U.S. patent application number 10/873960 was filed with the patent office on 2005-12-22 for comfort product.
This patent application is currently assigned to RiverPark Incorporated. Invention is credited to Bahash, Lisa Jane, Lipski, Michael Raymond.
Application Number | 20050278863 10/873960 |
Document ID | / |
Family ID | 35479002 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050278863 |
Kind Code |
A1 |
Bahash, Lisa Jane ; et
al. |
December 22, 2005 |
Comfort product
Abstract
An improved comfort product that uses an airflow through a heat
exchanger and into the comfort product to selectively heat or cool
an occupant has a support layer contacting and supporting a channel
layer. The channel layer has at least one channel with an opening
to accept air. The channel layer contacts and supports an
engineered distribution layer that has numerous small holes making
it air permeable. The engineered distribution layer contacts and
supports an air permeable comfort layer that is of such size and
shape to support an occupant of the comfort product. The comfort
product also has a heat exchanger assembly for supplying heated or
cooled air to the opening in the channel. The heat exchanger
assembly includes an air intake having an intake fan, an exhaust
outlet and a heat exchanger for selectively heating or cooling air
flowing through the heat exchanger resulting in selectively heated
or cooled supply air and exhaust air. The intake fan forces air
through the heat exchanger where some of the air is selectively
heated or cooled to be supplied to the comfort product and some air
is used as exhaust air (to remove the unwanted heat if the supplied
air is cooled or to warm the exhaust side of the heat exchanger if
the supply air is warmed.). The selectively heated or cooled supply
air then moves through the channels in the channel layer and the
exhaust air exits through the exhaust vent. The selectively heated
or cooled supply air then moves through the engineered distribution
layer where the numerous small holes diffuse the air and then the
selectively heated or cooled air then moves through the comfort
layer where the air is further diffused and where the selectively
heated or cooled air can selectively heat or cool an occupant of
the comfort product.
Inventors: |
Bahash, Lisa Jane;
(Plymouth, MI) ; Lipski, Michael Raymond;
(Pinckney, MI) |
Correspondence
Address: |
WILLIAM M HANLON, JR
YOUNG & BASILE, PC
3001 WEST BIG BEAVER ROAD
SUITE 624
TROY
MI
48084-3107
US
|
Assignee: |
RiverPark Incorporated
Elkhart
IN
|
Family ID: |
35479002 |
Appl. No.: |
10/873960 |
Filed: |
June 22, 2004 |
Current U.S.
Class: |
5/726 ;
5/652.2 |
Current CPC
Class: |
A01K 1/0353 20130101;
A47C 21/044 20130101; A47C 21/048 20130101 |
Class at
Publication: |
005/726 ;
005/652.2 |
International
Class: |
A47C 027/00 |
Claims
What is claimed is:
1. A comfort product having means to distribute air through the
comfort product comprising: a support layer; a channel layer; the
channel layer being in contact with and supported by the support
layer; the channel layer having at least one channel formed
therein; the channel layer having an opening connecting to the
channel; an engineered distribution layer; the engineered
distribution layer being in contact with and supported by the
channel layer; the engineered distribution layer having numerous
small holes making it air permeable; a comfort layer; the comfort
layer being in contact with and supported by the top engineered
distribution layer; the comfort layer being of such size and shape
to receive and support an occupant of the comfort product; the
comfort layer being air permeable; a fan assembly for supplying air
consisting of an air intake having an intake fan; whereby; the
intake fan can force air into and through the channels in the
channel layer; the air can then move through the engineered
distribution layer where the numerous small holes diffuse the air;
and the air can then move through the comfort layer where the air
is further diffused and where the air can comfort an occupant.
2. A comfort product having means to distribute temperature
conditioned air through the comfort product comprising: a support
layer; a channel layer; the channel layer being in contact with and
supported by the support layer; the channel layer having at least
one channel formed therein; the channel layer having an opening
connecting to the channel; an engineered distribution layer; the
engineered distribution layer being in contact with and supported
by the channel layer; the engineered distribution layer having
numerous small holes making it air permeable; a comfort layer; the
comfort layer being in contact with and supported by the top
engineered distribution layer; the comfort layer being of such size
and shape to receive and support an occupant of the comfort
product; the comfort layer being air permeable; a heat exchanger
assembly for supplying heated or cooled air consisting of: an air
intake having an intake fan; an exhaust outlet; a heat exchanger
for selectively heating or cooling air flowing through the heat
exchanger thereby providing selectively heated or cooled air and
exhaust air; whereby; the intake fan can force air through the heat
exchanger; the heat exchanger selectively heats or cools the air;
the selectively heated or cooled air can then move through the
channels in the channel layer; the selectively heated or cooled air
can then move through the engineered distribution layer where the
numerous small holes diffuse the air; and the selectively heated or
cooled air can then move through the comfort layer where the air is
further diffused and where the selectively heated or cooled air can
selectively heat or cool an occupant.
