A support cushion including a support insert surrounded by a foam rail for directing an air flow, a method for controlling its surface temperature, and a method for manufacturing the same

Abstract

A support cushion is provided for providing individual heating and cooling to a user on the support cushion. The support cushion includes a body support layer and an air distribution layer disposed adjacent to the body support layer. The air distribution layer includes a base plate and a foam rail disposed at least around the perimeter of the base plate to define a cavity having a support insert disposed therein. A fan is operably connected to the air distribution layer and supplies an air flow to the cavity of the air distribution layer. The air flow is directed through the support insert and through the body support layer.

Description

Related Applications

[0001] 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

[0002] The present invention relates to a support cushion, a method for controlling the surface temperature of a support cushion, and a method for manufacturing a support cushion. In particular, the present invention includes a support cushion such as a mattress assembly and utilizes a support insert surrounded by an air-impermeable foam rail to direct air to the surface of the support cushion.

Background Art

[0003] Aspects of sleep that provide successful rest are individual sleep comfort. Medical research suggests that sleep deprivation ("sleep debt") can have significant adverse effects on lifespan, productivity, and overall mental, emotional, and physical health. Chronic sleep debt has been associated with weight gain, and more specifically, it has been observed to not only affect the way the body processes and stores carbohydrates but also to change hormone levels that affect appetite. Additionally, sleep debt can lead to irritability, anxiety, lack of concentration, and moodiness, and some researchers have suggested a link between sleep debt and workplace accidents, traffic accidents, and general afternoon inattentiveness. Furthermore, sleep disorders are associated with high blood pressure, increased stress hormone levels, and irregular heartbeat, and further research has recently suggested that sleep deprivation affects immune function, resulting in increased susceptibility to illness and disease, such as cancer. Overall, researchers suggest that these various effects cause sleep debt to result in an annual productivity loss of $63 billion in the United States. Therefore, a support cushion that improves sleep comfort and reduces an individual's sleep debt is highly desirable and beneficial.

Summary of the Invention

[0004] The present invention includes a support cushion and a method for controlling the surface temperature of the support cushion. In particular, the present invention includes a support cushion such as a mattress assembly and utilizes a support insert surrounded by an air-impermeable foam rail to direct air towards the surface of the support cushion. Accordingly, the support cushion of the present invention enables a user to individualize a level of comfort, including sleep comfort, by controlling the amount and / or temperature of air flowing over the surface of the support cushion.

[0005] In one exemplary embodiment of the present invention, the support cushion is provided in the form of a mattress assembly that includes a body support layer having a first surface and a second surface opposite the first surface. The air distribution layer is disposed adjacent to the first surface of the body support layer, and the air distribution layer includes a base plate and a foam rail disposed at least around the periphery of the base plate to define a cavity. The support insert is then disposed within the cavity, and a fan is operably connected to the air distribution layer to supply 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.

[0006] In one exemplary embodiment, the foam rail includes an outer foam layer and an inner foam lining. The inner foam lining defines the sides of the cavity of the air distribution layer, and the inner foam lining is substantially air-impermeable. In another exemplary embodiment, the foam rail includes an air-impermeable coating along at least the sides of the cavity of the air distribution layer. In yet another exemplary embodiment, the air distribution layer is formed by carving a cavity from a single foam piece such that the base plate 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 supplied to the cavity of the air distribution layer spreads through the support insert before flowing through the body support layer.

[0007] In one exemplary embodiment, the support insert includes an array of springs, the array of springs being configured to support the body support layer. In another exemplary embodiment, the support insert includes one or more foam layers configured to support the body support layer.

[0008] The support cushion further includes an air flow unit, the air flow unit being operably connected to the inlet holes of the air distribution layer. The air flow unit includes a fan that supplies an air flow inside the support insert, and in some embodiments, further includes a heating unit and / or a cooling unit that supply a thermally controlled air flow inside the support insert. Substantially all of the air flowing into the support insert is directed through the upper body support layer. For this purpose, in some exemplary embodiments, the body support layer defines a plurality of channels extending from a first surface to a second surface. Thus, the air flowing out of the outlet holes is directed through the second surface of the body support layer via the plurality of channels.

