Patent Grant
10258163
It has been estimated that nearly one third of Americans are sleep deprived. Sleep is primarily a restorative process that influences the homeostatic regulation of the autonomic, neuroendocrine and immune systems of the human body. The quantity and quality of a person's sleep are both important factors in maintaining good health. Without proper sleep, people are more susceptible to illnesses, have a lower frustration tolerance and may tend to overreact when stresses occur in their lives, and have diminished capacities to concentrate, remember, learn and complete tasks. Thousands die each year in automobile accidents resulting when someone falls asleep at the wheel. There is even evidence that without proper sleep aspects of the aging process are accelerated and may shorten life span.
In order to achieve quality sleep, a person needs to make himself or herself as comfortable as possible. Accordingly, a comfortable mattress is an important factor in achieving quality sleep. Temperature is an additional important factor in achieving quality sleep. If the ambient air temperature is too warm, a person may have difficulty falling asleep and may be restless once he or she has fallen asleep. If the ambient air temperature is too cold, a person may dress warmly for bed and using multiple blankets. One common experience is that an amount of insulation that initially felt comfortably warm suddenly becomes unbearably hot. When this happens, physical effort to remove layers of insulation may be required again achieve a comfortable balance. Another common experience is the unconscious act of kick off blankets while sleeping and then waking up feeling cold.
An additional challenge to achieving a comfortable temperature for sleep is that fact that two people often sleep in the same room and on the same mattress. The ambient air temperature that is comfortable for one person may be too hot or too cold for that person's companion. A system providing a comfortable sleeping environment for two occupants of the mattress would be desirable. A system allowing a person occupying the port side of the bed to select a first temperature and, at the same time, allowing a person occupying the starboard side of the bed to select a second temperature different from the first temperature would also be desirable.
In one or more embodiments of the invention, a mattress is configured for placement on a foundation that has forced air ventilation with a plurality of air vents on the upwardly facing side of the foundation. The mattress is configured so that air from the air vents is permitted to pass through the mattress. The mattress comprises a base including a base layer and a transition layer bonded to the base layer by a layer of adhesive. The base layer comprises a polyurethane memory foam having a first density and the transition layer comprises a polyurethane memory foam having a second density that is less than the first density. The base defines two or more port-side flow channels located in a port portion of the base. Each port-side flow channel extends between an opening in a bottom surface of the base and an opening in a top surface of the base. The base defines two or more starboard flow channels located in a starboard portion of the base. Each starboard flow channel extends between an opening in the bottom surface of the base and an opening the top surface of the base.
The mattress includes a diffusing layer overlaying the top surface of the base. The diffusing layer is divided in the lengthwise direction by a dividing member so that the diffusing layer comprises a port diffusing member, a starboard diffusing member, and the dividing member disposed between the port diffusing member and the starboard diffusing member. The port diffusing member comprises a cellular structure defining a plurality of cells. The cells of the port diffusing member are disposed in fluid communication with each other to form a port volume defined by the cellular structure of the port diffusing member. The port volume defined by the cellular structure of the port diffusing member is in fluid communication with the port flow channels defined by the base. The starboard diffusing member comprises a cellular structure defining a plurality of cells. The cells of the starboard diffusing member are disposed in fluid communicating with each other to form a starboard volume defined by the cellular structure of the starboard diffusing member. The starboard volume defined by the cellular structure of the starboard diffusing member is in fluid communication with the starboard flow channels defined by the base.
In one or more embodiments, the dividing member comprises a closed cell foam material disposed between the port diffusing member and the starboard diffusing member so that the port volume does not fluidly communicate with the starboard volume through the dividing member. In one or more embodiments, the dividing member, the port diffusing member and the starboard diffusing member each having a height of between 1 inch and 3 inches.
In one or more embodiments, the mattress includes a diffusing fabric that is positioned to overlay the diffusing layer. The diffusing fabric defines a multiplicity of connected interstitial spaces. In one or more embodiments, the interstitial spaces are dimensioned and configured to allow air to flow through the diffusing fabric.
