EP3560389A1

EP3560389A1 - Mattress assembly and methods for active ventilation of a support cushion

Info

Publication number: EP3560389A1
Application number: EP19180957.3A
Authority: EP
Inventors: Paul E. Griese; Daniel S. Powell; Leslie A. Burton; Mario A. G. Nava
Original assignee: Tempur Pedic Management LLC
Current assignee: Tempur Pedic Management LLC
Priority date: 2015-04-23
Filing date: 2015-04-23
Publication date: 2019-10-30
Also published as: US20180098637A1; WO2016171692A1; HK1247537A1; AU2015392446A1; EP3285618B1; EP3285618A4; EP3285618A1; CN107529895A

Abstract

A mattress assembly comprises a body supporting layer having a first surface and a second surface opposite the first surface, an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer; a lower base layer positioned adjacent to the upper base layer (30) opposite the body supporting layer, the lower base layer defining a cavity extending through the lower base layer; a bottom layer positioned adjacent to the lower base layer opposite the upper base layer; and a fan positioned within the cavity in the lower base layer, characterized in that, the body supporting layer includes one or more porous foam inserts positioned over the one or more one or more air conduits defined by the upper base layer.

Description

The present invention relates to support cushions and methods for actively ventilating support cushions. In particular, the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw and amount of air through and away from the support cushion.
An aspect of successful and restful sleep is individual sleep comfort. Medical research suggests that sleep deprivation ("sleep debt") can have significant negative impacts on longevity, productivity, and overall mental, emotional, and physical health. Chronic sleep debt has been linked to weight gain and, more specifically, has been observed to not only affect the way the body processes and stores carbohydrates, but has also been observed to alter hormone levels that affect appetite. Moreover, sleep debt may result in irritability, impatience, inability to concentrate, and moodiness, which has led some researchers to suggest a link between sleep debt and worksite accidents, traffic incidents, and general afternoon inattentiveness. Furthermore, sleep disorders have been linked to hypertension, increased stress hormone levels, and irregular heartbeat, and additional research has recently suggested that a lack of sleep can affect immune function, resulting in increased susceptibility to illness and disease, e.g., cancer. In all, researchers have now suggested that sleep debt costs the United States $63 billion annually in lost productivity due to these various effects. Accordingly, a support cushion that improves sleep comfort and lowers individual sleep debt would be both highly desirable and beneficial.
The present invention relates to support cushions and methods for actively ventilating support cushions. In particular, the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw and amount of air through and away from the support cushion. Thus, the support cushions of the present invention allow a user to increase his or her level of comfort, including sleep comfort, by actively ventilating the support cushions.
In one exemplary embodiment of the present invention, a support cushion in the form of a mattress assembly is provided that includes a body supporting layer having a first surface and a second surface. The body supporting layer of the mattress assembly includes a first porous foam insert that is positioned in a first side of the body supporting layer, and a second porous foam insert that is positioned in a second side of the body supporting layer opposite the first porous foam insert. Both the first porous foam insert and the second porous foam insert are generally sized to support a torso of a user lying on the mattress assembly. Thus, as a result of the size and position of the first porous foam insert and the second porous foam insert, the first porous foam insert and the second porous foam insert are not only configured to support the torso of a user lying on the mattress assembly, but are also configured to assist in dissipating any heat generated by the torso of a user lying on the mattress assembly away from the body supporting layer and the remainder of the mattress assembly.
The body supporting layer of the mattress assembly is covered by a comfort portion or layer that is positioned atop the body supporting layer. The comfort layer defines a first plurality of channels and a second plurality of channels that extend through the comfort layer and that are positioned over the first porous foam insert and the second porous foam insert, respectively, of the body supporting layer. By positioning the channels over the first porous foam insert and the second porous foam insert, the channels of the comfort layer place the first porous foam insert and the second porous foam insert in fluid communication with not only the comfort layer, but also with the environment surrounding the mattress assembly and/or the body of a user lying on the mattress assembly. In addition to placing the first porous foam insert and the second porous foam insert in communication with the surrounding environment, however, the comfort layer also functions to provide a level of comfort to a body of a user or a portion of thereof that is resting on the mattress assembly.
