Patent Application
20170150822
The present invention relates to a support cushion cover assembly and, more particularly, to a support cushion cover assembly that makes use of an amount of hygroscopic material and an air pump to remove heat and humidity at the contact surface of a support cushion.
As is generally the case with support cushions and, in particular, with support cushions comprised of flexible foam or other body-conforming materials, the effectiveness of the support cushion in providing support to the body of a user is partly a function of how well the flexible foam responds to the contour of the particular user resting on the cushion. In this regard, support cushions made from temperature-sensitive visco-elastic foam are often particularly desirable as such support cushions are able to, change shape based, at least in part, upon the temperature of the supported body part. That conformance of the cushion to the body of a user, however, often causes more of the user's body to he in contact with the body support cushion, and thus, less of the body of the user is exposed to the ambient air around the cushion. The reduction in the amount of the body of the user exposed to ambient air, in turn, causes many users to find support cushions comprised of visco-elastic foam to “sleep hot” and, occasionally, such users will choose other types of support cushions, notwithstanding the supportive benefits associated with visco-elastic foam and similar types of body-conforming materials.
In an effort to remedy users' concerns of “sleeping hot” as a result of the body-confirming qualities of their support cushions, many support cushion manufacturers have incorporated so-called “cooling” technologies into their products. For example, many support cushions now incorporate latent heat storage units, such as phase change material, that absorb heat and provide a cooling sensation when in contact with the body of a user. Support cushions that include phase change material, however, often fail to account for the humidity that is also present at the contact surface of a support cushion as a result of the body-conforming qualities of the support cushion. In these situations, and despite the inclusion of phase change material in some support cushions, the humidity acts to trap heat in the microclimate zone adjacent to the contact surface of the support cushion (e.g., underneath the sheet but above the mattress cover surrounding a mattress), and thus, reduces the sleep comfort of a user lying on the support cushion.
The present invention includes a support cushion cover assembly and, more particularly, a support cushion cover assembly that makes use of an amount of hygroscopic material and an air pump to remove heat and humidity at the contact surface of a support cushion.
In one exemplary embodiment of the present invention, a support cushion cover assembly includes a support cushion cover having an upper panel, a bottom panel, and a continuous side panel that collectively define a cavity for enclosing a support cushion. The upper panel of the support cushion cover includes an amount of hygroscopic material and generally has a tap surface, a bottom surface, and a middle spacer layer that is positioned between the top surface and the bottom surface of the upper panel. The support cushion cover further includes a flexible tube that extends along a length of the upper panel and defines a plurality of fenestrations, with each fenestration spaced at a predetermined distance from each adjacent fenestration and in fluid communication with the middle spacer layer of the upper panel. In this regard, the support cushion cover assembly also includes an air pump that is operably connected to the flexible tube and is thus configured to deliver an amount of air into the flexible tube, through the plurality of fenestrations, and into the middle spacer layer of the upper panel.
The upper panel of the support cushion cover assembly generally has a thickness of about 5 mm to about 50 mm and can be characterized as including a first side edge, a second side edge, a head end, and a foot end. The foot end of the upper panel includes a release vent for releasing air from the middle spacer layer of the upper panel, while the head end of the upper panel is typically sealed, such that any air entering the middle space layer of the upper panel through the fenestrations in the flexible tube travels throughout the middle spacer layer before exiting the release vent at the foot end of the upper panel. In some embodiments, to further release air from the middle spacer layer, the top surface of the upper panel also defines a plurality of openings. For example, in certain embodiments, the top surface of the upper layer defines a plurality of openings in the top surface with a central region of the openings having a diameter greater than a diameter of the remainder of the openings to provide increased humidity and heat removal in an area of the support cushion cover that would be in contact with the torso of a user lying in a supine or prone position.
To facilitate the removal of heat and humidity from the upper panel of the support cushion assembly, the support cushion cover assembly may include two flexible tubes, a first flexible tube that extends along a length of the first side edge of the upper panel and a second flexible tube that extends along a length of the second side edge of the upper panel. In this regard, the first flexible tube and the second flexible tube are thus positioned and, configured to deliver an amount of air evenly through the fenestrations in the flexible tubes and into the middle spacer layer adjacent to both the first side edge and the second side edge of the upper panel. In some embodiments, to further facilitate the flow of air into the middle spacer layer, a first portion of fenestrations defined by a central portion of the flexible tubes has a diameter that is, greater than a diameter of a second portion of fenestrations defined by an upper portion and a lower portion of the flexible tubes, so as to deliver more air to the area of the middle spacer layer that would be adjacent to the torso of a user lying in a supine or prone position on the support cushion cover.
