HEAT-DISSIPATING BEDDING PRODUCT

Abstract

The present invention relates to bedding product having heat-dissipation and support properties provided by structural protrusions on the surface of the bedding product. The bedding product may comprise a first layer of foam, that includes a base support having an upper surface and a lower surface and a plurality of open and closed protrusions located on the upper surface of the base support. Each open protrusion comprises a cavity formed therein, wherein the cavity has a depth of at least 0.5 inch

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Patent Appl. No. 63/181,605 filed Apr. 29, 2021, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD

The present disclosure generally relates to a bedding product having heat-dissipation and support properties provided by structural protrusions on the surface of the bedding product.

BACKGROUND

Mattress manufacturers have made significant improvements in mattress comfort in recent decades. Some such improvements arose from the introduction of foams (e.g., polyurethane foam) and layering structures within the mattresses.

Foams have numerous characteristics, including density and firmness, that contribute to the “feel” of the mattress. Density generally refers to the amount of gas-containing cells within a foam matrix. Firmness generally refers to the rigidity of the matrix, such as polyurethane, itself. Varying the density and firmness of a foam can thus provide a mattress having a different feel. Further, many different mattresses possessing a broad spectrum of feel may be produced by combining layers of different types of foams. Yet, while foam mattresses have achieved broad acceptance for some improved aspects of comfort, some such mattresses have exhibited negative performance issues related to insufficient thermal comfort and support.

In general, conventional foams have a closed cell structure, which restricts air flow in the mattress and causes the foam to act as a thermal insulator with poor heat transfer characteristics. As a result, consumers tend to find that foam mattresses cause the user to feel too hot while sleeping. Conventional foam mattresses are also found to provide insufficient support to the individual laying on the mattress. This may be because many foams do not conform well to the curves of an individual's body, and thus the individual's bodyweight is selectively supported at only a few points of the foam rather than along the entire length of the foam adjacent to the individual's body. A related problem is often referred to as “bottoming out,” whereby the individual's weight on the foam compacts the foam to such a degree that resilience is lost. Typical foams bottom out and exhibit a hard feel as they are compacted by the weight of an individual's body.

Given the foregoing, there is a need for improved mattresses that provide greater thermal comfort and overall support.

SUMMARY

In one aspect, the disclosed technology relates to a bedding product including a first layer of foam, wherein the first layer includes: a base support having an upper surface and a lower surface; a plurality of open protrusions positioned on the upper surface of the base support, each open protrusion including a cavity formed therein, wherein the cavity has a depth of at least 0.5 inch; and a plurality of closed protrusions positioned on the upper surface of the base support. In some embodiments, the cavity of the open protrusion has a depth of at least 1 inch. In some embodiments, the open and closed protrusions are arranged in a pattern along the upper surface of the base support. In some embodiments, the open protrusions are arranged in one or more heat-sink groupings; the closed protrusions are arranged in one or more support groupings, and the heat-sink groupings and the support groupings are arranged in an alternating pattern. In some embodiments, at least one of the heat-sink grouping includes five or more open protrusions, and at least one of the support grouping includes five or more closed protrusions. In some embodiments, at least one of the support groupings forms a support zone positioned to correspond to a predetermined portion of a user's body and to provide resistance that promotes at least one effect on the user's body selected from blood circulation, recovery, and facilitation of slow wave sleep.

In some embodiments, the first layer defines an uppermost foam layer of the bedding product. In some embodiments, the bedding product includes a plurality of layers and the first layer is the uppermost support layer. In some embodiments, top surfaces of the open and closed protrusions define an uppermost foam surface of the bedding product. In some embodiments, at least one closed protrusion has a continuous top surface. In some embodiments, at least one closed protrusion is solid. In some embodiments, a top surface of at least one closed protrusion is outwardly rounded.

In some embodiments, the bedding product further includes a second layer directly attached to the lower surface of the base support. In some embodiments, the second layer is the same as the first layer. In some embodiments, the base support has a thickness of about 0.25 inches to about 3 inches. In some embodiments, the bedding product is a mattress. In some embodiments, the bedding product is a mattress topper.

In some embodiments, the bedding product provides greater heat-dissipation than a bedding product including a base support without protrusions. In some embodiments, the bedding product provides greater air flow than a bedding product including a base support without protrusions.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitute part of this specification, are illustrative of particular embodiments of the present disclosure and do not limit the scope of the present disclosure. The drawings are not to scale and are intended for use in conjunction with the explanations in the following detailed description.