Further included in the mattress assembly is an upper base layer that is positioned adjacent to the second surface of the body supporting layer. The upper base layer defines a first plurality of air conduits and a second plurality of air conduits that extend through the upper base layer and that are positioned below the first porous foam insert and the second porous foam insert, respectively, of the body supporting layer. By positioning the first plurality of air conduits and the second plurality of air conduits below the first porous foam insert and the second porous foam insert of the body supporting layer, the first plurality of air conduits and the second plurality of air conduits are thus placed in direct fluid communication with the first porous foam insert and the second porous foam insert, and create a pathway for air to flow from the body supporting layer and through the upper base layer.
In addition to the upper base layer, a lower base layer is also included in the exemplary mattress assembly and is positioned adjacent to the upper base layer opposite the body supporting layer. The lower base layer defines a first cavity and a second cavity, which both extend through the lower base layer. The first cavity of the lower base layer houses a fan assembly and is positioned below and is in fluid communication with the first plurality of air conduits in the upper base layer . Similarly, the second cavity houses a separate fan assembly and is positioned below and is in fluid communication with the second plurality of air conduits . In this regard, upon activation of the fan assemblies in the first cavity and the second cavity defined by the lower base layer, the fan assemblies draw air through the channels in the comfort layer, through the porous foam inserts in the body supporting layer, through air conduits in the upper base layer, and then through the fan assemblies and the lower base layer, where it is then exhausted air into a bottom layer of the mattress assembly that is positioned adjacent to the lower base layer opposite the upper base layer.
With further respect to the fan assemblies included in the mattress assembly, as indicated above, the fan assemblies are housed within the cavities of the lower base layer with the upper base layer covering the fan assemblies from above and the bottom layer covering the fan assemblies from below. In this regard, each of the fan assemblies includes a fan that is mounted in a housing sized to fit within one of the cavities defined by the lower base layer and to be frictionally held in position within the cavities even when the mattress assembly is moved, tipped, or otherwise adjusted. To further promote the frictional connection between the housings and the cavities defined by the lower base layer, the fan assemblies each further include a sleeve that is positioned between each of the housings and the respective cavities and that is comprised of a material which promotes friction between the cavities and the respective housings.
To provide an amount of control over the amount of air being moved by the fan and the active ventilation of the mattress assembly, an exemplary mattress assembly also includes a power supply for supplying electrical current to the fan assemblies and a controller for controlling the electrical current supplied to the fan assemblies from the power supply. To provide an additional level of control over the movement of air through the mattress, an exemplary mattress assembly can further include several features that are operably connected to the body supporting layer and provide input to the controller. For example, in some embodiments, an exemplary mattress assembly includes temperature sensors that are operably connected to porous foam inserts included in the body supporting layer and that provide temperature feedback to the controller to thereby not only allow the controller to selectively provide power to the fan assemblies and adjust how quickly or how much air is moved through the mattress assembly in response to the received temperature feedback, but to also maintain a desired temperature at the first surface of the body supporting layer. As another example, in some embodiments, pressure sensors are also operably connected to the body supporting layer and provide pressure feedback to the controller in response to a user resting upon or adjacent to the first surface of the body supporting layer.
Each of the exemplary support cushions described herein can also be used as part of a method for actively ventilating a support cushion. In some implementations, a method for actively ventilating a support cushion includes first providing a support of the present invention. Power, in the form of electrical current, is then supplied to the fans in the support cushion, such that the fan draws air from the first surface of the body supporting layer, through upper base layer and lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion to thereby actively ventilate the support cushion and dissipate any heat away from the body supporting layer of the support cushion.
Further features and advantages of the present invention will become evident to those of ordinary skill in the art after a study of the description, figures, and non-limiting examples in this document.

FIG. 1: is a perspective view of an exemplary support cushion, in the form of a mattress assembly, made in accordance with the present invention;
FIG. 2: is an exploded, perspective view of the exemplary mattress assembly of FIG. 1;
FIG. 3: is a cross-sectional view of the exemplary mattress assembly of FIG. 1 taken along line 3-3 of FIG. 1;
FIG. 4: is an exploded perspective view of a fan assembly included in the exemplary mattress assembly of FIG. 1; and
FIG. 5: is a cross-sectional view of another exemplary support cushion, in the form of another mattress assembly, made in accordance with the present invention and showing the mattress assembly having an adjustable foundation.

