BODY SUPPORT SYSTEM

TECHNICAL FIELD

The present disclosure generally relates to body support systems, and more particularly to furniture having features configured to enhance air flow therethrough.

BACKGROUND

Sleep is critical for people to feel and perform their best, in every aspect of their lives. Sleep is an essential path to better health and reaching personal goals. Indeed, sleep affects everything from the ability to commit new information to memory to weight gain. It is therefore essential for people to use bedding that is comfortable in order to achieve restful sleep.

Many different types of body supports, such as, for example, furniture and bedding include a spring assembly or spring pack to provide cushioning. For example, mattresses may include a plurality of springs that form a spring assembly or spring pack. Many mattresses have been designed to prevent heat from building up on a sleep surface of the mattress so that the sleep surface remains cool as a sleeper rests his or her body on the sleep surface. Some conventional spring assemblies/packs position at least some of the springs in fabric pockets to create strings of springs that are arranged to form the spring assembly/pack. Typically, a pocketed spring is manufactured at the same time as a plurality of other pocketed springs by encasing all of the individual springs in a common fabric. The effect is each pocketed spring is connected to adjacent pocketed springs via the single fabric to form a unitary spring assembly/pack. A spring assembly/pack is most often rectangular (with a row and column layout for the springs) and is dimensioned according to intended usage.

The encasing fabric is typically made from a non-air permeable material, e.g., polypropylene, which generally blocks air flow therethrough. However, the standard manner in which the single fabric joins the pocketed springs to form a spring assembly/pack usually creates spaces in between the pocketed springs. The manner of manufacture as well as density of springs and spring assembly/pack dimensions will determine the sizing of the spaces. As a consequence of the spaces, a measure of air flow through the spring assembly/pack is made possible. This contributes to the comfort of a user of a mattress (or other bedding and/or furniture using a pack) by providing some cooling to the sleep surface by reducing heat from building up on the sleep surface. However, the volume of the spring assembly/pack is mainly composed of pocketed springs (and not spaces) that block air flow therethrough, both vertically from top to bottom and laterally from end to end. As such, these spring assemblies/packs do not allow for sufficient air flow around and through the spring assembly/pack. Air therefore becomes trapped in and/or around the spring assembly/pack, which reduces and/or prevents proper air flow through the mattress and thus causes unwanted heat to build up on the sleep surface of the mattress. This disclosure describes an improvement over these prior art technologies.

SUMMARY

In one embodiment, in accordance with the principles of the present disclosure, an assembly comprises a fabric having opposite top and bottom walls and a side wall extending from the top wall to the bottom wall. The side wall is air permeable. A spring is encased by the fabric. In some embodiments, the top wall is non-air permeable. In some embodiments, the side wall includes a perforated material. In some embodiments, the side wall includes a perforated material, the perforated material configured to allow airflow therethrough at a rate of at least about 100 cubic feet per minute. In some embodiments, the top wall includes a non-perforated material and is non-air permeable. In some embodiments, the side wall and the top wall each include a perforated material, the perforated material of the top wall being coated such that the top wall is non-air permeable.

In one embodiment, in accordance with the principles of the present disclosure, a spring pack comprises a plurality of strings. The strings each have opposite top and bottom walls and a side wall extending from the top wall to the bottom wall. Inner surfaces of the walls define a plurality of pockets. The side wall is air permeable. A spring is positioned in each of the pockets. In some embodiments, the side wall includes a perforated material. In some embodiments, the side wall and the top wall each include a perforated material, the perforated material of the top wall being coated such that the top wall is non-air permeable.

In one embodiment, in accordance with the principles of the present disclosure, a body support comprises a chassis defining a cavity. A spring pack is positioned in the cavity. The spring pack comprises a plurality of strings. The strings each define a plurality of pockets. A spring is positioned in each of the pockets. The strings each have opposite top and bottom walls and a side wall extending from the top wall to the bottom wall. The side walls are air permeable. A comfort layer is positioned on top of the enclosure such that the comfort layer covers the spring pack. In some embodiments, the side walls each include a perforated material. In some embodiments, the side walls and the top walls each include a perforated material and the perforated material of the top walls is coated such that the top walls are non-air permeable. In some embodiments, the side walls and the top walls each include a perforated material such that the top walls are air permeable. In some embodiments, the body support is configured such that ambient air moves through the comfort layer and then moves laterally between and through the spring pack after the ambient air moves through the comfort layer. In some embodiments, the body support comprises an enclosure, the spring pack being positioned in the enclosure, the enclosure being positioned in the cavity such that the comfort layer covers the enclosure. The enclosure can comprise opposite top and bottom sides and a vertical side extending from the top side to the bottom side, the top side being air permeable. The body support can be configured such that ambient air moves through the comfort layer and the top side, the ambient air being configured to move laterally within the enclosure after the ambient air moves through the top side. The ambient air can move through the spring pack as the ambient air moves laterally within the enclosure. The ambient air can move between the strings and through the side walls as the ambient air moves laterally within the enclosure. In some embodiments, the body support is configured such that ambient air moves through the bottom side and into the enclosure, the ambient air being configured to move laterally within the enclosure after the ambient air moves through the bottom side, the ambient air moving through the top side and the comfort layer after moving laterally within the enclosure. The ambient air can move through the spring pack as the ambient air moves laterally within the enclosure. The ambient air can move between the strings and through the side walls as the ambient air moves laterally within the enclosure. In some embodiments, the body support comprises a base, the chassis being positioned on top of the base.