FIG. 1A is a cross-sectional view of an embodiment of a heat-dissipating bedding product disclosed herein, including heat-sink zones and support zones.

FIG. 1B is an image showing the upper surface of an embodiment of a heat-dissipating bedding product disclosed herein.

FIG. 1C is a top view of a portion of an embodiment of a heat-dissipating bedding product disclosed herein.

FIG. 1D is an enlarged perspective cross-sectional view of protrusions of an embodiment of a heat-dissipating bedding product disclosed herein.

FIG. 2A illustrates an example of a zoning pattern, including heat-sink zones and support zones, of an embodiment of a heat-dissipating bedding product disclosed herein.

FIG. 2B illustrates another example of a zoning pattern, including heat-sink zones and support zones, of an embodiment of a heat-dissipating bedding product disclosed herein.

FIG. 3 is a cross-sectional view of an embodiment of a multi-layer heat-dissipating bedding product disclosed herein.

FIG. 4 illustrates various zones of an embodiment of a heat-dissipating bedding product disclosed herein, wherein the zones correspond to portions of an individual's body.

DETAILED DESCRIPTION

The following discussion omits or only briefly describes conventional features of the disclosed technology that are apparent to those skilled in the art. It is noted that various embodiments are described in detail with reference to the drawings, in which like reference numerals represent like parts and assemblies throughout the several views. In drawings that depict multiple like components, a single representative component may be identified by the appropriate reference numeral. Reference to various embodiments does not limit the scope of the claims appended hereto. Additionally, any examples set forth in this specification are intended to be non-limiting and merely set forth some of the many possible embodiments for the appended claims. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, selected methods, devices, and materials are now described.

Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc. It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless otherwise specified, and that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

The present disclosure relates to a heat-dissipating bedding product 10 having surface designs that provide greater thermal comfort and overall support. In some embodiments, the disclosed surface designs improve air flow and cooling while simultaneously providing better support when the bedding product is in use.

Bedding Product

As used herein, the term “bedding product” includes, without limitation, mattresses, pillows, mattress toppers, seat cushions, back and lumbar supports, chair pads, benches and any product intended to support at least part of a body—e.g., a body of a mammal, such as a human. Unless otherwise stated, various dimensions of the bedding products disclosed herein are non-limiting and provided for illustrative purposes only.

FIGS. 1A-1D depict an illustrative embodiment of a heat-dissipating bedding product 10, which includes a first layer 12 comprising: a base support 15 having an upper surface 14 and a lower surface 16, and protrusions 18, 22 that extend upwards from the upper surface 14 of the base support 15. As shown, the first layer 12 is the uppermost layer of the bedding product 10. In some embodiments, the first layer 12 is the uppermost support layer of the bedding product 10, which means it is the uppermost layer of the product that is configured to provide physical support to the body of a user. In some embodiments, the first layer 12 is the uppermost foam layer of the bedding product 10, which means that it is the uppermost layer that comprises foam. In some embodiments, the base support 15 has a thickness 50 of about 0.25 inch to about 3 inches, about 0.25 inch to about 2.5 inches, about 0.25 inch to about 2 inches, about 0.25 inch to about 1.5 inches, about 0.25 inch to about 1 inch, 0.5 inch to about 3 inches, about 0.5 inch to about 2.5 inches, about 0.5 inch to about 2 inches, about 0.5 inch to about 1.5 inches, or about 0.5 inch to about 1 inch. In some embodiments, the base support 15 has a thickness 50 in a first direction, and the open 18 and closed 22 protrusions extend from the upper surface 14 of the base support 15 in the first direction.

In the first layer 12, the plurality of protrusions 18, 22 that extend upwards from the upper surface 14 of the base support 15 are separated by channels 32, as shown in FIGS. 1A-1D. In general, the protrusions may be open 18 or closed 22. For example, a first type of protrusion may be an open protrusion 18 having a cavity 20 formed in its top surface 26 that extends (e.g., curves) inward toward the base support 15. A second type of protrusion may be a closed protrusion 22 having a continuous, uninterrupted top surface 24. In some embodiments, the top surface 24 is substantially flat, convex, or outwardly rounded. In some embodiments, top surfaces 24, 26 of protrusions 18, 22, respectively, provide the uppermost surface of the first layer 12. In some embodiments, top surfaces 24, 26 of protrusions 18, 22, respectively, provide the uppermost foam surface of the bedding product 10.