[0009] To further facilitate the air flow through the body support layer, in some embodiments, the body support layer is composed of a porous viscoelastic foam. Such a porous foam, in some embodiments, has properties well suited for use in the body support layer of a mattress assembly, including an enhanced ability to allow fluid movement through the porous foam, and as a result, an enhanced ability to provide air movement through the body support layer of the mattress assembly. In this regard, the air exiting the support insert can then easily move through the body support layer to the second surface. When the air flow unit supplies heated or cooled air into the support insert, the increased air flow through the body support layer also improves the heating / cooling rate at the first surface of the body support layer.

[0010] Further features and advantages of the present invention will become apparent to those skilled in the art upon review of the description, drawings, and non-limiting examples herein.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 6

Figure 7

Best Mode for Carrying Out the Invention

[0012] The present invention includes a support cushion, and in particular, the present invention includes a support cushion such as a mattress assembly, and utilizes 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 enables a user to individualize the level of comfort, including sleep comfort, by controlling the amount and / or temperature of air flowing over the surface of the support cushion.

[0013] First, referring to FIGS. 1-3, in an exemplary embodiment of the present disclosure, a support cushion in the form of a mattress assembly 10 is illustrated, the mattress assembly 10 including a top 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 disposed 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 where 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.

[0014] The mattress assembly 10 further includes an air distribution layer 30 disposed adjacent to the first surface 72 of the insulator layer 70 (i.e., the first surface of the body support layer 75) and configured to support the body support layer 75. As will be described further below, the air distribution layer 30 includes a base plate 32 and foam rails 40, which define a cavity 50 in which a support insert 60 is disposed. Specifically, the support insert 60 is disposed on the bottom surface 54 of the cavity 50, and the side surface 52 of the cavity 50 surrounds the support insert 60 such that only the upper side of the support insert 60 opposite the bottom surface 54 of the cavity 50 remains exposed. Finally, the mattress assembly further includes a base layer 20 disposed adjacent to the base plate 32 of the air distribution layer 30.

[0015] The base layer 20 can take the form of a flexible (including foam) platform structure, a hard bottom, a platform structure, or the like, so that it can be used on an adjustable base, and provides a support surface on which the air distribution layer 30 can be located. In some embodiments, the base layer 20 may be substantially flat and fixed, but in other embodiments, the base layer 20 is adjustable and can move from a substantially flat position to any number of inclined positions desired by the user and known in the art. In embodiments where the base is adjustable, the mattress assembly 10 may also have positioning features for positioning the mattress assembly 10 and an adjustable base (not shown). As perhaps best shown in FIG. 3, the base layer 20 also defines at least one hole 26 that extends from the first surface 22 of the base layer 20 to the second surface 24 of the base layer 20, as will be further described below. Although not specifically shown in the drawings, in some embodiments, the base layer may be a mattress foundation, such as one used for use with an adjustable bed.

[0016] Referring further to FIGS. 2 and 3, as described above, the air distribution layer 30 includes a base plate 32 and a foam rail 40 disposed around the periphery of the base plate 32 so as to define a cavity 50 having a support insert 60 disposed therein. In this exemplary embodiment, the support insert 60 is formed by an array of springs 62, but other configurations are also contemplated, as will be further discussed below. In any case, the foam rail 40 and the support insert 60 are configured to support an insulating layer 70 and a comfort layer 80 (i.e., a body support layer 75). As perhaps best shown in FIG. 3, the base plate 32 also defines an inlet hole 34 that is positionally adjusted with the hole 26 defined in the base layer 20.

[0017] Referring now to FIGS. 1 and 2, the mattress assembly 10 further includes an air flow unit, herein generally shown as box 90, the air flow unit being operably connected by conduit 92 to an inlet hole 34 in the base plate 32 of the air distribution layer 30. Specifically, as shown in FIG. 2, flange 96 is operably connected to inlet hole 34, and flange 96 extends through inlet hole 34 in base plate 32 and also through hole 26 in base layer 20. Conduit 92 includes connector 94 at its distal end, and the connector is configured to engage flange 96 to provide a continuous air passageway between air flow unit 90 and cavity 50 of air distribution layer 30.

