SUPPORT CUSHION COVER ASSEMBLIES FOR REMOVING HEAT AND HUMIDITY

A support cushion cover assembly for removing humidity and heat from a contact surface of a support cushion is provided. The support cushion cover assembly comprises a support cushion cover that includes an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface. The support cushion cover further includes an amount of hygroscopic material and at least one flexible tube that defines a plurality of fenestrations. Each fenestration is in fluid communication with the middle spacer layer of the upper panel. An air pump is further included in the cover assembly and is operably connected to the flexible tube, such that an amount of air is delivered into the flexible tube and the middle spacer layer of the cover. Methods for removing humidity from a contact surface of a support cushion are also provided.

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Description
TECHNICAL FIELD

The present invention relates to a support cushion cover assembly and, more particularly, to a support cushion cover assembly that makes use of an amount of hygroscopic material and an air pump to remove heat and humidity at the contact surface of a support cushion.

BACKGROUND

As is generally the case with support cushions and, in particular, with support cushions comprised of flexible foam or other body-conforming materials, the effectiveness of the support cushion in providing support to the body of a user is partly a function of how well the flexible foam responds to the contour of the particular user resting on the cushion. In this regard, support cushions made from temperature-sensitive visco-elastic foam are often particularly desirable as such support cushions are able to, change shape based, at least in part, upon the temperature of the supported body part. That conformance of the cushion to the body of a user, however, often causes more of the user's body to he in contact with the body support cushion, and thus, less of the body of the user is exposed to the ambient air around the cushion. The reduction in the amount of the body of the user exposed to ambient air, in turn, causes many users to find support cushions comprised of visco-elastic foam to “sleep hot” and, occasionally, such users will choose other types of support cushions, notwithstanding the supportive benefits associated with visco-elastic foam and similar types of body-conforming materials.

In an effort to remedy users' concerns of “sleeping hot” as a result of the body-confirming qualities of their support cushions, many support cushion manufacturers have incorporated so-called “cooling” technologies into their products. For example, many support cushions now incorporate latent heat storage units, such as phase change material, that absorb heat and provide a cooling sensation when in contact with the body of a user. Support cushions that include phase change material, however, often fail to account for the humidity that is also present at the contact surface of a support cushion as a result of the body-conforming qualities of the support cushion. In these situations, and despite the inclusion of phase change material in some support cushions, the humidity acts to trap heat in the microclimate zone adjacent to the contact surface of the support cushion (e.g., underneath the sheet but above the mattress cover surrounding a mattress), and thus, reduces the sleep comfort of a user lying on the support cushion.

SUMMARY

The present invention includes a support cushion cover assembly and, more particularly, a support cushion cover assembly that makes use of an amount of hygroscopic material and an air pump to remove heat and humidity at the contact surface of a support cushion.

In one exemplary embodiment of the present invention, a support cushion cover assembly includes a support cushion cover having an upper panel, a bottom panel, and a continuous side panel that collectively define a cavity for enclosing a support cushion. The upper panel of the support cushion cover includes an amount of hygroscopic material and generally has a tap surface, a bottom surface, and a middle spacer layer that is positioned between the top surface and the bottom surface of the upper panel. The support cushion cover further includes a flexible tube that extends along a length of the upper panel and defines a plurality of fenestrations, with each fenestration spaced at a predetermined distance from each adjacent fenestration and in fluid communication with the middle spacer layer of the upper panel. In this regard, the support cushion cover assembly also includes an air pump that is operably connected to the flexible tube and is thus configured to deliver an amount of air into the flexible tube, through the plurality of fenestrations, and into the middle spacer layer of the upper panel.

The upper panel of the support cushion cover assembly generally has a thickness of about 5 mm to about 50 mm and can be characterized as including a first side edge, a second side edge, a head end, and a foot end. The foot end of the upper panel includes a release vent for releasing air from the middle spacer layer of the upper panel, while the head end of the upper panel is typically sealed, such that any air entering the middle space layer of the upper panel through the fenestrations in the flexible tube travels throughout the middle spacer layer before exiting the release vent at the foot end of the upper panel. In some embodiments, to further release air from the middle spacer layer, the top surface of the upper panel also defines a plurality of openings. For example, in certain embodiments, the top surface of the upper layer defines a plurality of openings in the top surface with a central region of the openings having a diameter greater than a diameter of the remainder of the openings to provide increased humidity and heat removal in an area of the support cushion cover that would be in contact with the torso of a user lying in a supine or prone position.

