Support cushion assemblies including electrically conductive fabric and associated cooling elements

Abstract

A support cushion assembly includes a body support portion, an electrically conductive fabric positioned atop the body support portion, and an active cooling element configured to selectively cool the body support portion. A controller is operatively connected to the electrically conductive fabric and to the active cooling element, and is configured to monitor a resistance of the electrically conductive fabric and adjust the active cooling element to maintain a target temperature the body support portion. Methods of controlling a temperature of a support cushion include steps of positioning an electrically conductive fabric on a support cushion, measuring a resistance of the electrically conductive fabric, and adjusting an active cooling element based on the measured resistance to maintain a target temperature of the support cushion.

Description

SUPPORT CUSHION ASSEMBLIES INCLUDING ELECTRICALLY CONDUCTIVE FABRIC AND ASSOCIATED COOLING ELEMENTSRELATED APPLICATIONS

[0001] This application claims priority from U.S. Provisional Application Serial No.63 / 749,761, filed January 27, 2025, the entire disclosure of which is incorporated herein by this reference.TECHNICAL FIELD

[0002] The present invention relates to support cushion assemblies including an electrically conductive fabric and an associated cooling element. In particular, the present invention relates to support cushion assemblies comprised of an electrically conductive fabric that is used to monitor the temperature of an upper surface of a body support portion of the support cushion assembly and to control an active cooling element and maintain a target temperature on the upper surface.BACKGROUND

[0003] An aspect of successful and restful sleep is individual sleep comfort. Medical research suggests that sleep deprivation (“sleep debt”) can have significant negative impacts on longevity, productivity, and overall mental, emotional, and physical health. Chronic sleep debt has been linked to weight gain and, more specifically, has been observed to not only affect the way the body processes and stores carbohydrates, but has also been observed to alter hormone levels that affect appetite. Moreover, sleep debt may result in irritability, impatience, inability to110898020 :vlconcentrate, and moodiness, which has led some researchers to suggest a link between sleep debt and worksite accidents, traffic incidents, and general afternoon inattentiveness. Furthermore, sleep disorders have been linked to hypertension, increased stress hormone levels, and irregular heartbeat, and additional research has recently suggested that a lack of sleep can affect immune function, resulting in increased susceptibility to illness and disease, e.g., cancer. In all, researchers have now suggested that sleep debt costs the United States billions of dollars annually in lost productivity due to these various effects. Accordingly, a support cushion assembly that improves sleep comfort and lowers individual sleep debt would be both highly desirable and beneficial.SUMMARY

[0004] The present invention includes support cushion assemblies comprising an electrically conductive fabric integrated with a thermal management control system. In particular, the present invention includes support cushion assemblies comprising an electrically conductive fabric that is used to monitor the temperature of an upper surface of a body support portion of the support cushion assembly and to control an active cooling element and maintain a target temperature on the upper surface. By maintaining the target temperature, the support cushion assembly thereby improves sleep comfort by providing a means to avoid an increase in the surface temperature of the support cushion.

[0005] In some exemplary embodiments of the present invention, a support cushion assembly is provided that comprises a body support portion having a first surface and a second surface opposite the first surface. An electrically conductive fabric is positioned atop the body support portion, and comprises a first metal bonded to a substrate. An active cooling element is further included in the support cushion assembly and is configured to selectively cool the first surface of the body support portion. A controller is also included and is operatively connected to 210898020 :vlthe electrically conductive fabric and to the active cooling element. The controller is configured to monitor the electrically conductive fabric and adjust the active cooling element to maintain a target temperature at the first surface of the body support portion. In some embodiments of the support cushion assemblies of the present invention, the target temperature is an ambient temperature.

[0006] In certain embodiments of the electrically conductive fabric, the substrate of the electrically conductive fabric is nylon, while the first metal comprises silver. In some embodiments, to assist in incorporating the fabric into a support cushion assembly, the electrically conductive fabric is in the form of a stretched knit fabric, and the substrate is a thread or yarn. In this regard, in certain embodiments, the support cushion assembly further comprises a cover for the body support portion and the electrically conductive fabric is incorporated into the cover.

