Patent Grant
8065763
1. Field of the Invention
This application relates to climate control, and more specifically, to climate control of a bed or similar device.
2. Description of the Related Art
Temperature-conditioned and/or ambient air for environmental control of living or working space is typically provided to relatively extensive areas, such as entire buildings, selected offices, or suites of rooms within a building. In the case of enclosed areas, such as homes, offices, libraries and the like, the interior space is typically cooled or heated as a unit. There are many situations, however, in which more selective or restrictive air temperature modification is desirable. For example, it is often desirable to provide an individualized climate control for a bed or other device so that desired heating or cooling can be achieved. For example, a bed situated within a hot, poorly-ventilated environment can be uncomfortable to the occupant. Furthermore, even with normal air-conditioning, on a hot day, the bed occupant's back and other pressure points may remain sweaty while lying down. In the winter time, it is highly desirable to have the ability to quickly warm the bed of the occupant to facilitate the occupant's comfort, especially where heating units are unlikely to warm the indoor space as quickly. Therefore, a need exists to provide a climate-controlled bed assembly.
In accordance with some embodiments of the present inventions, a climate controlled bed comprises a cushion member having an outer surface comprising a first side for supporting an occupant and a second side, the first side and the second side generally facing in opposite directions, the cushion member having at least one recessed area along its first side or its second side. In one embodiment, the bed further includes a support structure having a top side configured to support the cushion member, a bottom side and an interior space generally located between the top side and the bottom side, the top side and the bottom side of the support structure generally facing in opposite directions, a flow conditioning member at least partially positioned with the recessed area of the cushion member, an air-permeable topper member positioned along the first side of the cushion member and a fluid temperature regulation system. The fluid temperature regulation system includes a fluid transfer device, a thermoelectric device and a conduit system generally configured to transfer a fluid from the fluid transfer device to the thermoelectric device. The fluid temperature regulation system is configured to receive a volume of fluid and deliver it to the flow conditioning member and the topper member.
In one embodiment, a temperature control member for use in a climate controlled bed includes a resilient cushion material comprising at least one recessed area along its surface, at least one layer of a porous material, the layer being configured to at least partially fit within the recessed area of the cushion and a topper member being positioned adjacent to the cushion and the layer of porous material, the topper member being configured to receive a volume of air that is discharged from the layer of porous material towards an occupant.
According to some embodiments, a bed comprises a substantially impermeable mattress, having a first side and a second side, the first side and the second side being generally opposite of one another, the mattress comprising at least one openings extending from the first side to the second side, a flow conditioning member positioned along the first side of the mattress and being in fluid communication with the opening in mattress, at least one top layer being positioned adjacent to the flow conditioning member, wherein the flow conditioning member is generally positioned between the mattress and the at least one top layer and a fluid transfer device and a thermoelectric unit that are in fluid communication with the opening in the mattress and the flow conditioning member.
These and other features, aspects and advantages of the present inventions are described with reference to drawings of certain preferred embodiments, which are intended to illustrate, but not to limit, the present inventions. The drawings include twenty-six (26) figures. It is to be understood that the attached drawings are provided for the purpose of illustrating concepts of the present inventions and may not be to scale.
Various features and aspects of the embodiments disclosed herein are particularly useful in climate-controlled beds and similar devices, such as, for example, air chamber beds, adjustable beds, inner-spring beds, spring-free beds, memory foam beds, full foam beds, hospital beds, futons, sofas, reclining chairs, etc. However, it will be appreciated that such features and aspects may also be applied to other types of climate control seating assemblies, such as, for example, automobile or other vehicle seats, office chairs, sofas and/or the like.
With reference to the schematic illustration of
The lower portion 20 can include side rails, top rails and/or other structural and non-structural components that together help define a substantially hollow interior space 21. Some or all of the components to the lower portion 20 can be manufactured from one or more rigid or semi-rigid materials, such as, for example, plastic (e.g., blow molded, extruded, thermoformed, etc.), metal (e.g., steel, iron, etc.), wood, fiberglass, other synthetics and the like.