The present invention relates to support cushions and methods for actively ventilating support cushions. In particular, the present invention relates to support cushions, such as mattress assemblies, that make use of a fan located within the support cushion to draw an amount of air through and away from the support cushion. Thus, the support cushions of the present invention allow a user to increase his or her level of comfort, including sleep comfort, by actively ventilating the support cushions.
Referring first to FIGS. 1-3, in one exemplary embodiment of the present invention, a support cushion in the form of a mattress assembly 10 is provided that includes a body supporting layer 20 having a first surface 22, which is generally an upper surface of the body supporting layer 20, and a second surface 24, which is opposite the first surface 22 and is generally the lower surface of the body supporting layer 20. The body supporting layer 20 of the mattress assembly 10 includes a first porous foam insert 26a positioned in a first side 28 of the body supporting layer 20, and a second porous foam insert 26b that is positioned in a second side 29 of the body supporting layer 20 opposite the first porous foam insert 26a. Both the first porous foam insert 26a and the second porous foam insert 26b are generally sized to support a torso of a user lying on the mattress assembly 10. Thus, as a result of the size and position of the first porous foam insert 26a and the second porous foam insert 26b, the first porous foam insert 26a and the second porous foam insert 26b are not only configured to support the torso of a user lying on the mattress assembly 10, but the first porous foam insert 26a and the second porous foam insert 26b are also configured to assist in dissipating any heat generated by the torso of a user lying on the mattress assembly 10 away from the body supporting layer 20 and the remainder of the mattress assembly 10, as described in further detail below.
The body supporting layer 20 of the mattress assembly 10 is generally comprised of a continuous layer of flexible foam for suitably distributing pressure from a user's body or portion thereof across the body supporting layer 20. Such flexible foams include, but are not limited to, latex foam, reticulated or non-reticulated visco-elastic foam (sometimes referred to as memory foam or low-resilience foam), reticulated or non-reticulated non-visco-elastic foam, polyurethane high-resilience foam, expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. In the embodiment shown in FIGS. 1-4, the body supporting layer 20 is comprised of a visco-elastic foam that has a low resilience as well as a sufficient density and hardness, which allows pressure to be absorbed uniformly and distributed evenly across the body supporting layer 20 of the mattress assembly 10. Generally, such visco-elastic foams have a hardness of at least about 10 N to no greater than about 80 N, as measured by exerting pressure from a plate against a sample of the material to a compression of at least 40% of an original thickness of the material at approximately room temperature (i.e., 21 °C to 23°C), where the 40% compression is held for a set period of time as established by the International Organization of Standardization (ISO) 2439 hardness measuring standard. In some embodiments, the visco-elastic foam has a hardness of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, or about 80 N to provide a desired degree of comfort and body-conforming qualities.
The visco-elastic foam described herein for use in the mattress assembly 10 can also have a density that assists in providing a desired degree of comfort and body-conforming qualities, as well as an increased degree of material durability. In some embodiments, the density of the visco-elastic foam used in the body supporting layer 20 has a density of no less than about 30 kg/m³ to no greater than about 150 kg/m³. In some embodiments, the density of the visco-elastic foam used in the body supporting layer 20 of the mattress assembly 10 is about 30 kg/m³, about 40 kg/m³, about 50 kg/m³, about 60 kg/m³, about 70 kg/m³, about 80 kg/m³, about 90 kg/m³, about 100 kg/m³, about 110 kg/m³, about 120 kg/m³, about 130 kg/m³, about 140 kg/m³, or about 150 kg/m³. Of course, the selection of a visco-elastic foam having a particular density will affect other characteristics of the foam, including its hardness, the manner in which the foam responds to pressure, and the overall feel of the foam, but it is appreciated that a visco-elastic foam having a desired density and hardness can readily be selected for a particular application or mattress assembly as desired. Additionally, it is appreciated that the body supporting layers of the mattress assemblies need not be comprised of a continuous layer of flexible foam at all, but can also take the form of more traditional mattresses, including spring-based mattresses, without departing from the spirit and scope of the subject matter described herein.
With even further respect to the body supporting layer 20 of the mattress assembly 10 and, in particular, the porous foam inserts 26a, 26b included in the body supporting layer 20 of the mattress assembly 10, the porous foam inserts 26a, 26b are also comprised of a visco-elastic foam, but are generally comprised of a viscoelastic foam having a porosity greater than the visco-elastic foam included in the body supporting layer 20 to allow air to enter the porous foam inserts 26a, 26b more readily than the remainder of the body supporting layer 20. Of course, it is also contemplated that the porous foam inserts 26a, 26b need not be comprised of a visco-elastic foam at all, but that any number of porous flexible foams can be used to produce a porous foam insert having a porosity sufficient to allow for air to readily enter and move through. In this regard, the term "porous foam" or "porous flexible foam" (visco-elastic or otherwise) is used herein to generally refer to flexible foam having a cellular foam structure in which at least a portion of the cells of the foam are essentially skeletal. In other words, at least a portion of the cells of the foam are each defined by a plurality of apertured windows surrounded by cell struts, where the cell windows of the porous foam can be entirely absent (leaving only the cell struts) or substantially missing. In some embodiments, the foam is considered "porous" if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts). Such structures can be created by destruction or other removal of cell window material, by chemical or mechanical means, or by preventing the complete formation of cell windows during the manufacturing process of the foam. In some embodiments of the present invention, the term "porous" can thus be used interchangeably with the term "reticulated" when referring to flexible foam.