To facilitate the removal of heat and humidity from the upper panel of the support cushion assembly, the support cushion cover assembly may include two flexible tubes, a first flexible tube that extends along a length of the first side edge of the upper panel and a second flexible tube that extends along a length of the second side edge of the upper panel. In this regard, the first flexible tube and the second flexible tube are thus positioned and, configured to deliver an amount of air evenly through the fenestrations in the flexible tubes and into the middle spacer layer adjacent to both the first side edge and the second side edge of the upper panel. In some embodiments, to further facilitate the flow of air into the middle spacer layer, a first portion of fenestrations defined by a central portion of the flexible tubes has a diameter that is, greater than a diameter of a second portion of fenestrations defined by an upper portion and a lower portion of the flexible tubes, so as to deliver more air to the area of the middle spacer layer that would be adjacent to the torso of a user lying in a supine or prone position on the support cushion cover.

To deliver a sufficient amount of air into both the first flexible tube and the second flexible tube of the support cushion cover assembly of the present invention, the air pump of an exemplary support cushion cover assembly is generally in the form of a first air pump that is connected to the first flexible tube and a second air pump that is connected to the second flexible tube. In some embodiments, the first air pump and the second air pump can be independently controlled to thereby provide a greater amount of control over the air that is being supplied to a particular flexible tube and, consequently, to the middle spacer layer on a particular side of the support cushion cover assembly.

Regardless of whether an exemplary support cushion assembly includes single or multiple air pumps, each support cushion cover assembly also typically includes a controller for controlling the air supplied to the flexible tubes and the middle spacer layer. By including a controller in the support cushion cover assemblies, the amount of air being supplied to the flexible tubes and the middle spacer layer, or the amount of time that air is supplied to the flexible tubes and middle spacer layer, can be controlled to provide a desired amount of heat and humidily removal at the contact surface of a support cushion. For instance, in certain embodiments, the controller is configured to allow air to be supplied to the flexible tubes and the middle spacer layer for a predetermined amount of time, such as for an 8-hour sleeping period or for a length of time that corresponds to the time a user usually spends in a specific stage of the sleep cycle (e.g., REM sleep).

To provide an additional level of control over the removal of heat and humidity from the contact surface of a support cushion, in some embodiments, the support cushion cover assembly further includes one or more features that are operably connected to the upper panel of the support cushion cover assembly and provide input to the controller. Such features include, in some embodiments, humidity sensors that provide moisture feedback to the controller and allow the controller to, via the air pump, automatically begin providing air to the flexible tubes and the middle spacer layer when the moisture level in or adjacent to the upper panel reaches a particular level. In some embodiments, pressure sensors are included in an exemplary support cushion cover assembly and provide pressure feedback to the controller to allow the controller to, via the air pump, automatically begin providing air to the flexible tubes and the middle spacer layer when a user lies on the support cushion cover or otherwise places an amount of pressure on the support cushion cover. In yet other embodiments, temperature sensors are included in an exemplary support cushion cover assembly and provide temperature feedback to the controller to allow the controller to selectively provide air to the flexible tubes and the middle spacer layer in response to received temperature feedback and to maintain a desired temperature. Such desired humidity, pressure, or temperature feedback settings are, in certain embodiments, directly inputted or adjusted at the controller itself or, in other embodiments, can be transmitted to the controller from a remote control that is also operably connected to the controller and allows a user to remotely adjust the first surface of the body supporting portion to a desired temperature.

With further regard to the support cushion cover assemblies of the present invention, an exemplary support cushion cover assembly can, also be used as part of a method for removing the humidity from a contact surface of a support cushion. In some implementations, a method for removing the humidity from a contact surface of a support cushion includes first providing a support cushion cover that includes: an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface, with the upper panel defining one or more openings in the upper panel and the upper panel also including an amount of hygroscopic material for absorbing humidity present at a contact surface of the support cushion; and at least one flexible tube that extends along a length of the upper panel and defines a plurality of fenestrations, with each fenestration being in fluid communication with the middle spacer layer of the upper panel. An amount of air is then delivered into the flexible tube and the middle spacer layer of the support cushion cover assembly, such that the air flows into the middle spacer layer and through the openings to thereby remove the humidity absorbed by the hygroscopic material and, consequently, the heat and humidity at or adjacent to the contact surface of the support cushion.

Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of an exemplary support cushion cover assembly, in the form of a mattress cover assembly, made in accordance with the present invention;

FIG. 2 is a cross-sectional view of the exemplary mattress cover assembly of FIG. 1 taken along line 2-2 of FIG. 1;

FIG. 3 is a perspective view of another exemplary support cushion cover assembly, in the form of a mattress cover assembly, made in accordance with the present invention;

FIG. 4 is a perspective view of yet another exemplary support cushion cover assembly, in the form of a mattress cover assembly made in accordance with the present invention;

FIG. 5 is aside view of another exemplary support cushion cover assembly for use in a chair and made in accordance with the present invention; and

FIG. 6 is partial cross-sectional view of the exemplary support cushion cover assembly of FIG. 5 taken along line 6-6 of FIG. 5.

 DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present invention includes a support cushion cover assembly and, more particularly, a support cushion cover assembly that makes use of an amount of hygroscopic material and an air pump to remove heat and humidity from the contact surface of a support cushion.

Referring first to HOS. 1-2, in one exemplary embodiment of the present invention, a support cushion cover assembly is in the form of a mattress cover assembly 10 that includes a support cushion cover in the form of a mattress cover 11. The mattress cover 11 has an upper panel 14, a bottom panel 16, and a continuous side panel 18 that collectively define a cavity for enclosing a mattress 12. The upper panel 14 of the mattress cover 11 has a top surface 22, a bottom surface 24, and a middle spacer layer 26 that is positioned between the top surface 22 and the bottom surface 24. The upper panel 14 further includes an amount of hygroscopic material 29 that is incorporated into the upper panel 14 such that any humidity on or adjacent to the upper panel 14 is absorbed by the hygroscopic material 29, as described in further detail below.

With further respect to the upper panel 14 of the mattress cover 11, the upper panel generally can be characterized as including a first side edge 32, a second side edge 34, a head end 36, and a foot end 38. The upper panel 14 of the mattress cover 11 is dimensionally-sized to cover the mattress 12 and generally has a thickness of about 5 mm to about 50 mm, such that the upper panel 14 has a thickness sufficient to incorporate a desired amount of hygroscopic material and to allow a sufficient amount of air to move through the middle spacer layer 26. In this exemplary embodiments, the upper panel 14 also includes a pair of release vents 28a, 28b at the foot end 38 of the upper panel 14. Each of the release vents 28a, 28b is in fluid communication with and is configured to release air from the middle spacer layer 26 of the upper panel 14. The head end 36 of the upper panel 14, on other hand, is sealed, such that any air entering the middle space layer 26 of the upper panel 14 travels throughout the middle spacer layer 26 before exiting the release vents 28a, 28b at the foot end 38 of the upper panel 14.

To facilitate the flow of air through the middle spacer layer 26 and the removal of heat and humidity from the upper panel 14, the mattress cover 11 further includes a first flexible tube 40a that includes a plurality of fenestrations 42a and extends along the length of the first side edge 32, and a second flexible tube 40b that includes a plurality of fenestrations 42b and extends along a length of the second side edge 34. Each of the fenestrations 42a, 42b has an equal diameter and is spaced at a predetermined distance from each adjacent fenestration 42a, 42b. Further, each of the fenestrations 42a, 42b is in fluid communication with the middle spacer layer 26 of the upper panel 20 of the mattress cover 11. In this regard, the first flexible tube 40a and the second flexible tube 40b, along with the plurality of fenestrations 42a, 42b in the flexible tubes 40a, 40b. are thus positioned and configured to deliver an amount of air evenly through the fenestrations 42a, 42b in the flexible tubes 40a, 40b and into the middle spacer layer 26 adjacent to both the first side edge 32 and the second side edge 34 of the upper panel 14.