As illustrated in
In some embodiments, the bed 10 comprises one or more larger openings through air or other fluid can enter the interior space 21. For example, the lower portion 20 can include an opening that extends across along the bottom or other area of the bed 10. Such an opening can encompass the entire bottom surface of the bed or only a portion of it, as desired or required. In some embodiments, such openings can be covered by one or more air permeable fabrics or other layers. For example, a bottom opening in a bed can be covered by one or more layers of an “open-weave” fabric.
Further, if air is temperature-conditioned by a thermoelectric device 40, a volume of waste air downstream may be generated and may need to be removed from the interior space 21. In some embodiments, waste line conduits 48 can be used to deliver waste air or other fluid to outlets 28. The quantity, location, spacing, size, shape, style, configuration and/or other characteristics of the inlets 24 and outlets 28 can be modified as desired or required by a particular application. For example, in some embodiments, the inlets 24 and/or outlets 28 comprise vents that are positioned along the vertical face of the frame 22 as illustrated in
With continued reference to
In some embodiments, the cushion member 64 comprises a recessed area 66 along its top surface. In
As illustrated in
According to some embodiments, the recessed areas 66 of a cushion member 64 and/or any other component of the climate-controlled bed 10 can be configured to receive one or more flow conditioning members 70 or flow distribution members. The terms flow conditioning member and flow distribution members, which can be used interchangeably herein, are broad terms that can include any device, component, item or system capable of changing the flow pattern, direction or distribution of a fluid. As illustrated in
In some embodiments, as illustrated by way of example in
The flow conditioning member 70 can include a porous structure that is configured to receive a volume of air or other fluid from one or more inlets and distribute in a more even manner toward the side closest to the occupant. Thus, the flow conditioning member 70 can be used to advantageously spread the air (or other fluid) flow along its top surface as the air approaches an occupant.
In some embodiments, the flow conditioning member 70 comprises one or more resilient, rigid and/or semi-rigid materials having a porous structure (e.g., honeycomb, mesh, etc.). Such members can be formed using a generally intricate internal structure. For example, a porous foam can be used as the flow conditioning member 70. It will be appreciated, however, that softer or harder materials can also be used to fill the cavity of the recessed area 66, either in lieu of or in addition to foam. For instance, a semi-rigid or rigid thermoplastic, fiberglass and/or any other natural or synthetic material can be used.
The flow conditioning member 70 can include a single member or insert that can be placed within the recessed area 66 of the cushion member 60 (e.g., an insert, a spacer fabric or other component, a porous foam member, a bag or sac, etc.). Alternatively, the flow conditioning member 70 can comprise two or more different components (e.g., layers) that may or may not be attached to one another (e.g., a porous material situated within a shell, bag or the like). In one embodiment, flow condition member 70 includes an outer flange or other protruding member along its upper surface so as to better engage the corresponding surfaces of the cushion member 64. The flange (not shown) can be disposed partially or completely around the flow conditioning member 70 (e.g., air-permeable insert). The flow conditioning member 70 and the cushion member 60 can be separate member that can be attached or not attached to each other. Alternatively, the flow conditioning member 70 and the component into which it is positioned (e.g., the cushion member 60) can form a unitary structure.
Spacer fabrics or other porous structures can be situated within other flow conditioning devices or systems. For example, a spacer fabric, a porous foam, a bag or partial bag (e.g., completely or partially within a bag or similar device), an enclosure or partial enclosure and/or the like can be situated within a fluid distribution bag or other similar enclosure. The size, shape and other characteristics of such a bag/fabric combination can be configured to provide improved distribution coverage while maintaining a desired minimum air velocity. Preferably, the quantity, size and other properties of the fluid transfer devices (e.g., blower, pump, etc.) is selected based the area of the flow conditioning members included within a particular bed. Such a bag could be engineered or otherwise configured such that a fluid is permitted to move in some areas (e.g., towards the occupant) but not in other areas (e.g., the bottom, sides, away from the occupant, etc.).