Referring still to FIGS. 1-3, the body supporting layer 20 of the mattress assembly 10 is further covered by a comfort portion or layer 62 that is positioned atop the body supporting layer 20. The comfort layer 62 defines a first plurality of channels 66a and a second plurality of channels 66b that extend through the comfort layer 62 and that are positioned over the first porous foam insert 26a and the second porous foam insert 26b, respectively. By positioning the channels 66a, 66b over the first porous foam insert 26a and the second porous foam insert 26b, the channels 66a, 66b of the comfort layer 62 place the first porous foam insert 26a and the second porous foam insert 26b in fluid communication with not only the comfort layer 62, but also with the environment surrounding the mattress assembly 10 and/or the body of a user lying on the mattress assembly 10. In addition to placing the first porous foam insert 26a and the second porous foam insert 26b in communication with the surrounding environment, however, the comfort layer 62 also functions to provide a level of comfort to a body of a user or a portion of thereof that is resting on the mattress assembly 10. In this regard, the comfort layer 62 can also be comprised of a visco-elastic foam, but typically has a density, hardness, or both that is less than that of the body supporting layer 20 of the mattress assembly 10 such that the comfort layer 62 provides a softer surface on which to rest the body of a user. For example, in certain embodiments, the mattress assembly 10 includes a body supporting layer 20 that is comprised of visco-elastic foam with a density of about 80 kg/m³ and a hardness of about 13 N, while the comfort layer is comprised of a visco-elastic foam with a density of about 35 kg/m³ and a hardness of about 10 N.
Regardless of the particular types of foam included in the body supporting layer 20, the porous foam inserts 26a, 26b, and the comfort layer 62, further included in the mattress assembly 10 is an upper base layer 30 that is positioned adjacent to the second surface 24 of the body supporting layer 20. The upper base layer 30 defines a first plurality of air conduits 32a and a second plurality of air conduits 32b that extend through the upper base layer 30 and that are positioned below the first porous foam insert 26a and the second porous foam insert 26b, respectively, of the body supporting layer 20. By positioning the first plurality of air conduits 32a and the second plurality of air conduits 32b below the first porous foam insert 26a and the second porous foam insert 26b of the body supporting layer 20, the first plurality of air conduits 32a and the second plurality of air conduits 32b are thus placed in direct fluid communication with the first porous foam insert 26b and the second porous foam insert 26b, and create a pathway for air to flow from the body supporting layer 20 and through the upper base layer 30, the importance of which is also described in further detail below. Of course, pathways for air to flow from the body supporting layer 20 and through the upper base layer 30 can also be created by using a variety of other means, such as porous foam inserts with or without air conduits and which may be positioned in an exemplary upper base layer without departing from the spirit and scope of the subject matter described herein.
In addition to the upper base layer 30, and referring still to FIGS. 1-3, a lower base layer 40 is also included in the exemplary mattress assembly 10 and is positioned adjacent to the upper base layer 30 opposite the body supporting layer 20. The lower base layer 40 defines a first cavity 42a and a second cavity 42b, which both extend through the lower base layer 40. The first cavity 42a of the lower base layer 40 houses a fan assembly 80a and is positioned below and is in fluid communication with the first plurality of air conduits 32a in the upper base layer 30. Similarly, the second cavity 42b houses a separate fan assembly 80b and is positioned below and is in fluid communication with the second plurality of air conduits 32b. In this regard, upon activation of the fan assemblies 80a, 80b in the first cavity 42a and the second cavity 42b defined by the lower base layer 40, the fan assemblies 80a, 80b draw air through the channels 66a, 66b in the comfort layer 62, through the porous foam inserts 26a, 26b in the body supporting layer 20, through air conduits 32a, 32b in the upper base layer 30, and then through the fan assemblies 80a, 80b and the lower base layer 40, where it is then exhausted air into a bottom layer 50 of the mattress assembly 10 that is positioned adjacent to the lower base layer 40 opposite the upper base layer 30. In other words, by activating the fan assemblies 80a, 80b, any air and, consequently, any associated heat around or within the comfort layer 62 and the body supporting layer 20 that may be present as a result of a user lying on the mattress assembly 10 is drawn away from the comfort layer 62 and the body supporting layer 20 and is pulled through the mattress assembly 10 before being dissipated away from the mattress assembly 10 through the bottom layer 50.
With further regard to the upper base layer 30 and the lower base layer 40 of the mattress assembly 10, like the body supporting layer 20 and the comfort layer 62, the upper base layer 30 and the lower base layer 40 can also be comprised of a flexible foam, including any of the flexible foams described above with reference to the body supporting layer 20. The flexible foam comprising the body supporting layer 20, however, typically has a density less than that of the upper base layer 30 and the lower base layer 40, such that the upper base layer 30 and the lower base layer 40 have a density and hardness sufficient for supporting the body supporting layer 20 and the comfort layer 62 of the mattress assembly. For example, in the mattress assembly 10 shown in FIGS. 1-3, the upper base layer 30 and the lower base layer 40 are comprised of a higher density, porous polyurethane foam that provides sufficient support to the overlying body supporting layer 20 and the comfort layer, but that also provides an open environment in which air can move by virtue of its porous structure.