[0007] In some embodiments of the body support cushions of the present invention, the electrically conductive fabric comprises one or more sensor portions positioned atop the first surface of the body support portion, such that the one or more sensor portions can be characterized as being positioned at various regions atop the first surface of the body support portion. In some embodiments, the one or more sensor portions includes at least one of a head portion, a torso portion, and a leg portion. In some such embodiments, the electrically conductive fabric further includes a band that extends from each of the one or more sensor portions and that provides an electrical connection between the one or more sensor portions and the controller. An additional band is, in certain embodiments, further included and extends laterally along a side of the body support portion to provide an electrical connection between each band extending from a respective one of the sensor portions and the controller.310898020 :vl

[0008] The active cooling element included in the support cushion assemblies of the present invention is provided to cool the first surface of the body support portion and is typically positioned in an exemplary support cushion assembly so as to cool the first surface of the body support portion at the location of each of the one or more sensor portions. In some embodiments, the active cooling element includes a fan. In some such embodiments, the fan is positioned at or below the second surface and the body support portion is configured to allow air flow between the first surface and the second surface of the body support portion. In some other embodiments of the body support cushions of the present invention, the active cooling element includes a plurality of thermoelectric elements positioned in the body support portion itself.

[0009] To control the active cooling element, the controller monitors a resistance of the electrically conductive fabric and, as indicated above, adjusts the active cooling element based on that measured resistance. In some such embodiments, the controller comprises a proportional-integral-derivative controller for controlling the active cooling element. In some embodiments, the controller is then configured to use pulse-width modulation to adjust the active cooling element.

[0010] In some further embodiments of the support cushion assemblies of the present invention, the support cushion assembly is in the form of a mattress assembly. In some embodiments, a mattress assembly is provided that similarly comprises a body support portion having a first surface and a second surface opposite the first surface, an electrically conductive fabric positioned atop the first surface of the body support portion, and a controller operatively connected to the electrically conductive fabric and to the active cooling element, such that the controller is configured to monitor a resistance of the electrically conductive fabric and adjust the active cooling element to maintain a target temperature at the first surface of the body support410898020 :vlportion. Further included in the mattress assembly is then a base layer or foundation that is positioned adjacent to the second surface of the body support portion, and that houses or otherwise includes the active cooling element configured to selectively cool the first surface of the body support portion. In some embodiments, the controller can also be housed within the base layer.

[0011] Further provided, in some implementations of the present invention are methods of controlling a temperature of a support cushion. In some implementations, a method of controlling a temperature of a support cushion comprises steps of positioning an electrically conductive fabric on an upper surface of a support cushion and measuring a resistance of the electrically conductive fabric. Based on the measured resistance, an active cooling element is then adjusted to maintain a target temperature at the upper surface of the support cushion. In some implementations, measuring a resistance of the electrically conductive fabric comprises comparing the measured resistance to a predetermined resistance corresponding to a target temperature of the upper surface of the support cushion. A difference between the measured resistance and the predetermined resistance over time is subsequently calculated in some implementations, and a required adjustment to the active cooling element is determined based on the calculated difference. In some implementations, adjusting the active cooling element comprises pulse-width modulation of the active cooling element.

