Support pad comprising a support insert encapsulated by a foam guide for guiding an air flow, method for controlling the surface temperature of a

Abstract

A support mat for providing personalized heating and cooling to a user resting on the support mat is provided. The support pad includes a body support layer and an air distribution layer positioned adjacent the body support layer. The air distribution layer includes a substrate and a foam rail positioned at least around a periphery of the substrate to define a cavity within which a support insert is positioned. A fan is operatively connected to the air distribution layer and provides a flow of air into the cavity of the air distribution layer. A flow of air is directed through the support insert and into and through the body support layer.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Application No. 17 / 869,509, filed on July 20, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present invention relates to support cushions, methods for controlling the surface temperature of support cushions, and methods for making support cushions. In particular, the present invention includes support cushions, such as mattress assemblies, that utilize support inserts surrounded by air-impermeable foam rails to direct air to the surface of the support cushion. Background Art

[0004] One aspect of a successful and restful sleep is individual sleep comfort. Medical research suggests that sleep deprivation ("sleep debt") can have significant negative effects on lifespan, productivity, and overall mental, emotional, and physical health. Chronic sleep debt is associated with weight gain, and more specifically has been observed to affect not only the way the body processes and stores carbohydrates, but also to alter hormone levels that affect appetite. In addition, sleep debt can lead to irritation, danger, inability to concentrate, and mood, which has led some researchers to suggest a link between sleep debt and workplace accidents, traffic accidents, and general afternoon inattention. In addition, sleep disorders have been associated with high blood pressure, increased stress hormone levels, and irregular heartbeats, and additional studies have recently shown that lack of sleep can affect immune function, leading to increased susceptibility to illness and disease (e.g., cancer). In summary, researchers have now suggested that sleep debt costs $6.3 billion in lost productivity each year due to these various effects. Therefore, a support cushion that improves sleep comfort and reduces individual sleep debt would be highly desirable and beneficial. Summary of the invention

[0005] The present invention includes support cushions and methods for controlling the surface temperature of support cushions. In particular, the present invention includes support cushions, such as mattress assemblies, that utilize a support insert surrounded by an air-impermeable foam rail to direct air to the surface of the support cushion. Thus, the support cushion of the present invention allows a user to personalize their comfort level, including sleeping comfort, by controlling the amount and / or temperature of air flowing to the surface of the support cushion.

[0006] In one exemplary embodiment of the present invention, a support pad is provided in the form of a mattress assembly including a body support layer having a first surface and a second surface opposite the first surface. An air distribution layer is positioned adjacent to the first surface of the body support layer, wherein the air distribution layer includes a base plate and a foam rail positioned at least around a perimeter of the base plate, thereby defining a cavity. A support insert is then positioned within the cavity, and a fan is operatively connected to the air distribution layer to provide an air flow into the cavity of the air distribution layer. Specifically, the air flow is directed through the support insert and into and through the body support layer.

[0007] In one exemplary embodiment, the foam rail includes an outer foam layer and an inner foam liner. The inner foam liner defines a side surface of the cavity of the air distribution layer, and the inner foam liner is substantially air impermeable. In another exemplary embodiment, the foam rail includes an air impermeable coating along at least the side surface of the cavity of the air distribution layer. In yet another exemplary embodiment, the air distribution layer is formed by carving the cavity from a monolithic piece of foam such that the substrate and the foam rail are integrally formed. In any case, the foam rail is substantially air impermeable and the support insert is substantially air permeable such that air provided into the cavity of the air distribution layer diffuses through the support insert before flowing into and through the body support layer.

[0008] In one exemplary embodiment, the support insert includes an array of springs configured to support a body supporting layer. In another exemplary embodiment, the support insert includes one or more foam layers configured to support a body supporting layer.

[0009] The support cushion also includes an air flow unit that is operatively connected to the inlet hole of the air distribution layer. The air flow unit includes a fan that provides air flow to the interior of the support insert, and in some embodiments, also includes a heating unit and / or a cooling unit to provide a thermal control air flow to the interior of the support insert. Substantially all air flowing into the support insert is directed into and through the upper body support layer. To this end, in some exemplary embodiments, the body support layer defines a plurality of channels extending from the first surface to the second surface. Therefore, the air flowing out of the outlet hole will be directed into and through the second surface of the body support layer via the plurality of channels.

