MATTRESS THERMAL MANAGEMENT SYSTEM

Abstract

The disclosure generally relates to a mattress thermal management system, for example a mattress cooling and/or heating system and in particular a suction- and/or discharge-based cooling and/or heating system. Deck-mounted fans beneath a mattress operate in various embodiments to induce a uniform suction flow, a uniform discharge flow, and/or a combined suction/discharge (circulating) flow that enhances the cooling and/or heating rate of the mattress. Mattress-mounted heating units can be included. The mattress thermal management system can be incorporated into a conventional mattress/bed system or into an adjustable bed system.

Description

CROSS REFERENCE TO RELATED APPLICATION

Priority is claimed to U.S. Provisional Application No. 62/331,515 filed on May 4, 2016, which is incorporated by reference herein in its entirety.

STATEMENT OF GOVERNMENT INTEREST

None.

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

The disclosure generally relates to a mattress thermal management system, in particular a suction- and/or discharge-based cooling and/or heating system. Deck-mounted fans beneath a mattress operate in various embodiments to induce a uniform suction flow, a uniform discharge flow, and/or a combined suction/discharge (circulating) flow that enhances the cooling and/or heating rate of the mattress. Mattress-mounted heating units can be included. The mattress thermal management system can be incorporated into a conventional mattress/bed system or into an adjustable bed system.

SUMMARY

In one aspect, the disclosure relates to a mattress support structure (e.g., bed frame) comprising: (a) a mattress support having a top surface for supporting a mattress and an opposing bottom surface (e.g., corresponding to the area beneath the bed/bed frame/mattress support structure); (b) a fan mounted to the mattress support and adapted to transport air (i) from above the top surface of the mattress support to below the bottom surface of the mattress support, (ii) from below the bottom surface of the mattress support to above the top surface of the mattress support, or (iii) both (i) and (ii) (e.g., (i) and (ii) can represent appropriately mounted uni-directional fans, (iii) can represent a bi-directional fan adapted to transport air in either direction); and optionally (c) an electromechanical system adapted to control one or more (e.g., a plurality of) moveable support platforms, wherein the fan is coupled to and controllable by the electromechanical system (e.g., PLC controller mounted to the bed frame or mattress support structure, such as directly to the mattress support or indirectly to the mattress support via lower frame structure; electromechanical system/PLC controller can receive fan operation instructions/commands from a remote control for the adjustable bed). In a refinement, the mattress support comprises an airflow channel between the top surface and the bottom surface to permit airflow therethrough; and the fan is mounted to the mattress support in fluid communication with the airflow channel. In a refinement, the mattress deck is a stationary structure (e.g., a unitary flat member for a fixed mattress support structure or a plurality of flat members collectively defining a flat mattress deck surface for a fixed mattress support structure). In a refinement, the mattress support is an adjustable bed comprising at least one moveable mattress support (e.g., further including an adjustable bed frame to which the mattress support is mounted, such as directly or indirectly). In a refinement, the mattress deck comprises a plurality of support platforms independently moveable relative to each other (e.g., a multi-section mattress deck for an adjustable mattress support structure; each support platform can have at least one fan mounted thereto). In a further refinement, the mattress support structure can comprise a plurality of fans mounted to the mattress support (or support platforms). In one embodiment, the fans are all mounted to the mattress support in a manner adapted to transport air from above the top surface of the mattress support to below the bottom surface of the mattress support (e.g., a mattress-side suction configuration). In another embodiment, the fans are all mounted to the mattress support in a manner adapted to transport air from below the bottom surface of the mattress support to above the top surface of the mattress support (e.g., a mattress-side discharge configuration). In another embodiment, the fans are all mounted to the mattress support in a manner adapted to transport air (i) from above the top surface of the mattress support to below the bottom surface of the mattress support, and (ii) from below the bottom surface of the mattress support to above the top surface of the mattress support. In another embodiment, at least some of the fans are mounted to the mattress support in a manner adapted to transport air from above the top surface of the mattress support to below the bottom surface of the mattress support; and at least some of the fans are mounted to the mattress support in a manner adapted to transport air from below the bottom surface of the mattress support to above the top surface of the mattress support (e.g., a combined mattress-side discharge and mattress-side suction configuration for circulation).

In another aspect, the disclosure relates to a mattress assembly system comprising: (a) the mattress support structure according to any of the variously disclosed embodiments; (b) a mattress positioned above the mattress support of the mattress support structure; and optionally (c) an airflow spacer positioned intermediate the mattress support structure and the mattress, the airflow spacer adapted to direct airflow (i) to the fans from the mattress, (ii) from the fans to the mattress, or (iii) both (i) and (ii) over substantially the entire area of the mattress. In one refinement, the mattress assembly system further comprises a remote control adapted to transmit fan operational commands to the fan and optionally further adapted to transmit bed repositioning commands to a corresponding adjustable bed frame (e.g., directly to a PLC controller for the fan or a combined PLC controller for the fan and adjustable bed; indirectly to a PLC controller for the fan via a separate PLC controller for the adjustable bed; controller(s) can be mounted on any bed structure, such as the mattress deck or (adjustable) bed frame). In another refinement, the mattress is a conventional mattress. In another refinement, the mattress comprises a mattress containment frame and a plurality of foam cells distributed throughout the containment frame to collectively define a mattress sleep surface. In a further refinement, the mattress further comprises at least one of (a) a plurality of vent holes on a base portion of the mattress containment frame, the vent holes being positioned to permit airflow through the mattress between interstitial areas defined by adjacent foam cells; and (b) a plurality of locator pins on a base portion of the mattress containment frame, wherein each locator pin (i) is adapted to mate with a corresponding open cylindrical channel in a foam cell, and (ii) comprises an open area permitting airflow through the mattress via the open area and the cylindrical channel. In another refinement, the mattress assembly further comprises at least one of a heating unit and a cooling unit mounted to the mattress assembly at a location beneath the mattress support bottom surface, the heating unit and the cooling unit being positioned to direct heated air and cooled air, respectively, to a fan suction side. In another refinement, the airflow spacer is a separate structure from the mattress and the mattress support. In another refinement, the airflow spacer is an integral component of the mattress. In another refinement, the mattress support comprises an airflow channel between the top surface and the bottom surface to permit airflow therethrough; the airflow spacer comprises an airflow channel positioned on a bottom surface of the airflow spacer and in a corresponding location to the airflow channel of the mattress support to permit airflow therethrough; and the fan is mounted to the mattress support in fluid communication with the airflow channel of the mattress support and the corresponding airflow channel of the airflow spacer.