To deliver air into the first flexible tube 40a and the second flexible tube 40b, through the plurality of fenestrations 42a, 42b, and into the middle spacer layer 26. the mattress cover assembly 10 further includes a first air pump 60a that is operably connected to the first flexible tube 40a and a second air pump 60b that is operably connected to second flexible tube 40b. Both the first air pump 60a and the second air pump 60b are connected to discrete controllers 70a, 70b that are configured to control the amount of air supplied by the air pumps 60a, 60b. By including a controller 70a that is only connected to the first air pump 60a and a controller 70b that is only connected to the second air pump 60b, the first air pump 60a and the second air pump 60b can be independently controlled to allow a desired amount of air to be supplied to the first flexible tube 40a, to the plurality of fenestrations 42a, and into the middle spacer layer 26 adjacent to the first side edge 32 of the upper panel 14, while the same or a different amount of air is supplied to the second flexible tube 40b, to the plurality of fenestrations 42b, and into the middle spacer layer 26 adjacent to the second side edge 34 of the upper panel 14. For example, in the exemplary embodiment shown in FIGS. 1 and 2, the first air pump 60a and the second air pump 60b are individually controlled, such that it is possible to provide an increased amount of air to a user lying adjacent to the first side edge 32 of the upper panel 14 of the mattress cover 11 and who is prone to excessive heating, while a decreased amount of air is provided to a user lying adjacent to the second side edge 34 of the upper panel 14 of the mattress cover 11 and who is not prone to excessive heating. Of course, various other arrangements of air pumps and controllers, including the use of a single air pump having one or more diverters for directing an amount of air to a particular location, are also contemplated for use in accordance with the present invention and can be readily connected to an exemplary mattress cover without departing from the spirit and scope of the subject matter described herein. Additionally, it is contemplated that the term “air pump” is not limited to closed containers capable of propelling air, but is further inclusive of fans, blowers, and the like that are each capable directing an amount of air into a tube.

Turning now to the hygroscopic material 29 included in the upper panel 14 of the mattress cover 11, the hygroscopic material 29 is generally incorporated into both the top surface 22 and the middle spacer layer 26 such that the hygroscopic material 29 is positioned and configured to place the body of a user, or a portion thereof, resting on the mattress cover 11 in close proximity to the hygroscopic material 29. In this regard, as such a user generates heat and humidity (e.g., humidity in the form of perspiration) during sleep, the hygroscopic material 29 is effectively positioned to absorb any such humidity as it is generated, and is thus configured to reduce the amount of humidity at or adjacent to the contact surface (i.e., the upper surface) of the mattress 12.

The hygroscopic material 29 that is incorporated into the upper panel 14 is generally in the form of encapsulated hygroscopic material that has an increased capability of absorbing humidity and moisture from the surrounding environment relative to the other material included in the mattress cover 11. As the hygroscopic material 29 absorbs moisture from the surrounding environment, the hygroscopic material 29 thus continually absorbs humidity and any associated heat generated by the user. As air is pumped through the flexible tubes 40a, 40b and the plurality of fenestrations 42a, 42b, and into the middle spacer layer 26, the air moving inside the middle spacer layer 26 is then able to remove the absorbed moisture from the hygroscopic material 29 and release it through the vents 28a, 28b while, at the same time, providing a cooling effect to the user lying on the mattress cover II and allowing the hygroscopic material 29 to continue to absorb moisture from the surrounding environment.

As a refinement to the heat and humidity removal capabilities of the support cushion cover assemblies of the present invention and referring now to FIG. 3, in another exemplary embodiment, a mattress cover assembly 110 is provided that, like the mattress cover assembly 10 shown in FIGS. 1 and 2, includes a mattress cover 111 having an upper panel 114 with a top surface 122, a bottom surface 124, and a middle spacer layer 126 that is positioned between the top surface 122 and the bottom surface 124. The upper panel 114 also includes an amount of hygroscopic material 129 that is incorporated into the upper panel 114, as well as a pair of release vents 128a, 128b that are in fluid communication with and are configured to release air from the middle spacer layer 126 of the upper panel 114. The mattress cover 111 also includes a first flexible tube 140a that includes a plurality of fenestrations 142a, 146a and a second flexible tube 140b that includes a plurality of fenestrations 142b, 146b. The first flexible tube 140a is attached to a first air pump 160a and a controller 170a. and the second flexible tube 140b is attached to a second air pump 160b and a controller 170b.