In one embodiment, in accordance with the principles of the present disclosure, a mattress includes a base comprising an active air flow device and a duct. The duct has a first end coupled to the active air flow device and an opposite second end coupled to a top surface of the base. The duct defines an air channel that extends from the active air flow device and through the top surface. A chassis is positioned on top of the base such that a bottom wall of the chassis engages the top surface of the base. The chassis defines a cavity. The chassis comprises an opening extending through the bottom wall of the chassis such that the opening is in communication with the cavity, the duct being in communication with the opening. A spring pack is positioned in the cavity. The spring pack comprises a plurality of strings. The strings each have opposite top and bottom walls and a lateral wall extending from the top wall to the bottom wall of the string. The strings define a plurality of pockets. The lateral walls are air permeable. A comfort layer is positioned on top of the enclosure. In some embodiments, the lateral walls each include a perforated material. In some embodiments, the lateral walls and the top walls each include a perforated material and the perforated material of the top walls is coated such that the top walls are non-air permeable. In some embodiments, the mattress is configured such that ambient air moves through the comfort layer and then moves laterally between and through the spring pack after the ambient air moves through the comfort layer. The ambient air can move through the opening of the chassis and into the air flow channel after the ambient air moves laterally between and through the spring pack. In some embodiments, the mattress comprises an enclosure, the spring pack being positioned in the enclosure, the enclosure being positioned in the cavity such that the comfort layer covers the enclosure. The enclosure comprises opposite top and bottom sides and a vertical side extending from the top side to the bottom side, the top side being air permeable. The mattress is configured such that ambient air moves through the comfort layer and the top side, the ambient air being configured to move laterally within the enclosure after the ambient air moves through the top side. The ambient air can move through the spring pack as the ambient air moves laterally within the enclosure. The ambient air can move between the strings and the side walls as the ambient air moves laterally within the enclosure. The ambient air can move through the opening of the chassis and into the air flow channel after the ambient air moves laterally within the enclosure. The mattress is configured such that air in the air flow channel moves through the opening of the chassis and into the enclosure, the air being configured to move laterally within the enclosure after the air moves into the enclosure. The air can move through the spring pack as the air moves laterally within the enclosure. The ambient air can move between the strings and the side walls as the air moves laterally within the enclosure. The air can move through the top side and the comfort layer after the air moves laterally within the enclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more readily apparent from the specific description accompanied by the following drawings, in which:

FIG. 1 is a perspective view of one embodiment of a bedding system, in accordance with the principles of the present disclosure;

FIG. 2 is a perspective view of a component of the bedding system shown in FIG. 1;

FIG. 3 is a top view of one embodiment of a component of the bedding system shown in FIG. 1, in accordance with the principles of the present disclosure;

FIG. 4 is a side, perspective view of a portion of the component of the bedding system shown in FIG. 3;

FIG. 5 is a side view of a portion of the component of the bedding system shown in FIG. 3;

FIG. 6 is a top view of a portion of the component of the bedding system shown in FIG. 3;

FIG. 7 is a side view of a portion of the component of the bedding system shown in FIG. 3;

FIG. 8 is an example schematic of a portion of the component of the bedding system shown in FIG. 3;

FIG. 9 is a side, perspective view of a portion of the component of the bedding system shown in FIG. 3, showing air flow through and around the component of the bedding system shown in FIG. 3;

FIG. 10 is a top view of one embodiment of a component of the bedding system shown in FIG. 1, in accordance with the principles of the present disclosure;

FIG. 11 is side, perspective view of a portion of the component of the bedding system shown in FIG. 10;

FIG. 12 is a top view of a portion of the component of the bedding system shown in FIG. 10;

FIG. 13 is a side, perspective view of a portion of the component of the bedding system shown in FIG. 10, showing air flow through and around the component of the bedding system shown in FIG. 10;

FIG. 14 is a side view, in part phantom, of components of one embodiment of the bedding system shown in FIG. 1, showing air flow through one of the components;

FIG. 15 is a perspective view, in part phantom, of one embodiment of a bedding system, in accordance with the principles of the present disclosure;

FIG. 16 is a perspective view of a component of the bedding system shown in FIG. 1;

FIG. 17 is a side view of a component of the bedding system shown in FIG. 1;

FIG. 18 is a perspective view of one embodiment of a bedding system, in accordance with the principles of the present disclosure;

FIG. 19 is a side, cross-sectional view of components of the bedding system shown in FIG. 18;

FIG. 20 is a perspective view, in part phantom, of a component of the bedding system shown in FIG. 18;

FIG. 21 is a perspective view of a component of the bedding system shown in FIG. 18;

FIG. 22 is a side, cross-sectional view of components of the bedding system shown in FIG. 18, showing air flow through the bedding system; and

FIG. 23 is a side, cross-sectional view of components of the bedding system shown in FIG. 18, showing air flow through the bedding system.

Like reference numerals indicate similar parts throughout the figures.

DETAILED DESCRIPTION

The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure.

