .
  • pathways for air to flow from the body supporting layer 20 and through the upper base layer 30 can also be created by using a variety of other means, such as porous foam inserts with or without air conduits and which may he positioned in an exemplary upper base layer w ithout departing from the spirit and scope of the subject matter described herein.
  • a lower base layer 40 is also included in the exemplary mattress assembly 10 and is positioned adjacent to the upper base layer 30 opposite the body supporting layer 20,
  • the lower base layer 40 defines a first cavity *i2a and a second cavity 42b. w hich both extend through the low er base layer 40.
  • T he first cavity 42a of the lower base layer 40 houses a fan assembly 80a and is positioned below and is in fluid communication with the first plurality of air conduits 32a in the upper base layer 30.
  • the second cavity 42b houses a separate fan assembly 80b and is positioned below and is in fluid communication with the second plurality of air conduits 32b.
  • the fan assemblies 80a, 80b upon activation of the fan assemblies 80a, 80b in the first cav ity 42a and the second cavity 42b defined by the lower base layer 40.
  • the fan assemblies 80a. 80b draw air through the channels 66a, 66b in the comfort layer 62. through the porous foam inserts 26a. 26b in the body supporting layer 20. through air conduits 32a. 32b in the upper base layer 30, and then through the fan assemblies 80a. 80b and the lower base layer 40, where it is then exhausted air into a bottom layer 50 of the mattress assembly 10 that is positioned adjacent to the lower base layer 40 opposite the upper base layer 30.
  • any associated heat around or within the comfort layer 62 and the body supporting layer 20 that may be present as a result of a user lying on the mattress assembly 10 is drawn away from the comfort layer 62 and the body supporting layer 20 and is pulled through the mattress assembly 10 before being dissipated away from the mattress assembly 10 through the bottom layer 50.
  • the upper base layer 30 and the lower base layer 40 of the mattress assembly 10 can also be comprised of a flexible foam, including any of the flexible foams described above with reference to the body supporting layer 20,
  • the flexible foam comprising the body supporting layer 20 typically has a density less than that of the upper base layer 30 and the lower base layer 40.
  • the upper base layer 30 and the lower base layer 40 have a density and hardness sufficient for supporting the body supporting layer 20 and the comfort layer 62 of the mattress assembly.
  • the mattress assembly 10 show n in FIGS.
  • the tipper base layer 30 and the lower base layer 40 are comprised of a higher density, porous polyurethane foam that provides sufficient support to the overlying body supporting layer 20 and the comfort layer, but that also provides an open environment in which air can move by virtue of its porous structure.
  • the bottom layer 50 is further comprised of a breathable porous material that promotes the dispersion of the air, including the air exhausted into the bottom layer 50 by the fan assemblies 80a, 80b, but that also provides support to the remainder of the mattress assembly 10.
  • the porous materials included in the bottom layer 50 can be selected from a reticulated foam, knitted spacer fabric, textile, or a composite material.
  • a knitted spacer fabric can be included that is generally comprised of two exterior mesh textile substrates and an insert material such as polyester monofilaments w hich are configured to keep the two exterior mesh textile substrates separated.
  • Such knitted spacer fabrics include, by way of example, the WellcoolTM 3D spacer fabric manufactured by Quan/.bou Wellcool Cushion Technology Co.. Ltd (Fujian, China).
  • the body supporting layer 20. the upper base layer 30, and the lower base layer 40 arc general ly secured to one another to prevent the body supporting layer 20, the upper base layer 30, the lower base layer 40, the bottom layer 50. and the com fort layer 62 from moving relative to one another during use.
  • Various means of securing one layer of material to another can be used in this regard, included ing tape, hook and loop fasteners, conventional fasteners, stitches, and the like.
  • the body supporting layer 20. the upper base layer 30, the low er base layer 40. the bottom layer 50 are examples of the particular materials used in the bottom layer 50. in the mattress assembly 10.
  • an adhesive or cohesive bonding material to create a substantially continuous assembly w here the body supporting layer 20.
  • the upper base layer 30, the lower base layer 40, the bottom layer 50. and the comfort layer 62 are fully adhered to one another.
  • adhesive bonding materials include, for example, environmental!y-fnendly.
  • water based adhesives like SABA AQUA BOND RSD. a tw o-component water-based adhesive product produced by SABA DINX PHRLO BV . B-7000 ⁇ , Dinxperlo. Belgium.
  • the fan assemblies 80a. 80b included in the mattress assembly 10 are housed internally w ithin the mattress assembly 10. More specifically, the fan assemblies 80a, 80b are housed w ithin the cavities 42a, 42b of the lower base layer 40 with the upper base layer 30 covering the fan assemblies from above and the bottom layer 50 covering the fan assembl ies 80a, 80b from below. In this regard, each of the fan assemblies 80a, 80b inc ludes a fan 82a.
  • the fan assemblies 80a. 80b each further include a sleeve 88a. 88b that is positioned between each of the housings 84a. 84b and the respective cavities 42a.
  • each of the sleeves 88a, 88b provide a means of securing and positioning an air filter 86a, 86b within each of the fan assemblies 80a. 80b.
  • the mattress assembly 10 aiso includes a power supply 92 for supplying electrical current to the fan assemblies 80a, 80b and a controller 90 for controlling the electrical current supplied to the fan assemblies 80a, 80b from the power supply 92.