In another aspect, the disclosure relates to a method for cooling or heating a mattress, the method comprising: (a) providing the mattress assembly according to any of the variously disclosed embodiments; (b) operating the fans of the mattress assembly to actively cool or heat the mattress of the mattress assembly (e.g., also cooling or heating the mattress while a user of the bed is sleeping or laying on the mattress). In a refinement, the method comprises operating the fans to actively cool the mattress with ambient environmental air (e.g., operating the fan or fans in a mattress-side suction, discharge, or recirculation flow). In another refinement, the method comprises operating the fans to actively cool the mattress with actively cooled air (e.g., operating the fan or fans in a mattress-side suction, discharge, or recirculation flow; using an integrated cooling unit with the mattress assembly beneath the mattress support; using a remote cooling unit adapted to direct cooled air relative to ambient beneath the mattress support). In another refinement, the method comprises operating the fans to actively heat the mattress with actively heated air (e.g., operating the fan or fans in a mattress-side suction, discharge, or recirculation flow; using an integrated heating unit with the mattress assembly beneath the mattress support; using a remote heating unit adapted to direct heated air relative to ambient beneath the mattress support).

In another aspect, the disclosure relates to a mattress assembly system comprising: (a) a mattress support having a top surface for supporting a mattress and an opposing bottom surface, the mattress support comprising an airflow channel between the top surface and the bottom surface to permit airflow therethrough; (b) a fan mounted to the mattress support in fluid communication with the airflow channel, the fan being adapted to transport air (i) from above the top surface of the mattress support to below the bottom surface of the mattress support, (ii) from below the bottom surface of the mattress support to above the top surface of the mattress support, or (iii) both (i) and (ii); (c) a mattress positioned above the mattress support of the mattress support structure; (d) a heating unit mounted to the mattress or positioned between the mattress support and the mattress (e.g., heating unit mounted to a bottom mattress surface, a top mattress surface, an interior mattress location, a mattress support top surface, and/or an air flow spacer, if present); and (e) optionally an electromechanical system adapted to control the at least one moveable mattress support, wherein the fan and the heating unit are coupled to and controllable by the electromechanical system (e.g., a bed controller and associated power supply providing power and operational commands to the fan and the heating unit). In a refinement, the fan is positioned proximal to a head end of the mattress assembly system, and the heating unit is positioned proximal to an opposing foot end of the mattress assembly system. In a refinement, the mattress support is a stationary structure (e.g., a fixed, non-adjustable/articulatable bed). In a refinement, the mattress support is an adjustable bed comprising at least one moveable mattress support. In a refinement, the mattress support comprises a rigid mattress deck. In a refinement, the mattress support comprises a flexible support material. In a refinement, the mattress assembly system further comprises a remote control adapted to transmit (i) fan operational commands to the fan, and (ii) heating unit operational commands to the heating unit. In a refinement, the mattress is a conventional mattress. In a refinement, the mattress assembly system further comprises at least one of a heating unit and a cooling unit mounted to the mattress assembly at a location beneath the mattress support bottom surface, the heating unit and the cooling unit being positioned to direct heated air and cooled air, respectively, to a fan suction side.

In another refinement, the mattress assembly system comprises a plurality of fans mounted to the mattress support. In a particular refinement, the fans are all mounted to the mattress support in a manner adapted to transport air from above the top surface of the mattress support to below the bottom surface of the mattress support. In a particular refinement, the fans are all mounted to the mattress support in a manner adapted to transport air from below the bottom surface of the mattress support to above the top surface of the mattress support. In a particular refinement, the fans are all mounted to the mattress support in a manner adapted to transport air (i) from above the top surface of the mattress support to below the bottom surface of the mattress support, and (ii) from below the bottom surface of the mattress support to above the top surface of the mattress support. In a particular refinement, at least some of the fans are mounted to the mattress support in a manner adapted to transport air from above the top surface of the mattress support to below the bottom surface of the mattress support; and at least some of the fans are mounted to the mattress support in a manner adapted to transport air from below the bottom surface of the mattress support to above the top surface of the mattress support.

In another refinement, the mattress comprises the mattress comprises a mattress containment frame and a plurality of foam cells distributed throughout the containment frame to collectively define a mattress sleep surface. In a particular refinement, the mattress further comprises at least one of (a) a plurality of vent holes on a base portion of the mattress containment frame, the vent holes being positioned to permit airflow through the mattress between interstitial areas defined by adjacent foam cells; and (b) a plurality of locator pins on a base portion of the mattress containment frame, wherein each locator pin (i) is adapted to mate with a corresponding open cylindrical channel in a foam cell, and (ii) comprises an open area permitting airflow through the mattress via the open area and the cylindrical channel.

In another refinement, the mattress assembly system further comprises an airflow spacer positioned intermediate the mattress support structure and the mattress, the airflow spacer adapted to direct airflow (i) to the fans from the mattress, (ii) from the fans to the mattress, or (iii) both (i) and (ii) over substantially the entire area of the mattress. In a particular refinement, the airflow spacer is a separate structure from the mattress and the mattress support. In a particular refinement, the airflow spacer is an integral component of the mattress.

