Patent Application
20240285092
The present disclosure generally relates to mattress assemblies and/or pillows including at least one auxetic foam layer.
Mattresses such as those formed of polyurethane foam, latex foam, and the like, with or without coiled springs, are generally known in the art. One of the ongoing problems associated with mattress assemblies is user comfort and durability. To address user comfort, mattresses are often fabricated with multiple foam layers having varying properties such as density and hardness, among others, to suit the needs of the intended user. More recently, manufacturers have employed so-called memory foam, also commonly referred to as viscoelastic foams, which are generally a combination of polyurethane and one or more additives that increase foam density and viscosity, thereby increasing its viscoelasticity. These foams often have both closed and open cells but in some instances may be reticulated foam structures. When used in a mattress, the memory foam conforms to the shape of a user when the user exerts pressure onto the foam, thereby minimizing pressure points from the user's body. The memory foam then returns to its original shape when the user and associated pressure are removed.
Unfortunately, the foams used in current mattress assemblies can suffer from durability issues after prolonged repetitive use. Moreover, integrating the foam layer with the various fabric coverings especially when the foam layer is relatively thin can be difficult given the problems associated with sewing the combined fabric and foam layer. Oftentimes, the thinner foam layer does not have the structural integrity necessary to withstand the rigors of the sewing process resulting in tears within the foam layer and/or detachment.
Disclosed herein are mattress assemblies and pillows including at least one auxetic foam layer. Also, disclosed are pillows including at least one auxetic foam layer. In one or more embodiments, the mattress assembly includes at least one auxetic foam layer having a negative Poisson's ratio.
In one or more embodiments, a pillow includes at least one auxetic foam layer having a negative Poisson's ratio; and an envelope encapsulating the at least one auxetic foam layer.
The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.
Disclosed herein are mattress assemblies that include at least one auxetic foam layer. Relative to conventional foams, the at least one auxetic foam layer can provide greater durability, increased compressive support, and improved sewability, among other properties, compared to the standard (non-auxetic) foams used in mattress assemblies, e.g., non-auxetic polyurethane foams, non-auxetic latex foams, non-auxetic viscoelastic foams and the like, which can be open cell, closed cell or be fully or partially reticulated cellular structure. The mattress assemblies are not intended to be limited and can include all-foam mattress assemblies, mattress assemblies including a combination of one or more layers of foam and at least one layer of coil springs; and mattress assemblies including a combination of foam and air bladders. The mattress assemblies may be a mattress of any size, including standard sizes such as a twin, queen, oversized queen, king, or California king sized mattress, as well as custom or non-standard sizes constructed to accommodate a particular user or a particular room. Still further, the mattress assemblies can be configured as one-sided or two-sided mattresses depending on the configuration and the desired application.
The auxetic foam can be used in any one or more layers of the mattress assemblies including, but not limited to, the mattress core, topper layers, siderail assemblies, inserts, and the like. In one or more embodiments, the auxetic foam is a comfort layer (i.e., the topmost layer or layers of the mattress proximate to the sleeping surface). Exemplary comfort layers for mattress assemblies include, but are not limited to, the quilt layer, the top panel, or one or more layers of the mattress itself. Additionally, the innercore can include one or more auxetic foam layers. It should also be apparent that the one or more auxetic foam layers can also be utilized in pillows, the pillowtop layer, removable topper layers, and the like.
Auxetic foams are generally those foams that exhibit a negative Poisson's ratio (ν) as compared with conventional foams that exhibit a positive Poisson's ratio. The negative Poisson's ratio provides auxetic foams with unique properties compared to standard mattress foams having a positive Poisson's ratio. As used herein, the Poisson's ratio of a material is a measure of the extent to which a material becomes thinner while it is stretched, i.e., when a tensile force is applied, and is defined as the ratio of the transverse compressive strain to the longitudinal tensile strain when a material is undergoing a tensile load. An auxetic foam with a negative Poisson's ratio is one that expands in all directions when pulled in only one direction, thus increasing its thickness in the two directions perpendicular to the applied tension. In contrast, when compressed, the auxetic foam becomes thinner in the two directions perpendicular to the applied compression. Relative to conventional foams that have a positive Poisson's ratio, the auxetic foams undergoing compression can be configured to provide increased indention resistance. In one or more embodiments, the Poisson's ratio can be between −0.5 and −1 to provide the increased indention resistance relative to conventional foams, which advantageously permits the use of thinner (auxetic) foam layers as may be desired for some applications.