Similar to the upper base layer 30 and the lower base layer 40, the bottom layer 50 is further comprised of a breathable porous material that promotes the dispersion of the air, including the air exhausted into the bottom layer 50 by the fan assemblies 80a, 80b, but that also provides support to the remainder of the mattress assembly 10. In some embodiments, the porous materials included in the bottom layer 50 can be selected from a reticulated foam, knitted spacer fabric, textile, or a composite material. For instance, in some embodiments, it is contemplated that a knitted spacer fabric can be included that is generally comprised of two exterior mesh textile substrates and an insert material such as polyester monofilaments which are configured to keep the two exterior mesh textile substrates separated. Such knitted spacer fabrics include, by way of example, the Wellcool™ 3D spacer fabric manufactured by Quanzhou Wellcool Cushion Technology Co., Ltd (Fujian, China).
Regardless of the particular materials used in the bottom layer 50, in the mattress assembly 10, the bottom layer 50 as well as the comfort layer 62, the body supporting layer 20, the upper base layer 30, and the lower base layer 40 are generally secured to one another to prevent the body supporting layer 20, the upper base layer 30, the lower base layer 40, the bottom layer 50, and the comfort layer 62 from moving relative to one another during use. Various means of securing one layer of material to another can be used in this regard, including tape, hook and loop fasteners, conventional fasteners, stitches, and the like. In one particular embodiment, the body supporting layer 20, the upper base layer 30, the lower base layer 40, the bottom layer 50, and the comfort layer 62 are bonded together by an adhesive or cohesive bonding material to create a substantially continuous assembly where the body supporting layer 20, the upper base layer 30, the lower base layer 40, the bottom layer 50, and the comfort layer 62 are fully adhered to one another. Such adhesive bonding materials include, for example, environmentally-friendly, water based adhesives, like SABA AQUABOND RSD, a two-component water-based adhesive product produced by SABA DINXPERLO BV, B-7090 AA, Dinxperlo, Belgium.
Turning now to the fan assemblies 80a, 80b included in the mattress assembly 10, as indicated above and referring now to FIGS. 1-4, the fan assemblies are housed internally within the mattress assembly 10. More specifically, the fan assemblies 80a, 80b are housed within the cavities 42a, 42b of the lower base layer 40 with the upper base layer 30 covering the fan assemblies from above and the bottom layer 50 covering the fan assemblies 80a, 80b from below. In this regard, each of the fan assemblies 80a, 80b includes a fan 82a, 82b that is mounted in a housing 84a, 84b sized to fit within one of the cavities 42a, 42b defined by the lower base layer 40 and to be frictionally held in position within the cavities 42a, 42b even when the mattress assembly 10 is moved, tipped, or otherwise adjusted. To further promote the frictional connection between the housings 84a, 84b and the cavities 42a, 42b defined by the lower base layer 40, the fan assemblies 80a, 80b each further include a sleeve 88a, 88b that is positioned between each of the housings 84a, 84b and the respective cavities 42a, 42b and that is comprised of a material which promotes friction between the cavities 42a, 42b and the respective housings 84a, 84b, for example a textile. The sleeves 88a, 88b can also be comprised of a flame retardant material to provide a layer of fire suppression between the fan assemblies 80a, 80b and the rest of the mattress assembly 10. Furthermore, each of the sleeves 88a, 88b provide a means of securing and positioning an air filter 86a, 86b within each of the fan assemblies 80a, 80b.
Referring again to FIGS. 1-3, to provide an amount of control over the amount of air being moved by the fan and the active ventilation of the mattress assembly 10, the mattress assembly 10 also includes a power supply 92 for supplying electrical current to the fan assemblies 80a, 80b and a controller 90 for controlling the electrical current supplied to the fan assemblies 80a, 80b from the power supply 92. By including the controller 90 in the mattress assembly 10, the amount of electrical current supplied to the fan assemblies 80a, 80b from the power supply 92 can be controlled to allow for a desired amount of air to move through the mattress assembly 10 and, consequently, a desired amount of heat to be dissipated away from the body supporting layer 20 of the mattress assembly 10. For example, the controller 90 can be used to simply turn the fan assemblies 80a, 80b on or off depending on whether the user wishes to ventilate the mattress assembly 10 and remove heat from the body supporting layer 20 of the mattress assembly 10, or can be used to operate the fan assemblies 80a, 80b at a particular speed depending on how quickly the user wishes to ventilate the mattress assembly 10 and remove heat from the body supporting layer 20 of the mattress assembly 10. Alternatively, the controller 90 can also be configured to automatically control the electrical current supplied to the fan assemblies 80a, 80b from the power supply 92, such that the electrical current can be supplied to the fan assemblies 80a, 80b when the first surface 22 of the body supporting layer 20 reaches a desired temperature. As another example, the controller 90 can be configured to allow the electrical current to be supplied to the fan assemblies 80a, 80b from the power supply 92 for a predetermined time period, such as for an 8-hour sleeping period or for a length of time a user usually spends in a specific stage of the sleep cycle (e.g., REM sleep) in order to increase the sleep comfort of a user.
