U.S. patent application number 17/156904 was filed with the patent office on 2021-06-24 for temperature-regulating mattress.
The applicant listed for this patent is Casper Sleep Inc.. Invention is credited to Ara Acle, Jeff Chapin, Joshua Chen, Defne Civelekoglu, Christopher Sa Glaister, Russell Jelinek, Eric Konzelmann, Eric Lewis, Jeffrey Mekler.
Application Number | 20210186224 17/156904 |
Document ID | / |
Family ID | 1000005421148 |
Filed Date | 2021-06-24 |
United States Patent
Application |
20210186224 |
Kind Code |
A1 |
Chapin; Jeff ; et
al. |
June 24, 2021 |
Temperature-Regulating Mattress
Abstract
A temperature-regulating mattress system provides dynamic
adjustment of temperature and other parameters throughout a user's
sleep cycle to maximize the quality of the user's sleep, Features
of the system may include: (a) heating and cooling temperature
regulation (with dynamic custom profiles that control humidity and
are dual-zone); (b) smart controls (with remotes and apps that
learn from users to optimize settings and work with smart home
products such as Alexa and interactive lighting systems); (c)
comfort (with a mattress that provide the necessary support for its
users); and (d) sensors used for temperature and humidity
estimation algorithms, control mechanism, and additional inferences
from those sensors (pose, enrichment of biometric sensing data,
etc.).
Inventors: |
Chapin; Jeff; (Lander,
WY) ; Glaister; Christopher Sa; (Oakland, CA)
; Acle; Ara; (Oakland, CA) ; Civelekoglu;
Defne; (Berkeley, CA) ; Jelinek; Russell;
(Alameda, CA) ; Konzelmann; Eric; (Groveland,
CA) ; Lewis; Eric; (Ben Lomond, CA) ; Mekler;
Jeffrey; (Gilford, NH) ; Chen; Joshua; (San
Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Casper Sleep Inc. |
New York |
NY |
US |
|
|
Family ID: |
1000005421148 |
Appl. No.: |
17/156904 |
Filed: |
January 25, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16390194 |
Apr 22, 2019 |
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17156904 |
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62686653 |
Jun 18, 2018 |
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62738782 |
Sep 28, 2018 |
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62753032 |
Oct 30, 2018 |
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62808299 |
Feb 21, 2019 |
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62661623 |
Apr 23, 2018 |
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62966018 |
Jan 26, 2020 |
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62993687 |
Mar 23, 2020 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/15 20130101;
A47C 21/04 20130101 |
International
Class: |
A47C 21/04 20060101
A47C021/04; A47C 27/15 20060101 A47C027/15 |
Claims
1. A mattress system comprising: a laterally extending comfort
layer having a lower surface and an upper surface, said comfort
layer comprising an opening extending through said comfort layer
from the upper surface to the lower surface; a tubular insert
positioned within the opening of said comfort layer and having an
upper end and a lower end, said tubular insert having an
air-impermeable peripheral wall extending between the upper end and
the lower end of said tubular insert, said tubular insert further
comprising a first air-impermeable flange located at one of the
upper end and the lower end of said tubular insert and extending
around the opening at one of the upper surface and the lower
surface of said comfort layer; a laterally extending bottom layer
joined to the lower surface of said comfort layer, said bottom
layer having an aperture that is aligned with the opening at the
lower surface of said comfort layer, the aperture being equal to or
greater than the opening at the lower surface of said comfort
layer; a laterally extending top layer joined to the upper surface
of said comfort layer and having an aperture that is aligned with
the opening at the upper surface of said comfort layer, the
aperture being equal to or greater than the opening at the upper
surface of said comfort layer; wherein one of said top layer and
said bottom layer secures said first flange of said tubular insert
to said comfort layer.
2. The mattress system of claim 1, wherein said tubular insert
comprises a second air-impermeable flange located at the other one
of the upper end and the lower end of said tubular insert, said
second flange extending round the opening at the other one of the
upper surface of said comfort layer and the lower surface of said
comfort layer; and wherein the other one of said top layer and said
bottom layer secures said second flange of said tubular insert to
said comfort layer.
3. The mattress system of claim 1, wherein said laterally extending
comfort layer comprises a plurality of layers.
4. The mattress system of claim 1, wherein the opening in said
comfort layer is vertical.
5. The mattress system of claim 1, wherein the opening in said
comfort layer is slanted.
6. The mattress system of claim 1, wherein said tubular insert
comprises an encapsulated coil spring.
