Temperature-Regulating Mattress

Abstract

A temperature-regulating mattress system provides dynamic adjustment of temperature and other parameters throughout a user's sleep cycle to maximize the quality of the user's sleep, Features of the system may include: (a) heating and cooling temperature regulation (with dynamic custom profiles that control humidity and are dual-zone); (b) smart controls (with remotes and apps that learn from users to optimize settings and work with smart home products such as Alexa and interactive lighting systems); (c) comfort (with a mattress that provide the necessary support for its users); and (d) sensors used for temperature and humidity estimation algorithms, control mechanism, and additional inferences from those sensors (pose, enrichment of biometric sensing data, etc.).

Description

FIELD OF THE DISCLOSURE

The present disclosure relates generally to an improved mattress system with an ability to provide a dynamic responsive environment for its user or users.

BACKGROUND

The majority of people experience disruptions to their sleep due to temperature problems at least a few nights a month. Existing solutions (such as air conditioning, ceiling fans, room heaters, open windows and the like) are not effective for temperature regulation during sleep. There is therefore a need for an improved method to provide a comfortable sleeping experience by dynamically maintaining the proper temperature during the sleep cycle.

SUMMARY

A temperature-regulating mattress system provides dynamic adjustment of temperature throughout a user's sleep cycle to maximize the quality of the user's sleep, Features of the system may include: (a) heating and cooling temperature regulation (with dynamic custom profiles that control humidity and are dual-zone); (b) smart controls (with remotes and apps that learn from users to optimize settings and work with smart home products such as Alexa and interactive lighting systems); (c) comfort (with a mattress that provide the necessary support for its users); and (d) sensors used for temperature and humidity estimation algorithms, control mechanism, and additional inferences from those sensors (pose, enrichment of biometric sensing data, etc.).

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention and explain various principles and advantages of those embodiments.

FIG. 1A shows a functional diagram of the temperature-regulating mattress system.

FIG. 1B shows a block diagram of the temperature-regulating mattress system.

FIG. 2 shows a thermal diagram of the temperature-regulating mattress system.

FIG. 3 shows a temperature-regulating mattress system having integrated sensors.

FIG. 4A shows a wireless communication path diagram of a temperature-regulating mattress system.

FIG. 4B shows a wireless communication path diagram of an app controlling a mattress system.

FIGS. 5, 6, 7 and 8 show exploded views of a temperature-regulating mattress system.

FIGS. 9,10 and 11 show cross-sections of a temperature-regulating mattress system.

FIG. 12 shows a schematic of a sensor.

FIG. 13 shows a cross-section of a temperature-regulating mattress system with integrated sensors.

FIG. 14 shows sensors embedded in a comfort layer.

FIG. 15 shows sensors embedded in tethered layers.

FIG. 16 shows sensors embedded in a mattress cover.

FIG. 17 shows assembly of a cover over a mattress system.

FIG. 18A shows an exploded view of a mattress cover.

FIG. 18B shows an exploded view of a base cover.

FIG. 19 shows a detailed view of a seams within the mattress cover and base cover.

FIG. 20 shows further detail of the bottom cover of a temperature-regulating mattress system.

FIGS. 21 and 22 show schematics of an integrated mattress base.

FIGS. 23, 24A and 24B show schematics of a modular mattress base.

FIGS. 25 and 26 show schematics of a mattress base layer.

FIG. 27 shows internal wiring of a base layer.

FIG. 28 shows external wiring of a base layer.

FIGS. 29A and 29B show schematics of an adjustable base layer.

FIGS. 29C and 29D show hinges in an adjustable base layer.

FIG. 29E shows a folded base layer.

FIGS. 30A, 30B, 31 and 32 show schematics of an integrated airbox.

FIGS. 33A, 33B, 34 and 35 show schematics of a modular airbox.

FIG. 36 shows a cross-section of a mattress system showing air delivery channels.

FIGS. 37 and 38 show a schematic of air distribution patterns in a mattress system.

FIGS. 39A, 39B, 39C, 39D, 39E and 39F show various methods for sealing surface of holes or slots in a mattress.

FIGS. 40A, 40B and 40C show configurations to improve airflow in a mattress system.

FIG. 41A shows a schematic of a remote for a mattress system.

FIG. 41B shows a cross-section and FIG. 41C shows an exploded views of the remote in FIG. 41A.

FIGS. 42, 43, 44 and 45 show schematics of alternative remotes for mattress system.

FIGS. 46A, 46B, and 46C show various additional embodiments of holes or slots in a mattress.

FIGS. 47A and 47B show various additional embodiments of holes or slots in a mattress.

FIGS. 48A and 48B show various additional embodiments of holes or slots in a mattress.

FIGS. 49A and 49B show various additional embodiments of holes or slots in a mattress.

FIGS. 50A and 50B show various additional embodiments of holes or slots in a mattress.

FIG. 51 shows views of a mattress system using inserts with holes or slots.

FIGS. 52A, 52B, 52C, 52D, 52E, and 52F show various embodiments of the inserts in FIG. 51.

FIG. 53 shows another embodiment of a mattress system using inserts with holes or slots.

FIG. 54 shows an embodiment of a mattress system using inserts for forming holes or slots.

FIG. 55 shows another embodiment of a mattress system with holes or slots.

FIG. 56 shows another embodiment of a mattress system with holes or slots.

FIGS. 57A, 57B, 57C, and 57D show an embodiment of a seven-layer mattress system that uses tubular inserts.

FIGS. 58A, 58B, and 58C show cross-sectional views of another set of embodiments of a mattress system with holes or slots.

FIGS. 59A, 59B, and 59C show cross-sectional views of another set of embodiments of a mattress system using molded insert.

FIGS. 60A and 60B show cross-sectional views of a set of embodiments of a mattress system using die cut inserts.

FIGS. 61A, 61B, and 61C show cross-sectional views of a set of mattress system embodiments having drilled holes.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.

The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be clear to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION

I. Introduction

Devices and algorithm for determining and controlling temperature experienced by users under blankets in bedding may be deployed. Sensors positioned at the mattress surface are used in conjunction with a controls model for bedding to estimate and control user experienced temperature, humidity, and position on the bed. This includes devices being used for temperature and humidity estimation algorithms, control mechanism, and additional inferences from those sensors (pose, enrichment of biometric sensing data).

A variety of approaches may be used to sense temperature, humidity, and body pose at the surface of a mattress. Considered here are wireless surface sensors, as well as wired sensors and smart fabrics. A wireless surface sensor consists of a battery, antenna, temperature and humidity sensors, and a capacitive sensor. The surface sensor measures temperature and humidity using sensor mounted under metal grill. It uses the metal of the grill for capacitive sensing of human presence above the sensor, as well as for improved thermal contact to the sensed environment. It broadcasts temperature, humidity, capacitive presence (sensor payload) to controller at regular interval.

Surface sensors may be placed on a mattress or in holes on surface of mattress under mattress cover and fitted sheet.

Surface temperature, humidity, or presence sensors may also be implemented as a wired solution, or with smart fabrics.

A temperature control unit receives data (wired or wirelessly) from surface sensors, as well as from sensors measuring ambient air temperature and humidity. Based on this data received, the temperature control unit can control the amount and temperature of air added to the user's experienced temperature (blanket microclimate). The technology could apply to other methods of heating user's experienced temperature, including heated fabrics or foam.

Temperature and humidity directly measured from the surface sensor devices is not the same as what the user in the blanket microclimate is experiencing. Depending on blanket types, how well the blanket covers the mattress, how much heat or humidity the user is generating, and ambient conditions, temperature measured at the mattress surface may vary as much as 5-7° C. from the user-experienced temperature.

To estimate the user-experienced temperature, a temperature control unit estimates various thermal parameters of the bed. The device maintains a model of the bedding environment and continuously calibrates itself to best estimate the value of these various thermal resistances and capacitances. By estimating the value of these thermal parameters, the model can maintain an estimate of the user's experienced temperature. The device maintains a state-space model of the mattress and uses parameter identification techniques to estimate bedding parameters.

Mattresses that accommodate two users can incorporate airflow or heat flow across two zones of the mattress into their models for control to control two separate zones of user experienced temperatures.

Processing on data from surface sensors that allows system to estimate user's poses on the bed, which can be used to inform other algorithms and enrich other sensing data. The sensor knows when a body is in direct contact and can reject or adjust temperature readings as needed based on this information.

Smart bed, heating and cooling bed, use with algorithms that can incorporate temperature user experiences in bed, user pose on bed to improve readings of other signals from users, and for controlling temperature precisely enough to improve sleep.

The key physics being taking advantage of is that dynamics of the bed thermal system are governed by a set of differential equations with parameters corresponding to the amount of heat added by the user, the thermal resistance of the blanket (such as, is it thick or thin). Since it is known what heat is being input to the system from our temperature control unit, it is possible to use the shape of the heating or cooling curves measured at the surface sensors to estimate the parameters of the differential equations. The differential equation-based model of the system may be used to control its temperature.

Based on the model's prediction of the microclimate temperature, the control algorithm adjusts heat and blower parameters to achieve a tight degree of temperature control (within a degree or so), which is required to provide precise comfort profiles through the night that might improve a user's sleep.

The control algorithm is also able to consistently update the parameters it's measuring about the state of the bed through the night to account for user's disruption of blankets, introduction of ambient air into the microclimate, or other changes to the environment that might occur overnight. In this way, the control algorithm is robust to the way the user sleeps.

The surface sensors also measure humidity. The control algorithm estimates offset between surface measured humidity and user experienced humidity, and uses that information to help control humidity to within a comfortable band for the user.

The surface sensors also measure capacitive presence above them. If a sleeper is above the surface sensor, the capacitive presence may be used to reject the temperature measured by this sensor (offset by the user's body temperature in this case).

The surface sensor capacitive presence measurements may be used to estimate the pose of the user on the bed. This pose may be used to inform other algorithms in the device. For example, if there is a contactless heart monitoring system operating concurrently with the temperature and humidity control algorithm, pose sensing on the bed might help separate two user's heartbeats by assessing what relative strength of signal to expect from each user at various locations.

Further, devices and algorithm are described herein for introducing temperature interventions to improve sleep onset, depth, and wake inertia by measuring biometric signals, including heart rate, breathing rate, brain activity, motion, and/or temperature. Various temperature interventions are controlled, in part, by biometric sensors and algorithms estimating the user's state (for instance core body temperature, sleep stage) to provide the optimal temperature at the optimal time (comfort profile). Over time, the algorithm can learn what comfort profiles improve sleep onset, sleep depth, and wake inertia for a particular user.

Smart mattress control user experienced temperature in blanket microclimate (possibly with independent control of chest and feet), and measures motion, heart rate and respiration rate, amongst other biometric signals. Measurements of these various biometric signals can be through ballistocardiography performed from under-mattress, in-mattress, or in-mattress-cover, or through smart fabrics, wearables, radar, camera, or other sensing mechanisms.