[0018] With respect to air flow unit 90, although not explicitly shown, air flow unit 90 includes a fan that supplies an air flow through conduit 92 to cavity 50 of air distribution layer 30. Exemplary fans for use with air flow unit 90 provide an air flow greater than about 25 CFM, greater than about 30 CFM, or greater than about 35 CFM and have a water static pressure of less than about 50 mm, less than about 40 mm, or less than about 30 mm. Certain fans have an air flow greater than 35 CFM and a water static pressure less than 30 mm.

[0019] Also, in some embodiments, air flow unit 90 may further include a heating unit and / or a cooling unit to supply a thermally controlled air flow to cavity 50 of air distribution layer 30. For this purpose, the exemplary mattress assembly further includes a controller 98 for controlling air flow unit 90. By including controller 98 in mattress assembly 10, not only can the amount of air flow be controlled, but also the temperature of the air flow can be controlled.

[0020] Referring now to FIGS. 2 - 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 lining 44 that define the side surface 52 of the cavity 50. Each of the outer foam layer 42 and the inner foam lining 44 is made of a soft foam such as a latex foam, a reticulated or non-reticulated viscoelastic foam (sometimes referred to as a memory foam or a low-resilience foam), a reticulated or non-reticulated non-viscoelastic foam, a polyurethane high-resilience foam, an expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), or any combination thereof. The outer foam layer 42 can be composed of a substantially air-permeable foam, while the inner foam lining 44 is composed of a foam that is substantially air-impermeable. As used herein, the term "impermeable" generally means "low-permeable" and includes materials that may allow some vapor to escape and refers to materials that substantially prevent the movement of air through the material. For example, a low-permeable foam may be considered to have an air permeability between 0 - 0.05 l / sec in some embodiments. Similarly, the use of the term "permeable" herein generally refers to materials that substantially allow the movement of air through the material. Other configurations of the foam rail will be described later with respect to FIGS. 5A and 5B, but in any case, the foam rail is substantially air-impermeable. To further prevent air from flowing out of 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, the air flowing into the cavity 50 of the air distribution layer 30 cannot easily escape through the bottom or side surfaces of the air distribution layer 30. Therefore, substantially all of the air flowing into the cavity 50 of the air distribution layer 30 is directed out through the upper insulation layer 70 and the comfort layer 80 (i.e., the body support layer 75) from the upper portion of the air distribution layer 30.

[0021] For this purpose, referring particularly to FIG. 2 here, the insulating layer 70 extends from a first surface 72 to a second surface 74 and defines a plurality of paths 76 that are substantially aligned with the cavities 50 of the air distribution layer 30. Similarly, the comfort layer 80 defines a plurality of paths 86 that extend from a first surface 82 to a second surface 84, and each of the paths 86 of the comfort layer 80 is substantially aligned with a corresponding path 76 of the insulating layer 70. Thus, air flowing out of the cavities 50 of the air distribution layer 30 is directed toward the second surface 84 of the comfort layer 80 (i.e., the second surface of the body support layer 75) by flowing into the plurality of paths 76, 86. Of course, the shape and / or pattern of the paths 76 of the insulating layer 70 and the shape and / or pattern of the paths 86 of the comfort layer 80 are not limited, and in some embodiments, they may not be aligned. In some embodiments, the pattern of the paths is designed to provide a specific cooling effect to a user on the support cushion.

