U.S. patent application number 16/444740 was filed with the patent office on 2019-12-19 for breathable mattress foundation and sleep system.
The applicant listed for this patent is Neven Sleep, LLC. Invention is credited to Randy A. Reynolds.
Application Number | 20190380501 16/444740 |
Document ID | / |
Family ID | 68838827 |
Filed Date | 2019-12-19 |
View All Diagrams
United States Patent
Application |
20190380501 |
Kind Code |
A1 |
Reynolds; Randy A. |
December 19, 2019 |
BREATHABLE MATTRESS FOUNDATION AND SLEEP SYSTEM
Abstract
Embodiments of a ventilated sleep system and an
airflow/breathable mattress foundation are disclosed, and typically
may be configured to provide ventilation to a mattress, for example
through an upper surface of a foundation allowing airflow
therethrough. Typically, sleep system embodiments may include
mattresses with foam layers with ventilation passageways in fluid
communication with a lower surface of the mattress cover, which is
configured to allow airflow therethrough, and some embodiments may
also include foam pillars. Such sleep system embodiments typically
may have such a ventilation mattress atop such a ventilation
foundation, with airflow therebetween.
Inventors: |
Reynolds; Randy A.; (High
Point, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Neven Sleep, LLC |
Dallas |
TX |
US |
|
|
Family ID: |
68838827 |
Appl. No.: |
16/444740 |
Filed: |
June 18, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62686458 |
Jun 18, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/007 20130101;
A47C 21/048 20130101; A47C 27/148 20130101; A47C 21/044 20130101;
A47C 27/144 20130101; A47C 27/15 20130101 |
International
Class: |
A47C 21/04 20060101
A47C021/04; A47C 27/15 20060101 A47C027/15; A47C 27/00 20060101
A47C027/00; A47C 27/14 20060101 A47C027/14 |
Claims
1. A sleep system comprising: a mattress, which comprises: a
mattress cover; and one or more foam layers within the mattress
cover; wherein the mattress cover comprises a bottom surface;
wherein the bottom surface of the mattress cover comprises a
mattress air permeable element (e.g. high airflow fabric (for
example 150 gsm 100% polyester spacer fabric or mesh fabric and/or
restricting airflow CFM less than about 35% at 3 PSI and/or a
spacer fabric with a thickness of about 3.5 mm, a weight of about
245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))); wherein the
mattress is spring-free; wherein the one or more foam layers each
comprise a plurality of substantially vertical air passageways
which pass through the entire thickness of the corresponding foam
layer; wherein the one or more foam layers comprise: a base layer
of foam comprising a sculpted upper surface with a plurality of
foam pillars projecting upward; a transition layer of foam with
uniform thickness located atop and in contact with the upper
surface of the base foam layer; a middle sculpted layer of foam
having a sculpted lower surface with a plurality of foam pillars
projecting downward, wherein the middle sculpted layer of foam is
located atop and in contact with the transition layer of foam; and
a top layer of foam with uniform thickness, which is located above
the middle sculpted layer; and a mattress foundation, which
comprises: a support structure; and a foundation cover comprising
an upper surface; wherein the upper surface of the foundation cover
comprises a foundation air permeable element (e.g. high airflow
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))); and wherein the
mattress is located atop the foundation, and wherein the mattress
and foundation are in fluid communication with each other.
2. The sleep system of claim 1, wherein the middle sculpted layer
of foam further comprises a sculpted upper surface with a plurality
of foam pillars projecting upward; and wherein the foam pillars of
the middle sculpted layer of foam are sized within the range
including 1-to-1-4-to-1 with respect to the foam pillars of the
base layer of foam (such that the foam pillars of the middle
sculpted foam layer each range in cross-section size from being
equally sized to the base layer pillars down to being a quarter the
size of the base layer pillars (i.e. four middle sculpted layer
pillars per one base layer pillar)).
3. A sleep system comprising a mattress, which comprises: a cover;
wherein the cover comprises a bottom surface, and wherein the
bottom surface comprises an air permeable element (e.g. high
airflow fabric (for example 150 gsm 100% polyester spacer fabric or
mesh fabric and/or restricting airflow CFM less than about 35% at 3
PSI and/or a spacer fabric with a thickness of about 3.5 mm, a
weight of about 245 g/m.sup.2, and/or an air permeability of about
636 ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard
Test Method for Air Permeability of Textile Fabrics))).
4. The sleep system of claim 3, wherein the entire bottom surface
of the mattress cover is formed of high airflow mesh fabric.
5. The sleep system of claim 3, wherein the mattress cover further
comprises an upper surface, and wherein the upper surface comprises
a second air permeable element (e.g. high airflow fabric (for
example 150 gsm 100% polyester spacer fabric or mesh fabric and/or
restricting airflow CFM less than about 35% at 3 PSI and/or a
spacer fabric with a thickness of about 3.5 mm, a weight of about
245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))).
6. The sleep system of claim 3, wherein the mattress further
comprises one or more foam layers within the mattress cover. The
sleep system of claim 6, wherein the mattress is spring-free.
8. The sleep system of claim 6, wherein the one or more foam layers
(or in some embodiments, all foam layers) each comprise a plurality
of substantially vertical air passageways.
9. The sleep system of claim 8, wherein the one or more foam layers
comprise: a base layer of foam comprising a sculpted upper surface
with a plurality of foam pillars projecting upward; a transition
layer of foam with uniform thickness located atop and in contact
with the upper surface of the base foam layer; a middle sculpted
layer of foam having a sculpted lower surface with a plurality of
foam pillars projecting downward, wherein the middle sculpted layer
of foam is located atop and in contact with the transition layer of
foam; and a top layer of foam with uniform thickness, which is
located above the middle sculpted layer.
10. The sleep system of claim 9, wherein the middle sculpted layer
of foam further comprises a sculpted upper surface with a plurality
of foam pillars projecting upward.
11. The sleep system of claim 10, wherein the sculpted upper
surface of the middle sculpted layer of foam comprises pillars of a
different size than the sculpted lower surface of the middle
sculpted layer of foam.
12. The sleep system of claim 10, wherein the foam pillars of the
sculpted upper surface of the middle sculpted layer are a quarter
of the size of the corresponding pillars of the sculpted lower
layer of the middle sculpted layer of foam.
13. The sleep system of claim 9, wherein the foam pillars of the
middle sculpted layer of foam are sized within the range including
1-to-1-4-to-1 with respect to the foam pillars of the base layer of
foam (such that the foam pillars of the middle sculpted foam layer
each range in cross-section size from being equally sized to the
base layer pillars down to being a quarter the size of the base
layer pillars (i.e. four middle sculpted layer pillars per one base
layer pillar)).
14. The sleep system of claim 9, wherein the one or more foam
layers further comprises a penultimate foam layer with uniform
thickness located atop and in contact with the middle sculpted
layer and beneath and in contact with the top layer of foam.
15. The sleep system of claim 9, wherein at least some of the
substantially vertical air passageways in the foam layers align to
provide continuous airflow paths from the bottom surface of the
mattress to an upper surface of the mattress.
16. The sleep system of claim 3, further comprising a mattress
foundation, which comprises: a support structure; and a cover
comprising an upper surface, and wherein the upper surface of the
foundation cover comprises a foundation air permeable element (e.g.
high airflow fabric (for example 150 gsm 100% polyester spacer
fabric or mesh fabric and/or restricting airflow CFM less than
about 35% at 3 PSI and/or a spacer fabric with a thickness of about
3.5 mm, a weight of about 245 g/m.sup.2, and/or an air permeability
of about 636 ft3/ft2/minute at 0.018 PSI (e.g. per ASTM
D737-96--Standard Test Method for Air Permeability of Textile
Fabrics) and/or the entire upper surface comprises such high
airflow fabric)); wherein the mattress is located atop the
foundation and wherein the mattress and foundation are in fluid
communication with each other.
17. The sleep system of claim 16, wherein the foundation cover
further comprises a port and/or a second foundation air permeable
element (e.g. high airflow fabric (for example 150 gsm 100%
polyester spacer fabric or mesh fabric and/or restricting airflow
CFM less than about 35% at 3 PSI and/or a spacer fabric with a
thickness of about 3.5 mm, a weight of about 245 g/m.sup.2, and/or
an air permeability of about 636 ft3/ft2/minute at 0.018 PSI (e.g.
per ASTM D737-96--Standard Test Method for Air Permeability of
Textile Fabrics) and/or Polyester Non-Woven Fabric with a thickness
of about 0.004 mm and/or a weight of about 1.5 oz./ft.sup.2), for
example located on the lower surface of the foundation cover) for
fluid communication of the foundation with the outside
environment.
18. The sleep system of claim 17, further comprising an airflow
unit (operable to provide forced air flow through the foundation),
wherein the air flow unit is located within the support structure
and cover of the foundation.
19. The sleep system of claim 18, wherein the air flow unit
comprises filtration.
20. The sleep system of claim 18, wherein the air flow unit
comprises a climate control unit operable to cool or heat air.
21. The sleep system of claim 8, wherein the one or more foam
layers comprise two sculpted foam layers, each comprising a
sculpted surface with a plurality of foam pillars.
22. The sleep system of claim 21, wherein the two sculpted foam
layers comprise a lower sculpted foam layer with sculpted surface
facing upward; and an upper sculpted foam layer with sculpted
surface facing downward.
23. The sleep system of claim 22, wherein the upper sculpted foam
layer further comprises a second sculpted surface facing upward.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional of and claims priority
to related U.S. provisional patent application Ser. No. 62/686,458
filed Jun. 18, 2018 entitled "Breathable Mattress Foundation and
Sleep System".
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present disclosure,
reference is now made to the following brief description, taken in
connection with the accompanying drawings and detailed description,
wherein like reference numerals represent like parts.
[0005] FIG. 1A is a schematic diagram illustrating an exemplary
sleep/bedding system, in which a mattress may be used atop one of
two possible ventilating foundation exemplary variants;
[0006] FIG. 1B is a schematic diagram illustrating an alternate
exemplary sleep/bedding system, in which a mattress may be used
atop one of two possible ventilating foundation exemplary
variants;
[0007] FIGS. 1Ca, 1Cb and 1Cc illustrate a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
internal air input unit with optional HEPA filter and an access
panel, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view (from the foot of the bed), and FIG. 1Cc showing a top
view;
[0008] FIGS. 1Da, 1Db and 1Dc illustrate a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
external air input unit with optional HEPA filter and an access
panel, with FIG. 1Da showing a side view, FIG. 1Db showing an end
view (from the foot of the bed), and FIG. 1Dc showing a top
view;
[0009] FIG. 1E illustrates a perspective view of an exemplary
sleep/bedding system similar to FIGS. 1Ca, 1Cb and Cc;
[0010] FIGS. 2A1 and 2A2 illustrate an exemplary mattress
embodiment (without the cover being shown, to allow viewing of
internal components) which is an all-foam (e.g. spring-free)
mattress configured for ventilation, with FIG. 2A1 showing an
exploded perspective view of an exemplary mattress and FIG. 2A2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2A1;
[0011] FIGS. 2B1 and 2B2 illustrate an exemplary mattress
embodiment (similar to that of FIG. 2A1 in configuration, but
comprising different foam materials for at least some of the
layers) configured for ventilation, with FIG. 2B1 showing an
exploded perspective view of an exemplary mattress and FIG. 2B2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2B1;
[0012] FIG. 3 illustrates a top/plan view of an exemplary base
(sculpted) layer of foam (of the sort that might be used in FIG.
2A1, for example);
[0013] FIG. 4 illustrates a bottom/plan view of an exemplary middle
sculpted foam layer (of the sort that might be used in FIG. 2A1,
for example);
[0014] FIGS. 5A and 5B illustrate exemplary mattress embodiments
configured for ventilation;
[0015] FIGS. 6A and 6B illustrate detailed views of the middle
sculpted foam layers;
[0016] FIGS. 7A and 7B illustrate alternative detailed views of the
middle sculpted foam layers;
[0017] FIG. 8 illustrates an exemplary base foam layer similar to
that shown and described in FIG. 3; and
[0018] FIG. 9 illustrates via a schematic cross-section diagram an
exemplary sleep system having a ventilation mattress atop an
airflow/breathable (e.g. ventilation) foundation.
DETAILED DESCRIPTION
[0019] It should be understood at the outset that although
illustrative implementations of one or more embodiments are
illustrated below, the disclosed systems and methods may be
implemented using any number of techniques, whether currently known
or not yet in existence. The disclosure should in no way be limited
to the illustrative implementations, drawings, and techniques
illustrated below, but may be modified within the scope of the
appended claims along with their full scope of equivalents.
[0020] The following brief definition of terms shall apply
throughout the application:
[0021] The term "comprising" means including but not limited to,
and should be interpreted in the manner it is typically used in the
patent context.
[0022] The term "foam" means a material in a lightweight cellular
form, for example resulting from introduction of gas bubbles during
manufacture to produce a consistent cell structure, and/or any of
various light, porous, semirigid or spongy materials or cellular
solids, usually the solidified form of a liquid full of gas
bubbles, which may be used as a building material or for shock
absorption, and includes open cell foams such as polyurethane foam,
latex, memory foam, specialty memory foam, gel memory foam, gel
latex foam or other gel foams, etc.;
[0023] The term "IFD" means indentation force deflection, and
describes a well-known measurement system for foam firmness;
[0024] Directions, such as up (e.g. upward) and/or down (e.g.
downward), typically are intended to be based on the mattress (or
sleep system or foundation) in its normal sleeping position as
understood by persons of skill; for example, the upper surface of
the mattress might face the ceiling and/or serve as the sleep
surface upon which the user might lie, while the bottom surface of
the mattress might face the floor or ground and/or be placed atop a
foundation;
[0025] The phrases "in one embodiment," "according to one
embodiment," and the like generally mean that the particular
feature, structure or characteristic following the phrase may be
included in at least one embodiment of the present invention, and
may be included in more than one embodiment of the present
invention (importantly, such phrases do not necessarily refer to
the same embodiment);
[0026] If the specification describes something as "exemplary" or
as an "example," it should be understood that refers to a
non-exclusive example:
[0027] The terms "about" or "approximately" or the like, when used
with a number may mean that specific number, or alternatively, a
range in proximity to the specific number, as understood by persons
of skill in the art field (for example, +/-10%); and
[0028] If the specification states a component or feature "may,"
"can," "could," "should," "would," "preferably," "possibly,"
"typically," "optionally," "for example," "often," or "might" (or
other such language) be included or have a characteristic, that
particular component or feature is not required to be included or
have the characteristic. Such component or feature may be
optionally included in some embodiments, or it may be excluded.
[0029] Typical sleep or bedding systems may have a conventional
(typically inner-spring) mattress located atop a conventional box
spring foundation unit. In such conventional sleep systems, there
is typically no interaction (e.g. airflow) between the mattress and
the box spring foundation, other than the fact that the box spring
foundation supports (e.g. underlies) the mattress. While
conventional sleep systems may be sufficient for some
sleepers/users, many users might desire and are looking for an
improved sleep experience.
[0030] For example, many users might find conventional sleep
systems rather hot (especially when the mattress includes foam, and
most especially when the mattress includes memory foam), resulting
in a rather sweaty, uncomfortable night's sleep of the sort that
may result in restlessness and lack of deep slumber. Other users
may have allergy problems, and a conventional mattress may, over
time, collect dust and other allergens that might trouble the user
during sleep. Additionally, conventional inner-spring mattresses
may not support the user's body as effectively as desired, perhaps
resulting in discomfort.