3. A comfort product as in claim 2 wherein the heat exchanger
includes a Peltier circuit.
4. A comfort product as in claim 2 wherein the support layer is
made of high density foam.
5. A comfort product as in claim 2 wherein the support layer is
made of low density foam.
6. A comfort product as in claim 2 wherein the channel layer is
made of high density foam.
7. A comfort product as in claim 2 wherein the engineered
distribution layer is made of low density foam.
8. A comfort product as in claim 2 wherein the engineered
distribution layer is made of fiber paper.
9. A comfort product as in claim 2 wherein the comfort layer is
made of low density foam.
10. A comfort product as in claim 2 wherein the comfort layer is
made of blown fiber in a bag.
11. A comfort product as in claim 2 which includes a backrest.
12. A comfort product as in claim 11 wherein the backrest is
comprised mainly of low density foam.
13. A comfort product as in claim 2 wherein the channel is spiral
shaped.
14. A comfort product as in claim 2 wherein the channel is
vein-like.
15 . A comfort product as in claim 14 wherein the vein-line channel
has at least one connection opening and wherein the connection
opening can make an air-tight connection with a second connection
opening in another like comfort product.
16. A comfort product having means to distribute temperature
conditioned air through the comfort product comprising: a support
layer of either high density foam or low density foam; a channel
layer of high density foam; the channel layer being in contact with
and supported by the support layer; the channel layer having
channels formed therein; the channel layer having an opening
connecting to the channels; an engineered distribution layer fiber
paper or low density foam; the engineered distribution layer being
in contact with and supported by the channel layer; the engineered
distribution layer having numerous small holes making it air
permeable; a comfort layer of low density foam, layered fiber paper
or blown fiber in a bag; the comfort layer being in contact with
and supported by the top engineered distribution layer; the comfort
layer the comfort layer being of such size and shape to receive and
support an occupant of the comfort product; the comfort layer being
air permeable; a heat exchanger assembly for supplying heated or
cooled air consisting of: an air intake having an intake fan; an
exhaust outlet; a heat exchanger for selectively heating or cooling
air flowing through the heat exchanger thereby providing
selectively heated or cooled air and exhaust air; the heat
exchanger including a Peltier circuit whereby: the intake fan can
force air through the heat exchanger; the heat exchanger
selectively heats or cools the air; the selectively heated or
cooled air can then move through the channels in the channel layer;
the selectively heated or cooled air can then move through the
engineered distribution layer where the numerous small holes
diffuse the air; and the selectively heated or cooled air can then
move through the comfort layer where the air is further diffused
and where the selectively heated or cooled air can selectively heat
or cool an occupant.
17. A comfort product as in claim 16 wherein: the support layer has
a top side; the channel layer has a top side, a bottom side and at
least one lateral side; the bottom side of the channel layer being
in contact with and supported by the top side of the support layer;
the engineered distribution layer has a top side and a bottom side;
the bottom side of the engineered distribution layer being in
contact with and supported by the top side of the channel layer;
the comfort layer having a top side and a bottom side; the bottom
side of the comfort layer being in contact with and supported by
the top side of the engineered distribution layer; the top side of
the comfort layer supporting an occupant of the comfort
product;.
18. A comfort product as in claim 17 wherein: the channels in the
channel layer are formed in the top side of the channel layer; and
the opening in the channel layer connecting to the channels is in
the lateral side of the channel layer.
19. A comfort product as in claim 17 wherein: the channels in the
channel layer are formed in the top side of the channel layer; and
the opening in the channel layer connecting to the channels is in
the bottom of the channel layer.
20. A comfort product as in claim 17 wherein the channel in the
channel layer is spiral shaped.
21. A comfort product as in claim 20 wherein the spiral shaped
channel extends from the top side of the channel layer through the
channel layer to the bottom side of the channel layer.
22. A comfort product as in claim 16 wherein the channel is
vein-like.
23. A comfort product as in claim 22 wherein the vein-line channel
has at least connection opening and wherein the connection opening
can make an air-tight connection with a second connection opening
another like comfort product.
