Support cushion assembly including active ventilation system

Abstract

The support cushion assembly consists of a base and a support cushion placed on the base. The support cushion includes an upper and lower surface. The support cushion assembly further includes a ventilation system configured to draw air downward from the upper surface of the support and release the drawn air below the base.

Description

Related applications

[0001] This application claims priority to U.S. Provisional Application No. 63 / 448,937, filed on 28 February 2023, the full disclosure of which is incorporated herein by reference. [Technical Field]

[0002] The present invention relates to a support cushion assembly including an active ventilation system. In particular, a specific embodiment of the present invention relates to a body support cushion assembly including an active ventilation system that is in fluid communication with one or more foam layers of the support cushion. [Background technology]

[0003] Research has shown that a cooler sleep environment improves sleep quality by allowing people to fall asleep faster, toss and turn less, and sleep longer. Generally, it takes longer to fall asleep in a warm sleep environment, and once you do fall asleep in such an environment, sleep is often fragmented or interrupted. In fact, further research shows that when temperature fluctuations in the sleep environment are minimized or eliminated—that is, when a cool, constant temperature is maintained—people sleep better and feel more rested and energized the next day.

[0004] On the other hand, poor sleep quality can lead to sleep deprivation or "sleep debt," which can have serious negative impacts on lifespan, productivity, and overall mental, emotional, and physical health. Chronic sleep deprivation is linked to weight gain, specifically by affecting how the body processes and stores carbohydrates, as well as altering hormone levels that influence appetite. Furthermore, sleep deprivation can lead to irritability, anxiety, lack of concentration, and bad moods, and some researchers point to a link between sleep deprivation and workplace accidents, traffic accidents, and general afternoon inattention. Sleep disorders have also been linked to high blood pressure, increased stress hormones, and arrhythmias. More recent research suggests that sleep deprivation affects immune function, potentially increasing susceptibility to diseases and illnesses, such as cancer. Due to these various effects, researchers point out that sleep debt results in billions of dollars in productivity losses annually in the United States.

[0005] Therefore, a support cushion equipped with an active ventilation system that promotes and maintains a cooler sleeping environment, thereby reducing an individual's sleep debt, is highly desirable and beneficial. [Overview of the project]

[0006] The present invention includes a support cushion assembly having an active ventilation system in fluid communication with one or more foam layers of a support cushion. In some embodiments, a support cushion assembly is provided, comprising a top foam layer and a base foam layer, wherein the top foam layer has a cellular structure configured to allow airflow through the top foam layer at a faster rate than that through the base foam layer. The ventilation system is operably connected to the support cushion and is configured to ventilate through the support cushion by drawing air downward from the top foam layer and releasing the drawn-in air downward through the base foam layer of the support cushion. In some embodiments, to further facilitate air movement through the support cushion, holes are provided in the base foam layer of the support cushion, these holes extend through the base foam layer, and in certain embodiments, the holes also extend through the base on which the support cushion is placed.

[0007] In some embodiments, the foam layers of the exemplary support cushion described herein include various types and arrangements of foam to facilitate and control the airflow through the support cushion. In some embodiments, the top foam layer includes a mesh foam, and the base foam layer includes a non-mesh foam. In some embodiments, the support cushion further includes an intermediate foam layer, which is positioned between the top foam layer and the base foam layer and has a cellular structure configured such that air flows through the intermediate foam layer at a higher rate than through the base foam layer. In some embodiments, the intermediate foam layer also includes a mesh foam, and in some embodiments, the top foam layer, the intermediate foam layer, or both include a viscoelastic foam.

[0008] In some embodiments of the base foam layer included in the exemplary support cushion, the base foam layer comprises a single layer of foam. However, in other embodiments, the base foam layer itself may comprise multiple foam layers and / or foams of various types and arrangements, providing a sufficiently rigid and durable layer to support the top foam layer on top, while in certain embodiments assisting in directing airflow from the top foam layer through the base foam layer to the bottom of the support cushion. For example, in some embodiments, the base foam layer comprises one or more foam layers, each having a convex surface. As another example, in some embodiments, the base foam layer comprises a first base foam layer and a second base foam layer positioned below the first base foam layer. In some such embodiments, both the first and second base foam layers may comprise non-mesh foams, and the first base foam layer comprises a convex surface. In some of these embodiments comprising multiple base foam layers, a pair of foam end rails and a pair of foam side rails may be positioned on top of the second base foam layer. The pair of foam end rails and the pair of foam side rails collectively form the perimeter of the first base foam layer, and as air is drawn downward from the top foam layer, the foam end rails and foam side rails help to anchor the base foam layer to the other foam layers of the support cushion, and help to guide the airflow onto the convex surface of the first base foam layer and then downward (for example, through holes in the base foam layer) to the bottom of the support cushion.

[0009] To control the airflow through an exemplary support cushion, in some embodiments, a support cushion assembly manufactured according to the present invention includes a controller that communicates with a ventilation system and at least one sensor that communicates with the controller. The at least one sensor measures either a humidity value or a temperature value of the environment of the support cushion assembly. The controller is then configured to automatically turn on the ventilation system if the temperature or humidity value measured by the at least one sensor is above a predetermined value, and / or to automatically turn off the ventilation system if the temperature or humidity value measured by the at least one sensor is below a predetermined value.