[0010] To further facilitate air flow through the body support layer, in some embodiments, the body support layer is comprised of a porous viscoelastic foam. In some embodiments, such porous foams have properties that are well suited for use in the body support layer of a mattress assembly, including an enhanced ability to allow fluid to move through the porous foam, and thus provide enhanced air movement through the body support layer of the mattress assembly. In this regard, air exiting the support insert can then be easily transferred through the body support layer to the second surface. In the event that the air flow unit provides heated or cooled air into the support insert, the increased air flow through the body support layer will also increase the heating / cooling rate at the first surface of the body support layer.

[0011] Other features and advantages of the present invention will become apparent to one of ordinary skill in the art after studying the description, drawings and non-limiting examples in this document. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a perspective view of an exemplary support pad in the form of a mattress assembly made in accordance with the present invention;

[0013] Figure 2 is along Figure 1 The line 2-2 is intercepted Figure 1 A cross-sectional view of an exemplary mattress assembly;

[0014] Figure 3 yes Figure 1 A partially exploded perspective view of an exemplary mattress assembly;

[0015] Figure 4 yes Figure 2 A detailed view of the portion identified in the figure centered on the foam rail;

[0016] Figure 5A is a detailed view of another exemplary foam rail;

[0017] Figure 5B is a detailed view of yet another exemplary foam rail;

[0018] Figure 6 is a perspective view of another exemplary air distribution layer made in accordance with the present invention; and

[0019] Figure 7 is a graph illustrating the operating characteristics of an exemplary fan. DETAILED DESCRIPTION

[0020] The present invention includes support pads, and in particular, the present invention includes support pads, such as mattress assemblies, that utilize a support insert surrounded by an air-impermeable foam rail to direct air to a surface of the support pad. Thus, the support pad of the present invention allows a user to personalize their comfort level, including sleeping comfort, by controlling the amount and / or temperature of air flowing to the surface of the support pad.

[0021] First reference Figures 1 to 3 In one exemplary embodiment of the present disclosure, a support pad in the form of a mattress assembly 10 is shown, wherein the mattress assembly 10 includes an uppermost comfort layer 80 having a first surface 82 and a second surface 84 opposite the first surface 82, and an insulator layer 70 similarly having a first surface 72 and a second surface 74 opposite the first surface 72. The second surface 74 of the insulator layer 70 is positioned adjacent to the first surface 82 of the comfort layer 80. According to this exemplary embodiment, the insulator layer 70 and the comfort layer 80 are also collectively referred to as a body support layer 75, wherein the first surface 72 of the insulator layer 70 is the first surface of the body support layer 75, and the second surface 84 of the comfort layer 80 is the second surface of the body support layer 75.

[0022] The mattress assembly 10 also includes an air distribution layer 30 positioned adjacent to the first surface 72 of the insulation layer 70 (i.e., the first surface of the body support layer 75) and configured to support the body support layer 75. As discussed further below, the air distribution layer 30 includes a base plate 32 and a foam rail 40 that define a cavity 50 in which a support insert 60 is positioned. Specifically, the support insert 60 is positioned on a bottom surface 54 of the cavity 50, wherein the side surfaces 52 of the cavity 50 surround the support insert 60 such that only an upper side of the support insert 60 opposite the bottom surface 54 of the cavity 50 remains exposed. Finally, the mattress assembly also includes a base layer 20 positioned adjacent to the base plate 32 of the air distribution layer 30.

[0023] The base layer 20 can take the form of a flexible (including foam) platform structure to allow for use on an adjustable base or hard bottom, platform structure, etc., which provides a support surface upon which the air distribution layer 30 can be located. In some embodiments, the base layer 20 can be substantially flat and stationary; while in other embodiments, the base layer 20 can be adjustable and capable of moving from a substantially flat position to any number of inclined positions as desired by the user and as known in the art. In embodiments where the base is adjustable, the mattress assembly 10 may also have locating features for aligning the mattress assembly 10 with the adjustable base (not shown). As may be seen in the drawings, the base layer 20 can be arranged to be aligned with the base 10 and the adjustable base. Figure 3, the base layer 20 further defines at least one aperture 26 extending from a first surface 22 of the base layer 20 to a second surface 24 of the base layer 20, as discussed further below. Although not specifically shown in the figures, in some embodiments, the base layer may also be a mattress base, such as a mattress base for use with an adjustable bed.