In another aspect, the disclosure relates to method for cooling and heating a mattress, the method comprising: (a) providing the mattress assembly system according to any according to the various disclosed embodiments including the heating unit mounted to the mattress or positioned between the mattress support and the mattress; (b) operating the fan of the mattress assembly to actively cool the mattress of the mattress assembly system; and (c) operating the heating unit of the mattress assembly to heat the mattress of the mattress assembly system. In a refinement, the method comprises operating the fans to actively cool the mattress, and operating the heating unit to heat the mattress while a user is sleeping or laying on the mattress. In a refinement, the method comprises operating the fans to actively cool the mattress with ambient environmental air. In a refinement, the method comprises operating the fans to actively cool the mattress with actively cooled air. In a refinement, the method comprises operating the fans to actively heat the mattress with actively heated air.

Additional features of the disclosure may become apparent to those skilled in the art from a review of the following detailed description, taken in conjunction with the drawings, examples, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the disclosure, reference should be made to the following detailed description and accompanying drawings wherein:

FIG. 1 is a side exploded view of a mattress thermal management system according to the disclosure.

FIG. 2 is a top perspective illustration of a mattress and airflow spacer according to the disclosure.

FIGS. 3a and 3b illustrate bottom views of a mattress deck and an associated adjustable bed frame according to the disclosure (3a: twin deck and bed frame; 3b: queen deck and bed frame).

FIGS. 4a and 4b are schematics of the bottom side of the mattress deck of FIG. 3b showing possible placements of cooling fans.

FIG. 5 is a side view of mattress thermal management system embodiments according to the disclosure (A: mattress-side airflow discharge; B: mattress-side airflow suction; C: mattress-side airflow combined discharge and suction).

FIG. 6 is a top perspective illustration of a mattress containment frame according to the disclosure.

FIG. 7 is a side cut-away view of the mattress containment frame of FIG. 6 and a corresponding airflow spacer according to the disclosure.

FIG. 8 is a top view of a mattress incorporating heating elements attached to the foot end of the mattress.

FIG. 9 is a top view of a mattress incorporating heating elements attached to the foot end of the bed, and two vent units in the head end of the mattress that are each connected to a fan.

FIG. 10 is a bottom view of an adjustable bed incorporating vents manufactured into the foundation and mattress, each vent being connected to a fan.

While the disclosed apparatus and methods and are susceptible of embodiments in various forms, specific embodiments of the disclosure are illustrated (and will hereafter be described) with the understanding that the disclosure is intended to be illustrative, and is not intended to limit the claims to the specific embodiments described and illustrated herein.

DETAILED DESCRIPTION

The disclosure generally relates to a mattress thermal management system, for example a mattress cooling system and in particular a suction-based cooling system. In other embodiments, the mattress thermal management system can operate as a mattress heating system. Deck-mounted fans beneath a mattress operate in various embodiments to induce a uniform suction flow or a combined suction/discharge (circulating) flow that enhances the cooling or heating rate of the mattress. Suitably, air is used as the fluid heat transfer medium, whether the system is operating for mattress cooling or heating. In other embodiments, a gaseous fluid other than air may be used as a fluid heat transfer medium circulated by the deck-mounted fans (e.g., alone or in combination with air). Accordingly, references in the following description to “air” and “airflow” apply as well to various other gaseous heat transfer fluids more generally. In some embodiment, mattress-mounted heating units can be included with the deck-mounted fans to provide an integrated system for heating and cooling a bed system. The mattress cooling system can be incorporated into a conventional mattress/bed system or into an adjustable bed system.

One of the main complaints that people have about their mattresses and their sleep experience is that they either get too hot or cold during the night. Specifically, people complain that their feet do not remain warm throughout the night and/or that their body's core and head become too warm. One embodiment of the disclosed integrated system for heating and cooling solves these problems by having a bed (e.g., an adjustable bed) with a ventilated area at the head section of the bed that is cooled by a fan, and a heating pad at the foot end that warms the foot end.

In one embodiment, the disclosure relates to a bed (e.g., an adjustable bed) manufactured with vents in the head end of both the (adjustable) foundation and the mattress. The vents are connected to a fan that is attached to the vents at the underside of the adjustable foundation. When activated, the fans blow air through the vents, thereby cooling the mattress and the user of the mattress. At the food end of the mattress, one or more heating elements are attached the mattress and connected to the foundation's power supply via wire, thereby allowing the heating elements to draw power and heat the foot end of the mattress and keep the user of the mattress's feet warm.

In another embodiment, the disclosure relates to a bed (e.g., an adjustable bed) manufactured with one or more vents in either or both ends of the (adjustable) foundation and the mattress. The vents are each connected to a fan that is attached to the vents at the underside of the adjustable foundation. When activated, the fans blow air through the vents thereby cooling the mattress and the user of the mattress.

In another embodiment, the disclosure relates to a bed (e.g., an adjustable bed) with one or more heating elements are attached to the mattress or foundation at either or both ends of the foundation. The heating elements are connected to the foundation's power supply via wire, thereby allowing the heating elements to draw power and heat either or both ends of the mattress or foundation.

In another embodiment, the disclosure relates to a bed (e.g., an adjustable bed) manufactured with one or more vents in either or both ends of the (adjustable) foundation and the mattress. The vents are each connected to a fan that is attached to the vents at the underside of the adjustable foundation and, when activated, the fans blow air through the vents, thereby cooling the mattress and the user of the mattress. One or more heating elements are attached to the mattress or foundation at either or both ends of the foundation, and are connected to the foundation's power supply via wire, thereby allowing the heating elements to draw power and heat either or both ends of the mattress or foundation.