[0012] Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.510898020 :vlBRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1A is a perspective view of a body support portion including an electrically conductive fabric and made in accordance with the present invention;

[0014] FIG. IB is a perspective view of a base layer made in accordance with the present invention and illustrating the inclusion of a controller and three fans;

[0015] FIG.2 is perspective view of a support cushion assembly made in accordance with the present invention, and showing the body support portion of FIG. 1A positioned atop the base layer of FIG. IB;

[0016] FIG.3 is a partial view of the electrically conductive fabric included in the body support portion shown in FIG. 1A;

[0017] FIG. 4 is a perspective view of a support cushion including a base layer and a body support portion with an electrically conductive fabric positioned above the base layer and made in accordance with the present invention; and

[0018] FIG. 5 is a flow chart showing an exemplary implementation of a method of controlling a temperature of a support cushion in accordance with the present invention.DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0019] The present invention includes support cushion assemblies comprised of an electrically conductive fabric and an associated cooling element. In particular, the present invention includes support cushion assemblies comprised of an electrically conductive fabric that is used to monitor the temperature of an upper surface of a body support portion of the support cushion to thereby control an active cooling element and maintain a target temperature on the upper surface of the body support portion. By making use of the electrically conductive fabrics,610898020 :vlthe support cushions of the present invention thus allow a user to improve their sleep comfort by avoiding an increase in the surface temperature of the support cushion that would otherwise affect the user’s sleep.

[0020] Referring first to FIGS. 1 A-1B and FIG. 2, in one exemplary embodiment of the present invention, a support cushion assembly in the form of a mattress assembly 10 is provided that includes a body support portion 20, which is shown in detail in FIG. 1 A, and a base layer or foundation 40, which is shown in detail in FIG. IB. The body support portion 20 includes a first surface 22, which is an upper surface of the body support portion 20, and a second surface 24, which is the lower surface of the body support portion 20 and is opposite the first surface 22. The body support portion 20 of the mattress assembly additionally includes four sides 26a, 26b, 26c, 26d that define a perimeter of the body support portion 20.

[0021] Similarly, the base layer 40 includes a first surface 42, which is an upper surface of the base layer 40, and a second surface 44, which is the lower surface of the base layer 40 and is opposite the first surface 42. The base layer 40 of the mattress assembly 10 additionally includes four sides 46a, 46b, 46c, 46d that define a perimeter of the base layer 40. In this way, and as shown in FIG. 2, the body support portion 20 can thus be positioned on the base layer 40 such that the first surface 42 of the base layer 40 is adjacent to the second surface 24 of the body support portion 20 with the four sides 26a, 26b, 26c, 26d of the body support portion 20 substantially aligning with the four sides 46a, 46b, 46c, 46d of the base layer 40.

[0022] In the mattress assembly 10, the base layer 40 further includes a controller 50 and one or more active cooling elements in the form of fans 60a, 60b, 60c, and the body support portion 20 further includes an electrically conductive fabric 30 that is comprised of a first metal bonded to an underlying substrate. The electrically conductive fabric 30 is positioned atop the body710898020 :vlsupport portion 20 and along at least one of the four sides 26a, 26b, 26c, 26d of the mattress assembly 10, and the electrically conductive fabric 30 is operably connected to the controller 50 in the base layer 40. The controller 50 monitors the electrically conductive fabric 30 and adjusts the fans 60a, 60b, 60c to maintain a target temperature at the upper surface 22 of the body support portion 20, as described in further detail below.

[0023] Referring now more specifically to FIG. 1 A, the exemplary electrically conductive fabric 30 is incorporated into a cover 28 for the body support portion 20 and includes one or more sensor portions 32a, 32b, 32c. In particular, in the mattress assembly 10, the one or more sensor portions 32a, 32b, 32c are incorporated into the cover 28 itself such as by stitching or the like, and such that that the sensor portions 32a, 32b, 32c are continuous with the remainder of the cover 28. It is of course contemplated though that different ways of attaching or incorporating the sensor portions and, more specifically, the electrically conductive fabric into an exemplary support cushion assembly are also within the scope of the present invention, including connecting the sensor portions to the top surface of a cover such as by glue, hook and loop fasteners, or the like. Alternatively, it is contemplated that the exemplary electrically conductive fabric or sensor portions need not be incorporated into a cover at all, but can instead be connected directly to the upper surface of an exemplary body support portion itself.