[0010] In another embodiment of the present invention, another support cushion assembly with a ventilation system is provided. The support cushion assembly includes a foundation to which an air mover is attached. 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 support cushion assembly also includes holes extending from the bottom surface of the intermediate layer through the base foam layer and the foundation. The air mover draws air downward through the top foam layer and further disperses the drawn air around the body support cushion through the holes. In some embodiments, the air mover is in the form of a fan or an air pump.

[0011] In another embodiment, the support cushion assembly further includes a filter that is in fluid communication with a blower and operably connected to the blower. The filter and blower can be housed in a housing, such as a housing having an outlet, in certain embodiments. In some embodiments, the body support cushion assembly further includes a cartridge for providing aromatherapy to the drawn-in air, the cartridge being in fluid communication with the blower and filter.

[0012] In yet another embodiment of the present invention, a method for actively ventilating a support cushion is provided. In one such embodiment, the method includes providing a support cushion assembly comprising a support cushion placed on a base. Air is then drawn in from the environment surrounding the support cushion assembly, passing over the top surface of the support cushion, through the support cushion, downward, and further through holes extending through at least a portion of the support cushion and the base. The drawn-in air is filtered and then discharged into the surrounding environment.

[0013] Further features and advantages of this disclosure will become apparent to those skilled in the art upon consideration of the description, figures, and non-limiting embodiments herein. [Brief explanation of the drawing]

[0014] [Figure 1] Figure 1 is a perspective view of a support cushion assembly manufactured according to the present invention, which includes a support cushion in the form of a mattress placed on a base. [Figure 2] Figure 2 is a partially cutaway perspective view of the support cushion assembly shown in Figure 1. [Figure 3] Figure 3 is a perspective view of another support cushion manufactured according to the present invention, which includes multiple foam layers. [Figure 4] Figure 4 is a partially cutaway perspective view of the support cushion shown in Figure 3. [Figure 5] Figure 5 is a partial perspective view of the blower mounted below the base shown in Figure 1. [Figure 6] Figure 6 is a perspective view of the hole extending through the support cushion in Figure 1, with the top and middle layers of the support cushion removed to visualize the hole. [Figure 7] Figure 7 is a side cross-sectional view of a blower in the form of an air pump mounted on the base of a support cushion assembly according to the present invention. [Figure 8]FIG. 8 is a schematic diagram of an exemplary control system used to control a support cushion assembly in accordance with the present invention. [Figure 9] FIG. 9 is a perspective view of a mattress cover used in accordance with the present invention and includes a detailed view of a cross-section of the mattress cover. [Figure 10] FIG. 10 is an exploded perspective view of another support cushion manufactured in accordance with the present invention. [Figure 11] FIG. 11 is a perspective view of the completed assembly of the support cushion of FIG. 10. [Figure 12] FIG. 12 is a partially cut-away perspective view of the assembly of the support cushion of FIG. 10 and further shows the support cushion attached to a base and disposed on the base having a blower device thereunder. **DETAILED DESCRIPTION OF THE INVENTION**

[0015] The present invention includes a support cushion assembly comprising an active ventilation system. In particular, certain embodiments of the present invention include a support cushion assembly having an active ventilation system that fluidly communicates with one or more foam layers of the support cushion to provide ventilation through the support cushion. In some embodiments, such active ventilation mitigates temperature fluctuations in the environment surrounding the support cushion, allowing an individual resting on the support cushion to maintain a more consistent body temperature over a period of time (e.g., overnight). In some embodiments, the active ventilation draws ambient air from the environment through the support cushion assembly and then filters the air so that it does not contain bacteria, pollen, and other allergens or unpleasant substances such as dust mite secretions when the filtered air is released into the surrounding environment. Furthermore, by continuously supplying fresh air through the support cushion assembly, the surface temperature of the support cushion assembly and the relative humidity of the surrounding environment are kept more constant, preventing heat buildup or undesirable humidity from occurring in the support cushion itself or the surrounding environment. In some embodiments, the air can also be further adjusted to a desired temperature (in other words, cooled or heated) by continuously releasing a temperature-controlled airflow into the surrounding environment, so as to allow the support cushion assembly to maintain freshness and stay in an optimally dry and hygienic state.

[0016] Referring first to Figures 1 and 2, one embodiment of the present invention provides a support cushion assembly 10. 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 24. The support cushion assembly 10 generally has a longitudinal direction Lo of the support cushion assembly 10 and a lateral direction L extending between the sides of the mattress 20 in a direction perpendicular to the longitudinal direction Lo of the support cushion assembly 10. AIt has a head end 12 and a foot end 14 that define the support cushion assembly 10. The support cushion assembly 10 further includes a base 35 on which the mattress 20 is placed. A ventilation system 70 including a fan 72 is also included in the support cushion assembly 10, and more specifically, the ventilation system 70 is mounted on the base 35 so as to be configured to draw air downward from the upper surface 22 of the mattress 20 and then release the drawn air below the base 35, as will be described in more detail below.

[0017] With respect to the base 35, the base 35 generally consists of a base or frame 50 positioned on a plurality of legs 40. Furthermore, the base 35 includes a deck 60 positioned on the frame 50 and providing a support surface for the mattress 20, which is positioned on the deck 60 as shown above. In the exemplary embodiments shown in Figures 1-2, the deck 60, more generally the base 35, is fixed so that the position of the mattress 20 cannot be adjusted. Of course, the support cushion assemblies described herein are equally applicable to and intended to be used with adjustable bases to allow support cushions, such as mattresses, to be moved to alternative positions, such as a reading position or other preferred upright position, for example, for watching television or at times when the user may want to use the exemplary support cushion assembly but does not necessarily need to sleep. For additional information and guidance on the use of active air systems in relation to adjustable bases, see, for example, International Patent Application Publication 2020 / 006085, which is incorporated herein by reference in its entirety.