To deliver a sufficient amount of air into both the first flexible tube and the second flexible tube of the support cushion cover assembly of the present invention, the air pump of an exemplary support cushion cover assembly is generally in the form of a first air pump that is connected to the first flexible tube and a second air pump that is connected to the second flexible tube. In some embodiments, the first air pump and the second air pump can be independently controlled to thereby provide a greater amount of control over the air that is being supplied to a particular flexible tube and, consequently, to the middle spacer layer on a particular side of the support cushion cover assembly.
Regardless of whether an exemplary support cushion assembly includes single or multiple air pumps, each support cushion cover assembly also typically includes a controller for controlling the air supplied to the flexible tubes and the middle spacer layer. By including a controller in the support cushion cover assemblies, the amount of air being supplied to the flexible tubes and the middle spacer layer, or the amount of time that air is supplied to the flexible tubes and middle spacer layer, can be controlled to provide a desired amount of heat and humidily removal at the contact surface of a support cushion. For instance, in certain embodiments, the controller is configured to allow air to be supplied to the flexible tubes and the middle spacer layer for a predetermined amount of time, such as for an 8-hour sleeping period or for a length of time that corresponds to the time a user usually spends in a specific stage of the sleep cycle (e.g., REM sleep).
To provide an additional level of control over the removal of heat and humidity from the contact surface of a support cushion, in some embodiments, the support cushion cover assembly further includes one or more features that are operably connected to the upper panel of the support cushion cover assembly and provide input to the controller. Such features include, in some embodiments, humidity sensors that provide moisture feedback to the controller and allow the controller to, via the air pump, automatically begin providing air to the flexible tubes and the middle spacer layer when the moisture level in or adjacent to the upper panel reaches a particular level. In some embodiments, pressure sensors are included in an exemplary support cushion cover assembly and provide pressure feedback to the controller to allow the controller to, via the air pump, automatically begin providing air to the flexible tubes and the middle spacer layer when a user lies on the support cushion cover or otherwise places an amount of pressure on the support cushion cover. In yet other embodiments, temperature sensors are included in an exemplary support cushion cover assembly and provide temperature feedback to the controller to allow the controller to selectively provide air to the flexible tubes and the middle spacer layer in response to received temperature feedback and to maintain a desired temperature. Such desired humidity, pressure, or temperature feedback settings are, in certain embodiments, directly inputted or adjusted at the controller itself or, in other embodiments, can be transmitted to the controller from a remote control that is also operably connected to the controller and allows a user to remotely adjust the first surface of the body supporting portion to a desired temperature.
With further regard to the support cushion cover assemblies of the present invention, an exemplary support cushion cover assembly can, also be used as part of a method for removing the humidity from a contact surface of a support cushion. In some implementations, a method for removing the humidity from a contact surface of a support cushion includes first providing a support cushion cover that includes: an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface, with the upper panel defining one or more openings in the upper panel and the upper panel also including an amount of hygroscopic material for absorbing humidity present at a contact surface of the support cushion; and at least one flexible tube that extends along a length of the upper panel and defines a plurality of fenestrations, with each fenestration being in fluid communication with the middle spacer layer of the upper panel. An amount of air is then delivered into the flexible tube and the middle spacer layer of the support cushion cover assembly, such that the air flows into the middle spacer layer and through the openings to thereby remove the humidity absorbed by the hygroscopic material and, consequently, the heat and humidity at or adjacent to the contact surface of the support cushion.
Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.
The present invention includes a support cushion cover assembly and, more particularly, a support cushion cover assembly that makes use of an amount of hygroscopic material and an air pump to remove heat and humidity from the contact surface of a support cushion.
Referring first to HOS. 1-2, in one exemplary embodiment of the present invention, a support cushion cover assembly is in the form of a mattress cover assembly 10 that includes a support cushion cover in the form of a mattress cover 11. The mattress cover 11 has an upper panel 14, a bottom panel 16, and a continuous side panel 18 that collectively define a cavity for enclosing a mattress 12. The upper panel 14 of the mattress cover 11 has a top surface 22, a bottom surface 24, and a middle spacer layer 26 that is positioned between the top surface 22 and the bottom surface 24. The upper panel 14 further includes an amount of hygroscopic material 29 that is incorporated into the upper panel 14 such that any humidity on or adjacent to the upper panel 14 is absorbed by the hygroscopic material 29, as described in further detail below.