[0031] The presently disclosed embodiments may address one or more
of these issues. For example, disclosed embodiments may provide
ventilation (e.g. airflow), such that the mattress may better
breathe and/or disperse heat (e.g. improving sleep comfort while a
user is atop the mattress); disclosed embodiments may refresh the
mattress, for example sucking out stale air with potential
allergens (which could happen either when the user is atop the
mattress or, alternatively, when the user is not on the mattress
(for example, based on a timer)); and/or disclosed embodiments may
provide superior comfort/support. Typically, disclosed embodiment
sleep systems might have the mattress and foundation interact with
each other (for example, being in fluid communication, for example
fluid communication between the interior of the foundation and the
interior of the mattress through the upper surface of the
foundation and the lower surface of the mattress), to provide one
or more such sleep benefits, as persons of skill will understand
based on the disclosure below. Typical foundation embodiments might
comprise an upper surface (of a cover) allowing airflow
therethrough (and in some embodiments having an air flow unit (such
as a fan or air pump) operable to direct air through the upper
surface), while typical mattress embodiments might comprise a
bottom surface (of a cover) (and in some embodiments a top surface
of the cover) allowing airflow therethrough (and often also
including air/ventilation pathways (such as pinholes) vertically
throughout the mattress (for example, through an all foam mattress
or through the foam layers of the mattress)). Some mattress
embodiments might be configured to provide a billows effect (which
may drive airflow within the mattress and/or between the mattress
interior and the foundation). So, most disclosed sleep system
embodiments typically might have a ventilation mattress (e.g. with
a lower surface configured to allow airflow therethrough) atop a
ventilation foundation (e.g. with an upper surface configured to
allow airflow therethrough, which can also be termed an airflow
mattress foundation), with airflow therebetween. In some
embodiments, the foundation (e.g. via an air flow unit) or the
mattress (e.g. via a billows effect, in which movement of the user
atop the mattress causes air movement within the mattress that
might drive airflow between the mattress and the corresponding
foundation) might be configured to direct airflow therebetween.
[0032] Disclosed embodiments relate generally to mattress
ventilation sleep systems (and/or related foundations and/or
mattresses), which typically would include a mattress
ventilation/breathable foundation (e.g. an airflow foundation) in
conjunction with a mattress (for example, typically located atop
the foundation and typically a ventilation mattress). Typically,
the mattress ventilation/breathable foundation might comprise a
support structure (such as support struts and structural frame, for
example, which might be similar to a conventional box spring or
mattress foundation), operable to support a mattress in a manner
similar to a conventional mattress foundation (and which typically
might be substantially hollow, for example with an open hollow
cavity located between the side frame supports and the upper and
lower surface slats/struts (and in some embodiments, for example
depending on mattress size, one or more interior structural
supports (e.g. beam(s)) spanning from one side of the frame to
another and/or from the upper surface slats to the lower surface
slats of the foundation)); and a cover (including an upper, support
surface upon which the mattress would lay), which would typically
include a means for airflow between the foundation and the
supported mattress (e.g. an air permeable element/panel, such as
one or more panels of high air flow fabric, which could be spacer
fabric or mesh fabric, located in the upper surface of the
foundation cover, for example). Some embodiments might optionally
also include an air flow unit for the foundation (such as a forced
air supply unit (e.g. fan) operable to either blow air into the
supported mattress atop the foundation or suck air from the
supported mattress). In some embodiments, such an air flow unit
might include filtration (such as a HEPA filter), which might for
example be located at the intake and/or outtake for the air flow
unit. The air flow unit might be housed within the support
structure of the foundation in some embodiments, while in other
embodiments the air flow unit might be external to (for example,
mounted onto) the support structure (for example, mounted onto the
bottom surface of the cover/support structure and in fluid
communication with the hollow cavity within the cover/support
structure by an opening). For embodiments without an air flow unit,
a ventilation mattress configured to provide billows effect might
optionally be used atop the ventilation foundation, with the
billows effect driving and/or enhancing airflow between the
ventilation mattress and the ventilation (e.g. airflow) foundation
(although other embodiments could use the billows effect in
conjunction with an air flow unit).
[0033] Typically, the foundation cover would
surround/enclose/encompass the support structure on all sides, and
would include a means for airflow between the foundation and the
supported mattress (e.g. air permeable element/panel, such as high
airflow fabric, which could be spacer or mesh fabric, panel(s)) on
at least the upper surface of the cover (e.g. the surface which is
configured to support the mattress). Optionally, the lower surface
of the cover (e.g. forming the underside of the foundation) would
also include a similar means for airflow (e.g. between the
foundation and the external atmosphere) (e.g. air permeable
element/panel, such as high airflow fabric, which could be spacer
fabric or mesh fabric, panel(s)). Alternatively, the cover may have
some other means for airflow into the hollow cavity and/or interior
of the foundation from the external environment (such as ports,
vents, or other inlet(s) and/or similar means for airflow (e.g. air
permeable element/panel, such as high airflow fabric, which could
be spacer fabric or mesh fabric, panel(s)) on the sides and/or the
use of breathable material for one or more portions of the cover
other than the upper surface (e.g. a fabric material that is
breathable, even if less so than a high airflow fabric panel, for
example with the difference in sizing allowing for adequate
airflow). In some embodiments, such high airflow fabric, which
could be spacer fabric or mesh fabric, panel(s) may comprise spacer
mesh/knit fabric, for example configured to restrict airflow CFM
less than about 35% at 3 psi. In some embodiments, such high
airflow fabric (which could be spacer fabric or mesh fabric) panels
may be (inherently) fire resistant (FR--e.g. meeting US Federal
Std. 1633) and/or could be treated to be FR (e.g. with a spray-on
FR additive). For example, the high airflow fabric could be spacer
fabric and/or could have a thickness of about 3.5 mm, a weight of
about 245 g/m2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI.
[0034] In other embodiments (for example, using an airflow unit)
the foundation cover might be airtight/air impermeable (e.g. formed
of an airtight material such as fabric overtop a polyvinyl
substrate, for example) except for the attachment/fluid
communication port (e.g. inlet/outlet/opening) for the air flow
unit (which allows fluid communication between the external
environment and the hollow cavity within the foundation, for
example) and the means for airflow between the foundation and the
supported mattress (e.g. air permeable element/panel, such as high
airflow fabric, which could be spacer fabric or mesh fabric,
panel(s)). For example, the bottom and side surfaces of the
foundation cover would typically be airtight (except for the
inlet/outlet/opening for the air flow unit), while the upper
surface of the foundation cover (which would typically support
and/or contact the bottom surface of the mattress) would include
the means for airflow between the foundation (e.g. the air flow
unit) and the supported mattress (e.g. at least one air permeable
element/panel, such as one or more panels of high air flow fabric,
which could be spacer fabric or mesh fabric, located in the upper
surface of the foundation cover, for example). In some embodiments,
the entire upper surface of the foundation cover might be formed of
high airflow fabric, while in other embodiments, the upper surface
might include a plurality of panels of such high airflow fabric
and/or other means for allowing airflow between the foundation and
the supported mattress (such as air passageways).
[0035] Typically, air might flow through the hollow cavity of the
foundation to the upper surface of the foundation cover (as
directed by the air flow unit and/or billows effect, for example),
but alternatively, there could be tubing or ducts leading from the
air flow unit and/or air entry means (such as the airflow means on
the lower surface of the foundation) to the upper surface of the
foundation cover (e.g. to specific locations on the upper surface
of the foundation cover corresponding to the pinholes in the
supported mattress thereupon). In such embodiments, it might not be
necessary for the bottom and sides of the foundation cover to be
airtight.
[0036] Additionally, some embodiments of the air flow unit might
optionally comprise a climate control unit, which might cool and/or
heat air flowing through the air flow unit (for example, before the
air flows into the supported mattress atop the foundation). In some
embodiments, the climate control unit would be located within the
housing for the air flow unit, while in other embodiments, the
climate control unit might be located external to such housing
(e.g. it may be either separate or combined with the blower portion
of the air flow unit). Similarly, embodiments of the air flow unit
might optionally comprise an air ionizer (for electric
sterilization of air prior to entering the foundation) and/or an
ultraviolet germicidal irradiation light (for irradiating light
sufficiently to substantially destroy harmful microbes, such as
bacteria, prior to entering the foundation). As with the optional
climate control unit, the air ionizer and/or UV germicidal
irradiation light units could be located within the housing for the
air flow unit or (in other embodiments) located external to such
housing (e.g. each may be either separate or combined with the
blower portion of the air flow unit). Typically, the air flow unit
might be controlled/operated by a controller, which might be a
separate device and which might allow for remote control of the air
flow device (e.g. the blower and/or climate control unit). In some
embodiments, the controller and/or air flow unit may include a
timer, for example allowing the user to set the air flow unit for a
regular (for example daily or weekly) refresh cycle. And typically,
the air flow unit would be electrically powered (for example with a
plug allowing power to be drawn from a standard electrical wall
socket).
[0037] Without being held to any theory, Applicant believes that
airflow through some ventilation mattresses and/or sleep systems
may be improved based on a billows effect. For example, ventilation
passageways in the mattress in fluid communication with the lower
surface of the ventilation mattress (which typically has an airflow
means, such as high airflow fabric (such as spacer fabric or mesh
fabric)) may open and/or close based on movement of the user atop
the mattress, such that the user's natural body movements while
laying atop the mattress may provide a billows effect that
draws/sucks air in and/or expels/blows air out of the mattress via
such ventilation passageways (e.g. vertical pinholes)). The billows
effect could arise from mattresses with horizontal ventilation
passageways and/or vertical ventilation passageways. For example,
air might be blown out of some vertical ventilation passageways
(e.g. vertical pinholes) and sucked into other vertical ventilation
passageways (e.g. vertical pinholes), based on air pressure
gradients caused by the user's natural body movements atop the
mattress (for example, foam in the mattress surrounding the
ventilation passageways may compress when a user's body weight acts
upon the mattress, such that user movement atop the mattress may
provide a billows effect). In this way, the billows effect of such
ventilation mattresses may improve air circulation through the
mattress (especially when used with a ventilation foundation and/or
when the vertical ventilation passageways are in fluid
communication with the air flow means (e.g. high airflow mesh
fabric)), which may in turn also provide cooling and/or evaporation
benefits that could lead to a more comfortable sleep surface. The
ventilation mattress exemplary embodiments described herein may,
for example, provide such billows effect.
[0038] So typically in operation, air might be drawn into the
foundation (for example by the air flow unit, through the intake
opening/fluid communication port, and/or billows effect of a
ventilation mattress through and/or air entry means (such as the
airflow means on the lower surface of the foundation)), and then
forced out the upper surface (for example through a high airflow
fabric upper surface or panel(s)) and into the supported mattress.
This may allow for a supported mattress to be refreshed with clean
air and/or may enhance sleep comfort for a user lying atop the
mattress. Alternatively, air might be sucked out of the supported
mattress (for example by operating the air flow unit in reverse to
create suction and/or billows effect), into the foundation (for
example through the upper surface of the cover of the foundation,
perhaps through one or more high air flow fabric panels), and out
the air flow unit's outtake opening/fluid communication port (which
might be the same intake opening if the air flow device is operated
for blowing instead of suction in some embodiments) and/or air
entry/exit means (such as the airflow means on the lower surface of
the foundation). In some embodiments, the air flow unit might be
operable to run in forward (e.g. blowing mode) and/or reverse (e.g.
suction mode). So in some embodiments, the air flow unit might be
run in reverse (for example, suction mode to suck air from the
supported mattress) to refresh the mattress (e.g. a refresh cycle,
which in some embodiments might be periodically run), while the air
flow unit might be run in forward (for example, blowing mode to
blow fresh (e.g. filtered) and/or climate controlled (e.g. cooled
or heated) and/or ionized and/or UV sanitized air into the
supported mattress) to enhance sleep comfort atop the supported
mattress (for example, improving allergy conditions and/or
temperature and/or airflow for the user atop the supported
mattress, perhaps while the user is actually lying atop/sleeping on
the mattress). For sleep systems with a ventilation mattress
configured for billows effect, movement of the user atop the
mattress may pump air into and/or out of the mattress through the
lower surface of the mattress cover (with airflow means, such as
high airflow fabric) and/or the ventilation/breathable (e.g.
airflow) foundation (for example, through the upper surface of the
foundation with airflow means, such as high airflow fabric (which
could be spacer fabric or mesh fabric and/or could be the same as
the high airflow fabric of the mattress cover), into the hollow
cavity of the foundation, and/or through the lower surface of the
foundation (e.g. airflow means, such as high airflow fabric),
allowing for airflow between the ventilation mattress and the
ventilation foundation.
[0039] While it is possible that any sort of mattress might be used
to some advantage atop such a ventilation/breathable (e.g. airflow)
foundation, more typically specialized airflow (e.g. ventilation)
mattress embodiments might be used in conjunction with the
disclosed foundation embodiments (and in some embodiments, such
ventilation mattresses might be configured to provide billows
effect). For example, the mattress might comprise a mattress cover
having a bottom surface which includes a means for airflow between
the foundation and the supported mattress (e.g. into and/or out of
the mattress, for example at least one air permeable
element/panel). For example, in some embodiments the bottom surface
of the mattress cover might be formed of or include one or more
panels of high airflow fabric, which could be spacer fabric or mesh
fabric (or alternatively, the bottom surface of the mattress cover
might include air passageways, which might correspond to those of
the upper surface of the foundation cover). In some embodiments,
the top surface of the mattress cover might also comprise an air
permeable element/panel or other means of airflow into/out of the
mattress (e.g. high airflow fabric (such as spacer fabric or mesh
fabric) or loosely woven fabric panel(s)). And in some embodiments,
the remainder of the mattress cover might be (substantially) air
impermeable. Furthermore, the mattress might comprise one or more
(and typically a plurality of) primarily vertical air
pathways/passageways (e.g. pin holes), operable to allow air flow
vertically throughout the mattress (for example from the bottom of
the mattress to the top of the mattress). Some mattress embodiments
might also comprise horizontal ventilation passageways. In some
embodiments, the mattress might be an all-foam and/or spring-free
mattress. For example, the mattress might be formed entirely of
layers of foam, and each layer of foam might include vertical pin
holes/vertical passageways/pathways, at least some of which align
and/or are in fluid communication, for example to provide
continuous airflow passages/pathways/pinholes vertically throughout
the mattress (although in some embodiments, fluid communication
between vertical passageways in different foam layers might be via
horizontal channels/passageways).
[0040] Some such mattress embodiments might include one or more
foam layers having a sculpted surface with a plurality of foam
pillars. For example, some embodiments might have a base layer of
foam (e.g. the bottom layer of foam) with an upward facing sculpted
surface (e.g. the pillars of foam facing/projecting upward), and
another layer of foam (typically a middle foam layer, located
somewhere between the base foam layer and the uppermost (sleep
surface) layer of foam) with a downward facing sculpted surface
(e.g. the pillars of foam facing/projecting downward). Typically,
the sculpted foam layers would each have scoring (e.g. a series of
grooves/gaps) forming a grid on one surface (termed the sculpted
surface), with the grid pattern resulting in a plurality of foam
pillars projecting outward from a common, unified slab/base of foam
(e.g. the surface opposite the sculpted surface typically would be
flat, such that the foam pillars would all be joined together into
an integral whole layer at their bases/bottoms). The sculpted foam
layer(s) might effectively replace the support functionality of the
springs while also often providing added benefits. For example, a
sculpted foam surface (e.g. foam pillars) may provide more
flexibility in adjusting to various body contours than metal
springs, and therefore may be more effective in reducing pressure
points against the human body than traditional metal springs in
conventional mattresses. More specifically, the layer(s) of foam
with a sculpted surface would typically include a plurality of foam
pillars (or blocks), each of which is freestanding (e.g.
independent) with respect to the other pillars, but all of which
are joined together into a single integral base (which typically
has a flat exterior surface). So, the base portion of the pillars
are all joined together (e.g. a common base), while the remaining
freestanding portion of the layer of foam comprises a plurality of
independent pillars separated from one another by a gap or groove
on all sides. Stated another way, the sculpted layer(s) of foam may
comprise each a base portion (which typically is a uniform flat
sheet of foam) and a pillar portion (which typically comprises a
plurality of independent pillars or blocks of foam, each of which
is completely separate from the other pillars), with the pillar
portion being securely attached to a surface of the base portion
(so in effect the pillars project out from the flat base portion).
