Support cushion assembly including active ventilation system

Abstract

A support cushion assembly comprises a foundation and a support cushion that is positioned atop the foundation. The support cushion includes an upper surface and a bottom surface. The support cushion assembly further includes a ventilation system configured to pull air downwards from the upper surface of the support surface and to release the pulled air under the foundation.

Description

SUPPORT CUSHION ASSEMBLY INCLUDING ACTIVE VENTILATION SYSTEM RELATED APPLICATIONS

[0001] This application claims priority from U.S. Provisional Application Serial No. 63 / 448,937, filed February 28, 2023, the entire disclosure of which is incorporated herein by this reference. TECHNICAL FIELD

[0002] The present invention relates to support cushion assemblies including an active ventilation system. In particular, certain embodiments of the present invention relate to body support cushion assemblies including an active ventilation system that is in fluid communication with one or more foam layers of a support cushion. BACKGROUND

[0003] Research has shown that a cooler sleep environment promotes a better quality sleep by helping people fall asleep faster and stay asleep longer with less tossing and turning. Typically, it takes individuals longer to fall asleep in warmer sleep environments, and once sleep is achieved in such environments, it is often the case that the individual’s sleep may be broken up or fragmented. Indeed, additional research shows that people sleep better and feel more rested and revitalized the next day when temperature variations are minimized or eliminated within a given sleep environment, i.e., when a cooler, constant temperature is maintained. 1 TE104L:534US1P:1611085:2:LOUISVILLE

[0004] Poor sleep quality, on the other hand, leads to sleep deprivation or “sleep debt” that can have significant negative impacts on longevity, productivity, and overall mental, emotional, and physical health. Chronic sleep debt has been linked to weight gain and, more specifically, has been observed to not only affect the way the body processes and stores carbohydrates, but has also been observed to alter hormone levels that affect appetite. 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 inattentiveness. Sleep disorders have also been linked to hypertension, increased stress hormone levels, and irregular heartbeats, 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 all, researchers have now suggested that sleep debt costs the United States billions of dollars annually in lost productivity due to these various effects.

[0005] Accordingly, a support cushion with an active ventilation system that promotes and maintains a cooler sleep environment and thereby lowers individual sleep debt, would be both highly desirable and beneficial. SUMMARY

[0006] The present invention includes support cushion assemblies having an active ventilation system that is in fluid communication with one or more foam layers of a support cushion. In some embodiments, a support cushion assembly is provided that includes a top foam layer and a base foam layer, with the top foam layer having a cellular structure that is configured to allow air to flow through the top foam layer at a rate greater than that of the base foam layer. A ventilation system is operably connected to the support cushion and is configured to pull air downward from the top foam layer and then release the pulled air below the base foam layer of 2 TE104L:534US1P:1611085:2:LOUISVILLEthe support cushion to thereby provide ventilation through the support cushion. In some embodiments, to further facilitate the movement of air through the support cushion, a hole is defined by and extends through the base foam layer of the support cushion and, in certain embodiments, also extends through a foundation on which the support cushion is positioned.

[0007] In some embodiments, the foam layers of the exemplary support cushions described herein are comprised of various types and arrangements of foam to facilitate and control the flow of air through the support cushion. In some embodiments, the top foam layer comprises a reticulated foam and the base foam layer comprises a non-reticulated foam. In some embodiments, the support cushion further comprises an intermediate foam layer that is positioned between the top foam layer and the base foam layer, and that also has a cellular structure configured to allow air to flow through the intermediate foam layer at a rate greater than that of the base foam layer. In some embodiments, the intermediate foam layer is also comprised of a reticulated foam and, in certain embodiments, the top foam layer, the intermediate foam layer, or both are comprised of a visco-elastic foam.

[0008] In some embodiments of the base foam layers included in an exemplary support cushion, the base foam layer is comprised of a single layer of foam. In other embodiments, however, the base foam layer itself can be comprised of multiple layers of foam and / or can be comprised of various types and arrangements of foam to provide a sufficiently hard and durable layer that supports the overlying top foam layer while also, in certain embodiments, assisting in directing the flow of air downward from the top foam layer and through the base foam layer to underneath the support cushion. For instance, in some embodiments, the base foam layer is comprised of one or more layers of foam that each have a convoluted surface. As another example, in some embodiments, the base foam layer is comprised of a first base foam layer and a 3 TE104L:534US1P:1611085:2:LOUISVILLEsecond base foam layer positioned beneath the first base foam layer. In some such embodiments, both the first base foam layer and the second base foam layer can be comprised of a non- reticulated foam, with the first base foam layer including a convoluted surface. In some of these embodiments that include multiple base foam layers, a pair of foam end rails and a pair of foam side rails can be positioned atop the second base foam layer. The pair of foam end rails and the pair of foam side rails collectively form a perimeter around the first base foam layer, such that when air is pulled downward from the top foam layer, the foam end rails and foam side rails help to secure the base foam layer to the other foam layers of the support cushion and help to direct the flow of air over the convoluted surface of the first base foam layer and then downward (e.g., through a hole in the base foam layer) to below the support cushion.

[0009] To control the flow of air through an exemplary support cushion, in some embodiments, a support cushion assembly made in accordance with the present invention includes a controller in communication with the ventilation system and at least one sensor in communication with the controller. The at least one sensor measures one of a humidity value or a temperature value of an environment of the support cushion assembly. In turn, the controller is then configured to automatically turn on the ventilation system when the temperature or humidity value measured by the at least one sensor is above a predetermined value and / or automatically turn off the ventilation system when the temperature or humidity value measured by the at least one sensor is at or below a predetermined value.