Unlike the fenestrations 42a, 42b in the flexible tubes 40a, 40b shown in FIGS. 1-2, however, each of the fenestrations 142a, 142b, 146a, 146b in the flexible tubes 140a, 140b shown in FIG. 3 do not have equal diameters. Rather, in the mattress cover assembly 110 shown in FIG. 3, the flexible tubes 140a, 140b each include a central portion 144a, 144b that defines a first portion of fenestrations 142a, 142b having a diameter that is greater than a diameter of a second portion of fenestrations 146a, 146b defined by an upper portion 148a, 148b and a lower portion 149a, 149b of each flexible tube 140a, 140b. In this regard, the flexible tubes 140a, 140b are thus configured such that when is air is delivered to the flexible tubes 140a, 140b, a greater amount of air is released from the first portion of fenestrations 142a, 142b and is delivered to the portion of the middle spacer layer 126 that would be adjacent to the torso of a user lying in a supine or prone position on the mattress cover 111 and that would likely be exposed to excess heat and humidity. in other words, by providing the first portion of fenestrations 142a, 142b with a greater diameter than the second portion of fenestrations 146a, 146b, and delivering a greater amount of air to the portion of the middle spacer layer 126 that would be adjacent to the torso of a user, the upper panel 114 of the mattress cover 111 is configured to remove the heat and humidity from the location on the upper panel 114 where an excess amount heat and humidity is most likely to be found.

To provide an even further level of control over the removal of heat and humidity from the upper panel 114 of the mattress cover 111, the mattress cover assembly 110 further includes additional features that are operably connected to the upper panel 114 of the mattress cover 111 and provide input to the controllers 170a, 170b. In particular, and referring still to FIG. 3, the upper panel 114 of the mattress cover 111 includes a pair of humidity sensors 192a, 192b that independently provide moisture feedback to the controllers 170a, 170b on their respective sides of the upper panel 114 and allow the controllers 170a, 170b to, via the air pumps 160a, 160b, automatically begin providing air to the flexible tubes 140a, 140b and the middle spacer layer 126 when the moisture level at or adjacent to the upper panel 114 reaches a particular level. As also shown in FIG. 3, pressure sensors 196a, 196b are further included in the mattress cover assembly 110 and, more specifically, in the upper panel 114 of the mattress cover 111 to provide pressure feedback to the controllers 170a, 170b and allow the controllers 170a, 170b to, via the air pumps 160a, 160b, automatically begin providing air to the flexible tubes 140a, 140b and the middle spacer layer 126 when a user lies on the mattress cover 111 or otherwise places an amount of pressure on the mattress cover 111. Temperature sensors 194a, 194b are additionally included in upper panel 114 of the mattress cover 111 and provide temperature feedback to the controllers 170a, 170b to allow the controllers 170a, 170b to cause the air pumps 160a, 160b to selectively provide air to the flexible tubes 140a, 140b and the middle spacer layer 126 in response to received temperature feedback and to maintain a desired temperature, Such desired humidity, pressure, or temperature feedback settings can be directly inputted or adjusted at the controllers 170a, 170b or can be transmitted to the controllers 170a, 170b from a remote control that is also operably connected to the controller and allows a user to remotely adjust the sensors to a desired setting.

As an even further refinement to the heat and humidity removal capabilities of the support cushion over assemblies of the present invention and referring now to FIG. 4, in yet another exemplary embodiment, a mattress cover assembly 210 is provided that, like the mattress cover assemblies 10, 110 shown in FIGS. 1 and 2 and in FIG. 3, includes a mattress cover 211 having an upper panel 214 with a top surface 222, a bottom surface 224, and a middle spacer layer 226 that is positioned between the top surface 222 and the bottom surface 224 of the upper panel 214 of the mattress cover 211. The upper panel 214 also includes an amount of hygroscopic material 229 that is incorporated into the upper panel 214. The mattress cover assembly 210 further includes a first flexible tube 240a that includes a plurality of fenestrations 242a and a second flexible tube 240b that includes a plurality of fenestrations 242b, with the first flexible tube 240a attached to a first air pump 260a and a controller 270a and the second flexible tube 240b attached to a second air pump 260b and a controller 270b.