[0024] Still reference Figure 2 and Figure 3 As previously described, the air distribution layer 30 includes a base plate 32 and a foam rail 40 positioned about the perimeter of the base plate 32 so as to define a cavity 50, wherein a support insert 60 is positioned within the cavity 50. In the exemplary embodiment, the support insert 60 is formed by an array of springs 62, but other configurations are contemplated, as discussed further below. In any event, the foam rail 40 and support insert 60 are configured to support the insulation layer 70 and the comfort layer 80 (i.e., the body support layer 75). Figure 3 As perhaps best shown in FIG. 8 , the substrate 32 also defines an inlet aperture 34 that is aligned with the aperture 26 defined in the base layer 20 .

[0025] Reference now Figure 1 and Figure 2 The mattress assembly 10 also includes an air flow unit, generally shown here as a box 90, which is operatively connected to the inlet hole 34 in the base plate 32 of the air distribution layer 30 through a conduit 92. Specifically, as shown in FIG. Figure 2 As shown, flange 96 is operatively connected to inlet hole 34, wherein flange 96 extends through inlet hole 34 in base plate 32 and through hole 26 in base layer 20. Conduit 92 includes connector 94 at its distal end, connector 94 is configured to engage flange 96 to provide a continuous air passage between air flow unit 90 and cavity 50 of air distribution layer 30.

[0026] Regarding the air flow unit 90, although not explicitly shown, the air flow unit 90 includes a fan that provides air flow into the cavity 50 of the air distribution layer 30 through the duct 92. Exemplary fans used with the air flow unit 90 provide an air flow of greater than about 25 CFM, greater than about 30 CFM, or greater than about 35 CFM, and have a hydrostatic pressure of less than about 50 mm, less than about 40 mm, or less than about 30 mm. One particular fan has an air flow of greater than 35 CFM and a hydrostatic pressure of less than 30 mm.

[0027] It is also contemplated that in some embodiments, the air flow unit 90 further includes a heating unit and / or a cooling unit to provide a heat controlled air flow into the cavity 50 of the air distribution layer 30. To this end, the exemplary mattress assembly further includes a controller 98 for controlling the air flow unit 90. By including the controller 98 in the mattress assembly 10, not only the amount of the air flow can be controlled, but also the temperature of the air flow can be controlled.

[0028] Reference now Figures 2 to 4 , the foam rail 40 of the air distribution layer 30 is substantially air impermeable and includes an outer foam layer 42 and an inner foam liner 44 that defines a side surface 52 of the cavity 50. Each of the outer foam layer 42 and the inner foam liner 44 is made of a flexible foam, such as latex foam, a reticulated or non-reticulated viscoelastic foam (sometimes referred to as memory foam or low rebound foam), a reticulated or non-reticulated non-viscoelastic foam, a polyurethane high rebound foam, an expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), or any combination thereof. While the outer foam layer 42 may be comprised of a substantially air permeable foam, the inner foam liner 44 is comprised of a substantially air impermeable foam. When used herein, the term "impermeable" generally refers to a material that substantially prevents air from moving through the material, including materials that are "low permeable" and can allow some vapor to escape. For example, in some embodiments, it is expected that the low permeability foam has an air permeability between 0-0.05 liters / second. Similarly, the use of the term "permeable" herein generally refers to a material that substantially allows air to move through the material. The following description of the air permeable foam is provided herein. Figure 5A and Figure 5B Other configurations of the foam rail are discussed, but in all cases, the foam rail is substantially air impermeable. To further prevent air from escaping from the air distribution layer 30 except through the body support layer 75, in some embodiments, the base plate 32 is also substantially air impermeable. Thus, air that flows into the cavity 50 of the air distribution layer 30 cannot easily escape through the bottom or sides of the air distribution layer 30. Thus, substantially all of the air that flows into the cavity 50 of the air distribution layer 30 is directed out of the top of the air distribution layer 30 and into and through the insulator layer 70 and comfort layer 80 above (i.e., the body support layer 75).

[0029] For this purpose, and now with particular reference to Figure 2, the insulator layer 70 defines a plurality of channels 76 extending from the first surface 72 to the second surface 74 and substantially aligned with the cavity 50 of the air distribution layer 30. Similarly, the comfort layer 80 defines a plurality of channels 86 extending from the first surface 82 to the second surface 84, wherein each channel 86 of the comfort layer 80 is substantially aligned with a corresponding channel 76 of the insulator layer 70. Thus, air flowing out of the cavity 50 of the air distribution layer 30 will be directed to the second surface 84 of the comfort layer 80 (i.e., the second surface of the body support layer 75) by flowing into and passing through the plurality of channels 76, 86. Of course, the shape and / or pattern of the channels 76 in the insulator layer 70 and the shape and / or pattern of the channels 86 in the comfort layer 80 are not limited and may not be aligned in some embodiments. In some embodiments, the pattern of the channels is designed to provide a specific cooling effect for a user resting on the support cushion.