[0010] In another embodiment of the present invention, another support cushion assembly with a ventilation system is provided. The support assembly cushion includes a foundation having an air mover mounted thereon. The support cushion assembly further includes a support cushion, such as a mattress, having a base layer, an intermediate layer, and a top layer. The 4 TE104L:534US1P:1611085:2:LOUISVILLEsupport cushion assembly also includes a hole extending from a bottom surface of the intermediate layer through the base foam layer and the foundation. The air mover pulls air downward through the top foam layer and further through the hole and distributes the pulled air around the body support cushion. The air mover, in some embodiments, is in the form of a fan or an air pump.

[0011] In another embodiment, the support cushion assembly further includes a filter in fluid communication with and operably connected to the air mover. The filter and the air mover can be contained within a housing such as, in certain embodiments, a housing having a discharge outlet. The body support cushion assembly, in some embodiments, further includes a cartridge for providing aroma therapy to the pulled air, with the cartridge being in fluid communication with the air mover and the filter.

[0012] In yet another implementation of the present invention, a method of actively ventilating a support cushion is provided. In one such implementation, the method includes providing a support cushion assembly including a support cushion positioned atop a foundation. Air is then pulled from an environment surrounding the support cushion assembly through a top surface of the support cushion, downward through the support cushion, and further through a hole extending through at least a portion of the support cushion and the foundation. The pulled air is then filtered before being discharged back into the surrounding environment.

[0013] Further features and advantages of the present disclosure 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. 5 TE104L:534US1P:1611085:2:LOUISVILLEBRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG.1 is a perspective view of a support cushion assembly made in accordance with the present invention, and including a support cushion in the form of a mattress positioned atop a foundation;

[0015] FIG.2 is a partial cutaway view of the support cushion assembly of FIG.1;

[0016] FIG.3 is a perspective view of another support cushion made in accordance with the present invention, and including multiple foam layers;

[0017] FIG.4 is a partial cutaway view of the support cushion of FIG.3;

[0018] FIG.5 is a partial perspective view of an air mover mounted to and below the foundation of FIG.1;

[0019] FIG.6 is a perspective view of a hole extending through the support cushion of FIG. 1, with the top and intermediate layers of the support cushion removed to visualize the hole;

[0020] FIG.7 is a side sectional view of an air mover in the form of an air pump mounted to a foundation of a support cushion assembly in accordance with the present invention;

[0021] FIG.8 is a schematic diagram of an exemplary control system used to control a support cushion assembly in accordance with the present invention;

[0022] FIG.9 is a perspective view of a mattress cover used in accordance with the present invention, and including a detailed view of a cross section of the mattress cover;

[0023] FIG.10 is an exploded perspective view of another support cushion made in accordance with the present invention;

[0024] FIG.11 is an assembled perspective view of the support cushion of FIG.10; and

[0025] FIG.12 is an assembled and partial cutaway view of the support cushion of FIG.10, and further showing the support cushion positioned on a foundation with an air mover mounted to and below the foundation. 6 TE104L:534US1P:1611085:2:LOUISVILLEDESCRIPTION OF EXEMPLARY EMBODIMENTS

[0026] The present invention includes support cushion assemblies including an active ventilation system. In particular, certain embodiments of the present invention include support cushion assemblies having an active ventilation system that is in fluid communication with one or more foam layers of a support cushion so as to provide ventilation through the support cushion. In some embodiments, such active ventilation alleviates temperature fluctuations in the environment surrounding the support cushion and allows an individual resting on the support cushion to maintain a more consistent body temperature over a period of time (e.g., throughout the night). In some embodiments, the active ventilation pulls ambient air from the environment through the support cushion assembly and then filters the air such that when the filtered air is released to the surrounding environment, the air is free of bacteria, pollen, and other allergens or nuisances, such as the secretions of house dust mites. Moreover, by continuously pulling fresh air through the support cushion assembly, the surface temperature on the support cushion assembly and the relative humidity in the surrounding environment remain more constant such that there is no heat buildup and undesirable humidity in the support cushion itself or in the surrounding environment. In some embodiments, the air can also be further conditioned (i.e., cooled or heated) to a desired temperature by continuously releasing a temperature-controlled air flow to the surrounding environment, and doing so in a manner that allows the support cushion assembly to retain freshness and stay optimally dry and hygienic.

[0027] Referring first to FIGS.1 and 2, in one embodiment of the present invention, a support cushion assembly 10 is provided. The support cushion assembly 10 includes a support cushion in the form of a mattress 20 having an upper surface 22 and a lower or bottom surface 7 TE104L:534US1P:1611085:2:LOUISVILLE24. The support cushion assembly 10 generally has a head end 12 and a foot end 14 that, in turn, generally define a longitudinal direction Lo for the support cushion assembly 10 and, in a direction perpendicular to the longitudinal direction LOof the support cushion assembly 10, a lateral direction LA which extends between the sides of the mattress 20. The support cushion assembly 10 further includes a foundation 35 atop which the mattress 20 is positioned. A ventilation system 70 including a fan 72 is also included in the support cushion assembly 10 and, more specifically, is mounted to the foundation 35 such that the ventilation system 70 is configured to pull air downward from the upper surface 22 of the mattress 20 and then release the pulled air under the foundation 35, as described in further detail below.

[0028] With further respect to the foundation 35, the foundation 35 generally comprises a base or frame 50 positioned on a plurality of legs 40. Additionally, the foundation 35 includes a deck 60 that is disposed upon the frame 50 and that provides a support surface for the mattress 20, which, as indicated above, is positioned atop the deck 60. In the exemplary embodiment shown in FIGS.1-2, the deck 60 and, more generally, the foundation 35 is fixed such that the position of the mattress 20 is not adjustable. It is of course contemplated though that the support cushion assemblies described herein are equally applicable to and can be utilized with adjustable foundations to allow a support cushion, such as a mattress, to be moveable to alternate positions such as a reading position or other upright positions as may be desirable, for example, for watching television or during times when the user wants to use make use of an exemplary support cushion assembly, but not necessarily sleep. For additional information and guidance regarding the use of active air systems in connection with an adjustable base, see, e.g., International Patent Application Publication No. WO2020 / 006085, which is incorporated herein by reference in its entirety. 8 TE104L:534US1P:1611085:2:LOUISVILLE

[0029] In such support cushion assemblies that make use of an adjustable foundation, it is further contemplated that a mattress retainer (not shown) can be included and can extend from the deck of a foundation near the foot end of the exemplary support cushion or bed assembly so as to prevent the support cushion or mattress from sliding off from the deck as the adjustable base is articulated. It is also contemplated that the legs included in an exemplary foundation can also be a single structure or can be formed of a plurality of structures without departing from the spirit and scope of the present invention to allow for variation of the height of the bed assembly.