As discussed, the flow conditioning member 70 can be in fluid communication with the fluid transfer device 40 and the fluid conduits 44, 46 placed therebetween. In addition, where temperature conditioning of air or other fluid being delivered by the fluid transfer device 40 is desired, the air or other fluid can pass through or past a thermoelectric device 50, as illustrated in the schematic of
The embodiments described and/or illustrated herein can use a thermoelectric device 50 for temperature conditioning (e.g., selectively healing and/or cooling) the fluid flowing through the device. A preferred thermoelectric device is a Peltier thermoelectric module, which is well known in the art. Such devices typically include a main heat exchanger for transferring or removing thermal energy from the fluid flowing through the device and to the distribution systems. Typically, such devices also include a secondary (or waste) heat exchanger that extends from the thermoelectric device generally opposite the main heat exchanger. A single fluid transfer device 40 can be used to direct fluid over, through or in the vicinity of the main and/or waste heat exchangers for temperature conditioning purposes. In alternative embodiments, two or more fluid transfer devices can be used to move air or other fluid relative to the heat exchangers. For example, one fluid transfer device can be configured to convey air past the main heat exchanger while a second fluid transfer device can be configured to convey air past the waste heat exchanger.
In
As discussed herein, a single climate-controlled bed 10 can include one, two or more sets of fluid transfer devices, thermoelectric devices, conduits and/or other components. Therefore, the interior space 21 of the lower portion 20 or any other area in which these components are positioned should be sized accordingly.
In some embodiments, the fluid transfer device 40 (e.g., fan, blower, etc.) and the downstream thermoelectric device 50 can be included as part of an integrated design, e.g., an integrated module. Therefore, the need for a separate conduit 44 to deliver air or other fluid from the fluid transfer device 40 to the thermoelectric device 50 can be eliminated.
With continued reference to
With continued reference to
In addition, it will be appreciated that one or more layers or members can be added above, below and/or between the various components of the climate-controlled bed assemblies described and illustrated herein. Such layers or members can be used to provide additional comfort (e.g., cushioning), fatigue-relief and/or other advantages to an occupant. For example, an additional comfort layer or component can be included between the cushion member 64 and the top member 80. Moreover, such topper layers or members can be configured to provide resistance to fire and/or other hazards or elements.
Further, the bed can also comprise a heating device (e.g., resistive wire heater, heating pad, etc.) to supply heat and allow air to flow for cooling comfort. In addition, a non-slip friction layer can be positioned between the lower portion 20 and the upper portion (e.g., cushion member 64) to help prevent undesirable movement between the two portions.
One or more components of the bed 10, such as, for example, the top member 80 and the cushion member 64, can include a covering material (not shown). The covering material can be used to advantageously join various members and components of the bed together. According to some embodiments, the covering material is generally air-permeable and comprises a natural or synthetic fabric and/or the like.
In operation, according to one embodiment, ambient air enters the interior space 21 of the lower portion 20 of the bed via one or more inlets 24. As discussed, the bed can comprise one or more larger openings to permit air or other fluid to approach the fluid transfer devices 40. For example, the lower portion 20 can include an opening that extends across along the bottom or other area of the bed. Such an opening can encompass the entire bottom surface of the bed or only a portion of it, as desired or required. In some embodiments, such openings can be covered by one or more air permeable fabrics or other layers. For example, a bottom opening in a bed can be covered by one or more layers of an “open-weave” fabric.
The air is then drawn into an intake of one or more fluid transfer devices 40 and is conveyed past a thermoelectric device 50 using tubing or other conduit 44. The volume of air flowing past the main heat exchanger of the thermoelectric device 50 is selectively cooled and/or heated before being directed to the cushion member 64 of the upper portion 60 of the bed 10. This volume of temperature-conditioned air then enters one or more flow conditioning members 70 where it can be re-distributed toward the top surface of the bed 10. Alternatively, air or other fluid need not be temperature conditioned before being delivered to a flow conditioning member 70 or similar component. For example, air or other fluid can be delivered through, past or in the vicinity of a thermoelectric device that is not energized (e.g., not configured to cool or heat). In other embodiments, a fluid transfer device need not direct fluid through a thermoelectric device or other cooling/heating device at all.