Thus, the sculpted surface of the sculpted layer of foam would
typically be the distal surface of the pillars (or pillar portion).
Typically, the sculpted layer of foam may be formed by cutting a
pattern of grooves in one surface (which would then become the
sculpted surface) of an initially uniform (e.g. flat sheet with
constant thickness) sheet of foam, thereby forming a plurality of
foam pillars which extend out from the base portion (with the
pillar portion and the base portion integrally forming a single
layer of foam having different shapes/characteristics on opposing
sides). Thus, the sculpted layer of foam might also be termed a
contour cut layer of foam in some embodiments (since in many
embodiments the layer of foam is sculpted via cutting, for example
contour cutting). In other embodiments, it may be possible to form
the sculpted layer of foam by molding (with the mold forming the
pillar portion projecting outward from the base portion).
Typically, the substantially one entire surface of the sculpted
foam layer (e.g. the entire sculpted surface) would be entirely
comprised of such pillars (e.g. substantially the entire sculpted
surface of the sculpted foam layer would be formed of pillars),
although in other embodiments the sculpted surface might have
pillars only on a portion of the sculpted surface.
[0041] Typical mattress embodiments might have vertical pin holes
passing through (at least) the base portion of the sculpted foam
layers, and such pin holes might typically be positioned to align
with the grooves/gaps between the foam pillars (so that air could
flow continuously through the vertical pin holes and the grooves to
pass from one surface of the sculpted foam layer all the way
through to the other surface of the sculpted foam layer). In some
embodiments, the base layer of foam would comprise a foam component
having a sculpted surface (typically with pillars facing upward)
surrounded by foam edge support perimeter rails (which typically
would be solid blocks of foam encompassing the sides of the base
foam component with sculpted surface, and typically having an
uncompressed height approximately equal to the uncompressed height
of the base foam component (e.g. the upper surface of the edge
support perimeter rails would typically be approximately the same
as the uncompressed height of (e.g. flush with) the upper surface
of the foam pillars of the base foam component with sculpted
surface).
[0042] Typically, mattress embodiments would have at least one
(foam) layer located between the base sculpted foam layer (which
typically would have the sculpted surface (e.g. foam pillars)
facing upward) and the middle sculpted foam layer (which typically
would have the sculpted surface (e.g. foam pillars) facing
downward), and would have at least one (foam) layer located above
the middle sculpted foam layer (e.g. a sleep surface layer
(typically of foam) would be located atop the middle sculpted foam
layer). In some embodiments, the foam pillars of the base sculpted
foam layer would be larger (e.g. the cross-section/footprint/outer
surface of the pillars would be larger) than the foam pillars of
the middle sculpted foam layer. And as mentioned above, typically
the various (foam) layers of the mattress would each have vertical
pin holes, at least some of which would align to provide continuous
airflow from the bottom to the top of the mattress. For example, in
some embodiments all (foam) layers located above the base layer of
foam might have vertical pinholes which entirely align, even though
the base foam layer might have less vertical pinholes spaced
further apart such that only some of the pinholes in the remaining
layers align with pinholes in the base layer. Although the base
layer in some embodiments may have fewer pinholes spaced further
apart than the other layers of foam, air may be operable in some
such embodiments to move through the grooves in the base portion
(e.g. since the pinholes in the base portion may be in fluid
communication with the grooves in the base portion) to the pinholes
in the upper layers of foam which are not aligned with the pinholes
in the base layer of foam.
[0043] Not intending to be bound by theory, typically, the sculpted
layer of foam would have a plurality of foam pillars forming the
sculpted surface, and the pillars would be configured within the
sculpted foam layer and the mattress as a whole to essentially be
limited to movement only (or in some embodiments, primarily) in the
vertical direction (e.g. without any horizontal/sideways movement
of the pillars during use of the mattress). In other words, the
configuration of the foam layers of the mattress (for example, with
the layers placed in contact in such a way as to minimize shear or
torsion in the pillars during construction (e.g. essentially
placing the pillars only in compression) and with the layers
perhaps laminated together) would typically ensure that compression
on the top (e.g. sleep surface) of the mattress would be
transmitted to the foam pillars entirely as a vertical (e.g.
compression) force (without, for example, introducing any (e.g.
substantial) horizontal, shear, or torsion forces to the foam
pillars) for each affected foam pillar (although in some
embodiments, downward movement of such foam pillars might cause
closing of one or more vertical ventilation passageways in
proximity to the foam pillar). Additionally, each pillar of foam in
the sculpted layer would typically be configured for essentially
independent movement (e.g. each pillar moves independent of the
other surrounding/proximate pillars). This independence might arise
due to the contour cuts (e.g. grooves/gaps) separating the foam
pillars and/or the fact that the base of the foam pillars would be
linked by conformable foam (e.g. in the form of an integrated base
of foam linking all pillars together). So, embodiments might have
pillars of the sculpted foam layer configured for essentially
independent movement and/or essentially only vertical movement
during usage of the mattress (e.g. by a user lying atop the
mattress). Typical embodiments might have the pillars configured
for independent movement essentially only in the vertical
direction. For example, each foam pillar might be operable to move
vertically without substantially imparting any vertical movement to
surrounding/proximate foam pillars in the sculpted foam layer.
Thus, movement by one foam pillar typically might not impart any
movement to other foam pillars in proximity within the sculpted
foam layer (such that each pillar movement would independently
relate to its own loading from the sleep surface above). So, each
foam pillar of an exemplary sculpted foam layer in a disclosed
mattress embodiment may be operable to only (or in some embodiments
primarily) carry/support compression forces from directly above the
foam pillar. Of course, Applicant does not intend to be bound by
theory, but rather simply notes that the presently disclosed
embodiments may perform/operate differently and/or better. Such
configuration of the sculpted foam layer (with regard to movement)
may be quite different from the typical movement allowed/provided
by conventional metal springs (e.g. coil springs in a mattress).
Conventional coil spring mattresses have a series of springs which
typically are linked by wire across their top surfaces. Thus, the
coil springs do not move independently (e.g. movement by one coil
spring necessarily affects the surrounding coil springs due to the
rigid nature of the linking wire frame) and the linking wire frame
at the top of the coil springs may typically introduce non-vertical
(e.g. non-compression) forces into the springs (such that the coil
springs may flex and move horizontally and/or torsionally, for
example, in response to a user atop the mattress sleep surface).
Thus, the disclosed embodiments (with foam pillars in a spring-less
mattress) may perform quite differently in operation than a
conventional spring mattress. Applicant notes that disclosed
mattress embodiments typically do not include traditional springs,
but for example might be termed all-foam mattresses (e.g. all the
cushion/support elements are foam) and/or (metal/coil) spring-free
mattresses (e.g. no springs, even if the mattress embodiment may
include some other cushion/support element(s) in addition to or
instead of one or more foam elements). So for example, a
ventilation mattress configured for billows effect might comprise
one or more sculpted foam layers and/or a plurality of vertical
ventilation passageways (for example, passing from the lower
surface of the mattress through one or more foam layers, and in
some embodiments passing all the way through the mattress to its
upper surface), and typically might also have a lower (cover)
surface with airflow means, such as high airflow fabric (which
could be spacer fabric or mesh fabric), in fluid communication with
one or more of the vertical ventilation passageways.
[0044] While typical sleep system embodiments would comprise a
mattress embodiment atop a foundation embodiment, other embodiments
might be focused on only the mattress or only the foundation. In
other words, disclosed mattress embodiments could alternatively be
used with conventional foundation elements (or even
separately/alone), and disclosed foundation embodiments could
alternatively be used with conventional mattress elements (although
doing so might reduce potential benefits available through the
joint use of disclosed mattress embodiment(s) with disclosed
foundation embodiment(s), since the joint use of ventilation
mattress atop ventilation foundation may provide for improved fluid
communication therebetween). A preferred embodiment, however, would
typically place a mattress configured to allow airflow/air transfer
(e.g. airflow) through its bottom surface (and perhaps also
typically having some means of air distribution throughout the
mattress (e.g. pinholes/passageways) for air passing through the
bottom surface of the mattress) atop a foundation configured to
provide airflow/air transfer (for example, forced airflow, which
might be suction and/or blowing) through its upper surface.
[0045] Turning now to the figures for specific exemplary
embodiments, FIG. 1A illustrates exemplary embodiment(s) of a
ventilated sleep system 100 (typically comprising a mattress and a
foundation), with a ventilated mattress 140 used in conjunction
with (typically directly atop) a ventilation foundation (such as
either 120a or 120b, which basically differ regarding the location
of the air flow unit 130a). The mattress 140 has a bottom surface
142 which allows airflow into and/or out of the mattress 140. For
example, the bottom surface 142 of the mattress 140 cover might be
formed of or comprise high airflow fabric, such as spacer fabric or
mesh fabric (for example 150 gsm 100% polyester spacer mesh fabric
and/or restricting airflow CFM less than about 35% at 3 PSI and/or
a spacer fabric with a thickness of about 3.5 mm, a weight of about
245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics) and/or such high
airflow mesh panels may be (inherently) fire resistant (FR--e.g.
meeting US Federal Std. 1633)). In some embodiments, the high
airflow fabric could be inherently FR, while in others, a spray-on
or other FR treatment/additive might be used. In some embodiments,
the upper surface 122a/b of the mattress 140 might also allow
airflow into/out of the mattress 140 (for example, with the upper
surface of the mattress 140 cover being formed of or comprising
high airflow fabric, which could be similar to that used for the
bottom surface 142 of the mattress cover as described above).
[0046] Either foundation 120a (with an air flow unit 130a external
to the support structure of the foundation 120a and/or cover of the
foundation 120a, for example externally mounted on the foundation,
perhaps underneath the foundation 120a/b at or near the foot end of
the bed, for example centered from side to side, and in fluid
communication with the foundation 120a hollow cavity via
inlet/intake/opening 132a) or 120b (with air flow unit 130b located
within the foundation 120b support structure and/or cover, for
example mounted internally on the bottom/base panel of the
foundation 120b, perhaps within the foundation 120b at or near the
foot end of the bed, for example on the left side when looking at
the foundation 120b from the foot, and in fluid communication with
the external environment via inlet/intake/opening 132b) might
optionally be used with the mattress 140, with the mattress 140
being located atop either foundation 120a or 120b to form the
ventilated sleep system 100. In both foundation embodiments 120a
and 120b, the upper surface 122a or 122b, respectively, of the
foundation 120a/b would be configured to allow airflow out of
and/or into the foundation (for example, into a mattress 140
directly atop (and in contact with) the foundation. So for example,
the upper surface 122a or 122b of the foundation cover might be
formed of or comprise high airflow fabric, which could be spacer
fabric or mesh fabric (similar to that described above with respect
to the bottom surface 142 of the mattress cover, for example, to
allow airflow communication between the foundation and the mattress
140, for example). And typically, the foundation might be held
above the floor by a frame or legs 111a,b (which might be similar
to conventional bed frames used for conventional box springs, for
example, and which might provide sufficient clearance from the
floor to allow the required airflow for operation of the
ventilation mattress system). Typically, the frame would not
interfere with or block the inlet/intake/opening 132a for the air
flow unit 130a,b. As discussed above, some embodiments of the
foundation might not include an airflow unit, especially if the
ventilation foundation is used with a ventilation mattress (e.g.
configured for billows effect).
[0047] So in FIG. 1A, air might pass into the foundation 120a,b,
for example through a filter such as a HEPA filter and/or through a
climate control unit (which might, for example, be operable to cool
and/or heat the air) via an air flow unit 130a,b, passing through
the foundation 120a/b (e.g. hollow cavity) to exit through the
upper surface 122a,b of the foundation 120a/b and enter the bottom
surface 142 of the mattress 140 in order to pass (vertically)
through at least a portion of the mattress 140. In such a system,
the air flow unit 130a,b might pump air into the mattress 140
through the foundation 120a/b. Alternatively, air might flow
through the system in reverse, with the air flow unit 130a,b
sucking air out of the mattress 140 and into the foundation 120a/b
(and then out to the external environment). The air flow unit
130a,b typically might displace about 100-300 CFM, and typically
might operate at less than about 6 dB. In some embodiments, the
upper surface of the mattress 140 might also allow for airflow (for
example, being formed of or comprising high airflow fabric or
loosely woven fabric panels, similar to those previously
described). In some embodiments, the high airflow fabric panels
throughout the sleep system (or at least for the upper foundation
cover surface and lower mattress cover surface) might all be
similar and/or formed of the same material. In some embodiments,
the air flow unit 130a,b might be configured to allow for forward
and reverse operation (e.g. operable to allow air to be blown into
or sucked out of the mattress by the foundation 120a/b). The arrows
in FIG. 1A illustrate potential airflow in the system, as persons
of skill would understand.
[0048] Typically, the foundation(s) 120a,b of FIG. 1A would
comprise a hollow structure (formed for example by support struts
and a structural frame), and air would be pumped into/out of the
hollow structure cavity (for example by the air flow unit 130a,b).
In other words, in such embodiments, air would simply flow through
the hollow cavity of the foundation 120a/b as it interacts with the
mattress 140 and the outside environment. So for example, external
air might be drawn into the hollow cavity of the foundation 120a/b
through the inlet/intake/opening 132a,b, flow through the hollow
cavity to the upper surface of the foundation 120a,b, flow out of
the foundation 120a/b through the upper surface 122a,b and into the
mattress 140 through the mattress bottom surface 142, and then pass
through at least a portion of the mattress 140 (and in some
embodiments, air might flow all the way through the mattress 140
and optionally might flow out the upper surface of the mattress
140). Alternatively, air might flow into the hollow cavity of the
foundation 120a,b through the upper surface 122a,b (for example,
sucking air from the mattress 140 through the bottom surface 142 of
the mattress 140), through the hollow cavity of the foundation 120,
and out of the foundation 120 via inlet/intake (which in the case
would actually serve as an outtake)/opening 132a,b to the external
environment.
[0049] FIG. 1B illustrates an alternative embodiment sleep/bedding
system, similar to that of FIG. 1A. One version of the foundation
120b of FIG. 1B may have an access panel, which for example might
allow for easy access to change the HEPA filter and/or to provide
maintenance or repair to the air flow unit 130b. FIGS. 1Ca, 1Cb and
1Cc illustrate in more detail an exemplary sleep/bedding system
embodiment similar to FIG. 1B, having an internal (e.g.
mounted/located within the foundation frame/cover) air flow unit
130b, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view of the foot of the bed, and FIG. 1Cc showing a top view.
Typically, in the embodiment of FIGS. 1Ca, 1Cb and 1Cc the air flow
unit 130b might be located at (e.g. in proximity to) the foot of
the bed within the foundation. For example, the optional HEPA
filter might be located over the air intake, with air then flowing
through the blower to be expelled into the hollow cavity of the
foundation 120b. In some embodiments, there may be an access panel,
for example located on the upper surface of the foundation 120b
above the HEPA filter or air intake or air flow unit 130b. The
access panel might be a hinged section (for example, operable to
open by pivoting upward) of the upper foundation 120b surface
(although in some embodiments, the access panel portion of the
upper foundation 120b cover might not be air permeable, for example
to help direct air through the blower and into the foundation)
120b.