[0030] Regarding the body support layer 75, Figures 1 to 3 In the exemplary embodiment shown, the insulator layer 70 and the comfort layer 80 (i.e., the body support layer 75) of the mattress assembly 10 are formed of a continuous flexible foam layer for appropriately distributing pressure from the user's body or a portion thereof on the body support layer 75. Such flexible foams include, but are not limited to, latex foams, reticulated or non-reticulated viscoelastic foams (sometimes referred to as memory foams or low-resilience foams), reticulated or non-reticulated non-viscoelastic foams, polyurethane high-resilience foams, expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), or any combination thereof. Figures 1 to 3 In the illustrated embodiment, the insulator layer 70 and the comfort layer 80 are constructed of a viscoelastic foam having low elasticity and sufficient density and hardness, which allows pressure to be uniformly absorbed and evenly distributed on the body support layer 75 of the mattress assembly 10. Typically, such viscoelastic foams have a hardness of at least about 10N to no more than about 80N, as measured by applying pressure from a plate to a sample of the material at about room temperature (i.e., 21° C. to 23° C.) to compress at least 40% of the original thickness of the material, wherein the 40% compression is maintained for a set period of time, as established by the International Organization for Standardization (ISO) 2439 hardness measurement standard. In some embodiments, the viscoelastic foam has a hardness of about 10N, about 20N, about 30N, about 40N, about 50N, about 60N, about 70N, or about 80N to provide a desired degree of comfort and body conforming quality.

[0031] The viscoelastic foam used in the mattress assembly 10 described herein may also have a density that helps provide a desired degree of comfort and body conforming qualities as well as increased material durability. In some embodiments, the density of the viscoelastic foam used in the body support layer 75 is not less than about 30 kg / m 3 To not more than about 150kg / m 3In some embodiments, the density of the viscoelastic foam used in the body support layer 75 of the mattress assembly 10 is about 30 kg / m 3 , about 40kg / m 3 , about 50kg / m 3 , about 60kg / m 3 , about 70kg / m 3 , about 80kg / m 3 , about 90kg / m 3 , about 100kg / m 3 , about 110kg / m 3 , about 120kg / m 3 , about 130kg / m 3 , about 140kg / m 3 or about 150kg / m 3 . Of course, the selection of a viscoelastic foam having a particular density will affect other properties of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it will be appreciated that a viscoelastic foam having a desired density and hardness may be readily selected as needed for a particular application or mattress assembly. For example, the density, hardness, or both of the comfort layer 80 is typically less than the density, hardness, or both of the insulator layer 70, such that the comfort layer 80 provides a softer surface on which to rest the user's body or a portion thereof. Additionally, it will be appreciated that the insulator layer 70 and / or the comfort layer 80 of the mattress assembly need not be comprised of a continuous layer of flexible foam at all, but may also take the form of a more conventional mattress, including a spring-based mattress, without departing from the spirit and scope of the subject matter described herein.

[0032] To further promote air flow through the body support layer 75, in some embodiments, the insulation layer 70 and the comfort layer 80 are each composed of a substantially uniform porous viscoelastic foam layer. In this regard, the term "porous flexible foam" (viscoelastic or otherwise) is used herein to generally refer to a flexible foam having a porous foam structure, wherein at least a portion of the pores of the foam are substantially skeletal. In other words, at least a portion of the pores of the foam are each defined by a plurality of open-cell windows surrounded by pore struts, wherein the pore windows of the porous foam may be completely absent (leaving only the pore struts) or substantially missing. In some embodiments, the foam is considered to be "porous" if at least 50% of the pore windows are missing (i.e., windows with holes passing therethrough, or windows completely missing and thus leaving only the pore struts). Such a structure can be produced by destroying or otherwise removing the pore window material, by chemical or mechanical means, or by preventing the pore windows from being fully formed during the manufacturing process of the foam. In some embodiments of the present invention, when referring to flexible foams, the term "porous" can therefore be used interchangeably with the term "reticular".