[0018] Such a support cushion assembly utilizing an adjustable base may further include a mattress retainer (not shown), which may extend from the base deck near the foot end of the exemplary support cushion or bed assembly to prevent the support cushion or mattress from sliding off the deck as the adjustable base articulates. Furthermore, the legs included in the exemplary base are intended to be a single structure or formed of multiple structures, without departing from the spirit and scope of the invention, to allow for variations in the height of the bed assembly.

[0019] Regardless of the specific structure of the base included in the exemplary support cushion assembly of the present invention, the support cushion included in the assembly generally includes multiple foam layers configured and arranged to allow ambient air to move through the mattress. For example, as shown in the partial cross-section of the support cushion assembly 10 provided in Figure 2, the mattress 20 of the support cushion assembly 10 includes a bottom, base foam layer 130, a support or intermediate foam layer 160, and a comfort or top foam layer 190, where the base foam layer 130, the intermediate foam layer 160, and the top foam layer 190 are each composed of flexible foam having different properties or physical properties to provide a comfortable surface on which the user can rest and to facilitate air movement through the mattress 20 in a desired direction. In this regard, the terms “foam” or “flexible foam” are used herein to refer to any of a variety of lightweight, porous, semi-rigid, or spongy materials or cellular solids, which are, for example, lightweight cellular materials resulting from the introduction of gas bubbles during manufacturing to create a consistent cellular structure, and / or a solidified form of a liquid that is usually filled with gas bubbles, and which may be used as building materials or for shock absorption. Such types of flexible foams that can be used according to the present invention include, but are not limited to, polyurethane foams, latex, memory or viscoelastic foams, special memory foams, gel memory foams, gel latex foams, gel-injected foams, multi-gel foams, high thermal conductivity foams, and other gel foams.

[0020] Referring further to FIG. 2, the base foam layer 130 included in the mattress 20 is formed of a foam that can provide a sufficient base layer or support layer for the intermediate foam layer 160 and the 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 and has sufficient hardness and density values to support the intermediate foam layer 160 and the top foam layer 190 thereon. Typically, such a base foam layer 130 has a hardness of at least about 50 N and not exceeding about 300 N for desirable support. In other embodiments, the base foam layer 130 has a hardness of at least about 75 N and about 200 N or less. In still other embodiments, the base foam layer 130 has a hardness of at least about 100 N and about 175 N or less. In such embodiments, the hardness of the base foam layer 130 is determined by measuring the 40% indentation load deflection or "ILD" in accordance with the test procedure compliant with the DS / EN ISO 2439 standard.

[0021] Similarly, in some embodiments, the base foam layer 130 has a density of about 15 kg / m 3 or more and about 150 kg / m 3 or less. In other embodiments, the base foam layer 130 has a density of at least about 20 kg / m 3 and about 80 kg / m 3 or less. In still other embodiments, the base foam layer 130 has a density of at least about 25 kg / m 3 and about 60 kg / m 3 or less. In still other embodiments, the base foam layer 130 has a density of at least about 20 kg / m 3 and about 40 kg / m 3 or less. In some embodiments, the base foam layer 130 has a density of at least about 23 kg / m 3 and about 32 kg / m 3It has the following densities. In 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.

[0022] In some embodiments, it is even more desirable that the flexible foam base foam layer 130 can provide a degree of support that is substantially independent of the temperature experienced by the upper layer when supporting the user's body (in other words, independent of the user's body temperature). Therefore, in some embodiments, the base foam layer of the exemplary support cushion may be composed of a non-viscoelastic foam that is substantially insensitive to temperature changes in the range of about 10°C to 35°C. As used herein, a material is "substantially insensitive" to temperature changes if its hardness, as measured according to ISO standard 3386, changes by less than 10% over a temperature range of 10°C to 30°C. This temperature range should be considered illustrative and not limiting, as other temperature ranges are also possible.

[0023] To provide a base foam layer 130 having the hardness and density values ​​described above, in the mattress 20, the base foam layer 130 is formed of two layers of convoluted foam (e.g., egg crate foam) stacked on top of each other, and includes a non-planar upper surface defined by a plurality of curved or angular shapes. Of course, other types of foam, as well as base layers or bottom layers of other types and configurations, such as foam cores, gel foam cores, latex cores, inner spring layers, layers of individually wound or wrapped coils, expansion air systems, liquid systems (e.g., water), or base layers having a different number or type of foam layers, are also within the scope of the present invention.

[0024] As an example of a support cushion assembly utilizing a base foam layer including an alternative foam configuration, next with reference to Figures 3 and 4, another embodiment of the present invention provides a support cushion in the form of a mattress 220, which similarly includes a top foam layer 390 and an intermediate foam layer 360 having the same properties and characteristics as the top foam layer 190 and intermediate foam layer 160, as will be described in more detail below, as included in the mattress 20 shown in Figure 1. However, in the mattress 220 shown in Figures 3 and 4, the base foam layer 330 consists of a single layer of non-reticulated polyurethane foam having a cellular structure with the walls of the individual cells being substantially intact and having the same or the same hardness and density values ​​as described above with reference to the textured foam included in the embodiments shown in Figures 1 and 2. As another example, in some embodiments, it is further intended that the base foam layer may instead be composed of a permeable porous material such as a mesh foam, so that the base foam layer helps, at least partially, reduce the heat of higher layers due to the cellular structure of the foam in the base foam layer, and also provides the necessary support for the intermediate and top foam layers above it.