Core body temperature reduction has been shown to be important to the onset and depth of sleep. Sleep stage has been shown to be important to the body's thermal regulation ability. For instance, during REM sleep, the body isn't able to thermoregulate. Various thermal interventions (changes to user's experienced temperature under the blankets) can be used to manipulate core body temperature and enhance sleep.

The algorithms use biometric sensing data (motion, heart rate, and respiration rate) to estimate core body temperature and sleep stage. Temperature interventions are adjusted real-time based on the sensor and algorithm outputs.

By manipulating user's experienced temperature (through foot warming, skin warming, and other temperature profiles), the device can use the sensor and algorithm output to confirm that its temperature therapy is helping the user drop and maintain a low core body temperature through the night. Temperature therapy can be adjusted based on biometric feedback to do this. Wakes might be predicted by observing motion, heart rate, or sleep stage. Temperature profiles can be adjusted during the night to prevent those wakes or lull the user back to sleep once they awake.

Algorithms may control temperature experienced by a user in order to reduce sleep latency (fall asleep faster), stay asleep longer (fewer wakeups), sleep more deeply (more REM+Slow Wave Sleep), and nudge users into a shallower phase of sleep in time for their desired wakeup time.

The algorithm may run on an ecosystem of products that provide lighting, temperature, sound, and other therapies to improve sleep dynamically—they respond to sensors that are also distributed in the ecosystem. Sensors in the ecosystem measure experienced temperature and humidity, light exposure, heart rate, respiration rate, and other signals.

Algorithms can tune lighting, temperature, sound, and other therapies based on sleep quality observed from sensed data.

Smart bed, heating and cooling bed, use with algorithms that can incorporate temperature user experiences in bed, Helping normal users with thermoregulation to help them sleep, helping users with circulation problems (obesity, diabetes, etc.) and other sleep issues with thermoregulation to help them sleep, use of other ecosystem products (temperature, light, sound control before, during, and after sleep) to improve sleep with biometric sensing in the mattress as a feedback mechanism to tailor therapies.

The present devices may use independent temperature control at the torso and feet through the night to try to improve sleep. A naive temperature profile delivered by a control device might provide warmth as the user is falling asleep, cool the user while they're asleep to prevent night-time wakes, and warm the user up before wakeup.

The algorithm uses biometrics data to improve on this naive temperature control profile. Application of a temperature profile (heating feet, for instance) is intended to aid the body's normal thermoregulatory process during the night. This includes cooling down core body temperature during sleep onset, maintaining lowered core body temperature through the night, and increasing core body temperature before wake.

There is evidence that poor thermoregulation is implicated in poor sleep for diabetics, the obese, patients who suffer from Raynaud's disorder, and other circulatory and sleep issues. There is evidence that normal sleepers thermoregulatory process can be impacted by food and alcohol consumption before bed, or by hormonal cycles. Users whose thermoregulatory function is changed may need a temperature intervention to assist in falling asleep, staying asleep and waking up.

This thermoregulatory process can be tracked by watching a user's heart rate. As core body temperature decreases at the beginning of the night and increases at the end of the night (corresponding to metabolism rate decrease and increase), heart rate also increases and decreases. Heart rate data can be used to measure the impact of the temperature intervention and to adjust the temperature accordingly in real time.

Sleep staging data teased out from heart rate, respiration rate, motion, EEG, or eye movement detection can be used to assess quality or depth of sleep night for night, and use machine learning to optimize sleeping temperatures per user.

To help users fall asleep, foot warming or other temperature profiles may be used. In real time, the profiles watch their heart rate to make sure it is dropping as expected (corresponding to core body temperature decline).

Once the heart rate, respiration rate, and motion tracker detect that the user has fallen asleep, the next phase of temperature therapy begins.

While the user is asleep, the heart rate, respiration rate, and motion are used to predict when a user may wake up during the night. The same foot warming or other falling-asleep therapy applied to the user to help lull them back to sleep can be used.

Temperature profiles during the night that increase slow wave and REM sleep may be used. The algorithm measures how much slow wave and REM sleep was experienced per night and optimize sleep temperature profile night for night to increase this deeper sleep.

Finally, the heart rate may be used to track increasing core body temperature through full body warming in the time before the user has to wake up. The sleep stage is monitored to ensure the user is nudged out of deep or slow wave sleep.

This same concept of tracking heart rate, respiration rate, and motion through the night, tying them to core body temperature and sleep stage through the night, and tuning interventions like temperature during the night, can be applied to all products intended to help sleep. This includes light therapy, sound masking, and various mattress and blanket product choices (firmness, ergonomics, thermal and humidity performance of bedding). All of these products can be adjusted to improve sleep depth and quality, with biometric sensing as a feedback mechanism.

Biometric and other data that might be relevant as a marker for sleep quality (phone use, light exposure, diet, alcohol consumption) can be collected from an ecosystem of sleep sensors, as well. Interventions from a sleep ecosystem could include (in additional to temperature, light, and sound interventions) sleep coaching, diet recommendations, bedding recommendations. In this way a platform for sleep might be created amongst a wide variety of devices and data sources.

While various embodiments discussed herein show wireless and wired functionality in specific areas, any wired connection may function via a wireless connection and vice versa. In addition, any discussion of Bluetooth may include any other wireless protocol (including Wi-Fi), whether existing now or in the future. Further, any Bluetooth (or other wireless) node shown herein may operate as either a master or slave as appropriate.

In addition, the mattresses discussed herein may be of any size, including without limitation: twin, full, queen, king, California king and extra-long (of any size).

In addition, for a 2-user mattress, the features described herein may be independently adjusted to provide different experiences for each user.

Turning to a more detailed description, the various features of this temperature-regulating mattress may be classified into seven overall categories: System, Sensor, Cover, Base, Airbox, Airflow and Remote. Each will be discussed in turn.

II. System

The scope and functionality of the temperature-regulating mattress system taken in the aggregate is described herein.

Turning to FIG. 1A, shown us a functional diagram of the temperature-regulating mattress system 100. A legend 112 shows the various parts of this system: processor, radio/comms, input/sensor, output/actuator, remote, comfort layer and base layer.

A main board 108 comprises a system microcontroller unit (MCU) that provides overall governance of the system and communicates with other components through a Wi-Fi or Bluetooth radio. Two high voltage control boards 110 (HVCBs) comprise a control MCU that provides governance of the control boards and connects to the system MCU. The control MCU also interfaces with a plurality of relative humidity (RHT) sensors and current and voltage (I/V) sensing systems associated with either a heater or a fan. Two biometric sensors 102 comprise a biometric sensor and a biometric MCU that provides governance of the biometric sensor and connects to the system MCU. A plurality of surface sensors 104 comprise a sensors MCU that provides governance of a plurality of RHT sensors and presence sensors. Two remote systems 106 comprise a remote MCU that provides governance of the remote and communicates with the rest of the system via a Bluetooth radio. The remote MCU has inputs comprising a proximity sensor, button, rotary encoder and light sensor. The remote MCU outputs to a haptic actuator and a LED controller that drives LEDs.

Turning to FIG. 1B, shown is a block diagram of the temperature-regulating mattress system 150. A mattress 156 coordinates via Bluetooth with two mobile devices 152a, 152b, a cloud platform/backed 154 and two remotes 158a, 158b.

Although these figures show specific numbers of devices and specific types of radio communication, any number of devices and radio communication types may be used.

Turning to FIG. 2, shown is a thermal model 200 the temperature-regulating mattress system. At the top of the thermal model 200 is the atmosphere 205 followed by the resistance/capacitance a of blanket 210. This combined with the heat added by a user comprises a microclimate 240 that sits above the mattress and below the blanket. Additional resistance/capacitance 215 of the cover and fitted sheet below the user is associated with a temperature control unit 220 (airbox). Surface sensors 230 sit in between the matter and mattress cover.

The capacitor/resistor pair 225 models the thermal relationship between the airbox (temperature control unit 220) and the location of the surface sensors 230. In other words, how is the temperature of air coming out of the airbox affecting the temperature at the surface sensors due to convection/conduction/radiation between them?

The capacitor/resistor pair 235 models the thermal relationship between the temperature in the micro-climate (air under the covers that the user is in) and the temperature at the surface sensors (which are separated from the micro-climate by several layers of fabric, and therefore do not read the micro-climate temperature directly). Determining the parameters for these interfaces (e.g. how much does the temperature change between the two environments, or in other words how much thermal resistance is there between them) enables a good estimate of the micro-climate temperature from the temperature measured at the location of the surface sensors.

Turning to FIG. 3, shows a temperature-regulating mattress system having integrated sensors 300. This comprises a mattress 308 having a hidden base layer 310 on the bottom and a transparent mattress cover 311 on the top. Surface sensors 304a-304h and ventilation cuts 306a-306d are incorporated within the mattress 308. The surface sensors 304a-304h may include temperature, humidity and user presence sensors that are integrated into the mattress cover and are designed to be roll-packed. The ventilation cuts 306a-306d cut through the comfort layer near the torso and fee to allow air to distribute through the mattress.

The hidden base layer 310 is hidden by a fabric cap on a comfort layer and may be of any relevant size and shape. The transparent mattress cover 311 may have varying levels of opacity.

Turning to FIG. 4A, shown is a wireless communication path diagram 400 of a temperature-regulating mattress system. The mattress 422 is divided into two parts, side A 410a and side B 410b. Two consoles/remotes/user input devices 405a, 405b communicate with an electronics module 412 via Bluetooth. The electronics module 412 communicates through the cloud to wirelessly store and retrieve temperature profiles 450. The electronics module 412 may include fans, heaters, coolers, printed circuit boards and may be removable for servicing.

Based on the input of the console/remotes/user input devices 405a, 405b and the temperature profiles 450, the electronics module 412 interfaces with foot sensor groups 410a, 410b and torso sensor groups 408a, 408b. Each of the sensor groups communicates via Bluetooth with the appropriate temperature, relative humidity and pressure sensors. The sensors also may measure movement, presence, heart rate and breathing rate.

Although this FIG. 4A shows a wireless system, one or more portions of the system may be wired. Additional sensors may be placed within the mattress 422 as warranted. And although the electronics module 412 is shown at the foot of the bed 422, airboxes may be integrated in the foot and torso portions of the bed 422 (or other portions).

Turning to FIG. 4B, shown is a wireless communication path diagram of an app controlling a mattress system 4600. Comfort profile storage 4622 interfaces with cloud storage 4650, a remote 4604, an onboarding portal 4632 and a feedback portal 4634 and a mattress hub 4630.