To provide an additional level of control over the movement of air through the mattress assembly 10, the mattress assembly 10 also includes several features that are operably connected to the body supporting layer 20 and provide input to the controller 90. For example, as shown best in FIG. 2, the mattress assembly 10 includes temperature sensors 94a, 94b that are operably connected to porous foam inserts 26a, 26b included in the body supporting layer 20 and that provide temperature feedback to the controller 90 to thereby not only allow the controller 90 to selectively provide power to the fan assemblies 80a, 80b and adjust how quickly or how much air is moved through the mattress assembly 10 in response to the received temperature feedback, but to also maintain a desired temperature at the first surface 22 of the body supporting layer 20. As another example, and as also shown best in FIG. 2, pressure sensors 96a, 96b are also operably connected to the body supporting layer 20 and provide pressure feedback to the controller 90 in response to a user resting upon or adjacent to the first surface 22 of the body supporting layer 20, such that the controller 90 can automatically allow power to be provided to the fan assemblies 80a, 80b air to be moved through the mattress assembly 10 as soon as the user lies on the mattress assembly 10 or otherwise places an amount of pressure on the mattress assembly 10. An additional benefit of the inclusion of the pressure sensors 96a, 96b is that the controller 90 can be configured to automatically shut off the fan assemblies 80a, 80b if a user is no longer lying on the mattress assembly 10. Of course, such desired temperature or pressure feedback settings can be directed, inputted or adjusted at the controller 90 itself, or in certain embodiments of the present invention, can be transmitted to the controller 90 from a remote control (not shown) that is also operably connected to the controller 90.
As a refinement to the support cushions of the present invention, and referring now to FIG. 5, in another exemplary embodiment of the present invention, another support cushion in the form of a mattress assembly 110 is provided that includes additional features to increase the comfort and convenience of the user of the mattress assembly 110. Like the support cushion shown in FIGS. 1-4, the mattress assembly 110 also includes: a comfort layer 162 defining a plurality of channels 166; a body supporting layer 120 including a porous foam insert 126; an upper base layer 130 positioned below the body supporting layer 120 and defining a plurality of air conduits 132 in fluid communication with the porous foam insert 126; a lower base layer 140 defining a cavity 142 with a fan assembly 180 located within the cavity 142; and a bottom layer 150 positioned below the lower base layer 140. Further included in the mattress assembly, however, is an adjustable foundation 170 that is positioned below the bottom layer 150 and allows a user to place the mattress assembly 110 into one or more desired ergonomic positions.
As a further refinement to the support cushions of the present invention, various covers can also be included and used to cover various portions of the support cushions. For example and referring still to FIG. 5, a cover 172 is included in the mattress assembly 110 and surrounds the comfort layer 162, the body supporting layer 120, the upper base layer 130, the lower base layer 140, and the bottom layer 150 of the mattress assembly 110. In the mattress assembly 110, the cover 172 in the form of a fire sock that surround the various layers is comprised of a flame retardant material. It is also contemplated, however, that an exemplary cover of the present invention can also be comprised of another textile, such as cotton that provide an exemplary support cushion with a unitary appearance, but that also provides a user with a sufficiently soft surface on which to rest while being sufficiently breathable to allow air to be drawn through the cover and the exemplary support cushion.
As yet another refinement to the present invention, although the support cushions shown in FIGS. 1-3 and 5 are in the form of mattress assemblies 10, 110 and are dimensionally-sized to support a user lying in a supine or prone position, it is contemplated that the features described herein are equally applicable to other support cushions, such as head pillows, seat cushions, seat backs, neck pillows, leg spacer pillows, mattress topers, overlays, and the like. As such, the phrase "body support" or "body supporting" is used herein to refer to any and all such objects having any size or shape, and that are capable of supporting, or are generally used to support, the body of a user or a portion thereof. Furthermore, although the body supporting layer 20 of the mattress assembly 10 shown in FIGS. 1-3, includes two removable inserts 26a, 26b, two sets of air conduits 32a, 32b, two cavities 42a, 42b, and two fan assemblies 80a, 80b, it is also contemplated other embodiments may include any number of removable portions, conduits, cavities, and fan assemblies depending on the size and shape of the particular support cushion.
Each of the exemplary support cushions described herein can also be used as part of a method for actively ventilating a support cushion. In some implementations, a method for actively ventilating a support cushion includes first providing a support cushion having: a body supporting layer having a first surface and a second surface opposite the first surface; an upper base layer positioned adjacent to the second surface of the body supporting layer and defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer; a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer and defining a cavity extending through the lower base layer; a bottom layer positioned adjacent to the lower base layer opposite the upper base layer; and a fan located within the cavity define by the lower base layer. Power, in the form of electrical current, is then supplied to the fan, such that the fan draws air from the first surface of the body supporting layer, through upper base layer and lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion to thereby actively ventilate the support cushion and dissipate any heat away from the body supporting layer of the support cushion.
The present invention can also be described by means of the following clauses:

1. A support cushion, comprising:
- a body supporting layer having a first surface and a second surface opposite the first surface, the body supporting layer including one or more porous foam inserts;
- an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the one or more porous foam inserts;
- a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer, the lower base layer defining a cavity extending through the lower base layer;
- a bottom layer positioned adjacent to the lower base layer opposite the upper base layer; and
- a fan positioned within the cavity defined by the lower base layer.
2. The support cushion of clause 1, further comprising a comfort layer positioned adjacent to the first surface of the body supporting layer, the comfort layer including a top surface and a bottom surface opposite the top surface.
3. The support cushion of clause 2, wherein the comfort layer defines a plurality of channels extending from the top surface to the bottom surface of the comfort layer, the plurality of channels in fluid communication with the one or more porous foam inserts.
4. The support cushion of clause 3, wherein the bottom layer is comprised of a porous material.
5. The support cushion of clause 4, wherein the porous material is selected from the group consisting of porous foams, knitted spacer fabrics, textiles, and composite materials.
6. The support cushion of clause 1, further comprising a housing for the fan, the housing positioned within the cavity defined by the lower base layer.
7. The support cushion of clause 6, further comprising an air filter positioned within the housing.
8. The support cushion of clause 6, further comprising a sleeve positioned around the housing and within the cavity of the lower base layer.
9. The support cushion of clause 8, wherein the sleeve is comprised of a material configured to provide a frictional connection between the housing and the lower base layer.
10. The support cushion of clause 9, wherein the sleeve is comprised of a flame retardant material.
11. The support cushion of clause 1, wherein the body supporting layer, the upper base layer, and the lower base layer are comprised of a flexible foam.
12. The support cushion of clause 11, wherein the body supporting layer is comprised of a visco-elastic foam.
13. The support cushion of clause 11, wherein the flexible foam comprising the body supporting layer has a porosity less than that of the one or more porous foam inserts.
14. The support cushion of clause 1, wherein the body supporting layer has a density less than that of the upper base layer, the lower base layer, or both.
15. The support cushion of clause 2, wherein the comfort layer is comprised of a visco-elastic foam.
16. The support cushion of clause 15, wherein the body supporting layer is comprised of a visco-elastic foam, and wherein the comfort layer has a density less than that of the body supporting layer.
17. The support cushion of clause 1, further comprising:
- a power supply for supplying electrical current to the fan; and
- a controller for controlling the electrical current supplied to the fan from the power supply.
18. The support cushion of clause 17, wherein the controller is configured to allow power to be supplied to the fan for a predetermined time period.
19. The support cushion of clause 17, further comprising one or more temperature sensors for providing thermal feedback to the controller, the one or more temperature sensors operably connected to the body supporting layer.
20. The support cushion of clause 17, further comprising one or more pressure sensors for providing pressure feedback to the controller, the one or more pressure sensors operably connected to the body supporting layer.
21. The support cushion of clause 1, further comprising a cover configured to surround the body supporting layer, the upper base layer, the lower base layer, and the bottom layer.
22. The support cushion of clause 21, wherein the cover is comprised of a flame retardant material.
23. The support cushion of clause 21, wherein the cover is comprised of a textile.
24. A mattress assembly, comprising:
- a body supporting layer having a first surface and a second surface opposite the first surface;
- an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer;
- a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer, the lower base layer defining a cavity extending through the lower base layer;
- a bottom layer positioned adjacent to the lower base layer opposite the upper base layer; and
- a fan positioned within the cavity in the lower base layer.
25. The mattress assembly of clause 24, wherein the body supporting layer includes one or more porous foam inserts positioned over the one or more one or more air conduits defined by the upper base layer.
26. The mattress assembly of clause 24, further comprising an adjustable foundation positioned below the bottom layer.
27. A method of actively ventilating a support cushion, comprising:
- providing a support cushion including
  - a body supporting layer having a first surface and a second surface opposite the first surface,
  - an upper base layer positioned adjacent to the second surface of the body supporting layer, the upper base layer defining one or more air conduits extending through the upper base layer and in fluid communication with the body supporting layer,
  - a lower base layer positioned adjacent to the upper base layer opposite the body supporting layer, the lower base layer defining a cavity extending through the lower base layer,
  - a bottom layer positioned adjacent to the lower base layer opposite the upper base layer, and
  - a fan located within the cavity defined by the lower base layer; and
- supplying power to the fan, such that the fan draws air from the first surface of the body supporting layer, through the upper base layer and the lower base layer, and into the bottom layer and away from the body supporting layer of the support cushion.