[0025] Referring again to Figures 1 and 2, as described above, the support or intermediate foam layer 160 is placed on top of the base foam layer 130. The intermediate foam layer 160 is generally formed of an open-cell or mesh viscoelastic foam having a density greater than that of the base foam layer 130 and a hardness less than that of the base foam layer 130, and is configured or otherwise designed so that air from the top foam layer 190 of the mattress 20 is not only drawn through the top foam layer 190 but also enters the intermediate foam layer 160 and is drawn through the intermediate foam layer 160, as will be described in more detail below. In some embodiments, the intermediate foam layer 160 has a hardness of at least about 50 N and up to about 150 N, as measured by determining ILD 40% according to the DS / EN ISO2439 standard. In some embodiments, the intermediate foam layer 160 has a hardness of at least about 60 N and up to about 125 N. In other embodiments, the intermediate foam layer 160 has a hardness of at least about 70 N or more and about 100 N or less.

[0026] The intermediate foam layer 160 typically has a higher density than the base foam layer 130, but also a density that provides relatively high material durability. Of course, the density of the foam in the intermediate foam layer 160 (as with the other foam layers in assembly 10) can also affect other properties of the foam, such as how 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 approximately 40 kg / m³, as determined using the DS / EN ISO 845 standard. 3 More than about 150kg / m 3 It has the following density. In other embodiments, the intermediate foam layer 160 has a density of at least about 60 kg / m³. 3 Approximately 125kg / m or more 3 It has the following density. In yet another embodiment, the intermediate foam layer 160 has at least about 70 kg / m³ 3 More than about 100kg / m 3 It has the following density: In a particular embodiment, the intermediate foam layer 160 is approximately 80 kg / m³ 3 More than about 90kg / m 3 It has the following density:

[0027] As shown above, the comfort layer or top foam layer 190 is placed on top of the support layer or intermediate foam layer 160. Like the intermediate foam layer 160, the top foam layer 190 is made with an optimized cell structure, making it lighter and more breathable than the other layers, and designed to allow better airflow within the mattress assembly. In particular, the top foam layer 190 can also be made of open-cell or mesh-like viscoelastic foam, with thin capsule walls to provide more cooling force per cubic foot, and optionally injecting phase change material. In this way, as will be explained in more detail below, the open structure of the top foam layer 190 allows ambient air from the sleeping surface or top surface 22 of the mattress 20 to be drawn into the open cell structure of the top foam layer 190 and through the top foam layer 190 at a greater rate than that of the base foam layer 130, thereby keeping the surface temperature on the support cushion assembly 10 more constant, preventing or reducing heat buildup and undesirable humidity in the mattress 20, more specifically in the top foam layer 190 of the mattress 20, as best illustrated by the arrows in Figure 2.

[0028] In addition to increasing airflow through the mattress 20, the top foam layer 190 also provides a relatively soft and comfortable surface for the user's body to rest on. Coupled with the slow recovery properties of the viscoelastic foam, the top foam layer 190 is also configured to conform to the user's body, thereby distributing the force applied to the upper layer by the user's body. However, the top foam layer 190 typically has a lower density, hardness, or both, than the intermediate foam layer 160 of the mattress 20, and the top foam layer 190 provides a softer surface for the user's body or part of it to rest on. For example, in certain embodiments, the exemplary support cushion assembly has a density of approximately 80 kg / m³ 3 More than about 90kg / m 3 The following consists of an intermediate foam layer made of viscoelastic foam with a hardness of approximately 76N to 95N, and a density of approximately 80 kg / m³.3 More than about 90kg / m 3 This may include a top foam layer composed of a viscoelastic foam having a hardness of only about 50 N to about 67 N. Of course, in some embodiments, the top foam layer 190 may be configured to have other hardness and density values, including the hardness and density values ​​within the range described above with respect to the intermediate foam layer 160 and the top foam layer 190, which may be desired for specific applications.

[0029] With respect to the foam layers included in an exemplary support cushion assembly of the present invention, the foam layers may be joined to one another in a variety of ways, including but not limited to melting, welding, sewing, adhesive bonding, or other forms or combinations thereof. In some embodiments, the foam layers can be attached by stapling, riveting, mechanical bonding via friction or interference fitting, bonding via adhesive, glue, cement, or other materials having adhesive properties, sewing, hook and loop fasteners, zippers, Denison tags, snaps, and / or other reversible means, and / or combinations thereof.

[0030] For the purposes of this embodiment, the various layers are generally joined to each other with adhesives, cements, and other adhesive materials. Thus, in some embodiments, each layer may further include adhesives located at the interface between various layers, in certain embodiments. For example, in the exemplary embodiments shown in Figures 1-2, the top foam layer 190 and the intermediate foam layer 160 are bonded at the interface between the two layers, but only at the periphery of those layers so as not to obstruct the movement of air through the interior portion of the layers. Specific examples of adhesives that can be used according to the present invention include hot melt, aqueous, pressure-sensitive adhesives, fire-resistant adhesives, and mixtures thereof. Furthermore, the layers and / or adhesives may further include silica, metal layers, plastics such as acrylic, modacrylic, polyolefin, latex, polyurethane, and combinations and / or blends thereof. Furthermore, the layers may further include biocides, preservatives, odor blockers, fragrances, pigments, dyes, stain inhibitors, antistatic agents, antifouling agents, waterproofing agents, moisture-absorbing and wicking agents, as known in the art.