The onboarding portal 4632 is designed to collect data about the user before the user goes to sleep. The data may include the user's gender, age, weight, sleep pattern, sleep location, desired temperature, desired relative humidity and the like. The onboarding portal 4632 may be used to control sleep parameters through the sleeping process. The remote 4604 may also be used during the sleep period to adjust sleep parameters through the sleep process. The advantage of the remote 4604 over the outboarding portal 4632 is that the remote 4604 only requires simple actions such as a push, twist or gesture to control the sleep parameters. This allows the user to easily and quietly adjust parameters throughout the sleep period without having to boot up an onboarding portal 4632 on a phone, tablet or other portable device.

At the end of a sleep period, a user may use a feedback portal 4634 to report on the quality of sleep, the temperature, the humidity and other parameters during the sleep period. This data is reported to the comfort profile storage 4622 to update the user profiles as appropriate.

The hub 4630 may also interface wirelessly with sensor groups 4605, 4606 having temperature, relative humidity and pressure sensors. The hub 4630 may interface with heaters 4612 and fans 4614 in the mattress system and their related exhaust temperature and humidity sensors 4610.

Although both onboarding portal 4632 and feedback portal 4634 are shown routing through cloud, one or both of portals may connect directly to a mattress control main board via Bluetooth/Wi-Fi/wireless or wired connection.

FIGS. 5, 6, 7 and 8 show exploded views of a temperature-regulating mattress system.

Turning to FIG. 5, shown is an exploded views of a temperature-regulating mattress system 500. On the left is an unexploded mattress view. On the right side, an exploded view shows a comfort layer 510 on the top, followed by comfort layer stiffness adjusters 512, followed by a base layer 514. The comfort layer stiffness adjusters 512 may be flexible structures made from foam, rubber, gel or other flexible materials. They may also be air permeable to aid in air distribution. The base may form protrusions from air paths between the mattress and bed frame or foundation.

Sandwiched between the comfort layer 510 and the base layer 514 is an electronics module 516. The electronics module 516 may include fans, heaters, printed circuit boards and may be removable for servicing.

A side view of a cross-section of a mattress system shows the electronics module 516 and an air distribution system 518 for distributing the air throughout the mattress. The system may be either incorporated into foam as molded or cut channels or a separately molded part that is inserted into a cavity under the comfort layers.

Turning to FIG. 6, shown are various views of a temperature-regulating mattress system 600. On the left is a complete mattress view 604a with the air intake module 606a jutting out. On the top right, the complete mattress view 604b is shown with the combined electronics module 608a and air intake module 606d. This may include fans, heaters, printed circuit boards and may be removable for servicing.

On the middle right and bottom right shown is a semi-transparent mattress in a perspective view 604c and side view 604d with the combined electronics module 608b, 608c and air intake module 606b, 606c in its place on the bottom of the mattress 604c, 604d.

The views also show comfort and diffusion materials 610a, 610b along with a distribution layer 612 below those materials. The comfort and diffusion materials 610a, 610b may be air permeable materials diffuses and distributes air delivered by the distribution layer 612. The distribution layer 612 may be either incorporated into foam as molded or cut channels or a separate part that is inserted into cavity under comfort layers.

Turning to FIG. 7, shown are various views of a temperature-regulating mattress system 700. On the left is a complete mattress with a comfort cover top 705 and an air permeable cover top 708. On the bottom shown is the placement of electronics module 714.

This may include fans, heaters, printed circuit boards and may be removable for servicing.

On the right shown is the placement of air intake 712 and diffusion materials 710 that may be air permeable material that diffuses and distributes air.

Turning to FIG. 8, shown is a complete mattress exploded view 800. The top layer is a cover top 802, followed by a series of comfort layers 804, followed by a distribution layer 806, followed by an intake layer 808 and followed by a cover bottom 812. Installed on the intake layer 808 are electronic modules 810 that may include fans, heaters, printed circuit boards and may be removable for servicing.

The cover top 802 may be comfortable and air permeable. The distribution layer 806 may be either incorporated into foam as molded or cut channels or, alternatively, be a separate part that is inserted into a cavity under comfort layers. The intake layer 808 may be about 2 inches in height and consist of flexible, structural impermeable materials with air channels. The cover bottom 812 may have air permeability and be durable.

FIGS. 9,10 and 11 show cross-sections of a temperature-regulating mattress system.

Turning to FIG. 9, shown is a mattress cross-section first embodiment 900 consisting of a comfort layer cross-section 901 and a base layer cross-section 951. The comfort layer cross-section 901 includes a mattress cover top panel 905 over a top panel foam insert 906 that are joined at a stitch seam 908. On the side is a mattress cover outer border 910 and a mattress cover inner border 912 that are joined with the base via a mattress cover to base cover zipper 920. On the top are embedded surface sensors 903 and surface sensor patches 904.

The comfort layer 901 is partially surrounded by a mattress fire sock 914. A mattress cover zipper 916 secures a mattress cover base panel 918 and a mattress cover to base cover zipper 820. A surface sensor plug 926 provides power to the system.

Within the mattress itself are foam comfort layers 924 with an embedded ergonomic gel matrix 922. Cut vertically through the mattress are air-impermeable surfaces 902 for air passage.

The base layer 951 cross-section includes a base top panel 958 and a base cover zipper 960 that secures a base cover border 962. A mattress cover to base cover zipper 966 secures a base cover base panel 968. On the top is a biometric sensor 956. On the side is a surface sensor socket 952. On the bottom is an AC power socket 972 and AC power cord 970.

Across the base layer cross-section 951 are a series of expanded polypropylene (EPP) segments 976. A torso airbox 974 and feet air box 984 are integrated within the EPP segments 976. Each airbox includes a fan 978a, 978b and a heater 980a, 980b. Air ducts 982a, 982b allow air to circulate throughout the height of the base layer 951.

The EPP Segments 976 shown in this figure and elsewhere in the application consist of expanded polypropylene chosen because of its lightweight and strong properties. It may be easily molded in various shapes including molding including nuts that for screws to be inserted thereto. These segments may also comprise expanded polyethylene (EPE) expanded polystyrene (EPS) and be injection molded, blow molded, rotationally molded, pressure formed or vacuum formed.

Turning to FIG. 10, shown is a mattress cross-section second embodiment 1000 consisting of a comfort layer cross-section 1001 and a base layer cross-section 1051. The comfort layer cross-section 1001 includes a mattress cover outer top panel 1005 over a top panel foam insert 1007 that are joined at a stitch seam 1008. On the side is a mattress cover outer border 1011 and a mattress cover inner border 1012 held together by an inner cover to outer cover snap 1010. The mattress cover inner border 1012 is also the mattress cover inner top panel 1006 at the top of the mattress.

On the top are embedded surface sensors 1003 and surface sensor patches 1004.

The comfort layer 1001 is partially surrounded by a mattress fire sock 1014. A mattress cover zipper 1016 secures a mattress cover base panel 1018 and a mattress cover to base cover zipper 1020. A surface sensor plug 1026 provides power to the system.

Within the mattress itself are foam comfort layers 1024 with an embedded ergonomic gel matrix 1022. Cut vertically through the mattress are air-impermeable surfaces 1002 for air passage.

The base layer 1051 cross-section includes a base top panel 1058 and a base cover zipper 1060 that secures a base cover border 1062. A mattress cover to base cover zipper 1066 secures a base cover base panel 1068. On the top is a biometric sensor 1056. On the side is a surface sensor socket 1052. On the bottom is an AC power socket 1072 and AC power cord 1070.

Across the base layer cross-section 1051 are a series of expanded polypropylene (EPP) segments 1076. A torso airbox 1074 and torso air box 1084 are integrated within the EPP segments 1076. Each airbox includes a fan 1078a, 1078b and a heater 1080a, 1080b. Air ducts 1082a, 1082b allow air to circulate throughout the height of the base layer 1051.

Turning to FIG. 11, shown is a mattress cross-section third embodiment 1100 consisting of a comfort layer 1101 cross-section, an airbox layer 1106 cross-section, an intake layer 1103 cross-section and an adjustable base 1104 cross-section. The adjustable base may be folded about the gaps shown.

The comfort layer 1101 may be about 11.5 inches comprises a plurality of temperature, humidity, motion sensors 1102a-1102e below the mattress cover and is surrounded by a comfort layer fire sock 1122. On the top is a comfort layer cover 1120 and within are comfort foam layers 1124. Vertical sealed inside surfaces 1110 allow for air distribution through the comfort layer 1101 while prevented lateral airflow.

The airbox layer 1106 may be 2 inches and includes a biometric sensor 1112, and 2 airboxes 1130a, 1130b (one torso, one foot, each having a heater and fan that are not shown) surrounded by an airbox chassis 1128a, 1128b. The biometric sensor 1112 may measure heart rate, breathing rate and presence sensing.

Between each airbox chassis 1128, 1128b and the airbox cover 1126a, 1126b is thermoformed foam 1118a, 1118b. Also incorporated are temperature and humidity sensor downstream of the heater 1114a, 1114b and temperature and humidity sensor upstream of the fan 1116a, 1116b.

The intake layer 1103 may be about 2 inches comprises intake layer foam 1132 and surrounded by an intake layer fire sock 1134.

III. Sensors

The scope and functionality of sensors within a temperature-regulating mattress system is described herein. Such sensors may measure one or more of the following: temperature, (relative) humidity, pressure/presence, movement, presence, heart rate, breathing rate and other biometric parameters.

Turning to FIG. 12, shown is a schematic of a wireless sensor system 1200. Within the system, there is a metal grille 1205 over electronics for temperature and humidity sensing 1210 powered by a battery 1220. The sensor system 1200 communicates wirelessly via an antenna 1230.

Turning to FIG. 13, shown is a cross-section of a temperature-regulating mattress system 1300 with various integrated or embedded sensors.

A user lies on the mattress 1340 along the dashed line 1325 with bedding 1310 above and a sheet 1330 and mattress protector 1335 below. Sensors may be integrated or embedded in all parts of the system, including at foot sensor 1320, a top-of-sheet sensor 1345, an under-sheet sensor 1350 and an embedded sensor 1355. Single or multiple sensors per user may be used.

Turning to FIG. 14, shown are sensors embedded in a comfort layer mattress system 1400.

A series of sensors are wired into comfort layer at the foot 1410a and the torso 1410b. Wires 1420 run through the mattress system 1400 that are installed in the comfort layer before the cover is installed. The wires 1420 then are directed to a connector 1430 that interfaces with the base 1440. The power of the base layer 1440 may also power the sensors 1410a, 1410b via the connector 1430 and wires 1420.

Turning to FIG. 15, shown are sensors embedded in tethered layers mattress system 1500. A sensor band 1510 wraps around a comfort layer 1515 and is secured 1520 to the base layer 1525. The sensor band 1510 may include multiple sensors of various functions and includes an electric connection when secured 1520 so that the power of the base layer 1525 may also power the sensor band 1510.

The sensor band 1510 is covered with sheeting by the user.

There may also be wider bands or multiple bands in this system. Or the band footprint may extend to any part of the mattress and have multiple cutouts.

Turning to FIG. 16, shown are sensors embedded in a cover mattress system 1600.