In general, open protrusions 18 provide increased heat-dissipation and air flow within the bedding product 10 via cavities 20. In some embodiments, the open protrusions 18 are arranged in groupings to form heat-sink groupings or heat-sink zones 4 along upper surface 14 of base support 15. In some embodiments, a grouping includes a plurality of the same type of protrusion e.g., a plurality of open protrusions 18 or a plurality of closed protrusions 22. In some embodiments, the bedding product 10 provides greater air flow and/or heat-dissipation than a bedding product without protrusions 18, 22. In some embodiments, a grouping may include five or more open protrusions 18 and/or five or more closed protrusions 22. In other embodiments, a grouping includes a plurality of different types of protrusions—i.e., some open 18 and some closed 22. In some embodiments, a grouping of one type of protrusion is positioned directly adjacent to a grouping of a different type of protrusion. In some embodiments, the groupings are configured in a certain arrangement, such as rows. In some embodiments, the groupings are arranged in a pattern such as an alternating pattern.

In general, closed protrusions 22 provide the bedding product 10 with increased support. In some embodiments, the closed protrusions 22 may be solid or hollow. In some embodiments, the closed protrusion 22 has a continuous top surface 24. In other embodiments, the closed protrusion 22 has a perforated top surface 24. In some embodiments, one or more closed protrusions 22 has a greater stiffness than one or more open protrusions 18. In some embodiments, the closed protrusions 22 are arranged in groupings to form support groupings or support zones 2 along upper surface 14 of base support 15. Support zones 2 may promote blood circulation, recovery, and/or facilitation of slow wave sleep.

The heat-sink zones 4 and support zones 2 may be arranged in a variety of different patterns, as desired. Bedding product 10 may include a plurality of zones, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more zones. In one non-limiting example, an embodiment comprising at least two zones may have a plurality of rows (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more rows) of open protrusions 18 (i.e., a grouping of open protrusions 18) that form a heat-sink zone 4 positioned directly adjacent a plurality of rows (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more rows) of closed protrusions 22 (i.e., a grouping of closed protrusions 22) that form a support zone 2, optionally in a repeating pattern. In some embodiments, the pattern extends across more than 75% (e.g., more than 80%, more than 90%, or 100%) of the entire upper surface 14 of base support 15. In some embodiments, the pattern may include the same number of arrangements (e.g., rows) in each grouping, such as five arrangements of open protrusions 18 followed by five arrangements of closed protrusions 22. In other embodiments, the pattern may include different numbers of arrangements (e.g., rows) in each grouping, such as: seven arrangements of open protrusions 18 followed by three arrangements of closed protrusions 22; or three arrangements of a combination of open 18 and closed protrusions 22, followed by four arrangements of open protrusions 18, followed by three arrangements of closed protrusions 22; or other desirable configurations. In some embodiments, the open 18 and closed 22 protrusions of the first layer 12 may have a random or unorganized arrangement.

In some embodiments, the support zones 2 are positioned together in areas of the upper surface 14 of the base support 15 so as to directly support select parts of a user's body, such as the head, neck, shoulders, waist, hips, legs, feet, or any combination thereof. In some embodiments, one or more support zones 2 are arranged between heat-sink zones 4 in order to provide increased heat-dissipation and comfort. For example, FIGS. 2A and 2B show support zones 2 positioned together on the surface of the bedding product 10 so as to directly support the various parts of a user's body. As shown in these figures, each support zone 2 is formed by a plurality of rows of closed protrusions 22, with the more centrally positioned support zones 2 arranged between heat-sink zones 4, each of which is formed by a plurality of rows of open protrusions 18. In some embodiments, closed protrusions 22 and open protrusions 18 may be arranged together so as to provide both support and heat-dissipation within a single zone or region of the bedding product 10.

The embodiments described herein are not limited to this particular configuration of zones and divisions. Instead, a variety of zones and arrangements thereof is possible. The size of the zones shown in FIGS. 2A and 2B may be determined using human anthropometric data. For example, a person may be selected as one of typical size and height for a human adult, or one representing a range of adult sizes and heights, such as adults ranging from 4′-10″ in size to 6′-10″ in height, 5′-0″ to 6′-0″ in height, or any other suitable range. Non-limiting and representative examples of the length of various zones is shown in FIG. 4, but other dimensions are possible and contemplated by the present disclosure. As depicted in FIG. 4, bedding product 10 includes five zones 40, 42, 44, 46, 48.