24. A comfort product as in claim 16 which includes a backrest.
25. A comfort product having means to distribute temperature
conditioned air through the comfort product comprising: a support
layer of high density foam or low density foam; the support layer
having a top side; a channel layer of high density foam; the
channel layer having a top side, a bottom side and at least one
lateral side; the bottom side of the channel layer being in contact
with and supported by the top side of the support layer; the top
side of the channel layer having channels formed therein; the
channel layer having an opening, the opening connecting to the
channels; an engineered distribution layer of fiber paper or low
density foam; the engineered distribution layer having a top side
and a bottom side; the bottom side of the engineered distribution
layer being in contact with and supported by the top side of the
channel layer; the engineered distribution layer having numerous
small holes making it air permeable; a comfort layer of low density
foam, layered fiber paper or blown fiber in a bag; the comfort
layer having a top side and a bottom side; the bottom side of the
comfort layer being in contact with and supported by the top side
of the engineered distribution layer; the top side of the comfort
layer being of such size and shape to receive and support an
occupant of the comfort product; the comfort layer being air
permeable; a back rest foam of low cut density foam; the back rest
being in contact with and supported by the top side of the comfort
layer; a heat exchanger assembly for supplying heated or cooled air
consisting of: an air intake having an intake fan; an exhaust
outlet; an air conduit having a first end and a second end; the
first end of the air conduit connected to the air intake; the
second end of the air conduit connected to a heat exchanger for
selectively heating or cooling air flowing through the heat
exchanger from the air conduit thereby providing selectively heated
or cooled air and exhaust air; the heat exchanger including a
Peltier circuit; an air supply tube connected to the heat exchanger
at a first end receiving the selectively heated or cooled air; the
air supply connected to the opening in the channel layer; whereby;
the intake fan can force air through the air intake, into the air
conduit and through the heat exchanger; the heat exchanger
selectively heats or cools the air; the selectively heated or
cooled air can move through the air supply tube; the selectively
heated or cooled air can then move through the channels in the
channel layer; the selectively heated or cooled air can then move
through the engineered distribution layer where the numerous small
holes diffuse the air; and the selectively heated or cooled air can
then move through the comfort layer where the air is further
diffused and where the selectively heated or cooled air can
selectively heat or cool an occupant.
26. A comfort product as in claim 25 wherein the channel in the
channel layer is spiral shaped.
27. A comfort product as in claim 26 wherein the spiral shaped
channel extends from the top side of the channel layer through the
channel layer to the bottom side of the channel layer.
28. A comfort product as in claim 25 wherein the channel is
vein-like.
29. A comfort product as in claim 28 wherein the vein-like channel
has at least one connection opening and wherein the connection
opening can make an air-tight connection with a second connection
opening another like comfort product.
30. A comfort product as in claim 25 wherein the opening in the
channel layer connecting to the channels is in the lateral side of
the channel layer.
31. A comfort product as in claim 25 wherein the opening in the
channel layer connecting to the channels is in the bottom of the
channel layer.
32. A comfort product as in claim 25 wherein the heat exchanger
assembly has a switch assembly to activate or deactivate the heat
exchanger assembly.
33. A comfort product as in claim 32 wherein the switch assembly
includes a pressure activated switch.
34. A comfort product as in claim 25 wherein the heat exchanger
assembly is mounted in a space defined by an opening in the support
layer, the channel layer and the scrim so the heat exchanger
assembly fits in the interior of the comfort product.
35. A comfort product as in claim 25 wherein the heat exchanger
assembly is mounted exterior of a space defined the support layer,
the channel layer and the scrim so the heat exchanger assembly is
exterior to the remainder of the comfort product.
36. A comfort product having means to distribute temperature
conditioned air through the comfort product manufactured by a
process such that: a support layer is die cut from high density
foam or low density foam to form a structure having a top; a
channel layer is die cut from high density foam to form a structure
having a top, bottom and at least one side; the channel layer
having channels formed in the top side of the channel layer; an
engineered distribution layer is die cut from fiber paper or low
density foam to form a structure having a top and a bottom; the
engineered distribution layer having holes formed to allow the
passage of air from the bottom side of the engineered distribution
layer to the top side of the engineered distribution layer; a
comfort layer of such size and shape to receive and support an
occupant of the comfort product is die cut from low density foam or
is made of blown fiber collected in a bag to form a structure
having a top side and a bottom side; the bottom side of the channel
layer being glued to the top side of the support layer using foam
glue so that the channel layer is in contact with and supported by
the support layer; the bottom side of the engineered distribution
layer being glued to the top side of the channel layer using foam
glue so that the engineered distribution layer is in contact with
and supported by the channel layer; the bottom side of the comfort
layer being glued to the top side of the engineered distribution
layer using foam glue so that the comfort layer is in contact with
and supported by the engineered distribution layer; a heat
exchanger assembly being connected to the channels of the channel
layer to force selectively heated or cooled air through the
channels, up through the holes in the engineered distribution layer
where the air is diffused and through the comfort layer where the
air is further diffused to heat or cool the top of the comfort
layer.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to comfort products and more
particularly to comfort products in which an airflow is produced
through the comfort product. The comfort product can include a heat
exchanger through which the air is forced to selectively heat or
cool an occupant of the comfort product. Applications of the
invention include beds for pets and human occupants.
BACKGROUND OF THE INVENTION
[0002] For as long as people have been sleeping in beds there have
been problems with people being either too warm or too cold while
in the bed. In the past people would warm bricks in the fireplace
and insert these bricks under the sheets or even the mattress to
warm the bed before entering. As the industrial revolution made
consumer products more affordable this practice gave way to people
taking hot water bottles to bed with them for the same purpose.