[0024] Regardless of the manner in which the electrically conductive fabric is associated with the body support portion, and referring still to FIG. 1 A, the sensor portions 32a, 32b, 32c are generally located atop the first surface 22 of the body support portion 20 with each sensor portion 32a, 32b, 32c located in a corresponding region of first surface 22 the body support portion 20, namely, a head region, a torso region, and a leg region of the body support portion 20. The electrically conductive fabric 30 further includes a plurality of bands 34a, 34b, 34c, 34d810898020 :vlwith at least one band 34a, 34b, 34c extending from a corresponding one of the three sensor portions 32a, 32b, 32c and down one of the sides 26a of the body support portion 20. In the exemplary body support portion 20 shown in FIG. 1A, an additional band 34d extends laterally along the side 26a of the body support portion 20 connecting each of the other bands 34a, 34b, 34c to one another and to the controller 50. In this way and advantageously, the use of the plurality of bands 34a, 34b, 34c, 34d made from the electrically conductive fabric 30 allows for electrical connection between the sensor portions 32a, 32b, 32c and the controller 50 without requiring the use of wiring in the body support portion 20.

[0025] As perhaps shown best in the partial view of the electrically conductive fabric 30 in FIG. 3, the electrically conductive fabric 30 included in the exemplary mattress assembly is a stretched knit or woven fabric that is comprised of a plurality of individual yarns 36, with each yarn 36 coated with the first metal before being assembled into the knit or woven configuration. In particular, in the electrically conductive fabric 30, the yam 36 making up the electrically conductive fabric 30 is comprised of a nylon that is first coated with silver before being arranged in the knit or woven configuration. In this way, by coating the yarn 36 in such a manner, it has been observed that the electrically conductive fabric 30 is imparted with a degree of durability and stretch-ability that allows the electrically conductive fabric 30 to not only be stretched across a bed and effectively utilized on such a surface, but is also able to withstand damage that may be caused by typical wear and tear. In contrast to mattress assemblies that incorporate wire-based systems into a mattress, the stretch knit configuration and construction of the present invention, which makes use of the metallized coated yarns 36 to form the electrically conductive fabric 30, do not readily break or come apart and continue to be capable of conducting electricity or heat910898020 :vlafter being subjected to repeated articulation, bouncing, or other tests to its durability that are encountered during normal use of the mattress assembly.

[0026] As would be recognized by those skilled in the art, numerous methods can be used to coat or otherwise incorporate a metal into an underlying substrate including, but not limited to, printing, padding, direct coating, vapor deposition, and the like. Such methods can be used to apply a metal to a substrate in a variety of different patterns and configurations. To coat the nylon comprising the yarn 36 with silver in the electrically conductive fabric 30, however, the nylon is typically first coated with a silver nitrate solution that then undergoes a reduction reaction to create an ionic bond between the nylon and the silver. In this regard, in some embodiments, a chemical plating solution can be utilized in which silver nitrate, a reducing agent, and certain complexing agents (e.g., an alkali, a buffer, and a stabilizer) are typically used to control and promote the autocatalytic process for the production of the coated yarns. Such reagents for a reduction reaction that allow for the production of the silver-coated nylon yams can include stannous chloride, hydrochloric acid, silver nitrate, sodium hydroxide, and an ammonium solution.

[0027] Of course, it is further contemplated that other metals, including, but not limited to copper, nickel, aluminum, and the like, can also be incorporated into an exemplary support cushion to monitor the temperature of an upper surface of the support cushion and can readily be selected for a particular application without departing from the spirit and scope of the subject matter described herein. It would also be appreciated by those skilled in the art, that a variety of other activators and reagents can also be selected for a particular reaction and can be selected depending on the particular metal utilized and the materials included in the underlying substrate (e g., the yam) without departing from the spirit and scope of the subject matter described herein.1010898020 :vlWithout wishing to be bound by any particular theory or mechanism, however, it is believed that by making use of a metalizing process that coats an underlying substrate such as the silver / nylon reduction reaction described above, an electrically conductive fabric can be produced that is more durable than a printed or padded application as the ionic bond created during the reaction allows for a bond that is more durable to abrasion and that will not lose its adhesion to the substrate over time, as is often the case with other coating applications or with printing. For additional guidance regarding the production of an electrically conductive fabric, see, e.g., International Patent Application Publication No. WO 2024 / 158917, which is incorporated herein by reference in its entirety.