[0031] As a further improvement to the exemplary support cushion assembly of the present invention, and as a further improvement to the use of adhesive around the exemplary mattress assembly, in some embodiments, it is additionally intended that the assembly does not need to be composed of foam layers having the same dimensions and / or surface characteristics, but may also be composed of foams of different arrangements and types. For example, referring to Figures 10-12, another exemplary embodiment provides a mattress 720 for use in an exemplary support cushion assembly, the mattress 720 having an upper surface 722 and a lower surface 724, and further including a top foam layer 790 and an intermediate foam layer 760. Both the top foam layer 790 and the intermediate foam layer 760 are composed of a mesh viscoelastic foam and have the same or similar density and hardness values ​​as described above with reference to the top foam layer 190 and intermediate foam layer 160 of the mattress 20 shown in Figures 1-2. However, in mattress 720, the bottom layer or base foam layer 730 is not composed of two identical foam layers, but rather includes a first base foam layer 734 of folded polyurethane foam located immediately below the intermediate foam layer 760, and a second base foam layer 731 of polyurethane foam having a substantially smooth surface and located 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 the same hardness and density values ​​as described above with reference to the base foam layer 130 of mattress 20.

[0032] To assist in securing the various layers of the mattress 720 together, the base foam layer 730 of the mattress 720 further includes a pair of end foam rails 732b and a pair of side foam rails 732a, each formed from the same polyurethane foam as the second base foam layer 731. The end foam rails 732b and side foam rails 732a are fixed to the upper surface of the second base foam layer 731 and effectively and collectively form the perimeter of the first base foam layer 734. In this way, the first base foam layer 734 is not only positioned within the perimeter formed by the end foam rails 732b and side foam rails 732a, but the upper surfaces of the end foam rails 732b and side foam rails 732a also provide a more rigid edge along the perimeter of the mattress 720 compared to what would be present if the uneven foam of the first base foam layer 734 extended to the edge of the mattress 720, while the upper surfaces of the end foam rails 732b and side foam rails 732a provide a substantially smooth surface to which the intermediate layer 760 can be secured.

[0033] Referring more generally to Figures 1-2, 3-4, and 10-11, each top foam layer 190, 390, 790 and each intermediate foam layer 160, 360, 760 are made with a cellular structure optimized to allow air to move through the layers, and as shown above, to enable airflow through the top foam layers 190, 390, 790 and intermediate foam layers 160, 360, 760 of each mattress 20, 220, 720 at a higher speed than that of the base foam layers 130, 330, 730. In particular, in the exemplary support cushion, each top foam layer 190, 390, 790 and each intermediate foam layer 160, 360, 760 are generally made of a mesh-like viscoelastic foam having a cellular structure configured to provide an airflow rate greater than about 2.00 l / sec, e.g., an airflow rate of about 2.0 l / sec to about 10.00 l / sec, while the base foam layers 130, 330, 730 are made of a non-mesh-like conventional polyurethane foam having an airflow rate of less than about 0.5 l / sec or less than 2.00 l / sec, e.g., an airflow rate of about 0.01 l / sec to about 2.00 l / sec. In such embodiments, the airflow rate can be determined by testing the airflow of the foam chamber using an FX3300Lab Air IV apparatus (Textest Instruments, Schwerzenbach, Switzerland) in accordance with ASTM D3574-17 (Test G) standard.

[0034] However, in order to facilitate and enable airflow from the top foam layers 190, 390, 790 and the intermediate foam layers 160, 360, 760 to and through the base foam layers 130, 330, 730 of each mattress 20, 220, 720, holes 80, 380, 780 are opened that completely penetrate the base foam layers 130, 330, 730 of each mattress 20, 220, 720, air drawn in through the top foam layers 190, 390, 790 and the intermediate foam layers 160, 360, 760 of each mattress 20, 220, 720 comes into contact with the base foam layers 130, 330, 730, moves downward through the holes 80, 380, 780 and through the base foam layers 130, 330, 730, and is finally released below the mattress 20, 220, 720. In the embodiments shown in Figures 1-2, 3-4, and 10-12, each hole 80, 380, 780 is substantially circular and in the form of a series of columns or tubes extending from the bottom of each intermediate foam layer 160, 360, 760 to the bottom of the base foam layer 130, 330, 730. Of course, it is understood that multiple holes of various shapes can also be incorporated into exemplary support cushions such as mattresses without departing from the spirit and scope of the present invention. Similarly, it should be understood that the holes 80, 380, 780 of each mattress 20, 220, 720 may or may not be lined, depending on different embodiments and as may be desired to facilitate airflow through the holes 80, 380, 780 and the various layers 130, 160, 190, 330, 360, 390, 730, 760, 790 of each exemplary mattress 20, 220, 720.