[0022] Regarding the body support layer 75, in the exemplary embodiments shown in FIGS. 1-3, the insulating layer 70 and the comfort layer 80 (i.e., the body support layer 75) of the mattress assembly 10 are composed of a continuous layer of soft foam for preferably distributing the pressure from the user's body or a part thereof across the body support layer 75. Such soft foams include, but are not limited to, latex foam, reticulated or non-reticulated viscoelastic foam (sometimes called memory foam or low-resilience foam), reticulated or non-reticulated non-viscoelastic foam, polyurethane high-resilience foam, foamed polymer foam (e.g., foamed ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), or any combination thereof. In the embodiments shown in FIGS. 1-3, the insulating layer 70 and the comfort layer 80 are composed of viscoelastic foam having low resilience and sufficient density and hardness, which enables the pressure to be uniformly absorbed and uniformly distributed across the body support layer 75 of the mattress assembly 10. Generally, such viscoelastic foam has a hardness of at least about 10 N to about 80 N or less, measured by applying pressure to a sample of the material from a plate to at least 40% compression of the original thickness of the material at approximately room temperature (i.e., 21°C to 23°C), and that 40% compression is held for a certain time as defined by the International Organization for Standardization (ISO) 2439 hardness measurement standard. In some embodiments, the viscoelastic foam has a hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, or about 80 N to provide a desired level of comfort and body-conforming quality.

[0023] The viscoelastic foams described herein for use in the mattress assembly 10 can also have a density that helps provide a desired degree of comfort and body conforming quality, as well as an increase in the degree of durability of the material. In some embodiments, the density of the viscoelastic foam used in the body support layer 75 has a density of about 30 kg / m3 or more and about 150 kg / m3 or less. In some embodiments, the density of the viscoelastic foam used in the body support layer 75 of the mattress assembly 10 is about 30 kg / m3, about 40 kg / m3, about 50 kg / m3, about 60 kg / m3, about 70 kg / m3, about 80 kg / m3, about 90 kg / m3, about 100 kg / m3, about 110 kg / m3, about 120 kg / m3, about 130 kg / m3, about 140 kg / m3, or about 150 kg / m3. Of course, the selection of a viscoelastic foam having a particular density affects other properties of the foam, including the firmness of the foam, the way the foam responds to pressure, and the overall feel of the foam, but it is understood that a viscoelastic foam having the desired density and firmness can be readily selected for a particular intended use or mattress assembly. For example, the comfort layer 80 typically has a density, firmness, or both that is lower than the density, firmness, or both of the insulation layer 70 so as to provide a softer surface upon which the user's body or a part thereof rests. Further, the insulation layer 70 and / or the comfort layer 80 of the mattress assembly need not be composed of a continuous layer of soft foam, but it is understood that they can take the form of more traditional mattresses, including spring-based mattresses, without departing from the spirit and scope of the subject matter described herein.

[0024] To further promote the airflow 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 layer of a porous viscoelastic foam. In this regard, the term "porous soft foam" (viscoelastic or otherwise) is generally used herein to refer to a soft foam having a cellular foam structure in which at least a portion of the cells of the foam are essentially a framework. In other words, at least a portion of the cells of the foam are each defined by a plurality of openings surrounded by cell struts, and the cell windows of the porous foam are either absent (leaving only the cell struts) or substantially absent. In some embodiments, when at least 50% of the cell windows are missing (i.e., windows having openings therethrough, or completely missing, thus leaving only the cell struts), the foam is considered "porous". Such a structure can be created by chemical or mechanical means, or by preventing the complete formation of the cell windows during the manufacturing process of the foam, by destroying or otherwise removing the cell window material. In some embodiments of the present invention, the term "porous" can thus be used interchangeably with the term "reticulated" when referring to a soft foam.

[0025] Regardless of the manufacturing process used to produce the porous foam, the porous foam, due to its open-cell structure, has enhanced capabilities that allow for the movement of fluids through the porous foam, and as a result, has properties well-suited for use in the body support layer 75 of the mattress assembly 10, including the ability to provide enhanced air movement through the body support layer 75 of the mattress assembly 10. In this regard, the air exiting the air distribution layer 30 can then easily move 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). When the air flow unit 90 supplies heated or cooled air to the support insert 60, the increased air flow through the body support layer 75 also improves 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).

[0026] 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 composed of a soft foam material selected to provide a 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, but in some other embodiments, the foam rail 40 provides a harder feel than the support insert 60. Similarly, in some embodiments, the foam rail 40 can provide substantially the same feel and support as the body support layer 75, but in some other embodiments, the foam rail 40 provides a harder feel than the body support layer 75.