A series of sensors are wired into the cover layer 1615 at the foot 1610a and the torso 1610b. The cover layer 1615 is designed to be placed over the comfort layer 1640. Wires 1650 run through the cover layer 1615. The wires 1615 are directed to a connector wire 1620 that terminates at a snap connector 1623 that interfaces with the base 1625. The power of the base layer 1625 may also power the sensors 1610a, 1610b via the connector 1620 and wires 1650.

IV. Cover

The scope and functionality of covers within a temperature-regulating mattress system is described herein. The cover may consist of any suitable materials, including latex, memory foam, polyester blends, feathers, wool, cotton, flannel, silk and bamboo. Connecting systems such as zippers may be replaced by any other connector such hook and loop fasteners (Velcro®), snaps, tape and the like.

Turning to FIG. 17, shown is an assembly of a cover over a mattress system 1700. A mattress core 1710 is shown separated from a base 1720. After being zipped, an assembled mattress core plus base 1730 is shown.

Turning to FIG. 18A, shown is an exploded view 1800 of a mattress cover. Shown staring from the top is a top panel 1802, a foam insert 1804, an inner border 1806, a bottom panel 1808 and an outer border 1810

Turning to FIG. 18B, shown shows an exploded view 1850 of a base cover. Shown starting from the top is a top panel 1852, a border 1854 and a bottom panel 1856.

Turning to FIG. 19, shown is a detailed view of a seams within a mattress system 1900 with a cover mattress layer 1990 having lower zipper teeth 1985 and a cover base layer 1992 having upper zipper teeth 1983.

On the top shown is a mattress cover outer border 1902 and a mattress cover inner border 1906. In the top inset shown is a mattress cover top panel 1908, an optional top panel foam insert 1910, a mattress cover outer border 1902 and a mattress cover inner border 1906 all joined together by stitching 1930.

On the bottom shown is a base cover border 1904. In the bottom inset shown is a mattress cover outer border 1902 and an interchangeable reverse coil zipper 1980a joined together by stitching 1957. Also shown is a base cover mesh fabric 1960 and an interchangeable reverse coil zipper 1980b joined together by stitching 1955. Also shown is lower zipper teeth 1985 and upper zipper teeth 1983 joined together by stitching 1956 and zipper 1975. This zipper 1975 is designed to join the cover mattress layer 1990 and a cover base layer 1992.

Turning to FIG. 20 shown is further detail of the bottom cover of a temperature-regulating mattress system. On left side, shown is a spacer fabric sample 12050, a spacer fabric sample 22054, a fabric diagram 2052 and a spacer fabric sample 32056. The fabric diagram 2502 shows a front surface, a back surface and spacer yarn in between the front surface and back surface.

On the right side, shown is a mattress cross section detail system 2000. Shown is a cover top 2010 that may be comfortable and air permeable and a cover bottom 2025. The cover top 2010 and cover bottom 2025 surround comfort layers 2015 (that may be about 10 inches in height) and an intake layer 2020. The intake layer 2020 may be about 2 inches in height and have a flexible impermeable structure with air channels on the perimeter side 2060a and bottom 2060b, 2060c, 2060d, 2060e.

Airflow through the air channels 2060a, 2060b, 2060c, 2060d, 2060e are enabled because the cover bottom 2025 may be constructed from spacer fabric or similar material (as shown on the left side of FIG. 20). This fabric allows air to move freely through the cover bottom 2025 in both the perpendicular and parallel directions. In particular, airflow moves through the fabric parallel to the surface when the underside and vertical sides of the mattress are blocked by bedframe and bedding.

V. Base

The scope and functionality of bases within a temperature-regulating mattress system is described herein. The base may include components integrated within the base structure or modular components affixed to the base structure (or a combination of the two).

FIGS. 21 and 22 show schematics of an integrated base.

FIG. 21 shows a schematic of an integrated base 2100 have a mattress 2110 and a base 2120 powered by wire 2140. Air distribution may take place in the mattress 2110. Biometric sensors 2130 may be integrated within the base 2120. Such sensors may include hear rate/breathing rate/presence sensing and other biometrics.

Also shown is an integrated torso module 2150a and an integrated foot module 2150b. These modules 2150a, 2150b may jut out from base 2120 because of the airboxes contained therein or may be level with the base 2120. The base 2120 may include electronics, fans, heaters and air intake apparatuses.

Turning to FIG. 22, shown is a base system detail 2200 with foam panels 2210, a fabric hinge 2220, thermoformed foam 2230 and permeable fabrics 2240a, 2240b. As will be shown below, the fabric hinge will allow the base 2120 to be folded in various combinations.

FIGS. 23, 24A and 24B show schematics of a modular base.

Turning to FIG. 23, shown is a schematic of a modular base system 2300.

Temperature, humidity and motion sensors 2302a-2302f are incorporated below the mattress cover within the mattress 2306. Modules 2304a, 2304b (each of which is split into 2 parts) that at least contain airboxes (not shown) are installed on the base 2310.

Biometric sensors 2308 may be integrated within the base 2310. Such sensors may include hear rate/breathing rate/presence sensing and other biometrics.

The modules 2304a, 2304b are normally assembled by the end user and connected to the base 2310 electrically. This may produce better packaging solutions with smaller boxes.

Turning to FIG. 24A, shown is a modular base system detail 2400 without the module installed. Shown is a permeable fabric 2420 and a thermoformed tray 2430 with a power cable storage 2410.

Turning to FIG. 24B, shown is a modular base system detail 2400 with the module 2480 installed. Shown is a permeable fabric 2470a, 2470b and a power connection 2460.

The system is designed so that the module 2480 is snapped into a thermoformed tray 2430 where the power cable located in the power cable storage 2410 is connected to the power connection 2460. This provides power to the module 2480. Similar setups for 3 other modules (not shown) may be implemented.

Turning to FIG. 25, shown is a schematic of a base layer with cover 2500. The fabric cover 2510 (shown as transparent) may be of any suitable material that is either opaque, translucent or transparent. This allows the base layer components to be contained in a fabric shell. The fabric cover 2510 may be permeable so as to allow air to be distributed to holes in the mattress installed above the base layer (not shown). A segmented structure 2530 comprising several segments that allow the base layer to fold for shipment and flex for compatibility with adjustable bases.

Turning to FIG. 26, shown is a schematic of a base layer without a cover 2600. A biometric sensor track 2610 is inlaid to measure dynamic sleeping profiles for the mattress user, including measuring breathing rate, heart rate and movement throughout the night. Five rigid panels 2650a, 2650b, 2650c, 2650d, 2650e are installed over five molded EPP segments 2640a, 2640b, 2640c, 2640d, 2640e. This segmented structure comprising several segments allows the base layer to fold for shipment and flex for compatibility with adjustable bases.

A torso airbox system 2602b is installed within rigid panel 2650c flush with the top of the base layer. Ramps 2630c, 2630d are carved out of the rigid panel 2650c to allow for airflow. In the alternative, the torso airbox system 2602b may include integrated ramps on the left and right to allow for airflow.

A foot airbox system 2602a is installed within rigid panel 2650e flush with the top of the base layer. Ramps 2630a, 2630b are carved out of the rigid panel 2650e to allow for airflow. In the alternative, the foot airbox system 2602a may include integrated ramps on the left and right to allow for airflow.

Turning to FIG. 27, shown is an internal wiring schematic of a base layer 2700. Within the base layer 2700 are a wiring system 2710 that connects (among other possible devices) a biometric sensor strip 2720, a torso airbox 2730, a feet airbox 2740 and a surface sensor interconnect 2750. The torso airbox 2730 and feet airbox 2740 each include two fans on the side and an electrical component in the middle to control operation of the airboxes 2730, 2740. The surface sensor interconnect 2750 interfaces with other sensors throughout the mattress system to providing inputs to the airboxes 2730, 2740 and transmit outputs from the biometric sensor strip 2720.

Turning to FIG. 28, shown are five external wiring schematics within a base layer.

Schematic 12810 shows a wiring system sourced on the side of the foot of the mattress. A top view, side flat view and side folded view are shown.

Schematic 22820 shows a wiring system sourced on the bottom of the middle of the mattress. A top view, side flat view and side folded view are shown.

Schematic 32830 shows a wiring system sourced on the top of the middle of the mattress. A top view, side flat view and side folded view are shown.

Schematic 42840 shows a wiring system sourced on the bottom of the head of the mattress. A top view, side flat view and side folded view are shown.

Schematic 52850 shows a wiring system sourced on the top of the head of the mattress. A top view, side flat view and side folded view are shown.

The foregoing schemes may be adjusted such that the wiring is sourced at any other position within the mattress.

Turning to FIG. 29A, shown are various schematics of an adjustable base layer and its associated mattress. Making the base layer adjustable allows the mattress system to be formed into various configurations for additional user comfort and for easier shipping.

On the top left, shown is an articulating mattress system 2910 with four segments in the base layer to allow for such articulation. On the bottom left, shown is an internal view of the same articulating mattress system 2920 with four segments: head (the widest segment), torso (including an airbox), legs and feet (including an airbox). On the top right, shown is an overhead schematic view of the same articulating mattress system 2930 with the same four segments. On the bottom right, the same articulating mattress system 2940 with the same four segments is set in an exemplary configuration. Here, the head segment is set at a 116-degree angle from the torso segment, the torso segment is set at a 142-degree angle from the legs section and the legs section is set at a 142-degree angle from the feet section.

The foregoing system may have a different number of layers capable of being articulated in angles ranging from above 0 degrees to 180 degrees.

Turning to FIG. 29B, shown is a partially exploded view of schematic of a base of an articulating mattress system 2950. The schematic shows five segments joined together with sixteen hinges 2975 shown in an exploded view. The first, second and fourth segments 2942a, 2942b, 2942c include no visible electronic parts. The third segment 2951a includes an integrated torso airbox system 2947a and the fifth segment 2951b includes an integrated feet airbox system 2947b. The entire system is powered via a power cord 2971 and an internal wiring system (not shown).

Turning to FIG. 29C, shown is a detail view of an adjustable base layer hinge 2990. On the left side, an overhead view shows the hinge 2975 (which may be the same hinge as in FIG. 29B) joining two segments 2924a, 2924b together. The cross section of hinge 2975 and the two segments 2924a, 2924b at line A-A is shown on the right side. Here it can be seen that the hinge 2975 flexibly joins the two segments 2924a, 2924b because the hinge 2975 includes two circular protrusions 2976a, 2976b that snap into two circular receptacles 2980a, 2980b. The circular receptables 2980a, 2980b may be carved out of the material that comprises the two segments 2924a, 2924b such that the circular protrusions 2976a, 2976b remain ensconced in the two segments 2924a, 2924b at any angle the two segments 2924a, 2924b may be set. These angles may include those shown in FIG. 29A.