[0035] Next, to allow air to flow out from the mattresses 20, 720, referring more closely to the embodiments shown in Figures 1-2, 5-6, and 10-12, holes 80, 780 also extend through the deck 60 of the base 35 associated with each support cushion assembly 10, 710. The ventilation system 70, including the fan 72, is attached to the deck 60 via a number of fasteners (F), such as screws. Of course, the ventilation system 70 and the fan 72 can be attached to the deck 60 by other means, and it should be understood that a hose (not shown) can also be placed between the mattress 20 and the deck 60 to establish a connection in order to ensure airflow when the support cushion assembly 10, 710 or mattresses 20, 720 are raised.

[0036] However, in order to allow sufficient airflow through the mattress 20, 720, the fan 72 generally has dimensions of 12 cm x 12 cm and a height of about 2.5 cm. Next, the fan 72 generally requires an operating voltage of about 5 volts to about 15 volts so that the fan can reach a rotational speed of 2200 rpm and provide an airflow of about 75 cfm, while operating at a noise level of 30 dBA or less, so that the assembly 10, 710 can move a sufficient amount of air without disturbing the sleep of a user resting on the assembly 10, 710. Furthermore, a number of different fans can be included in the support cushion assembly of the present invention and are intended to be selected for a particular assembly or application based on the desired airflow or based on the specific characteristics of the foam layer included in the exemplary assembly, without departing from the spirit and scope of the subject matter described herein.

[0037] Regardless of the specific configuration, the fan 72 creates a vacuum such that ambient air is drawn downward through each top foam layer 190, 790 and each intermediate foam layer 160, 760 of each mattress 20, 720, through each hole 80, 780, and through the base foam layers 130, 730 and the deck 60 of the base 35, as shown by the action arrows in Figures 2 and 12. More specifically, as the air is drawn downward through the mattress 20 as shown in Figure 2, the air flows easily through the mesh foam with a more open cell structure contained in the top foam layer 190 and the intermediate foam layer 160, until it meets the base foam layer 130, which is a non-mesh foam with a closed cell structure. At that point, a small amount of air can move through the base foam layer 130 of the mattress 20, but most of the air being drawn downward is drawn through the intermediate foam layer 160 towards the hole 80, and eventually through the hole 80 to below the base foam layer 130. Similarly, as air is drawn downwards into the mattress 720, it moves easily through the more open cell structure of the mesh foam contained in the top foam layer 790 and the intermediate foam layer 760 until it reaches the uneven surface of the closed-cell non-mesh foam of the first base foam layer 734. Then, again, a small amount of air can move through the base foam layer 730 of the mattress 720, but most of the air being drawn downward is drawn through the intermediate foam layer 160 towards the hole 80, and eventually through the hole 780 to below the base foam layer 730. However, by including foam end rails 732b and foam side rails 732a in the base foam layer 730, air can also be drawn from the intermediate foam layer 760 across the uneven surface of the first base foam layer 734 in a manner that increases the efficiency of air being drawn through the mattress 720.

[0038] As air is drawn downwards through the foam layers 130, 160, 190, 730, 760, and 790 of each mattress 20, 720 and through the deck 60 of the base 35, the air is released into the surrounding environment, reducing heat buildup and undesirable humidity in the mattresses 20, 720 and the surrounding environment, thereby providing the user with better sleep. Advantageously, since ambient air is drawn in from outside the top surfaces 22, 722 of each mattress 20, 720, a person does not feel the wind on their body, as would be the case when using overhead fans or other ventilation devices used to lower the room temperature. Furthermore, since ambient air is drawn in from near the outside of the top surfaces 22, 722 of each mattress 20, 720, dust, insects, and other debris are not drawn in from under the bed and blown towards the person resting on the mattress 20.

[0039] Referring more specifically to Figures 2 and 12, and further considering the ventilation system 70, the fan 72 is generally located within a housing 240 made of a rigid material (e.g., the same rigid material as the base 35) and having a substantially rectangular shape. The base 35 serves as the top surface of the housing 240, and the housing 240 further has a cage-like or mesh bottom surface 250 which can be made of metal or nylon mesh, and the mesh openings are configured to allow the fan 72 to expel ambient air drawn in from the environment through the support cushion assemblies 10, 710 into the bedroom environment.

[0040] As an improvement to the present invention, the ventilation system 70 included in the support cushion assemblies 10, 710 shown in Figures 2 and 12 is in the form of a fan 72, but it is also intended that blowers of various other types and configurations can be incorporated into the exemplary support cushion assembly. For example, in another embodiment of the present invention, referring to Figure 7, a ventilation system 470 is used, and a blower in the form of an air pump 472 is used. The air pump 472 is attached to a first rigid connector 474, which is connected to a flexible conduit 476 made of corrugated tubing and is in fluid communication with the flexible conduit 476, which is connected to a second rigid connector 477 and is in fluid communication with the 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 base 435 for use with the exemplary support cushion assembly. In this manner, similar to the embodiments described above with reference to Figures 1 to 6, the air pump 472 is configured to draw air downward through the mattress 420 and release the drawn-in air below the base. Next, an air filter 490, such as a high-efficiency particulate air (HEPA) filter and / or other air purification structure, as well as an aromatherapy cartridge 492, are placed within the ventilation system 470 so that filtered air and / or scented air are discharged into the surrounding environment.