In some embodiments, the bedding product 10 may be a mattress or mattress topper that includes a plurality of zones, each of which is configured to correspond to (i.e., be positioned generally under) an area of the body of a person who is lying on the bedding product 10. For example, such a mattress or mattress topper may include one or more of the following zones: head/neck 40, shoulders 42, waist 44, hips 46, and legs/feet 48.

In some embodiments, the heat-dissipating bedding product 10 comprises a single layer, such as a layer that is not structurally secured to other layers. In other embodiments, the heat-dissipating bedding product 10 comprises a plurality of layers, wherein a first layer 12 is structurally secured to one or more other layers (above and/or below the first layer 12) to form a multi-layer bedding product 10. In some embodiments of a multi-layer bedding product 10, two or more of the layers are configured as described for first layer 12 and thus may include both heat-sink 4 and support zones 2 to further improve heat-dissipation and comfort provided by the bedding product 10. For example, FIG. 3 depicts two layers of a bedding product 10, wherein each layer comprises a combination of open 18 and closed protrusions 22. As shown in this figure, each layer provides a different zoning pattern, which may increase the depth of the heat-sinks 4 in some zones and thus may increase heat-dissipation and comfort. In another embodiment, each layer may provide the same zoning pattern. In yet another embodiment, a first layer 12 may be structurally secured to one or more other layers (above and/or below the first layer 12) that does not include heat-sink zones 4 and/or support zones 2, or that includes fewer or more heat-sink zones 4 and/or support zones 2. In some embodiments, lower layers may provide the bedding product 10 with additional performance enhancing properties.

In some multi-layer embodiments, “structurally secured” refers to a first layer 12 being affixed to an adjacent (i.e., overlying or underlying) layer via an upper and/or lower surface 16 of the first layer 12. The first layer 12 may be affixed to the adjacent layer(s) continuously across more than 75% (e.g., more than 80%, more than 90%, or 100%) of the upper 14 and/or lower 16 surface of the first layer 12. In other embodiments, the first layer 12 is affixed to the adjacent layer(s) in a different manner—e.g., non-continuous, along an interior periphery between the layers, along the edges of the layers, etc. In some embodiments, more than 75% (e.g., more than 80%, more than 90%, or 100%) of the top surfaces of the open and closed protrusions 24, 26 of first layer 12 may be structurally secured to the lower surface 16 of an overlying layer. In some multi-layer embodiments, the first layer 12 may be the uppermost support layer.

Layers of bedding product 10 may be affixed to each other by any suitable means known in the art. For example, layers may be sprayed-on, injection molded, extruded, coextruded, laminated, stapled, tacked, welded, laminated, mechanically affixed via friction or interference fit, adhered via one or more of an adhesive, a glue, a cement, or other material with adhesive properties, stitched, affixed via hook and loop fastener, a Zipper, a Dennison-style tag, snaps, and/or other reversible means, and combinations thereof.

Non-limiting examples of suitable adhesives include hot melt, water-based, and pressure-sensitive adhesives, fire-resistant adhesives, mixtures thereof, and other suitable adherent materials or fasteners known in the art. Suitable hot melt adhesives include those available from Henkel (Rocky Hill, Conn.) and UPACO brand adhesives available from Worthen Industries (Nashua, N.H.). Suitable water-based adhesives include water-based adhesives under the SIMALFA brand available from Alfa Adhesives, Inc. (Hawthorne, N.J.). In some embodiments, a layer may further include a silica, a metallic layer, a plastic, such as an acrylic, a modacrylic, a polyolefin, a latex, a polyurethane, and combinations and/or blends thereof.

In some embodiments, each layer may further include one or more biocides, preservatives, odor blocking agents, scents, pigments, dyes, stain guards, antistatic agents, anti-soiling agents, water-proofing agents, moisture wicking agents, and combinations thereof.

One or more lower layers may be of any thickness suitable for a bedding product. For example, one or more lower layers may have a thickness of about 12 inches or less, such as about 10 inches or less, about 8 inches or less, about 6 inches or less, about 4 inches or less, about 2 inches or less, about 1 inch or less, about 0.5 inch or less.