Unlike the mattress cover assemblies 10, 110 shown in FIGS. 1-3, however, to release air from the middle spacer layer 226 of the upper panel 214 of the mattress cover 211, the mattress cover not only includes a pair of release vents 228a, 228b that are in fluid communication with the middle spacer layer 226 of the upper panel 214, but the top surface 222 of the upper panel 214 also defines openings 223, 225 in the upper panel 214 to release an additional amount of air from the middle spacer layer 226 and, consequently, remove additional heat and humidity. In the embodiment shown in FIG. 4, the top surface 222 of the upper panel defines a central region of openings 223 having a diameter great than the remainder of openings 225 defined by the top surface 222 to thereby provide increased humidity and heat removal in the area of the upper panel 214 of the mattress cover 211 that would be in contact with the torso of a user lying in a supine or prone position and which would be exposed to excess heat and humidity. In this regard, it is contemplated that other configurations and arrangements of openings can be selected and incorporated into an exemplary mattress cover assembly of the present invention as desired or as needed for a particular support cushion or application without departing from the spirit and scope of the subject matter described herein.

Referring still to FIG. 4, to provide a mattress cover 211 that is sufficiently “breathable” and allows air, heat, and moisture to travel through the mattress cover 211 to the hygroscopic material 229, but yet is also is sufficiently soft and durable and able to provide an increased cooling sensation to a user lying on the mattress cover 211, the mattress cover 211 is comprised of a textile that incorporates phase change material 227 into the upper panel 214. The phase change material 227 that is incorporated into the upper panel 214 of the mattress cover is typically comprised of microspheres that include substances having a high heat of fusion and that store or release heat as the substances oscillate between solid and liquid form (i.e., phase change materials). As the phase change material 227 included in the upper panel 214 changes from solid to liquid form (i.e., melts) as the result of heat generated by a user lying on the mattress cover 211, the phase change material 227 thus continually absorbs heat and provides a cooling effect to the user, which is in addition to the cooling effect of the hygroscopic material 229 and the flow of air through the upper panel 214, until all of the phase change material 227 has been transformed from a solid to a liquid form. Of course, it is contemplated that phase change material need not be included in an exemplary cover assembly at all, but that numerous other textiles, including silk and textiles having varying percentages of cotton that are sufficiently breathable and capable of providing a cooling sensation can also be readily used in any of the cover assemblies described herein and can be selected for a particular cover assembly or a particular application or type of mattress as desired.

In addition to using a textile to provide a sufficiently breathable and durable surface, the exemplary cover assembly 210 also typically incorporates one or more flame-retardant materials into the mattress cover 211. By incorporating a flame-retardant material (e.g., a fire sock) into the mattress cover 211, the mattress cover assembly 210 thus provides a flame-retardant barrier that completely surrounds an underlying mattress, such as the visco-elastic foam mattresses described herein below.

As yet another refinement to the present invention, although the support cushion covers shown in FIGS. 1-4 are in the form of mattress covers 11, 111, 211 and are dimensionally sized to cover a mattress, it is contemplated that the features described herein are equally applicable to seat cushions, seat backs, neck pillows, leg spacer pillows mattress toppers, overlays, and the like. As such, the phrase “support cushion” is used herein to refer to any and all such objects having any size and shape, and that are capable of or are generally used to support the body of a user or a portion thereof. For example, as shown in FIGS. 5 and 6, support cushion cover assemblies made in accordance with the present invention are incorporated into the back 313 and seat 312 of a desk chair 310. Each support cushion cover assembly of the desk chair 310 includes a support cushion cover 311 having an upper panel 314 with a top surface 322, a bottom surface 324, and a middle spacer layer 326 that is positioned between the top surface 322 and the bottom surface 324. The upper panel 314 also includes an amount of hygroscopic material 329 and, through the middle spacer layer 326, is in fluid communication with flexible tubes 340 that are attached to an air pump 360 and a controller 370 to thereby provide for the removal of heat and humidity from the seat 312 and back 313 of the desk chair 310.

With respect to the flexible foams used in the mattresses and support cushions that are covered by the cover assemblies of the present invention, the mattresses and support cushions are generally comprised of a flexible foam that has a low resilience as well as a sufficient density and hardness, which allows pressure to be absorbed uniformly and distributed evenly across the various mattresses and other support cushions. Such flexible foams include, but are not limited to: latex foam; reticulated or non-reticulated visco-elastic foam (sometimes referred to as memory foam or low-resilience foam): reticulated or non-reticulated non-visco-elastic foam; high-resilience polyurethane foam; expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene); and the like.