[0041] As with other features that may be included in the exemplary support cushion assembly, various control systems can be incorporated into the existing assembly to control the ventilation system of the support cushion assembly of the present invention, as will be recognized to those skilled in the art. Let us look at Figure 8, a schematic diagram showing one such control system that can be used for the exemplary support cushion assembly of the present invention, where the support cushion assembly utilizes an adjustable base. As shown in Figure 8, in the control system 500, the controller 502 is wired to various other service equipment for the support cushion assembly. In particular, the controller 502 is connected to two blowers 570, supplies power and control signals to the blowers 570, and also communicates with two actuators 504 for articulating the adjustable base. A power supply 506, such as an AC power supply that converts power to DC to power the DC fans of the blowers 570 or the actuators 504, is electrically connected to the controller 502. Furthermore, the controller 502 includes one or more USB chargers 508 that can be used to charge a smartphone, smart pad, or other electrical device while the user is sleeping or, alternatively, while sleeping, and / or to further control various functions 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 will be described in more detail below). The exemplary control system 500 shown in Figure 8 also includes a vibrator motor 510 that communicates electrically with the controller 502 and can be configured to provide a massage function to the support cushion, including the exemplary support cushion assembly.

[0042] Other functions, such as under-base lighting 512 and humidity and / or temperature sensors 520, are included in the control system 500 and powered for use. In some embodiments, the humidity and temperature sensors 520 are used for automating a ventilation system included in a particular support cushion assembly. In this regard, the humidity and / or temperature sensors 520 are configured to sense specific parameters of the sleeping environment / room, in other words, humidity and temperature, respectively. If the measured values ​​of the specific parameters are above or below predefined values ​​(either automatically entered into the system or manually entered by the user), the ventilation system automatically shuts off or turns on. For example, a person might want the fan 570 to operate when the room temperature is above 72 degrees Fahrenheit. Thus, when the temperature sensor 520 detects a temperature of 74 degrees Fahrenheit in the room, a wireless or wired signal is sent to the controller 502, which can activate the fan 570. The fan 570 continues to release conditioned air and remains operational until the temperature sensor 520 detects a temperature below 72 degrees Fahrenheit. At that point, another signal is sent to the controller 502 to stop or shut down the blower 570.

[0043] As will be apparent to those skilled in the art, such a controller 502 typically utilizes a processor and a communication module and is programmed to execute instructions stored in memory. In this specification, the term “memory” is used to refer to a physical device (computer-readable medium) used to non-temporarily store programs (instruction sequences) or data (e.g., program state information) for use in an electronic device. With regard to communication modules included in the exemplary controller or other components of the present invention, such communication modules may include communication circuits configured to wirelessly communicate with a remote control device, a mobile device (e.g., a smartphone or tablet), or an additional processor via wireless communication, as will be described in more detail below. In this regard, the controller 502 itself may be controlled by a wired or wireless remote control, or by a mobile device (e.g., a smartphone or tablet). The wireless remote control may be connected using radio frequency (RF), infrared, Wi-Fi, Bluetooth®, ZigBee, or other wireless communication standards. The remote control may be a standalone remote control with hard keys and buttons, a touchscreen, or any combination for user input. Furthermore, a mobile device in the form of a smartphone or smartpad may be used with a mobile application that connects to the controller 502 via a known communication standard. The controller 502 may also be equipped with a battery backup system. The battery backup system can be charged by the electrical connection that supplies power to the controller 502. The battery backup allows the system to be controlled for at least a certain period of time even when power is not supplied.

[0044] Referring next to Figure 9, as a further improvement of the present invention, a mattress cover 630 can also be used according to the present invention to allow airflow within the mattress to pass through. According to the present invention, it is desirable that the airflow from the upper surface of the support cushions included in the exemplary assembly is not obstructed, or at least restricted. Thus, the mattress cover 630 is configured to restrict the blockage of the holes in the exemplary support cushion assembly so that air providing ventilation can continue to flow from the mattress assembly. The cover 630 consists of a border 672 and an inner panel 674 formed of spacer fabric 676. The spacer fabric 676 is formed of a bidirectional stretchable material, meaning that it can stretch in two directions, for example, horizontally from head to toe and transversely from side to side relative to the bed. The spacer fabric 676 includes an upper layer 676a and a lower layer 676b, and a three-dimensional cross structure 676c is formed between the upper layer 676a and the lower layer 676b, providing a volume or void through which air can flow. The third direction (vertical as depicted) has limited stretchability compared to the horizontal direction.

[0045] The spacer fabric 676 may include woven or knitted materials and / or extruded plastic materials including polyethylene, polyester, other plastics, or a combination of any or other thereof. According to some embodiments, one of the layers 676a, 676b may be formed of polyester and spandex. In some embodiments, these materials may be formed in the same or different thread sizes, and in other embodiments, multiple sizes of one or more materials may be utilized. For example, in an exemplary and non-limiting embodiment, the layer may include 150 denier polyester and 40 denier and 70 denier spandex. The other of the layers 676a, 676b may be 150 denier polyester and 40 denier spandex. The illustrated three-dimensional cross structure 676c extending between the layers 676a, 676b may, in a non-limiting example, be 30 denier polyester. The pattern may be random, repeating, or a combination of fibers. Furthermore, the spacer fabric 676 is resilient so that it can be used repeatedly without degrading and losing its thickness. Thus, this material maintains the volume between layers 676a and 676b, allowing sufficient airflow through it. A non-limiting example of this spacer fabric 676 is commercially available from Global Textile Alliance of China (Hangzhou, China).