7. The mattress system of claim 1, wherein said air-impermeable
peripheral wall of said tubular insert is accordion shaped, to
allow for contraction and expansion of said tubular insert in
response to changes in vertical loading on said insert.
8. A mattress system comprising: a plurality of laterally extending
foam layers joined together, said plurality of foam layers having
an upper surface and a lower surface, said plurality of foam layers
further having at least one opening extending between the upper
surface and the lower surface of said plurality of foam layers; an
at least one foam insert positioned within said at least one
opening, said at least one foam insert having an upper surface and
a lower surface, said at least one foam insert further comprising a
hole running from the upper surface of said at least one foam
insert to the lower surface of said at least one foam insert; and a
fan located below said plurality of foam layers, said fan
configured to force air through the hole in said foam insert toward
the upper surface of said foam insert; wherein the interior surface
of said hole in the foam insert is air-impermeable; wherein the
upper surface of said at least one foam insert is aligned with the
upper surface of said plurality of laterally extending foam layers;
and wherein the lower surface of said at least one foam insert is
aligned with the lower surface of said plurality of laterally
extending foam layers.
9. The mattress system of claim 8, wherein the interior surface of
said foam insert is air-impermeable due to a self-skinning property
of said foam insert.
10. The mattress system of claim 8, wherein the interior surface of
said foam insert is air-impermeable due to a sealant applied to the
interior surface.
11. The mattress system of claim 8, wherein the hole in said foam
insert is vertical.
12. The mattress system of claim 8, wherein the hole in said foam
insert is slanted.
13. The mattress system of claim 8, further including a thermal
conditioning element positioned between said fan and said foam
insert, said thermal conditioning element enabling thermal
conditioning of the air forced by said fan through the hole in said
foam insert.
14. A mattress comprising: a plurality of laterally extending foam
layers joined together, said plurality of foam layers having an at
least one opening therethrough, said opening located in a torso
zone of said mattress; a foam insert positioned withing the
opening, said foam insert comprising a hole therethrough for
allowing airflow between a top surface of said mattress and a
bottom surface of said mattress; wherein the interior surface of
said hole in air-impermeable; and wherein said foam insert
increases support in the torso zone of said mattress.
15. The mattress system of claim 14, wherein the interior surface
of said foam insert is air-impermeable due to a self-skinning
property of said foam insert.
16. The mattress system of claim 14, wherein the interior surface
of said foam insert is air-impermeable due to an applied
sealant.
17. The mattress system of claim 14, wherein the hole in said foam
insert is vertical.
18. The mattress system of claim 14, wherein the hole in said foam
insert is slanted.
19. The mattress in claim 14, wherein said foam insert is
molded.
20. The mattress in claim 14, wherein said foam insert comprises a
plurality of stacked die cut foam layers.
Description
REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 16/390,194 filed on Apr. 22, 2019, which
itself claims the benefit of:
[0002] 1) U.S. Provisional Application Ser. No. 62/661,623 filed on
Apr. 23, 2018;
[0003] 2) U.S. Provisional Application Ser. No. 62/686,653 filed on
Jun. 18, 2018;
[0004] 3) U.S. Provisional Application Ser. No. 62/738,782 filed on
Sep. 28, 2018;
[0005] 4) U.S. Provisional Application Ser. No. 62/753,032 filed on
Oct. 30, 2018; and
[0006] 5) U.S. Provisional Application Ser. No. 62/808,299 filed on
Feb. 21, 2019;
This application also claims the benefit of U.S. Provisional
Application Ser. No. 62/966,018 filed on Jan. 26, 2020, and of U.S.
Provisional Application Ser. No. 62/993,687 filed on Mar. 23, 2020.
Each of the applications identified above is incorporated by
reference herein in its entirety.
FIELD OF THE DISCLOSURE
[0007] The present disclosure relates generally to an improved
mattress system with an ability to provide a dynamic responsive
environment for its user or users.
BACKGROUND
[0008] The majority of people experience disruptions to their sleep
due to temperature problems at least a few nights a month. Existing
solutions (such as air conditioning, ceiling fans, room heaters,
open windows and the like) are not effective for temperature
regulation during sleep. There is therefore a need for an improved
method to provide a comfortable sleeping experience by dynamically
maintaining the proper temperature during the sleep cycle.