With respect to the hardness of the visco-elastic foams used in certain of the mattresses and flexible foam layers, suitable visco-elastic foams typically have a hardness of at least about 10 N to no greater than about 80 N as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the material at approximately room temperature (i.e., 21° C. to 23° C.), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard. In some embodiments, the visco-elastic foam can have a hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, car about 80 N to provide a desired degree of comfort and body-conforming qualities.

With respect to the density of the visco-elastic foams used in certain of the mattresses and flexible foam layers, suitable visco-elastic foams have a density that also assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability. In some embodiments, the density of the isco-elastic foam used in the mattresses and flexible foam layers is no less than about 30 kg/m3 to no greater than about 150 kg/m3. In some embodiments, the density of the visco-elastic foam that is used is about 30 kg/m3, about 40 kg/m3, about 50 kg/m3, about 60 kg/m3, about 70 kg/m3, about 80 kg/m3, about 90 kg/m3, about 100 kg/m3, about 110 kg/m3, about 120 kg/m3, about 130 kg/m3, about 140 kg/m3, or about 150 kg/m3. Of course, the selection of a visco-elastic foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it should be appreciated that a visco-elastic foam having a desired density and hardness can readily be selected for a particular application or assembly as desired.

Additionally, it should be appreciated that the visco-elastic foam used in the mattresses and other support cushions described for use with the cover assemblies of the present invention need not be comprised of a single piece of visco-elastic foam, but can be comprised of multiple layers of visco-elastic foam with the layers having different densities and hardnesses. For example, in some embodiments, a visco-elastic foam mattress can be utilized that includes a lower supporting layer of visco-elastic foam with a density of about 80 kg/m3 and a hardness of about 13 N, and an upper comfort layer of visco-elastic foam with a density of about 35 kg/m3 and a hardness of about 10 N.

With further regard to the support cushion cover assemblies of the present invention. an exemplary support cushion cover assembly can also be used as part of a method for removing the humidity from a contact surface of a support cushion or, in other words. from the surface of a support cushion that is contacted by the body of a user, or a portion thereof. In some implementations, a method for removing the humidity from a contact surface of a support cushion includes first providing a support cushion cover assembly that includes: an upper panel having a top surface, a bottom surface, and a middle spacer layer that positioned between the top surface and the bottom surface, with the upper panel defining one or more openings in the upper panel and the upper panel also including an amount of hygroscopic material for absorbing humidity present at a contact surface of the support cushion; and at least one flexible tube that extends along a length of the upper panel and defines a plurality of fenestrations, with each fenestration being in fluid communication with the middle spacer layer of the upper panel. An amount of air is then delivered into the flexible tube and the middle spacer layer of the support cushion cover assembly, such that the air flows into the middle spacer layer and through the openings to thereby remove the humidity absorbed by the hygroscopic material and, consequently, the humidity at the contact surface of the support cushion.

The references set forth in the following list are incorporated herein by reference.

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One of ordinary skill in the art will recognize that additional embodiments or implementations are possible without departing from the teachings of the present invention or the scope of the claims which follow. This detailed description, and particularly the specific details of the exemplary embodiments and implementations disclosed herein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

Claims

1. A support cushion cover assembly, comprising:

a support cushion cover including an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface, the upper panel including an amount of hygroscopic material, and at least flexible tube extending along a length of the upper panel and defining, a plurality of fenestrations, each fenestration spaced at a predetermined distance from each adjacent fenestration, and each fenestration in fluid communication with the middle spacer layer of the upper panel; and
an air pump operably connected to the flexible tube, the air pump configured to deliver an amount of air into the flexible tube, through the fenestrations, and into the middle spacer layer.

2. The support cushion cover assembly of claim 1, wherein the upper panel of the support cushion cover can be characterized as including a first side edge, a second side edge, a head end, and a foot end.

3. The support cushion cover assembly of claim 2, wherein the foot end includes one or more release vents for releasing air from the middle spacer layer of the upper panel.

