The present application is generally related to sleep products including mattresses, mattress toppers and pillows, and is more specifically related to mattresses, mattress toppers and pillows containing gels utilized for providing a cool sleeping surface. The present application is also related to pillow covers having gel layers for providing cool sleeping surfaces for pillows.
In one embodiment, the present application includes a flexible gel panel disposed atop a mattress of a bed. In one embodiment, the gel panel may be placed atop a mattress and under a fitted sheet secured over the mattress. In one embodiment, the flexible gel panel may be sewn into or incorporated into a bed covering such as a mattress topper or a fitted sheet. In one embodiment, the flexible gel panel may be incorporated into a pillow or a pillow case.
In one embodiment, a gel panel includes a cured gel layer that is disposed between a flexible top layer and a fabric bottom layer. The gel layer preferably includes one or more well-known gel materials such as a polyether gel that is cured and bonded to the top layer and the bottom layer.
In one embodiment, the flexible top layer is a TPU film (e.g., a polyurethane film), such as that sold by American Polyfilm, Inc. of Branford, Conn.. The TPU film may be provided on rolls. In one embodiment, the TPU film has a thickness of about 1 mil, and a width of up to 70 inches or more.
The TPU film preferably exhibits a polyurethane film's mechanical properties such as high durability, abrasion resistance, and low temperature flexibility.
In one embodiment, the fabric bottom layer may be a flexible fabric. In one embodiment, the fabric bottom layer is a four way stretchable non-woven fabric. Decorative borders, trim, quilting and other features and options may be used to enhance the aesthetics and “hand” of the product.
In one embodiment, the flexible gel panel includes a clear top layer, a central gel layer, and a fabric bottom layer. The clear top layer and the fabric bottom layer are desirably bonded to the gel layer during curing of the gel layer. The assembled gel panel may be sewn into a finished cover. The cover may include a gusset, a false gusset, a zippered removable insert, and/or a “skirt” that is adapted to stretch down and around a mattress.
In one embodiment, the bottom layer may include a phase change fabric such as that sold by Outlast. In one embodiment, the fabric bottom layer may include a lightweight fabric and/or a mesh fabric to allow for maximum cooling benefit.
In one embodiment, a single gel panel or a series of gel panels may be incorporated into a single unit. The configuration and size of a flexible gel panel may be modified to accommodate beds having different sizes such as Extra Twin—75″×39″; Full—75″×54″; Queen—80″×60″; King—80″×76″; and California King—84″×72″.
The flexible gel panels may be fabricated and/or modified to accommodate various percentages of a surface area, i.e. the entire surface, a partial surface area, a single zone of a surface area, or multiple zones of a surface area.
In one embodiment, the flexible gel panel has a thickness of about 0.1-10 mm, which may be determined by the depth of the mold that is used for fabricating the gel panel.
Although the present invention is not limited by any particular theory of operation, it is believed that incorporating flexible gel panels into sleep products provides a cooler surface temperature for an extended period of time, which enables more restful and rejuvenating sleep. Many sleep products now incorporate memory foam. Studies have shown that memory foam is in insulator. As a result, memory foam products are typically known as having “hot” sleep surfaces. The present invention incorporates a flexible gel panel into a memory foam topper or mattress, or a gel panel may be used as a stand-alone unit to provide an initially cooler sleep surface to assist a user in falling asleep more easily.
As documented in Example 1 below, during use, sleep products having flexible gels or flexible gel pads incorporated therein take longer to warm. In fact, as shown in Example 1, when a gel topper or gel panel is used in combination with a foam pad or on top of other materials, it takes up to 5.5 times longer for the gel to warm to temperature levels when compared to sleep products in which gels are not utilized.
In one embodiment, the flexible gel panel may be removed from the sleep product such as a mattress topper or pillow case so that the sleep product may be laundered. After the sleep product is laundered, the flexible gel panel may be re-inserted into the sleep product. In one embodiment, the sleep product may include one or more fasteners that may be opened for removing the gel panel prior to laundering the sleep product. After the gel panel has been re-inserted back into the laundered sleep product, the one or more fasteners may be closed. The one or more fasteners that may be used include zippers, Velcro® fasteners, buttons, hooks, stitching and/or thread.
In December 2011, the Dr. Oz Show profiled one of Applicant's products as being a Top 12 healthy item for use in 2012. Dr. Oz selected a memory foam pillow with a gel panel because its use promoted better sleep and a healthier lifestyle.
Dr. Oz stated that research has indicated that sleep deprivation causes weight gain. In particular, decreased sleep activates a hormone that increases appetite. Obtaining an appropriate amount of sleep can burn up to 300 more calories per night. That equates to about 30 lbs in a year.