[0030] Regardless of the particular construction of the foundation included in an exemplary support cushion assembly of the present invention, the support cushion included in the assembly generally includes a plurality of foam layers that are configured and arranged to allow for movement of ambient air through the mattress. For instance, as shown in the partial cutaway view of the support cushion assembly 10 provided in FIG.2, the mattress 20 of the support cushion assembly 10 includes a lower, base foam layer 130, a support or intermediate foam layer 160, and a comfort or top foam layer 190, with the base foam layer 130, intermediate foam layer 160 and top foam layer 190 each comprised of a flexible foam having different characteristics or physical properties to provide a comfortable surface on which a user may rest and to promote the movement of air in a desired direction through the mattress 20. In this regard, the terms “foam” or “flexible foam” are used herein to refer to a material in a lightweight cellular form, for example resulting from introduction of gas bubbles during manufacture to produce a consistent cell structure, and / or any of various light, porous, semi-rigid or spongy materials or cellular solids, usually the solidified form of a liquid full of gas bubbles, which may be used as a building material or for shock absorption. Such types of flexible foam capable of use in accordance with the present invention include, but are not limited to, flexible foams such as polyurethane foam, 9 TE104L:534US1P:1611085:2:LOUISVILLElatex, memory or viscoelastic foam, specialty memory foam, gel memory foam, gel latex foam, gel infused foam, a multi-gel foam, a high thermal conductivity foam, other gel foams, and the like.

[0031] Referring still to FIG.2, the base foam layer 130 included in the mattress 20 is formed of a foam capable of providing a sufficient base or supporting layer for the intermediate foam layer 160 and top foam layer 190 of the mattress 20. More specifically, in the mattress 20, the base foam layer 130 is a non-reticulated conventional polyurethane foam having hardness and density values sufficient to support the overlying intermediate foam layer 160 and top foam layer 190. Typically, such a base foam layer 130 has a hardness of at least about 50 N and no greater than about 300 N for desirable support. In other embodiments, the base foam layer 130 has a hardness of at least about 75 N and no greater than about 200 N. In still other embodiments, the base foam layer 130 has a hardness of at least about 100 N and no greater than about 175 N. In one particular embodiment, the base foam layer 130 has a hardness of 100 N to about 140N. In such embodiments, the hardness of the base foam layer 130 is determined by measuring an indentation load deflection or “ILD” of 40% according to the test procedure governed by the DS / EN ISO 2439 standard.

[0032] Similarly, in some embodiments, the base foam layer 130 has a density of no less than about 15 kg / m3and no greater than about 150 kg / m3. In other embodiments, the base foam layer 130 has a density of at least about 20 kg / m3and no greater than about 80 kg / m3. In still other embodiments, the base foam layer 130 has a density of at least about 25 kg / m3and no greater than about 60 kg / m3. In further still other embodiments, the base foam layer 130 has a density of at least about 20 kg / m3and no greater than about 40 kg / m3. In some embodiments, the base foam layer 130 has a density of at least about 23 kg / m3and no greater than about 32 kg / m3. 10 TE104L:534US1P:1611085:2:LOUISVILLEIn such embodiments, the density of the base foam layer 130 is determined by measuring the apparent overall density using the DS / EN ISO 845 standard.

[0033] In some embodiments, it is further desirable that the base foam layer 130 of flexible foam be capable of providing some degree of support that is substantially independent of temperatures experienced by the upper layers when supporting a user’s body (i.e., independent of a user’s body heat). Therefore, in some embodiments, the base foam layer of an exemplary support cushion can be comprised of non-viscoelastic foam that is substantially insensitive to temperature changes within a range of between about 10 and 35 degrees Celsius. As used herein, a material is “substantially insensitive” to temperature changes if the material exhibits a change in hardness of less than 10% measured by ISO Standard 3386 through the range of temperatures between 10 and 30 degrees Celsius. Other temperature ranges are also capable of use and therefore the temperature range should only be considered illustrative and not limiting.

[0034] To provide a base foam layer 130 having the above-described hardness and density values, in the mattress 20, the base foam layer 130 is formed of two layers of convoluted foam (e.g., egg crate foam) that includes a non-planar upper surface defined by a plurality of curved or angular shapes and that is stacked together. Of course, other types of foam as well as other types and configurations of a base or bottom layer are also within the scope of the present invention including, but not limited to, base layers making use of a foam core, a gel foam core, a latex core, an inner spring layer, a layer of individually wrapped or encased coils, an inflated air system, a liquid system (e.g., water), or base layers having different numbers or types of layers of foam.

[0035] As one example of a support cushion assembly making use of a base foam layer including an alternative foam configuration, and referring now to FIGS.3 and 4, in another 11 TE104L:534US1P:1611085:2:LOUISVILLEembodiment of the present invention, a support cushion in the form of a mattress 220 is provided that similarly includes a top foam layer 390 and an intermediate foam layer 360 having the same characteristics and properties of the top foam layer 190 and the intermediate foam layer 160 included in the mattress 20 shown in FIG.1 and as described in further detail below. However, in the mattress 220 shown in FIGS.3 and 4, the base foam layer 330 is comprised of a single layer of non-reticulated polyurethane foam having a cellular structure in which the walls of the individual cells are substantially intact and having hardness and density values similar or the same as that described above with reference to the convoluted foam included the embodiment shown in FIGS.1 and 2. As another example, in some embodiments, it is further contemplated that the base foam layer can instead be comprised of a breathable porous material, such as a reticulated foam, to allow the base layer to assist in reducing heat in the higher layers, due at least in part to the cellular structure of the foam of the base foam layer, but yet still provide the requisite support for the overlying intermediate and top foam layers.