In one or more embodiments, the mattress includes a comfort layer overlaying the diffusing fabric. In one or more embodiments, the comfort layer comprises a Talalay latex foam having a thickness dimension with a value between 1 inch and 3 inches. In one or more embodiments, the comfort layer defines a pattern of vertically extending bore holes and each vertically extending bore hole has a diameter of at least 0.20 inches. In one or more embodiments, each vertically extending bore hole has a diameter of at least 0.30 inches. In one or more embodiments, each vertically extending bore hole has a diameter of at least 0.40 inches. In one or more embodiments, each vertically extending bore hole defined by a port portion of the comfort layer fluidly communicates with the port volume defined by the port diffusing member via interstitial spaces defined by the diffusing fabric. In one or more embodiments, each vertically extending bore hole defined by a starboard portion of the comfort layer fluidly communicates with the starboard volume defined by the starboard diffusing member via interstitial spaces defined by the diffusing fabric.
In one or more embodiments, the mattress includes a cover layer positioned to overlay the comfort layer. In one or more embodiments, the cover layer comprises a first woven fabric, a second woven fabric, and a matt of non-woven fibers disposed between the first woven fabric and the second woven fabric. In one or more embodiments, the first woven fabric comprises plurality of woven fibers and the first woven fabric is coated with a phase changing gel material.
In one or more embodiments, the mattress defines a plurality of port-side air flow paths that extend through the mattress. In one or more embodiments, each of the port-side airflow paths extends through one of the port airflow channels defined by the base, the port volume defined by the cellular structure of the port diffusing member, the interstitial spaces defined by the diffusing fabric, and one of the vertically extending bore holes defined by the port portion of the comfort layer. In one or more embodiments, the mattress defines a plurality of starboard-side air flow paths extending through the mattress. In one or more embodiments, each of the starboard-side airflow paths extends through one of the starboard airflow channels defined by the base, the starboard volume defined by the cellular structure of the starboard diffusing member, the interstitial spaces defined by the diffusing fabric, and one of the vertically extending bore holes defined by the starboard portion of the comfort layer.
A feature and advantage of embodiments is a mattress configured to work in conjunction with a foundation that has forced air ventilation with a plurality of air vents on the upward facing side of the foundation. A feature and advantage of embodiments is a mattress configured to permit air from air vents of the foundation to pass through the mattress.
A feature and advantage of embodiments is a mattress that is permeable to air flow provided by a forced air ventilation unit. A feature and advantage of embodiments is a mattress configured to allow air from the forced air ventilation unit to pass through with high efficiency and low-pressure drop. A feature and advantage of embodiments is a system that increases the comfort of the user by heating and/or cooling of the air before the air passes through the mattress.
A feature and advantage of embodiments is a system that allows the person occupying the port side of a bed to select a flow of air having one temperature and, at the same time, allows the person occupying the starboard side of the bed to select a flow of air having another temperature different from the first mentioned temperature. The system may include a mattress configured to reduce or prevent mixing of air passing through the port side portion of the mattress with air passing through the starboard side portion of the mattress.
A feature and advantage of embodiments is a system that provides a level of airflow sufficient to prevent the accumulation of carbon dioxide in the area surrounding the occupant of a bed. A feature and advantage of embodiments is a system that provides a level of airflow sufficient to prevent the accumulation of carbon dioxide in bedding.
In one or more embodiments, the polyurethane memory foam of the base layer has a density no less than about 20 kg/m3 and no greater than about 200 kg/m3, the density being measured using the method described in ASTM D3574-2011. In one or more embodiments, the polyurethane memory foam of the base layer has a density no less than about 30 kg/m3 and no greater than about 175 kg/m3. In one or more embodiments, the polyurethane memory foam of the base layer has a density no less than about 40 kg/m3 and no greater than about 150 kg/m3.