SUMMARY
[0009] A temperature-regulating mattress system provides dynamic
adjustment of temperature throughout a user's sleep cycle to
maximize the quality of the user's sleep, Features of the system
may include: (a) heating and cooling temperature regulation (with
dynamic custom profiles that control humidity and are dual-zone);
(b) smart controls (with remotes and apps that learn from users to
optimize settings and work with smart home products such as Alexa
and interactive lighting systems); (c) comfort (with a mattress
that provide the necessary support for its users); and (d) sensors
used for temperature and humidity estimation algorithms, control
mechanism, and additional inferences from those sensors (pose,
enrichment of biometric sensing data, etc.).
BRIEF DESCRIPTION OF THE FIGURES
[0010] The accompanying figures, where like reference numerals
refer to identical or functionally similar elements throughout the
separate views, together with the detailed description below, are
incorporated in and form part of the specification, and serve to
further illustrate embodiments of concepts that include the claimed
invention and explain various principles and advantages of those
embodiments.
[0011] FIG. 1A shows a functional diagram of the
temperature-regulating mattress system.
[0012] FIG. 1B shows a block diagram of the temperature-regulating
mattress system.
[0013] FIG. 2 shows a thermal diagram of the temperature-regulating
mattress system.
[0014] FIG. 3 shows a temperature-regulating mattress system having
integrated sensors.
[0015] FIG. 4A shows a wireless communication path diagram of a
temperature-regulating mattress system.
[0016] FIG. 4B shows a wireless communication path diagram of an
app controlling a mattress system.
[0017] FIGS. 5, 6, 7 and 8 show exploded views of a
temperature-regulating mattress system.
[0018] FIGS. 9,10 and 11 show cross-sections of a
temperature-regulating mattress system.
[0019] FIG. 12 shows a schematic of a sensor.
[0020] FIG. 13 shows a cross-section of a temperature-regulating
mattress system with integrated sensors.
[0021] FIG. 14 shows sensors embedded in a comfort layer.
[0022] FIG. 15 shows sensors embedded in tethered layers.
[0023] FIG. 16 shows sensors embedded in a mattress cover.
[0024] FIG. 17 shows assembly of a cover over a mattress
system.
[0025] FIG. 18A shows an exploded view of a mattress cover.
[0026] FIG. 18B shows an exploded view of a base cover.
[0027] FIG. 19 shows a detailed view of a seams within the mattress
cover and base cover.
[0028] FIG. 20 shows further detail of the bottom cover of a
temperature-regulating mattress system.
[0029] FIGS. 21 and 22 show schematics of an integrated mattress
base.
[0030] FIGS. 23, 24A and 24B show schematics of a modular mattress
base.
[0031] FIGS. 25 and 26 show schematics of a mattress base
layer.
[0032] FIG. 27 shows internal wiring of a base layer.
[0033] FIG. 28 shows external wiring of a base layer.
[0034] FIGS. 29A and 29B show schematics of an adjustable base
layer.
[0035] FIGS. 29C and 29D show hinges in an adjustable base
layer.
[0036] FIG. 29E shows a folded base layer.
[0037] FIGS. 30A, 30B, 31 and 32 show schematics of an integrated
airbox.
[0038] FIGS. 33A, 33B, 34 and 35 show schematics of a modular
airbox.
[0039] FIG. 36 shows a cross-section of a mattress system showing
air delivery channels.
[0040] FIGS. 37 and 38 show a schematic of air distribution
patterns in a mattress system.
[0041] FIGS. 39A, 39B, 39C, 39D, 39E and 39F show various methods
for sealing surface of holes or slots in a mattress.
[0042] FIGS. 40A, 40B and 40C show configurations to improve
airflow in a mattress system.
[0043] FIG. 41A shows a schematic of a remote for a mattress
system.
[0044] FIG. 41B shows a cross-section and FIG. 41C shows an
exploded views of the remote in FIG. 41A.
[0045] FIGS. 42, 43, 44 and 45 show schematics of alternative
remotes for mattress system.
[0046] FIGS. 46A, 46B, and 46C show various additional embodiments
of holes or slots in a mattress.
[0047] FIGS. 47A and 47B show various additional embodiments of
holes or slots in a mattress.
[0048] FIGS. 48A and 48B show various additional embodiments of
holes or slots in a mattress.
[0049] FIGS. 49A and 49B show various additional embodiments of
holes or slots in a mattress.
[0050] FIGS. 50A and 50B show various additional embodiments of
holes or slots in a mattress.
[0051] FIG. 51 shows views of a mattress system using inserts with
holes or slots.
[0052] FIGS. 52A, 52B, 52C, 52D, 52E, and 52F show various
embodiments of the inserts in FIG. 51.
[0053] FIG. 53 shows another embodiment of a mattress system using
inserts with holes or slots.