During another program, Dr. Oz introduced a sleep doctor, Dr. Michael Breus, author of a book entitled, “The Sleep Doctor's Diet Plan.” Dr. Breus explained that there is a direct relationship between sleep and weight control. A lack of sleep causes an increase in cortisol production and an increase in appetite. An increase in cortisol levels also makes individuals crave high carbohydrate and high fat foods. Less sleep also results in individuals having less REM sleep, which is the type of sleep during which most calories are burned. Dr. Breus also talked about other hormones related to lack of sleep and concluded with a statement that there are many reasons why sleep and weight control are directly related. Dr. Oz stated, “I did the math and if you can increase just one hour a night of sleep (from 7 to 8 hours) you'd lose 14 lbs in a year.”
Although the present invention is not limited by any particular theory of operation, it is believed that providing a cooler sleep surface using a gel layer will enable individuals to fall asleep faster, which will allow the body to sleep more, and help individuals lose weight.
These and other preferred embodiments of the present invention will be described in more detail below.
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In one embodiment, the grooves 30 of the mold may have other shapes such as square, circular, triangular, or other geometric shapes or patterns. In one embodiment, the grooves 30 of the mold may be multi-dimensional.
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In one embodiment, the first and second mold parts 20, 20′ are closed, whereby the fabric sheet 36 conforms to the shape of the grooved face of the second mold part 20′. Heat and pressure are preferably applied to the laminate through the first and second mold parts 20, 20′ to form a flexible gel panel 40 including a TPU film 34, a gel layer 38, and a flexible fabric layer 36. The flexible gel panel 40 preferably has a first surface 42 that conforms to the grooved face of the first mold part 20 and a second surface 44 that conforms to the grooved face of the second mold part 20′.
In one embodiment, the second mold part 20′ is not used. After the gel is dispensed atop the first mold part 20, the fabric layer 36 is placed over the top surface of the gel material and the gel is cured, whereby the fabric layer 36 is bonded to the top surface of the gel layer. The fabric layer 36 preferably conforms to the shape of the cured gel layer for mirroring the shape of the cured gel layer.
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One embodiment of the present invention discloses gel that is arrayed as elongated gel tubes. In other embodiments, however, the gel of the gel panel may have a different pattern or shape, such as a square pattern or shape, a circular pattern or shape, a multi-dimensional pattern or shape, or other geometric patterns or shapes (e.g. triangular).
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Various sleep products were tested to determine how long it took for the products to warm to certain temperature levels and to record the maximum temperature for each of the sleep products. As documented below, during use, sleep products having flexible gels or flexible gel pads incorporated therein take longer to warm, and may take up to 5.5 times longer to warm to certain temperature levels when compared to sleep products in which gels are not utilized.
Each of eight submitted samples was subjected to a temperature monitoring test. The eight submitted samples were as follows:
Each sample was subjected to a temperature monitoring test whereby a thermocouple was placed in the following locations of the samples: the center of the top surface, at the point of heat application; the center of the bottom surface; the center of the interior (embedded in filling); and the outer edge. An electronic heating pad was placed in the center of each sample. The electronic heating pad was made in China and was distributed by Kaz, Inc. model number HP750. The heating pad was set to the temperature setting that maintained a temperature of 90° F.+/5° (32° C.+/−)3° . A weight of 20 lbs. was placed on the heating pad. The temperature at each thermocouple was monitored for 90 minutes, with a reading taken every 30 seconds. The electronic heating pad was removed for the last 30 minutes of the test. During the test, a thermal image of each sample was taken at 10 minute intervals. The test results for each sample are provided in the charts below.
Based on the resting results, Sample 1—the Foam/Gel Pillow sample, exhibited the lowest thermal conductivity properties compared to all of the other samples evaluated. Under the same heat load conditions (which simulated actual use), it took the Foam/Gel Pillow (gel side up) approximately 5.5 times longer to reach its maximum temperature, and its maximum temperature, was on average, 7° C. lower than the other samples evaluated.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, which is only limited by the scope of the claims that follow. For example, the present invention contemplates that any of the features shown in any of the embodiments described herein, or incorporated by reference herein, may be incorporated with any of the features shown in any of the other embodiments described herein, or incorporated by reference herein, and still fall within the scope of the present invention.
The present application claims benefit of U.S. Provisional Application No. 61/757,115, filed Jan. 26, 2013, entitled ‘COOLING GEL PANELS INCORPORATED INTO PILLOW CASES, MATTRESSES AND MATTRESS TOPPERS”, and U.S. Provisional Application No. 61/592,396, filed Jan. 30, 2012, entitled “GEL PANELS FOR USE WITH MATTRESSES AND MATTRESS TOPPERS”, the disclosures of which are hereby incorporated by reference herein.
Number | Date | Country | |
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61757115 | Jan 2013 | US |