One or more lower layers may comprise one or more materials selected from fabric, natural fiber, synthetic fiber, a ticking layer, a quilt layer, a thread layer, a film, a foam, a gel, a gel foam, a multi gel foam, a high thermal conductivity foam, a woven layer, a nonwoven layer, a fire-resistant layer, a non-skid layer, and combinations thereof. In some embodiments, the bedding product 10 includes a component core layer, which may comprise any suitable mattress core construction material such as, but not limited to, foam core, gel foam core, latex core, an inner spring layer, a layer of individually wrapped coils, an inflated air system, a liquid system (e.g., water), or a combination thereof.

In some embodiments, the bedding product 10 may be a final product, inclusive of all layers, having a thickness of about 0.25 inch to about 25 inches, such as about 1 inch to about 25 inches, about 2 inches to about 25 inches, about 3 inches to about 25 inches, about 4 inches to about 25 inches, about 5 inches to about 25 inches, about 1 inch to about 20 inches, about 2 inches to about 20 inches, about 3 inches to about 20 inches, about 4 inches to about 20 inches, or about 5 inches to about 20 inches.

Open/Closed Protrusions

As described above, the bedding product 10 may include protrusions 18, 22 positioned on the upper surface 14 of the base support 15. The protrusions 18, 22 may be directly attached to the base support 15 (e.g., integrally formed as a single piece) or may be separate and/or detachable from the base support 15. In some embodiments, the base support 15 and protrusions 18, 22 are formed from the same material. Methods of manufacturing the bedding product 10, including the base support 15 and protrusions 18, 22, are described in below.

The dimensions and shapes of open protrusions 18 and closed protrusions 22 may vary. For example, as illustrated in FIG. 1D, the height 52 of a closed protrusion 22 may be greater than the height 52 of an open protrusion 18, wherein the height 52 is measured from the upper surface 14 of the base support 15 to the highest portion of the protrusion. Alternatively, the height 52 of a closed protrusion 22 may be the same as or less than the height 52 of an open protrusion 18. Non-limiting examples of suitable heights 52 for an open protrusion 18, closed protrusion 22, or both include: about 0.25 inch to about 2 inches, about 0.25 inch to about 1.75 inches, about 0.25 inch to about 1.5 inches, about 0.25 inch to about 1.25 inches, about 0.25 inch to about 1.0 inch, about 0.25 inch to about 0.75 inch, about 0.5 inch to about 2 inches, about 0.5 inch to about 1.75 inches, about 0.5 inch to about 1.5 inches, about 0.5 inch to about 1.25 inches, about 0.5 inch to about 1.0 inch, and about 0.5 inch to about 0.75 inch.

As illustrated in FIG. 1D, the width (or diameter) of a closed protrusion 22 refers to a lower width 56 as measured between two furthermost separated points on the upper surface 14 of the base support 15 closest to the rising side walls on either side of a closed protrusion 22, and an upper width 58 as measured between two furthermost separated points on the top surface 24 of a closed protrusion 22. The width (or diameter) of an open protrusion 18 refers to an interior upper width 60 as measured between two furthermost separated points at the top of the cavity 20 interior wall of the open protrusion 18, and an interior lower width as measured between two furthermost separated points at the bottom of the cavity 20 interior wall of the open protrusion 18. Non-limiting suitable examples of any of the foregoing widths for an open protrusion 18, closed protrusion 22, or both include: about 0.5 inch to about 7 inches, about 0.5 inch to about 6 inches, about 0.5 inch to about 5 inches, about 0.5 inch to about 4 inches, about 0.5 inch to about 3 inches, about 0.5 inch to about 2 inches, about 1 inch to about 7 inches, about 1 inch to about 6 inches, about 1 inch to about 5 inches, about 1 inch to about 4 inches, about 1 inch to about 3 inches, and about 1 inch to about 2 inches. Any width of a closed protrusion 22 may be greater than, less than, or the same as any width of an open protrusion 18. In some embodiments, the lower width 56 of a closed protrusion 22 is greater than the interior upper width 60 of an open protrusion 18.

In some embodiments, a width of an open or closed protrusion 18, 22 may be selected so as to achieve a desired temperature range of the bedding product 10 while in use, whereby greater widths may allow for a greater degree of heat-dissipation and/or support. A single bedding product 10 may include open 18 and closed 22 protrusions of varying widths in order to provide the bedding product 10 with multiple, varied thermal and support patterns in.