  • the controller 90 By including the controller 90 in the mattress assembly ! 0. the amount of electrical current supplied to the fan assemblies 80a. 80b front the power supply 92 can be controlled to allow for a desired amount of air to move through the mattress assembly 10 and. consequently, a desired amount of heat to be dissipated away from the body supporting layer 20 of the mattress assembly 10.
  • the controller 90 can be used to simply turn the fan assemblies 80a, 80b on or off depending on w hether the user wishes to ventilate the mattress assembly 10 and remove heat from the body supporting layer 20 of the mattress assembly 10, or can be used to operate the fan assemblies 80a. 80b at a particular speed depending on how quickly the user wishes to ventilate the mattress assembly 10 and remove heat from the body supporting layer 20 of the mattress assembly 10.
  • the controller 90 can also be configured to automatically control the electrical current supplied to the fan assemblies 80a, 80b from the power supply 92, such that the electrical current can be supplied to the fan assemblies 80a, 80b when the first surface 22 of the body supporting layer 20 reaches a desired temperature.
  • the controller 90 can be configured to allow the electrical current to be supplied to the fan assemblies 80a. 80b from the power supply 92 for a predetermined time period, such as for an 8-hour sleeping period or for a length of time a user usually spends in a specific stage of the sleep cycle (e.g.. RFM sleep) in order to increase the sleep comfort of a user,
  • a predetermined time period such as for an 8-hour sleeping period or for a length of time a user usually spends in a specific stage of the sleep cycle (e.g.. RFM sleep) in order to increase the sleep comfort of a user
  • the mattress assembly 10 also includes several features that are operably connected to the body supporting layer 20 and provide input to the controller 90. for example, as shown best in FIG. 2.
  • the mattress assembly 10 includes temperature sensors 94a. 94b that are operably connected to porous (bam inserts 26a, 26b included in the body supporting layer 20 and that provide temperature feedback to the controller 90 to thereby not only allow the controller 90 to selectively provide power to the fan assemblies 80a, 80b and adjust how quickly or how much air is moved through the mattress assembly 10 in response to the received temperature feedback, but to also maintain a desired temperature at the first surface 22 of the body supporting layer 20.
  • FIG. 2 As another example, and as also shown best in FIG. 2.
  • pressure sensors 96a. 96b are also operably connected to the body supporting layer 20 and provide pressure feedback to the controller 90 in response to a user resting upon or adjacent to the ⁇ list surface 22 of the body supporting layer 20, such that the controller 90 can automatically allow power to be provided to the fan assemblies 80a. 80b air to be moved through 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.
  • An additional benefit of the inclusion of the pressure sensors 96a. 96b is (hat the controller 90 can be configured to automatically shut off the fan assemblies 80a. 80b if a user is no longer lying on the mattress assembly 10.
  • a remote control not shown
  • FIG. 5 in another exemplary embodiment of the present invention, another support cushion in the form of a mattress assembly f 10 is provided that includes additional features to increase the comfort and convenience of the user of the mattress assembly f 10. Like the support cushion show n in FIGS. 1 -4.
  • the mattress assembly 1 10 also includes: a comfort layer 162 defining a plurality of channels 166; a body supporting layer 120 including a porous foam insert 126; an upper base layer 130 positioned below the body supporting layer 120 and defining a plurality of air conduits 132 in fluid communication w ith the porous foam insert 126; a lower base layer 140 defining a cavity 142 w ith a fan assembly 1 80 located w ithin the cavity 142: and a bottom layer 1 50 positioned below the lower base layer 140.
  • an adjustable foundation 1 70 is included in the mattress assembly, however, is an adjustable foundation 1 70 that is positioned below the bottom layer 150 and allows a user to place the mattress assembly 1 10 into one or more desired ergonomic positions.
  • a cover 172 is included in the mattress assembly ! 10 and surrounds the comfort layer 162, the body supporting layer 1 20. the upper base layer 130, the lower base layer 140. and the bottom layer 1 50 of the mattress assembly 1 10.
  • the cover 172 in the form of a fire sock that surround the various layers is comprised of a flame retardain material.
  • an exemplar, cover of the present invention can also be comprised of another textile, such as cotton that provide an exemplary support cushion with a unitary appearance, but that also provides a user with a sufficiently soft surface on which to rest while being sufficiently breathable to allow air to he drawn through the cover and the exemplary support cushion.
  • another textile such as cotton that provide an exemplary support cushion with a unitary appearance, but that also provides a user with a sufficiently soft surface on which to rest while being sufficiently breathable to allow air to he drawn through the cover and the exemplary support cushion.
  • FIGS. 1 -3 and 5 are in the form of mattress assemblies 10. 1 10 and are dimeiisional!y-sized to support a user lying in a supine or prone position
  • the features described herein are equally applicable to other support cushions, such as head pillows, seat cushions, seat backs, neck pillows, leg spacer pillows, mattress topers, overlays, and the like.
  • the phrase "body support' * or "body supporting'” is used herein to refer to any and all such objects having arty size or shape, and that are capable of supporting, or are generally used to support, the body of a user or a portion thereof.
  • the body supporting layer 20 of the mattress assembly 10 shown in FIGS. i -3. includes two removable inserts 26a, 26b, two sets of air conduits 32a, 32b. two cavities 42a, 42b. and two tan assemblies 80a, 80b, it is also contemplated other embodiments may include any number of removable portions, conduits, cavities, and fan assemblies depending on the size and shape of the particular support cushion.
  • a method for actively ventilating a support cushion includes first providing a support cushion having: a body supporting layer having a first surface and a second surface opposite the first surface; an upper base layer positioned adjacent to the second surface of the body supporting layer and defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer: a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer and defining a cav ity extending through the lower base layer; a bottom layer positioned adjacent to the lower base layer opposite the upper base layer: and a fan located within the cavity define by the lower base layer.