[0050] FIGS. 1Da, 1Db and 1Dc illustrate in more detail an
exemplary sleep/bedding system embodiment similar to FIG. 1B,
having an external (e.g. mounted/located outside the foundation
120b frame/cover, for example mounted beneath the foundation 120b)
air flow unit 130a (shown in FIG. 1B), with FIG. 1Da showing a side
view, FIG. 1Db showing an end view of the foot of the bed, and FIG.
1Dc showing a top view. Typically, the air flow unit 130a of FIGS.
1Da, 1Db and 1Dc might be mounted to the bottom surface of the
foundation at or in proximity to the foot of the bed (perhaps
located towards the center between the sides). And again, there may
be an access panel, which for example might typically be located on
the housing of the air flow unit to allow access to the HEPA filter
and/or blower. FIG. 1E illustrates an exemplary sleep/bedding
system in 3D perspective view, showing that externally the
sleep/bedding system would resemble a conventional mattress atop a
conventional box-spring foundation unit (e.g. a typical
conventional bed).
[0051] FIGS. 2A1 and 2A2 illustrate an exemplary ventilation
mattress 240A, which is an all-foam (or spring-free) mattress
formed of a plurality of foam layers 250 (with the base layer being
a sculpted foam layer 250 having the sculpted surface (with foam
pillars) facing upward, a middle sculpted foam layer 250 having the
sculpted surface (with foam pillars) facing downward, a sleep
surface layer, at least one foam layer (e.g. transition layer)
between the middle sculpted foam layer 250 and the base sculpted
foam layer, and/or a foam layer located between the sleep surface
layer 270 and the middle sculpted foam layer 250). While FIG. 2A1
shows the foam components of the mattress (e.g. with the cover
removed) in perspective view, FIG. 2A2 shows a side cross-section
view of the same mattress. FIGS. 2B1 and 2B2 illustrate a similar
all foam mattress (e.g. with the foam components removed from the
cover), and differs primarily in the particular foam material
selected (with the embodiment of FIG. 2A1 being formed of
conventional high density foam (e.g. all component foam layers are
formed of conventional high density foam), and the embodiment of
FIG. 2B1 having the top two layers formed of memory foam, for
example gel memory foam, while the remaining layers are formed of
conventional high density foam). And in some embodiments, all such
foam layers would be adhered into an integrated whole (e.g.
laminated) and/or enclosed/encased in a cover, thereby forming an
integrated mattress.
[0052] So in FIG. 2A1, the mattress 240A comprises a base layer of
foam 242 (which comprises a sculpted foam element 243 with the
sculpted surface (e.g. the foam pillars) facing/extending upward)
located as the bottom layer of foam in the mattress 240A, a middle
sculpted foam layer 250 with the sculpted surface (e.g. foam
pillars) facing/projecting downward and located above the base
layer (although typically not directly above or in contact with the
base layer), a transition foam layer 260 located between (and
typically in contact with) the base layer of sculpted foam 242 and
the middle layer of sculpted foam 250, a top/sleep surface layer of
foam 270 (typically located as the uppermost foam layer 250 in the
mattress 240A), and (optionally) a second (e.g. penultimate) layer
of foam 280 located between the sleep surface layer 270 and the
middle sculpted foam layer 250. FIG. 2A1 shows the foam layers of
the mattress 240A without the cover (not shown), illustrating the
order and orientation of the foam layers in this mattress
embodiment. Typically, the foam layers are arranged one atop
another in the order described above, with proximate layers
contacting one another (e.g. the base layer 242 is the bottom
layer, the transition layer 260 is located atop and in contact with
the base layer 242, the middle sculpted foam layer 250 is located
atop and in contact with the transition layer, the second
(penultimate) layer 280 is located atop and in contact with the
middle sculpted foam layer 250, and the top (sleep surface) layer
270 is located atop and in contact with the second (penultimate)
layer 280 and forms the upper foam layer of the mattress 240A).
Typically, the layers would all be encased within a cover (not
shown here), and typically the cover would have a bottom surface
with means for airflow (for example, one or more panels of high
airflow fabric, such as spacer fabric or mesh fabric). Also, in
some embodiments, the upper surface of the cover might include
means for airflow (for example, an air permeable element, such as
one or more panels of high airflow fabric, such as spacer fabric or
mesh fabric).
[0053] In FIG. 2A1, the base layer 242 comprises a sculpted foam
element/layer 243 with upward facing sculpted surface (e.g. foam
pillars 248 projecting upward and separated by a series (e.g. grid)
of gaps or grooves or cuts 247), and edge perimeter rails of foam
244 which surround/encase the sculpted foam element 243 on all
sides (e.g. about/around the perimeter of the sculpted foam element
243). Typically, the edge support perimeter rails 244 might be
formed of the same foam as the base layer sculpted foam element 243
and/or might have the same uncompressed height as the sculpted foam
element 243 (e.g. the upper surface of the edge support perimeter
rails 244 might be approximately level with the upper surface of
the foam pillars 248 of the sculpted foam element 243 when both are
uncompressed). In the embodiment of FIG. 2A1, the foam pillars 248
would typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars 248 might
typically have a width of about 0.75 inches and a depth of about 3
inches. So for example, the gaps/grooves 247 in the base layer 242
might typically have a depth ranging from about 1/2 to 2/3 the
total height for the base layer 242, for example about 60% in some
exemplary embodiments. In addition, the joined bases of the foam
pillars 248 of the sculpted foam element 243 typically would have a
plurality of pinholes (e.g. essentially vertical air passageways),
as will be described in greater detail below. In alternate
embodiments, the pinholes might pass through both the base portion
and the pillar portion of one or more of the sculpted foam layers
250.
[0054] In FIG. 2A1, the transition layer of foam 260 would
typically be a flat sheet of foam with a plurality of pinholes 265
(e.g. essentially vertical air passageways). In the embodiment of
FIG. 2A1, the transition layer 260 would typically have the same
width and length dimensions (e.g. depending on whether the mattress
240A is a twin, full/double, queen, king, etc.) as the base layer
242 (e.g. including both the sculpted foam element 243 and the
surrounding edge support perimeter rails 244), although in other
embodiments (in which the foam pillars 248 are lower than the
surrounding edge support perimeter rails 244, for example by a
height approximately equal to the thickness of the transition
layer, the transition layer 260 might be sized to fit over just the
sculpted foam element 243 of the base layer 242 (e.g. so that it
would be located within the edge support perimeter rails 244 as
well).
[0055] The middle sculpted foam layer 250 of FIG. 2A1 would
typically be sized (e.g. width and length) approximately the same
as the base layer 242 and/or the transition layer 260 (and
typically the same as the layers atop it as well), and would be
oriented with the sculpted surface (e.g. foam pillars 258)
facing/projecting downward. In the embodiment of FIG. 2A1, the foam
pillars 258 would typically have a square rectangular outer surface
(and/or cross-section) of about 2 inches by 2 inches, and the
gaps/grooves 257 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves 257 in the
middle sculpted layer 250 might typically have a depth ranging from
about 1/2 to 2/3 the total height for the middle sculpted layer,
for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars 258 of the middle
sculpted layer 250 typically would have a plurality of pinholes 255
(e.g. essentially vertical air passageways), as will be described
in greater detail below. Typically, the pinholes 255 of the middle
sculpted foam layer 250 would be spaced and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer
260 (and typically also the same as the layers located above it),
with the pinholes 255 aligning vertically with the pinholes 265.
And typically, at least some of the pinholes 255/265 would also
align with the pinholes 245 in the base layer 242 (e.g. the
sculpted foam element 243 of the base layer 242). For example,
every other pinhole 255/265 might align with a pinhole 245 (and
groove/gap 247) in the sculpted foam element of the base layer.
[0056] The second (penultimate) foam layer 280 and the upper (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
2A1, both the second (penultimate) foam layer 280 and the upper
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress 240A
is a twin, full/double, queen, king, etc.) as the base layer 242,
the transition layer 260, and/or the middle sculpted layer 250.
And, the pinholes 285, 275 of the second (penultimate) foam layer
280 and the top (sleep surface) layer 270 respectively would
typically be spaced and/or oriented/located the same (identically)
as the pinholes 265 in the transition foam layer 260 and the
pinholes 255 in the middle sculpted foam layer 250, with the
pinholes 285, 275 aligning vertically with the pinholes 265, 255.
Thus, the pinholes 265, 255, 285, and 275 of FIG. 2A1 would
typically align to form continuous airflow pathways from the upper
surface of the base layer 242 upward to the upper surface of the
mattress 240A (although in other embodiments, only some of the
pinholes might align). And typically, at least some of the pinholes
285/275 would also align with the pinholes 245 in the base layer
242 (e.g. the sculpted foam element 243 of the base layer 242). For
example, every other pinhole 285/275 might align with a pinhole 245
(and groove/gap 247) in the sculpted foam element 243 of the base
layer 242. In other embodiments, the pinholes 265, 255, 285, and
275 might all align with the pinholes 245 in the base layer 242
(e.g. the pinholes in all the layers could be spaced equally so
they all align to form continuous air flow pathways from the bottom
surface of the mattress to the upper surface of the mattress
240A).
[0057] Similarly, FIG. 2A2 shows a cross-section view of the foam
elements 243 of the mattress 240A shown in FIG. 2A1. In this
embodiment, the base layer 242 typically would have an uncompressed
height of about 5 inches, the transition layer 260 typically would
have an uncompressed height of about 1.25 inches, the middle
sculpted foam layer 250 typically would have an uncompressed height
of about 3 inches, the second (penultimate) foam layer 280
typically would have an uncompressed height of about 1.75 inches,
and the top (sleep surface) layer 270 typically would have an
uncompressed height of about 1.25 inches. In FIG. 2A2, the foam
layers 250 would typically vary in firmness, from softest at the
top to hardest/firmest at the bottom. For example, the top (sleep
surface) layer 270 would typically be the softest layer of foam
(for example, IFD of about 14), the second (penultimate) layer 280
would typically be somewhat firmer that the top layer (for example,
IFD of about 20), the middle sculpted foam layer 250 would
typically be somewhat firmer than the second (penultimate) layer
280 (for example, IFD of about 35), the transition layer 260
typically would be somewhat firmer than the middle sculpted layer
(for example, IFD of about 45), while the base layer 242 might
typically have the same firmness as the transition layer 260 (for
example, IFD of about 45). In other embodiments, the base layer 242
might be somewhat firmer than the transition layer 260. Typically,
the edge support perimeter rails 244 would have the same firmness
(e.g. IFD) and/or be formed of the same foam as the sculpted foam
element 243 of the base layer. In other embodiments, the firmness
of the various layers may differ and/or may vary differently from
the descriptions above. And in FIG. 2A2, the thickness (e.g.
lateral width) of the edge support perimeter rails typically would
be about 4 inches (or in other embodiments, about the same size as
one of the foam pillar's 248 square rectangular outer surface
(and/or cross-section) sides).
[0058] FIG. 2A2 also shows the alignment of the pinholes 265, 255
(and gap 257), 285, and 275, and the fact that every other pinhole
265, 255, 285, 275 aligns with a pinhole 245 (and gap 247) of the
base layer 242 in this embodiment. The alignment of pinholes may
allow continuous airflow upward from the bottom surface of the
mattress 240A to the upper surface of the mattress 240A and/or
downward from the upper surface of the mattress 240A to the bottom
surface of the mattress 240A, as illustrated by the exemplary
airflow arrows (except along the perimeter edges where the edge
support perimeter rails 244 may not have pinholes, in some
embodiments). In some embodiments, the pinholes may be hole punched
into the foam sheets/layers, while in other embodiments the
pinholes might be formed for example by molding of the foam
sheets/layers). And in some embodiments, the gaps/grooves 247, 257
might be cut/scored into the foam to form the sculpted surface(s),
while in other embodiments the gaps/grooves 247, 257 might be
formed for example by molding (e.g. due to the shape of the foam
mold forming the layer(s)). The upper surface of the top layer of
foam 270 forms the sleep surface 272 (although typically there
would be a cover, not shown here, lying atop/encasing the
foam).
[0059] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers), while the lower/bottom
sculpted foam layer (e.g. the base layer) would typically be
oriented with its sculpted surface facing upward. And typically
(although optionally), there would be one or more foam layers
located above the uppermost sculpted foam layer (e.g. the middle
sculpted foam layer), with these top foam layers having a softer
IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
fabric (such as spacer fabric or mesh fabric), typically allowing
airflow comparable to the upper/top surface of the ventilation
foundation upon which such a mattress would typically operate). So
as discussed above, the mattress embodiment would typically have a
bottom cover surface allowing airflow therethrough (e.g. one or
more panels restricting airflow cubic feet per minute less than
about 35% at 3 PSI and/or allowing approximately 100-300 CFM flow
therethrough when used with an airflow unit and/or a billows effect
mattress), and the ventilation foundation (upon/atop which the
mattress embodiment would typically be used) typically would also
have an upper/top cover surface allowing airflow therethrough (for
example, similar to the airflow allowed by the bottom surface of
the cover of the mattress), such that the joint mattress-foundation
sleep/bedding system embodiment typically would effectively allow
airflow between the foundation and the mattress (for example, based
on an airflow unit in or on the foundation).
[0060] FIGS. 2B1 and 2B2 show a similar foam mattress 240B formed
of multiple layers of foam (typically within a cover (not shown)).
The embodiment of FIGS. 2B1 and 2B2 is substantially the same in
structure as the embodiment of FIGS. 2A1 and 2A2, primarily
differing in the foam material used. For example, in FIG. 2B1, the
top two layers might be memory foam (for example, gel memory foam).
Persons of skill will understand that the foam materials and/or
characteristics of the layers of foam for such exemplary mattresses
may differ, for example being selected based on the specific needs
of the particular mattress.
[0061] FIG. 3 illustrates an exemplary base foam layer 242 (similar
to that of FIG. 2A1, for example), showing the sculpted surface
(e.g. upper surface) of the sculpted foam element 243 (with foam
pillars 248 separated by gaps/grooves 247 in a grid) and the edge
support perimeter rails 244 in plan view (of the upper, sculpted
surface). As noted above, the foam edge support perimeter rails 244
surround and abut all four sides of the sculpted foam element 243,
and they each may typically have a width (e.g. lateral dimension)
approximately equal to one of the sides of the square rectangular
outer surface (and/or cross-section) of the foam pillars 248.
Typically (as shown in FIG. 3), all of the foam pillars 248 would
be equally sized (for example, they might all be equally sized with
a square cross-section, as for example formed by a grid of
grooves/gaps 247 in which the longitudinal grooves/gaps 247 are
equally spaced, and the lateral gaps/grooves 247 are also equally
spaced apart by the same amount as the longitudinal gaps, for
example forming a grid that resembles a checkerboard). So for
example in the embodiment of FIG. 3, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars 248 might
typically have a width of about 0.75 inches and a depth of about 3
inches.