The present disclosure is directed to systems that are configured to support a body of a user, while providing adequate air flow to prevent heat from building up and/or provide an enhanced level of comfort. In some embodiments, the present disclosure is directed to a bedding system, such as, for example, a mattress that is constructed to actively provide air flow through the mattress. However, it is to be understood that the present disclosure is not limited to bedding systems and/or mattresses and may be directed to other items, such as, for example, furniture that is configured to support a body of a user. For example, all or part of the systems described herein can be used in conjunction with a chair, sofa, or other item that is configured to support a body of a user. Indeed, it is envisioned that components of the systems described herein, such as, for example, spring packs, can be used with any type of body support that includes springs and/or a spring pack.

In some embodiments, wherein the system is directed to a mattress, the components of the mattress work together to promote air flow through the mattress and thus enhance the comfort of the mattress user. Indeed, the mattresses of the present disclosure are configured to further increase the air flow therethrough via use of an improved spring pack. In some embodiments, the mattress comprises a base that contains a controllable active air flow source such as a fan. An enclosure is positioned on top of the base. The enclosure contains a pocketed spring coil pack. A comfort layer is positioned on top of the enclosure. A user rests on a top surface of the comfort layer. The fan is operatively connected to the enclosure through an air channel, such as an interconnected series of flanges. The enclosure is made to be air permeable only through one surface. In one configuration, the enclosure surface contacting the base (“bottom surface”) includes the air channel segment and is otherwise not air permeable; the oppositely-located enclosure surface (“top surface”) is air permeable; and the surface(s) that connect the bottom surface with the top surface (“side surface(s)”) are not air permeable. The enclosure top surface contacts the comfort layer bottom surface. The comfort layer is air permeable such as via perforations formed therethrough from the bottom surface to the top surface. In operation, air flows from the base fan to the interior of the enclosure and passes through the spaces in the spring pack. The air flow is constrained (by the enclosure non-permeable bottom and side surface(s)) to exit the enclosure top surface and then passes through the air permeable comfort layer to the top surface for the user to experience the cooling effect of the air flow.

In some embodiments, the spring pack includes a plurality of pocketed springs and the spring pack is contained within a defined volume, which represents a particular air flow barrier. Significantly, it has been determined that permitting air flow specifically in the lateral direction within the enclosure is notably effective for promoting air flow to the comfort layer and, thus, the entire mattress. This enables other novel options, as provided by the invention, to increase the air flow through the spring pack. In some embodiments, the spring pack uses a perforated fabric material. The material can comprise a single layer can be non-woven, non-stretching and non-coated. The perforated fabric material can have a selected thickness (about 50 cm).

In some embodiments, the perforated fabric material has a selected fabric weight (about 40-120 grams per square meter or about 65-80 grams per square meter). The perforated fabric material has perforations of a selected shape and/or size (circular about 2.0 mm to 3.0 mm diameter or circular about 2.5 mm to 3.0 mm diameter. The perforations of the perforated fabric material may be displayed or formed in a selected pattern (e.g., a pattern having a selected hole size and a selected distance between holes). It is recognized that the hole distance and the hole size are traded off one another, e.g., enlarge the holes but increase the distance, to maintain fabric strength/obtain a certain fabric strength, while still achieving desired air flow.

In some embodiments the perforations of the perforated fabric material are only (or predominately) on a curved surface of the pocketed spring (and not on the top or bottom bases). In some cases, this may be accomplished in the initial manufacture of the pocketed spring or by adding a material or coating to the top and bottom bases to block perforations initially formed on the top and bottom bases and achieving a functionally similar pocketed spring.

In some embodiments the perforated fabric material can have a selected air permeability (about 100 cubic feet per meter (CFM) (as comparison, same fabric material (non-woven polypropylene of 80 gsm) without perforations would have about 60 CFM). The perforated fabric material may have indicia to indicate firmness of the spring pack. Standard manufacturing processes and/or machinery, with no or minor modifications, may be used to implement the features described herein.

As used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references “upper” and “lower” are relative and used only in the context to the other, and are not necessarily “superior” and “inferior”.

The following discussion includes a description of a bedding system in accordance with the principles of the present disclosure. Alternate embodiments are also disclosed. Reference will now be made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures. Turning to FIGS. 1-17, there are illustrated components of one embodiment of a body support system 100.

Body support system 100 includes a body support, such as, for example, a mattress 102. Mattress 102 includes a chassis 104 comprising a bottom wall 106. Chassis 104 includes a front wall 108 and a back wall 110 opposite wall 108. Chassis 104 further includes a first side wall 112 and a second side wall 114 opposite side wall 112. Walls 108, 110 and side walls 112, 114 each extend upwardly from wall 106. Wall 106 and inner surfaces of walls 108, 110 and side walls 112, 114 define a cavity 116, as shown in FIG. 2, for example. In some embodiments, wall 108 and wall 110 are continuous with side wall 112 and side wall 114 such that walls 108, 110 and side walls 112, 114 form a continuous circumferential wall. In some embodiments, at least one of wall 106, wall 108, wall 110, side wall 112 and side wall 114 includes an air permeable material. In some embodiments, at least one of wall 106, wall 108, wall 110, side wall 112 and side wall 114 includes a non-air permeable material. In some embodiments, chassis 104 includes a top surface 118 and an opposite bottom surface 120. Walls 108, 110 and side walls 112, 114 each extend from surface 120 to surface 118. In some embodiments, surface 118 is air permeable and walls 106, 108, 110 and side walls 112, 114 are non-air permeable.