Turning to FIG. 29D, shown is a detail view of another adjustable base layer hinge. A side view 2901 shows a double hinge 2904a, 2904b ensconced within two segments 2903a, 2903b. A top view 2902 shows the same double hinge 2904a, 2904b ensconced within two segments 2903a, 2903b. The advantage of this embodiment is that the hinge structure is reinforced in both directions so that flexibility of the two segments 2903a, 2903b to bend in both directions is enhanced.

Turning to FIG. 29E, shown is a foldable base layer system 2991. A folded base layer 2995 shows five segments folded on top of one another on a bed frame 2993. The folded nature of these five segments may be accomplished by using the hinges shown in either FIG. 29C or 29D.

VI. Airbox

The scope and functionality of airboxes within a temperature-regulating mattress system is described herein. The airboxes may include components integrated within the base structure or modular components affixed to the base structure (or a combination of the two).

The general function of an airbox in the base layer is the selective use of a fan and a heater to generate heated air or cooled air that will be forcefully blown into areas of the mattress installed above the base layer. Although positive temperature coefficient (PTC) heaters are shown in this section, any suitable convection heater or thermoelectric heater may be substituted.

In addition, an airbox may be used without the heater for delivery of air at the ambient air temperature. In addition, an airbox may be used with a cooler for delivery air cooler than the ambient air temperature. In addition, an airbox may be coupled with a humidifier or dehumidifier to adjust the relative humidity of the delivered air.

In general, airboxes may be installed in the center of the base layer (to provide air to the torso area of a mattress user) and at the bottom of the base layer (to provide air to the feet area of a mattress user).

FIGS. 30A, 30B, 31 and 32 show schematics of an airbox that is integrated into the base layer.

Turning to FIG. 30A, shown is top view of an integrated airbox 3000 with air exhausts 3002a, 3002b that may output warmed air. The air exhausts 3002a, 3002b include ramps that allow for enhanced air distribution to the rest of the mattress.

Turning to FIG. 30B, shown is bottom view of an integrated airbox 3050 with air inlets 3004a, 3004b. The air inlets 3004a, 3004b may draw ambient air for possible heating and further distribution with the mattress system.

Turning to FIG. 31, shown is a cross-section view of an integrated airbox 3100. The ducting/enclosure top 3105 covers a first blower 3110a and a PTC heater 3115a pair and a second blower 3110b and a PTC heater pair 3115b, both of which are installed on an enclosure bottom 3125. Also included is logic board and wiring 3120 that controls the power and operation of each of the blower/PTC heater pairs 3110a, 3115a, 3110b, 3115b.

Turning to FIG. 32, shown is an integrated airbox system 3200. Intake airflow 3245 enters a blower 3220, proceeds to a heater 3210 and then is outputted via lateral airflow 3250 and upward airflow 3260. Downstream sensors 3230 and upstream sensors 3240 may measure temperature and humidity of the passing air (where downstream and upstream means downstream and upstream from the blower 3220 and heater 3210). This data can be passed to the rest of the mattress system to keep the mattress environment comfortable for the user.

FIGS. 33A, 33B, 34 and 35 show schematics of a modular airbox that is affixed to the base layer.

Turning to FIG. 33A, shown is top view of a modular airbox 3300 with air exhausts 3310a, 3310b that may output warmed air.

Turning to FIG. 33B, shown is bottom view of a modular airbox 3350 with air inlets 3355a, 3355b. The air inlets 3355a, 3355b may draw ambient air for possible heating and further distribution with the mattress system.

Turning to FIG. 34, shown is an exploded view of a modular airbox 3400. The exterior comprises a ducting/enclosure mounting frame 3410, endcaps 3405a, 3405b and an enclosure 3440. The interior comprises a first blower 3402a and a PTC heater 3404a pair and a second blower 3402b and a PTC heater pair 3404b and a logic board and wiring 3450 that controls the power and operation of each of the blower/PTC heater pairs 3402a, 3402b, 3404a, 3404b.

Turning to FIG. 35, shown is an integrated airbox system 3500. Intake airflow 3520 enters a blower 3504, proceeds to a heater 3502 and then is outputted via lateral airflow 3510 and upward airflow 3530 though the holes on top of the airbox. Downstream sensors 3550 and upstream sensors 3560 may measure temperature and humidity of the passing air (where downstream and upstream means downstream and upstream from the blower 3504 and heater 3502). This data can be passed to the rest of the mattress system to keep the mattress environment comfortable for the user.

Turning to FIG. 36 shows a cross-section of a mattress system 3600 having air delivery channels. Here, the air entry 3630 passes through holes in the base or through a vertical perimeter or through body of spacer fabric. The air then passes through the electronics module 3640. The outputted air passes through distribution ducts 3610 then exits the mattress via a series of vertical exhausts 3620. The volume of the distribution ducts 3610 may vary along its length to affect air distribution patterns across the surface area of the mattress. The electronics module 3640 may include a blower, heater and sensors on one or more printed circuit boards (PCBs). There may be two or more electronics modules 3640 in the mattress system 3600. The electronics module 3640 may be removable for servicing and upgrades.

FIGS. 37 and 38 show different air distribution patterns for air exiting a mattress. Turning to FIG. 37, shown is a schematic of air distribution patterns in a mattress system 3710 that primarily provide torso and feet airflow through the mattress top. Turning to FIG. 38, shown is a schematic of air distribution patterns in a mattress system 3720 that primarily provides airflow throughout the entirety of the mattress top.

VII. Airflow

The scope and functionality of devices that improve airflow within a temperature-regulating mattress system is described herein.

FIGS. 39A, 39B, 39C, 39D, 39E and 39F show various methods for sealing surface of holes or slots in a mattress cut through the foam comfort layers. Sealed holes prevent the fluid flow horizontally into the foam through the walls of the cutout or from the underside. These methods may be combined in a mattress system. (The pointers in FIGS. 39A-39F are shown on the right side of the slots, they may equally apply to the left side of the slots.)

Turning to FIG. 39A (liquid sealant solution), shown is a sealant system 3900 with foam comfort layers 3902 adjacent to dried sealant on the side 3904a and bottom 3904b. These sealants dry to form an impermeable skin (made from, for example, gel, silicon, rubber or adhesive). The sealant may be poured in the hole or sprayed using a nozzle.

Turning to FIG. 39B (molded/self-skinning solution), shown is a sealant system 3910 with foam comfort layers 3912 adjacent to an impermeable foam on the side 3914a and bottom 3914b. Here the, impermeable foam may be created in the hole by the comfort foam layers 3912 poured sequentially into the mold. The surfaces touching the side and bottom self-skin creating an impermeable surface.

Turning to FIG. 39C (molded/insert), shown is a sealant system 3920 with foam comfort layers 3922 adjacent to a single impermeable foam insert 3924. Here the, impermeable foam insert 3924 may be molded from self-skinning or a pneumatic foam is assembled into the comfort layers 3922 using adhesive.

Turning to FIG. 39D (flexible insert), shown is a sealant system 3930 with foam comfort layers 3932 adjacent to a flexible tube 3934. Here a thin-walled flexible tube 3934 is inserted into the hole and is held into place by friction and/or adhesive. The hole may be expanded during insertion to aid in installation. Possible flexible tube 3934 materials include gel, silicone, rubber, latex, polymers or a flexible duct hose.

Turning to FIG. 39E (flexible insert with flange), shown is a sealant system 3940 with foam comfort layers 3942 adjacent to a flexible tube with flange 3944. Here a thin-walled flexible tube with flange 3944 is inserted into the hole and is held into place by friction and/or adhesive. The hole may be expanded during insertion to aid in installation. Possible flexible tube with flange 3944 materials include gel, silicone, rubber, latex, polymers or a flexible duct hose. The flange 3946 adds impermeability to the underside of the mattress.

Turning to FIG. 39F (encapsulated spring insert), shown is a sealant system 3950 with foam comfort layers 3952 adjacent to a low stiffness coil spring 3954. The low stiffness coil spring 3954 is encapsulated in a sealant such as: an impenetrable polyethylene pocket or sleeve; over-molded rubber; pneumatic foam; or a flexible duct hose. The spring holds the hole open while providing minimal vertical stiffness.

Turning to FIG. 46A (flexible insert), shown is a sealant system 4630 with foam comfort layers 4632 adjacent to a flexible tube 4634. Here, a thin-walled flexible tube 4634 is inserted into the angled hole and is held into place by friction and/or adhesive. The hole may be expanded during insertion to aid in installation. Possible flexible tube 4634 materials include gel, silicone, rubber, latex, polymers or a flexible duct hose.

Turning to FIG. 46B (flexible insert with flange), shown is a sealant system 4640 with foam comfort layers 4642 adjacent to a flexible tube with a flange 4644, where the flange portion is identified by reference numeral 4646. Here, a thin-walled flexible tube with flange 4644 is inserted into the angled hole and is held into place by friction and/or adhesive. The hole may be expanded during insertion to aid in installation. Possible flexible tube with flange 4644 materials include gel, silicone, rubber, latex, polymers or a flexible duct hose. The flange 4646 adds impermeability to the underside of the mattress.

Turning to FIG. 46C (encapsulated spring insert), shown is a sealant system 4650 with foam comfort layers 4652 adjacent to a low stiffness coil spring 4654. The low stiffness coil spring 4654 is encapsulated in a sealant such as: an impenetrable polyethylene pocket or sleeve; over-molded rubber; pneumatic foam; or a flexible duct hose. The encapsulated low stiffness coils spring 4654 is inserted into the angled hole. The spring holds the hole open while providing minimal vertical stiffness.

FIGS. 47A and 47B show an additional embodiment of sealed vertical holes or slots in a mattress. Turning to FIG. 47A (sealant, or flexible insert with a flange and sealant), shown is a sealant system 4740 with foam comfort layers 4742 adjacent to a sealed vertical hole 4744. The hole 4744 is sealed either by a sealant or via an insert as described above. The sealant system 4740 also includes flanges or sealant that extend across the top and bottom surfaces of the mattress, to extend the sealed areas around the hole(s). In the figure, the bottom flange or sealant is identified by reference numeral 4746 and the top flange or sealant is identified by reference numeral 4748. When using, a thin-walled flexible tube, the tube is inserted into the hole and is held into place by friction and/or adhesive. The hole may be expanded during insertion to aid in installation. Possible flexible tube with flange materials include gel, silicone, rubber, latex, polymers or a flexible duct hose. The sealant or flange(s) 4746 and 4748 add impermeability to the underside and the top of the mattress, respectively.

Turning to FIG. 47B (sealant, or flexible insert with a flange and sealant), shown is a sealant system 4750 with foam comfort layers 4752 adjacent to a sealed angled hole 4754. The hole 4744 is sealed either by a sealant or via an insert as described above. The sealant system 4750 also includes flanges or sealant that extend across the top and bottom surfaces of the mattress, to extend the sealed areas around the hole(s). In the figure, the bottom flange or sealant is identified by reference numeral 4756 and the top flange or sealant is identified by reference numeral 4758. When using, a thin-walled flexible tube, the tube is inserted into the hole and is held into place by friction and/or adhesive. The hole may be expanded during insertion to aid in installation. Possible flexible tube with flange materials include gel, silicone, rubber, latex, polymers or a flexible duct hose. The sealant or flange(s) 4756 and 4758 add impermeability to the underside and the top of the mattress, respectively.