In one or more embodiments, the polyurethane memory foam of the base layer has a hardness no less than about 10 N and no greater than about 300 N, the hardness being measured using the indentation force deflection method described in ASTM D3574-2011. In one or more embodiments, the polyurethane memory foam of the base layer has a hardness no less than about 20 N and no greater than about 200 N. In one or more embodiments, the polyurethane memory foam of the base layer has a hardness no less than about 30 N and no greater than about 100 N.
In one or more embodiments, the polyurethane memory foam of the base layer comprises a closed cell foam material. In one or more embodiments, the Talalay latex foam of the comfort layer comprises a closed cell foam material. In one or more embodiments, the cellular structure of the port diffusing member comprises an open cell, reticulated polyurethane foam structure. In one or more embodiments, the cellular structure of the starboard diffusing member comprises an open cell reticulated polyurethane foam structure.
In one or more embodiments, the diffusing fabric spans continuously across a top surface of the diffusing layer. In one or more embodiments, the diffusing fabric comprises a plurality of fabric patches that do not span across a top surface of the diffusing layer. For example, one fabric patch may be positioned above each of the flow channels defined by the base. In one or more embodiments, the diffusing layer spans continuously across the top surface of the base.
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In an embodiment, a diffusing layer 132 overlays the top surface 126 of the base 102. In an embodiment, the diffusing layer 132 comprises a port diffusing member 136, a starboard diffusing member 138 and a dividing member 134 disposed between the port diffusing member 136 and the starboard diffusing member 138. The dividing member 134 has a forward end and a rearward end. In an embodiment, the dividing member 134 extends in a forward direction from the rearward end 116 to the forward end 114 and extends in a rearward direction from the forward end 114 to the rearward end 116. In an embodiment, the port diffusing member 136 comprises a cellular structure 140 defining a plurality of cells 142. In these embodiments, the cells 142 of the port diffusing member 136 fluidly communicate with each other to form a port volume 144 defined by the cellular structure 140 of the port diffusing member 136. The port volume 144 is in fluid communication with the port-side flow channels 120 in an embodiment. In an embodiment, the starboard diffusing member 138 comprising a cellular structure 140 defining a plurality of cells 142. In these embodiments, the cells 142 of the starboard diffusing member 138 fluidly communicate with each other to form a starboard volume 146 defined by the cellular structure 140 of the starboard diffusing member 138. The starboard volume 146 is in fluid communication with the starboard flow channels 128 in an embodiment. In an embodiment, the dividing member 134 comprises a closed cell foam material disposed between the port diffusing member 136 and the starboard diffusing member 138 so that the port volume 144 is not in fluid communication with the starboard volume 146 via the dividing member 134. In an embodiment, the dividing member 134 has a length, a width and a height, the length being greater than the height, the height being greater than the width.
The mattress 100 may further include a diffusing fabric 148 overlaying the diffusing layer 132 in some embodiments. In an embodiment, the diffusing fabric 148 comprises a plurality of warp fibers 176 and a plurality of weft fibers 178. In an embodiment, each of the warp fibers 176 extends in forward and rearward directions and each of the weft fibers extend in porward and starboard directions. The fibers of the diffusing fabric 148 define a multiplicity of connected interstitial spaces 150 and the interstitial spaces 150 allow air to flow through the diffusing fabric x in some embodiments.
The mattress 100 may further include a comfort layer 152 overlaying the diffusing fabric 148 in some embodiments. In an embodiment, the comfort layer 152 comprising a Talalay latex foam having a thickness dimension with a value between 1 inch and 3 inches. In an embodiment, the comfort layer 152 defines a plurality of bore holes 156. In an embodiment, each of the bore holes 156 extends in an upward direction from a lower opening 190 in a lower surface 194 of the comfort layer 152 to an upper opening 188 in an upper surface 192 of the comfort layer 152 and extends in a downward direction from the lower opening 190 in the lower surface 194 of the comfort layer to the upper opening 188 in the upper surface 192 of the comfort layer 152.