These practices have the inconveniences of being temporary (in that
the heat brought to bed slowly dissipates) and time consuming (in
that considerable preparation must occur). Plus neither of these
methods actually cool the bed--they only provide heat.
[0003] With the advent of effective central heating and air
conditioning, many people forgo heating pads and hot water bottles
in favor of heating or cooling the room or enclosure where the bed
is located. While this method does provide a constant modified
temperature for the space in which the bed sits it also has
disadvantages. One disadvantage is it is expensive and inefficient
to heat or cool areas that are not occupied (such as areas outside
of the bed during sleep) when the person really just wants their
immediate area--the bed--to be comfortable. Another disadvantage is
the bed itself can sometimes be warmer or colder than the
surrounding air, to the discomfort of the person sleeping. Yet
another disadvantage is warming or cooling the entire enclosure may
not be feasible if the bed is not in a building; e.g. if it is in a
recreational vehicle or in the sleeping compartment of a
semi-truck.
[0004] There have been efforts in the past to provide localized
heating or cooling of a comfort product such as a bed using forced
air in order to overcome the problems of expense, inefficiency and
localized temperature spikes. U.S. Pat. Nos. 2,461,432 and
2,493,067 show such efforts dating back to the late 1940s and early
1950s. These earlier inventions were often cumbersome and
complicated which made them expensive to produce and use. U.S. Pat.
No. 6,336,237 B1 shows a ventilated mattress that uses forced air
from a cooling/warming air-delivery box to heat or cool an
occupant. While less complicated than the previous inventions, this
mattress still relies upon the structure of a traditional
inner-spring mattress making it expensive and therefore unsuitable
for use outside of the home or for a lower cost application such as
a pet bed.
[0005] There have also been efforts to produce ventilated comfort
products for use outside of the home or in lower cost applications.
The modular ventilated bed disclosed in U.S. Pat. No. 4,665,575
shows a bed designed for use outside of a home, but it does not
include forced air for heating or cooling which limits its
effectiveness at transferring heat to or from the occupant. U.S.
Pat. No. 6,553,935 discloses a pet bed that does use forced air but
does not include a mechanical or electronic heat transfer device to
heat or cool the air, relying instead on ice-packs or heating
packs. This limits the usefulness of the invention much the same
way as the old heating bricks or hot water bottles did since the
ice-packs will melt or the heating packs will cool and the cooling
or heating will end.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide an
improved comfort product that uses an airflow through the comfort
product and which has none of the limitations of the prior art
described above. It is a further object of the present invention to
provide an improved comfort product that uses an airflow through a
heat exchanger and into and through the comfort product to
selectively heat or cool an occupant of the comfort product and
which has non of the limitations of the prior art described
above.
[0007] In one preferred embodiment of the present invention the
improved comfort product has a support layer contacting and
supporting a channel layer. The channel layer has at least one
channel with an opening to accept air. The channel layer contacts
and supports an engineered distribution layer that has numerous
small holes making it air permeable. The engineered distribution
layer contacts and supports an air permeable comfort layer that is
of such size and shape to support an occupant of the comfort
product. The comfort product also has a fan assembly for supplying
air to the opening in the channel. The fan assembly includes an air
intake having an intake fan which forces air into and through the
comfort product. The moves to and through the channels in the
channel layer, then moves through the engineered distribution layer
where the numerous small holes diffuse the air and then the air
then moves through the comfort layer where the air is further
diffused and where the air can comfort an occupant of the comfort
product.
[0008] In another preferred embodiment of the present invention the
improved comfort product has a support layer contacting and
supporting a channel layer. The channel layer has at least one
channel with an opening to accept air. The channel layer contacts
and supports an engineered distribution layer that has numerous
small holes making it air permeable. The engineered distribution
layer contacts and supports an air permeable comfort layer that is
of such size and shape to support an occupant of the comfort
product. The comfort product also has a heat exchanger assembly for
supplying heated or cooled air to the opening in the channel. The
heat exchanger assembly includes an air intake having an intake
fan, an exhaust outlet and a heat exchanger for selectively heating
or cooling air flowing through the heat exchanger resulting in
selectively heated or cooled supply air and exhaust air. The intake
fan forces air through the heat exchanger where some of the air is
selectively heated or cooled to be supplied to the comfort product
and some air is used as exhaust air (to remove the unwanted heat if
the supplied air is cooled or to warm the exhaust side of the heat
exchanger if the supply air is warmed.). The selectively heated or
cooled supply air then moves to and through the channels in the
channel layer and the exhaust air exits through the exhaust vent.
The selectively heated or cooled supply air then moves through the
engineered distribution layer where the numerous small holes
diffuse the air and then the selectively heated or cooled supply
air then moves through the comfort layer where the air is further
diffused and where the selectively heated or cooled supply air can
selectively heat or cool an occupant of the comfort product.