A spring pack 122 is configured to be positioned in cavity 116. Spring pack 122 includes a fabric 124 that is formed into a string 126 such that the string 126 includes a plurality of pockets 128. A spring 130 is positioned in each of pockets 128. Spring pack 122 includes one or a plurality of strings 126, as shown in FIG. 3, for example. Each of strings 126 has one of springs 130 positioned in each of the pockets 128 of each of the strings 126. Strings 126 may be coupled together to define spring pack 122. Fabric 124 is arranged such that strings 126 each include a top surface 132 and an opposite bottom surface 134. A side surface 136 connects and/or extends from surface 132 to surface 134. In some embodiments, surfaces 134 directly engage wall 106 when spring pack 122 is positioned within cavity 116. In some embodiments, at least one of surfaces 136 directly engages the inner surface of one of walls 108, 110, 112, 114 when spring pack 122 is positioned within cavity 116. In some embodiments, at least one of surfaces 136 is/are spaced apart from the inner surface of at least one of walls 108, 110, 112, 114 when spring pack 122 is positioned within cavity 116.

In some embodiments, fabric 124 includes a plurality of distinct layers of material. In some embodiments, fabric 124 includes a single layer of material. In some embodiments, the single layer of fabric 124 has a thickness of at least about 50 cm. It is envisioned that fabrics having a thickness of less than 50 cm would not have sufficient strength to prevent tearing, for example, during manufacturing, handling and/or use of mattress 202. In some embodiments, the single layer of fabric 124 has a thickness of about 50 cm to about 100 cm. In some embodiments, the single layer of fabric 124 has a thickness of about 50 cm to about 80 cm. In some embodiments, the single layer of fabric 124 has a thickness of about 50 cm to about 60 cm.

In some embodiments, fabric 124 has a fabric weight of about 40 grams per square meter (gsm) to about 120 gsm. In some embodiments, fabric 124 has a fabric weight of about 50 gsm to about 100 gsm. In some embodiments, fabric 124 has a fabric weight of about 55 gsm to about 90 gsm. In some embodiments, fabric 124 has a fabric weight of about 60 gsm to about 95 gsm. In some embodiments, fabric 124 has a fabric weight of about 65 gsm to about 80 gsm. It is envisioned that fabrics with fabric weights less than 40 gsm would not have sufficient strength to prevent tearing, for example, during manufacturing, handling and/or use of mattress 202.

Fabric 124 includes a perforated fabric, as shown in FIG. 7, for example. In some embodiments, shown in FIGS. 3-9, surfaces 136 are air permeable. That is, in some embodiments, the perforated fabric 124 allows surfaces 136 to be air permeable. Likewise, the perforated fabric 124 can allow surfaces 134 and/or surfaces 132 to be air permeable. In that the perforated fabric 124 allows surfaces 132, 134, 136 to be air permeable, air is permitted to move through surfaces 132, 134, 136 such that air can move in and out of pockets 128. Indeed, if fabric 124 were not perforated and/or air permeable, air may be able to move vertically and/or laterally between adjacent strings 126 and/or pockets 128, but would not be able to move through fabric 124 such that the air can move in and out of pockets 128. However, by providing fabric 124 as a perforated material, air flow in and out of pockets 128 is permitted, as shown in FIG. 9, for example. In some embodiments, the perforated material is a non-woven material. In some embodiments, the perforated material is a non-stretching material.

Fabric 124 includes a plurality of spaced apart holes, such as, for example, perforations 138, as shown in FIGS. 7 and 8, for example, to define the perforated material discussed herein. Perforations 138 may have a selected size and/or pattern configured to maximize the amount of air flow in and out of pockets 128 through fabric 124. For example, in some embodiments, perforations 138 may have a uniform size (e.g., diameter) and a common shape, such as, for example, circular. In some embodiments, one or more of perforations 138 can have various shape configurations, such as, for example, circular, oval, oblong, polygonal, irregular, uniform, non-uniform, variable and/or tapered. In some embodiments, perforations can have different shapes, such as, for example, different alternating shapes. In some embodiments, one or more of perforations 138 can have a size of about 1.0 cm to about 3.0 cm. In some embodiments, one or more of perforations 138 can have a size of about 1.5 cm to about 3.0 cm. In some embodiments, one or more of perforations 138 can have a size of about 2.0 cm to about 3.0 cm. In some embodiments, one or more of perforations 138 can have a size of about 2.5 cm to about 3.0 cm. In some embodiments, one or more of perforations 138 can have a size of about 2.5 cm. It is envisioned that perforations larger than 3.0 cm would result in a fabric that would not have sufficient strength to prevent tearing, for example, during manufacturing, handling and/or use of mattress 202. Moreover, it further envisioned that perforations larger than 3.0 cm would be undesirable as the relatively large size of the perforations would allow one or more portions of one or more springs (e.g., springs 130) to extend through the perforations. In some embodiments, perforations 138 allow fabric 124 to be air permeable. In some embodiments, fabric 124 has an air permeability of about 50 cubic feet per meter (cfm) to about 150 cfm due, at least in part, to perforations 138. In some embodiments, fabric 124 has an air permeability of about 75 cubic feet per meter cfm to about 125 cfm. In some embodiments, fabric 124 has an air permeability of about 90 cubic feet per meter cfm to about 110 cfm. In some embodiments, fabric 124 has an air permeability of about 100 cfm.