  • Power in the form of electrical current, is then supplied to the fan, such that the fan draws air from the first surface of the body supporting layer, through upper base layer and lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion to thereby actively ventilate the support cushion and dissipate any heat away from the body supporting layer of the support cushion.

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  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

A support cushion is provided for moving an amount of air through the support cushion. The support cushion includes a body supporting layer having a removable portion, an upper base layer defining one or more air conduits In fluid communication with the removable portion, a lower base layer defining a cavity, and a bottom layer. A fan is positioned within the cavity such that the fan is in fluid communication with the one or more air conduits defined by the upper base layer. The fan is thus capable of drawing air from the top surface of the body supporting layer, through the removable portion, through the one or more air conduits in the upper base layer, and exhausting the air into the bottom layer. Methods of actively ventilating a support cushion are also provided.

Description

SUPPORT CUSHIONS AND METHODS FOR ACTIVE VENTILATION OF SAME
TECHNICAL FIELD
[0001] The present invention relates to support cushions and methods for actively ventilating support cushions. In particular, the present invention relates to support cushions, such as mattress assemblies, that make use of a Fan located within the support cushion to draw and amount of air through and aw ay from the support cushion.
BACKGROUND
[0002] An aspect of successful and restful steep is individual sleep comfort. Medical research suggests that sleep deprivation ("steep debt") 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 w ay the body processes and stores carbohydrates, but has also been observed to alter hormone levels that affect appetite. Moreover, 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 inaitemiveness. furthermore, sleep disorders have been linked to hypertension, increased stress hormone levels, and irregular heartbeat, and additional research has recently suggested that a lack of sleep can affect immune function, resulting in increased susceptibility to illness and disease, e.g.. cancer. In ail, researchers have now suggested that sleep debt costs the United States $63 billion annual ly in lost productivity due to these various effects. Accordingly, a support cushion that improves sleep comfort and lowers individual sleep debt would be both highly desirable and beneficial.
SUMMARY
[0003] The present invention relates to support cushions and methods for actively ventilating support cushions. In particular, the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw and amount of air through and away from the support cushion. Thus, the support cushions of the present invention allow a user to increase his or her level of comfort, including steep comfort, by actively ventilating the support cushions.
[0004] In one exemplar} embodiment of the present invention, a support cushion in the form of a mattress assembly is provided that includes a body supporting layer having a first surface and a second surface. The body supporting layer of the mattress assembly includes a first porous foam insert that is positioned in a first side of the body supporting layer, and a second porous foam insert that is positioned in a second side of the body supporting layer opposite the first porous foam insert. Both the first porous foam insert and the second porous foam insert are generally sized to support a torso of a user lying on the mattress assembly. T hus, as a result of the size and position of the first porous foam insert and the second porous foam insert, the first porous foam insert and the second porous foam insert are not only- configured to support the torso of a user lying on the mattress assembly, but are also configured to assist in dissipating any heat generated by the torso of a user lying on the mattress assembly away front the body supporting layer and the remainder of the mattress assembly.
[0005] The body supporting layer of the mattress assembly is covered by a comfort portion or layer that is positioned atop the body supporting layer. The comfort layer defines a first plurality of channels and a second plurality of channels that extend through the comfort layer and that are positioned over the first porous foam insert and the second porous foam insert, respectively, of the body supporting layer. By positioning the channels over the first porous foam insert and the second porous foam insert, the channels of the comfort layer place the first porous foam insert and the second porous foam insert in fluid communication with not only the comfort layer, but also with the environment surrounding the mattress assembly and/or the body of a user lying on the mattress assembly. In addition to placing the first porous loan) insert and the second porous foam insert in communication with the surrounding environment, however, the comfort layer also functions to provide a level of comfort to a body of a user or a portion of thereof that is resting on the mattress assembly.
[0006] Further included in the mattress assembly is an upper base layer that is positioned adjacent to the second surface of the body supporting layer. The upper base layer defines a first plurality of air conduits and a second plurality of air conduits that extend through the upper base layer and that are positioned below the first porous foam insert and the second porous foam insert, respectively, of the body supporting layer. By positioning the first plurality of air conduits and the second plurality of air conduits below the first porous foam insert and the second porous foam insert of the body supporting layer, the first plurality of air conduits and the second plurality of air conduits are thus placed in direct fluid communication with the first porous foam insert and the second porous foam insert, and create a pathway for air to flow from the body supporting layer and through the upper base layer.
[0007] In addition to the upper base layer, a lower base layer is also included in the exemplary mattress assembly and is positioned adjacent to the upper base layer opposite the body supporting layer. The lower base layer defines a first cavity and a second cavity, w hich both extend through the lower base layer. The first cavity of the lower base layer houses a fan assembly and is positioned belovv and is in fluid communication with the first plurality of air conduits in the upper base layer . Similarly, the second cavity houses a separate fan assembly and is positioned below and is in fluid communication w ith the second plurality of air conduits . In this regard, upon activation of the fan assemblies in the first cavity and the second cavity defined by the lower base layer, the fan assemblies draw air through the channels in the comfort layer, through the porous foam inserts in the body supporting layer, through air conduits in the upper base layer, and then through the fan assemblies and the low er base layer, where it is then exhausted air into a bottom layer of the mattress assembly that is positioned adjacent to the lower base layer opposite the upper base layer.