[0062] FIG. 3 also shows the pinholes 245 in the base layer 242,
which are typically located in the joined base portion of the foam
pillars 248 of the base layer 242 so that they exit into the
gaps/grooves 247 separating the foam pillars 248. In other words,
the pinholes 245 typically do not pass through the projecting foam
pillar 248 portion of the base layer 242 sculpted foam element 243,
but rather pass only through the integral base portion of the
sculpted foam element 243 (e.g. the bottom portion where the foam
pillars are joined together into an integral whole) such that the
pinholes 245 extend upward from the bottom of the base layer 242 to
exit within the gaps/grooves 247 between the foam pillars 248. The
pinholes 245 of FIG. 3 typically might have a diameter of about 0.5
inches (and typically would all be about the same size), and
typically would be spaced apart approximately 3.937 inches. So for
example, the pinholes 245 typically might be located within the
gaps/grooves 247 at locations in proximity to the corners of each
foam pillar 248 of the base layer 242 (e.g. at the grid groove
intersections).
[0063] Similarly, FIG. 4 illustrates an exemplary middle sculpted
surface layer 250 (similar to that of FIG. 2A1, for example),
showing the sculpted surface (e.g. the bottom surface) (with foam
pillars 258 separated by gaps/grooves 257 in a grid) in plan view
(of the sculpted surface). Typically (as shown in FIG. 4), all of
the foam pillars 258 would be equally sized (for example, they
might all be equally sized with a square cross-section, as for
example formed by a grid of grooves/gaps 257 in which the
longitudinal grooves/gaps 257 are equally spaced, and the lateral
gaps/grooves are also equally spaced apart by the same amount as
the longitudinal gaps, for example forming a grid that resembles a
checkerboard). So for example in the embodiment of FIG. 4, the foam
pillars 258 would typically have a square rectangular outer surface
(and/or cross-section) of about 2 inches by 2 inches, and the
gaps/grooves 257 forming the grid resulting in the foam pillars 258
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. While the embodiment of FIG. 2A1, for example,
has the foam pillars 258 of the middle sculpted foam layer sized to
be about 1/4 the size of the foam pillars 248 of the base layer
(e.g. 2 inches by 2 inches versus 4 inches by 4 inches, such that
each 4.times.4 pillar in the base layer of FIG. 2A1, for example,
might have four 2.times.2 pillars in the middle sculpted layer
located above it); in other embodiments, the ratio of the foam
pillar sizing may vary (for example, the foam pillars 258 could be
the same size as the foam pillars 248 in some embodiments, or the
foam pillars 258 might be 1/2, 1/3, 1/8, or 1/16 the size of the
foam pillars 248 in other embodiments). Typically, the sizing ratio
would be such that at least some of the gaps/grooves 257 in the
middle sculpted foam layer would align with at least some of the
gaps/grooves 247 of the base layer (since that may be important to
aid in alignment of pinholes in some embodiments, as well as
perhaps providing consistent support and/or comfort
characteristics).
[0064] FIG. 4 also shows the pinholes 255 in the middle sculpted
layer 250, which are typically located in the joined base portion
of the foam pillars 258 of the middle sculpted layer 250 so that
they exit into the gaps/grooves 257 separating the foam pillars
258. In other words, the pinholes 255 typically do not pass through
the projecting foam pillar 258 portion of the middle sculpted foam
layer 250, but rather pass only through the integral base portion
of the middle sculpted layer 250 (e.g. the bottom portion where the
foam pillars 258 are joined together into an integral whole) such
that the pinholes 255 extend downward from the top of the middle
sculpted layer 250 to exit within the gaps/grooves 257 between the
foam pillars 258. The pinholes 255 of FIG. 4 typically might have a
diameter of about 0.25 inches (and typically would all be about the
same size), and typically would be spaced apart approximately
1.9685 inches. So for example, the pinholes 255 typically might be
located within the gaps/grooves 257 at locations in proximity to
the corners of each foam pillar 258 in the middle sculpted layer
250 (e.g. at the grid groove intersections). As discussed above,
the pinholes in the foam layers (of an exemplary mattress) above
the middle sculpted layer 250 (as well as perhaps an underlying
transition layer) typically would be sized and spaced (e.g.
located) identical to those in the middle sculpted layer 250, in
order to form continuous airflow pathways upward.
[0065] FIG. 5A illustrates an exemplary ventilation mattress 540,
which is an all-foam (or spring-free) mattress formed of a
plurality of foam layers (with the base layer being a sculpted foam
layer having the sculpted surface (with foam pillars) facing
upward, a middle sculpted foam layer having the sculpted surface
(with foam pillars) facing downward, a sleep surface layer, at
least one foam layer (e.g. transition layer) between the middle
sculpted foam layer and the base sculpted foam layer, and/or a foam
layer located between the sleep surface layer and the middle
sculpted foam layer). FIG. 5B illustrates a similar all foam
mattress (e.g. with the foam components removed from the cover),
and differs primarily in the middle layer construction. In some
embodiments, all such foam layers would be adhered into an
integrated whole (e.g. laminated) and/or enclosed/encased in a
cover, thereby forming an integrated mattress.
[0066] So in FIG. 5A, the mattress 540 comprises a base layer of
foam 242 (which comprises a sculpted foam element with the sculpted
surface (e.g. the foam pillars) facing/extending upward) located as
the bottom layer of foam in the mattress 540 (wherein the base
layer 242 may be similar to the base layer 242 described above), a
middle sculpted foam layer 550 with the sculpted surface (e.g. foam
pillars) facing/projecting downward and located above the base
layer 242 (although typically not directly above or in contact with
the base layer 242), a transition foam layer 260 located between
(and typically in contact with) the base layer of sculpted foam 242
and the middle layer of sculpted foam 550 (wherein the transition
foam layer 260 may be similar to the transition foam layer 260
described above), a top/sleep surface layer of foam 270 (typically
located as the uppermost foam layer in the mattress, wherein the
top surface layer 270 may be similar to the top surface layer 270
described above), and (optionally) a second (e.g. penultimate)
layer of foam 280 located between the sleep surface layer 270 and
the middle sculpted foam layer 550 (wherein the second layer of
foam 280 may be similar to the second layer of foam 280 described
above).
[0067] FIG. 5A shows the foam layers of the mattress 540 without
the cover (not shown), illustrating the order and orientation of
the foam layers 550 in this mattress embodiment. Typically, the
foam layers 550 are arranged one atop another in the order
described above, with proximate layers contacting one another (e.g.
the base layer 242 is the bottom layer, the transition layer 260 is
located atop and in contact with the base layer, the middle
sculpted foam layer 550 is located atop and in contact with the
transition layer 260, the second (penultimate) layer 280 is located
atop and in contact with the middle sculpted foam layer 550, and
the top (sleep surface) layer 270 is located atop and in contact
with the second (penultimate) layer 280 and forms the upper foam
layer of the mattress 540). Typically, the layers would all be
encased within a cover (not shown here), and typically the cover
would have a bottom surface with means for airflow (for example,
one or more panels of high airflow fabric, such as spacer fabric or
mesh fabric. Also, in some embodiments, the upper surface of the
cover might include means for airflow (for example, an air
permeable element, such as one or more panels of high airflow
fabric).
[0068] In FIG. 5A, the base layer 242 comprises a sculpted foam
element/layer 243 with upward facing sculpted surface (e.g. foam
pillars 248 projecting upward and separated by a series (e.g. grid)
of gaps or grooves or cuts 247), and edge perimeter rails of foam
244 which surround/encase the sculpted foam element 243 on all
sides (e.g. about/around the perimeter of the sculpted foam element
243). Typically, the edge support perimeter rails 244 might be
formed of the same foam as the base layer sculpted foam element 243
and/or might have the same uncompressed height as the sculpted foam
element 243 (e.g. the upper surface of the edge support perimeter
rails 244 might be approximately level with the upper surface of
the foam pillars 248 of the sculpted foam element 243 when both are
uncompressed).
[0069] In the embodiment of FIG. 5A, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars might typically
have a width of about 0.75 inches and a depth of about 3 inches. So
for example, the gaps/grooves 247 in the base layer might typically
have a depth ranging from about 1/2 to 2/3 the total height for the
base layer, for example about 60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the sculpted foam
element 243 typically would have a plurality of pinholes 265 (e.g.
essentially vertical air passageways), as will be described in
greater detail below. In alternate embodiments, the pinholes might
pass through both the base portion and the pillar portion of one or
more of the sculpted foam layers 550.
[0070] In FIG. 5A, the transition layer of foam 260 would typically
be a flat sheet of foam with a plurality of pinholes 265 (e.g.
essentially vertical air passageways). In the embodiment of FIG.
5A, the transition layer 260 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base layer 242 (e.g.
including both the sculpted foam element 243 and the surrounding
edge support perimeter rails 244), although in other embodiments
(in which the foam pillars are lower than the surrounding edge
support perimeter rails, for example by a height approximately
equal to the thickness of the transition layer, the transition
layer 260 might be sized to fit over just the sculpted foam element
243 of the base layer 242 (e.g. so that it would be located within
the edge support perimeter rails 244 as well).
[0071] The middle sculpted foam layer 550 of FIG. 5A would
typically be sized (e.g. width and length) approximately the same
as the base layer 242 and/or the transition layer 260 (and
typically the same as the layers atop it as well), and would be
oriented with the sculpted surface (e.g. foam pillars 554)
facing/projecting downward. In the embodiment of FIG. 5A, the foam
pillars 554 would typically have a square/rectangular outer surface
(and/or cross-section) of about 4 inches by 4 inches, and the
gaps/grooves 557 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves 557 in the
middle sculpted layer 550 might typically have a depth ranging from
about 1/2 to 2/3 the total height for the middle sculpted layer
550, for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the middle
sculpted layer 550 typically would have a plurality of pinholes 555
(e.g. essentially vertical air passageways), as will be described
in greater detail below.
[0072] In the embodiment shown in FIG. 5A, the pinholes 555 of the
middle sculpted foam layer 550 may be spaced and/or
oriented/located the same (identically) as the pinholes 245 of the
base layer 242. And typically, at least some of the pinholes 555
may align with the pinholes 265 in the transition foam layer 260
(as well as the layers located above it), with some of the pinholes
265 aligning with the pinholes 555. For example, every other
pinhole 265 might align with a pinhole 555 in the middle sculpted
foam layer 550.
[0073] The middle layer 550 may also comprise an additional set of
pillars 552 located on the top surface of the middle layer 550. In
the embodiment of FIG. 5A, the top pillars 552 may be sized
differently than the bottom pillars 554 (for example, the top
pillar 552 might be 1/4 the (cross-section) size of the bottom
pillars 554, with four top pillars 552 for each corresponding
bottom pillar, although in other embodiments the top and bottom
pillars 552/554 could be the same size). In the embodiment of FIG.
5A, the pinholes 555 may align with every groove 557 in the bottom
pillars 554, while the pinholes 555 may align with every other
groove 553 in the top pillars 552. In some embodiments, the grooves
553 of the top pillars 552 may align with the pinholes 275, 285 of
the top (sleep surface) layer 270 and second layer 280.
[0074] The second (penultimate) foam layer 280 and the upper (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
5A, both the second (penultimate) foam layer 280 and the upper
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base layer 242, the
transition layer 260, and/or the middle sculpted layer 550. And,
the pinholes 285, 275 of the second (penultimate) foam layer 280
and the top (sleep surface) layer 270 respectively would typically
be spaced and/or oriented/located the same (identically) as the
pinholes 265 in the transition foam layer 260 and optionally the
pinholes 555 in the middle sculpted foam layer 550, with the
pinholes 285, 275 aligning vertically with the pinholes 265, 555.
Thus, the pinholes 265, 555, 285, and 275 of FIG. 5A would
typically align to form continuous airflow pathways from the upper
surface of the base layer 242 upward to the upper surface of the
mattress (although in other embodiments, only some of the pinholes
might align). And typically, at least some of the pinholes 285/275
would also align with the pinholes 245 in the base layer 242 (e.g.
the sculpted foam element 243 of the base layer). For example,
every other pinhole 285, 275 might align with a pinhole 245 (and
groove/gap 247) in the sculpted foam element 243 of the base layer
242. In other embodiments, the pinholes 265, 555, 285, and 275
might all align with the pinholes 245 in the base layer 242 (e.g.
the pinholes in all the layers could be spaced equally so they all
align to form continuous air flow pathways from the bottom surface
of the mattress to the upper surface of the mattress).
[0075] In FIG. 5A, the foam layers would typically vary in
firmness, from softest at the top to hardest/firmest at the bottom.
For example, the top (sleep surface) layer 270 would typically be
the softest layer of foam (for example, IFD of about 14), the
second (penultimate) layer 280 would typically be somewhat firmer
than the top layer (for example, IFD of about 20), the middle
sculpted foam layer 550 would typically be somewhat firmer than the
second (penultimate) layer 280 (for example, IFD of about 35), the
transition layer 260 typically would be somewhat firmer than the
middle sculpted layer 550 (for example, IFD of about 45), while the
base layer 242 might typically have the same firmness as the
transition layer 260 (for example, IFD of about 45). In other
embodiments, the base layer 242 might be somewhat firmer than the
transition layer 260. Typically, the edge support perimeter rails
244 would have the same firmness (e.g. IFD) and/or be formed of the
same foam as the sculpted foam element 243 of the base layer 242.
In other embodiments, the firmness of the various layers may differ
and/or may vary differently from the descriptions above. In some
embodiments, the thickness (e.g. lateral width) of the edge support
perimeter rails 244 typically would be about 4 inches (or in other
embodiments, about the same size as one foam pillar 248 square
rectangular outer surface (and/or cross-section) sides).
[0076] The alignment of pinholes may allow continuous airflow
upward from the bottom surface of the mattress to the upper surface
of the mattress 540 and/or downward from the upper surface of the
mattress to the bottom surface of the mattress 540 (except along
the perimeter edges where the edge support perimeter rails may not
have pinholes, in some embodiments). In some embodiments, the
pinholes may be hole punched into the foam sheets/layers, while in
other embodiments the pinholes might be formed for example by
molding of the foam sheets/layers).
[0077] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers and/or the upper sculpted foam
layer might have both an upper and lower sculpted surface), while
the lower/bottom sculpted foam layer (e.g. the base layer) would
typically be oriented with its sculpted surface facing upward. And
typically (although optionally), there would be one or more foam
layers located above the uppermost sculpted foam layer (e.g. the
middle sculpted foam layer), with these top foam layers having a
softer IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
fabric (such as spacer fabric or mesh fabric), typically allowing
airflow comparable to the upper/top surface of the ventilation
foundation upon which such a mattress would typically operate). So
as discussed above, the mattress embodiment would typically have a
bottom cover surface allowing airflow therethrough (e.g. one or
more panels restricting airflow per cubic feet per minute less than
about 35% at 3 PSI), and the ventilation foundation (upon/atop
which the mattress embodiment would typically be used) typically
would also have an upper/top cover surface allowing airflow
therethrough (for example, similar to the airflow allowed by the
bottom surface of the cover of the mattress), such that the joint
mattress-foundation sleep/bedding system embodiment typically would
effectively allow airflow between the foundation and the mattress
(for example, based on an airflow unit in or on the
foundation).
[0078] FIG. 5B shows a similar foam mattress 542 formed of multiple
layers of foam (typically within a cover (not shown). The
embodiment of FIG. 5B is substantially the same in structure as the
embodiment of FIG. 5A, primarily differing in the construction of
the middle layer 560. In the embodiment of FIG. 5B the middle
sculpted foam layer 560 would typically be sized (e.g. width and
length) approximately the same as the base layer 242 and/or the
transition layer 260 (and typically the same as the layers atop it
as well), and would be oriented with the sculpted surface (e.g.
foam pillars 556) facing/projecting downward. In the embodiment of
FIG. 5B, the foam pillars 556 would typically have a square
rectangular outer surface (and/or cross-section) of about 2 inches
by 2 inches, and the gaps/grooves 557 forming the grid resulting in
the foam pillars might typically have a width of about 0.375 inches
and a depth of about 1.75 inches. So for example, the gaps/grooves
in the middle sculpted layer might typically have a depth ranging
from about 1/2 to 2/3 the total height for the middle sculpted
layer, for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the middle
sculpted layer 560 typically would have a plurality of pinholes 555
(e.g. essentially vertical air passageways), as will be described
in greater detail below. Typically, the pinholes 555 of the middle
sculpted foam layer 560 would be spaced and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer
260 (and typically also the same as the layers located above it),
with the pinholes 555 aligning vertically with the pinholes 265.