FIG. 1 is a side exploded view of a mattress thermal management (e.g., cooling and/or heating) system 10 according to the disclosure. The illustrated mattress thermal management system 10 includes a mattress deck (or mattress support) 100, optionally an airflow spacer 200 positioned thereon, and a mattress 300 positioned above the mattress deck 100 (e.g., sitting upon the airflow spacer 200 when present or sitting directly on the mattress deck 100). At least one fan 120 and at least one heater 140 provide thermal management in the form of heating and/or cooling. FIG. 2 is a top perspective illustration of the mattress 300 according to a particular embodiment of the disclosure. More generally, the mattress thermal management system 10 and components thereof can be used with a fixed-frame bed or an adjustable-frame bed.

The mattress deck 100 includes a deck support platform 110, for example including a plurality of deck support platforms 110A-110D as illustrated. A single unitary deck support platform 110 is suitable for a conventional (non-adjustable) bed assembly. A deck support platform 110 formed from a plurality of deck support platforms 110A-110D is suitable for an adjustable bed assembly. In some embodiments the support platform(s) 110 can be formed from a rigid support material such as wood or metal. In other embodiments the support platform(s) can be formed from a flexible fabric or material. The deck support platform 110 includes a fan 120 (e.g., axial fan, centrifugal fan, cross-flow fan, or other means for blowing or otherwise transporting air or gaseous fluid) mounted thereto, for example plurality of fans 120A-120D as illustrated. While each deck support platform 110A-110D is illustrated as having a corresponding fan 120A-120D, each platform 110A-110D can have none, one, or more than one corresponding fans 120 mounted thereto. Each fan 120 is mounted to the deck 110 adjacent to, within, or otherwise in fluid communication with a corresponding airflow channel 130, thereby permitting airflow through the mattress 300, the airflow spacer 200 (when present), and the mattress deck (i.e., via the airflow channel 130 and the fan 120) in either direction.

Each fan 120 has a suction side 122 (i.e., a fan surface/plane across which air is drawn from the external environment into the fan interior) and a discharge side 124 (i.e., a fan surface/plane across which air is expelled from the fan interior to the external environment). As illustrated, the fan 120 can be mounted on its suction side 122 to the deck support platform 110, thereby creating a suction air flow during fan operation, drawing air through the mattress 300 and expelling the air beneath the deck support platform 110 to the external environment underneath the bed. As alternatively illustrated, the fan 120 can be mounted on its discharge side 124 to the deck support platform 110, thereby creating a discharge air flow during fan operation, drawing air from the external environment underneath the bed, through the deck support platform 110 and then through the mattress 300. In some embodiments, the fans 120A-120D are all mounted in the same suction/discharge orientation (e.g., all mounted on their suction sides 122 to the platform 110; all mounted on their discharge sides 124 to the platform 110). In other embodiments, the fans 120A-120D are mounted in a mixed suction/discharge orientation (e.g., some mounted on their suction sides 122 to the platform 110 and some mounted on their discharge sides 124 to the platform 110). In some embodiments, some or all of the fans 120A-120D are unidirectional fans (i.e., having fixed suction and discharge sides, being intended to transport air in a single direction). In some embodiments, some or all of the fans 120A-120D are bidirectional fans (i.e., having variable suction and discharge sides depending on impeller rotation, being capable of transporting air in two different (opposing) directions).

The airflow spacer 200 can be any type of structure that includes an open void volume permitting airflow therethrough and directing the airflow to improve the spatial distribution (e.g., uniformity thereof) of airflow through the mattress 300 (e.g., in particular when the fans 120A-120D are positioned at discrete, non-uniformly spaced locations in the deck support platform 110). Suitably, the airflow spacer 200 is a formed from a flexible material to accommodate a moveable deck support platform 110 of an adjustable bed. Suitable structure for the airflow spacer 200 includes a mesh fabric (e.g., three-dimensional fabric) or other porous material, a manifold structure, a duct structure, a channel structure, and a cavity structure. In some embodiments, the airflow spacer 200 is a separate structure from the mattress 300 and the mattress deck 100. In other embodiments, the airflow spacer 200 can be an integral component of the mattress deck 100 (e.g., with the platform(s) 110 thereof) or it can be an integral component of the mattress 300 (e.g., with the base 310 thereof).

The mattress 300 is not particularly limited, and it can be a conventional mattress 300 (e.g., a spring or coil mattress, memory foam mattress, air mattress) with a base 310 (e.g., a continuous fabric material) suitable for use on a mattress support structure such as a fixed bed frame or an adjustable bed frame. In the illustrated embodiment, the mattress 300 includes a mattress containment frame 305 including a plurality of foam cells (or foam springs) 340 positioned in the frame 305 to provide the sleeping support surface for the mattress. The mattress containment frame 305 includes a lower/bottom base 310, sidewalls 320, and endwalls 330 which generally define the interior frame 305 volume housing the foam cells 340. The sidewalls 320 and endwalls 330 suitably are formed from a foam material. The base 310 can be a generally continuous fabric material (e.g., a continuous surface but sufficiently thin and porous at a small scale to permit airflow therethrough between the mattress 300 and the airflow spacer 200, such as a fabric material). In some embodiments, the base 310 can include one or more larger open areas (e.g., airflow channels) to enhance the rate of airflow therethrough between the mattress 300 and the airflow spacer 200. The mattress 300 and optionally the airflow spacer 200 (e.g., as a separate or integral component of the mattress 300) are generally positioned above the mattress support 100, for example sitting directly atop the deck support sections 110A-110D.