[0036] Referring again to FIGS.1 and 2, and as described above, disposed on top of the base foam layer 130 is a support or intermediate foam layer 160. The intermediate foam layer 160 is generally formed of an open-cell or reticulated viscoelastic foam having a density greater than and a hardness less than that of the base foam layer 130, and that is configured or otherwise designed to allow air from the top foam layer 190 of the mattress 20 to be pulled down through the top foam layer 190 as well as into and through the intermediate foam layer 160, as described in further detail below. In some embodiments, the intermediate foam layer 160 has a hardness of at least about 50 N and no greater than about 150 N, as measured by, again, determining the ILD40% according to the DS / EN ISO 2439 standard. In some embodiments, the intermediate foam layer 160 has a hardness of at least about 60 N and no greater than about 125 N. In other 12 TE104L:534US1P:1611085:2:LOUISVILLEembodiments, the intermediate foam layer 160 has a hardness of at least about 70 N and no greater than about 100 N. In one particular embodiment, the intermediate foam layer 160 has a hardness of about 76 N to about 95 N.

[0037] The intermediate foam layer 160, while typically having a density greater than that of the base foam layer 130, also has a density providing a relatively high degree of material durability. Of course, the density of the foam in the intermediate foam layer 160 (as well as in the other foam layers of the assembly 10) can also impact other characteristics of the foam, such as the manner in which the intermediate foam layer 160 responds to pressure, and the feel of the foam. In some embodiments, the intermediate foam layer 160 has a density of no less than about 40 kg / m3and no greater than about 150 kg / m3as determined using the DS / EN ISO 845 standard. In other embodiments, the intermediate foam layer 160 has a density of at least about 60 kg / m3and no greater than about 125 kg / m3. In still other embodiments, the intermediate foam layer 160 has a density of at least about 70 kg / m3and no greater than about 100 kg / m3. In one particular embodiment, the intermediate foam layer 160 has a density of about 80 kg / m3to about 90 kg / m3.

[0038] As also indicated above, disposed on top of the support or intermediate foam layer 160 is a comfort or top foam layer 190. The top foam layer 190, similar to the intermediate foam layer 160, is also made with an optimized cellular structure designed to be lightweight and more breathable than other layers to promote and enable better airflow through the mattress assembly. In particular, the top foam layer 190 is also comprised of an open-cell or reticulated viscoelastic foam that is also designed with a thinner capsule wall to provide more cooling power per cubic foot and which can, optionally, be infused with a phase change material. In this way, and as described in further detail below, the open structure of the top foam layer 190 allows ambient air 13 TE104L:534US1P:1611085:2:LOUISVILLEfrom the sleeping or upper surface 22 of the mattress 20 to be pulled down into and through the open cell structure of the top foam layer 190 at a rate greater than that of the base foam layer 130 in order to allow the surface temperature on the support cushion assembly 10 to remain more constant and prevent or, at the least, reduce heat buildup and undesirable humidity in the mattress 20 and, more specifically, in the top foam layer 190 of the mattress 20, as perhaps shown best by the arrows in FIG.2.

[0039] In addition to allowing increased air flow through the mattress 20, the top foam layer 190 also provides a relatively soft and comfortable surface for a user’s body to rest. Coupled with the slow recovery characteristic of the viscoelastic foam, the top foam layer 190 is also configured to conform to a user’s body, thereby distributing the force applied by the user’s body upon the top layer. However, the top foam layer 190 typically has a density, hardness, or both that is less than that of the intermediate foam layer 160 of the mattress 20, such that the top foam layer 190 provides a softer surface on which to rest the body of a user or a portion thereof. For example, in certain embodiments, an exemplary support cushion assembly can include an intermediate foam layer that is comprised of viscoelastic foam with a density of about 80 kg / m3to 90 kg / m3and a hardness of about 76N to about 95N, along with a top layer that is comprised of a viscoelastic foam with a density of about 80 kg / m3to 90 kg / m3and a hardness of only about 50 N to about 67 N. Of course, in some embodiments, the top foam layer 190 can also be configured to have other hardness and density values, including hardness and density values within the ranges described above with respect to the intermediate foam layer 160 and top foam layer 190 and as may be desired for a particular application.

[0040] With further respect to the foam layers included in an exemplary support cushion assembly of the present invention, the foam layers can be bonded together in a variety of 14 TE104L:534US1P:1611085:2:LOUISVILLEmanners including, but not limited to, melting, welding, sewing, adhesive bonding, or other forms or combinations of the foregoing. In some embodiments, the foam layers can be stapled, tacked, mechanically affixed via friction or interference fit, adhered via an adhesive, a glue, a cement, or other material with adhesive properties, stitched, affixed via hook and loop fastener, a zipper, a Dennison-style tag, snaps, and / or other reversible means, and combinations thereof.

[0041] For purposes of the present embodiments, the various layers are generally joined to one another with adhesives including glues, cements and other materials with adhesive properties. As such, in some embodiments, each layer can further include an adhesive that, in certain embodiments, is located at the interfaces between the various layers. For example, in the exemplary embodiment shown in FIGS.1-2, the top foam layer 190 and the intermediate foam layer 160 are glued together at the interface between those two layers but only around the perimeters of those layers so as not interfere with the movement of air through the interior portions of the layers. Specific examples of adhesives capable of use in accordance with the present invention include hot melt, water-based, and pressure-sensitive adhesives, fire-resistant adhesives, and mixtures thereof. Further, a layer and / or an adhesive may further include a silica, a metallic layer, a plastic, such as an acrylic, a modacrylic, a polyolefin, a latex, a polyurethane, and combinations and / or blends thereof. In addition, a layer may further include biocides, preservatives, odor blocking agents, scents, pigments, dyes, stain guards, antistatic agents, anti- soiling agents, water-proofing agents, moisture wicking agents, and the like, as are known in the art.