[0027] Regarding the base layer 20, in the exemplary embodiments shown in FIGS. 1-3, the base layer 20 is also composed of a viscoelastic foam, but other materials including non-viscoelastic foams are also contemplated. In some embodiments, the viscoelastic foam of the base layer 20 is substantially the same as the viscoelastic foam of the body support layer 75. In some other embodiments, the porosity of the foam used for the body support layer 75 is greater than the porosity of the base layer 20.

[0028] Referring now to FIGS. 2 and 3, as described above, the exemplary support insert 60 is formed of an array of springs 62. The exemplary springs are individually "pocketed" coils. Each individual pocketed coil can have a spring or coil wrapped or placed within a fabric cover. This cover can be a spacer fabric known in the art and can be permeable. In some cases, the spacer fabric that makes up the cover can be formed from a material that is stretchable in two directions, which means that it can stretch in two dimensions, such as horizontally, in a head-to-toe direction and a side-to-side direction across the bed. The spacer fabric can include a woven or knitted material and / or an extruded plastic material including polyethylene, polyester, other plastics, or any combination of these or others. These individually pocketed coils are then arranged in rows or columns surrounding and stitched together to form a coupling unit, such as support insert 60. In some embodiments, the rows and columns are positioned such that each row forms a straight line and each column forms a straight line. In other embodiments, the rows and columns are arranged offset from each other to form a pattern, such as a checkerboard pattern. The use of pocketed coils or a layer of pocketed coils can provide a more comfortable mattress surface because the coils are relatively individually flexible, such that each coil can flex individually without affecting adjacent coils.

[0029] In some embodiments, the spring or coil can be constructed of steel wire, high carbon spring wire, high carbon piano wire, cooper coated high carbon wire, aluminum coated high carbon wire, cold drawn upholstery wire type "A", "B", or "C", or any other type of wire known in the art. The wire used in the structure of the spring or coil can be in the range of 12 to 20 gauge. In other embodiments, the spring or coil can be constructed of a polymeric material, such as plastic or polyurethane. In some embodiments, the spring or coil can have a diameter in the range of about 10 millimeters to about 150 millimeters. The raw height of the spring or coil can range from about 0.5 inches to about 12 inches, and the height of the spring or coil within the pocket can also range from about 0.5 inches to about 12 inches. In some embodiments, the preload of the spring or coil is in the range of 0 to 5 pounds, and the spring constant is in the range of 0.25 to 5.0 pounds per inch. In some embodiments, the coil shape can be linear compression, although in other embodiments, the coil shape can be variable compression, linear cylindrical, or variable diameter to achieve variable compression. Regardless of the particular configuration, the support insert 60 is substantially air permeable such that air supplied to the cavity 50 of the air distribution layer 30 spreads through the support insert 60 before flowing through the insulation layer 70 into the insulation layer 70.

[0030] Although not explicitly shown, in other exemplary embodiments of the present invention, it should be understood that the support insert can include a soft foam instead of or in addition to the spring arrangement. In some exemplary embodiments, the foam support insert is composed of a viscoelastic foam similar to the body support layer. The soft foam material can be selected to provide a preferred feel and support characteristics. For example, in some embodiments, the foam support insert can provide substantially the same feel and support 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. Further, the foam insert can include structural elements such as a path extending through the foam insert to further increase the air flow through the foam insert. Furthermore, the foam insert can be configured to provide substantially the same feel and support as the body support layer. Additionally, it is contemplated that the foam insert can include, for example, a plurality of foam layers having various configurations including different densities, hardnesses, and / or porosities.

[0031] To prevent the various layers of the mattress assembly 10 from moving relative to each other during use, various means of fixing one layer of material to another layer can be used, including tape, hook-and-loop fasteners, conventional fasteners, stitches, adhesives, and the like. Such adhesive bonding materials include, for example, environmentally friendly aqueous adhesive products such as SABA AQUABOND RSD, which is a two-component aqueous adhesive product produced by SABA DINXPERLO BV in Dinxperlo, Belgium, B-7090 AA.