In some embodiments, fabric 124 may include a pattern in which perforations 138 define a plurality of rows 140 and a plurality of columns 142, as shown in FIG. 7, for example. In the embodiment shown in FIG. 7, perforations 138 are uniformly spaced apart from one another and are arranged such that perforations 138 of each column 142 are aligned with a perforation 138 of each row 140 along a horizontal axis X1 and perforations 138 of each row 140 are aligned with a perforation 138 of each column 142 along a vertical axis X2 that extends perpendicular to horizontal axis X1. That is, perforations 138 of adjacent columns 142 are aligned along horizontal axis X1 and/or perforations 138 of adjacent rows 140 are aligned along vertical axis X2. This arrangement is configured to allow air flow in and out of pockets 128, as shown in FIG. 9, for example.

In one embodiment, shown in FIG. 8, perforations 138 are uniformly spaced apart from one another and are arranged such that perforations 138 of a respective column 142 are not aligned with a perforation 138 of an adjacent row 140 along horizontal axis X1 and perforations 138 of each row 140 are not aligned with a perforation 138 of an adjacent column 142 along vertical axis X2. That is, perforations 138 are staggered between adjacent rows 140 and columns 142 such that perforations 138 are each uniformly spaced apart from one another without perforations 138 of adjacent rows 140 and columns 142 being aligned along horizontal axis X1 and/or vertical axis X2. This arrangement is configured to allow air flow in and out of pockets 128, as shown in FIG. 9, for example.

In some embodiments, shown in FIGS. 10-13, a portion of fabric 124 of each of strings 126 is coated with a material 144 such that top surfaces 132 are non-air permeable. In some embodiments, material 144 is a polymer coating. This arrangement is configured to increase the amount of lateral air flow in and out of pockets 128. For example, when top surfaces 132 are air permeable (e.g., are not coated with material 144), air that is flowing in and out of pockets 128 can move laterally in and out of pockets 128, in the directions shown by arrows A and B in FIG. 9. Because top surfaces 132 are air permeable (e.g., are not coated with material 144), air that is flowing in and out of pockets 128 may move vertically through top surfaces 132 in the direction shown by arrow C in FIG. 9. However, when top surfaces 132 are non-air permeable (e.g., are coated with material 144), air that is flowing in and out of pockets 128 is prevented from moving vertically through top surfaces 132. As such, making top surfaces 132 non-air permeable allows a greater amount of air flow in and out of pockets 128 in the directions shown by arrows A and B (FIG. 13) than is permitted when top surfaces 132 are air permeable (FIG. 9). Indeed, in embodiments wherein top surfaces 132 are non-air permeable, the air that would otherwise move vertically through top surfaces 132 (if top surfaces 132 were air permeable) will instead move laterally, in the directions shown by arrows A and B. Therefore, providing non-air permeable top surfaces 132 is functional to increase the amount of lateral air flow in and out of pockets 128 than would otherwise be permitted if top surfaces 132 were air permeable, as would be understood by one of ordinary skill in the art.

In addition to, or in place of the non-air permeable top surfaces 132 discussed above, in some embodiments, one or more of bottom surfaces 134 of strings may be non-air permeable. Similar to the non-air permeable top surfaces 132 discussed above, a portion of fabric 124 of each of strings 126 is coated with a material, such as, for example, material 144, such that bottom surfaces 134 are non-air permeable. In some embodiments, the material (e.g., material 144) is a polymer coating. This arrangement is configured to increase the amount of lateral air flow in and out of pockets 128. For example, when top surfaces 132 and bottom surfaces 134 are air permeable (e.g., are not coated with material 144), air that is flowing in and out of pockets 128 can move laterally in and out of pockets 128, in the directions shown by arrows A and B in FIG. 9. Because top surfaces 132 and bottom surfaces 134 are air permeable (e.g., are not coated with material 144), air that is flowing in and out of pockets 128 can move vertically through top surfaces 132 in the direction shown by arrow C in FIG. 9 and/or vertically through bottom surfaces 134 in a direction opposite the direction shown by arrow C. However, when top surfaces 132 and bottom surfaces 134 are non-air permeable (e.g., are coated with material 144), air that is flowing in and out of pockets 128 is prevented from moving vertically through top surfaces 132 and/or bottom surfaces 134. As such, making top surfaces 132 and bottom surfaces 134 non-air permeable allows a greater amount of air flow in and out of pockets 128 in the directions shown by arrows A and B (FIG. 13) than is permitted when top surfaces 132 and bottom surfaces 134 are air permeable (FIG. 9). Indeed, in embodiments wherein top surfaces 132 bottom surfaces 134 are non-air permeable, the air that would otherwise move vertically through top surfaces 132 (if top surfaces 132 were air permeable) and/or the air that would otherwise move vertically through bottom surfaces 134, will instead move laterally, in the directions shown by arrows A and B. Therefore, providing non-air permeable top surfaces 132 and bottom surfaces 134 is functional to increase the amount of lateral air flow in and out of pockets 128 than would otherwise be permitted if top surfaces 132 and bottom surfaces 134 were air permeable, as would be understood by one of ordinary skill in the art.