FIGS. 48A and 48B show an additional embodiment of sealed vertical holes or slots in a mattress. Turning to FIG. 48A (a vertical insert), shown is a sealant system 4840 with foam comfort layers 4842 adjacent to a vertically oriented insert 4849, which may be constructed from polymers rubber, fabric or foam, such as reticulated foam. The outer surface 4844 of the insert 4849 is made impermeable by an impermeable fabric, polymer, or applied flexible sealant. Alternatively, the insert 4849 is placed within the flexible impermeable tube, of the type described above. The sealant system 4840 may also include optional flanges or sealant that extend across the top and bottom surfaces of the mattress, to extend the sealed areas around the holes. In the figure, the bottom flange or sealant is identified by reference numeral 4846 and the top flange or sealant is identified by reference numeral 4848. The sealant or flange(s) 4746 and 4748 add impermeability to the underside and the top of the mattress, respectively.

Turning to FIG. 48B (an angled insert), shown is a sealant system 4850 with foam comfort layers 4852 adjacent to an angularly oriented insert 4859, which may be constructed from polymers rubber, fabric or foam, such as reticulated foam. The outer surface 4854 of the insert 4859 is made impermeable by an impermeable fabric, polymer, or applied flexible sealant. Alternatively, the insert 4859 is placed within the flexible impermeable tube, of the type described above. The sealant system 4850 may also include optional flanges or sealant that extend across the top and bottom surfaces of the mattress, to extend the sealed areas around the holes. In the figure, the bottom flange or sealant is identified by reference numeral 4856 and the top flange or sealant is identified by reference numeral 4858. The sealant or flange(s) 4756 and 4758 add impermeability to the underside and the top of the mattress, respectively.

FIGS. 49A and 49B show an additional embodiment of sealed vertical holes or slots in a mattress. Turning to FIG. 49A (a vertical insert or applied sealant, with an additional layer), shown is a sealant system 4940 with foam comfort layers 4942 adjacent to a vertically oriented insert 4944, which may be constructed from polymers rubber, fabric, or foam, such as reticulated foam. The sealant system 4840 includes flanges or sealant that extend across the top and bottom surfaces of the foam comfort core layers, to extend the sealed areas around the holes. In the figure, the bottom flange or sealant is identified by reference numeral 4946 and the top flange or sealant is identified by reference numeral 4948. Each of the flanges or sealant 4946 and 4948 is secured by an additional layer 4947 and 4949, respectively, that is added to the top and/or bottom of the foam comfort core. The additional layer has holes in it to match the holes that run through the comfort core layers. The additional layer may be made from a permeable, semi-permeable, or impermeable material.

Turning to FIG. 49B (an angled insert or applied sealant, with an additional layer), shown is a sealant system 4950 with foam comfort layers 4952 adjacent to an angularly oriented insert 4954, which may be constructed from polymers rubber, fabric, or foam, such as reticulated foam. The sealant system 4840 includes flanges or sealant that extend across the top and bottom surfaces of the foam comfort core layers, to extend the sealed areas around the holes. In the figure, the bottom flange or sealant is identified by reference numeral 4956 and the top flange or sealant is identified by reference numeral 4958. Each of the flanges or sealant 4956 and 4958 is secured by an additional layer 4957 and 4959, respectively, that is added to the top and/or bottom of the foam comfort core. The additional layer has holes in it to match the holes that run through the comfort core layers. The additional layer may be made from a permeable, semi-permeable, or impermeable material.

FIGS. 50A and 50B show an additional embodiment of sealed vertical holes or slots in a mattress. Here, to maintain better support to a user, the holes through the foam comfort core layers are made relatively small. Turning to FIG. 50A (vertical insert or applied sealant with an additional layer), shown a sealant system 5040 with foam comfort layers 5042 adjacent to a vertically oriented insert 5044. Flanges or sealant extend across the bottom face 5046 and the top face 5048 to extend the sealed areas around the hole(s). An additional top layer 5049 and an additional bottom layer 5047, each having a hole of larger diameter then the hole through the comfort-core layers, are added to the top and bottom, respectively. Due to the larger hole diameter in these additional top and bottom layers, the area available to air passing through the hole at the top and bottom surfaces is larger than that of the hole through the foam comfort core layers 5042. As a result, air passing through the fabric that is in contact with the top and bottom of the foam core layers has a larger area to pass through and therefore reduces resistance loss.

Turning to FIG. 50B (angular insert or applied sealant with an additional layer), shown a sealant system 5050 with foam comfort layers 5052 adjacent to an angularly oriented insert 5054. Flanges or sealant extend across the bottom face 5056 and the bottom face 5048 to extend the sealed areas around the hole(s). An additional top layer 5059 and an additional bottom layer 5057, each having a hole of larger diameter then the hole through the comfort-core layers, are added to the top and bottom, respectively. Due to the larger hole diameter in these additional top and bottom layers, the area available to air passing through the hole at the top and bottom surfaces is larger than that of the hole through the foam comfort layers 5052. As a result, air passing through the fabric that is in contact with the top and bottom of the foam comfort layers has a larger area to pass through and therefore reduces resistance loss.

FIG. 51 shows the cross-section and top views of a mattress system using inserts with holes or slots. In this embodiment, the assembly 5100 includes comfort layers 5102 with two rows of openings 5104 (e.g., pill-shaped slots). Inserts 5106 with dual holes 5108 are located within the slotted openings 5104. Note, the number of rows of slotted openings in the comfort layers and the number of holes 5108, and their layout, in each insert 5106 could be varied. The inserts 5106, which are assembled into the openings 5104, may be formed from molded or machined pieces of foam that incorporate holes through them. The inserted pieces could be molded from self-skinning foam, or have their surfaces sealed in other ways, for example spraying with a liquid sealant. The holes in the inserts can be of various shape, sizes, and angles. For example, in some embodiments the angle could be such that one could see all the way down through the hole when looking from above the insert. In other embodiments, the angle could be large enough such that one could not see all the way down through the hole when looking from above the insert.

FIGS. 52A, 52B, 52C, 52D, 52E, and 52F show various embodiments of the inserts in FIG. 51. Turning to FIG. 52A, shown is an insert 5200 with two angularly running holes 5202 with sealed surfaces. The topmost portion of the figure shows a cross-section of the insert 5200. The next portion down in the FIG. 52A depicts the insert from the bottom, along section A-A. Right below, FIG. 52A shows two side views of the insert 5200, from different directions. Finally, the lowest portion of the figure depicts the view of the insert from the top.

Turning to FIG. 52B, shown is a two-part insert 5220 having two angularly running holes 5222 with sealed surfaces. The two parts, constituting two halves of the insert, are joined together to form the insert. The topmost portion of the figure shows a cross-section of the insert 5220. The next portion down in the FIG. 52B depicts one half of the insert, when viewed from the bottom. Right below, FIG. 52A shows two side views of the insert 5220, from different directions. Right below that, FIG. 52B shows one half of the insert, viewed from the top. Finally, the lowest portion of the figure depicts the two halves of the insert joined together 5226, forming the insert, viewed from the bottom.

Turning to FIG. 52C, shown is an insert 5230 with two angularly running holes 5232 with sealed surfaces. The topmost portion of the figure shows a cross-section of the insert 5230. As can be seen from the cross-sectional view, each hole changes its angle as it passes through the insert. The next portion down in the FIG. 52C depicts the insert from the bottom, along section A-A. Right below, FIG. 52C shows two side views of the insert 5230, from different directions. Finally, the lowest portion of the figure depicts the view of the insert from the top.

Turning to FIG. 52D, shown is a cross-sectional view of an insert 5240 with a single hole having a conical shape. Turning to FIG. 52E, shown is a cross-sectional view of an insert 5250 with a single hole having a circular shape. Turning to FIG. 52F, shown is a cross-sectional view of an insert 5260 with a single hole having a circular shape that is narrower than in FIG. 52E, but that flares out at top and bottom of the insert. In each of the embodiments, the surfaces of the holes are sealed to prevent air loss.

FIG. 53 shows another embodiment of the mattress system using inserts with holes or slots. The upper portion of FIG. 53 shows the top view of the mattress system and the lower portion of the figure shows a cross-sectional view of the mattress system along section A-A. From the top view, one can see the mattress system 5300 includes five sections, 5301a, 5301b, 5301c, 5301d, and 5301e. Sections 5301b and 5301d are molded or machined insert sections that are assembled in between the sections 5301a, 5301c, and 5301e of regular foam comfort layers. The insert sections have holes running through them. These holes can have various shapes, e.g., circles, squares, rectangles, etc. and may be vertical or angled. The cross-sectional view of the mattress system at the bottom of FIG. 53 shows an angular hole 5304 in the insert 5301b and also shows an angular hole 5306 in the insert 5301d. The foam comfort layers are designated by reference numeral 5302.

FIG. 54 shows an embodiment of the mattress system 5400 using inserts for forming holes or slots in the system. The upper portion of FIG. 54 shows the top view of the mattress system and the lower portion of the figure shows a cross-sectional view of the mattress system along section A-A. This embodiment differs from the embodiment in FIG. 53 in that the molded or machined insert-sections 5402 and 5404 are assembled in cutouts in the regular foam comfort layers 5406. Once installed, the inserts form one side of each hole. The cross-sectional view of the mattress system at the bottom of FIG. 53 shows an angular hole formed by the combination of the insert 5404 and the comfort layers 5406. These holes can have various shapes, e.g., circles, squares, rectangles, etc. and may be vertical or angled. Sealing may be achieved by employing a self-skinning molded foam for the insert, or by applying a liquid sealant to a permeable foam or foam layers.

FIG. 55 shows another embodiment of the mattress system 5500 with holes or slots. The upper portion of FIG. 55 shows the top view of the mattress system and the lower portion of the figure shows a cross-sectional view of the mattress system along section A-A. From the top view, one can see the mattress system 5500 includes five sections, 5501a, 5501b, 5501c, 5501d, and 5501e, of comfort layers that are either cut along cut lines 5504 and separated or are formed along cut lines 5504. The cut face(s) of each of the five sections, along the line(s) 5504, is then sealed. Sealing may be achieved by, for example, applying liquid sealant to the cut faces, or laminating an impermeable membrane to the cut faces. The sections are then assembled together, forming sealed vertical or angled holes withing the mattress system 5500. The holes can have various shapes, e.g., circles, squares, rectangles, triangular, etc. The cross-sectional view of the mattress system 5500 at the bottom of FIG. 55 shows the angular holes formed in the comfort layers 5502.