FIGS. 3a and 3b illustrate a bottom view of a mattress deck 100 and an associated adjustable bed frame 400 according to the disclosure (3a: twin deck and bed frame; 3b: queen deck and bed frame). The adjustable frame 400 generally provides the mechanical, electrical, and electronic support and articulation components for the mattress system 10 and mattress deck 100. As illustrated, the adjustable frame 400 includes a frame support 410. Each deck support section 110A-110D can be fixedly or removably mounted (e.g., via bolts, screws, or other fastener or adhesive components) to the underlying frame support 410 such that when one or more sections of the frame support section 410 are articulated, the deck support sections 110A-110D are correspondingly articulated. As illustrated, the adjustable frame 400 further includes a subframe 430, for example a rigid, non-articulatable frame structure which sits on a floor or within a decorative bed frame common in the furniture industry such as a platform bed (e.g., via various leg elements, not shown) and provides stability for the mattress system 10 as the adjustable frame 400 is articulated to various different positions. The adjustable frame 400 can further include one or more support members 420 connecting structure between the subframe 430 and the frame support 410. As further illustrated, the adjustable frame 400 can include one or more actuators 440 variously mounted to one or more of the subframe 430, a support member 420, and the frame support 410. In some embodiments, the subframe 430, the support members 420, and the frame support 410 can be formed from metal such as steel. The actuators 440 can be any of those commonly known in the art. The actuators 440 and, correspondingly, the configuration or position of the adjustable frame 400, mattress support 100, and mattress 300 can be controlled and adjusted by a suitable power supply 450, adjustable bed controller 450 (e.g., programmable logic controller or otherwise, which may be integrated with the power supply or separate structure), and a remote control 460 to deliver repositioning commands and/or thermal management system commands (e.g., fans/system on or off; fans/system in heating or cooling mode; fan/system intensity/speed; heater on or off; heater temperature or heating intensity). In some embodiments, a programmable timer may be incorporated into the adjustable bed controller 450, the remote control 460, or otherwise, thus allowing the fans 120 and/or heater 140 to be programmably operated in any desired heating and/or cooling mode at a user-specified fan intensity/speed, temperature set point, start time, a user-specified duration, and/or a user-specified end time.

In some embodiments, the controller 450 is a combined controller providing power and send/receive command/control functionality to both the adjustable bed frame 400 (e.g., repositioning commands, power to actuators 440, etc.) and the thermal management system 10 (e.g., thermal management commands, power to fans 120, power to heater 140, etc.). In other embodiments, the controller 450 can include two separate controller structures: a first controller providing power and send/receive command/control functionality to the adjustable bed frame 400 and a second controller providing power and send/receive command/control functionality to the thermal management system 10. In such embodiments, the first and second controllers can be electronically connected (e.g., wired or wireless connection), for example in a master-slave arrangement. For example, the first controller can be a master controller capable of receiving commands from the remote 460 for both the adjustable bed frame 400 and the thermal management system 10, and then the first controller can pass commands for the thermal management system 10 to the second controller for execution. In other embodiments, each of the first and second controllers may be configured to independently receive and execute commands from the remote 460.

The remote control 460 is not particularly limited. In an embodiment, the remote 460 includes a touch screen 462 to receive user commands (e.g., regarding adjustable bed position, fan operation, heating/cooling modes, timing of same, etc.) and/or to display to the user the current status of the adjustable bed position and/or the thermal management system (e.g., reflecting confirmation of successfully executed commands as sensed and reported by the controller 450). In some embodiments, the remote 460 can be a wired unit connected to the controller 450, for example a dedicated remote 460 for the adjustable bed. In other embodiments, the remote 460 can include a wireless transceiver for communication (e.g., two-way communication) with a corresponding transceiver in the controller 450. Any suitable wireless communication protocol may be used to send commands from the remote 460 to the controller 450 (e.g., and optionally to receive feedback from the 450 confirming successful execution of the sent commands), for example including infrared (IR) and/or radio frequency (RF) (e.g., WIFI, BLUETOOTH, or otherwise) wireless protocols. In some embodiments, the wireless remote 460 can be communication matched with the controller 450, for example using a communication key or code key transmitted and received between the remote 460 and controller 450 to confirm that the controller 450 may receive and execute user commands from the remote 460 (e.g., further including a confirmation from the controller 450 to the remote 460 that the communication key or code key has been received and accepted). The wireless remote 460 can be a dedicated remote 460 for the adjustable bed. In other embodiments, the wireless remote 460 can be a mobile electronic device (e.g., cell phone, smart phone, tablet computer) running a software application providing a user interface for control of adjustable bed functions and/or thermal management system functions. The remote 460 also can implement various memory functions associated with the adjustable bed and/or thermal management system, for example using memory-stored settings related to the same in one or more of the remote 460, the controller 450, and a location separate from the remote 460 and the controller 450 (e.g., at a remote network location). Memory settings related to adjustable bed position, thermal management settings (e.g., fan speed, duration, start/stop time, temperature set point), or both can be stored in memory (e.g., based on a user indication to save one or more settings as presets for later recall) using the remote 460, and the memory settings can be recalled at a later time by the remote 460 as command for execution by the controller 450. In some embodiments, the memory setting can relate to a single setting (e.g., an adjustable bed position, a thermal management setting). In other embodiments, the memory setting can represent a global command relating to multiple settings (e.g., one or more adjustable bed positions for multiple bed segments, one or more thermal management settings, combinations thereof, etc.).