And typically, at least some of the pinholes 555/265 would also
align with pinholes in the base layer 242 (e.g. the sculpted foam
element 243 of the base layer). For example, every other pinhole
555, 265 might align with a pinhole (and groove/gap 247) in the
sculpted foam element 243 of the base layer 242.
[0079] The middle layer 560 may also comprise an additional set of
pillars 552 located on the top surface of the middle layer 560. In
the embodiment of FIG. 5A, the top pillars 552 may be sized the
same (identical) as the bottom pillars 554. In the embodiment of
FIG. 5A, the pinholes 555 may align with every groove 557 in the
bottom pillars 554, and the pinholes 555 may align with every
groove 553 in the top pillars 552.
[0080] FIGS. 6A-6B illustrate detailed views of the middle sculpted
foam layers 550 and 560. The middle sculpted foam layer 550 of FIG.
6A may comprise top pillars 552 and bottom pillars 554 that differ
in size. For example, the top pillars 552 may typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, while the bottom pillars 554 may typically have
a square rectangular outer surface (and/or cross-section) of about
4 inches by 4 inches. The middle sculpted foam layer 560 of FIG. 6B
may comprise top pillars 552 and bottom pillars 554 that are the
same in size. For example, the top pillars 552 may typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, and the bottom pillars 556 may also typically
have a square rectangular outer surface (and/or cross-section) of
about 2 inches by 2 inches. Typically, the foam pillars of the
middle sculpted foam layer would be sized with respect to the
pillars of the base layer of foam within a range including
1-to-1-4-to-1 with respect to cross-section (such that the foam
pillars of the middle sculpted foam layer each range in size from
being equally sized to the base layer pillars down to being a
quarter the size of the base layer pillars (i.e. four middle
sculpted layer pillars per one base layer pillar)), with each top
foam pillar of the middle sculpted foam layer often being equally
sized and each bottom foam pillar of the middle sculpted foam layer
often being equally sized. So for example, the base layer foam
pillars might be 4.times.4 inches in cross-section, and the middle
sculpted foam layer might have pillars that are 4.times.4 inches or
2.times.2 inches (for example, the bottom pillars of the middle
sculpted foam layer could be 4.times.4 inches or 2.times.2 inches,
while the top pillars of the middle sculpted foam layer could be
2.times.2 inches (or 4.times.4 inches)).
[0081] Additionally, the pinholes 555 in the middle sculpted layers
550 and 560 may align with the grooves 557 in the bottom pillars
554/556 in both embodiments. Therefore, the pinholes 555 of the
middle sculpted layer 550 of FIG. 6A may be fewer in number and
spaced differently than the pinholes 555 of the middle sculpted
layer 560 of FIG. 6B.
[0082] In the embodiment shown in FIG. 6A, the middle sculpted foam
layer 550 may be formed of one piece of foam, wherein the pillars
552/554 and pinholes 555 may be formed by sculpting and/or molding
a single piece of foam. In the embodiment shown in FIG. 6B, the
middle sculpted foam layer 560 may be formed of one piece of foam,
wherein the pillars 552/556 and pinholes 555 may be formed by
sculpting and/or molding a single piece of foam.
[0083] FIGS. 7A-7B illustrate alternative detailed views of the
middle sculpted foam layers 550 and 560. In FIGS. 7A-7B, the middle
layers 550 and 560 may comprise two different types of foam joined
together using adhesive. The middle layers 550 and 560 may be
similar to those described in FIGS. 6A-6B, except that the layers
may be formed of two pieces of foam instead of one.
[0084] In the embodiment shown in FIG. 7A, the middle sculpted foam
layer 550 may be formed of two pieces of foam, wherein the pillars
552 and partial pinholes 555 may be formed by sculpting and/or
molding a first piece of foam 720, and the pillars 554 and partial
pinholes 555 may be formed by sculpting and/or molding a second
piece of foam 722. Then, the two pieces of foam 720 and 722 may be
joined together and laminated to form the middle sculpted foam
layer 550.
[0085] In the embodiment shown in FIG. 7B, the middle sculpted foam
layer 560 may be formed of two pieces of foam, wherein the pillars
552 and partial pinholes 555 may be formed by sculpting and/or
molding a first piece of foam 720, and the pillars 556 and partial
pinholes 555 may be formed by sculpting and/or molding a second
piece of foam 724. Then, the two pieces of foam 720 and 724 may be
joined together and laminated to form the middle sculpted foam
layer 560.
[0086] FIG. 8 illustrates an exemplary base foam layer 242 similar
to that shown and described in FIG. 3.
[0087] FIG. 9 illustrates a ventilation/breathable sleep system 900
(e.g. with ventilation mattress 910 (preferably configured for
billows effect) atop a ventilation/breathable (airflow) foundation
920). This sleep system embodiment allows airflow (e.g. fluid
communication) between the mattress 910 and the foundation 920
(which may be one way or two way air flow, depending on the
specific configuration and/or operation) via the interface of the
upper surface (e.g. with high airflow fabric, such as spacer fabric
or mesh fabric 922) of the foundation 920 and the lower surface
(e.g. with high airflow fabric, such as spacer fabric or mesh
fabric 912) of the mattress 910 (and typically, the same type
and/or amount of high airflow fabric would be used for both the
upper surface of the foundation and the lower surface of the
mattress). The ventilation/breathable (e.g. airflow) mattress
foundation 920 of FIG. 9 is configured to allow for air to pass
through the foundation, for example from the external environment
to a ventilation mattress 910 located on the upper surface of the
foundation 920 through a high airflow fabric on the upper surface
(e.g. air might flow through the lower surface of the foundation
(which typically comprises high airflow fabric) from the external
environment, through the hollow cavity of the foundation (e.g.
within the frame structural support of the foundation and the
enclosing cover), and through the upper surface of the foundation)
and/or from such a ventilation mattress to the external environment
through a high airflow fabric on the upper surface of the
foundation (e.g. air might flow from the mattress into the
foundation through the upper surface of the foundation, through the
hollow cavity of the foundation (e.g. within the frame structural
support of the foundation and the enclosing cover), and through the
lower surface of the foundation, which typically comprises high
airflow fabric, into the external environment).
[0088] Typically, the foundation embodiment of FIG. 9 would include
a support structure and a foundation cover, located on and
typically encompassing/enclosing the support structure to form a
hollow cavity inside the foundation (which would be substantially
open in FIG. 9, for example with no interior elements that might
block airflow except for optionally one or more internal support
beams--although in other embodiments, there could be internal
structure so long as it does not substantially interfere with
airflow through the foundation) (and in FIG. 9, there would be no
airflow unit for forced air). Typically, the upper surface of the
support structure of the foundation would include a plurality of
slats (spaced apart, but providing ample support for a mattress),
which would typically comprise wood slats. In some embodiments,
there may be one or two support beams for the support structure of
the foundation as well (e.g. on the upper surface of the
foundation). The foundation cover would include an upper surface
(configured for the mattress to rest atop and/or to be located
atop/above the upper surface of the foundation support structure)
having one or more means for airflow (e.g. air permeable element,
such as high airflow fabric, such as spacer fabric or mesh fabric
(for example 150 gsm 100% polyester spacer mesh fabric restricting
airflow CFM less than about 35% at 3 PSI and/or spacer fabric with
a thickness of about 3.5 mm, a weight of about 245 g/m.sup.2,
and/or an air permeability of about 636 ft3/ft2/minute at 0.018 PSI
and/or such high airflow panels may be (inherently) fire resistant
(FR--e.g. meeting US Federal Std. 1633). In the embodiment shown in
FIG. 9, the foundation cover also has a lower surface (e.g.
directed towards the ground/floor) which also has a similar means
for airflow/air permeable element/high airflow fabric. For example,
the lower surface might comprise polyester non-woven fabric (as an
air permeable dust protector) with a thickness of about 0.004 mm
and/or a weight of about 1.5 oz./ft.sup.2. In the embodiment of
FIG. 9, (substantially/approximately) the entire upper and lower
surface of the foundation cover would be formed of high airflow
fabric (for example 150 gsm 100% polyester spacer mesh fabric
restricting airflow CFM less than about 35% at 3 PSI and/or spacer
fabric with a thickness of about 3.5 mm, a weight of about 245
g/m.sup.2, and/or an air permeability of about 636 ft3/ft2/minute
at 0.018 PSI and/or such high airflow mesh fabric may be
(inherently) fire resistant (FR--e.g. meeting US Federal Std.
1633)). In some embodiments, the high airflow fabric could also be
fire resistant, for example inherently FR and/or made FR by a FR
additive (e.g. chemically treated with FR solution) and/or able to
meet or exceed U.S. Federal Std. 1633. In other embodiments, the
foundation and/or sleep system may meet or exceed the 1633 burn
test requirements even when using non-FR cover materials and/or
substrate materials.
[0089] In FIG. 9, the foundation might also include a substrate
underlying the upper surface of the foundation cover, for example
located between and typically in contact with the upper surface
portion of the foundation cover and the upper surface (e.g. slats)
of the foundation support structure. Typically, such substrate
would span (substantially/approximately) the entire upper surface
of the foundation support structure (e.g. underlie
substantially/approximately the entire upper surface of the
foundation cover) and would be firm enough to prevent the cover
(upper surface) from sinking between the slats of the upper surface
of the support structure/frame. Additionally, the substrate would
typically be sufficiently breathable to not restrict airflow any
more than the upper surface and/or lower surface of the foundation
cover and/or the billows effect produced by the mattress and/or
could provide air permeability from 140-250 ft3/ft2/minute at 0.018
PSI (per ASTM D737-96 Standard) and/or about 212 ft3/ft2/minute at
0.018 PSI. The breathability/permeability could either be due to
use of a sufficiently air permeable material for the substrate,
perforations providing the required breathability, and/or
combinations thereof In some embodiments, the substrate would also
be fire resistant, for example meeting or exceeding U.S. Federal
Standard 1633. So typically, the entire foundation and/or sleep
system should be able to meet or exceed U.S. Federal Std. 1633. In
some embodiments, the substrate might comprise a fiber pad and/or a
nylon webbing. In some exemplary embodiments, the substrate might
be polyester non-woven fabric with a thickness of about 0.05 mm, a
weight of about 4.8 oz./ft.sup.2, and/or an air permeability of
about 212 ft3/ft2/minute (e.g. at 0.018 PSI and/or per ASTM D737-96
Standard). The overall/composite air permeability of the foundation
(e.g. accounting for both the upper and lower surfaces of the cover
and the substrate) might typically be at least 100 ft3/ft2/minute
(e.g. at 0.018 PSI and/or per ASTM D737-96 Standard), at least 125
ft3/ft2/minute (e.g. at 0.018 PSI and/or per ASTM D737-96
Standard), at least 140 ft3/ft2/minute (e.g. at 0.018 PSI and/or
per ASTM D737-96 Standard), about 142 ft3/ft2/minute (e.g. at 0.018
PSI and/or per ASTM D737-96 Standard), 140-212 ft3/ft2/minute (e.g.
at 0.018 PSI and/or per ASTM D737-96 Standard), 140-636
ft3/ft2/minute (e.g. at 0.018 PSI and/or per ASTM D737-96
Standard), 125-212 ft3/ft2/minute (e.g. at 0.018 PSI and/or per
ASTM D737-96 Standard), or 100-212 ft3/ft2/minute (e.g. at 0.018
PSI and/or per ASTM D737-96 Standard), by way of example.
[0090] Prior conventional foundations had low to no airflow
capabilities, in part due to the materials previously used to meet
the FR standards and/or in part due to the lack of focus regarding
breathability of the mattresses (e.g. since high airflow mattresses
and/or mattresses with billows effect were not previously a
particular concern). Disclosed embodiments may address the FR issue
by using an upper surface cover material for the foundation (and/or
substrate) that is fire resistant and/or by using a foundation
design/construction that overcomes/addresses the FR requirements
without the need for FR materials. While such fire resistance could
come from treatments (e.g. topical application of FR chemicals, for
example with a spray-on FR additive and/or simply due to
design/construction), in FIG. 9 the upper surface of the foundation
cover (e.g. the one or more high airflow panels) may be formed of
or comprise inherently FR high airflow fabric (although other
embodiments may use cover material that is not FR, which may still
render the entire foundation or sleep system sufficiently FR). In
some embodiments, the lower surface of the foundation cover could
also comprise the same type of high airflow fabric material
(although in other embodiments, a breathable dust cover material,
such as polyester non-woven fabric with a thickness of about 0.004
mm and/or a weight of about 1.5 oz./ft.sup.2, might be
sufficient).
[0091] One illustrative example of an exemplary breathable
foundation embodiment might include the following specifics, merely
as a non-exclusive example: An upper surface of the cover
comprising spacer fabric (on top of foundation and just above the
Polyester Non-Woven Fabric substrate) with a thickness of about 3.5
mm, a weight of about 245 g/m.sup.2, and/or air permeability of
about 636 ft3/ft2/minute at 0.018 PSI (e.g. per ASTM
D737-96--Standard Test Method for Air Permeability of Textile
Fabrics); Polyester Non-Woven Fabric substrate (e.g. underneath the
Spacer Fabric and on top of wooden slats of the support/frame) with
a thickness of about 0.05 mm, a weight of about 4.8 oz./ft.sup.2,
and/or an air permeability of about 212 ft3/ft2/minute (e.g. at
0.018 PSI and/or per ASTM D737-96--Standard Test Method for Air
Permeability of Textile Fabrics); and a Polyester Non-Woven Fabric
lower surface of the cover (e.g. as an underneath foundation
breathable dust protector) with a thickness of about 0.004 mm
and/or a weight of about 1.5 oz./ft.sup.2. Such an exemplary
foundation might have a composite air permeability of about 142
ft3/ft2/minute (e.g. at 0.018 PSI and/or per ASTM D737-96--Standard
Test Method for Air Permeability of Textile Fabrics). Stated
another way, the composite air permeability of such a breathable
foundation might be about 142 ft3/ft2/minute (e.g. at 0.018 PSI
and/or per ASTM D737-96--Standard Test Method for Air Permeability
of Textile Fabrics) greater than a standard, conventional mattress
foundation.