Therefore, in some embodiments, the thermoelectric devices 50 can be turned on or off depending on whether thermal conditioning is desired or required. Further, the amount of thermal conditioning occurring to the fluid directed past a thermoelectric device 50 or other temperature conditioning device can be varied. In other words, the extent to which air or other fluid is temperature conditioned can be advantageously controlled by varying the voltage or electrical current being supplied to a thermoelectric device. Thus, the thermoelectric devices 50 can be configured to provide different amounts of heating and/or cooling based on the electrical current being supplied to them and/or other factors. Further, the speed of the fluid transfer devices 40 can be varied to control how much fluid is transferred to the flow conditioning members 70, either in addition to or in lieu of adjusting the extent of cooling or heating occurring at the thermoelectric device's heat exchangers.
In other embodiments, one or more other methods of controlling the temperature and/or fluid flowrate can be used. For example, one or more valves or other flow or pressure regulating devices can be used within the fluid distribution system between the fluid transfer devices 40 and the flow conditioning members 70. In other embodiments, the back pressure of the air delivery system can be advantageously adjusted to provide the flowrate and temperature of fluid to the bed assembly. In some arrangements, this can be accomplished at least in part by the use of valves or other flow or pressure regulating devices. In yet other embodiments, the types of spacer fabrics, flow conditioning members and/or other components of the climate controlled bed assembly can be modified to achieve the desired thermal conditioning effect.
The air can then flow toward an occupant situated on the bed 10 by passing through one or more air-permeable top members 80. In addition, a volume of ambient air flowing toward the thermoelectric device 50 will be directed to the waste heat exchanger where it also undergoes temperature conditioning (e.g., if air is cooled as it passes the main heat exchanger, air is heated as it passes the waste heat exchanger, and vice versa). This volume of waste air is then conveyed away from the interior space 21 of the lower portion 20 through one or more outlets 28. Alternatively, the waste air can be discharged into an interior portion 21 of the lower portion 20 without the use of a conduit to convey it from the thermoelectric device 50 to an outlet 28.
As discussed, the cushion member 64 need not include a recessed area. For example, in the embodiment of the bed 10′ illustrated in
As discussed, a climate-controlled bed 10A can include one, two or more fluid transfer devices 40A, 40B, 40C, thermoelectric devices 50A, 50B, 50C and other related components. By way of illustration, the bed 10A depicted in
With continued reference to
As shown in
In the embodiment illustrated in
As illustrated in
In
In other embodiments, as discussed with reference to
With reference to
With continued reference to
In
With continued reference to
The embodiment of the climate-controlled bed 210 illustrated in
With continued reference to the top view of
Moreover, the frame structure 322 depicted in
With continued reference to
In any of the embodiments illustrated herein, such as, for example, the climate controlled beds shown in
With reference to
With further reference to
As shown in the cross-section view of
In order to assist in better distributing air or fluid flow that enters the flow conditioning members 570 situated within the recessed areas 566 of the upper portion 560, a flow diverter 571 can be placed on the top surface of one or more flow conditioning members 570, as shown in
The use of diverters can be used to provide a more uniform distribution of the fluid to the occupant due to the fact that conditioned fluid may appear to originate in a single spot. Such diverters can be configured to move the fluid laterally through one or more distribution layers. The use of diverters 571 can be used to provide a more uniform distribution of the air or other fluid being delivered to an occupant. By strategically positioning such diverters 571 in the vicinity where air flow enters the recessed area of the cushion member 564, air is spread laterally throughout the corresponding flow conditioning or distribution members 570.