With further respect to the upper panel 14 of the mattress cover 11, the upper panel generally can be characterized as including a first side edge 32, a second side edge 34, a head end 36, and a foot end 38. The upper panel 14 of the mattress cover 11 is dimensionally-sized to cover the mattress 12 and generally has a thickness of about 5 mm to about 50 mm, such that the upper panel 14 has a thickness sufficient to incorporate a desired amount of hygroscopic material and to allow a sufficient amount of air to move through the middle spacer layer 26. In this exemplary embodiments, the upper panel 14 also includes a pair of release vents 28a, 28b at the foot end 38 of the upper panel 14. Each of the release vents 28a, 28b is in fluid communication with and is configured to release air from the middle spacer layer 26 of the upper panel 14. The head end 36 of the upper panel 14, on other hand, is sealed, such that any air entering the middle space layer 26 of the upper panel 14 travels throughout the middle spacer layer 26 before exiting the release vents 28a, 28b at the foot end 38 of the upper panel 14.
To facilitate the flow of air through the middle spacer layer 26 and the removal of heat and humidity from the upper panel 14, the mattress cover 11 further includes a first flexible tube 40a that includes a plurality of fenestrations 42a and extends along the length of the first side edge 32, and a second flexible tube 40b that includes a plurality of fenestrations 42b and extends along a length of the second side edge 34. Each of the fenestrations 42a, 42b has an equal diameter and is spaced at a predetermined distance from each adjacent fenestration 42a, 42b. Further, each of the fenestrations 42a, 42b is in fluid communication with the middle spacer layer 26 of the upper panel 20 of the mattress cover 11. In this regard, the first flexible tube 40a and the second flexible tube 40b, along with the plurality of fenestrations 42a, 42b in the flexible tubes 40a, 40b. are thus positioned and configured to deliver an amount of air evenly through the fenestrations 42a, 42b in the flexible tubes 40a, 40b and into the middle spacer layer 26 adjacent to both the first side edge 32 and the second side edge 34 of the upper panel 14.
To deliver air into the first flexible tube 40a and the second flexible tube 40b, through the plurality of fenestrations 42a, 42b, and into the middle spacer layer 26. the mattress cover assembly 10 further includes a first air pump 60a that is operably connected to the first flexible tube 40a and a second air pump 60b that is operably connected to second flexible tube 40b. Both the first air pump 60a and the second air pump 60b are connected to discrete controllers 70a, 70b that are configured to control the amount of air supplied by the air pumps 60a, 60b. By including a controller 70a that is only connected to the first air pump 60a and a controller 70b that is only connected to the second air pump 60b, the first air pump 60a and the second air pump 60b can be independently controlled to allow a desired amount of air to be supplied to the first flexible tube 40a, to the plurality of fenestrations 42a, and into the middle spacer layer 26 adjacent to the first side edge 32 of the upper panel 14, while the same or a different amount of air is supplied to the second flexible tube 40b, to the plurality of fenestrations 42b, and into the middle spacer layer 26 adjacent to the second side edge 34 of the upper panel 14. For example, in the exemplary embodiment shown in
Turning now to the hygroscopic material 29 included in the upper panel 14 of the mattress cover 11, the hygroscopic material 29 is generally incorporated into both the top surface 22 and the middle spacer layer 26 such that the hygroscopic material 29 is positioned and configured to place the body of a user, or a portion thereof, resting on the mattress cover 11 in close proximity to the hygroscopic material 29. In this regard, as such a user generates heat and humidity (e.g., humidity in the form of perspiration) during sleep, the hygroscopic material 29 is effectively positioned to absorb any such humidity as it is generated, and is thus configured to reduce the amount of humidity at or adjacent to the contact surface (i.e., the upper surface) of the mattress 12.
The hygroscopic material 29 that is incorporated into the upper panel 14 is generally in the form of encapsulated hygroscopic material that has an increased capability of absorbing humidity and moisture from the surrounding environment relative to the other material included in the mattress cover 11. As the hygroscopic material 29 absorbs moisture from the surrounding environment, the hygroscopic material 29 thus continually absorbs humidity and any associated heat generated by the user. As air is pumped through the flexible tubes 40a, 40b and the plurality of fenestrations 42a, 42b, and into the middle spacer layer 26, the air moving inside the middle spacer layer 26 is then able to remove the absorbed moisture from the hygroscopic material 29 and release it through the vents 28a, 28b while, at the same time, providing a cooling effect to the user lying on the mattress cover II and allowing the hygroscopic material 29 to continue to absorb moisture from the surrounding environment.