The auxetic foam layer can have an open cell or a closed cell structure. Fabrication of open cell auxetic foam structures typically include a thermomechanical process including volumetric compression of a conventional open cell foam in a mold, which buckles cellular ribs to impose a re-entrant cell structure followed by thermal fixing of the imposed structure. Closed cell foams can be manufactured using a bespoke pressure vessel or by steam processing. Alternatively, the auxetic foam structure can be fabricated by additive manufacturing, which can be used to provide more complex and uniform structures. The mechanical properties are generally dictated by their internal microstructures.
In one or more embodiments, the hardness property of the auxetic foam layer generally has an indention load deflection (ILD) at 25% deflection the range would be 5-120 pounds force and for 65% deflection the range would be 6.8-188 measured in accordance with ASTM D-3574 and/or ASTM D 3575. In one or more embodiments, the density of the auxetic foam layer can generally range from about 0.5 to about & pounds per cubic foot.
Various embodiments of the disclosure are described herein with reference to the related drawings. Alternative embodiments of the disclosure can be devised without departing from the scope of this disclosure. Various connections and positional relationships (e.g., over, below, adjacent, etc.) are set forth between elements in the following description and in the drawings. These connections and/or positional relationships, unless specified otherwise, can be direct or indirect, and the present invention is not intended to be limiting in this respect. Accordingly, a coupling of entities can refer to either a direct or an indirect coupling, and a positional relationship between entities can be a direct or indirect positional relationship. Moreover, the various tasks and process steps described herein can be incorporated into a more comprehensive procedure or process having additional steps or functionality not described in detail herein.
The following definitions and abbreviations are to be used for the interpretation of the claims and the specification. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.
Additionally, the term “exemplary” is used herein to mean “serving as an example, instance or illustration.” Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. The terms “at least one” and “one or more” can be understood to include any integer number greater than or equal to one, i.e., one, two, three, four, etc. The terms “a plurality” can be understood to include any integer number greater than or equal to two, i.e., two, three, four, five, etc. The term “connection” can include both an indirect “connection” and a direct “connection.”
The terms “about,” “substantially.” “approximately,” and variations thereof, are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. Furthermore, variation can occur from inadvertent error in measuring procedures, differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods, and the like. In one aspect, the term “about” means within 10% of the reported numerical value. In another aspect, the term “about” means within 5% of the reported numerical value. Yet, in another aspect, the term “about” means within 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the reported numerical value.
As used herein, the articles “a” and “an” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. Therefore, “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.
For the sake of brevity, conventional techniques related to making and using aspects of the disclosure may or may not be described in detail herein. Accordingly, in the interest of brevity, many conventional implementation details are only mentioned briefly herein or are omitted entirely without providing the well-known system and/or process details.
Turning now to
In
By way of example, the top panel layer 16 can be a quilt panel including an auxetic foam layer as shown more clearly in
As shown, the quilt panel layer is provided adjacent to each upholstery layer and provides direct contact with the sleeper during use and thus the immediate perception of softness or “feel.” Each quilt panel layer commonly includes a layer of mesh or cloth bottom or backing material, a layer of foam material positioned over the backing material, a layer of fiber or filler material (quilt fill) positioned over the foam, and finally a layer of ticking forming the cover. The number of layers of foam and quilt fill in the quilt panel layer can vary depending on the desired comfort level, quality, and expense of the mattress. All of the different layers including the auxetic foam layer can be stitched together, typically in a conventional quilting machine (not shown) with thread, to form a quilt stitch pattern. The quilt stitch pattern holds the components of the layers together and provides a composite structure to the quilt panel layer.
Optionally, instead of a quilt foam layer a non-quilted top foam panel can be utilized having a similar structure albeit non-quilted. In the case of a (non-quilted) top panel, the peripheral edges of the first and second fabric layers 46, 48 and the auxetic foam layer 50 are sewn together and attached to the border. The fabric layers can be any desired sheet of material, such as cotton, linen, synthetic fibers or a mixture thereof. The fabric covering can be quilted or non-quilted. At the peripheral edge, the quilt or top panel as well as the border can include a flange to attach the border to the quilt panel that can form rolled edges, e.g., 52, 54. Advantageously, the use of an auxetic foam layer permits the use of thinner layers given the increased durability relative to conventional foams.
The top panel or the quilt panel layers can include additional foam layers, insulating layers, water-resistant layers, or fire-resistant layers as may be desired for different applications. The various layers may be laminated together, joined by adhesive or otherwise combined to form a single sheet of material. The size of the sheets formed may vary according to the application, but in certain embodiments, the sheets may be sized as is conventional for mattress manufacture.