The thermal mattress system 10 can further include one or more temperature sensors 160 (e.g., a thermocouple or other suitable conventional means for sensing temperature). The sensor(s) 160 can be located at any desired location(s) in the mattress system, for example on the mattress deck 100, the airflow spacer 200, the mattress 300, and/or the adjustable bed frame 400. For example, the sensors(s) can be located on a fan 120 surface (e.g., as illustrated; such as on or near an intake or exhaust surface), a deck support 110 surface (e.g., bottom or top side thereof), a heater 140 surface (e.g., when mounted to the mattress 300 or between the mattress 300 and the deck support 110), an interior or exterior surface of the airflow spacer 200, an interior or exterior surface of the mattress 300 or a component thereof (e.g., base 310, sidewall 320, endwall 330, foam cylinder 340, top or bottom surface of mattress 300 as a whole). The temperature sensor(s) 160 can be coupled to the controller 450 (e.g., a component thereof for the thermal management system 10) for form a temperature feedback control loop for the thermal management system 10. Given a temperature set point (e.g., preset or selected by a user), the controller 450 can be programmed to monitor current temperature and adjust the thermal management system 10 settings based on the set point (e.g., increase or decrease heating or cooling such as by adjusting fan intensity/speed, fan operation duration, heater temperature or intensity, heater operation duration, heating/cooling unit output temperature). In some embodiments, a user can enter a desired set point in terms of a user-sensible temperature (e.g., mattress upper surface temperature, ambient temperature above the mattress upper surface), and the controller 450 feedback control loop logic can be programmed to use the temperature actually sensed at a different location by the sensor 160 as a proxy for the set point (e.g., by specifying or determining a relationship between the desired set point and the sensed temperature).

As shown, the fans 120 may be irregularly spaced/positioned on the underside of the mattress deck 100 to accommodate other mechanical and/or electronic bed components, in particular for the adjustable bed frame 200. The fans 120 can be powered and controlled by the electromechanical system of the adjustable bed (e.g., illustrated via the wires from fans to the power supply/programmable logic controller 450 (PLC), which can provide power to the fans 120 and can provide operating instructions to the fans 120, for example as received from an external remote control unit 460 for the adjustable bed). FIG. 4a is a schematic of the bottom side of the mattress deck 100 of FIG. 3b showing the placement of four cooling fans 120 as well as optional placement locations 120′ for additional fans (e.g., if greater airflow is desired). FIG. 4b is a schematic of the bottom side of the mattress deck 100 in alternative embodiment including one fan 120 in the head section 110A and one fan 120 in the foot section 110B of the mattress deck 100.

FIG. 5 is a side view of mattress cooling system embodiments according to the disclosure (A: mattress-side airflow discharge; B: mattress-side airflow suction; C: mattress-side airflow combined discharge and suction). In FIG. 5A, both fans 120 are mounted (or otherwise operating in) a mattress-side discharge orientation in which airflow is transported from beneath the deck support platform 110 and up through the mattress 300. In FIG. 5B, both fans 120 are mounted (or otherwise operating in) a mattress-side suction orientation in which airflow is transported from above the mattress 300, through the mattress 300 and the deck support platform 110, and to the area beneath the deck support platform 110. In FIG. 5C, the fans 120 are alternatively mounted (or otherwise operating in) in a mattress-side suction orientation and a mattress-side discharge orientation, thereby creating a recirculating airflow pattern for enhanced cooling effectiveness. In any of the of the various fan 120 configurations and operating modes (e.g., mattress-side suction, discharge, or recirculation flow), the operation of the fans and be used to actively cool the mattress 300 with ambient environmental air, for example from either above the mattress 300, below the mattress deck 100, or both.

Other cooling embodiments for cooling the mattress 300 of the mattress system 10 are possible. For example, in the embodiments illustrated in FIGS. 5A and 5C, a cooler or cooling unit 150 may be positioned below the mattress deck 100 (e.g., mounted thereto and/or to mattress support structure therebelow such as the adjustable bed frame 400 or a component thereof), and the cooler 150 can be positioned to cool air 152 being fed upwards into the mattress 300 (e.g., by either fan 120 illustrated in FIG. 5A; by the left-illustrated fan 120 in FIG. 5C), thus actively cooling the mattress 300. In an embodiment, the cooler 150 can be a portable cooling or air conditioning unit 150 capable of cooled air relative to the ambient environment. Alternatively, the cooler 150 may be positioned remotely from the mattress deck 100 (or bed more generally) and the cooler 150 can direct cold air 152 from the remote location to the fans 120 for circulation through the mattress 300. The remote cooler 150 can be a portable cooling or air conditioning unit 150 spaced proximately to direct cold air 152 below the mattress deck 100 to be fed upwards into the mattress 300. In some embodiments, the remote cooler 150 can be an HVAC (heating, ventilation, air conditioning) system or a component thereof, such as a home HVAC system configured to direct cold air 152 below the mattress deck 100 to be fed upwards into the mattress 300. In embodiments including a cooler 150, the mattress system 10 may be independently operated at the discretion of the user in a cooling mode using ambient environmental air (e.g., as described above without the cooler 150 being active) or a cooling mode using the cold air 152 from the cooler 150 to cool the mattress 300.

In some embodiments, the mattress system 10 can be adapted to heating the mattress 300 instead of cooling. For example, in the embodiments illustrated in FIGS. 5A and 5C, a heater or heating unit 140 may be positioned below the mattress deck 100 (e.g., mounted thereto and/or to mattress support structure therebelow such as the adjustable bed frame 400 or a component thereof), and the heater 140 can be positioned to heat air 142 being fed upwards into the mattress 300 (e.g., by either fan 120 illustrated in FIG. 5A; by the left-illustrated fan 120 in FIG. 5C), thus actively heating the mattress 300. In an embodiment, the heater 140 can be a portable heating unit 140 such as an electrically powered semiconductor-based micro thermal module capable of providing radiant heat relative to the ambient environment. Alternatively, the heater 140 may be positioned remotely from the mattress deck 100 (or bed more generally) and the heater 140 can direct hot air 142 from the remote location to the fans 120 for circulation through the mattress 300. The remote heater 140 can be a portable heating unit 140 spaced proximately to direct hot air 142 below the mattress deck 100 to be fed upwards into the mattress 300. In some embodiments, the remote heater 140 can be an HVAC system or a component thereof (e.g., where the same HVAC system is capable of providing cool air for cooling as above or hot air for heating), such as a home HVAC system configured to direct hot air 142 below the mattress deck 100 to be fed upwards into the mattress 300. In embodiments including a heater 140, the mattress system 10 may be independently operated at the discretion of the user in either a cooling mode (e.g., as described above without the heater 140 being active) or in a heating mode (e.g., with the heater 140 actively supplying heat to the airflow entering the mattress 300).