[0092] In FIG. 9, a ventilation mattress 910 may be used atop the
ventilation (e.g. airflow) foundation 920, to form a ventilation
sleep system 900. The ventilation mattress would typically have a
mattress cover (encompassing/enclosing the support/cushioning
elements of the mattress) with a lower surface (configured to rest
atop the foundation and to be located in proximity to and/or
contact the upper surface of the foundation), and the lower surface
of such ventilation mattress would typically include one or more
means for airflow (e.g. air permeable element, such as high airflow
fabric, such as spacer fabric or mesh fabric 912 (for example 150
gsm 100% polyester spacer mesh fabric restricting airflow CFM less
than about 35% at 3 PSI and/or a spacer fabric with a thickness of
about 3.5 mm, a weight of about 245 g/m.sup.2, and/or an air
permeability of about 636 ft3/ft2/minute at 0.018 PSI (e.g. per
ASTM D737-96--Standard Test Method for Air Permeability of Textile
Fabrics) and/or such high airflow mesh fabric may be (inherently)
fire resistant (FR--e.g. meeting US Federal Std. 1633))), for
example similar to a spacer fabric or mesh fabric 922 of the upper
surface of the corresponding ventilation foundation 920 and, in
some embodiments, of the lower surface of the ventilation
foundation 920. In some embodiments, the ventilation foundation 920
also includes an air-permeable non-woven fabric 924, for example,
disposed beneath the spacer fabric or mesh fabric 922 of the upper
surface of the ventilation foundation. In some embodiments,
(substantially/approximately) the entire lower surface of the
mattress cover would be formed of the high airflow fabric (e.g.
three-dimensional/spacer fabric) and/or the amount (e.g. surface
area) and/or location of such high airflow fabric panel(s) would
correspond/match (e.g. be approximately the same as) that of the
corresponding foundation (on which the mattress would lay atop). In
some embodiments, the mattress cover's upper surface would be
similar to that of the lower surface of the mattress cover (e.g.
with respect to airflow and/or materials)--although in other
embodiments, it could differ (for example, providing less airflow
and/or loft). Additionally, in some embodiments the
[0093] In some embodiments, the ventilation mattress would also be
configured to provide a billows effect, which (with body movement
of a user atop the ventilation mattress) might move air between the
foundation and mattress of the ventilation sleep system. For
example, the mattress support-comfort elements (e.g. within the
mattress cover) might include one or more foam layers with vertical
ventilation passageways therethrough and/or one or more foam layers
having a sculpted surface of foam pillars (for example, as
described above with respect to FIG. 2A1-FIG. 8). In some
embodiments, the foam pillars of the sculpted surface would cover
substantially/approximately one entire surface of a foam layer
(e.g. a top and/or bottom surface of one or more foam layers, which
might for example substantially span the mattress). In FIG. 9, two
foam layers may be present as having sculpted surfaces with foam
pillars, for example with the base layer having the sculpted
surface facing upward and the other sculpted layer having its
sculpted surface facing downward (for example, with two foam
pillars of the upper sculpted layer spanning a side of a single
foam pillar of the base layer, which could mean 2 or 4 smaller
pillars per larger base pillar for example). Some embodiments could
also include one or more horizontal ventilation passageways (which
in some embodiments might be formed by the gaps/grooves forming the
grid of foam pillars of the sculpted surface of one or more foam
layers and/or could be channels formed in a surface of a foam
layer). Typically, the vertical ventilation passageways and/or the
horizontal ventilation passageways would be in fluid communication
with the lower surface of the mattress cover (such that the billows
effect would circulate air into and/or out of the mattress through
the lower surface of the mattress cover) and/or with each other
(such that the billows effect might use the entire ventilation
passageway system to maximize effectiveness). And in some
embodiments, the vertical ventilation passageways and/or horizontal
ventilation passageways might also be in fluid communication with
the upper surface of the mattress (e.g. with at least some vertical
ventilation passageways aligned to span the thickness of the entire
mattress, from the lower mattress cover surface to the upper
mattress cover surface), which would typically also include one or
more means for airflow (e.g. air permeable element, such as high
airflow fabric, such as spacer fabric or mesh fabric (for example
150 gsm 100% polyester spacer mesh fabric and/or restricting
airflow CFM less than about 35% at 3 PSI and/or a spacer fabric
with a thickness of about 3.5 mm, a weight of about 245 g/m.sup.2,
and/or an air permeability of about 636 ft3/ft2/minute at 0.018 PSI
(e.g. per ASTM D737-96--Standard Test Method for Air Permeability
of Textile Fabrics) and/or such high airflow fabric may be
(inherently) fire resistant (FR--e.g. meeting US Federal Std.
1633))). The upper surface of the mattress cover might be similar
in materials and/or airflow to the lower surface of the mattress
cover, or it could be formed of some other breathable material
(e.g. with a loose weave), even if less breathable than the lower
surface of the mattress cover. In FIG. 9 and similar embodiments,
the mattress support/comfort elements/components would not include
metal springs and/or would be (substantially) all-foam (e.g. a
plurality of foam layers). One or more of the foam layers might be
fire resistant, and in some embodiments might be inherently FR. The
mattress as a whole and/or the ventilation sleep system (formed by
the ventilation mattress atop the ventilation foundation as a
whole) would typically meet or exceed U.S. Fed. Std. 1633 with
respect to fire resistance. In some embodiments, the foam pillars
of the sculpted surface would cover substantially/approximately one
entire surface of a foam layer (e.g. a top and/or bottom surface of
one or more foam layers).
[0094] So for example, ventilation passageways in the mattress
(e.g. in one or more foam layers within the mattress cover) in
fluid communication with the lower surface of the ventilation
mattress (which typically has an airflow means, such as high
airflow fabric, such as spacer fabric or mesh fabric) may open
and/or close based on movement of the user atop the mattress, such
that the user's natural body movements while laying atop the
mattress may provide a billows effect that draws/sucks air in
and/or expels/blows air out of the mattress via such ventilation
passageways (e.g. vertical pinholes)). The billows effect could
arise from mattresses with horizontal ventilation passageways
and/or vertical ventilation passageways. For example, air might be
blown out of some vertical ventilation passageways (e.g. vertical
pinholes) and sucked into other vertical ventilation passageways
(e.g. vertical pinholes), based on air pressure gradients caused by
the user's natural body movements atop the mattress (for example,
foam in the mattress surrounding the ventilation passageways may
compress when a user's body weight acts upon the mattress, such
that user movement atop the mattress may provide a billows effect).
In this way, the billows effect of such ventilation mattresses may
improve air circulation through the mattress (especially when used
with a ventilation foundation and/or when the ventilation
passageways are in fluid communication with the air flow means
(e.g. high airflow fabric)), which may in turn also provide cooling
and/or evaporation benefits that could lead to a more comfortable
sleep surface. The ventilation mattress exemplary embodiments
described herein may, for example, provide such billows effect.
[0095] Thus, when a ventilation mattress is located atop a
ventilation/breathable foundation (as in FIG. 9), with the lower
surface of the mattress cover directly adjacent to and/or
contacting the upper surface of the ventilation foundation cover,
movement of the user atop the mattress may drive air into and out
of the mattress and/or between the mattress and the foundation (for
example, due to a billows effect). Typically, the ventilation
mattress and the ventilation/breathable foundation are selected to
correspond, for example having similar airflow capabilities (e.g.
with the lower surface of the mattress cover matching the upper
surface of the foundation cover) and/or to match airflow
capabilities (of one or both), for example to the billows effect
capability of the mattress (or alternatively to the airflow rate of
the air flow unit of some foundation embodiments). This improved
airflow may enhance comfort for the user, for example dissipating
heat build-up (which can be particularly helpful for certain types
of foam, such as memory foam) and/or moisture build-up. It may also
help to refresh the mattress, for example moving dust and other
allergens out of the mattress. Thus, disclosed foundations,
mattresses, and/or sleep systems may provide users with a better
night's sleep.
[0096] The following are particular embodiments of the subject
matter disclosed herein.
[0097] Embodiment No. 1 is a sleep system comprising a mattress,
which comprises a mattress cover; and one or more foam layers
within the mattress cover; wherein the mattress cover comprises a
bottom surface; wherein the bottom surface of the mattress cover
comprises a mattress air permeable element (e.g. high airflow
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))); wherein the
mattress is spring-free; wherein the one or more foam layers each
comprise a plurality of substantially vertical air passageways
which pass through the entire thickness of the corresponding foam
layer; wherein the one or more foam layers comprise: a base layer
of foam comprising a sculpted upper surface with a plurality of
foam pillars projecting upward; a transition layer of foam with
uniform thickness located atop and in contact with the upper
surface of the base foam layer; a middle sculpted layer of foam
having a sculpted lower surface with a plurality of foam pillars
projecting downward, wherein the middle sculpted layer of foam is
located atop and in contact with the transition layer of foam; and
a top layer of foam with uniform thickness, which is located above
the middle sculpted layer; and a mattress foundation, which
comprises a support structure; and a foundation cover comprising an
upper surface; wherein the upper surface of the foundation cover
comprises a foundation air permeable element (e.g. high airflow
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))); and wherein the
mattress is located atop the foundation, and wherein the mattress
and foundation are in fluid communication with each other.
[0098] Embodiment No. 2 is the sleep system of Embodiment No. 1,
wherein the middle sculpted layer of foam further comprises a
sculpted upper surface with a plurality of foam pillars projecting
upward; and wherein the foam pillars of the middle sculpted layer
of foam are sized within the range including 1-to-1-4-to-1 with
respect to the foam pillars of the base layer of foam (such that
the foam pillars of the middle sculpted foam layer each range in
cross-section size from being equally sized to the base layer
pillars down to being a quarter the size of the base layer pillars
(i.e. four middle sculpted layer pillars per one base layer
pillar)).
[0099] Embodiment No. 3 is a sleep system comprising a mattress,
which comprises a cover; wherein the cover comprises a bottom
surface, and wherein the bottom surface comprises an air permeable
element (e.g. high airflow fabric (for example 150 gsm 100%
polyester spacer fabric or mesh fabric and/or restricting airflow
CFM less than about 35% at 3 PSI and/or a spacer fabric with a
thickness of about 3.5 mm, a weight of about 245 g/m.sup.2, and/or
an air permeability of about 636 ft3/ft2/minute at 0.018 PSI (e.g.
per ASTM D737-96--Standard Test Method for Air Permeability of
Textile Fabrics))).
[0100] Embodiment No. 4 is the sleep system of Embodiment No. 3,
wherein the entire bottom surface of the mattress cover is formed
of high airflow mesh fabric.
[0101] Embodiment No. 5 is the sleep system of Embodiment No. 3,
wherein the mattress cover further comprises an upper surface, and
wherein the upper surface comprises a second air permeable element
(e.g. high airflow fabric (for example 150 gsm 100% polyester
spacer fabric or mesh fabric and/or restricting airflow CFM less
than about 35% at 3 PSI and/or a spacer fabric with a thickness of
about 3.5 mm, a weight of about 245 g/m.sup.2, and/or an air
permeability of about 636 ft3/ft2/minute at 0.018 PSI (e.g. per
ASTM D737-96--Standard Test Method for Air Permeability of Textile
Fabrics))).
[0102] Embodiment No. 6 is the sleep system of Embodiment No. 3,
wherein the mattress further comprises one or more foam layers
within the mattress cover.
[0103] Embodiment No. 7 is the sleep system of Embodiment No. 6,
wherein the mattress is spring-free.
[0104] Embodiment No. 8 is the sleep system of Embodiment No. 6,
wherein the one or more foam layers (or in some embodiments, all
foam layers) each comprise a plurality of substantially vertical
air passageways.
[0105] Embodiment No. 9 is the sleep system of Embodiment No. 8,
wherein the one or more foam layers comprise a base layer of foam
comprising a sculpted upper surface with a plurality of foam
pillars projecting upward; a transition layer of foam with uniform
thickness located atop and in contact with the upper surface of the
base foam layer; a middle sculpted layer of foam having a sculpted
lower surface with a plurality of foam pillars projecting downward,
wherein the middle sculpted layer of foam is located atop and in
contact with the transition layer of foam; and a top layer of foam
with uniform thickness, which is located above the middle sculpted
layer.
[0106] Embodiment No. 10 is the sleep system of Embodiment No. 9,
wherein the middle sculpted layer of foam further comprises a
sculpted upper surface with a plurality of foam pillars projecting
upward.
[0107] Embodiment No. 11 is the sleep system of Embodiment No. 10,
wherein the sculpted upper surface of the middle sculpted layer of
foam comprises pillars of a different size than the sculpted lower
surface of the middle sculpted layer of foam.
[0108] Embodiment No. 12 is the sleep system of Embodiment No. 10,
wherein the foam pillars of the sculpted upper surface of the
middle sculpted layer are a quarter of the size of the
corresponding pillars of the sculpted lower layer of the middle
sculpted layer of foam.
[0109] Embodiment No. 13 is the sleep system of Embodiment No. 9,
wherein the foam pillars of the middle sculpted layer of foam are
sized within the range including 1-to-1-4-to-1 with respect to the
foam pillars of the base layer of foam (such that the foam pillars
of the middle sculpted foam layer each range in cross-section size
from being equally sized to the base layer pillars down to being a
quarter the size of the base layer pillars (i.e. four middle
sculpted layer pillars per one base layer pillar)).
[0110] Embodiment No. 14 is the sleep system of Embodiment No. 9,
wherein the one or more foam layers further comprises a penultimate
foam layer with uniform thickness located atop and in contact with
the middle sculpted layer and beneath and in contact with the top
layer of foam.
[0111] Embodiment No. 15 is the sleep system of Embodiment No. 9,
wherein at least some of the substantially vertical air passageways
in the foam layers align to provide continuous airflow paths from
the bottom surface of the mattress to an upper surface of the
mattress.
[0112] Embodiment No. 16 is the sleep system of Embodiment No. 3,
further comprising a mattress foundation, which comprises a support
structure; and a cover comprising an upper surface, and wherein the
upper surface of the foundation cover comprises a foundation air
permeable element (e.g. high airflow fabric (for example 150 gsm
100% polyester spacer fabric or mesh fabric and/or restricting
airflow CFM less than about 35% at 3 PSI and/or a spacer fabric
with a thickness of about 3.5 mm, a weight of about 245 g/m.sup.2,
and/or an air permeability of about 636 ft3/ft2/minute at .018 PSI
(e.g. per ASTM D737-96--Standard Test Method for Air Permeability
of Textile Fabrics) and/or the entire upper surface comprises such
high airflow fabric)); wherein the mattress is located atop the
foundation and wherein the mattress and foundation are in fluid
communication with each other.
[0113] Embodiment No. 17 is the sleep system of Embodiment No. 16,
wherein the foundation cover further comprises a port and/or a
second foundation air permeable element (e.g. high airflow fabric
(for example 150 gsm 100% polyester spacer fabric or mesh fabric
and/or restricting airflow CFM less than about 35% at 3 PSI and/or
a spacer fabric with a thickness of about 3.5 mm, a weight of about
245 g/m.sup.2,and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics) and/or Polyester
Non-Woven Fabric with a thickness of about 0.004 mm and/or a weight
of about 1.5 oz./ft.sup.2), for example located on the lower
surface of the foundation cover) for fluid communication of the
foundation with the outside environment.
[0114] Embodiment No. 18 is the sleep system of Embodiment No. 17,
further comprising an airflow unit (operable to provide forced air
flow through the foundation), wherein the air flow unit is located
within the support structure and cover of the foundation.
[0115] Embodiment No. 19 is the sleep system of Embodiment No. 18,
wherein the air flow unit comprises filtration.
[0116] Embodiment No. 20 is the sleep system of Embodiment No. 18,
wherein the air flow unit comprises a climate control unit operable
to cool or heat air.
[0117] Embodiment No. 21 is the sleep system of Embodiment No. 8,
wherein the one or more foam layers comprise two sculpted foam
layers, each comprising a sculpted surface with a plurality of foam
pillars.
[0118] Embodiment No. 22 is the sleep system of Embodiment No. 21,
wherein the two sculpted foam layers comprise a lower sculpted foam
layer with sculpted surface facing upward; and an upper sculpted
foam layer with sculpted surface facing downward.
[0119] Embodiment No. 23 is the sleep system of Embodiment No. 22,
wherein the upper sculpted foam layer further comprises a second
sculpted surface facing upward.