[0008] With further respect to the fan assemblies included in the mattress assembly, as indicated above, the fan assemblies are housed w iihin the cavities of the lower base layer w ith the upper base layer covering the fan assemblies from above and the bottom layer covering the fan assemblies from below. In this regard, each of the fan assemblies includes a fan that is mounted in a housing sized to fit within one of the cavities defined by the lower base layer and to be fricttonally held in position within the cavities even when the mattress assembly is moved, tipped, or otherwise adjusted. To further promote the fractional connection between the housings and the cavities defined by the lower base layer, the fan assemblies each furthe r include a sleeve that is positioned between each of the housings and the respective cavities and that is comprised of a material w hich promotes friction between the cavities and the respective housings.
[0009] To provide an amount of control over the amount of air being moved by the fan and the active ventilation of the mattress assembly, an exemplary mattress assembly also includes a power supply for supplying electrical current to the fan assemblies and a controller for controlling the electrical current supplied to the fan assemblies from the power supply. To provide an additional level of control over the movement of air through the mattress, an exemplary mattress assembly can further include several features that are operably connected to the body supporting layer and provide input to the controller. For example, in some embodiments, an exemplary mattress assembly includes temperature sensors that are operably connected to porous foam inserts included in the body supporting layer and that provide temperature feedback to the controller to thereby not only allow the controller to selectively prov ide power to the fan assemblies and adjust how quickly or how much air is moved through the mattress assembly in response to the received temperature feedback, but to also maintain a desired temperature at the first surface of the body supporting layer. As another example, in some embodiments, pressure sensors are also operably connected to the body supporting layer and provide pressure feedback to the controller in response to a user resting upon or adjacent to the first surface of the body supporting layer.
[0010] Each of the exemplary support cushions described herein can also be used as part of a method for actively ventilating a support cushion, in some implementations, a method for actively ventilating a support cushion includes first providing a support of the present invention. Power, in the form of electrical current, is then supplied to the fans in the support cushion, such that the fan draw s air from the first surface of the body supporting layer, through upper ba.se layer and lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion to thereby actively ventilate the support cushion and dissipate any heat away from the body supporting lay er of the support cushion.
[0011] Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective v iew of an exemplary support cushion, in the form of a mattress assembly, made in accordance with the present invention:
[0013] FIG. 2 is an exploded, perspective v iew of the exemplary mattress assembly of FIG. 1 :
[0014] FIG. 3 is a cross-sectional view of the exemplary mattress assembly of T IG. 1 taken along line 3-3 of FIG. 1 :
[0015] FIG. 4 is an exploded perspective view of a fan assembly included in die exemplary mattress assembly of FIG. 1 : and |()0I6j FIG. 5 is a cross-sectional view of another exemplary support cushion, in the form of another mattress assembly, made in accordance w ith the present invention and showing the mattress assembly having an adjustable foundation.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0017] The present invention relates to support cushions and methods for actively ventilating support cushions. In particular, the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw an amount of air through and away from the support cushion. Thus, the support cushions of the present invention allow a user to increase his or her level of comfort, including sleep comfort, by actively ventilating the support cushions.
[0018] Referring first to FIGS. 1 -3, in one exemplary embodiment of the present invention, 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. which is generally an upper surface of the body supporting layer 20. and a second surface 24. w hich is opposite the first surface 22 and is generally the lower surface of the body supporting layer 20. The body supporting layer 20 of the mattress assembly 10 includes a first porous foam insert 26a positioned in a first side 28 of the body supporting layer 20. and a second porous foam insert 26b that is positioned in a second side 29 of the body supporting layer 20 opposite the first porous foam insert 26a. Both the first porous foam insert 26a and the second porous foam insert 26b are generally sized to support a torso of a user lying on the mattress assembly 'Thus, as a result of the size and position of the first porous foam insert 26a and the second porous foam insert 26b. the first porous foam insert 26a and the second porous foam insert 26b are not only configured to support the torso of a user lying on the mattress assembly 10. but the first porous foam insert 26a and the second porous foam insert 26b are also configured to assist in dissipating any heat generated by the torso of a user lying on the mattress assembly 10 away from the body supporting layer 20 and the remainder of the mattress assembly 10, as described in further detail below.
[0019] 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. Such 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-resi lience foam ), reticulated or non-retieutaled non-visco-eiastic loam, polyurethane high-resilience foam, expanded polymer foams (e.g.. expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. In the embodiment shown in FIGS. 1 -4. the bods .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 hod}' supporting layer 20 of the mattress assembly 10. Generally, .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.. 2 ! ~C to 23f>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. In some embodiments, the viseo- 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 prov ide a desired degree of comfort and body- conforming qualities.
[0020] 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. In some embodiments, 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' to no greater than about 1 50 kg/m \ In some embodiments, the density of the visco-elastic foam used in the body supporting layer 20 of the mattress assembly 10 is about 30 kg m 1. about 40 kg/m ', about 50 kg m\ about 60 kg/m\ about 70 kg/m-\ about 80 kg/m\ about 90 kg/m \ about 100 kg/m-5. about 1 10 kg''m \ about 120 kg/nv\ about 130 kg/m '. about 140 kg/m \ or about 150 kg/m?. Of course, the selection of a visco-elastic foam having a particular density n il! 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 ibam 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.