In some embodiments, fabric 124 includes indicia 147 that is indicative of one or more characteristics of spring pack 122, such as, for example, the firmness of spring pack 122. In some embodiments, indicia 147 may include a number relating to the firmness of spring pack 122. For example, indicia 147 may include a number between 0.0 and 3.0, wherein 3 or 3.0 is indicative of a plush spring pack 122 and 0 or 0.0 is indicative of a firm spring pack 122; 1 or 1.0 may be indicative of a medium firm spring pack 122; and 2 or 2.0 may be indicative of a medium plush spring pack 122. Alternatively, or in addition, indicia 147 can include words to indicate the firmness of spring pack 122, such as, for example, firm, medium firm, medium plush and plush. Indicia 147 may be located anywhere on spring pack 122, such as, for example on one or more of top surfaces 132 of strings 126 such that indicia 147 is visible when a comfort layer of mattress 102 is removed/spaced apart from chassis 104, as shown in FIG. 3, for example. In some embodiments, indicia 147 may be located on one or more of side surfaces 136 of strings 126, as shown in FIG. 5, for example, such that indicia 147 is not visible unless spring pack 122 is removed from chassis 104. It is envisioned that indicia 147 may include any numbers and/or words, depending upon a particular application.

In some embodiments, spring pack 122 is positioned in cavity 116 such that surfaces 134 directly engage wall 106 and/or at least one of surfaces 136 directly engages the inner surface of one of walls 108, 110, 112, 114 when spring pack 122 is positioned within cavity 116, as discussed above. In some embodiments, spring pack 122 is positioned in a bag, such as, for example, an enclosure 146, as shown in FIGS. 14 and 15. Enclosure 146 includes a top surface 148 and an opposite bottom surface 150. Enclosure 146 includes a side surface 152 extending from surface 148 to surface 150. Enclosure 146 includes an outer surface 154 and an opposite inner surface 156. Surface 156 defines a cavity 158. Spring pack 122 is positioned in cavity 158. In some embodiments, spring pack 122 is enclosed within cavity 158 and/or enclosure 146 completely surrounds spring pack 122. In some embodiments, at least one of surfaces 148, 150, 152 includes an air permeable material. In some embodiments, at least one of surfaces 148, 150, 152 includes a non-air permeable material. In some embodiments, enclosure 146 may include a zippered opening, or other closable opening configured to be opened and closed to remove spring pack 122 from enclosure 146 and/or to insert spring pack 122 into enclosure 146.

Enclosure 146 is positioned within cavity 116 such that surface 150 of enclosure 146 directly engages wall 106 of chassis 104. In some embodiments, surface 146 of enclosure 146 directly engages the inner surfaces of at least one of one of walls 108, 110, 112, 114 of chassis 104 when enclosure 146 is positioned within cavity 116. In some embodiments, surface 146 of enclosure 146 is spaced apart from the inner surfaces of at least one of one of walls 108, 110, 112, 114 of chassis 104 when enclosure 146 is positioned within cavity 116. Enclosure 146 is configured to increase the amount of air flow through mattress 102. For example, when air is moved into enclosure 146 through surface 150 of enclosure 146 in the direction shown by arrow D in FIG. 14, the air will move in and out of pockets 128 in the directions shown by arrows A and B in FIGS. 9 and 13, and will then move through surface 148 of enclosure 146 in the direction shown by arrow D. Alternatively, when air is moved into enclosure 146 through surface 148 of enclosure 146 in the direction shown by arrow E in FIG. 15, the air will move in and out of pockets 128 in the directions shown by arrows A and B in FIGS. 9 and 13, and will then move through surface 150 of enclosure 146 in the direction shown by arrow E.

Mattress 102 includes a comfort layer 160 that is configured to be positioned on chassis 104 such that comfort layer 160 covers spring pack 122 and/or enclosure 146. In particular, a bottom surface 162 of comfort layer 160 directly engages top surfaces of walls 108, 110, 112, 114 to couple comfort layer 160 to chassis 104. An opposite top surface 164 of comfort layer 160 defines a sleep surface of mattress 102, such as, for example, a surface of mattress 102 that one or more sleeper's rest their body(ies) upon. In some embodiments, comfort layer 160 includes a cushion or cushioning material to provide cushioning to the sleeper(s) that lie on top of surface 164. In some embodiments, comfort layer 160 includes a plurality of spaced apart perforations. In some embodiments, at least one of the perforations is positioned between surfaces 162, 164. In some embodiments, at least one of the perforations extends into surface 162 without extending through surface 164. In some embodiments, at least one of the perforations extends into surface 164 without extending through surface 162. In some embodiments, at least one of the perforations extends through surface 162 and surface 164. The perforations increase the breathability of comfort layer 160 to increase the rate of flow of air and/or moisture through comfort topper 160.

Comfort layer 160 is removeably coupled to chassis 104 to allow comfort layer 160 to be removed from chassis 104 for cleaning or to replace comfort layer 160 with a new comfort layer 160, as discussed herein. For example, comfort layer 160 can be removed from chassis 104 and can then be replaced with a new comfort layer 160. In some embodiments, comfort layer 160 can be a mat, a mattress topper or a mattress. It is envisioned that comfort layer 160 can have various thicknesses. For example, comfort layer 160 can have a thickness that is less than 1 inch, a thickness that is greater than 3 inches or any thickness between 0.1 inches and 12 inches. In some embodiments, comfort layer 160 can be variously connected with chassis 104, such as, for example, with one or more zippers.