[0054] FIG. 54 shows an embodiment of a mattress system using
inserts for forming holes or slots.
[0055] FIG. 55 shows another embodiment of a mattress system with
holes or slots.
[0056] FIG. 56 shows another embodiment of a mattress system with
holes or slots.
[0057] FIGS. 57A, 57B, 57C, and 57D show an embodiment of a
seven-layer mattress system that uses tubular inserts.
[0058] FIGS. 58A, 58B, and 58C show cross-sectional views of
another set of embodiments of a mattress system with holes or
slots.
[0059] FIGS. 59A, 59B, and 59C show cross-sectional views of
another set of embodiments of a mattress system using molded
insert.
[0060] FIGS. 60A and 60B show cross-sectional views of a set of
embodiments of a mattress system using die cut inserts.
[0061] FIGS. 61A, 61B, and 61C show cross-sectional views of a set
of mattress system embodiments having drilled holes.
[0062] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions of
some of the elements in the figures may be exaggerated relative to
other elements to help to improve understanding of embodiments of
the present invention.
[0063] The apparatus and method components have been represented
where appropriate by conventional symbols in the drawings, showing
only those specific details that are pertinent to understanding the
embodiments of the present invention so as not to obscure the
disclosure with details that will be clear to those of ordinary
skill in the art having the benefit of the description herein.
DETAILED DESCRIPTION
I. Introduction
[0064] Devices and algorithm for determining and controlling
temperature experienced by users under blankets in bedding may be
deployed. Sensors positioned at the mattress surface are used in
conjunction with a controls model for bedding to estimate and
control user experienced temperature, humidity, and position on the
bed. This includes devices being used for temperature and humidity
estimation algorithms, control mechanism, and additional inferences
from those sensors (pose, enrichment of biometric sensing
data).
[0065] A variety of approaches may be used to sense temperature,
humidity, and body pose at the surface of a mattress. Considered
here are wireless surface sensors, as well as wired sensors and
smart fabrics. A wireless surface sensor consists of a battery,
antenna, temperature and humidity sensors, and a capacitive sensor.
The surface sensor measures temperature and humidity using sensor
mounted under metal grill. It uses the metal of the grill for
capacitive sensing of human presence above the sensor, as well as
for improved thermal contact to the sensed environment. It
broadcasts temperature, humidity, capacitive presence (sensor
payload) to controller at regular interval.
[0066] Surface sensors may be placed on a mattress or in holes on
surface of mattress under mattress cover and fitted sheet.
[0067] Surface temperature, humidity, or presence sensors may also
be implemented as a wired solution, or with smart fabrics.
[0068] A temperature control unit receives data (wired or
wirelessly) from surface sensors, as well as from sensors measuring
ambient air temperature and humidity. Based on this data received,
the temperature control unit can control the amount and temperature
of air added to the user's experienced temperature (blanket
microclimate). The technology could apply to other methods of
heating user's experienced temperature, including heated fabrics or
foam.
[0069] Temperature and humidity directly measured from the surface
sensor devices is not the same as what the user in the blanket
microclimate is experiencing. Depending on blanket types, how well
the blanket covers the mattress, how much heat or humidity the user
is generating, and ambient conditions, temperature measured at the
mattress surface may vary as much as 5-7.degree. C. from the
user-experienced temperature.
[0070] To estimate the user-experienced temperature, a temperature
control unit estimates various thermal parameters of the bed. The
device maintains a model of the bedding environment and
continuously calibrates itself to best estimate the value of these
various thermal resistances and capacitances. By estimating the
value of these thermal parameters, the model can maintain an
estimate of the user's experienced temperature. The device
maintains a state-space model of the mattress and uses parameter
identification techniques to estimate bedding parameters.
[0071] Mattresses that accommodate two users can incorporate
airflow or heat flow across two zones of the mattress into their
models for control to control two separate zones of user
experienced temperatures.
[0072] Processing on data from surface sensors that allows system
to estimate user's poses on the bed, which can be used to inform
other algorithms and enrich other sensing data. The sensor knows
when a body is in direct contact and can reject or adjust
temperature readings as needed based on this information.
[0073] Smart bed, heating and cooling bed, use with algorithms that
can incorporate temperature user experiences in bed, user pose on
bed to improve readings of other signals from users, and for
controlling temperature precisely enough to improve sleep.