[0032] Next, referring to FIG. 5A, in another exemplary embodiment of the present invention, an exemplary foam rail 140 of the air distribution layer 130 includes an outer foam layer 142 and an impermeable or semi-permeable coating 144 in place of the inner foam lining. In this regard, the term "impermeable coating" is generally used herein to refer to a material that substantially prevents air from flowing through the coating, and the term "semi-permeable coating" is generally used herein to refer to a material that prevents at least a portion of the air from flowing through the material, which can include, for example, a low permeability material. For example, the low permeability material can have an air permeability between 0 - 5 ft 3 / ft 2 / min, between 0 - 10 ft 3 / ft 2 / min, or between 0 - 20 ft 3 / ft 2 / min. The exemplary coating 144 can include, but is not limited to, materials such as hot melt adhesives, soft elastomeric coatings, or gels. Regarding hot melt adhesives, in some embodiments, an aqueous hot melt adhesive that produces a non-tacky impermeable layer when dry is used. The hot melt adhesive needs to have a viscosity sufficient to bridge the foam cell structure when applied in order to form a coating on top of the foam rather than sink into the foam cell structure. According to some embodiments, a viscosity of at least 100 centipoises is considered sufficient for application. The overall thickness of the exemplary hot melt adhesive layer is between 0 - 0.100 inches and may, in some cases, require passing through one or more coating passes to achieve the desired thickness. The exemplary hot melt adhesive can also have sufficient flexibility when dry to avoid cracking during load cycles (e.g., compression) to which the foam is repeatedly subjected during use of the mattress. Similar characteristics can be considered for embodiments where the coating is formed of a soft elastomer or gel. According to some embodiments, the coating is formed by heating / melting the foam itself to form a "skin" that exhibits similar characteristics to the exemplary hot melt adhesives described above.

[0033] Next, referring to FIG. 5B, in another exemplary embodiment of the present invention, instead of the foam rail including both an outer foam layer and an inner foam lining or coating, in the exemplary air distribution layer 230 shown in FIG. 5B, the foam rail 240 is made of a single foam component. According to this embodiment, the foam rail 240 is composed of a foam that is substantially air-impermeable without adding an inner foam lining or coating.

[0034] In the exemplary embodiments shown in FIGS. 1-5A, the foam rails 40, 140, 240 are attached to the base plates 32, 132, 232, for example, by an adhesive. However, in some cases, it is conceivable that the foam rail and the base plate are formed from a single piece of soft foam such that the base layer has an integral structure. This is particularly advantageous in embodiments where the foam rail is made of a single foam component without an additional inner lining or coating since the air distribution layer can be formed by creating cavities from a single foam piece such that the base plate and the foam rail are integrally formed. According to these embodiments, the foam block formed by creating the cavities is preferably made of a foam that is substantially air-impermeable or has a low permeability, for example, an air permeability between 0 - 0.05 l / sec.

[0035] In the embodiments shown in FIGS. 1-3, there is only one cavity 50 that extends substantially throughout the upper portion of the air distribution layer 30 and includes a corresponding support insert 60, but it is understood that the embodiments described herein need not be limited to a single cavity. For example, referring now to FIG. 6, in another embodiment of the present invention, an exemplary air distribution layer 330 defines two cavities 350a, 350b and corresponding support structures 360a, 360b. More specifically, the foam rail 340 includes an intermediate foam rail 346 in addition to an outer foam layer 342 disposed around the perimeter of the base plate 332, similar to the outer foam layer 42 of the exemplary foam rail 40 described above with reference to FIGS. 1-4, and the intermediate foam rail 346 also extends along substantially the center of the air distribution layer 330 that divides the air distribution layer 330 into a left side and a right side. Separate inner foam linings 344a, 344b are then located within each cavity 350a, 350b, and the inner foam linings 344a, 344b are substantially air-impermeable similar to the inner foam lining 44 described above with reference to FIGS. 1-4. By varying the number and location of the cavities and support structures disposed across the air distribution layer, air is directed outward from the support structures in a predetermined pattern through the body support layer.

[0036] It is understood that the exemplary body support layer 75 illustrated in FIGS. 1-3 includes an insulating layer 70 and a comfort layer 80, but this is not intended to be limiting. In some embodiments, the body support layer may have only a single layer or other layer(s) instead of or in addition to the insulating layer 70 and comfort layer 80 described above.