[0028] Turning now to the body support portion 20 itself, the body support portion 20 of the mattress assembly 10 is generally comprised of a continuous layer of flexible foam that is capable of suitably distributing pressure from a user’s body or portion thereof across the body support portion 20, but that may be prone to retaining heat given the nature of the foam. Such flexible foams include, but are not limited to, latex foam, reticulated or non-reticulated viscoelastic foam (sometimes referred to as memory foam or low-resilience foam), reticulated or nonreticulated non-visco-elastic foam, polyurethane high-resilience foam, expanded polymer foams (e g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. In the embodiment shown in FIG. 1 A and FIG. 2, the body support portion 20 is comprised of a visco-elastic foam that has a low resilience as well as a sufficient density and hardness, which allows pressure to be absorbed uniformly and distributed evenly across the body support portion 20 of the mattress assembly. Generally, such visco-elastic foams have a hardness of at least about 10 N to no greater than about 80 N, as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the1110898020 :vlmaterial at approximately room temperature (i.e., 21 °C to 23°C), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard. In some embodiments, the visco-elastic foam has a hardness of about ION, 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 degree of comfort and body-conforming qualities.

[0029] The visco-elastic foam described herein for use in the mattress assembly can also have a density that assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability. In some embodiments, the density of the visco-elastic foam used in the body support portion 20 has a density of no less than about 30 kg / m3to no greater than about 150 kg / m3. In some embodiments, the density of the visco-elastic foam used in the body support portion 20 of the mattress assembly 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 visco-elastic foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it is appreciated that a viscoelastic foam having a desired density and hardness can also readily be selected for a particular application or mattress assembly as desired.

[0030] Additionally, it is appreciated that the body support portions of the mattress assemblies of the present invention need not be comprised of a continuous layer of flexible foam at all, but can also take the form of more traditional mattresses, including spring-based mattresses, without departing from the spirit and scope of the subject matter described herein.1210898020 :vl

[0031] Referring once again FIGS. 1 A and IB, each of the fans 60a, 60b, 60c of the base layer 40 is positioned such that when the body support portion 20 is positioned on the base layer 40, with each fan 60a, 60b, 60c located below a corresponding location of a sensor portion 30a, 30b, 30c of the electrically conductive fabric 30 of the body support portion 20. It is contemplated that in some embodiments, the controller 50 can adjust each fan 60a, 60b, 60c separately to maintain the target temperature of the body support portion 20 in each region where there is a sensor portion 30a, 30b, 30c. To this end, the plurality of bands 34a, 34b, 34c, 34d are in some instances electrically separated so that each sensor portion 30a, 30b, 30c can be separately monitored by the controller 50. Although not expressly shown, the body support portion 20 and base layer 40 are configured to allow the fans 60a, 60b, 60c to cool the upper surface 22 of the body support portion 20. Support cushions which include fans to provide cooling of an upper surface are described, for example, in U.S. Patent Nos. 11,375,825;11,160,386; 10,827,845; 9,955,791; 8,881,328, as well as U.S. Patent Application Publication No. 2018 / 0098637, each of which is incorporated herein by this reference.