[0033] Regardless of the manufacturing process used to produce the porous foam, the porous foam, due to its pore structure, has properties that are well suited for use in the body support layer 75 of the mattress assembly 10, including an enhanced ability to allow fluid to move through the porous foam, and therefore provide enhanced air movement through the body support layer 75 of the mattress assembly 10. In this regard, air exiting the air distribution layer 30 can then be easily transferred through the body support layer 75 to the second surface 84 of the comfort layer 80 (i.e., the second surface of the body support layer 75). In the event that the air flow unit 90 provides heated or cooled air into the support insert 60, the increased air flow through the body support layer 75 will also increase the heating / cooling rate at the second surface 84 of the comfort layer 80 (i.e., the second surface of the body support layer 75).

[0034] The base plate 32, the foam rail 40, or both the base plate 32 and the foam rail 40 of the air distribution layer 30 are also constructed of a flexible foam material that is selected to provide preferred feel and support characteristics. For example, in some embodiments, the foam rail 40 can provide substantially the same feel and support as the support insert 60, while in some other embodiments, the foam rail 40 provides a firmer feel than the support insert 60. Likewise, in some embodiments, the foam rail 40 can provide substantially the same feel and support as the body support layer 75, while in some other embodiments, the foam rail 40 provides a firmer feel than the body support layer 75.

[0035] About grassroots 20, Figure 1-Figure 3 In the exemplary embodiment shown, base layer 20 is also constructed of viscoelastic foam, but other materials including non-viscoelastic foams are also contemplated. In some embodiments, the viscoelastic foam of base layer 20 is substantially the same as the viscoelastic foam of body supporting layer 75. In some other embodiments, the porosity of the foam used in body supporting layer 75 is greater than the porosity of base layer 20.

[0036] Reference now Figure 2 and Figure 3As previously described, the exemplary support insert 60 is formed by an array of springs 62. The exemplary springs are individual "pocketed" coils. Each individual pocketed coil may include a spring or coil wrapped or encapsulated in a fabric cover. The cover may be referred to as a spacer fabric in the art and may be permeable. In some cases, the spacer fabric including the cover may be formed of a biaxial stretch material, meaning that it is stretchable in two dimensions, such as horizontal directions, such as head to toe and transversely relative to the bed from one side to the other. The spacer fabric may include a woven or knitted material, and / or may include an extruded plastic material, including polyethylene, polyester, other plastics, or any combination of these or others. These individually pocketed coils may then be arranged in rows or columns within the perimeter and sewn together to form a cohesive unit, such as the support insert 60. In some embodiments, the rows and columns are aligned so that each row forms a straight line and each column forms a straight line. In other embodiments, the rows and columns are arranged to be offset from each other, such as to form a checkerboard pattern. The use of pocketed coils or layers of pocketed coils can provide a more comfortable mattress surface when the coils are made relatively individually flexible so that each coil can flex individually without affecting adjacent coils.

[0037] In some embodiments, the spring or coil can be made of steel wire, high carbon spring wire, high carbon piano wire, copper coated high carbon wire, aluminum coated high carbon wire, cold drawn decorative wire type "A", "B" or "C" or any other type of wire known in the art. The wire used in the construction of the spring or coil can be in the range of 12 to 20 gauge. In other embodiments, the spring or coil can be made of a polymer material, such as plastic or polyurethane. In some embodiments, the diameter of the spring or coil can be in the range of about 10 mm to about 150 mm. The original height of the spring or coil can be in the range of about 0.5 inches to about 12 inches, and the height of the spring or coil in the bag can also be in the range of about 0.5 inches to about 12 inches. In some embodiments, the range of spring or coil preload is 0 to 5 pounds of force, and the range of spring stiffness is 0.25 to 5.0 pounds of force per inch. In some embodiments, the coil geometry can be linear compression; while in other embodiments, the coil geometry can be variable compression, linear cylindrical or variable diameter to achieve variable compression. Regardless of the specific configuration, the support insert 60 is substantially air permeable such that air provided into the cavity 50 of the air distribution layer 30 diffuses through the support insert 60 before flowing into and through the insulator layer 70 .

[0038] Although not explicitly shown, it should be understood that in other exemplary embodiments of the present invention, the support insert may also include a flexible foam, instead of or in addition to the spring array. In some exemplary embodiments, the foam support insert is composed of a viscoelastic foam similar to the body support layer. The flexible foam material can be selected to provide preferred feel and support characteristics. For example, in some embodiments, the foam support insert can provide a feel and support substantially the same as the foam rails of the air distribution layer, while in some other embodiments, the foam support insert can provide a softer feel than the foam rails of the air distribution layer. In addition, the foam insert may include structural elements, such as channels extending through the foam insert to further increase airflow through the foam insert. In addition, the foam insert can be configured to provide a feel and support substantially the same as the body support layer. It is also conceivable that the foam insert may include multiple foam layers, each foam layer having various configurations, including, for example, different densities, hardnesses, and / or porosities.