[0009] In yet another preferred embodiment of the present invention
the improved comfort product has a support layer made of either
high density foam or low density foam contacting and supporting a
channel layer made of high density foam. The channel layer has at
least one channel with an opening to accept air. The channel layer
contacts and supports an engineered distribution layer made of
either fiber paper or low density foam. The engineered distribution
layer has numerous small holes making it air permeable. The
engineered distribution layer contacts and supports an air
permeable comfort layer made of low density foam of blown fiber
contained in a bag. The comfort layer is of such size and shape to
support an occupant of the comfort product. The comfort product
also has a heat exchanger assembly for supplying heated or cooled
air to the opening in the channel. The heat exchanger assembly
includes an air intake having an intake fan, an exhaust outlet and
a Peltier circuit heat exchanger (such as described in U.S. Pat.
No. 5,618,167 though any configuration of a Peltier circuit could
work) for selectively heating or cooling air flowing through the
heat exchanger resulting in selectively heated or cooled supply air
and exhaust air. The intake fan forces air through the Peltier
circuit heat exchanger where some of the air is selectively heated
or cooled to be supplied to the comfort product and some air is
used as exhaust air (to remove the unwanted heat if the supplied
air is cooled or to warm the exhaust side of the heat exchanger if
the supply air is warmed.). The selectively heated or cooled supply
air then moves through the channels in the channel layer and the
exhaust air exits through the exhaust vent. The selectively heated
or cooled supply air then moves through the engineered distribution
layer where the numerous small holes diffuse the air and then the
selectively heated or cooled air then moves through the comfort
layer where the air is further diffused and where the selectively
heated or cooled air can selectively heat or cool an occupant of
the comfort product.
[0010] In still another preferred embodiment of the present
invention the improved comfort product has a support layer made of
either high density foam or low density foam. The support layer has
a top side that contacts and supports a channel layer made of high
density foam. the channel layer has a top side, a bottom side and
at least one lateral side. The top side of the channel layer has at
least one channel formed therein. The channel layer also has an
opening to accept air. This opening is connected to at least one of
the channels. The top side of the channel layer is in contact with
a bottom side of an engineered distribution layer and supports the
engineered distribution layer. The engineered distribution layer is
made of either fiber paper or low density foam, has a top side, and
has numerous small holes between the bottom side and the top side
of the engineered distribution layer formed therein making it air
permeable. The top side of the engineered distribution layer is in
contact with and supports a bottom side of a comfort layer made of
low density foam or blown fiber in a bag. The comfort layer also
has a top side and is of a size and shape to receive and support an
occupant on this top side. A back rest made of low density foam is
in contact with a supported by the top side of the comfort layer.
The comfort product includes a heat exchanger assembly for
supplying heated or cooled air to the opening in the channel. The
heat exchanger assembly includes an air intake having an intake
fan, and an air conduit having a first end connected to the air
intake and a second end connected to a Peltier circuit heat
exchanger (such as described in U.S. Pat. No. 5,618,167 though any
configuration of a Peltier circuit could work) for selectively
heating or cooling air flowing through the heat exchanger resulting
in selectively heated or cooled supply air and exhaust air. The
intake fan forces air through the air conduit and into Peltier
circuit heat exchanger where some of the air is selectively heated
or cooled to be supplied to the comfort product though an air
supply tube and some air is used as exhaust air (to remove the
unwanted heat if the supplied air is cooled or to warm the exhaust
side of the heat exchanger if the supply air is warmed.) vented
through the exhaust vent. The air supply tube connects to the
opening in the channel layer to supply the selectively heated or
cooled supply air to the channels in the channel layer. The
selectively heated or cooled supply air then moves through the
engineered distribution layer where the numerous small holes
diffuse the air and then the selectively heated or cooled air then
moves through the comfort layer where the air is further diffused
and where the selectively heated or cooled air can selectively heat
or cool an occupant of the comfort product.
[0011] In still yet another preferred embodiment of the present
invention there is a process to manufacture a comfort product
having means to distribute temperature conditioned air through the
comfort product. In this process a support layer is die cut from
high density foam or low density foam to form a structure having a
top. A channel layer is die cut from high density foam to form a
structure having a top, bottom and at least one side and the top of
the channel layer has channels formed therein. An engineered
distribution layer is die cut from fiber paper or low density foam
to form a structure having a top and a bottom with the engineered
distribution layer has holes formed to allow the passage of air
from the bottom side of the engineered distribution layer to the
top side of the engineered distribution layer. A comfort layer of
such size and shape to receive and support an occupant of the
comfort product is die cut from low density foam or is made of
blown fiber collected in a bag to form a structure having a top
side and a bottom side. The bottom side of the channel layer is
glued to the top side of the support layer using foam glue so that
the channel layer is in contact with and supported by the support
layer. The bottom side of the engineered distribution layer is
glued to the top side of the channel layer using foam glue so that
the engineered distribution layer is in contact with and supported
by the channel layer. The bottom side of the comfort layer is glued
to the top side of the engineered distribution layer using foam
glue so that the comfort layer is in contact with and supported by
the engineered distribution layer. A heat exchanger assembly is
connected to the channels of the channel layer to force selectively
heated or cooled air through the channels, up through the holes in
the engineered distribution layer where the air is diffused and
through the comfort layer where the air is further diffused to heat
or cool the top of the comfort layer.