FIG. 6 is a top perspective illustration of a mattress containment frame 305 according to the disclosure, and FIG. 7 is a side cut-away view of the mattress containment frame 305 and a corresponding airflow spacer 200 according to the disclosure. In an embodiment, the base 310 of the frame 305 can include a plurality of locator recesses 312 that are size and shaped (e.g., cylindrical as shown) to accommodate and seat corresponding foam cells 340. Each locator recess 312 includes a locator pin (or protrusion) 314 that mates with the corresponding open cylindrical channel 342 of a foam cell 340. The locator pin 314 has an open top area 318 to permit airflow through the open cylindrical channel of the foam cell 340, through the open top area of the locator pin 314, and then into the airflow spacer 200. As further illustrated, the base 310 includes a plurality of vent holes 316 positioned to permit airflow through the interstitial areas between adjacent foam cells 340 and the airflow spacer 200. The locator pin 314 open areas and vent holes 316 permit air circulation within the mattress 300, thereby enhancing the cooling effect of the fans 120. In the illustrated embodiment of FIG. 7, the airflow spacer 200 has an open channel-type structure and it further includes an open airflow channel area (or hole) 230 that generally corresponds to a similarly positioned airflow channel 130 in the deck support platform 110. In other mattress embodiments, airflow channels/structures through the thickness of the mattress 300 can be incorporated into a conventional mattress 300 as desired, thereby providing an airflow path for cooling and/or heating airflow paths between the top and bottom of the mattress 300 (e.g., similar to those provided by the vent holes 316 and open areas 318 in the illustrated embodiment), for example also in fluid communication with the open airflow channel area (or hole) 230 (e.g., in the bottom of the airflow spacer 200) and the airflow channel 130 in the mattress deck support 110.

FIGS. 1 and 8-10 illustrate another embodiment of the disclosure including a heating unit 140 associated with the mattress 300, for example to provide an integrated heating and cooling system in combination with the fan 120. The heating unit 140 is generally either mounted to the mattress 300 or otherwise positioned between the mattress support 100 and the mattress 300. For example, as illustrated in FIGS. 1 and 8, the heating unit 140 can be mounted to the bottom surface of the mattress 300. In other embodiments, the heating unit 140 can be mounted to the top surface of the mattress 300 (FIG. 9), at an interior mattress location (e.g., within the mattress 300), to the mattress support 100 top surface, and/or to the air flow spacer 200 (if present). The heating unit 140 can be any suitable means for heating the mattress 300, for example an electrical strip or pad. In some embodiments, the heating unit 140 is electrically coupled to the controller 450 (e.g., including an integrated or separate power supply) of the mattress system 10, thus allowing operation and control of the heating unit 140 via the controller 450 (e.g., using the remote control 460 to send control commands for the heating unit 140 to the controller 450).

FIGS. 9 and 10 illustrate an embodiment in which the fan 120 is coupled to a vent/air flow channel directing air blown by the fan 120 through the mattress 300 to cool a user on the mattress 300. The vent is illustrated as air flow channels 130, 230 which are in fluid communication with each other and the fan 120, the air flow channel 130 extending through the deck support platform 110 and the air flow channel 230 extending though through at least a portion of the width of the mattress 300 (e.g., through the entire width or less than the entire width of the mattress 300).

In the embodiments shown in FIGS. 8-10, the heating unit 140 is positioned at or near a foot region 300D of the mattress. Conversely, the fan 120 is positioned at or near a head region 300A of the mattress (e.g., on the head section 110A of the deck support platform 110). The illustrated embodiments are particularly useful for cooling the body core and head while heating the feet and legs of a user while sleeping on the mattress 300.

Rawls-Meehan U.S. Pat. Nos. 7,321,811, 7,465,280, 7,805,785, 7,930,783, 7,933,669, 7,979,169, 8,019,486, 8,032,263, 8,032,960, 8,046,114, 8,046,115, 8,046,116, 8,046,117, 8,050,805, 8,069,512, 8,078,336, 8,078,337, 8,150,562, 8,375,488, 8,565,934, and 8,682,457, and U.S. Publication No. 2015/0313370 are incorporated herein by reference in their entireties and variously disclose mattresses including foam springs or foam cells and materials/configurations therefor, adjustable bed assemblies including adjustable mattress frames, electrical, mechanical, and electronic components associated therewith, and remote controls for use therewith, all of which may be used individually or collectively in combination with the mattress cooling system described herein.

EXAMPLES

The following examples illustrate the disclosed compositions and methods, but they are not intended to limit the scope of any claims thereto.

The queen bed illustrated in FIG. 3b and FIG. 4a was tested for its ability to cool a heated mattress, including a conventional mattress and a foam cell mattress as illustrated in FIG. 2. An electrical heating pad was used to heat the mattress for a fixed period (about 15 minutes), then the heating pad was removed, and then the mattress was allowed to cool with the fans operating to enhance cooling. The fans, which were operating in a mattress-side suction orientation (e.g., as illustrated in FIG. 5B), were effective at cooling the mattress and returning it to an ambient environmental temperature over a period of about 4 to 8 minutes.

Because other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the disclosure is not considered limited to the example chosen for purposes of illustration, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this disclosure.

Accordingly, the foregoing description is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the disclosure may be apparent to those having ordinary skill in the art.

All patents, patent applications, government publications, government regulations, and literature references cited in this specification are hereby incorporated herein by reference in their entirety. In case of conflict, the present description, including definitions, will control.