[0037] Similarly, in the embodiments shown in FIGS. 1-3, although there is a single inlet hole 34 in the base plate 32 of the air distribution layer 30, it is contemplated that a plurality of inlet holes can also be used without departing from the spirit and scope of the present invention. It is further contemplated that the inlet can be located on the side surface of the air distribution layer 30 with corresponding holes defined through the foam rails 40 of the air distribution layer. Still further, in the embodiments shown in FIGS. 1 and 2, the air flow unit 90 is connected by a conduit 92 such that the air flow unit 90 is disposed at a distance away from the remainder of the mattress assembly 10, but other locations are contemplated including attaching the air flow unit 90 to the base layer 20 and / or within the scope of the mattress assembly 10.

[0038] As a further improvement, to ensure that fresh air enters the base layer, the mattress assembly can further include a filter that allows only filtered air to enter the inlet hole and that holds a bag to escape particulate matter such as smoke, dust, dirt, pollen, mold, bacteria, hair, or insects that could otherwise accumulate inside the mattress and restrict the air flow. Of course, various types of filters including, but not limited to, charcoal filters to remove chemicals and / or unpleasant odors can be readily incorporated into the exemplary mattresses 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 perfume can be further added to the assembly (e.g., in front of the fan) such that scented air is directed towards the surface of the support cushion assembly.

[0039] Each of the exemplary support cushions described herein can also be used as part of a method for controlling the surface temperature of the support cushion. In some embodiments, the method for controlling the surface temperature of the support cushion includes first providing the support cushion of the present invention. Next, a current is supplied to the air flow unit such that the fan of the air flow unit pushes an amount of air out of the cavity of the air distribution layer, through the support insert, through the body support layer, and out from the second surface of the body support layer. In embodiments where the air flow unit includes a heating unit and / or a cooling unit, a current can also be supplied to the heating / cooling unit such that the temperature of the air flowing out from the first surface of the body support layer is adjusted.

[0040] Examples Referring now to Table 1 and FIG. 7 below, one exemplary fan having an air volume of about 38.5 CFM and a water static pressure of about 28.7 mm was used with an exemplary mattress made in accordance with the present invention. To supply heat and moisture simulating a user sleeping on the mattress, an instrument was positioned on the mattress and the fan was operated at different fan speeds. Then, measurements were taken at the surface of the mattress for each fan speed 5 minutes, 20 minutes, and 8 hours after the start of the test. As shown, when the fan was not used (e.g., fan speed 0), the temperature of the surface of the mattress increased significantly between each of the 5-minute, 20-minute, and 8-hour measurements, and ultimately reached an increase of 67.6°F after 8 hours. In comparison, even when the fan was operating at a fan speed of 50%, the temperature of the surface of the mattress only increased by 26°F after 8 hours, and at fan speeds of 80% and above, the temperature of the surface of the mattress had an increase of 20°F or less. [Table 1]

[0041] Those skilled in the art will recognize that further embodiments are possible without departing from the teachings of the present invention or the scope of the following claims. This detailed description, particularly the specific details of the exemplary embodiments disclosed herein, is provided primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom. Modifications will be 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 cushion, comprising: a body support layer having a first surface and a second surface opposite the first surface; an air distribution layer disposed adjacent to the first surface of the body support layer, the air distribution layer including a base plate and a foam rail disposed at least around the periphery of the base plate to define a cavity, the air distribution layer further including a support insert disposed within the cavity; a fan operably connected to the air distribution layer, the fan for supplying an air flow to the cavity of the air distribution layer such that the air flow is directed through the support insert and through the body support layer. A support cushion.

2. The foam rail is substantially air-impermeable, and the support insert is substantially air-permeable such that air supplied to the cavity of the air distribution layer spreads through the support insert before flowing through the body support layer. The support cushion according to claim 1.

3. The foam rail prevents air from flowing out of the air distribution layer except through the body support layer. The support cushion according to claim 1.

4. The foam rail includes an outer foam layer and an inner foam lining, the inner foam lining defining the side surface of the cavity of the air distribution layer. The support cushion according to claim 1.