The shape of a protrusion may vary. In some embodiments, the outer perimeter of a protrusion (e.g., the overall shape of the cavity 20 of an open protrusion 18 and/or the overall shape of a closed protrusion 22), as viewed from a top view looking down at the bedding product 10 beneath, may have a shape that is round, square, oval, triangle, rectangular, polygonal, hexagonal, star shaped, spiral, or the like. Other shapes are possible. The shape may be symmetrical or asymmetrical. The protrusions 18, 22 of a particular embodiment may be all of the same shape, or may be different shapes—e.g., some square and some round. In some embodiments, some or all of the protrusions 18, 22 in a first zone may have the same shape, and some or all of the protrusions 18, 22 in a second zone may have a different shape.

One or more dimension of each open protrusion 18 may be the same throughout the bedding product 10—e.g., all open protrusions 18 having the same depth 54 of the cavity 20. Alternatively, one or more dimension of each open protrusion 18 may vary throughout the bedding product 10—e.g., the depth 54 of the cavity 20 of open protrusions 18 in a first zone may be greater than the depth 54 of the cavity 20 of open protrusions 18 in a second zone. Similarly, one or more dimension of each closed protrusion 22 may be the same throughout the bedding product 10—e.g., all closed protrusions 22 having the same height 52. Alternatively, one or more dimension of each closed protrusion 22 may vary throughout the bedding product 10—e.g., the height 52 of closed protrusions 22 in a first zone may be greater than the height 52 of closed protrusions 22 in a second zone.

An open protrusion 18 includes a rim 19 at the top of an inner wall 23, which defines the cavity 20. The thickness 66 of rim 19 may vary—e.g., about 0.25 inch to about 2 inches, about 0.25 inch to about 1.5 inches, about 0.25 inch to about 1 inch, or 0.25 inch to about 0.75 inch. In some embodiments, open protrusions 18 having a thicker rim 66 provide more support.

The shape of a cavity 20 may vary. In some embodiments, the overall interior shape of the cavity 20 is rounded or angular. In some embodiments, at least a portion (e.g., at least 0.25 inch, at least 0.5 inch, or at least 1 inch) of the bottom interior surface of the cavity 20 is flat, convex, or concave. In some embodiments, at least a portion (e.g., at least 0.25 inch, at least 0.5 inch, or at least 1 inch) of the height of an inner wall 23 of the cavity 20 is straight. In some embodiments, at least a portion (e.g., at least 0.25 inch) of an inner wall 23 of the cavity 20 is rounded.

The depth 54 of the cavity 20, as measured from the bottom (i.e., lowermost interior point) of the cavity 20 to the top of the rim 19, may vary. Non-limiting examples of suitable depths 54 of cavity 20 include: at least 0.5 inch, at least 1 inch, at least 1.5 inches, at least 2 inches, at least 2.5 inches, about 0.5 inch to about 5 inches, about 0.5 inch to about 4 inches, about 0.5 inch to about 3 inches, about 0.5 inch to about 2 inches, or about 0.5 inch to about 1.0 inch.

As shown in FIG. 1D, channels 32 are provided between protrusions 18, 22 of the bedding product 10. In some aspects, the depth of a channel 32 is the same as the height 52 of an adjacent protrusion. In some embodiments, as depicted in FIG. 1D, the depth of a cavity 20 may be less than the depth of an adjacent channel 32. In other embodiments, the depth 54 of a cavity 20 may be greater than or the same as the depth of an adjacent channel 32. The lower width 64 of a channel 32 is defined as the widest distance along the upper surface 14 of the base support 15 between two adjacent protrusions 18, 22. The upper width 62 of a channel 32 is defined as the widest distance between the tops 24, 26 of two adjacent protrusions 18, 22. In some embodiments, the upper width 62 and lower width 64 of the channel 32 may be the same. In some embodiments, the upper width 62 may be larger than the lower width 64 of the channel 32. In some embodiments, the upper width 62 may be smaller than the lower width 64 of the channel 32. In some embodiments, regions or zones of a bedding product 10 having channels 32 with a larger width will provide more air flow and heat-dissipation in those regions or zones. A single bedding product 10 may have channels 32 of varying lower widths 64 in order to provide multiple, varied thermal patterns in body-contacting zones of the bedding product 10.

The channels 32 can be formed, for example, by molding, cutting, digging trenches into, routing, using surface modification techniques on, convoluting, compression cutting or otherwise working the support layer. The channels 32 may be formed at the same time that the protrusions 18, 22 are formed.