[0039] In order to prevent the layers of the mattress assembly 10 from moving relative to each other during use, various means of securing one layer of material to another layer may be used, including tape, hook and loop fasteners, conventional fasteners, stitching, adhesives, etc. Such adhesive bonding materials include, for example, environmentally friendly water-based adhesives such as SABA AQUABOND RSD, a two-component water-based adhesive product produced by SABA DINXPERLO BV, B-7090AA, Dinxperlo, Belgium.

[0040] Reference now Figure 5AIn another exemplary embodiment of the present invention, the exemplary foam rail 140 of the air distribution layer 130 includes an outer foam layer 142 and an impermeable or semi-permeable coating 144, rather than an inner foam liner. In this regard, the term "impermeable coating" is used herein to generally refer to a material that substantially prevents air from flowing through the coating, and the term "semi-permeable coating" is used herein to generally refer to a material that prevents at least a portion of air from flowing through the material, which may, for example, include a low-permeability material. For example, the air permeability of the low-permeability material may be between 0-5ft3 / ft2 / min, between 0-10ft3 / ft2 / min, or between 0-20ft3 / ft2 / min. The exemplary coating 144 may include, but is not limited to, a hot melt adhesive, a flexible elastomeric coating, or a gel-like material. With regard to the hot melt adhesive, in some embodiments, a water-based hot melt adhesive is used, which produces a non-sticky impermeable layer when dried. The hot melt adhesive must be viscous enough to bridge the foam cell structure when applied so as to produce a coating on the foam rather than sinking into the foam cell structure. According to some embodiments, a viscosity of at least 100 centipoise is considered to be sufficiently viscous for application. The total thickness of the exemplary hot melt adhesive layer is between 0-0.100", which in some cases may require more than one coating pass to achieve the desired thickness. The exemplary hot melt adhesive must also be flexible enough when dry to avoid cracking during repeated loading cycles (e.g., compression) of the foam during mattress use. Similar properties are expected for embodiments where the coating is made of a flexible elastomer or gel. According to some embodiments, the coating is formed by heating / melting the foam itself to form a "skin" that also exhibits similar properties to the exemplary hot melt adhesive described above.

[0041] Reference now Figure 5B In another exemplary embodiment of the present invention, rather than the foam rail comprising an outer foam layer and an inner foam lining or coating, Figure 5B In the illustrated exemplary air distribution layer 230, the foam rail 240 is made from a single foam piece. According to this embodiment, the foam rail 240 comprises a substantially air impermeable foam without the addition of an internal foam liner or coating.

[0042] exist Figures 1 to 5AIn the exemplary embodiment shown, the foam rail 40, 140, 240 is attached to the base plate 32, 132, 232, for example, by an adhesive; however, it is contemplated that in some cases the foam rail and base plate are formed from a single piece of flexible foam, such that the base layer is characterized as having a unitary construction. This is particularly advantageous in embodiments in which the foam rail is made from a single piece of foam without any additional lining or coating, because the air distribution layer can be formed by carving cavities from a unitary piece of foam, such that the base plate and the foam rail are integrally formed. According to these embodiments, the foam block in which the cavities are carved to form is preferably made of a foam that is substantially impermeable to air or has a low permeability (e.g., an air permeability between 0-0.05 1 / sec).

[0043] exist Figures 1 to 3 In the illustrated embodiment, there is only one cavity 50 with a corresponding support insert 60 that extends across substantially the entire top of the air distribution layer 30, but it should be understood that the embodiments described herein need not be limited to a single cavity. Figure 6 In another embodiment of the present invention, the exemplary air distribution layer 330 defines two chambers 350a, 350b and corresponding support structures 360a, 360b. More specifically, except including an outer foam layer 342 positioned around the perimeter of the base plate 332, similar to the above reference Figures 1 to 4 The outer foam layer 42 of the exemplary foam rail 40 is depicted, and the foam rail 340 also includes an intermediate foam rail 346 that extends substantially along the center of the air distribution layer 330, thereby dividing the air distribution layer 330 into a left side and a right side. Then, a separate inner foam liner 344a, 344b is located in each cavity 350a, 350b, wherein the inner foam liner 344a, 344b is substantially air-impermeable, similar to the above reference Figures 1 to 4 Depicted inner foam liner 44. By modifying the number and location of cavities and support structures positioned across the air distribution layer, air is directed out of the support structure and through the body supporting layer in a predetermined pattern.