Throughout this document, various references are mentioned. All such references are incorporated herein by reference, including the references set forth in the following list:

References

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

Claims

A mattress assembly (10), comprising:
a body supporting layer (20) having a first surface (22) and a second surface (24) opposite the first surface (22);

an upper base layer (30) positioned adjacent to the second surface (24) of the body supporting layer (20), the upper base layer (30) defining one or more air conduits (32a, 32b) extending through the upper base layer (30) and in fluid communication with the body supporting layer (20);

a lower base layer (40) positioned adjacent to the upper base layer (30) opposite the body supporting layer (20), the lower base layer (40) defining a cavity (42a, 42b) extending through the lower base layer (40);

a bottom layer (50) positioned adjacent to the lower base layer (40) opposite the upper base layer (30); and

a fan (80a, 80b) positioned within the cavity (42a, 42b) in the lower base layer (40),
characterized in that
the body supporting layer (20) includes one or more porous foam inserts (26a, 26b) positioned over the one or more one or more air conduits (32a, 32b) defined by the upper base layer (30).
The mattress assembly of claim 1, further comprising an adjustable foundation (170) positioned below the bottom layer (50).
A method of actively ventilating a support cushion (10), comprising:
providing a support cushion (10) including
a body supporting layer (20) having a first surface (22) and a second surface (24) opposite the first surface (22),
an upper base layer (30) positioned adjacent to the second surface (24) of the body supporting layer (20), the upper base layer (30) defining one or more air conduits (32a, 32b) extending through the upper base layer (30) and in fluid communication with the body supporting layer (20),
a lower base layer (40) positioned adjacent to the upper base layer (30) opposite the body supporting layer (20), the lower base layer (40) defining a cavity (42a, 42b) extending through the lower base layer (40),
a bottom layer (50) positioned adjacent to the lower base layer (40) opposite the upper base layer (30), and
a fan (80a, 80b) located within the cavity (42a, 42b) defined by the lower base layer (40);

supplying power to the fan (80a, 80b), such that the fan (80a, 80b) draws air from the first surface (22) of the body supporting layer (20), through the upper base layer (30) and the lower base layer (40), and into the bottom layer (50) and away from the body supporting layer (20) of the support cushion (10), and

positioning one or more porous foam inserts (26a, 26b) over the one or more air conduits (32a, 32b) defined by the upper base layer (30).