The present invention relates to climate control of sleeping surfaces such as mattresses and mattress toppers, and more generally to air-conditioning of sleep environments.
Many people suffer temperature and humidity related discomfort when trying to sleep. Many people have difficulty sleeping because they feel too hot, too cold, or suffer from night sweating. Many such people do not find sufficient relief from being too hot by merely cooling the room where they sleep because the sleep surface becomes too warm where the sleeper's body rests. There are existing mattresses or other devices that provide some airflow through, or around, the sleep surface, but do not provide for cooling directly beneath the surface of the sleeper's body, where the body may block vertically-orientated air passages preventing or reducing cooling directly beneath the sleeper's body. Although there are devices intended to address this problem, there is no effective mattress topper that provides thermal and humidity amelioration in a format suitable for use upon an existing bed and mattress.
In one mattress topper, temperature-controlled liquid is directed to flow through a network of fluid-carrying channels arranged in a blanket-like layer positioned upon the mattress surface to control the temperature of the sleep surface. But although such mattresses provide surface cooling, they provide no facility for removing excess humidity and hot air from the sleep environment. The sleep environment as described herein is intended to mean the space between the sleep surface on which a sleeper lies, and the bedding (e.g. sheets and blankets or duvet) under which the sleeper typically lies.
Other devices use forced air introduced directly into and moving through the sleep environment, or over the sleeper, to effect thermal and humidity amelioration, but do not cool the surface beneath the sleeper. The sleeper in this case typically continues to experience discomfort at the surface where the sleeper's body contacts the sleep surface.
Yet other devices provide for cooling the surface and the sleep environment by passing conditioned air through the surface of the bed, but require the use of a specialty bed having a configuration or thickness or rigidity unsuitable for use as a mattress topper. A sleeper who wants to use an existing bed or mattress, in this case, cannot do so.
A mattress topper for providing improved comfort to a sleeper comprises a pressure distribution layer defining an interior volume. The pressure distribution layer has substantially air-impermeable side walls and a substantially air-impermeable base, and a top surface having at least a region that is air permeable. The pressure distribution layer further comprises a support material contained within the interior volume, the support material having high air permeability and mechanical strength sufficient to substantially maintain separation of the top surface of the distribution layer from the base of the distribution layer when a sleeper lies upon the mattress topper. The mattress topper further comprises at least one air inlet port, and at least one electrically powered air circulation device for drawing air into the interior volume of the pressure distribution layer via the at least one air inlet port. A lateral air-flow layer is disposed above the pressure distribution layer and is configured to provide air flow both upwardly and laterally. In some embodiments the pressure distribution layer is configured to provide substantially unimpeded air flow both upwardly and laterally.
In some embodiments of the above-described mattress topper, the lateral air-flow layer comprises an air-permeable first surface, and an air-permeable second surface separated by substantially vertically oriented polymer fibers joined at one end to the first surface and at an opposite end to the second surface, the fibers spaced so as to allow air flow between the first surface and the second surface. In some embodiments the fibers are spaced so as to allow substantially unimpeded air flow between the first surface and the second surface.
In some embodiments of the above-described mattress toppers, the mattress topper further comprises a resilient comfort layer disposed between the pressure distribution layer and the lateral air-flow layer. The comfort layer has air passages extending through its thickness to allow air escaping from the pressure distribution layer to pass through the comfort layer substantially below the sleeper's body, while substantially preventing air flow not close to the sleeper's body.
In some embodiments of the above-described mattress toppers, the mattress topper further comprises a controller housed within the interior volume of the pressure distribution layer, for controlling operation of the air circulation device. In some embodiments the controller is configured for wireless communication. In some embodiments of the above-described mattress toppers, the mattress topper further comprises a manual control device, for controlling or adjusting operation of the mattress topper.
In some embodiments of the above-described mattress toppers, the at least one air circulation device is disposed within the interior volume of the pressure distribution layer. In some embodiments, an air circulation device is situated in each of four corner regions of the pressure distribution layer.
In some embodiments of the above-described mattress toppers, the mattress topper further comprises at least one heating element situated in the top surface of the pressure distribution layer.
In some embodiments of the above-described mattress toppers, the mattress topper further comprises at least one temperature sensor.
In some embodiments of the above-described mattress toppers, the mattress topper further comprises an air-permeable cover housing the pressure distribution layer and the lateral air-flow layer.