4. The support cushion cover assembly of claim 2, wherein the support cushion cover includes a first flexible tube extending along a length of the first side edge, and a second flexible tube extending along a length of the second side edge.

5. The support cushion cover assembly of claim 4, wherein the air pump comprises a first air pump operably connected to the first flexible tube and a second air pump operably connected to the second flexible tube.

6. The support cushion cover assembly of claim 5, wherein the first air pump and the second air pump are independently controlled.

7. The support cushion cover assembly of claim 1, wherein the plurality of fenestrations includes a first portion of fenestrations defined by a central portion of the flexible tube and a second portion of fenestrations defined by an upper portion and a lower portion of the flexible tube, and wherein the first portion of fenestrations has a diameter greater than a diameter of the second portion of fenestrations.

8. The support cushion cover assembly of claim 1, wherein the top surface of the upper panel defines a plurality of openings for releasing air from the middle spacer layer.

9. The support cushion cover assembly of claim 1, wherein the plurality of openings includes a central region of openings having a diameter greater than a diameter of the remainder of the openings.

10. The support cushion cover assembly of claim 1, further comprising a controller for controlling an amount of air supplied to the flexible tube, through the fenestrations, and into the middle spacer layer.

11. The support cushion cover assembly of claim 10. wherein the controller is configured to allow air to be supplied to the flexible tube and the middle spacer layer for a predetermined amount of time.

12. The support cushion cover assembly of claim 10, further comprising a humidity sensor for providing moisture feedback to the controller.

13. The support cushion cover assembly of claim 10, further comprising a temperature sensor for providing thermal feedback to the controller.

14. The support cushion cover assembly of claim 10, further comprising a pressure sensor for providing pressure feedback to the controller.

15. The support cushion cover assembly of claim 1, wherein the support cushion cover is comprised of a flame-retardant material.

16. The support cushion cover assembly of claim 1, wherein the upper panel further includes an amount of phase change material.

17. The support cushion cover assembly of claim 1, wherein the support cushion cover further comprises a bottom panel and a continuous side panel, such that the upper panel, the bottom panel, and the continuous side panel collectively define a cavity for enclosing a mattress.

18. The support cushion cover assembly of claim 1. wherein the upper panel has a thickness of about 5 mm to about 50 mm.

19. A support cushion cover, comprising:

an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface, the upper panel including an amount of hygroscopic material, and
at least one flexible tube extending along a length of the upper panel and defining a plurality of fenestrations, each fenestration spaced at a predetermined distance from each adjacent fenestration, and each fenestration in fluid communication with the middle spacer layer of the upper panel such that the flexible tube is configured to deliver an amount of air into the middle spacer layer.

10. A mattress assembly, comprising:

a flexible foam mattress;
a mattress cover including an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface, the upper panel including an amount of hygroscopic material, and at least one flexible tube extending along a length of the upper panel and defining a plurality of fenestrations, each fenestration in fluid communication with the middle spacer layer of the upper panel; and
an air pump operably connected to the flexible tube, the air pump configured to deliver an amount of air into the flexible tube and the middle spacer layer of the mattress cover.

21. The mattress assembly of claim 20, wherein the flexible foam is a visas-elastic foam.

22. A method for removing humidity from a contact surface of a support cushion, comprising:

providing a support cushion cover including an upper panel having a top surface, a bottom surface, and a middle spacer layer positioned between the top surface and the bottom surface, the upper panel defining one or more openings in the upper panel, and the upper panel including an amount of hygroscopic material, and at least one flexible tube extending along a length of the upper panel and defining a plurality of fenestrations, each fenestration in fluid communication with the middle spacer layer of the upper panel; and
delivering an amount of air into the flexible tube and the middle spacer layer of the support cushion cover.
Patent History
Publication number: 20170150822
Type: Application
Filed: Jun 25, 2014
Publication Date: Jun 1, 2017
Applicant: Tempur-Pedic Management, LLC (Lexington, KY)
Inventors: Hamid GHANEI (Greensboro, NC), Stephen SWITZER (Highpoint, NC)
Application Number: 15/320,797
Classifications
International Classification: A47C 21/04 (20060101); A47C 27/14 (20060101); A47C 27/00 (20060101); A47C 7/74 (20060101); A47C 31/00 (20060101);