FIG. 56 shows another embodiment of a mattress system with vertical holes or slots. The left side of FIG. 56 shows a cross-sectional view of the mattress system and the right side of the figure shows a top view of the mattress system. As can be seen from the cross-sectional view, the mattress system 5600 is composed of seven layers (labeled L1 through L7), with L1 being the topmost layer and L7 being the bottommost layer. The cross-sectional view also shows two holes 5602 and 5604 cut through the layers. Hole 5602 is located in the middle of the mattress (torso zone) and hole 5604 is located at the right end of the mattress (foot zone). In this embodiment, some of the mattress layers include multiple sections of different materials, having different densities and ILD characteristics, or may include similar materials having different characteristics. For example, the topmost (first) layer L1 includes two sections, left and right. In one preferred embodiment, the left section could be hypersoft foam, labeled in the figure as L1A, and the left section could be viscoelastic foam, labeled as L1B. The third layer down, L3, for example, includes three sections (left, middle, and right). In one embodiment, the middle section could be hypersoft foam having one set of characteristics (labeled L3B), and the right and left sections could be hypersoft foam having another set of characteristics (labeled L3A). Some of the materials that may be used in the various layers include hypersoft foam, viscoelastic foam, high resiliency foam, convoluted foam, and rubber.

Looking at the top view of the mattress system 5600 (right side of FIG. 56), one can see the two sections of the first layer L1. The top view also shows that the holes 5602 and 5604 have an oval slotted shape. Each row of holes running across the mattress is further divided into two groups (left and right), allowing the mattress system 5600 to accommodate two occupants.

FIGS. 57A, 57B, 57C, and 57D show an embodiment of a seven-layer mattress system that uses tubular inserts. FIG. 57A shows a top view of the mattress system 5700, with two rows of oval-shaped holes (slots) 5702 and 5704. FIG. 57B shows a cross-sectional view of the mattress system 5700 along the line A-A in FIG. 57A, illustrating the row of holes 5704 across the mattress. FIG. 57C shows a detailed view of the mattress system 5700 in area B of FIG. 57B. Specifically, FIG. 57C shows two holes, one labeled 5704a and another labeled 5704b, each passing through the seven layers of the mattress system 5700. A plastic (or rubber) insert 5706 is placed in each hole. The insert includes flanges on top and bottom. Importantly, the flanges do not protrude all the way to the top and/or bottom of the mattress system 5700. Instead, the top mattress layer covers up the upper flanges from the top and the bottom mattress layer covers up the lower flanges from the bottom. This way, the upper flange of each insert is secured between the first and second mattress layers and the lower flange of each insert is secured between the sixth and seventh mattress layers. Such a construction not only prevents the inserts from separating from the mattress layers, but also provides aesthetically pleasing design, as the insert flanges are not visible to the user. In the preferred embodiment, the inserts have an accordion type design, which allows them to contract and expand together with the mattress layers in response to the different forces applied to the mattress system 5700 by the occupants.

FIG. 57D shows a cross-sectional view of the mattress system along the line C-C in FIG. 57A. It depicts the inserts 5706 in the hole(s) 5702 in the middle of the mattress (torso zone) and in the hole(s) 5704 at one end of the mattress (foot section). Similar to the mattress system 5600 in FIG. 56, the cross-sectional view of mattress system 5700 in FIG. 57D shows the mattress layers having various sections of various materials.

FIGS. 58A, 58B, and 58C show cross-sectional views of another set of embodiments of a mattress system with holes or slots. Similar to the mattress system 5600 in FIG. 56, the cross-sectional views in FIGS. 58A, 58B, and 58C show seven-layer mattress systems where some of the layers are composed of various sections of different material.

Turning to FIG. 58A, shown is a cross-sectional view of a seven-layer mattress system 5800 with vertically placed rubber inserts 5802.

Turning to FIG. 58B, shown is a cross-sectional view of a seven-layer mattress system 5810 with rubber inserts 5814 placed in the holes 5816 and 5818 that are running at a slight angle. At the angle shown in FIG. 58B, when looking straight down from above the insert 5814, one can see all the way through the hole to the bottom of the mattress.

Turning to FIG. 58C, shown is a cross-sectional view of a seven-layer mattress system 5820 with rubber inserts 5824 placed in the holes 5826 and 5828 that are running at a greater angle then the one in FIG. 58B. At the angle shown in FIG. 58C, when looking straight down from above the insert 5824, one cannot see all the way through the hole to the bottom of the mattress.

FIGS. 59A, 59B, and 59C show cross-sectional views of another set of embodiments of a mattress system with holes or slots. Similar to the mattress systems in FIGS. 58A, 58B, and 58C the cross-sectional views in FIGS. 59A, 59B, and 59C also show seven-layer mattress systems, 5900, 5910, and 5920 respectively, where some of the layers are composed of various sections of different materials. In contrast to the embodiments in FIGS. 58A, 58B, and 58C, however, the inserts 5902, 5912, and 5922 in the FIGS. 59A, 59B, and 59C, respectively, are molded pneumatic inserts that, when inserted, span layers two (L2) through six (L6) in both the torso and foot zones of the mattress system. The top and bottom layers (L1 and L7) have holes that line up with the holes in the inserts. In FIG. 59A, the holes in the insert 5902 run vertically; in FIG. 59B, the holes in the inserts 5912 run at a slight angle off vertical; and in FIG. 59C, the holes in the inserts 5922 run at a greater angle off vertical, such that when looking straight down from above the insert, one cannot see all the way through the hole to the bottom of the mattress. Because the walls of each hole should be substantially impermeable to air, the inserts 5902, 5912, and 5922 should either be made of substantially impermeable material, self-skinning foam, or have liquid sealant applied to them.

FIGS. 60A and 60B show cross-sectional views of another set of embodiments of a mattress system with holes or slots. Similar to the mattress systems in FIGS. 59A and 5B, the cross-sectional views in FIGS. 60A and 60B also show seven-layer mattress systems, 6000 and 6010 respectively, where some of the layers are composed of various sections of different materials. In contrast to the embodiments in FIGS. 59A and 59B, however, the inserts 6002 and 6012 in the FIGS. 60A and 60B, respectively, are pneumatic fabricated die cut inserts, which, when inserted, span layers two (L2) through six (L6) in both the torso and foot zones of the mattress system. The top and bottom layers (L1 and L7) have holes that line up with the holes in the inserts. In FIG. 60A, the hole in the insert 6002 runs vertically; and in FIG. 60B, the hole in the insert 6012 runs at an angle. Because each insert is made up of stacked, die cut material layers, the angularly running hole in the insert 6012 appears to have stepped edges. Because the walls of each hole should be substantially impermeable to air, the inserts 6002, and 6012 should either be made of substantially impermeable material(s), self-skinning foam(s), or have liquid sealant applied to them.

FIGS. 61A, 61B, and 61C show cross-sectional views of another set of embodiments of a mattress system with holes. Similar to the mattress systems in FIGS. 59A, 58B, and 58C the cross-sectional views in FIGS. 61A, 61B, and 61C also show seven-layer mattress systems, 6100, 6110, and 6120 respectively, where some of the layers are composed of various sections of various materials. In contrast to the embodiments in FIGS. 59A, 59B, and 59C, however, the mattress systems in the FIGS. 59A, 59B, and 59C include inserts drilled holes. In FIG. 61A, the holes 6102 are drilled vertically; in FIG. 61B, the holes are drilled at a slight angle off vertical; and in FIG. 61C, the holes are drilled at a greater angle off vertical, such that when looking straight down from above a hole, one cannot see all the way through it to the bottom of the mattress. Because the walls of each hole should be substantially impermeable to air the material in the sections of the layers where the holes are locations should either be made of substantially impermeable material, self-skinning foam, or have liquid sealant applied to them.

Each of the methods of sealing the hole walls discussed above can be applied to holes that are angled along their axis, and of any cross-section, e.g., circular, elliptical, rectangular, square, etc. For example, FIGS. 46A, 46B, and 46C, which correspond to FIGS. 39D, 39E, and 39F, respectively, show holes that are angled along their axis.

In addition, the various insert embodiments may be used interchangeably or in combinations to achieve the required airflow in the mattress.

As an example, the invented mattress may include a laterally extending comfort layer, which itself may include a plurality of layers, said comfort layer having a lower surface and an upper surface, said comfort layer comprising an opening extending through said comfort layer from the upper surface to the lower surface; a tubular insert positioned within the opening of said comfort layer and having an upper end and a lower end, said tubular insert having an air-impermeable peripheral wall extending between the upper end and the lower end of said tubular insert, said tubular insert further comprising a first air-impermeable flange located at one of the upper end and the lower end of said tubular insert and extending around the opening at one of the upper surface and the lower surface of said comfort layer; a laterally extending bottom layer joined to the lower surface of said comfort layer, said bottom layer having an aperture that is aligned with the opening at the lower surface of said comfort layer, the aperture being equal to or greater than the opening at the lower surface of said comfort layer; a laterally extending top layer joined to the upper surface of said comfort layer and having an aperture that is aligned with the opening at the upper surface of said comfort layer, the aperture being equal to or greater than the opening at the upper surface of said comfort layer; wherein one of said top layer and said bottom layer secures said first flange of said tubular insert to said comfort layer. The tubular insert may comprise a second air-impermeable flange located at the other one of the upper end and the lower end of said tubular insert, said second flange extending round the opening at the other one of the upper surface of said comfort layer and the lower surface of said comfort layer; and wherein the other one of said top layer and said bottom layer secures said second flange of said tubular insert to said comfort layer.

As another example, the invented mattress system may include a plurality of laterally extending foam layers joined together, said plurality of foam layers having an upper surface and a lower surface, said plurality of foam layers further having at least one opening extending between the upper surface and the lower surface of said plurality of foam layers; an at least one foam insert positioned within said at least one opening, said at least one foam insert having an upper surface and a lower surface, said at least one foam insert further comprising a hole running from the upper surface of said at least one foam insert to the lower surface of said at least one foam insert; and a fan located below said plurality of foam layers, said fan configured to force air through the hole in said foam insert toward the upper surface of said foam insert; wherein the interior surface of said hole in the foam insert in air-impermeable; wherein the upper surface of said at least one foam insert is aligned with the upper surface of said plurality of laterally extending foam layers; and wherein the lower surface of said at least one foam insert is aligned with the lower surface of said plurality of laterally extending foam layers. The interior surface of the foam insert may be made air-impermeable due to self-skinning property of the foam insert, such as use of a foam having self-skinning property. Alternatively, the interior surface of the foam insert may be made air-impermeable by applying a sealant.

As another example, the invented mattress system may include a plurality of laterally extending foam layers joined together, said plurality of foam layers having an at least one opening therethrough, said opening located in a torso zone of said mattress; a foam insert positioned withing the opening, said foam insert comprising a hole therethrough for allowing airflow between a top surface of said mattress and a bottom surface of said mattress; wherein the interior surface of said hole in air-impermeable; and wherein said foam insert increases support in the torso zone of said mattress.