[0042] As a further refinement to the exemplary support cushion assemblies of the present invention and with further regard to the use of an adhesive around the perimeter of an exemplary mattress assembly, in some embodiments, it is additionally contemplated that the assemblies 15 TE104L:534US1P:1611085:2:LOUISVILLEneed not be comprised of foam layers having identical dimensions and / or surface features but can be comprised of different arrangements and types of foam as well. For instance, and referring now to FIGS.10-12, in another exemplary embodiment, a mattress 720 for use in an exemplary support cushion assembly is provided in which the mattress 720 has an upper surface 722 and a lower surface 724, and further includes a top foam layer 790 and an intermediate foam layer 760. Both the top foam layer 790 and the intermediate foam layer 760 are comprised of reticulated visco-elastic foam and have density and hardness values similar to or the same as those described above with reference to the top foam layer 190 and intermediate foam layer 160 of the mattress 20 shown in FIGS.1-2. In the mattress 720, however, the bottommost or base foam layer 730 is not comprised of two identical layers of foam, but is instead comprised of a first base foam layer 734 of convoluted polyurethane foam positioned immediately below the intermediate foam layer 760, and a second base foam layer 731 of polyurethane foam having substantially smooth surfaces and positioned below the first base foam layer 734. In this particular embodiment, both the first base foam layer 734 and the second base foam layer 731 similarly include hardness and density values the same as those discussed above with reference to the base foam layer 130 of the mattress 20.

[0043] To assist in securing the various layers of the mattress 720 together, further included in the base foam layer 730 of the mattress 720 is a pair of end foam rails 732b and a pair of side foam rails 732a, which are each formed from the same polyurethane foam as the second base foam layer 731. The end foam rails 732b and the side foam rails 732a are secured to the top surface of the second base foam layer 731, and effectively and collectively form a perimeter around the first base foam layer 734. In this way, not only is the first base foam layer 734 positioned within the perimeter formed by the end foam rails 732b and the side foam rails 732a, 16 TE104L:534US1P:1611085:2:LOUISVILLEbut the top surface of the end foam rails 732b and the side foam rails 732a provide a substantially smooth surface against which the intermediate layer 760 may be secured while also providing a more solid edge along the perimeter of the mattress 720 as compared to what would be present should the convolute foam of the first base foam layer 734 extend to the edge of the mattress 720.

[0044] Referring now more generally to FIGS.1-2, 3-4, and 10-11, to allow the air to move through the layers and as indicated above, each top foam layer 190, 390, 790 and each intermediate foam layer 160, 360, 760 is made with an optimized cellular structure to allow airflow through the top foam layers 190, 390, 790 and the intermediate foam layers 160, 360, 760 of each mattress 20, 220, 720 at a rate greater than that of the base foam layers 130, 330, 730. In particular, in the exemplary support cushions, each top foam layer 190, 390, 790 and each intermediate foam layer 160, 360, 760 is generally made of a reticulated visco-elastic foam have a cellular structure configured to provide an airflow rate of greater than about 2.00 l / sec, such as an air flow rate in the range of about 2.01 l / sec to about 10.00 l / sec, while the base foam layers 130, 330, 730 are made of a non-reticulated conventional polyurethane foam having an airflow rate of less than about 0.5 l / sec or less than about 2.00 l / sec, such as an air flow rate in the range of of about 0.0 l / sec to about 2.00 l / sec. In such embodiments, the air flow rates can be determined by testing the foam layers for air permeability on an FX 3300 LabAir IV Instrument (Textest Instruments, Schwerzenbach, Switzerland) according to the ASTM D3574-17 (Test G) standard while making use of equipment according to the ASTM D737 standard with a clamping system.

[0045] To promote and allow airflow to move from the top foam layers 190, 390, 790 and from the intermediate foam layers 160, 360, 760 and into and through the base foam layers 130, 17 TE104L:534US1P:1611085:2:LOUISVILLE330, 730 of each mattress 20, 220, 720, however, a hole 80, 380, 780 is drilled entirely through the base foam layers 130, 330, 730 of each mattress 20, 220, 720 such that air pulled through the top foam layers 190, 390, 790 and the intermediate foam layers 160, 360, 760 of each mattress 20, 220, 720 contacts the base foam layers 130, 330, 730 and then travels downward through the hole 80, 380, 780 past the base foam layers 130, 330, 730 and ultimately, is released below the mattress 20, 220, 720. In the embodiments shown in FIGS.1-2, 3-4, and 10-12 each hole 80, 380, 780 is substantially circular and in the form of a lined cylinder or tube that extends from a bottom of each intermediate foam layer 160, 360, 760 to a bottom of the base foam layers 130, 330, 730. Of course, it is appreciated that multiple holes of varying shapes can also be incorporated into an exemplary support cushion, such as a mattress, without departing from the spirit and scope of the present invention. Likewise, it should be appreciated that the hole 80, 380, 780 in each mattress 20, 220, 720 can be lined or unlined according to different embodiments and as may be desired to facilitate the flow of air through the hole 80, 380, 780 and the various layers 130, 160, 190, 330, 360, 390, 730, 760, 790 of each exemplary mattress 20, 220, 720.

[0046] Referring now more particularly to the embodiments shown in FIGS.1-2, 5-6, and 10-12 to allow air to flow out of the mattresses 20, 720, the holes 80, 780 also extend through the deck 60 of the foundation 35 associated with each support cushion assembly 10, 710. The ventilation system 70 including the fan 72 is then mounted to the deck 60 via multiple fasteners (F), such as screws. Of course, it should be appreciated that the ventilation system 70 and fan 72 can be mounted to the deck 60 by other means and that a hose (not shown) can also or alternatively be positioned between the mattress 20 and the deck 60 to establish a connection in 18 TE104L:534US1P:1611085:2:LOUISVILLEorder to secure airflow when the support cushion assembly 10, 710 or mattress 20, 720 is elevated.