In some embodiments, mattress 102 includes a platform, such as, for example, a base 166 that is configured to space chassis 104 apart from a floor, such as, for example, a floor of a room that mattress 102 is positioned in. In particular, base 166 includes a bottom surface 168 that is configured to directly engage the floor and an opposite top surface 170. Chassis 104 is configured to be positioned on top of base 166 such that bottom wall 106 and/or a bottom surface of at least one of walls 108, 110, 112, 114 of chassis 104 directly engages top surface 170. In some embodiments, base 166 includes one or more active air flow devices, such as, for example, fans and surface 170 includes one or a plurality of openings configured to allow air flow therethrough. In some embodiments, base 166 does not include any active air flow devices.

In one embodiment, shown in FIGS. 18-23, body support system 100 includes a body support, such as, for example, a mattress 302. Mattress 302 includes a base 304 having a frame 306. Frame 306 includes a bottom wall 308 that is configured to be positioned on a floor, such as, for example, a floor of a room that mattress 302 is positioned in. Frame 306 includes a top wall 310 opposite wall 308, a first side wall 312 and a second side wall 314 opposite side wall 312, as best shown in FIG. 20. At least a portion of side walls 312, 314 extend from wall 308 to wall 310. In some embodiments, frame 306 may include one or a plurality of passageways 316 that extend through wall 308 and side walls 312, 314 to allow air flow therethrough in the directions shown by arrows F and G in FIG. 20. However, it is envisioned that frame may not include any passageways, such as, for example, passageways 316 such that side walls 312, 314 each extend continuously from wall 308 to wall 310 and continuously from a front wall 318 of frame 306 to an opposite back wall 320 of frame 306.

Base 304 includes a first duct 322 having a first end 324 coupled to side wall 312 and an opposite second end 326 coupled to wall 310. An inner surface 328 of duct 322 defines a first air flow channel 330 that extends through wall 310 and/or side wall 312. A first air flow device, such as, for example, a first fan 332 is positioned in and/or adjacent to air flow channel 330 and is configured to move air through air flow channel 330 in opposite directions, as discussed herein. Base 304 includes a second duct 334 having a first end 336 coupled to side wall 314 and an opposite second end 3336 coupled to wall 310. An inner surface 340 of duct 334 defines a first air flow channel 342 that extends through wall 310 and/or side wall 314. A second air flow device, such as, for example, a second fan 344 is positioned in and/or adjacent to air flow channel 342 and is configured to move air through air flow channel 342 in opposite directions, as discussed herein. In some embodiments, duct 322 and/or duct 334 comprises an interconnected series of flanges. In some embodiments, duct 322 may be positioned entirely within air flow channel 330 and/or duct 334 may be positioned entirely within air flow channel 342. In some embodiments, duct 322 may be coupled to or positioned in side wall 312 and/or duct 334 may be coupled to or positioned in side wall 314.

Mattress 302 includes a chassis 346 that is configured to be positioned on top of base 304. In particular, chassis 346 includes a bottom wall 348 that directly engages top wall 310 of frame 306 when chassis 346 is positioned on top of base 304. Chassis 346 includes spaced apart openings 350, 352 extending through wall 348. In some embodiments, air channel 330 is aligned and/or in communication with opening 350 when chassis 346 is positioned on top of base 304 and/or air channel 342 is aligned and/or in communication with opening 352 when chassis 346 is positioned on top of base 304. In some embodiments, end 326 of duct 322 extends through opening 350 and/or end 338 of duct 334 extends through opening 352 when chassis 346 is positioned on top of base 304. In some embodiments, wall 348 is non-air permeable, exclusive of openings 350, 352. That is, the only portions of wall 348 that permits air flow therethrough is openings 350, 352 and the portions of wall 348 surrounding openings 350, 352 are non-air permeable and do not permit air flow therethrough.

Chassis 346 includes a front wall 354 and an opposite rear wall 356. Chassis 346 further includes a first side wall 358 and an opposite second side wall 360. Side walls 358, 360 each extend from wall 354 to wall 356. In some embodiments, walls 354, 356 and side walls 358, 360 each extend upwardly from wall 348. Inner surfaces of walls 354, 356 and side walls 358, 360 define a cavity 362. In some embodiments, wall 354 and wall 356 are continuous with side wall 358 and side wall 360 such that walls 354, 356 and side walls 358, 360 form a continuous circumferential wall. In some embodiments, at least one of wall 348, wall 354, wall 356, side wall 358 and side wall 360 includes an air permeable material. In some embodiments, at least one of 348, wall 354, wall 356, side wall 358 and side wall 360 includes a non-air permeable material. In some embodiments, chassis 346 includes a top surface 364 and an opposite bottom surface 366. Walls 354, 356 and side walls 358, 360 each extend from surface 364 to surface 366. In some embodiments, surface 364 is air permeable and walls 348, 354, 356 and side walls 358, 360 are non-air permeable.

In some embodiments, only spring pack 122 is positioned in cavity 362. That is, spring pack 122 is positioned in cavity 362 without spring pack 122 being positioned in cavity 158 of enclosure 146 and/or enclosure 146 being positioned in cavity 362. Spring pack 122 is positioned in cavity 362 such that bottom surfaces 134 of strings 126 directly engage bottom wall 348 of chassis 346. In some embodiments, at least one of side surfaces 136 of strings 126 directly engages the inner surface of at least one of walls 354, 356 and/or the inner surface of at least one of side walls 358, 360 when spring pack 122 is positioned in cavity 362. In some embodiments, side surfaces 136 of strings 126 are spaced apart from the inner surface of at least one of walls 354, 356 and/or the inner surface of at least one of side walls 358, 360 when spring pack 122 is positioned in cavity 362.