As discussed, the flow conditioning member 570 can comprise a spacer fabric/fluid distribution bag combination that is inlaid into another filler material. However, a spacer fabric or other similar flow distribution or flow conditioning member can be used with any of the embodiments of a climate controlled bed disclosed herein without the use of a bag or other enclosure. In some embodiments, if the bag/fabric member is undersized, the occupant may not realize adequate distribution coverage. The bag or other enclosure can comprise a plurality of openings through which air or other fluid can exit. In some embodiments, the use of a bag can help serve as a diverter to provide more enhanced distribution of air or other fluid within a spacer fabric or other flow conditioning member. In addition, the inlaid spacer fabric or other flow conditioning member 570 can include edges that are generally sealed in order to reduce or prevent lateral airflow to selected areas. Alternatively, if the filler layer includes non-porous areas, such sealed edges or other features may not be required.
With continued reference to
Another embodiment of an upper portion 660 for use in a climate-controlled bed 610 is illustrated in
With continued reference to
Stitching can also be used to control unwanted lateral flow of fluids. For example, stitches can be added around the perimeter of the device to prevent the fluid from moving outside one or more desired conditioned areas. The use of the proper stitching compression, patterns and/or other features can help provide a path for the fluid (e.g., air) to flow toward one or more occupants. The size of the stitching and the density of the stitches can be modified or otherwise controlled to provide even fluid distribution to an occupant. Thus, by using even only a single sheet of spacer fabric and controlling the flow of fluid using stitching, lamination and/or other systems, a more cost effective upper portion 660 or topper assembly can be realized. Accordingly, engineered stitching and/or other similar features can allow for improved fluid flow while enhancing the comfort level for an occupant.
As described in the various embodiments herein, climate-controlled beds require some means of moving air or other fluid through the top surface of the bed (or similar assembly) in the direction of one or more occupants. However, it should be appreciated that beds constructed of solid or substantially solid cores may require alternative solutions. This is especially important since solid core beds are becoming increasingly more popular. As discussed herein, the solid cores of such bed assemblies can be to channel fluids for improved distribution toward an occupant and/or to channel waste air or fluid away from a climate controlled bed assembly.
The cross-sectional view of
As illustrated in
In
Likewise, as illustrated in
One important consideration associated with moving fluids within an air conditioned bed is accommodating fluid intakes and exhausts. Thus, in some embodiments of the devices and systems illustrated and disclosed herein, the fluid delivery system advantageously includes an efficient means of receiving fluids from the surrounding environment and delivering them to the bed or other seating assembly.
In some embodiments, it may be desirable for the fluid intake to be located in an area that reduces noise or other occupant discomfort. Further, the intake can be isolated from other undesirable fluids that may enter the fluid distribution system. In one embodiment, one or more ducts can be used to reduce such undesirable contamination or mixing. However, it should be appreciated that the use of ducts can generally increase the cost, complexity, possibly failure modes and the likelihood of other undesirable occurrences, as they may become detached or otherwise become compromised.
In some embodiments, as shown in
Further, it may be desirable to reduce the level of noise generated by the fluid transfer device (e.g., fan, blower, combination fan/TED device, etc.). For example, the noise reduction can help make the environment more conducive for sleeping or resting. Foam or other sound reducing materials can be used as liners on the inside of the bed skirt or other components of a climate-controlled bed assembly to help reduce the sound that originates from within or under the bed.
In addition, as beds are presently being constructed using a number of new techniques, it is important to provide air conditioned bed components or stand-alone toppers that are capable of integrating with such new designs and making use of their inherent advantages.
Another embodiment of a climate-controlled bed assembly is illustrated in
The various embodiments described herein can include one or more control strategies or features to further enhance the operation and function of the climate-controlled bed assembly. For example, the bed can include a control system that is configured to regulate the air temperature and/or velocity of the temperature-conditioned fluid. In some embodiments, this can be accomplished by modifying the speed of a fluid transfer device (e.g., fan, blower, etc.) and/or varying the direction and/or magnitude of electrical current being delivered to the system's thermoelectric devices. Accordingly, the climate controlled bed can include one or more control schemes which regulate the operation of the various components of the climate control system. In some embodiments, the climate control system can be incorporated into the climate controlled bed assembly (e.g., either directly on the bed, via a separate controller and/or the like).