[0012] Other advantages and embodiments of the present invention
will become more apparent from the following detailed description
read in conjunction with the accompanying drawings.
[0013] Other applications of the present invention will become
apparent to those skilled in the art when the following description
of the best mode contemplated for practicing the invention is read
in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The description herein makes reference to the accompanying
drawings wherein like reference numerals refer to like parts
throughout the several views, and wherein:
[0015] FIG. 1 is a perspective view of the improved comfort product
of the present invention showing the human bed embodiment.
[0016] FIG. 2 is a perspective view of the improved comfort product
of the present invention showing the pet bed embodiment.
[0017] FIG. 3 is an exploded perspective view of the pet bed
embodiment of the improved comfort product of the present
invention.
[0018] FIG. 4 is a perspective view of the channel layer showing a
spiral channel that extends though the entire height of the channel
layer.
[0019] FIG. 5 is a perspective view of the channel layer showing a
vein-like channel structure where at least one channel can connect
to a channel of a similar comfort product.
[0020] FIG. 6 is perspective view of the engineered distribution
layer.
[0021] FIG. 7 is a perspective view of the heat exchanger assembly
showing a view of from a perspective external to the comfort
product.
[0022] FIG. 8 is a perspective view of the heat exchanger assembly
showing a partial sectional view from a perspective internal to the
comfort product.
[0023] FIG. 9 is side view of the comfort product showing the heat
exchanger assembly fitted into the comfort product.
[0024] FIG. 10 is a perspective view of the comfort product showing
the heat exchanger assembly external to the rest of the comfort
product.
[0025] FIG. 11 is a sectional view of the comfort product showing
the direction of air travel in through the heat exchanger assembly
and out through the comfort layer.
[0026] FIG. 12 is a top view of the improved comfort product of the
present invention showing the human bed embodiment connected to
another improved comfort product of the present invention showing
the human bed embodiment.
[0027] FIG. 13 is a schematic of a Peltier circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The following descriptions are of exemplary embodiments
only, and are not intended to limit the scope, application of
configuration of the invention in any way. Rather, the following
descriptions provide a convenient illustration for implementing
exemplary embodiments of the invention. Various changes to the
described embodiments may be made in the function and arrangement
of the elements described without departing from the scope of the
invention as set for in the claims. Referring to FIGS. 1, there is
shown an improved structure of a comfort product 10 having means to
distribute temperature conditioned air 20 through the comfort
product 10. The comfort product 10 has a support layer 30, a
channel layer 40, an engineered distribution layer 60 and a comfort
layer 70. In addition the comfort product 10 has a heat exchanger
assembly 80 to selectively heat or cool air 20 and to provide this
selectively heated or cooled air 20 to the comfort product 10.
[0029] The support layer 30 is made of either a high density foam,
preferably polyurethane though it can be of any high density foam
material, or of a low density foam such as polyurethane foam. The
high density foam provides a stronger base and the low density foam
acts to absorb shocks and vibrations to the comfort product. Either
material can be used based on the final design needs of the comfort
product. The material of the support layer is preferably die cut to
make it easier to mass produce the support layer 30 and thereby
reduce costs. In one preferred embodiment of the present invention
the support layer 30 is a generally rectangular shape with a top
32, a bottom 34, and sides 36 though the support layer does not
need to be this exact shape.
[0030] The channel layer 40 is also made of a high density air
impermeable foam, preferably polyurethane though again it can be of
any high density foam material. This material is also preferably
die cut to make it easier to mass produce the channel layer 40 and
thereby reduce costs. The channel layer 40 has a top 42, a bottom
44, and at least one lateral side 46 though the channel layer can
have more than one lateral side 46. The channel layer 40 does not
need to be rectangular, though it should be generally the same size
and shape (from a top or bottom view) as the support layer 30.
[0031] The channel layer 40 has channels 50 through which air 20
can flow. These channels 50 can take many forms. One preferred
embodiment of the channels is a spiral shape 52 as shown in FIG. 4.