In an embodiment, each of the bore holes 156 defined by a port part 112 of the comfort layer 152 fluidly communicates with the port volume 144 defined by the port diffusing member 136 via interstitial spaces 150 defined by the diffusing fabric 148. Also in an embodiment, each of the bore holes defined by a starboard part 110 of the comfort layer 152 fluidly communicates with the starboard volume 146 defined by the starboard diffusing member 138 via interstitial spaces 150 defined by the diffusing fabric 148.
The mattress 100 may further include a cover layer 158 overlaying the comfort layer 152 in some embodiments. In an embodiment, the cover layer 158 comprises a first woven fabric 160, a second woven fabric 162 and a plurality of non-woven fibers 166 disposed between the first woven fabric 160 and the second woven fabric 162. In an embodiment, the first woven fabric 160 comprising a plurality of woven fibers that are coated with a phase changing gel material.
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In one or more embodiments, the cover layer 158 of a mattress 100 comprises a first woven fabric 160, a second woven fabric 162, and a plurality of non-woven fibers 166 disposed between the first woven fabric 160 and the second woven fabric 162. In one or more embodiments, the first woven fabric 160 comprises a plurality of warp fibers 176A and a plurality of weft fibers 178A. In one or more embodiments, each of the warp fibers 176A extends in forward and rearward directions and each of the weft fibers 178A extend in porward and starboard directions. In one or more embodiments, the second woven fabric 162 comprises a plurality of warp fibers 176B and a plurality of weft fibers 178B. In one or more embodiments, each of the warp fibers 176B extends in forward and rearward directions and each of the weft fibers 178B extend in porward and starboard directions. In one or more embodiments, the first woven fabric 160 is coated with a phase changing material. In one or more embodiments, the weft fibers 178A, the weft fibers 178B, the warp fibers 176A, the warp fibers 176B, and/or the non-woven fibers 166 are coated with a material having phase changing characteristics. Examples of coating materials having phase changing characteristics that may be suitable in some applications are described in the following United States patents, all of which are hereby incorporated by reference herein: U.S. Pat. Nos. 5,366,801, 6,207,738, and 6,514,362.
In one or more embodiments, the weft fibers 178A and the warp fibers 176B of the first woven fabric 160 comprise fibers having phase changing characteristics. In one or more embodiments, the weft fibers 178A, the weft fibers 178B, the warp fibers 176A, the warp fibers 176B, and/or the non-woven fibers 166 comprise fibers having phase changing characteristics. Examples of fibers having phase changing characteristics that may be suitable in some applications are described in the following United States Patents, all of which are hereby incorporated by reference herein: U.S. Pat. Nos. 4,756,958, 5,885,475, 7,666,500, and 8,679,627.
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The following United States patents are hereby incorporated by reference herein:
U.S. Pat. Nos. 9,192,245, 9,211,017, 6,052,853, 6,336,237, 6,370,718, 7,037,188, 7,127,763, 9,265,352, 7,240,386, 8,997,279, 7,334,280, 7,914,611, 8,372,182, 8,881,328, 8,918,930, 9,138,064, 9,211,017, 7,877,827, 7,996,936, 8,065,763, 8,181,290, 8,191,187, 8,332,975, 8,402,579, 8,408,012, 8,418,286, 8,424,315, 8,424,314, 8,621,687, 8,732,874, 8,782,830, 8,893,329, 9,121,414, 9,125,497, and RE44272. These United States patents are incorporated by reference for all purposes. Such purposes may include, by way of example and not limitation, the purposes described in MPEP section 2163.07(B). For example, components illustrated in these patents may be utilized with embodiments described in this detailed description.
The United States patents mentioned in all sections of this patent application are hereby incorporated by references in their entirety for all purposes.
All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.
Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.
This application claims the benefit of U.S. Provisional Patent Application No. 62/318,006, filed Apr. 4, 2016, the disclosure of which is incorporated by reference herein in its entirety.
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