[0044] It should also be understood that although Figures 1 to 3 The exemplary body support layer 75 shown includes an insulator layer 70 and a comfort layer 80, but this is not intended to be limiting. In some embodiments, instead of or in addition to the insulator layer 70 and the comfort layer 80 described above, the body support layer may include only a single layer or other layers.

[0045] Likewise, despite Figures 1 to 3In the illustrated embodiment, there is a single inlet hole 34 in the base plate 32 of the air distribution layer 30, but it is contemplated that multiple inlet holes may be used without departing from the spirit and scope of the present invention. It is also contemplated that the inlet may be located on the side of the air distribution layer 30, with corresponding holes defined through the foam rails 40 of the air distribution layer. Furthermore, although in Figure 1 and Figure 2 In the illustrated embodiment, the air flow unit 90 is connected via a conduit 92 so that the air flow unit 90 is positioned a distance away from the rest of the mattress assembly 10, but other locations are contemplated, including mounting the air flow unit 90 to the base layer 20 and / or within the confines of the mattress assembly 10.

[0046] As an additional improvement, to ensure fresh air enters the base layer, the mattress assembly may also include a filter so that only filtered air is allowed to enter the inlet hole and the bag remains free of particles, such as smoke, dust, dirt, pollen, mold, bacteria, hair or insects, which may otherwise accumulate on the interior of the mattress and restrict airflow. Of course, it is contemplated that various types of filters, including but not limited to charcoal filters for removing chemicals and / or unpleasant odors, may be readily incorporated into the exemplary mattress of the present invention without departing from the spirit and scope of the subject matter described herein. In some embodiments, it is further contemplated that an air freshener or fragrance may be further added to the assembly (e.g., before the fan) so that scented air is directed to the surface of the support pad assembly.

[0047] Each of the exemplary support cushions described herein can also be used as part of a method of controlling the surface temperature of a support cushion. In some embodiments, the method of controlling the surface temperature of a support cushion includes first providing a support cushion of the present invention. An electric current is then supplied to an air flow unit such that a fan of the air flow unit pushes a certain amount of air into the cavity of the air distribution layer, through the support insert, through the body support layer, and out of the second surface of the body support layer. For embodiments in which the air flow unit includes a heating unit and / or a cooling unit, an electric current can also be supplied to the heating / cooling unit such that the temperature of the air flowing out of the first surface of the body support layer is adjusted.

[0048] Example

[0049] Now refer to Table 1 and Figure 7, an exemplary fan having an air flow of about 38.5 CFM and a hydrostatic pressure of about 28.7 mm was used in conjunction with an exemplary mattress made according to the present invention. The fan was operated at different fan speeds, with the device positioned on the mattress to provide heat and moisture simulating a user sleeping on the mattress. Measurements were then taken at the surface of the mattress for 5 minutes, 20 minutes, and 8 hours for each fan speed in the test. As shown, without using the fan (e.g., fan speed of 0), the temperature at the surface of the mattress increased significantly between each of the 5 minute, 20 minute, and 8 hour measurements, ultimately reaching a 67.6°F increase after the entire 8 hours. In contrast, even if the fan was only operated at 50% fan speed, the temperature at the surface of the mattress increased by only 26°F after the entire 8 hours, and at 80% and higher fan speeds, the temperature increase at the surface of the mattress was less than 20°F.

[0050]

[0051] Table 1

[0052] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of the present invention or the scope of the appended claims. This detailed description, especially the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations should be understood therefrom, because modifications will become apparent to those skilled in the art upon reading this disclosure and can be made without departing from the spirit or scope of the claimed invention.

Claims

1. A support pad, comprising: a body supporting layer having a first surface and a second surface opposite the first surface; an air distribution layer positioned adjacent the first surface of the body supporting layer, the air distribution layer comprising a base plate and a foam rail positioned at least about a perimeter of the base plate to define a cavity, and the air distribution layer further comprising a support insert positioned within the cavity; as well as A fan is operatively connected to the air distribution layer, the fan for providing an air flow into the cavity of the air distribution layer such that the air flow is directed through the support insert and into and through the body supporting layer.