[0021] With even further respect to the body supporting layer 20 of the mattress assembly 10 and, in particular, the porous loan) inserts 26a. 26b included in the body supporting layer 20 of the mattress assembly 10, the porous foam inserts 26a. 26b are also comprised of a viseo-elasttc foam, but are generally comprised of a viscoelasiic foam having a porosity greater than the viseo-elastie foam included in the body supporting layer 20 to allow air to enter the porous foam inserts 26a, 26b more readily than the remainder of the body supporting layer 20. Of course, it is also contemplated that the porous foam inserts 26a, 26b need not be comprised of a viseo-elastie foam at all. but that any number of porous flexible foams can be used to produce a porous foam insert having a porosity sufficient to allow for air to readily enter and move through. In this regard, the term "porous foam" or "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. In other words, at least a portion of the cells of the foam are each def ined 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. In some embodiments, the foam is considered ' porous" if at least 50% of the windows of the cells are missing ( i.e.. w indows hav ing apertures therethrough, or w indows that are completely missing and therefore leaving only the cell struts ). Such structures can be created by destruction or other removal of ceil window material, by chemical or mechanical means, or by preventing the complete formation of celt window s during the manufacturing process of the foam. In some embodiments of the present invention, the term "porous'' can thus be used interchangeably w ith the term "reticulated'' when referring to flexible foam.
[0022] Referring still to FIGS. 1 -3, the body supporting layer 20 of the mattress assembly 10 is further covered by a comfort portion or layer 62 (hat is positioned atop the body supporting layer 20. The comfort layer 62 defines a first plurality of channels 66a and a second plurality of channels 66b that extend through the comfort layer 62 and that are positioned over the first porous foam insert 26a and the second porous foam insert 26b. respectively. By positioning the channels 66a, 66b over the first porous foam insert 26a and the second porous foam insert 26b. the channels 66a, 66b of the comfort layer 62 place the first porous foam insert 26a and the second porous foam insert 26b in fluid communication w ith not only the comfort layer 62. but also with the environment surrounding the mattress assembly 10 and/or the body of a user lying on the mattress assembly 10. In addition to placing the first porous foam insert 26a and the second porous foam insert 26b in communication with the surrounding environment, however, the comfort layer 62 also functions to provide a level of comfort to a body of a user or a portion of thereof that is resting on the mattress assembly 10. In this regard, the comfort layer 62 can also be comprised of a visco-elastie foam, but 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 62 provides a softer surface on which to rest the body of a user. For example, in certain embodiments, the mattress assembly 10 includes a body supporting layer 20 that is comprised of visco-elastie foam with a density of about 80 kg/m;i and a hardness of about 13 N, while the comfort layer is comprised of a visco-elastic foam with a density of about 35 kg/nr and a hardness of about 10 N.
[0023] Regardless of die particular types of foam included in the body supporting layer 20, the porous foam inserts 26a, 26b. and the comfort layer 62. further included in the mattress assembly 10 is an upper base layer 30 that is positioned adjacent to the second surface 2*1 of the body supporting layer 20. The upper base layer 30 defines a first plurality of air conduits 32a and a second plurality of air conduits 32b that extend through the upper base layer 30 and that are positioned below the first porous foam insert 26a and the second porous foam insert 26b, respectively, of the body supporting layer 20, By positioning the first plurality of air conduits 32a and the second plurality of air conduits 32b below the first porous foam insert 26a and the second porous foam insert 26b of the body supporting layer 20, the first plurality of air conduits 32a and the second plurality of air conduits 32b are thus placed in direct fluid communication with the first porous foam insert 26b and the second porous foam insert 26b, and create a pathway for air to flow from the body supporting layer 20 and through the upper base layer 30, the importance of which is also described in further detail below . Of course, pathways for air to flow from the body supporting layer 20 and through the upper base layer 30 can also be created by using a variety of other means, such as porous foam inserts with or without air conduits and which may he positioned in an exemplary upper base layer w ithout departing from the spirit and scope of the subject matter described herein.
[0024] In addition to the upper base layer 30. and referring still to FIGS. 1 -3. a lower base layer 40 is also included in the exemplary mattress assembly 10 and is positioned adjacent to the upper base layer 30 opposite the body supporting layer 20, The lower base layer 40 defines a first cavity *i2a and a second cavity 42b. w hich both extend through the low er base layer 40. T he first cavity 42a of the lower base layer 40 houses a fan assembly 80a and is positioned below and is in fluid communication with the first plurality of air conduits 32a in the upper base layer 30. Similarly, the second cavity 42b houses a separate fan assembly 80b and is positioned below and is in fluid communication with the second plurality of air conduits 32b. In this regard, upon activation of the fan assemblies 80a, 80b in the first cav ity 42a and the second cavity 42b defined by the lower base layer 40. the fan assemblies 80a. 80b draw air through the channels 66a, 66b in the comfort layer 62. through the porous foam inserts 26a. 26b in the body supporting layer 20. through air conduits 32a. 32b in the upper base layer 30, and then through the fan assemblies 80a. 80b and the lower base layer 40, where it is then exhausted air into a bottom layer 50 of the mattress assembly 10 that is positioned adjacent to the lower base layer 40 opposite the upper base layer 30. In other words, by activating the fan assemblies 80a, 80b, any air and. consequently, any associated heat around or within the comfort layer 62 and the body supporting layer 20 that may be present as a result of a user lying on the mattress assembly 10 is drawn away from the comfort layer 62 and the body supporting layer 20 and is pulled through the mattress assembly 10 before being dissipated away from the mattress assembly 10 through the bottom layer 50.