[0032] As previously mentioned, the controller 50 monitors the electrically conductive fabric 30 to adjust the fans 60a, 60b, 60c. According to some exemplary embodiments, the controller 50 monitors the resistance of the electrically conductive fabric 30. When the electrically conductive fabric 30 is heated, for example from a user lying on the body support portion 20, the resistance of the electrically conductive fabric 30 will increase. This change in resistance can be measured by the controller 50 to not only indicate when the upper surface 22 of the body support portion 20 is heated, but to indicate when a temperature of a particular region of the upper surface 22 of the body support portion 20 increases. For example, the controller 50 may run a known current through the electrically conductive fabric 30 and measure the resulting voltage to1310898020 :vlcalculate the resistance of the electrically conductive fabric 30 in much the same way that an ohmmeter operates. As another example, in some embodiments, the controller 50 can individually run a known current through each of a plurality of bands 34a, 34b, 34c such that the resistance in each of the sensor portions 30a, 30b, 30c can be separately measured. In this way, within a given region of the body support portion 20 or a given one of the a sensor portions 30a, 30b, 30c, if the heat increases while the supplied voltage remains constant, the resulting change in resistance will cause a corresponding change in current. By measuring the current, resistance can be calculated or inferred in that particular region or sensor portion 30a, 30b, 30c such that monitoring either the current or the resistance will provide the necessary information to adjust the active cooling element accordingly.

[0033] According to some exemplary embodiments, the controller 50 includes a proportional-integral-derivative (PID) controller with the resistance of the electrically conductive fabric 30 used as input and operation of the fans 60a, 60b, 60c as output. That is to say, the controller 50 continuously, or nearly continuously, monitors the resistance of the electrically conductive fabric 30 and compares it to a predetermined resistance that corresponds to the target temperature (e.g., ambient temperature) of the upper surface 22 of the body support portion 20. The controller 50 uses the difference between the measured resistance and the predetermined resistance over time to determine what output is required to cool the upper surface 22 of the body support portion 20 as desired.

[0034] According to some exemplary embodiments, the controller 50 uses pulse-width modulation (PWM) to control the fans 60a, 60b, 60c. PWM controls electrical power or amplitude provided to the fans 60a, 60b, 60c by switching a supply on and off rapidly. PWM drives switch transistors on and off at a high frequency (typically 10 to 20 Hz). In operation,1410898020 :vlupon a user lying on the body support portion 20, each of the sensor portions 32a, 32b, 32c of the electrically conductive fabric 30 will warm at varying rates and the resistance of the sensor portions 32a, 32b, 32c will correspondingly increase. This change in resistance is monitored by the PID controller, which uses the PWM drive to control a motor drive or variable voltage supply to each fan 60a, 60b, 60c. Again, and advantageously, each region of the body support portion 20 can be monitored and controlled separately. Furthermore, as the PID controller provides a constant feedback loop, in some embodiments, the fans 60a, 60b, 60c can begin operation slowly before gradually increasing while observing the system’s behavior. In addition, methods such as the Ziegler-Nichols or trial-and-error can be utilized to determine a preferable response.

[0035] In the exemplary mattress assembly described above with reference to FIGS. 1A and IB, the sensor portions 32a, 32b, 32c are generally elliptical and the plurality of bands 34a, 34b, 34c, 34d are narrow and wire-like. However, the electrically conductive fabric of the present invention may be formed in a variety of different shapes. For example, and referring now to FIG. 3, another exemplary mattress assembly 110 is provided which includes a body support portion 120 positioned on abase layer 140. The body support portion 120 shown in FIG. 3 includes an electrically conductive fabric 130 with three sensor portions 132a, 132b, 132c located atop a first surface 122 of the body support portion 120 similar to the body support portion 20 described above with respect to FIGS. 1 A and FIG. 2. However, the sensor portions 132a, 132b, 132c shown in FIG. 4 are strips which extend across the entire width of the body support portion 120. Bands 134a, 134b, 134c, which extend between and connect the sensor portions 132a, 132b, 132c to the controller 140, are also strips of roughly the same width as the sensor portions 132a, 132b, 132c. A vertically aligned band 134c then extends down the side 126a of the body support portion 120 and is electrically connected to a wire 152 on the base layer1510898020 :vl140 that leads to the controller 150. A metallic snap fastener 154, which is shown in detail in FIG. 3, is used to electrically connect the vertically aligned band 134c on the body support portion 120 to the wire 152 on the base layer 140. Advantageously, the metallic snap fastener 154 provides for a secure electrical connection but will automatically disconnect should the body support portion 120 move relative to the base layer 140 without damaging either of the body support portion 120 or the base layer 140. Of course, the use of wire connectors, clips, soldering, and the like can also be used to operably connect the electrically conductive fabric 130 to controller 150 and are contemplated to be within the scope of the present invention.