[0047] To allow for sufficient air flow through the mattresses 20, 720, however, the fan 72 generally has dimensions of 12 cm x 12 cm and a height of about 2.5 cm. The fan 72 then generally requires an operating voltage of about 5 to about 15 volts such that the fan is capable of reaching a speed of rotation of 2200 rpm and providing an air flow of about 75 cfm while still operating at a noise level of 30 dBA or less so as to provide an assembly 10, 710 capable of moving a sufficient amount of air without disturbing the sleep of a user resting on the assembly 10, 710. It is further contemplated though that a number of different fans can be included in a support cushion assembly of the present invention and can be selected for a particular assembly or application based on the desired air flow or on the particular characteristics of the foam layers include in an exemplary assembly without departing from the spirit and scope of the subject matter described herein.

[0048] Regardless of the particular configuration, the fan 72 creates a vacuum such that ambient air is pulled downwardly through each top foam layer 190, 790 and through each intermediate foam layer 160, 760 of each mattress 20, 720 and, by way of each hole 80, 780, through the base foam layer 130, 730 as well the deck 60 of the foundation 35, as shown by the action arrows in FIGS.2 and 12. More specifically, as the air is pulled downwardly in the mattress 20 shown in FIG.2, the air travels readily through the more open cell structure of the reticulated foam included in the top foam layer 190 and the intermediate foam layer 160 until it meets the closed cell, non-reticulated foam of the base foam layer 130. At that point, and while a small amount of air is able to travel through the base foam layer 130 of the mattress 20, the majority of the air being pulled downward is pulled through the intermediate foam layer 160 19 TE104L:534US1P:1611085:2:LOUISVILLEtowards the hole 80 and ultimately through the hole 80 to below the base foam layer 130. Similarly, as the air is pulled downwardly in the mattress 720, the air travels readily through the more open cell structure of the reticulated foam included in the top foam layer 790 and the intermediate foam layer 760 until it meets the convoluted surface of the closed cell, non- reticulated foam of the first base foam layer 734. Subsequently, and again while a small amount of air is also able to travel through the base foam layer 730 of the mattress 720, the majority of the air being pulled downward is pulled through the intermediate foam layer 160 towards the hole 80 and ultimately through the hole 780 to below the base foam layer 730. However, by including the foam end rails 732b and foam side rails 732a in the base foam layer 730, air is also able to be pulled from the intermediate foam layer 760 and across the convoluted surface of the first base foam layer 734 in a manner that increases the efficiency with which the air is pulled through the mattress 720.

[0049] Once the air is pulled downwardly through the foam layers 130, 160, 190, 730, 760, 790 of each mattress 20, 720 and through the deck 60 of the foundation 35, the air is then expelled into the surrounding environment, such that heat buildup and undesired humidity in the mattresses 20, 720, as well as the surrounding environment, is reduced to thereby provide for better sleep for the user. Advantageously, due to the ambient air being pulled from around the exterior of the upper surface 22, 722 of each mattress 20, 720, the individual does not feel a draft on the body like would be the case with the use of an overhead fan or other air mover that may be used to reduce room temperature. Even further, because the ambient air is pulled from around the exterior of the upper surface 22, 722 of each mattress 20, 720, no dust bugs or other debris is pulled from underneath the bed and blown towards an individual resting atop the mattress 20. 20 TE104L:534US1P:1611085:2:LOUISVILLE

[0050] With more particular reference to FIGS.2 and 12, and with further regard to the ventilation system 70, the fan 72 is generally positioned in a housing 240 made of a rigid material (e.g., the same rigid material as the foundation 35) and having a substantially- rectangular shape. The foundation 35 acts as the top face of the housing 240, while the housing 240 further has a cage-like or mesh-like bottom face 250 that can be made of a metal or nylon mesh, such that the openings in the mesh allows the ambient air being pulled by the fan 72 from the environment and through the support cushion assembly 10, 710 to be discharged into the bedroom environment

[0051] As a refinement to the present invention, while the ventilation system 70 included in the support cushion assemblies 10, 710 shown in FIGS.2 and 12 is in the form of a fan 72, it is also contemplated that various other types and configurations of air movers can also be incorporated into an exemplary support cushion assembly. For instance, in another embodiment of the present invention and with reference to FIG.7, a ventilation system 470 is utilized and makes use of an air mover in the form of an air pump 472. The air pump 472 is attached to a first rigid connector 474 that is, in turn, connected to and in fluid communication with a flexible conduit 476 made of a corrugated tubing that is, in turn, connected to and is in fluid communication with a second rigid connector 477. The second rigid connector 477 is then operably connected to a collar 478 that connects the second rigid connector 477 to a hole 480 formed in the deck 460 of a foundation 435 for use with an exemplary support cushion assembly. In this way, similar to the embodiments described above with reference to FIGS.1-6, the air pump 472 is configured to pull air downward through the mattress 420 and release the pulled air below the foundation. An air filter 490, such as a high efficiency particulate air (HEPA) filter and / or other air cleaning structure, as well as an aroma therapy cartridge 492, is then positioned 21 TE104L:534US1P:1611085:2:LOUISVILLEwithin the ventilation system 470 such that filtered air and / or scented air can be discharged into the surrounding environment.