5. The inner foam lining is substantially air-impermeable. The support cushion according to claim 4.

6. The foam rail includes an air-impermeable coating along at least the side surface of the cavity of the air distribution layer. The support cushion according to claim 1.

7. The air distribution layer is formed by creating a cavity from a single foam piece such that the base plate and the foam rail are integrally formed. The support cushion according to claim 1.

8. The support insert includes an array of springs, the array of springs configured to support the body support layer. The support cushion according to claim 1.

9. The support insert includes one or more foam layers, the one or more foam layers configured to support the body support layer. The support cushion according to claim 1.

10. The body support layer defines a plurality of paths extending from the first surface to the second surface, and the plurality of paths are substantially aligned with the cavities of the air distribution layer. The support cushion according to claim 1.

11. The body support layer includes an insulating layer disposed adjacent to the air distribution layer and a comfort layer disposed adjacent to the insulating layer on the side opposite to the air distribution layer. The support cushion according to claim 1.

12. The insulating layer, the air distribution layer, or both the insulating layer and the air distribution layer are composed of a viscoelastic foam. The support cushion according to claim 11.

13. The body support layer is composed of a viscoelastic foam. The support cushion according to claim 1.

14. The base plate of the air distribution layer defines holes, and the conduit is directed from the fan through the holes into the cavities of the air distribution layer. The support cushion according to claim 1.

15. Further comprising a base layer disposed adjacent to the lower surface of the base plate, The foam rails are disposed along the upper surface of the base plate on the side opposite to the lower surface, The base layer defines holes, the base plate of the air distribution layer defines holes that are aligned with the holes of the base layer, and the conduit directs air from the fan through the holes of the base layer and through the holes of the base plate of the air distribution layer into the cavities of the air distribution layer. The support cushion according to claim 1.

16. Further comprising a heating unit, a cooling unit, or both a heating unit and a cooling unit configured to supply a thermally controlled air flow to the cavities of the air distribution layer. The support cushion according to claim 1.

17. A method of controlling an air flow through a support cushion, comprising: Providing a support cushion, wherein the support cushion comprises: A body support layer having a first surface and a second surface opposite the first surface; An air distribution layer disposed adjacent to the first surface of the body support layer, the air distribution layer including a base plate and foam rails disposed at least around the periphery of the base plate to define a cavity having a support insert disposed therein. A fan operably connected to the air distribution layer, the fan for supplying an air flow to the cavity of the air distribution layer, and, a step having, Supplying an electric current to the fan so that the fan pushes an amount of ambient air into the cavity of the air distribution layer, a step; Moving the amount of ambient air through the support insert, through the body support layer, and out from the second surface of the body support layer, a step having, Method.

18. A method of manufacturing a support cushion, Providing an air distribution layer defining a cavity on an upper portion of the air distribution layer, the cavity having a bottom surface and side surfaces, a step; Placing a support insert within the cavity on the bottom surface of the cavity, the side surfaces of the cavity surrounding the support insert such that only the upper surface of the support insert on the side opposite the bottom surface of the cavity remains exposed, a step; Placing a body support layer above an upper portion of the air distribution layer, the body support layer having a first surface and a second surface opposite the first surface, defining a plurality of paths extending from the first surface to the second surface, the plurality of paths being substantially positionally adjusted with respect to the cavity of the air distribution layer, a step having, The side surfaces of the cavity of the air distribution layer are substantially air-impermeable, and the support insert is substantially air-permeable, Method.

19. The step of providing the air distribution layer includes creating a cavity from a single-piece foam for forming the air distribution layer, the single-piece foam being substantially air-impermeable, The method according to claim 18.

20. The step of providing the air distribution layer, Providing a base plate, Placing foam rails around a periphery of the base plate so as to define the cavity, including, The method according to claim 18.

21. Further having the step of applying a coating to the foam rails to form an air-impermeable coating on the side surfaces of the cavity, The method according to claim 20.

22. Further having the step of heating the foam rails to form an air-impermeable coating on the side surfaces of the cavity, The method according to claim 20.

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