[0025] With further regard to the upper base layer 30 and the lower base layer 40 of the mattress assembly 10. like the body supporting layer 20 and the comfort layer 62, the upper base layer 30 and the lower base layer 40 can also be comprised of a flexible foam, including any of the flexible foams described above with reference to the body supporting layer 20, The flexible foam comprising the body supporting layer 20, however, typically has a density less than that of the upper base layer 30 and the lower base layer 40. such that the upper base layer 30 and the lower base layer 40 have a density and hardness sufficient for supporting the body supporting layer 20 and the comfort layer 62 of the mattress assembly. For example, in the mattress assembly 10 show n in FIGS. 1 -3, the tipper base layer 30 and the lower base layer 40 are comprised of a higher density, porous polyurethane foam that provides sufficient support to the overlying body supporting layer 20 and the comfort layer, but that also provides an open environment in which air can move by virtue of its porous structure.
[0026] Similar to the upper base layer 30 and the lower base layer 40. the bottom layer 50 is further comprised of a breathable porous material that promotes the dispersion of the air, including the air exhausted into the bottom layer 50 by the fan assemblies 80a, 80b, but that also provides support to the remainder of the mattress assembly 10. In some embodiments, the porous materials included in the bottom layer 50 can be selected from a reticulated foam, knitted spacer fabric, textile, or a composite material. For instance, in some embodiments, it is contemplated that a knitted spacer fabric can be included that is generally comprised of two exterior mesh textile substrates and an insert material such as polyester monofilaments w hich are configured to keep the two exterior mesh textile substrates separated. Such knitted spacer fabrics include, by way of example, the Wellcool™ 3D spacer fabric manufactured by Quan/.bou Wellcool Cushion Technology Co.. Ltd (Fujian, China).
[0027] Regardless of the particular materials used in the bottom layer 50. in the mattress assembly 10. the bottom layer 50 as well as the comfort layer 62, the body supporting layer 20. the upper base layer 30, and the lower base layer 40 arc general ly secured to one another to prevent the body supporting layer 20, the upper base layer 30, the lower base layer 40, the bottom layer 50. and the com fort layer 62 from moving relative to one another during use. Various means of securing one layer of material to another can be used in this regard, includ ing tape, hook and loop fasteners, conventional fasteners, stitches, and the like. In one particular embodiment, the body supporting layer 20. the upper base layer 30, the low er base layer 40. the bottom layer 50. and the comfort layer 62 are bonded together by an adhesive or cohesive bonding material to create a substantially continuous assembly w here the body supporting layer 20. the upper base layer 30, the lower base layer 40, the bottom layer 50. and the comfort layer 62 are fully adhered to one another. Such adhesive bonding materials include, for example, environmental!y-fnendly. water based adhesives. like SABA AQUA BOND RSD. a tw o-component water-based adhesive product produced by SABA DINX PHRLO BV . B-7000 ΛΛ, Dinxperlo. Belgium.
[0028] Turning now to the fan assemblies 80a. 80b included in the mattress assembly 10, as indicated above and referring now to FIGS. 1 -4, the fan assemblies are housed internally w ithin the mattress assembly 10. More specifically, the fan assemblies 80a, 80b are housed w ithin the cavities 42a, 42b of the lower base layer 40 with the upper base layer 30 covering the fan assemblies from above and the bottom layer 50 covering the fan assembl ies 80a, 80b from below. In this regard, each of the fan assemblies 80a, 80b inc ludes a fan 82a. 82b that is mounted in a housing 84a, 84b sized to fit w ithin one of the cavities 42a, 42b defined by the lower base layer 40 and to be frictiona!!y held in position w ithin the cavities 42a. 42b even w hen the mattress assembly 1 0 is moved, tipped, or otherwise adjusted. To further promote the frictional connection between the housings 84a, 84b and the cav ities 42a, 42b defined by the low er base layer 40. the fan assemblies 80a. 80b each further include a sleeve 88a. 88b that is positioned between each of the housings 84a. 84b and the respective cavities 42a. 42b and that is comprised of a material which promotes friction between the cavities 42a. 42b and the respective housings 84a, 84b. for example a textile. The sleeves 88a, 88b can also be comprised of a flame retardant material to provide a layer of fice suppression betw een the fan assembl ies 80a. 80b and the rest of the mattress assembly 10. Furthermore, each of the sleeves 88a, 88b provide a means of securing and positioning an air filter 86a, 86b within each of the fan assemblies 80a. 80b.