[0052] To control the ventilation system of the support cushion assemblies of the present invention as well as other features that may be included in an exemplary support cushion assembly, various control systems can be incorporated into an existing assembly as would be recognized by those skilled in the art. FIG.8 is a schematic diagram showing one such control system capable of being used in an exemplary support cushion assembly of the present invention in which the support cushion assembly makes use of an adjustable base. As shown in FIG.8, in the control system 500, a controller 502 is wired to various other service facilities for the support cushion assembly. In particular, the controller 502 is connected to two air movers 570 to provide power and control signals to the air movers 570, and is in further communication with two actuators 504 for articulating the adjustable base. A power supply 506, such as an AC power supply which converts power to DC for powering of DC fans of the air movers 570 or the actuators 504 is electrically connected to the controller 502. Additionally, the controller 502 provides for one or more USB chargers 508 so that a smart phone, smart pad or other electrical devices may be charged while the user is sleeping or alternatively while the user is in bed and / or may be used to further control the various features of the support cushion assembly, such as the ventilation system (e.g., the temperature or humidity level at which the ventilation system turns on, as described in further detail below). The exemplary control system 500 shown in FIG.8 also includes vibrator motors 510 which are in electrical communication with the controller 502 and which can be configured to provide a massaging function to a support cushion included an exemplary support cushion assembly. 22 TE104L:534US1P:1611085:2:LOUISVILLE

[0053] Other features such as under foundation lighting 512 and moisture and / or temperature sensors 520 are included in the control system 500 and are powered for use. In some embodiments, the moisture and temperature sensors 520 are used for automation of the ventilation system included in a particular support cushion assembly. In this regard, the moisture and / or temperature sensors 520 are configured to sense a particular parameter of the sleeping environment / room, i.e., humidity and temperature, respectively. If the measurement of the particular parameter is above or below a predefined value (either automatically entered into the system or manually entered by the user via user input), then the ventilation system will automatically shut off or turn on. For example, an individual may desire activation of the air movers 570 when the temperature of the room is 72° F or greater. Thus, if the temperature sensor 520 senses a temperature of 74° F in the room, a wireless or wired signal may be sent to the controller 502 to activate the air movers 570. The air movers 570 will continue to release conditioned air and operate until the temperature sensor 520 detects a temperature of less than 72° F. At that point, another signal may be sent to controller 502 to deactivate or shut down the air movers 570.

[0054] As would be apparent to those skilled in the art, such a controller 502 typically makes use of a processor and a communications module and is programmed to execute instructions stored in memory. The term “memory” is used herein to describe physical devices (computer readable media) used to store programs (sequences of instructions) or data (e.g. program state information) on a non-transient basis for use in an electronic device. With respect to the communications module included in an exemplary controller or other component of the present invention, such communications modules can include communications circuitry configured to wirelessly communicate with a remote control, a mobile device (e.g. a smart phone or tablet), or 23 TE104L:534US1P:1611085:2:LOUISVILLEan additional processor over wireless communication, as described in further detail below. In this regard, the controller 502 itself can be controlled by a wired remote control or a wireless remote control or may be controlled by a mobile device (e.g., a smart phone or a tablet). The wireless remote control may be connected by radio frequency (RF), infrared, Wi-Fi, Bluetooth, ZigBee or other wireless communication standards. The remote may be a stand-alone remote control with hard keys or buttons, touch screen or some combination for user input. Further, a mobile device in the form of a smart phone or smart pad can be used along with a mobile application which connects by a known communication standard to the controller 502. The controller 502 can also have a battery backup system. The battery backup system can be charged by an electrical connection which powers the controller 502. The battery backup can also provide that the system may be controlled for at least some period of time while power service may be unavailable.

[0055] Referring now to FIG.9, as a further refinement to the present invention, a mattress cover 630 can also be utilized in accordance with the present invention and to allow for passage of air flow through the mattress. In accordance with the present invention, it is desirable to not impede, or at least limit impedance, of air flow from the upper surface of a support cushion included in an exemplary assembly. As such, the mattress cover 630 is configured to limit the plugging of holes in an exemplary support cushion assembly so that air can continue to flow providing a ventilating function from the mattress assembly. The cover 630 comprises a border 672 and an inner panel 674 which is formed of a spacer fabric 676. The spacer fabric 676 is formed of a bi-directionally stretched material, meaning it is stretchable in two dimensions, such as the horizontal directions, for example head to toe and laterally, side to side relative a bed. The spacer fabric 676 includes an upper layer 676a and a lower layer 676b , and is also formed with a 24 TE104L:534US1P:1611085:2:LOUISVILLEthree-dimensional cross-structure 676c between upper and lower layers 676a and 676b, which provides a volume or air space through which air can flow. The third dimension (vertically as depicted) is of limited stretch capability as compared to the horizontal directions.

[0056] The spacer fabric 676 may include a woven, or knit material, and / or may include extruded plastic materials including polyethylene, polyester, other plastics or combinations of any of these or others. According to some embodiments, one of the layers 676a, 676b can be formed of polyester, and spandex. In some embodiments, these materials may be formed of the same or differing thread sizes and in other embodiments multiple sizes of one or more materials may be utilized. For example, in the illustrative, non-limiting embodiment, the layer can contain 150 Denier polyester with 40 Denier and 70 Denier spandex. The other of the layers 676a, 676b may be 150 Denier polyester and a 40 Denier spandex. The three-dimensional cross structure 676c shown extending between layers 676a, 676b may be a 30 Denier polyester, as one non- limiting example. The pattern may be random or may be repeating or some combination of fibers. Additionally, the spacer fabric 676 is resilient to allow repeated uses without degradation and losing its thickness dimension. Thus, the material maintains the volume between the layers 676a, 676b to allow adequate airflow there through. One non-limiting example of this spacer fabric 676 is commercially marketed by Global Textile Alliance of China (Hangzhou, China).

[0057] Finally, although the support cushions shown in FIGS.1-4 and referenced throughout the present specification is in the form of a mattress assembly in which air is pulled downward through the exemplary mattress assemblies, it is contemplated that the direction of the fans and air movers described herein can be reversed such that the air can be pushed through an exemplary mattress assembly due, at least in part, to the arrangement of the foam layers in an exemplary assembly. Moreover, although the support cushions described herein are in the form 25 TE104L:534US1P:1611085:2:LOUISVILLEof mattress assemblies that are dimensionally-sized to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to seat cushions, seat backs, pillows, mattress topers, overlays, and the like. As such, the phrase “support cushion” and the like is used herein to refer to any and all such objects having any size or shape, and that are capable of or are generally used to support the body of a user or a portion thereof.