As a result, the invented insert not only functions to allow airflow from the bottom to the top of the mattress, but it also functions as a support element. Because the invented inserts may be placed in areas other than the torso zone of the mattress (e.g., foot section, hip section, shoulder section, head section, etc.), the present invention allows for mattress designs that are not only provide better temperature regulation but are optimized to provide increased support to a user human anatomy. The foam inserts disclosed above may not have any air holes but could be used merely for providing specific localized support in and across the various mattress zones. For example, foam inserts in the torso zone might provide greater support then the foam inserts in the foot zone. In addition, insert provided support could also vary across a single zone.

The invented foam insert may be formed by molding or by died cutting. For example, an insert including a plurality of die cut layers may have its hole created by a stacked combination of the holes die cut in each of the layers. In such a situation, if the insert hole is either slanted or has a cross-sectional area that varies from the bottom to the top of the insert, the interior surface of the resulting hole will have a stepped profile.

FIGS. 40A, 40B and 40C show various constructions that improve airflow throughout a mattress system. They may be used singly or in combination.

Turning to FIG. 40A, shown is a partial mattress system cross-section 3960 where a mattress 3961 includes a plurality of vertical cutouts 3962. A specially formed EPP segment 3966 has a raised edge that increases the pressure around the duct outlet perimeter. This compresses the bottom foam layer 3963 and creates a better seal between the base layer and the mattress. Another portion of the EPP segment 3965 (partially shown) also compresses the bottom foam layer 3963. The blower/heater combination 3964 may be inserted into the EPP segment as well to complete construction of the base layer interfacing with the mattress.

Turning to FIG. 40B, shown is a partial mattress system cross-section 3970 with a frame 3972 installed at the bottom of the foam layers. As shown in the inset 3971 on the top left, the frame 3972 incorporates holes that lets air through from the base layer to the mattress layer. The holes in the frame 3972 may “match up” with the holes in the mattress. Alternatively, the frame 3972 may have only edges with an open middle. The frame edges 3974a, 3974b may consist of impermeable but flexible material (such as EPP) that solidifies the installation of the frame 3972 within the mattress.

One purpose of the frame 3972 is to create air space between the mattress cover 3973 and the underside of the foam 3975. This increases area that the air can flow through the mattress cover 3973 which results in lower pressure drop and less losses in flow.

Turning to FIG. 40C, shown is a partial mattress cross-section 3990 with a mattress having vertical air passages 3994a, 3994b, 3994c, 3994d taking air blown from airboxes 3992a, 3992b through ducts 3991a, 3991b. Underneath the airboxes 3992a, 3992b and their related EPP segments (not shown) is a permeable base cover (also not shown) that allows the air to be drawn in by the airboxes 3992a, 3992b. Surrounding the mattress on the top and the sides is a permeable mattress cover (not shown) that allows the air to be pushed out through the vertical air passages 3994a, 3994b, 3994c, 3994d. In contrast, portions of the top of the base layer and the bottom of the mattress layer 3993a, 3993b and 3993c may be made of an impermeable material such as rubber having lamination. This material improves airflow throughout the mattress by maximizing the amount of air drawn in by the airboxes 3992a, 3992b actually passing through ducts 3991a, 3991b.

VIII. Remote

The scope and functionality of remotes to allow the user to control features within a temperature-regulating mattress system is described herein. The purpose of these remotes includes allowing users to make real-time adjustments to mattress parameters without the user having to get out of bed. This is especially useful when the user wants to make an adjustment in the midst of a sleep cycle.

The properties of the remote discussed herein may be mixed and varied as needed to provide various functions for the mattress system.

In addition to these remotes, an app may be used to control similar features of the mattress in addition to providing an interface for more complex operations (such as those described above in FIG. 4B).

Turning to FIG. 41A, shown is a schematic of a remote 4000 for a mattress system. The remote 4000 is generally puck-shaped and incorporates a full surface tactile button 4002 and is capable of recognizing gesture sensing 4004 performed on the remote 4000. The remote 4000 is capable of rotations 4006 and has a haptic motor 4012. Alight indicator 4010 is installed on the top of the remote 4000. A gradient light indicator 4014 emanates from the bottom of the remote 4000. Installed on the bottom of the remote 4000 is a reset button 4008 and LED 4016.

Turning to FIG. 41B, shown is a cross-section of the remote in FIG. 41A integrated with its base 4100 and a cross-section of the remote separated from its base 4110. The rotating member 4112 is selectively separable and attachable from its base 4114 to allow for battery access.

Turning to FIG. 41C, shown is an exploded view 4150 of the remote in FIG. 41A. Moving from top to bottom, shown is a dial top 4152, a linear resonant actuator/haptic motor 4154, capacitive touch sensor 4156, a PCB 4158, a light pipe/diffuser 4160, a battery housing 4162, batteries 4164, a rotating plate 4166, a bearing 4168 and a base with rubber grip 4170.

The PCB 4158 may contain an internal management unit, accelerometer or gyroscope.

FIGS. 42, 43, 44 and 45 show schematics of alternative remotes for mattress system.

Turning to FIG. 42, shown is a schematic of a log-shaped remote system 4200. This log-shaped remote system 4200 includes a touch and press surface 4210, an emanating light 4220 and a re-charging port door 4230.

Turning to FIG. 43, shown is a schematic of a flip-over remote system 4300. On the left, the remote 4310 is in profile mode. Here the profile mode may show the remote is in standby mode (represented by Z's in one color). A press on the remote 4320 may be used by a user to cycle between desired features and a twist of the remote 4330 may increase or decrease the temperature, airflow or other feature parameter. When activated the color of the Z's may change, telling the user that the status of the remote or parameter has changed.

The remote may be flipped 4340 to enter basic mode 4350. Here a press may turn the remote on or off 4360 and a twist 4370 may activate or adjust various features in the mattress system.

Turning to FIG. 44, shown is a schematic of a bounce-back remote system 4400. This remote is constructed so a left or right twist of the dial always springs back to the center. A press 4410 on the remote may start the system. A twist 4420 on the remote may adjust various system parameters. A double press 4430 on the remote may pause the system. Along press 4440 (such as 3 seconds) may turn the system off.

Turning to FIG. 45, shown is a remote horizontal gesture system 4510 and a remote vertical gesture system 4520 that may control features of a mattress system. The gesture sensing module in the remote detects mid-air horizontal and vertical gestures.

IX. Conclusion

In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.

The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

Moreover, in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not listed.

The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features are grouped together in various embodiments for streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.

Claims

1. A mattress system comprising: a laterally extending comfort layer having a lower surface and an upper surface, said comfort layer comprising an opening extending through said comfort layer from the upper surface to the lower surface;a tubular insert positioned within the opening of said comfort layer and having an upper end and a lower end, said tubular insert having an air-impermeable peripheral wall extending between the upper end and the lower end of said tubular insert, said tubular insert further comprising a first air-impermeable flange located at one of the upper end and the lower end of said tubular insert and extending around the opening at one of the upper surface and the lower surface of said comfort layer;a laterally extending bottom layer joined to the lower surface of said comfort layer, said bottom layer having an aperture that is aligned with the opening at the lower surface of said comfort layer, the aperture being equal to or greater than the opening at the lower surface of said comfort layer;a laterally extending top layer joined to the upper surface of said comfort layer and having an aperture that is aligned with the opening at the upper surface of said comfort layer, the aperture being equal to or greater than the opening at the upper surface of said comfort layer;wherein one of said top layer and said bottom layer secures said first flange of said tubular insert to said comfort layer.

2. The mattress system of claim 1, wherein said tubular insert comprises a second air-impermeable flange located at the other one of the upper end and the lower end of said tubular insert, said second flange extending round the opening at the other one of the upper surface of said comfort layer and the lower surface of said comfort layer; and wherein the other one of said top layer and said bottom layer secures said second flange of said tubular insert to said comfort layer.

3. The mattress system of claim 1, wherein said laterally extending comfort layer comprises a plurality of layers.

4. The mattress system of claim 1, wherein the opening in said comfort layer is vertical.

5. The mattress system of claim 1, wherein the opening in said comfort layer is slanted.

6. The mattress system of claim 1, wherein said tubular insert comprises an encapsulated coil spring.

7. The mattress system of claim 1, wherein said air-impermeable peripheral wall of said tubular insert is accordion shaped, to allow for contraction and expansion of said tubular insert in response to changes in vertical loading on said insert.

8. A mattress system comprising: a plurality of laterally extending foam layers joined together, said plurality of foam layers having an upper surface and a lower surface, said plurality of foam layers further having at least one opening extending between the upper surface and the lower surface of said plurality of foam layers;an at least one foam insert positioned within said at least one opening, said at least one foam insert having an upper surface and a lower surface, said at least one foam insert further comprising a hole running from the upper surface of said at least one foam insert to the lower surface of said at least one foam insert; anda fan located below said plurality of foam layers, said fan configured to force air through the hole in said foam insert toward the upper surface of said foam insert;wherein the interior surface of said hole in the foam insert is air-impermeable;wherein the upper surface of said at least one foam insert is aligned with the upper surface of said plurality of laterally extending foam layers; andwherein the lower surface of said at least one foam insert is aligned with the lower surface of said plurality of laterally extending foam layers.

9. The mattress system of claim 8, wherein the interior surface of said foam insert is air-impermeable due to a self-skinning property of said foam insert.

10. The mattress system of claim 8, wherein the interior surface of said foam insert is air-impermeable due to a sealant applied to the interior surface.

11. The mattress system of claim 8, wherein the hole in said foam insert is vertical.

12. The mattress system of claim 8, wherein the hole in said foam insert is slanted.

13. The mattress system of claim 8, further including a thermal conditioning element positioned between said fan and said foam insert, said thermal conditioning element enabling thermal conditioning of the air forced by said fan through the hole in said foam insert.

14. A mattress comprising: a plurality of laterally extending foam layers joined together, said plurality of foam layers having an at least one opening therethrough, said opening located in a torso zone of said mattress;a foam insert positioned withing the opening, said foam insert comprising a hole therethrough for allowing airflow between a top surface of said mattress and a bottom surface of said mattress;wherein the interior surface of said hole in air-impermeable; andwherein said foam insert increases support in the torso zone of said mattress.

15. The mattress system of claim 14, wherein the interior surface of said foam insert is air-impermeable due to a self-skinning property of said foam insert.

16. The mattress system of claim 14, wherein the interior surface of said foam insert is air-impermeable due to an applied sealant.

17. The mattress system of claim 14, wherein the hole in said foam insert is vertical.

18. The mattress system of claim 14, wherein the hole in said foam insert is slanted.

19. The mattress in claim 14, wherein said foam insert is molded.

20. The mattress in claim 14, wherein said foam insert comprises a plurality of stacked die cut foam layers.