[0036] As a further refinement, while the support cushion assemblies described herein are described as including an electrically conductive fabric positioned on an upper surface of a body support portion, it is contemplated that the electrically conductive fabrics can also be incorporated into a support cushion as part of a multi-layer construction. For example, in some embodiments, an exemplary support cushion assembly can include a multilayer construction including: (1) a top comfort layer comprised of flexible foam having a lower density and / or hardness; (2) an intermediate electrically conductive fabric layer positioned below the top comfort layer; and (3) an active cooling element positioned in a structural foam or polymer-based support base positioned below the intermediate electrically conductive fabric layer and having a density and / or hardness greater than that of the comfort layer.

[0037] Moreover, although the above described mattress assembly 10 makes use of fans as an active cooling element to cool the upper surface of the body support portion, it is contemplated that other active cooling elements can be used in an exemplary support cushion made in the accordance with the present invention without departing from the spirit and scope of the subject matter described herein. For example, a plurality of thermoelectric elements (i.e.,1610898020 :vlPeltier elements) can be included in or on the body support portion in addition to, or instead of, the inclusion of fans. Support cushions which include thermoelectric elements to provide cooling of an upper surface are described, for example, in U.S. Patent Nos. 9,913,546; 9,408,475, as well as U.S. Patent Application Publication No. 2016 / 0128487, each of which is incorporated herein by this reference. Other actively cooling elements (e.g., circulated fluid cooling) are also contemplated for use as active cooling elements with the assemblies described herein.

[0038] Lastly, although the support cushions shown in FIGS. 1A, IB, 2 and 4 are in the form of mattress assemblies and are generally dimensionally-sized to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to head pillows, seat cushions, seat backs, neck pillows, leg spacer pillows, mattress toppers, overlays, and the like. As such, the phrase “body support” or “body supporting” is used herein to refer to any and all such objects having any size or shape, and that are capable of or are generally used to support the body of a user or a portion thereof.

[0039] Referring now to FIG. 5, further provided, in some implementations of the present invention are methods for controlling a temperature of a support cushion. In one exemplary implementation, a method of controlling a temperature of a support cushion includes an initial step of positioning an electrically conductive fabric on an upper surface of a support cushion, as indicated by step S210. A resistance of the electrically conductive fabric is then measured, as indicated by step S220. In some implementations, measuring a resistance of the electrically conductive fabric comprises comparing the measured resistance to a predetermined resistance corresponding to a target temperature of the upper surface of the support cushion. A difference between the measured resistance and the predetermined resistance overtime is subsequently calculated in some implementations, as indicated by step S230, and a required adjustment to the1710898020 :vlactive cooling element is determined based on the calculated difference, as indicated by step S240. An active cooling element (e.g., a fan) is then adjusted to maintain a target temperature at the upper surface of the support cushion, as indicated by step S250. In some implementations, adjusting the active cooling element comprises pulse- width modulation of the active cooling element.

[0040] One of ordinary skill in the art will recognize that additional embodiments are also possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.1810898020 :vl

Claims

CLAIMSWhat is claimed is:

1. A support cushion assembly, comprising:a body support portion having a first surface and a second surface opposite the first surface;an electrically conductive fabric positioned atop the first surface of the body support portion, the electrically conductive fabric comprising a first metal bonded to a substrate;an active cooling element configured to selectively cool the first surface of the body support portion; anda controller operatively connected to the electrically conductive fabric and to the active cooling element, the controller configured to monitor a resistance of the electrically conductive fabric and adjust the active cooling element to maintain a target temperature at the first surface of the body support portion.