[0029] Referring again to FIGS. 1 -3, to prov ide an amount of control over the amount of air being moved by the fan and the active ventilation of the mattress assembly ! O. the mattress assembly 10 aiso includes a power supply 92 for supplying electrical current to the fan assemblies 80a, 80b and a controller 90 for controlling the electrical current supplied to the fan assemblies 80a, 80b from the power supply 92. By including the controller 90 in the mattress assembly ! 0. the amount of electrical current supplied to the fan assemblies 80a. 80b front the power supply 92 can be controlled to allow for a desired amount of air to move through the mattress assembly 10 and. consequently, a desired amount of heat to be dissipated away from the body supporting layer 20 of the mattress assembly 10. For example, the controller 90 can be used to simply turn the fan assemblies 80a, 80b on or off depending on w hether the user wishes to ventilate the mattress assembly 10 and remove heat from the body supporting layer 20 of the mattress assembly 10, or can be used to operate the fan assemblies 80a. 80b at a particular speed depending on how quickly the user wishes to ventilate the mattress assembly 10 and remove heat from the body supporting layer 20 of the mattress assembly 10. Alternatively, the controller 90 can also be configured to automatically control the electrical current supplied to the fan assemblies 80a, 80b from the power supply 92, such that the electrical current can be supplied to the fan assemblies 80a, 80b when the first surface 22 of the body supporting layer 20 reaches a desired temperature. As another example, the controller 90 can be configured to allow the electrical current to be supplied to the fan assemblies 80a. 80b from the power supply 92 for a predetermined time period, such as for an 8-hour sleeping period or for a length of time a user usually spends in a specific stage of the sleep cycle (e.g.. RFM sleep) in order to increase the sleep comfort of a user,
[0030] To prov ide an additional level of control over the movement of air through the mattress assembly 10. the mattress assembly 10 also includes several features that are operably connected to the body supporting layer 20 and provide input to the controller 90. for example, as shown best in FIG. 2. the mattress assembly 10 includes temperature sensors 94a. 94b that are operably connected to porous (bam inserts 26a, 26b included in the body supporting layer 20 and that provide temperature feedback to the controller 90 to thereby not only allow the controller 90 to selectively provide power to the fan assemblies 80a, 80b and adjust how quickly or how much air is moved through the mattress assembly 10 in response to the received temperature feedback, but to also maintain a desired temperature at the first surface 22 of the body supporting layer 20. As another example, and as also shown best in FIG. 2. pressure sensors 96a. 96b are also operably connected to the body supporting layer 20 and provide pressure feedback to the controller 90 in response to a user resting upon or adjacent to the {list surface 22 of the body supporting layer 20, such that the controller 90 can automatically allow power to be provided to the fan assemblies 80a. 80b air to be moved through 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. An additional benefit of the inclusion of the pressure sensors 96a. 96b is (hat the controller 90 can be configured to automatically shut off the fan assemblies 80a. 80b if a user is no longer lying on the mattress assembly 10. Of course, such desired temperature or pressure feedback settings can be directed, inputted or adjusted at the controller 90 itself, or in certain embodiments of the present invention, can be transmitted to the controller 90 from a remote control (not shown) that is also operably connected to the controller 90.
[0031] As a refinement to the support cushions of the present invention, and referring now to FIG. 5, in another exemplary embodiment of the present invention, another support cushion in the form of a mattress assembly f 10 is provided that includes additional features to increase the comfort and convenience of the user of the mattress assembly f 10. Like the support cushion show n in FIGS. 1 -4. the mattress assembly 1 10 also includes: a comfort layer 162 defining a plurality of channels 166; a body supporting layer 120 including a porous foam insert 126; an upper base layer 130 positioned below the body supporting layer 120 and defining a plurality of air conduits 132 in fluid communication w ith the porous foam insert 126; a lower base layer 140 defining a cavity 142 w ith a fan assembly 1 80 located w ithin the cavity 142: and a bottom layer 1 50 positioned below the lower base layer 140. Further included in the mattress assembly, however, is an adjustable foundation 1 70 that is positioned below the bottom layer 150 and allows a user to place the mattress assembly 1 10 into one or more desired ergonomic positions.
[0032] As a further refinement to the support cushions of the present invention, various covers can also be included and used to cover various portions of the support cushions. For example and referring still to FIG. 5, a cover 172 is included in the mattress assembly ! 10 and surrounds the comfort layer 162, the body supporting layer 1 20. the upper base layer 130, the lower base layer 140. and the bottom layer 1 50 of the mattress assembly 1 10. In the mattress assembly 1 10. the cover 172 in the form of a fire sock that surround the various layers is comprised of a flame retardain material. It is also contemplated, however, that an exemplar, cover of the present invention can also be comprised of another textile, such as cotton that provide an exemplary support cushion with a unitary appearance, but that also provides a user with a sufficiently soft surface on which to rest while being sufficiently breathable to allow air to he drawn through the cover and the exemplary support cushion.
[0033] As yet another refinement to the present invention, although the support cushions shown in FIGS. 1 -3 and 5 are in the form of mattress assemblies 10. 1 10 and are dimeiisional!y-sized to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to other support cushions, such as head pillows, seat cushions, seat backs, neck pillows, leg spacer pillows, mattress topers, overlays, and the like. As such, the phrase "body support'* or "body supporting'" is used herein to refer to any and all such objects having arty size or shape, and that are capable of supporting, or are generally used to support, the body of a user or a portion thereof. Furthermore, although the body supporting layer 20 of the mattress assembly 10 shown in FIGS. i -3. includes two removable inserts 26a, 26b, two sets of air conduits 32a, 32b. two cavities 42a, 42b. and two tan assemblies 80a, 80b, it is also contemplated other embodiments may include any number of removable portions, conduits, cavities, and fan assemblies depending on the size and shape of the particular support cushion.
[0034] F.ach of the exemplary support cushions described herein can also be used as part of a method for actively ventilating a support cushion. In some implementations, a method for actively ventilating a support cushion includes first providing a support cushion having: a body supporting layer having a first surface and a second surface opposite the first surface; an upper base layer positioned adjacent to the second surface of the body supporting layer and defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer: a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer and defining a cav ity extending through the lower base layer; a bottom layer positioned adjacent to the lower base layer opposite the upper base layer: and a fan located within the cavity define by the lower base layer. Power, in the form of electrical current, is then supplied to the fan, such that the fan draws air from the first surface of the body supporting layer, through upper base layer and lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion to thereby actively ventilate the support cushion and dissipate any heat away from the body supporting layer of the support cushion.