This summary does not necessarily describe the entire scope of all aspects. Other aspects, features, and advantages will be apparent to those of ordinary skill in the art upon review of the following description of specific embodiments.
It is to be understood that the attached drawings are provided for the purpose of illustrating various embodiments and aspects of the present invention and may not be to scale.
Air-conditioned mattress toppers, as described herein, can be used for improving the temperature and humidity comfort of a sleeper and can be used in conjunction with the sleeper's existing mattress or bed. Some embodiments of such mattress toppers are sufficiently thin and conformable to be used on top of an existing mattress or bed without adversely affecting the physical comfort of the existing mattress or bed. In some embodiments, sufficiently thin means having a thickness less than 3 inches. In some embodiment, sufficiently thin means having a thickness less than about 2 inches. In some embodiment, the air-conditioned mattress topper has a thickness in the range of about 1 to 3 inches. In some embodiment, the air-conditioned mattress topper has a thickness in the range of about 1 to 2 inches. In some embodiments, sufficiently conformable means being so deformable and flexible so that perceived deformability of the underlying mattress is not significantly affected by the presence of the mattress topper.
Embodiments of the mattress toppers described herein comprise features that can address difficulties of achieving properly distributed air flow within a mattress topper, without the use of pipes or other somewhat rigid conduits, and without generating significant acoustic noise when creating a desired level of air flow. It can be challenging to achieve air flow and sufficiently uniform distribution of air flow within a thin mattress topper, for example, due to frictional losses. Addressing these issues by increasing air pressure is generally undesirable because the generation of the high air pressure by the use of fans or blowers can create a level of acoustic noise that disrupts sleep, and is therefore undesirable for sleepers. Embodiments of the mattress toppers described herein provide for well-distributed, low-pressure movement of air through the thin structure of the mattress topper without generating acoustic noise having a significant volume, or undesirable timbre. Low noise and well distributed flow can be accomplished by using highly permeable interior materials and by locating blowers so as to minimize or reduce the distance between the blowers and the sleeper's typical position where the air exits the mattress topper. Accordingly, in some embodiments blowers are located in the four corner regions of the mattress topper, outside the sleep area. In some embodiments blowers are located in just the two corners at the foot-end of the mattress topper. The blowers can also be suspended by foam structures and surrounded by foam structures, thus minimizing or reducing conduction of blower vibration and sound. Embodiments of the mattress toppers described herein can be used to provide cooling directly under the sleeper's body, and cooling in the sleep environment beneath the bedding that is normally covering the sleeper. This is accomplished by the forced distribution of air through the mattress topper, with some air passing directly beneath the sleeper's body cooling the surface contacting the sleeper's body, and at least some of the air being exhausted from the sleep environment carrying away heat and humidity. In some embodiments, the mattress topper also comprises heating elements for warming the sleep surface and sleep environment, for use in situations where the sleeper desires heating instead of cooling.
Thus, the air-conditioned mattress toppers described herein can be used to control or adjust the temperature of a sleep environment by moving conditioned forced air within and through the mattress topper. Embodiments of the mattress topper have air-conditioning, control, heating, and temperature sensing elements contained within an air-permeable cover. In use, the mattress topper is positioned on top of a mattress for providing cooling and/or heating of a sleeper who lies on the mattress topper. Preferably, the mattress topper has a thin thickness of two inches or less and is sufficiently pliable so as to not adversely affect the comfort of the underlying bed. Cooling is provided by movement of ambient air from outside the mattress topper, drawn into the mattress topper by electric blowers, such as Toyon TD7025k centrifugal blowers, or other suitable devices, such air passing within the mattress topper and eventually exiting through the upper surface of the mattress topper. In some embodiments, heating can be provided by heating the interior of the mattress topper by passing electric current through an array of heating wires embedded in the topper, so that the surface of the mattress topper achieves an elevated temperature. In some embodiments, the mattress topper comprises a lower layer, a comfort layer, an upper layer and, in some embodiments, an encasement or cover. The lower layer contains one or more air circulation devices, such as blowers, fans or pumps. These can be electrically powered and, in operation, draw air into the lower layer of the mattress topper and move the air within and through the lower layer. The lower layer is preferably structured so that the pressure within it is substantially equalized, for example, as described in further detail below. The comfort layer comprises a soft and/or resilient material with a plurality of air passages extending through the thickness of the material from one major surface to the other. In some embodiments, the comfort layer comprises a foam rubber material. In some embodiments, the upper layer comprises a three-dimensional structured textile configured to allow upward and lateral movement of air. The above-described layers and their components can be contained within an air-permeable encasement or cover. The cover can be, for example, a zippered cover that can be removed for cleaning, or to allow access to the components of the mattress topper that are housed therein.