2. The support cushion assembly of claim 1, wherein the electrically conductive fabric comprises one or more sensor portions positioned atop the first surface of the body support portion.

3. The support cushion assembly of claim 2, wherein the one or more sensor portions includes at least one of a head portion, a torso portion, and a leg portion.1910898020 :vl4. The support cushion assembly of claim 2, wherein the electrically conductive fabric comprises a band extending from each of the one or more sensor portions, the band for providing an electrical connection between the one or more sensor portions and the controller.

5. The support cushion assembly of claim 4, wherein the electrically conductive fabric further comprises an additional band extending laterally along a side of the body support portion, the additional band connecting each band extending from the one or more sensor portions to the controller.

6. The support cushion assembly of claim 1, further comprising a cover for the body support portion, wherein the electrically conductive fabric is incorporated into the cover for the body support portion.

7. The support cushion assembly of claim 1, wherein the substrate comprises nylon.

8. The support cushion assembly of claim 1, wherein the first metal comprises silver.

9. The support cushion assembly of claim 1, wherein the electrically conductive fabric is in a form of a stretched knit fabric, and wherein the substrate is a thread or yarn.

10. The support cushion assembly of claim 2, wherein the active cooling element is positioned to cool the first surface of the body support portion at a location of each of the one or more sensor portions.2010898020 :vl11. The support cushion assembly of claim 1, wherein the active cooling element comprises a fan.

12. The support cushion assembly of claim 11, wherein the fan is positioned at or below the second surface of the body support portion.

13. The support cushion assembly of claim 1, wherein the active cooling element includes a plurality of thermoelectric elements positioned in the body support portion.

14. The support cushion assembly of claim 1, wherein the target temperature is an ambient temperature.

15. The support cushion assembly of claim 1, wherein the controller comprises a proportional-integral-derivative controller for controlling the active cooling element.

16. The support cushion assembly of claim 1, wherein the controller is configured to use pulse- width modulation to adjust the active cooling element.

17. The support cushion assembly of claim 1, wherein the body support portion is comprised of a visco-elastic foam.2110898020 :vl18. The support cushion assembly of claim 1 , wherein the body support portion is dimensionally-sized to support a user lying in a supine or prone position.

19. A mattress assembly, comprising:a body support portion having a first surface and a second surface opposite the first surface;an electrically conductive fabric positioned atop the first surface of the body support portion, the electrically conductive fabric comprising a first metal bonded to a substrate;a base layer positioned adjacent to the second surface of the body support portion, the base layer including an active cooling element configured to selectively cool the first surface of the body support portion; anda controller operatively connected to the electrically conductive fabric and to the active cooling element, the controller configured to monitor a resistance of the electrically conductive fabric and adjust the active cooling element to maintain a target temperature at the first surface of the body support portion.

20. A method of controlling a temperature of a support cushion, comprising:positioning an electrically conductive fabric on an upper surface of a support cushion; measuring a resistance of the electrically conductive fabric; andadjusting, based on the measured resistance, an active cooling element to maintain a target temperature at the upper surface of the support cushion.2210898020 :vl21. The method of claim 20, wherein measuring a resistance of the electrically conductive fabric comprises comparing the measured resistance to a predetermined resistance corresponding to the target temperature of the upper surface of the support cushion.

22. The method of claim 21, further comprising:calculating a difference between the measured resistance and the predetermined resistance overtime; anddetermining a required adjustment to the active cooling element based on the calculated difference.

23. The method of claim 21, wherein adjusting the active cooling element comprises pulsewidth modulation of the active cooling element.2310898020 :vl

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