[0046] Finally, the support cushions shown in Figures 1-4 and referenced throughout this specification are in the form of mattress assemblies through which air is drawn downward, but it is intended that the direction of the fans and blowers described herein can be reversed so that air can be pushed through the exemplary mattress assembly, at least in part due to the arrangement of the foam layers in the exemplary assemblies. Furthermore, the support cushions described herein are in the form of mattress assemblies having dimensions for supporting a user lying in a supine or prone position, but it is intended that the features described herein are similarly applicable to seat cushions, seat backs, pillows, mattress toppers, overlays, etc. Thus, in this specification, terms such as “support cushion” are used to refer to any object of any size or shape that is capable of supporting or commonly used to support the user’s body or part thereof.

[0047] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of the present invention or the following claims. This detailed description, in particular the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding and from which no unnecessary limitations should be understood.

Claims

1. A support cushion comprising a top foam layer and a base foam layer, wherein the top foam layer has a cellular structure configured to allow air to flow through the top foam layer at a higher speed than that of the base foam layer, and A ventilation system configured to draw air downward from the top foam layer and release the drawn-in air downward from the base foam layer of the support cushion, Support cushion assembly.

2. The holes are defined by the base foam layer and further include holes extending through the base foam layer. The support cushion assembly according to claim 1.

3. The aforementioned top foam layer includes a mesh foam. The support cushion assembly according to claim 1.

4. The system further comprises an intermediate foam layer disposed between the top foam layer and the base foam layer, wherein the intermediate foam layer has a cell structure configured to allow air to flow through the intermediate foam layer at a higher speed than that of the base foam layer. The support cushion assembly according to claim 1.

5. The top foam layer, the intermediate foam layer, or both thereof include a viscoelastic foam. The support cushion assembly according to claim 4.

6. The base foam layer includes a non-mesh foam. The support cushion assembly according to claim 1.

7. The base foam layer includes one or more layers having an uneven surface. The support cushion assembly according to claim 1.

8. The base foam layer comprises a first base foam layer and a second base foam layer disposed below the first base foam layer. The support cushion assembly according to claim 1.

9. The first base foam layer and the second base foam layer include a non-mesh foam. The support cushion assembly according to claim 8.

10. The first base foam layer includes an uneven surface, The support cushion according to claim 8.

11. The base foam layer further comprises a pair of foam end rails and a pair of foam side rails disposed on the second base foam layer, The pair of foam end rails and the pair of foam side rails collectively form the periphery of the first base foam layer. The support cushion according to claim 8.

12. The support cushion is positioned below the support cushion and further comprises a base that supports the support cushion. The support cushion assembly according to claim 1.

13. The hole is further defined by the base foam layer and the foundation and extends through them, The support cushion assembly according to claim 12.

14. The ventilation system is configured to draw air downward from the top foam layer of the support cushion and release the drawn-in air through the holes to the base. The support cushion assembly according to claim 13.

15. The system further comprises a controller that communicates with the ventilation system, and at least one sensor that communicates with the controller. The support cushion assembly according to claim 1.

16. The at least one sensor measures either the humidity or temperature of the environment surrounding the support cushion assembly. The support cushion assembly according to claim 15.

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

18. The aforementioned support cushion is a mattress. The support cushion assembly according to claim 1.

19. base, A support cushion placed on the base, the support cushion having a base layer, an intermediate layer, and a top layer. A hole extending from the bottom surface of the intermediate layer through the base layer and the foundation, A blower is attached to the base and has fluid communication with the hole, and is configured to draw air downward through the top layer of the support cushion and through the hole, Support cushion assembly.

20. The top layer of the support cushion includes a mesh-like viscoelastic foam, The support cushion assembly according to claim 19.

21. The intermediate layer includes a viscoelastic foam. The support cushion assembly according to claim 19.

22. The base layer includes a flexible foam, The support cushion assembly according to claim 19.

23. The blowing device is a fan or an air pump. The support cushion assembly according to claim 19.

24. The blower further includes a filter operably connected to the blower, The support cushion assembly according to claim 23.

25. The filter and the blower are housed within the housing. The support cushion according to claim 24.

26. The housing has an outlet, The support cushion according to claim 25.

27. The device further includes a cartridge for imparting fragrance to the drawn-in air, the cartridge being in fluid communication with the blower and the filter. The support cushion according to claim 25.

28. It is a support cushion, A top foam layer made of a mesh foam, An intermediate foam layer disposed below the top foam layer, wherein the intermediate foam layer includes a mesh foam, and A base foam layer is disposed below the aforementioned intermediate foam layer and includes a non-mesh foam, wherein the base foam layer is as follows: The first base foam layer has an uneven surface on the top. A second base foam layer is disposed below the first base foam layer. A support cushion comprising a pair of foam end rails and a pair of foam side rails disposed on the second base foam layer, wherein the pair of foam end rails and the pair of foam side rails collectively form the periphery of the first base foam layer, and A ventilation system is provided, configured to draw air downward from the top foam layer through the intermediate foam layer and the base foam layer, and to release the drawn-in air downward from the base foam layer of the support cushion, Support cushion assembly.

29. The aforementioned support cushion is a mattress. The support cushion according to claim 28.

30. To provide a support cushion assembly including a support cushion placed on a base, Air is drawn in from the environment surrounding the support cushion assembly through a hole that passes over the upper surface of the support cushion, extends downward through the support cushion, and penetrates at least a portion of the support cushion and the base. Filtering the air that is drawn in, This includes the fact that filtered air is released back into the environment. Active ventilation method for support cushions.

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