[0058] One of ordinary skill in the art will 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. 26 TE104L:534US1P:1611085:2:LOUISVILLE

Claims

CLAIMS What is claimed is :

1. A support cushion assembly, comprising: a support cushion including a top foam layer and a base foam layer, the top foam layer having a cellular structure configured to allow air flow through the top foam layer at a rate greater than that of the base foam layer; and a ventilation system configured to pull air downward from the top foam layer and release the pulled air below the base foam layer of the support cushion.

2. The support cushion assembly of claim 1, further comprising a hole defined by and extending through the base foam layer.

3. The support cushion assembly of claim 1, wherein the top foam layer comprises a reticulated foam.

4. The support cushion assembly of claim 1, further comprising an intermediate foam layer positioned between the top foam layer and the base foam layer, the intermediate foam layer having a cellular structure configured to allow air flow through the intermediate foam layer at a rate greater than that of the base foam layer.

5. The support cushion assembly of claim 4, wherein the top foam layer, the intermediate foam layer, or both are comprised of a visco-elastic foam. 27 TE104L:534US1P:1611085:2:LOUISVILLE6. The support cushion assembly of claim 1, wherein the base foam layer comprises a non- reticulated foam.

7. The support cushion assembly of claim 1, wherein the base foam layer comprises one or more layers having a convoluted surface.

8. The support cushion assembly of claim 1, wherein the base foam layer comprises a first base foam layer and a second base foam layer positioned beneath the first base foam layer.

9. The support cushion assembly of claim 8, wherein the first base foam layer and the second base foam layer comprise a non-reticulated foam.

10. The support cushion of claim 8, wherein the first base foam layer includes a convoluted surface.

11. The support cushion of claim 8, wherein the base foam layer further comprises a pair of foam end rails and a pair of foam side rails positioned atop the second base foam layer, the pair of foam end rails and the pair of foam side rails collectively forming a perimeter around the first base foam layer.

12. The support cushion assembly of claim 1, further comprising a foundation positioned below and supporting the support cushion. 28 TE104L:534US1P:1611085:2:LOUISVILLE13. The support cushion assembly of claim 12, further comprising a hole defined by and extending through the base foam layer and the foundation.

14. The support cushion assembly of 13, wherein the ventilation system is configured to pull air downward from the top foam layer of the support cushion and through the hole to release the pulled air under the foundation.

15. The support cushion assembly of claim 1, further comprising a controller in communication with the ventilation system, and at least one sensor in communication with the controller.

16. The support cushion assembly of claim 15, wherein the at least one sensor measures one of a humidity value or a temperature value of an environment of the support cushion assembly.

17. The support cushion assembly of claim 16, wherein the controller automatically turns on the ventilation system when the temperature or humidity value measured by the at least one sensor is above a predetermined value, and / or wherein the controller automatically turns off the ventilation system when the temperature or humidity value measured by the at least one sensor is below a predetermined value.

18. The support cushion assembly of claim 1, wherein the support cushion is a mattress.

19. A support cushion assembly, comprising: 29 TE104L:534US1P:1611085:2:LOUISVILLEa foundation; a support cushion positioned atop the foundation, the support cushion having a base layer, an intermediate layer, and a top layer; a hole extending from a bottom surface of the intermediate layer through the base layer and the foundation; and an air mover mounted to the foundation and in fluid communication with the hole, the air mover configured to pull air downward through the top layer of the support cushion and through the hole.

20. The support cushion assembly of claim 19, wherein the top layer of the support cushion comprises a reticulated viscoelastic foam.

21. The support cushion assembly of claim 19, wherein the intermediate layer comprises a viscoelastic foam.

22. The support cushion assembly of claim 19, wherein the base layer comprises a flexible foam.

23. The support cushion assembly of claim 19, wherein the air mover is a fan or an air pump.

24. The support cushion assembly of claim 23, further including a filter operably connected to the air mover. 30 TE104L:534US1P:1611085:2:LOUISVILLE25. The support cushion of claim 24, wherein the filter and the air mover are contained within a housing.

26. The support cushion of claim 25, wherein the housing has a discharge outlet.

27. The support cushion of claim 25, further including a cartridge for providing an aroma to the pulled air, the cartridge in fluid communication with the air mover and the filter.

28. A support cushion assembly, comprising: a support cushion including a top foam layer comprised of a reticulated foam, an intermediate foam layer positioned beneath the top foam layer, the intermediate foam layer comprised of a reticulated foam, and a base foam layer positioned beneath the intermediate foam layer and comprised of a non-reticulated foam, the base foam layer including a first base foam layer having a convoluted upper surface, a second base foam layer positioned beneath the first base foam layer, and a pair of foam end rails and a pair of foam side rails positioned atop the second base foam layer, the pair of foam end rails and the pair of foam side rails collectively forming a perimeter around the first base foam layer; and a ventilation system configured to pull air downward from the top foam layer, through the intermediate foam layer and the base foam layer, and release the pulled air below the base foam layer of the support cushion. 31 TE104L:534US1P:1611085:2:LOUISVILLE29. The support cushion of claim 28, wherein the support cushion is a mattress.

30. A method of actively ventilating a support cushion, comprising: providing a support cushion assembly including a support cushion positioned atop a foundation; pulling air from an environment surrounding the support cushion assembly through a top surface of the support cushion, downward through the support cushion, and through a hole extending through at least a portion of the support cushion and the foundation; filtering the pulled air; and discharging the filtered air back into the environment. 32 TE104L:534US1P:1611085:2:LOUISVILLE

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