In some embodiments, spring pack 122 is positioned in cavity 158 of enclosure 146 and enclosure is positioned in cavity 362 such that bottom surface 150 of enclosure 146 directly engages bottom wall 348 of chassis 346. In some embodiments, side surface 152 of enclosure 146 directly engages the inner surface of at least one of walls 354, 356 and/or the inner surface of at least one of side walls 358, 360 when enclosure 146 is positioned in cavity 362. In some embodiments, side surface 152 of enclosure 146 is spaced apart from the inner surface of at least one of walls 354, 356 and/or the inner surface of at least one of side walls 358, 360 when enclosure 146 is positioned in cavity 362.

Comfort layer 160 is configured to be positioned on chassis 346 such that comfort layer 160 covers spring pack 122 and/or enclosure 146. In particular, bottom surface 162 of comfort layer 160 directly engages top surfaces of walls 354, 356, 358, 360 to couple comfort layer 160 to chassis 346. In some embodiments, comfort layer 160 can be variously connected with chassis 346, such as, for example, with one or more zippers.

In some embodiments, fans 332, 344 are each configured to create negative pressure such that the negative pressure created by fans 332, 344 draws ambient air that surrounds mattress 302 through comfort layer 106 shown by arrow H in FIG. 22. In embodiments wherein mattress 302 does not include enclosure 146, the ambient air that is drawn through comfort layer 106 moves directly through strings 126 and/or pockets 128. In embodiments wherein mattress 302 includes enclosure 146, the ambient air that is drawn through comfort layer 106 moves directly through at least one of surfaces 148, 150, 152 of enclosure 146 and into cavity 158 of enclosure 146. The ambient air in cavity 158 moves through strings 126 and pockets 128.

In embodiments wherein top surfaces 132 of strings 126 are air permeable (e.g., are not coated with material 144), the ambient air that is drawn through comfort layer 106 moves through top surfaces 132, side surfaces 136 and/or pockets 128. In embodiments wherein top surfaces 132 of strings 126 are non-air permeable (e.g., are coated with material 144), the ambient air that is drawn through comfort layer 106 moves through side surfaces 136 of strings 126 and through pockets 128 without moving through top surfaces 132. The ambient air can move laterally in and out of pockets 128, in the directions shown by arrows A and B in FIG. 9.

After moving laterally in and out of pockets 128, in the directions shown by arrows A and B in FIG. 9, the negative pressure generated by fans 332, 344 causes the ambient air to move in the direction shown by arrow H in FIG. 22. In embodiments wherein mattress 302 does not include enclosure 146, the ambient air that is drawn through comfort layer 106 moves directly into and through air channels 330, 342 such that the ambient air moves out of mattress 302 through ends 324, 336 of ducts 322, 344. In embodiments wherein mattress 302 includes enclosure 146, the ambient air that is drawn through comfort layer 106 moves through bottom surface 150 of enclosure 146; after moving through bottom surface 150, the ambient air moves into and through air channels 330, 342 such that the ambient air moves out of mattress 302 through ends 324, 336 of ducts 322, 344.

In some embodiments, fans 332, 344 are each configured to create positive pressure such that the positive pressure created by fans 332, 344 causes ambient air to move into air channels 330, 342 and/or causes air in air channels 330, 342 to move into cavity 362 in the direction shown by arrow I in FIG. 23. In embodiments wherein mattress 302 does not include enclosure 146, the air in cavity 362 moves directly through strings 126 and/or pockets 128. In embodiments wherein mattress 302 includes enclosure 146, the air in cavity 362 moves directly through at least one of surfaces 148, 150, 152 of enclosure 146 and into cavity 158 of enclosure 146. The air in cavity 158 moves through strings 126 and pockets 128.

In embodiments wherein top surfaces 132 of strings 126 are air permeable (e.g., are not coated with material 144), the air in cavity 158 moves through side surfaces 136 and/or top surfaces 132 of strings 126. In embodiments wherein top surfaces 132 of strings 126 are non-air permeable (e.g., are coated with material 144), the air in cavity 158 moves through side surfaces 136 of strings 126 without moving through top surfaces 132. The air can move laterally in and out of pockets 128, in the directions shown by arrows A and B in FIG. 9.

In embodiments wherein mattress 302 does not include enclosure 146, the air that moves laterally in and out of pockets 128, moves through comfort layer 106 in the direction shown by arrow I and exits mattress 302 through comfort layer 106, such as, for example, through the perforations in comfort layer 106. In embodiments wherein mattress 302 includes enclosure 146, the air that moves laterally in and out of pockets 128 moves through top surface 148 of enclosure and through comfort layer 106 in the direction shown by arrow I and exits mattress 302 through comfort layer 106, such as, for example, through the perforations in comfort layer 106.

It will be understood that various modifications may be made to the embodiments disclosed herein. For example, features of any one embodiment can be combined with features of any other embodiment. Therefore, the above description should not be construed as limiting, but merely as exemplification of the various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

BODY SUPPORT SYSTEM

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