[0035] Throughout this document, various references are mentioned. A ll such references are incorporated herein by reference, including the references set forth in the following list: REFERENC ES
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[0036] One of ordinary skill in the art w ill recognize that additional embodiments are also possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

Claims

CLAIMS What is claimed is:
1 . A support cushion, comprising:
a body supporting layer having a first surface and a second surface opposite the first surface, the body supporting layer including one or more porous foam inserts:
an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the one or more porous foam inserts;
a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer, the lower base layer defining a cav ity extending through the lower base layer;
a bottom layer positioned adjacent to the lower base layer opposite the upper base layer; and
a fan positioned w ithin the cavity defined by the lower base layer.
2. The support cushion of claim 1 , further comprising a comfort layer positioned adjacent to the first surface of the body supporting layer, the comfort layer including a top surface and a bottom surface opposite the top surface.
5. The support cushion of claim 2. wherein the comfort layer defines a plurality of channels extending from the top surface to the bottom surface of the comfort layer, the plurality of channels in fluid communication w ith the one or more porous foam inserts.
4. The support cushion of claim .>. wherein the bottom layer is comprised of a porous material.
5. The support cushion of claim 4, wherein the porous material is selected from the group consisting of porous foams, knitted spacer fabrics, textiles, and composite materials.
6. T he support cushion of claim I . further comprising a housing for ihe fan, the housing positioned w ithin the cavity defined by the lower base layer.
7. T he support cushion of claim 6. further comprising an air filter positioned within the housing.
8. T he support cushion of claim 6, further comprising a sleeve positioned around the housing and within the cavity of the lower base layer.
9. The support cushion of claim 8. wherein the sleeve is comprised of a material configured to provide a frictional connection between the housing and the lower base layer.
10. The support cushion of claim 0. wherein the sleeve is comprised of a flame retardant material.
1 1. The support cushion of claim 1, wherein the body supporting layer, the upper base layer, and the lower base layer are comprised of a flexible foam.
1 2. The support cushion of claim 1 1, wherein the body supporting layer is comprised of a visco-elastic foam.
13. The support cushion of claim I I . wherein the flexible foam comprising the body supporting layer has a porosity less than that of the one or more porous loam inserts.
14. 'The support cushion of claim 1. wherein the body supporting layer has a density less than that of the upper base lay er, the lower base layer, or both.
1 5. T he support cushion of claim 2. wherein the comfort layer is comprised of a visco- elastic foam.
16. T he support cushion of claim 1 5, wherein the bods supporting layer is comprised of a visco-elastic foam, and wherein the comfort layer has a density less than that of the body supporting layer.
I 7, The support cushion of claim I . further comprising:
a power supply for supplying electrical current to the fan; and a controller for controlling the electrical current supplied to the fan from the power supply.
18. The support cushion of claim 17, wherein the controller is configured to allow power to be supplied to the fan for a. predetermined time period.
19. The support cushion of claim 17. further comprising one or more tem perature sensors for providing thermal feedback to the controller, the one or more temperature sensors operably connected to the body supporting layer,
20. The support cushion of claim 1 7. further comprising one or more pressure sensors for providing pressure feedback to the controller, the one or more pressure sensors operably connected to the body supporting layer,
21. The support cushion of claim 1. further comprising a cover configured to surround the body supporting layer, the upper base layer, the lower base layer, and the bottom layer.
22. The support cushion of claim 2 1 , wherein the cover is comprised of a flame retardarit material.
23. The support cushion of claim 21, wherein the cover is comprised of a textile.
24. A mattress assembly, comprising:
a body supporting layer having a first surface and a second surface opposite the first surface:
an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer;
a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer, the lower base layer defining a cavity extending through the lower base layer;
a bottom layer positioned adjacent to the lower base layer opposite the upper base layer; and
a fan positioned within the cavity in the lower base layer.
25. The mattress assembly of claim 24, wherein the body supporting layer includes one or more porous foam inserts positioned over the one or more one or more air conduits defined by the upper base layer.
26. The mattress assembly of claim 24. further comprising an adjustable foundation positioned below the bottom layer.
27. A method of actively venti lating a support cushion, comprising:
providing a support cushion including
a body supporting layer having a first surface and a second surface opposite the first surface.
an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer.
a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer, the lower base layer defining a cavity extending through the lower base las er.
a bottom layer positioned adjacent to the lower base layer opposite the upper base layer, and
a fan located within the cavity defined by the lower base layer; and supplying power to the fan. such that the fan draws air from the first surface of the body supporting layer, through the upper base layer and the lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion.
PCT/US2015/027262 2015-04-23 2015-04-23 Support cushions and methods for active ventilation of same WO2016171692A1 (en)

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AU2015392446A AU2015392446A1 (en) 2015-04-23 2015-04-23 Support cushions and methods for active ventilation of same
CN201580079015.4A CN107529895A (en) 2015-04-23 2015-04-23 Supporting pad and the method for making its active divulge information
PCT/US2015/027262 WO2016171692A1 (en) 2015-04-23 2015-04-23 Support cushions and methods for active ventilation of same
EP19180957.3A EP3560389A1 (en) 2015-04-23 2015-04-23 Mattress assembly and methods for active ventilation of a support cushion
EP15890095.1A EP3285618B1 (en) 2015-04-23 2015-04-23 Support cushions with active ventilation
US15/568,368 US20180098637A1 (en) 2015-04-23 2015-04-23 Support cushions and methods for active ventilation of same
HK18107171.6A HK1247537A1 (en) 2015-04-23 2018-05-31 Support cushions and methods for active ventilation of same

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EP (2) EP3560389A1 (en)
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