Foams

One or more layers of the bedding product 10 may comprise foam. In some embodiments, the first layer 12 of the bedding product 10 comprises foam. In some embodiments, the first layer 12 is made from a material consisting entirely of foam.

As used herein, “foam” refers to any type of air filled matrix structures including, without limitation, conventional foam, high resilience foam, latex foam rubber, viscoelastic foam, polyurethane foam, memory foam, slow recovery foam, ground foam, latex foam, reflex foam, continuous foam, hyper-soft resilient foam, hyper-soft high airflow viscoelastic foam, or combinations thereof. In some embodiments, the foam may be hyper-soft high airflow viscoelastic foam. In other embodiments, the foam may be viscoelastic polyurethane foam or memory foam. See U.S. 2005/0278852. These examples are provided for illustrative purposes only; the foam can have other compositions in other embodiments. Memory foam is generally temperature-sensitive, so environmental temperatures or a user's body heat may affect how the foam feels. For example, memory foam responds to a user's body heat and molds around the user; thus, the foam may aid in relieving pressure points, preventing pressure sores, improving circulation and the like. Higher density memory foam may mold to a warm human body in a few minutes.

In some embodiments, the foam may be polyurethane foam made from a formulation comprising an isocyanate, a surfactant, and a polyol blend comprising a vegetable oil polyol. See U.S. Pat. No. 7,700,661. In some embodiments, the foam may be polyurethane foam made from a formulation comprising a polyol blend comprising a petrochemical polyol and a vegetable oil polyol, and an isocyanate blend comprising a 2, 4 toluene diisocyanate (TDI) isomer and a 2, 6 TDI isomer, wherein the ratio of petrochemical polyol to vegetable oil polyol in the polyol blend is about equal to the ratio of the 2, 4 TDI isomer to the 2, 6 TDI isomer in the isocyanate blend. See U.S. Pat. No. 7,700,661. In some embodiments, the foam may further include one or more additives such as, without limitation, activators, stabilizers, amines, colorants, dyes, pigments, fragrances, chain-extending agents, surface-active agents (i.e., surfactants), fillers, and combinations thereof.

Methods of Manufacturing

Methods for fabricating a heat-dissipating bedding product 10 with heat-sink zones 4 and support zones 2 are next described. In one embodiment, the method includes (a) providing a support layer comprising substrate material; (b) forming a plurality of open protrusions 18 into the support layer using Surface Modification Technology (SMT), the open protrusions 18 having a cavity 20 formed in the top surface 26; (c) forming a plurality of closed protrusions 22 having a continuous top surface 24. In some embodiments, the open 18 and closed 22 protrusions are arranged into zones. Zones comprising open protrusions 18 will act as a heat-sink 4 to improve heat-dissipation. Zones comprising closed protrusions 22 will come in contact with, and provide support to, one or more parts of the body selected from the group consisting of the head/neck 40, shoulders 42, waist 44, hips 46, and legs/feet 48, and any combination thereof.

In some embodiments, the substrate material is conventional foam, high resilience foam, latex foam rubber, viscoelastic foam, polyurethane foam, memory foam, slow recovery foam, ground foam, latex foam, reflex foam, continuous foam, hyper-soft resilient foam, hyper-soft high airflow viscoelastic foam, or a combination thereof.

In some embodiments, the open 18 and closed 22 protrusions may be formed by molding the foam substrate material into protrusions 18, 22 that are raised above the first layer 12, and in the case of the open protrusions 18, may comprise a cavity 20 in the top surface 26. In alternative embodiments, the open 18 and closed 22 protrusions may be formed separately from the first layer 12, and can be glued or otherwise affixed to the first layer 12.

In some embodiments, the protrusions are formed using SMT of the foam substrate, including compression cutting or convoluting. See U.S. Pat. No. 5,534,208. A raised pattern of foam may be formed as heat-sink 4 and support 2 groupings using convoluting and/or compression cutting. The convoluting process may include feeding a slab of foam (such as flexible polyurethane, bonded/combined or memory foam) through a convoluter, which includes a set of patterned rollers and a blade that cuts the foam to produce two identical parts. The convoluter draws the foam across its blade in a generally horizontal direction to form two surfaces at the location where the foam splits. The studs of the patterned rollers apply pressure to the foam as the blade splits the compressed foam. The rollers are each set at a constant throughput speed (such as up to 65′/min, or another speed that is appropriate for the material) and have identical spacing from the blade. The closer the rollers are to the blade, the deeper the valley of the patterns in the foam. The rollers can be removed and replaced with stud patterns that will produce the desired patterns and spacing in the foam.