[0120] Embodiment No. 24 is a ventilation (e.g. airflow/breathable)
mattress foundation comprising a support structure; and a cover
comprising an upper surface, and wherein the upper surface of the
foundation cover comprises a foundation air permeable element (e.g.
high airflow fabric (for example 150 gsm 100% polyester spacer
fabric or mesh fabric and/or restricting airflow CFM less than
about 35% at 3 PSI and/or a spacer fabric with a thickness of about
3.5 mm, a weight of about 245 g/m.sup.2, and/or an air permeability
of about 636 ft3/ft2/minute at 0.018 PSI (e.g. per ASTM
D737-96--Standard Test Method for Air Permeability of Textile
Fabrics) and/or the entire upper surface comprises such high
airflow fabric)).
[0121] Embodiment No. 25 is the foundation of Embodiment No. 24,
wherein the cover further comprises a second foundation air
permeable element (e.g. high airflow fabric (for example 150 gsm
100% polyester spacer fabric or mesh fabric and/or restricting
airflow CFM less than about 35% at 3 PSI and/or a spacer fabric
with a thickness of about 3.5 mm, a weight of about 245 g/m.sup.2,
and/or an air permeability of about 636 ft3/ft2/minute at 0.018 PSI
(e.g. per ASTM D737-96--Standard Test Method for Air Permeability
of Textile Fabrics) and/or Polyester Non-Woven Fabric with a
thickness of about 0.004 mm and/or a weight of about 1.5
oz./ft.sup.2)), for example located on the lower surface of the
foundation cover) for fluid communication of the foundation with
the outside environment.
[0122] Embodiment No. 26 is the foundation of Embodiment No. 24,
wherein the entire upper surface of the foundation cover comprises
a high airflow fabric (e.g. high airflow spacer fabric or mesh
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))).
[0123] Embodiment No. 27 is the foundation of Embodiment No. 26,
wherein the entire lower surface of the foundation cover comprises
a high airflow fabric (e.g. high airflow spacer fabric or mesh
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics) and/or Polyester
Non-Woven Fabric with a thickness of about 0.004 mm and/or a weight
of about 1.5 oz./ft.sup.2)).
[0124] Embodiment No. 28 is the foundation of one of Embodiment
Nos. 24-27, further comprising a substrate located beneath the
upper surface of the foundation cover.
[0125] Embodiment No. 29 is the foundation of Embodiment No. 28,
wherein the substrate is breathable and/or FR (e.g. Polyester
Non-Woven Fabric with a thickness of about 0.05 mm, a weight of
about 4.8 oz./ft.sup.2, and/or an air permeability of about 212
ft3/ft2/minute and/or spans the entire upper surface of the
foundation, e.g. across all slats of the support/frame).
[0126] Embodiment No. 30 is the foundation of one of Embodiment
Nos. 26-29, wherein the upper surface of the cover of the
foundation is (e.g. inherently) FR.
[0127] Embodiment No. 31 is a ventilated sleep system comprising a
ventilation (airflow/breathable) mattress foundation as in one of
Embodiment Nos. 24-30; and a ventilated mattress located atop the
foundation.
[0128] Embodiment No. 32 is the sleep system of Embodiment No. 31,
wherein the ventilated mattress is configured to provide a billows
effect.
[0129] Embodiment No. 33 is the sleep system of one of Embodiment
Nos. 31-32, wherein the mattress comprises a mattress cover
encompassing the mattress, wherein the mattress cover comprises a
lower surface, and wherein the lower surface of the mattress cover
comprises a mattress air permeable element (e.g. high airflow
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))).
[0130] Embodiment No. 34 is the sleep system of on of Embodiment
Nos. 32-33, wherein the mattress comprises one or more foam layers,
wherein one of the one or more foam layers comprises ventilation
passageways in fluid communication with the lower surface of the
mattress, and one of the one or more foam layers comprises a
sculpted surface (e.g. having a plurality of foam pillars, which
typically would be separated from each other by gaps or grooves
forming a grid).
[0131] Embodiment No. 35 is the sleep system of Embodiment No. 34,
wherein the ventilation passageways comprise a plurality of
vertical ventilation passageways.
[0132] Embodiment No. 36 is the sleep system of Embodiment No. 35,
wherein the gaps/grooves of the sculpted foam layer (e.g. forming
the foam pillars) form horizontal ventilation passageways.
[0133] Embodiment No. 37 is the sleep system of one of Embodiment
Nos. 31-36, wherein the mattress and the foundation are in fluid
communication.
[0134] Embodiment No. 38 is the sleep system of one of Embodiment
Nos. 31-37, wherein the mattress cover further comprises an upper
surface with an air permeable element (e.g. high airflow fabric
(for example 150 gsm 100% polyester spacer fabric or mesh fabric
and/or restricting airflow CFM less than about 35% at 3 PSI and/or
a spacer fabric with a thickness of about 3.5 mm, a weight of about
245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))).
[0135] Embodiment No. 39 is a ventilation mattress comprising one
or more foam layers; and a cover enclosing/encompassing the foam
layers; wherein the cover comprises a lower surface with an air
permeable element (e.g. high airflow fabric (for example 150 gsm
100% polyester spacer fabric or mesh fabric and/or restricting
airflow CFM less than about 35% at 3 PSI and/or a spacer fabric
with a thickness of about 3.5 mm, a weight of about 245 g/m.sup.2,
and/or an air permeability of about 636 ft3/ft2/minute at 0.018 PSI
(e.g. per ASTM D737-96--Standard Test Method for Air Permeability
of Textile Fabrics))); and wherein the foam layers of the mattress
are configured to provide a billows effect.
[0136] Embodiment No. 40 is the mattress of Embodiment No. 39,
wherein at least one of the foam layers (and in some embodiments
all foam layers) comprises ventilation passageways in fluid
communication with the lower surface of the mattress cover.
[0137] Embodiment No. 41 is the mattress of one of Embodiment Nos.
39-40, wherein at least one of the foam layers comprises a sculpted
surface (e.g. with foam pillars, separated by a gird of
grooves/gaps and typically spanning substantially all of the foam
layer surface).
[0138] Embodiment No. 42 is the mattress of one of Embodiment Nos.
39-41, wherein the mattress cover further comprises an upper
surface with an air permeable element (e.g. high airflow fabric
(for example 150 gsm 100% polyester spacer fabric or mesh fabric
and/or restricting airflow CFM less than about 35% at 3 PSI and/or
a spacer fabric with a thickness of about 3.5 mm, a weight of about
245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics))), and wherein the
ventilation passageways are in fluid communication with the upper
surface of the mattress cover.
[0139] Embodiment No. 43 is a method of forming a ventilation sleep
system (e.g. comprising any of claims 1-42), comprising the steps
of providing a ventilation (e.g. airflow) mattress foundation;
providing a ventilation mattress; placing/configuring the mattress
atop the foundation in a configuration for providing fluid
communication between the mattress and the foundation.
[0140] Embodiment No. 44 is the method of Embodiment No. 43,
wherein the ventilation mattress is configured to provide airflow
through a lower surface of its cover.
[0141] Embodiment No. 45 is the method of one of Embodiment Nos.
43-44, wherein the ventilation foundation is configured to provide
airflow through an upper surface of its cover.
[0142] Embodiment No. 46 is the method of one of Embodiment Nos.
43-44, wherein the ventilation mattress is configured to provide a
billows effect.
[0143] Embodiment No. 47 is the method of one of Embodiment Nos.
43-46, further comprising configuring the mattress to provide
airflow through a lower and/or upper surface of its cover.
[0144] Embodiment No. 48 is the method of one of Embodiment Nos.
43-47, further comprising constructing the mattress by providing a
mattress cover with a lower surface comprising an air permeable
element (e.g. high airflow fabric (for example 150 gsm 100%
polyester spacer fabric or mesh fabric and/or restricting airflow
CFM less than about 35% at 3 PSI and/or a spacer fabric with a
thickness of about 3.5 mm, a weight of about 245 g/m.sup.2, and/or
an air permeability of about 636 ft3/ft2/minute at 0.018 PSI (e.g.
per ASTM D737-96--Standard Test Method for Air Permeability of
Textile Fabrics))); placing one or more foam layers within a
mattress cover; and closing the cover so that the cover
encloses/encompasses the foam layers.
[0145] Embodiment No. 49 is the method of one of Embodiment Nos.
43-48, wherein the one or more foam layers are configured for
billows effect.
[0146] Embodiment No. 50 is the method of one of Embodiment Nos.
43-49, wherein one or more of the foam layers comprises a plurality
of ventilation passageways and/or a sculpted foam surface forming a
plurality of foam pillars (e.g. spanning substantially an entire
surface of one of the foam layers).
[0147] Embodiment No. 51 is the method of one of Embodiment Nos.
43-50, wherein the ventilation passageways are in fluid
communication with the lower surface of the mattress cover (and/or
the upper surface of the mattress).
[0148] Embodiment No. 52 is the method of one of Embodiment Nos.
43-51, wherein the ventilation passageways provide fluid
communication through the mattress (thickness) from the lower
surface to the upper surface.
[0149] Embodiment No. 53 is the method of one of Embodiment Nos.
43-52, further comprising constructing the foundation by providing
a foundation cover with an upper surface comprising an air
permeable element (e.g. high airflow fabric (for example 150 gsm
100% polyester spacer fabric or mesh fabric and/or restricting
airflow CFM less than about 35% at 3 PSI and/or a spacer fabric
with a thickness of about 3.5 mm, a weight of about 245 g/m.sup.2,
and/or an air permeability of about 636 ft3/ft2/minute at 0.018 PSI
(e.g. per ASTM D737-96--Standard Test Method for Air Permeability
of Textile Fabrics))) configured for fluid communication with the
ventilation mattress; providing a structural support/frame;
enclosing the structural support frame with the foundation cover,
thereby forming a hollow cavity within the foundation.
[0150] Embodiment No. 54 is the method of one of Embodiment Nos.
43-53, wherein the foundation cover further comprises a lower
surface comprising an air permeable element (e.g. high airflow
fabric (for example 150 gsm 100% polyester spacer fabric or mesh
fabric and/or restricting airflow CFM less than about 35% at 3 PSI
and/or a spacer fabric with a thickness of about 3.5 mm, a weight
of about 245 g/m.sup.2, and/or an air permeability of about 636
ft3/ft2/minute at 0.018 PSI (e.g. per ASTM D737-96--Standard Test
Method for Air Permeability of Textile Fabrics) and/or Polyester
Non-Woven Fabric with a thickness of about 0.004 mm and/or a weight
of about 1.5 oz./ft.sup.2)) configured to allow fluid communication
with an external environment.
[0151] Embodiment No. 55 is the method of one of Embodiment Nos.
43-54, further comprising selecting the ventilation mattress to
correspond to the ventilation foundation.
[0152] Embodiment No. 56 is the method of one of Embodiment Nos.
43-55, wherein airflow/fluid communication between the mattress and
the foundation is (solely) generated by billows effect of user
movement atop the mattress.
[0153] Embodiment No. 57 is the method of one of Embodiment Nos.
55-56, wherein the ventilation mattress corresponds to the
ventilation foundation when the type and/or amount (e.g. surface
area) and/or the location of the high airflow fabric for the
ventilation mattress matches/corresponds to/is the same as that for
the ventilation foundation.
[0154] For additional details that may be relevant for some
embodiments (particularly some mattress embodiments and/or systems
having mattress embodiments), U.S. patent application Ser. No.
14/681,278 (entitled "Independent Foam Spring Mattress" and filed
Apr. 8, 2015, along with related provisional patent application No.
61/977,989 entitled "Independent Foam Spring Mattress" and filed
Apr. 10, 2014), U.S. patent application Ser. No. 15/183,348
(entitled "Mattress Ventilating Foundation and Sleep System" filed
Jun. 15, 2016), and U.S. patent application Ser. No. 14/471,689
(entitled "Moisture Dissipation Mattress Component" and filed Aug.
28, 2014) are hereby incorporated by reference for all purposes as
if reproduced in their entirety to the extent that they are
compatible (e.g. not inconsistent) with and/or do not directly
contradict disclosure herein (e.g. the explicit disclosure herein
would always govern/trump in instances of contradiction,
inconsistency, or incompatibility). Specifically, details about the
foam layers and/or formation of the foam layers from the
incorporated by reference U.S. Patent Applications might be used in
some mattress and/or sleep system embodiments (for example, within
a mattress cover as described herein).
[0155] While various embodiments in accordance with the principles
disclosed herein have been shown and described above, modifications
thereof may be made by one skilled in the art without departing
from the spirit and the teachings of the disclosure. The
embodiments described herein are representative only and are not
intended to be limiting. Many variations, combinations, and
modifications are possible and are within the scope of the
disclosure. Alternative embodiments that result from combining,
integrating, and/or omitting features of the embodiment(s) are also
within the scope of the disclosure. Accordingly, the scope of
protection is not limited by the description set out above, but is
defined by the claims which follow, that scope including all
equivalents of the subject matter of the claims. Each and every
claim is incorporated as further disclosure into the specification
and the claims are embodiment(s) of the present invention(s).
Furthermore, any advantages and features described above may relate
to specific embodiments, but shall not limit the application of
such issued claims to processes and structures accomplishing any or
all of the above advantages or having any or all of the above
features.
[0156] Additionally, the section headings used herein are provided
for consistency with the suggestions under 37 C.F.R. 1.77 or to
otherwise provide organizational cues. These headings shall not
limit or characterize the invention(s) set out in any claims that
may issue from this disclosure. Specifically and by way of example,
although the headings might refer to a "Field," the claims should
not be limited by the language chosen under this heading to
describe the so-called field. Further, a description of a
technology in the "Background" is not to be construed as an
admission that certain technology is prior art to any invention(s)
in this disclosure. Neither is the "Summary" to be considered as a
limiting characterization of the invention(s) set forth in issued
claims. Furthermore, any reference in this disclosure to
"invention" in the singular should not be used to argue that there
is only a single point of novelty in this disclosure. Multiple
inventions may be set forth according to the limitations of the
multiple claims issuing from this disclosure, and such claims
accordingly define the invention(s), and their equivalents, that
are protected thereby. In all instances, the scope of the claims
shall be considered on their own merits in light of this
disclosure, but should not be constrained by the headings set forth
herein.
[0157] Use of broader terms such as "comprises", "includes", and
"having" should be understood to provide support for narrower terms
such as "consisting of", "consisting essentially of", and
"comprised substantially of". Use of the terms "optionally," "may,"
"might," "possibly," and the like with respect to any element of an
embodiment means that the element is not required, or
alternatively, the element is required, both alternatives being
within the scope of the embodiment(s). Also, references to examples
are merely provided for illustrative purposes, and are not intended
to be exclusive.
[0158] While several embodiments have been provided in the present
disclosure, it should be understood that the disclosed systems and
methods may be embodied in many other specific forms without
departing from the spirit or scope of the present disclosure. The
present examples are to be considered as illustrative and not
restrictive, and the intention is not to be limited to the details
given herein. For example, the various elements or components may
be combined or integrated in another system or certain features may
be omitted or not implemented.
[0159] Also, techniques, systems, subsystems, and methods described
and illustrated in the various embodiments as discrete or separate
may be combined or integrated with other systems, modules,
techniques, or methods without departing from the scope of the
present disclosure. Other items shown or discussed as directly
coupled or communicating with each other may be indirectly coupled
or communicating through some interface, device, or intermediate
component, whether electrically, mechanically, or otherwise. Other
examples of changes, substitutions, and alterations are
ascertainable by one skilled in the art and could be made without
departing from the spirit and scope disclosed herein.
* * * * *