With continued reference to the system's control features, the climate-controlled bed assembly can be configured to measure and record the temperatures at one or more locations or of one or more system components. Such data can be advantageously incorporated into a control scheme. For example, the temperature at or near the surface of the bed (e.g., the temperature which most accurately assesses what an occupant feels) can be measured and provided to a control module for display, automatic temperature adjustment and/or the like. Further, the control components of the system can be in the form of a closed loop.
In some embodiments, a wand or some other type of remote controller can be used for occupant interaction. For example, the temperature at or near the surface of the bed can be displayed on the wand. Additional control capabilities, such as, for example, temperature adjustment, mode selection, ON/OFF, etc., can also be included. For instance, the wand can permit a user to select “SLEEP” mode wherein the temperature and volume of air being conditioned and delivered toward the occupant is adjusted according to that occupant's desired sleep environment and/or ambient conditions. In one arrangement, the climate-controlled bed can include a thermal alarm that helps to adjust (e.g., increase, decrease) temperatures at or near the surface of the bed to generally coincide with biological increase or other changes in an occupant's body temperature at or near the end of the sleep cycle.
In addition, as discussed herein with respect to certain embodiments, the bed can also comprise various heating and/or cooling zones to allow an occupant to customize the temperature and feel at various portions of the bed. Further, such a feature allows each occupant using a single bed to select a desired operational mode. Further, the bed can include one or more power supplies (e.g., AC outlet, DC power, such as a rechargeable battery, etc.). Such power supply modules and components can be discretely positioned on or within selected areas of the bed assembly.
With continued reference to the bed's climate control system, it will be appreciated that the devices, systems and methods described herein can be used in conjunction with other devices, systems and methods to further enhance the effectiveness of heating and/or cooling. For example, the beds can comprise a sterling pump. Further, the bed can be configured to utilize advantages related to the use of phase change materials and the use of water towards temperature control. Moreover, as discussed, thermally conditioned air or other fluid can be directed to selected areas of the bed, such as, for example, the pillow, lower back, legs, etc. For instance, an occupant can choose to provide relatively cool air to his or her head, while providing warmer air to his or her feet.
The effectiveness of the bed's climate control system can be further enhanced by returning temperature conditioned air back to the fluid transfer device. In addition, the in some embodiments, a thermistor can be positioned within or on one or more topper members, cushion members and/or other components of the climate-controlled bed. In alternative embodiments, a thermistor can be positioned generally next to an occupant, such as, for example, near the occupant's side, head, foot, pillow and/or the like.
In some embodiments, the climate-controlled bed assembly can comprise a radio alarm that can be configured to work in conjunction with a thermal alarm to turn on and/or off at particular times. As with other operational features, this can be customized by an occupant to his or her preference.
The flow conditioning members, such as inserts, can include liners and/or coating for enhanced protection against moisture or other substances, for enhanced air impermeability (where desired) and/or the like. The use of certain coatings, linings, materials and/or the like can help reduce thermal losses while the conditioned air is being transferred within the climate control system. Further, the use of separate liners can facilitate the manufacture, assembly, repair, maintenance and/or other activities related to climate-controlled bed assemblies. In addition, according to some embodiments, some or all of the channels, recesses and other features in the bed assembly can be advantageously molded at the time the respective component is being manufactured. Alternatively, these features can be cut-out or otherwise shaped after the respective items are constructed.
In addition, in order to prevent damage to the internal components of the climate control system (e.g., fluid transfer device, thermoelectric device, conduits, flow conditioning members, etc.) and to enhance the quality of the air being used to selectively heat and/or cool the bed, one or more intake filters can be positioned upstream of the fluid inlet into the climate control system. According to some arrangements, the filter comprises a dust cover or a similar device. In some embodiments, such filters can be scented to provide a more pleasant environment for the bed's occupant.
Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while the number of variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to perform varying modes of the disclosed inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.
This application claims the priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/851,574, filed Oct. 13, 2006 and U.S. Provisional Application No. 60/971,197, filed Sep. 10, 2007, the entirety of which is hereby incorporated by reference herein.
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