Alternatively, in a compression cutting process, a sheet of foam having an upper and lower surface, is compressed by a pressure component against a dye surface that bears a desired pattern. The spacing between the pressure component and die surface is such as to force of the upper surface of the foam slab against the die surface with sufficient force to extrude foam portions into the depressions, while portions of the foam surface underlying the flat end surfaces are compressed against the compression component. Just beyond the point of compression between the die surface and the compression component, the slab advances against cutting blade which is positioned between the die surface and the compression component to slice though the foam slab and cut away those portions of the foam extruding into the depressions while sparing the foam portions compressed by the die surface and the compression component. The foam slab is cut in this fashion to produce a heat-dissipating bedding product 10 with a three-dimensionally shaped surface and a scrap sheet, which consists of the foam material extruded into the slots and cut away from the slab. The pattern will create the desired open 18 and/or closed 22 protrusions in the heat-sink 4 or support 2 zones of the foam, as described above. The material running through the equipment will be pressed onto the pattern, as a blade cuts out the compressed sections. This will create a bedding product 10 with the open 18 and/or closed 22 protrusions of the desired pattern. In some embodiments the die surface and pressure components are on cylindrical rollers.

In general, the end result of both operations is a patterned foam sheet with open 18 and/or closed 22 protrusion areas, as shown by way of example in FIGS. 1A-1D. Patterns may vary in size and shape to achieve optimal heat-dissipation and support. The above manufacturing operations are described for illustrative purposes sonly; the protrusions 18, 22 can be formed by other operations.

Although the present inventive concepts have been described in considerable detail with reference to certain preferred embodiments thereof, other versions are possible. Therefore, the spirit and scope of the invention should not be limited to the description and the various specific examples described within this specification. All references cited and/or discussed in this specification are hereby incorporated by reference in their entireties.

Claims

1. A bedding product comprising a first layer of foam, wherein the first layer comprises:

a base support having an upper surface and a lower surface;

a plurality of open protrusions positioned on the upper surface of the base support, each open protrusion comprising a cavity formed therein, wherein the cavity has a depth of at least 0.5 inch; and

a plurality of closed protrusions positioned on the upper surface of the base support.

2. The bedding product of claim 1, wherein the cavity of the open protrusion has a depth of at least 1 inch.

3. The bedding product of claim 1, wherein the open and closed protrusions are arranged in a pattern along the upper surface of the base support.

4. The bedding product of claim 1, wherein:

the open protrusions are arranged in one or more heat-sink groupings;

the closed protrusions are arranged in one or more support groupings, and

the heat-sink groupings and the support groupings are arranged in an alternating pattern.

5. The bedding product of claim 4, wherein at least one of the heat-sink grouping comprises five or more open protrusions, and at least one of the support grouping comprises five or more closed protrusions.

6. The bedding product of claim 4, wherein at least one of the support groupings forms a support zone positioned to correspond to a predetermined portion of a user's body and to provide resistance that promotes at least one effect on the user's body selected from blood circulation, recovery, and facilitation of slow wave sleep.

7. The bedding product of claim 1, wherein the first layer defines an uppermost foam layer of the bedding product.

8. The bedding product of claim 1, wherein the bedding product comprises a plurality of layers and the first layer is the uppermost support layer.

9. The bedding product of claim 1, wherein top surfaces of the open and closed protrusions define an uppermost foam surface of the bedding product.

10. The bedding product of claim 1, wherein at least one closed protrusion has a continuous top surface.

11. The bedding product of claim 1, wherein at least one closed protrusion is solid.

12. The bedding product of claim 1, wherein a top surface of at least one closed protrusion is outwardly rounded.

13. The bedding product of claim 1, further comprising a second layer directly attached to the lower surface of the base support.

14. The bedding product of claim 13, wherein the second layer is the same as the first layer.

15. The bedding product of claim 1, wherein the base support has a thickness of about 0.25 inches to about 3 inches.

16. The bedding product of claim 1, wherein the bedding product is a mattress.

17. The bedding product of claim 1, wherein the bedding product is a mattress topper.

18. The bedding product of claim 1, wherein the bedding product provides greater heat-dissipation than a bedding product comprising a base support without protrusions.

19. The bedding product of claim 1, wherein the bedding product provides greater air flow than a bedding product comprising a base support without protrusions.