The elements are configured to draw air at ambient temperature from the surrounding environment into the lower layer, pressurizing the lower layer substantially equally throughout the interior volume of the lower layer. The lower layer has a top surface that is somewhat air permeable. In some embodiments, a substantially impermeable comfort layer is positioned on the somewhat air-permeable top surface of the lower layer, and the comfort layer limits air flow except where air passages extending through the thickness of comfort layer provide for air to pass. The air passages are positioned so as to be substantially beneath the sleeper's body. The upper layer of the mattress topper is configured to allow air from the air passages to pass through the upper layer and, encountering the surface of the sleeper's body, to pass laterally within the upper layer to provide heating or cooling to the sleeper's body, and particularly the surface of sleeper's body that lies in contact with the top surface of the mattress topper. The air eventually exhausts into the sleep environment, further cooling those parts of the sleeper's body which do not contact the surface of the mattress topper, and finally exiting the sleep environment carrying heat and excess moisture from the sleep environment.
In some embodiments the air-conditioned mattress topper has an associated control system that responds to sensor inputs, algorithms and parameters to adjust the degree of heating and/or cooling that the mattress topper applies to the sleeper's body. The control system can provide sleep diagnostics (assessing quality of sleep) and may have learning algorithms that use sleep diagnostics to adjust heating and/or cooling controls so as to seek to maintain optimal sleep quality.
Referring now to the drawings
Referring now to
Considering now the internal layers of the mattress topper 10, each in turn,
A controller 35 is also located within the interior volume of pressure distribution layer 24. Controller 35 controls electrically powered components in the mattress topper, such as air circulation devices 32 and heating elements 36, and receives signals from at least one temperature sensor 37 and other sensors (not shown in
In practice, controller 35 may automatically control the temperature of the mattress topper based on pre-programmed parameters, inputs from sensors and/or inputs from the sleeper. In some embodiments, the sleeper can affect inputs by operating communication device 92 to set operational modes, and to set operational parameters such as start time, end time, and baseline temperature. Controller 35, when configured in an automatic mode of operation, may begin controlling temperature of the mattress topper at the start time, and responding to temperature sensors 37, baseline temperature, and current time, adjust air circulation device(s) 32 and heating elements 36 in order to achieve a temperature in the mattress topper that is related to the baseline temperature set by the sleeper. In another mode of operation, the sleeper may control the temperature directly without automatic controls and may directly adjust the temperature using communication device 92, or by operating manual buttons 96 on manual control device 94 connected to controller 35 and accessible from the outside surface of the mattress topper 10, as shown in
In some situations, separate mattress toppers (each housed in a separate an air-permeable cover) can be placed side by side on one bed. For example, two single- or twin-sized mattress toppers can be place side-by-side on a king bed. In some embodiments of the mattress toppers described herein, individual mattress toppers can be produced in various sizes to fit different sizes of bed (for example, a single, twin, double, queen or king bed). Mattress toppers for larger beds may have additional blowers, heating elements, temperature sensors, and the like, relative to mattress toppers for smaller beds. In some embodiments, for beds that accommodate two sleepers, operating parameters for each side of the mattress topper can be independently controlled. In some embodiments, the mattress topper has two portions internally (each with its own pressure distribution layer having an air-flow restrictive top surface), but with a combined lateral air-flow layer overlying both pressure distribution layers, and an optional shared comfort layer disposed between the side-by-side pressure distribution layers and the combined lateral air-flow layer, all housed in an air-permeable cover.
It is contemplated that part of any aspect or embodiment discussed in this specification can be implemented or combined with part of other aspects or embodiments discussed in this specification.
While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, that the invention is not limited thereto since modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings.
This application claims priority of U.S. Provisional Application No. 62/862,762, filed on Jun. 18, 2019, the disclosure of which is incorporated by reference in its entirety.
Number | Date | Country | |
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62862762 | Jun 2019 | US |