2. The support pad according to claim 1, wherein: The foam rail is substantially air impermeable and the support insert is substantially air permeable such that air provided into the cavity of the air distribution layer diffuses through the support insert before flowing into and through the body supporting layer.

3. The support pad according to claim 1, wherein: The foam rails prevent air from escaping the air distribution layer except through the body supporting layer.

4. The support pad according to claim 1, wherein: The foam rail includes an outer foam layer and an inner foam liner defining side surfaces of the cavity of the air distribution layer.

5. The support cushion of claim 4, wherein the inner foam liner is substantially air impermeable.

6. The support cushion of claim 1 wherein the foam rail comprises an air impermeable coating along at least a side surface of the cavity of the air distribution layer.

7. The support pad according to claim 1, wherein: The air distribution layer is formed by carving the cavity from a unitary piece of foam such that the base plate and the foam rail are integrally formed.

8. The support cushion of claim 1, wherein the support insert comprises an array of springs configured to support the body supporting layer.

9. The support cushion of claim 1, wherein the support insert comprises one or more foam layers configured to support the body support layer.

10. The support cushion of claim 1, wherein the body supporting layer defines a plurality of channels extending from the first surface to the second surface, the plurality of channels being substantially aligned with the cavities of the air distribution layer.

11. The support cushion of claim 1 , wherein the body supporting layer includes an insulator layer disposed adjacent to the air distribution layer and a comfort layer disposed adjacent to the insulator layer opposite the air distribution layer.

12. The support pad of claim 11, wherein the insulator layer, the air distribution layer, or both the insulator layer and the air distribution layer are comprised of a viscoelastic foam.

13. The support cushion of claim 1, wherein the body supporting layer is comprised of a viscoelastic foam.

14. The support pad of claim 1 wherein the substrate of the air distribution layer defines apertures and a duct directs air from the fan through the apertures and into the cavity of the air distribution layer.

15. The support pad of claim 1, further comprising a base layer positioned adjacent to a lower surface of the substrate; in, the foam rail being positioned along an upper surface of the base plate opposite the lower surface; as well as wherein the base layer defines holes, the base plate of the air distribution layer defines holes aligned with the holes of the base layer, and a duct directs air from the fan through the holes of the base layer, through the holes of the base plate of the air distribution layer, and into the cavity of the air distribution layer.

16. The support cushion of claim 1, further comprising a heating unit, a cooling unit, or both a heating unit and a cooling unit configured to provide a thermally controlled air flow into the cavity of the air distribution layer.

17. A method of controlling airflow through a support cushion, comprising the steps of: A support pad is provided, the support pad having: a body supporting layer having a first surface and a second surface opposite the first surface; an air distribution layer positioned adjacent the first surface of the body supporting layer, the air distribution layer comprising a base plate and a foam rail positioned at least about a perimeter of the base plate to define a cavity, wherein a support insert is positioned within the cavity; as well as a fan operatively connected to the air distribution layer, the fan for providing an air flow into the cavity of the air distribution layer; supplying an electric current to the fan so that the fan pushes a volume of ambient air into the cavity of the air distribution layer; as well as The amount of ambient air is moved through the support insert, through the body supporting layer, and out of the second surface of the body supporting layer.

18. A method for manufacturing a support pad, comprising the steps of: providing an air distribution layer defining a cavity on a top portion of the air distribution layer, the cavity having a bottom surface and side surfaces; positioning a support insert in the cavity on a bottom surface of the cavity, wherein side surfaces of the cavity surround the support insert such that only an upper side of the support insert opposite the bottom surface of the cavity remains exposed; and positioning a body supporting layer on top of the air distribution layer, the body supporting layer having a first surface and a second surface opposite the first surface and defining a plurality of channels extending from the first surface to the second surface, the plurality of channels being substantially aligned with the cavities of the air distribution layer; Wherein the side surfaces of the cavity of the air distribution layer are substantially air impermeable and the support insert is substantially air permeable.

19. The method of claim 18, wherein: The step of providing the air distribution layer includes carving cavities from a unitary piece of foam to form the air distribution layer, wherein the unitary piece of foam is substantially air impermeable.

20. The method of claim 18, wherein: The steps of providing the air distribution layer include: providing a substrate; and A foam rail is positioned around the perimeter of the base plate to define the cavity.

21. The method according to claim 20, further comprising the steps of: A coating is applied to the foam rail to form an air impermeable coating on the side surface of the cavity.

22. The method according to claim 20, further comprising the steps of: The foam rail is heated to form an air impermeable coating on the side surface of the cavity.

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