Throughout the specification, where the compositions, processes, or apparatus are described as including components, steps, or materials, it is contemplated that the compositions, processes, or apparatus can also comprise, consist essentially of, or consist of, any combination of the recited components or materials, unless described otherwise. Component concentrations can be expressed in terms of weight concentrations, unless specifically indicated otherwise. Combinations of components are contemplated to include homogeneous and/or heterogeneous mixtures, as would be understood by a person of ordinary skill in the art in view of the foregoing disclosure.

PARTS LIST

• 10 mattress system (cooling or heating)
• 100 mattress deck or support
• 110 deck support platform (sections 110A-D)
• 120 fan or means for blowing/transporting air (fans 120A-D)
• 122 suction side of fan
• 124 discharge side of fan
• 130 air flow channel
• 140 heating unit
• 142 heated air
• 150 cooling unit
• 152 cooled air
• 160 temperature sensor
• 200 airflow spacer
• 230 airflow channel
• 300 mattress
• 305 containment frame
• 310 base
• 312 locator recess
• 314 locator pin
• 316 vent hole
• 318 open top area
• 320 sidewalls
• 330 endwalls
• 340 foam cells or foam springs
• 342 cylindrical channel
• 400 adjustable bed frame
• 410 frame support
• 420 support member
• 430 subframe
• 440 actuator
• 450 power supply
• 460 remote control
• 462 touch screen

Claims

1. A mattress assembly system comprising:

(a) a mattress support having a top surface for supporting a mattress and an opposing bottom surface, the mattress support comprising an airflow channel between the top surface and the bottom surface to permit airflow therethrough;

(b) a fan mounted to the mattress support in fluid communication with the airflow channel, the fan being adapted to transport air (i) from above the top surface of the mattress support to below the bottom surface of the mattress support, (ii) from below the bottom surface of the mattress support to above the top surface of the mattress support, or (iii) both (i) and (ii);

(c) a mattress positioned above the mattress support of the mattress support structure; and

(d) a heating unit mounted to the mattress or positioned between the mattress support and the mattress.

2. The mattress assembly system of claim 1, wherein the fan is positioned proximal to a head end of the mattress assembly system, and the heating unit is positioned proximal to an opposing foot end of the mattress assembly system.

3. The mattress assembly system of claim 1, wherein the mattress support is a stationary structure.

4. The mattress assembly system of claim 1, wherein the mattress support is an adjustable bed comprising at least one moveable mattress support.

5. The mattress assembly system of claim 4, further comprising:

(e) an electromechanical system adapted to control the at least one moveable mattress support, wherein the fan and the heating unit are coupled to and controllable by the electromechanical system.

6. The mattress assembly system of claim 1, wherein the heating unit is mounted to the mattress.

7. The mattress assembly system of claim 1, wherein the heating unit is positioned between the mattress support and the mattress.

8. The mattress assembly system of claim 1, comprising a plurality of fans mounted to the mattress support.

9. The mattress assembly system of claim 8, wherein the fans are all mounted to the mattress support in a manner adapted to transport air from above the top surface of the mattress support to below the bottom surface of the mattress support.

10. The mattress assembly system of claim 8, wherein the fans are all mounted to the mattress support in a manner adapted to transport air from below the bottom surface of the mattress support to above the top surface of the mattress support.

11. The mattress assembly system of claim 8, wherein the fans are all mounted to the mattress support in a manner adapted to transport air (i) from above the top surface of the mattress support to below the bottom surface of the mattress support, and (ii) from below the bottom surface of the mattress support to above the top surface of the mattress support.

12. The mattress assembly system of claim 8, wherein:

at least some of the fans are mounted to the mattress support in a manner adapted to transport air from above the top surface of the mattress support to below the bottom surface of the mattress support; and

at least some of the fans are mounted to the mattress support in a manner adapted to transport air from below the bottom surface of the mattress support to above the top surface of the mattress support.

13. The mattress assembly system of claim 1, further comprising a remote control adapted to transmit (i) fan operational commands to the fan, and (ii) heating unit operational commands to the heating unit.

14. The mattress assembly system of claim 1, wherein the mattress is a conventional mattress.

15. The mattress assembly system of claim 1, wherein the mattress comprises a mattress containment frame and a plurality of foam cells distributed throughout the containment frame to collectively define a mattress sleep surface.

16. The mattress of mattress assembly system of claim 15, wherein the mattress further comprises at least one of

(a) a plurality of vent holes on a base portion of the mattress containment frame, the vent holes being positioned to permit airflow through the mattress between interstitial areas defined by adjacent foam cells; and

(b) a plurality of locator pins on a base portion of the mattress containment frame, wherein each locator pin (i) is adapted to mate with a corresponding open cylindrical channel in a foam cell, and (ii) comprises an open area permitting airflow through the mattress via the open area and the cylindrical channel.

17. The mattress assembly system of claim 1, further comprising at least one of a heating unit and a cooling unit mounted to the mattress assembly at a location beneath the mattress support bottom surface, the heating unit and the cooling unit being positioned to direct heated air and cooled air, respectively, to a fan suction side.

18. The mattress assembly system of claim 1, further comprising:

an airflow spacer positioned intermediate the mattress support structure and the mattress, the airflow spacer adapted to direct airflow (i) to the fans from the mattress, (ii) from the fans to the mattress, or (iii) both (i) and (ii) over substantially the entire area of the mattress.

19. A method for cooling and heating a mattress, the method comprising:

(a) providing the mattress assembly system of claim 1;

(b) operating the fan of the mattress assembly to actively cool the mattress of the mattress assembly system; and

(c) operating the heating unit of the mattress assembly to heat the mattress of the mattress assembly system.

20. The method of claim 19, comprising operating the fans to actively cool the mattress, and operating the heating unit to heat the mattress while a user is sleeping or laying on the mattress.

21. The method of claim 19, comprising operating the fans to actively cool the mattress with ambient environmental air.