Another preferred embodiment is a vein-like shape 54 as shown in
FIG. 5. If the support layer 30 is made of a high density, air
impermeable foam the channels 50 can either extend all the way from
the top of the channel layer 42 to the bottom of the channel layer
44 as in FIG. 4 or the channels 50 can be grooves in the top of the
channel layer 42 that do not extend through to the bottom of the
channel layer, as in FIG. 5. If the support layer 30 is made of low
density foam that is air permeable the channels 50 should be
grooves in the top of the channel layer 42 that do not extend
through to the bottom of the channel layer, as in FIG. 5, so air
forced through the channels does not exit through the support layer
20. At least one part of the channels 50 should have an opening 56
connecting to the heat exchanger assembly 80. This opening 56 can
either be in a lateral side of the channel layer 46, as shown in
FIG. 4, or may be in the bottom of the channel layer 44, as shown
in FIG. 5. The channels 50 can also have one or more connection
openings 58 in one of the lateral sides of the channel layer 46, as
shown in FIG. 12. These connection openings 58 can either be closed
off with a plug 59 or can be open and connected to connection
openings 58b in channels 50b of an adjacent improved comfort
product 10b of the present invention.
[0032] The engineered distribution layer 60 is made of either fiber
paper or low density foam, such as a thin sheet of layered fiber
material or polyurethane foam. The engineered distribution layer 60
has holes 62 which allow the passage of air 20. The scrim 60 may be
air impermeable or may be air permeable as long as the majority of
the air 20 tends to pass through the holes 62. In one preferred
embodiment of the present invention the holes 62a are smallest
nearest the opening 56 (as air would travel along the channels 50)
in the channel layer and grow larger 62b the farther they are from
the opening 56 (again as air would travel along the channels 50) as
shown in FIG. 11. The engineered distribution layer has a top side
64 and a bottom side 66 and is preferably die cut to make it easier
to mass produce the engineered distribution layer 60 and thereby
reduce costs. The engineered distribution layer 60 should be
roughly the same size and shape of the channel layer 40 from a top
perspective and the holes 62 should align with the channels 50 when
assembled.
[0033] The comfort layer 70 can be made of either air permeable low
density foam, preferably layered fiber or polyurethane foam, though
it can be made of any air permeable low density foam material, This
material is also preferably die cut to make it easier to mass
produce the comfort layer 70 and thereby reduce costs. The comfort
layer 70 can also be made of a blown fiber in a bag like in a
pillow. The comfort layer 70 should have a top 72 and a bottom 74.
The comfort layer 70 does not need to be rectangular, though it
should be sized and shaped to be able to support an occupant and
generally the same size and shape (from a top or bottom view) as
the support layer 30, channel layer 50 and engineered distribution
layer 60.
[0034] The comfort product 10 can also include a backrest 76 made
of low density foam, preferably layered fiber or polyurethane foam,
though it can be made of any air permeable low density foam
material, or made of a blown fiber in a bag. In one embodiment,
showing in FIG. 2, the backrest 76 is supported by the top 72 of
the comfort layer 70. In another embodiment, not shown, the
backrest 76 extends down to and is supported by the top 42 of the
channel layer 40. The backrest 76 can take many forms depending on
the use intended for the comfort product. One embodiment, shown in
FIGS. 2 and 3 is a backrest 76 for a pet on the pet bed embodiment.
The backrest 76 can also be a pillow-top attachment 76b to the
human bed embodiment as shown in FIG. 1. The backrest 76 can be a
constant height or can be a varied height, as in FIGS. 2 and 3,
allowing occupants of different sizes to find a comfortable resting
position using the backrest.
[0035] The heat exchanger assembly 80 includes a cover panel 82
with an external side 84 and an internal side 86. The cover panel
82 has an air intake vent 88 and an air exhaust outlet 90 which
allow air 20 to pass through the cover panel 82. The air intake
vent 88 can include an air filter if so desired. An air intake fan
92 is attached to the internal side 86 of the cover panel 82 to
draw air into and force the air through the heat exchanger assembly
80. An enclosed air conduit 94 (shown in the partial sectional view
of FIG. 8) accepts the air 20 from the air intake fan 92 and passes
the air over a Peltier circuit heat exchanger 100.
[0036] A basic design for the Peltier circuit heat exchanger 100 is
shown in a schematic, FIG. 13, and has a set of metal fins forming
supply section 102 and a second set of metal fins forming an
exhaust section 104. In between the supply section 102 and the
exhaust section 104 are two different types of electrical
conductors or semiconductors--such as a P type semiconductor 106
and an N type semiconductor 108. If current flows one direction
through the Peltier circuit heat exchanger 100, shown as I.sub.1 in
FIG. 13, the supply section 102 is heated and the exhaust section
104 is cooled. If current flows the other direction through the
Peltier circuit heat exchanger 100, shown as I.sub.2 in FIG. 13,
then the supply section 102 is cooled and the exhaust section is
heated 104. The Peltier circuit heat exchanger 100 can also include
a thermister to regulate the temperatures of the supply section 102
and exhaust section 104. The present invention is not limited to
this one description of a Peltier heat exchanger as the heat
exchanger circuit of the present invention can be any type of
Peltier heat exchanger circuit.