As a refinement to the heat and humidity removal capabilities of the support cushion cover assemblies of the present invention and referring now to
Unlike the fenestrations 42a, 42b in the flexible tubes 40a, 40b shown in
To provide an even further level of control over the removal of heat and humidity from the upper panel 114 of the mattress cover 111, the mattress cover assembly 110 further includes additional features that are operably connected to the upper panel 114 of the mattress cover 111 and provide input to the controllers 170a, 170b. In particular, and referring still to
As an even further refinement to the heat and humidity removal capabilities of the support cushion over assemblies of the present invention and referring now to
Unlike the mattress cover assemblies 10, 110 shown in
Referring still to
In addition to using a textile to provide a sufficiently breathable and durable surface, the exemplary cover assembly 210 also typically incorporates one or more flame-retardant materials into the mattress cover 211. By incorporating a flame-retardant material (e.g., a fire sock) into the mattress cover 211, the mattress cover assembly 210 thus provides a flame-retardant barrier that completely surrounds an underlying mattress, such as the visco-elastic foam mattresses described herein below.
As yet another refinement to the present invention, although the support cushion covers shown in
With respect to the flexible foams used in the mattresses and support cushions that are covered by the cover assemblies of the present invention, the mattresses and support cushions are generally comprised of a flexible foam that has a low resilience as well as a sufficient density and hardness, which allows pressure to be absorbed uniformly and distributed evenly across the various mattresses and other support cushions. Such flexible foams include, but are not limited to: latex foam; reticulated or non-reticulated visco-elastic foam (sometimes referred to as memory foam or low-resilience foam): reticulated or non-reticulated non-visco-elastic foam; high-resilience polyurethane foam; expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene); and the like.
With respect to the hardness of the visco-elastic foams used in certain of the mattresses and flexible foam layers, suitable visco-elastic foams typically have a hardness of at least about 10 N to no greater than about 80 N as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the material at approximately room temperature (i.e., 21° C. to 23° C.), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard. In some embodiments, the visco-elastic foam can have a hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, car about 80 N to provide a desired degree of comfort and body-conforming qualities.
With respect to the density of the visco-elastic foams used in certain of the mattresses and flexible foam layers, suitable visco-elastic foams have a density that also assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability. In some embodiments, the density of the isco-elastic foam used in the mattresses and flexible foam layers is no less than about 30 kg/m3 to no greater than about 150 kg/m3. In some embodiments, the density of the visco-elastic foam that is used is about 30 kg/m3, about 40 kg/m3, about 50 kg/m3, about 60 kg/m3, about 70 kg/m3, about 80 kg/m3, about 90 kg/m3, about 100 kg/m3, about 110 kg/m3, about 120 kg/m3, about 130 kg/m3, about 140 kg/m3, or about 150 kg/m3. Of course, the selection of a visco-elastic foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it should be appreciated that a visco-elastic foam having a desired density and hardness can readily be selected for a particular application or assembly as desired.
Additionally, it should be appreciated that the visco-elastic foam used in the mattresses and other support cushions described for use with the cover assemblies of the present invention need not be comprised of a single piece of visco-elastic foam, but can be comprised of multiple layers of visco-elastic foam with the layers having different densities and hardnesses. For example, in some embodiments, a visco-elastic foam mattress can be utilized that includes a lower supporting layer of visco-elastic foam with a density of about 80 kg/m3 and a hardness of about 13 N, and an upper comfort layer of visco-elastic foam with a density of about 35 kg/m3 and a hardness of about 10 N.
With further regard to the support cushion cover assemblies of the present invention. an exemplary support cushion cover assembly can also be used as part of a method for removing the humidity from a contact surface of a support cushion or, in other words. from the surface of a support cushion that is contacted by the body of a user, or a portion thereof. In some implementations, a method for removing the humidity from a contact surface of a support cushion includes first providing a support cushion cover assembly that includes: an upper panel having a top surface, a bottom surface, and a middle spacer layer that positioned between the top surface and the bottom surface, with the upper panel defining one or more openings in the upper panel and the upper panel also including an amount of hygroscopic material for absorbing humidity present at a contact surface of the support cushion; and at least one flexible tube that extends along a length of the upper panel and defines a plurality of fenestrations, with each fenestration being in fluid communication with the middle spacer layer of the upper panel. An amount of air is then delivered into the flexible tube and the middle spacer layer of the support cushion cover assembly, such that the air flows into the middle spacer layer and through the openings to thereby remove the humidity absorbed by the hygroscopic material and, consequently, the humidity at the contact surface of the support cushion.
The references set forth in the following list are incorporated herein by reference.
One of ordinary skill in the art will recognize that additional embodiments or implementations are possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments and implementations disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2014/043993 | 6/25/2014 | WO | 00 |