The level of support and comfort provided by such a mattress assembly, often referred to as “firmness,” is a function of both the number and characteristics of the upholstery topper and the quilting panel layers about the top and optional bottom of the innercore and of the performance characteristics of the innercore.
Each upholstery topper layer 49 commonly includes an insulating layer of material in direct contact with the innercore to mask or insulate from the sleeper the noise that may be produced by the interaction between components of the innercore in the case of an innerspring assembly and also to prevent softer upholstery materials from falling or pocketing into the innerspring. This insulating layer can be constructed of, for example, wire mesh, plastic mesh, woven fabric, or non-woven fabric. Each upholstery topper layer can further include at least one auxetic foam layer, which affects the firmness of the mattress. It should be understood that additional layers of padding can be provided for each upholstery topper layer, the number of padding layers depending upon the comfort level and quality of the mattress.
In one or more embodiments, the auxetic foam layer can further include a phase change material (PCM). The phase change material (PCM) layer can be coated directly onto the auxetic, foam layer, PCMs generally operate on the principle that a material requires a relatively significant amount of energy (heat) to change from a solid to a liquid and then back from a liquid to a solid. PCMs can therefore absorb large amounts of heat or energy from their environment and return large amounts of heat to their environment. This effective absorption, store and release of heat can be used to help regulate the temperature of an environment.
In one or more embodiments, suitable PCMs include, without limitation, microencapsulated PCMs. Any of a variety of processes known in the art may be used to microencapsulate PCMs. One of the most typical methods which may be used to microencapsulate a PCM is to disperse droplets of the molten PCM in an aqueous solution and to form walls around the droplets using techniques such as coacervation, interfacial polymerization, or in situ polymerization, all of which are well known in the art. For example, the methods are well known in the art to form gelatin capsules by coacervation, polyurethane or polyurea capsules by interfacial polymerization, and urea-formaldehyde, urea-resorcinol-formaldehyde, and melamine formaldehyde capsules by in situ polymerization. The microencapsulated PCMs can then be dispersed in a liquid vehicle such as a gel and applied to the above noted surfaces or substrate.
Encapsulation of the PCM creates a tiny, microscopic container for the PCM. This means that regardless of whether the PCM is in a solid state or a liquid state, the PCM will be contained. The size of the microcapsules typically range from about 1 to 100 microns and more typically from about 2 to 50 microns. The capsule size selected will depend on the application in which the microencapsulated PCM is used.
The microcapsules will typically have a relatively high payload of phase change material, typically at least 70% by weight, more typically at least 80% by weight, and in accordance with some embodiments, the microcapsules may contain more than 90% phase change material.
In still other embodiments, one of the first and second polymeric layers can include thermally conductive fillers by themselves or in addition to the PCM. Thermally conductive fillers such as various fibers, powder, flakes, needles, and the like can be dispersed within the foam matrix. In one embodiment, the thermally conductive fillers are nanoparticles with at least one dimension that measures 1000 nanometers or less, e.g., nanowires, and nanostrands.
The thermally conductive fillers can be formed of metals, metal oxides, polymers, inorganic compounds and the like. By way of example, suitable materials may be made of carbon, graphene, graphite, platinum, aluminum, diamond, gold, silver, silicon, copper, iron, nickel, and the like; polymers such as stretched polyethylene nanofibers and the like, and mixtures thereof. In most embodiments, the selected material has a thermal conductivity greater than 10 watts per meters-Kelvin (W/m*K). By way of example, aluminum has a thermal conductivity of about 235 W/m*K; stretched polyethylene fibers is estimated to be about 180 W/m*K, and graphene has a theoretical conductivity of about 5000 W/m*K.
Turning now to
The mattress assemblies and/or pillows, and any variations thereof, may be manufactured using techniques known in the art of mattress/pillow making, with variations to achieve the mattress/pillow described above. Likewise, the various mattress layers in the mattress assemblies described above may be adjoined to one another using an adhesive or may be thermally bonded to one another or may be mechanically fastened to one using another hog rings, staples, and/or other techniques known in the art. It should also be apparent that the auxetic foam layer can be integrated in mattress assemblies including pocketed coils, air bladders, non-auxetic foams, and combinations thereof.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
The present application claims the benefit of U.S. Provisional Application No. 63/487,423, filed on Feb. 28, 2023, incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63487423 | Feb 2023 | US |