[0037] When the Peltier circuit heat exchanger 100 is in operation
the supply section 102 accepts air 20 from the air conduit 94 and
either heats or cools the air 20 depending on the direction of
current flow through the Peltier circuit heat exchanger 100. The
supply section then channels this air to an air supply tube 96
which leads to and is connected to the opening 56 in the channel
layer 40 so that the selectively heated or cooled supply air 20a is
forced to flow into the channels 50. At the same time a portion of
the air 20 passes over the exhaust section 104 to equalize the
temperature of the exhaust section 104 and becomes exhaust air 20b.
This exhaust air 20b exits through an exhaust tube 98 and out of
the exhaust vent outlet 90.
[0038] The improved comfort product 10 is assembled so that the
bottom 44 of the channel layer 40 is glued to the top 32 of the
support layer 30 with a foam glue. The bottom side 64 of the
engineered distribution layer 60 is glued in a like manner to the
top 42 of the channel layer 40 in such a way that the holes 62
align with the channels 50 to allow air 20 to pass. The bottom 74
of the comfort layer 70 is glued in a like manner to the top side
62 of the engineered distribution layer 60. Each layer should be
assembled so they generally align themselves with the other layers
from a top or bottom perspective.
[0039] The layered construction and laminated assembly makes the
improved comfort product easier and cheaper to manufacture. Each
separate layer can be die cut out of a larger stock of material
using an automated process. Since the different layers have
different properties they can be made out of different materials as
necessary. The final laminated assembly allows each of these
different materials to work in concert to form the present
invention.
[0040] In one preferred embodiment of the present invention as
shown in FIG. 9 the heat exchanger assembly 80 fits into a recess
110 cut into the support layer 30, channel layer 50 and engineered
distribution layer 60. The cover panel 82 fits into a second
smaller recess 112 cut into the support layer 30, channel layer 50,
engineered distribution layer 60 and comfort layer 70. When
assembled, the heat exchanger assembly is contained by the rest of
the improved comfort product 10 with only the cover panel 82
visible from a top or side perspective. This allows the entire
comfort product, including the heat exchanger, to fit into a
compact area. The cover panel 82 can include a switch 114 allowing
selective heating, cooling or just fan operation of the heat
exchanger assembly 80 as well as an LED indicator 116 to let an
operator know which operation has been selected.
[0041] In another preferred embodiment of the present invention as
shown in FIG. 10 the heat exchanger assembly 80 remains external to
the rest of the comfort product 10. This embodiment allows mounting
of the heat exchanger assembly 80 in a position where the exhaust
air 20b can exit through the exhaust vent 90 at a position removed
from the comfort product 10. This distance could be useful if the
comfort product 10 were mounted in a frame assembly in a small
space, like the sleeping quarters in a semi-truck, where the
exhaust air 20b could negatively affect the temperature of the
surrounding air. In such a situation the heat exchanger assembly 80
could be mounted near a side wall to allow the exhaust air 20 to be
vented directly outside.
[0042] In addition, the present invention can include a pressure
switch 118 preferably mounted between the engineered distribution
layer 60 and the comfort layer 70. This pressure switch 118 can
control whether the heat exchanger assembly 80, including the air
intake fan 92 and circuit heat exchanger 100 are engaged. When the
improved comfort product 10 is used the occupant's weight triggers
the pressure switch 118 which in turn triggers the heat exchanger
assembly 80, including the air intake fan 92 and circuit heat
exchanger 100 to engage.
[0043] When in operation the heat exchanger assembly 80 draws in
air 20. The heat exchanger assembly 80 can selectively heat the air
20, cool the air 20 or can leave the air 20 at the ambient
temperature. The selectively heated or cooled air 20a passes
through the air supply tube 96, though the opening 56 in the
channel layer 40 and into the channels 50. As the air 20 flows
through the channels 50 some air escapes through the holes 62 in
the scrim 60. The air pressure lowers as the air 20 moves through
the channels 50 so the air 20 would tend to flow out faster through
the first holes 62 it encounters if the holes are of equal size. To
ensure an even distribution of airflow through all of the holes 62,
the holes 62a the air 20 first encounters can be smaller in size
than the holes 62b the air 20 encounters farther downstream. In
addition, the width and/or depth of the channels may be varied to
encourage constant air pressure through the channels. Properly
tuned, the airflow through any one hole 62a should be fairly equal
to the airflow through any other hole 62b. The air 20 is further
diffused as it passes up though the comfort layer 70. This process
diffuses the selectively heated or cooled air to provide even
heating or cooling over the entire top side 72 of the comfort layer
of the improved comfort product 10.
[0044] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiment, it is to be understood that the invention is not to be
limited to the disclosed embodiments but, on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the appended claims, which
scope is to be accorded the broadest interpretation so as to
encompass all such modifications and equivalent structures as is
permitted under the law.
* * * * *