[0074] The key physics being taking advantage of is that dynamics
of the bed thermal system are governed by a set of differential
equations with parameters corresponding to the amount of heat added
by the user, the thermal resistance of the blanket (such as, is it
thick or thin). Since it is known what heat is being input to the
system from our temperature control unit, it is possible to use the
shape of the heating or cooling curves measured at the surface
sensors to estimate the parameters of the differential equations.
The differential equation-based model of the system may be used to
control its temperature.
[0075] Based on the model's prediction of the microclimate
temperature, the control algorithm adjusts heat and blower
parameters to achieve a tight degree of temperature control (within
a degree or so), which is required to provide precise comfort
profiles through the night that might improve a user's sleep.
[0076] The control algorithm is also able to consistently update
the parameters it's measuring about the state of the bed through
the night to account for user's disruption of blankets,
introduction of ambient air into the microclimate, or other changes
to the environment that might occur overnight. In this way, the
control algorithm is robust to the way the user sleeps.
[0077] The surface sensors also measure humidity. The control
algorithm estimates offset between surface measured humidity and
user experienced humidity, and uses that information to help
control humidity to within a comfortable band for the user.
[0078] The surface sensors also measure capacitive presence above
them. If a sleeper is above the surface sensor, the capacitive
presence may be used to reject the temperature measured by this
sensor (offset by the user's body temperature in this case).
[0079] The surface sensor capacitive presence measurements may be
used to estimate the pose of the user on the bed. This pose may be
used to inform other algorithms in the device. For example, if
there is a contactless heart monitoring system operating
concurrently with the temperature and humidity control algorithm,
pose sensing on the bed might help separate two user's heartbeats
by assessing what relative strength of signal to expect from each
user at various locations.
[0080] Further, devices and algorithm are described herein for
introducing temperature interventions to improve sleep onset,
depth, and wake inertia by measuring biometric signals, including
heart rate, breathing rate, brain activity, motion, and/or
temperature. Various temperature interventions are controlled, in
part, by biometric sensors and algorithms estimating the user's
state (for instance core body temperature, sleep stage) to provide
the optimal temperature at the optimal time (comfort profile). Over
time, the algorithm can learn what comfort profiles improve sleep
onset, sleep depth, and wake inertia for a particular user.
[0081] Smart mattress control user experienced temperature in
blanket microclimate (possibly with independent control of chest
and feet), and measures motion, heart rate and respiration rate,
amongst other biometric signals. Measurements of these various
biometric signals can be through ballistocardiography performed
from under-mattress, in-mattress, or in-mattress-cover, or through
smart fabrics, wearables, radar, camera, or other sensing
mechanisms.
[0082] Core body temperature reduction has been shown to be
important to the onset and depth of sleep. Sleep stage has been
shown to be important to the body's thermal regulation ability. For
instance, during REM sleep, the body isn't able to thermoregulate.
Various thermal interventions (changes to user's experienced
temperature under the blankets) can be used to manipulate core body
temperature and enhance sleep.
[0083] The algorithms use biometric sensing data (motion, heart
rate, and respiration rate) to estimate core body temperature and
sleep stage. Temperature interventions are adjusted real-time based
on the sensor and algorithm outputs.
[0084] By manipulating user's experienced temperature (through foot
warming, skin warming, and other temperature profiles), the device
can use the sensor and algorithm output to confirm that its
temperature therapy is helping the user drop and maintain a low
core body temperature through the night. Temperature therapy can be
adjusted based on biometric feedback to do this. Wakes might be
predicted by observing motion, heart rate, or sleep stage.
Temperature profiles can be adjusted during the night to prevent
those wakes or lull the user back to sleep once they awake.
[0085] Algorithms may control temperature experienced by a user in
order to reduce sleep latency (fall asleep faster), stay asleep
longer (fewer wakeups), sleep more deeply (more REM+Slow Wave
Sleep), and nudge users into a shallower phase of sleep in time for
their desired wakeup time.
[0086] The algorithm may run on an ecosystem of products that
provide lighting, temperature, sound, and other therapies to
improve sleep dynamically--they respond to sensors that are also
distributed in the ecosystem. Sensors in the ecosystem measure
experienced temperature and humidity, light exposure, heart rate,
respiration rate, and other signals.
[0087] Algorithms can tune lighting, temperature, sound, and other
therapies based on sleep quality observed from sensed data.
[0088] Smart bed, heating and cooling bed, use with algorithms that
can incorporate temperature user experiences in bed, Helping normal
users with thermoregulation to help them sleep, helping users with
circulation problems (obesity, diabetes, etc.) and other sleep
issues with thermoregulation to help them sleep, use of other
ecosystem products (temperature, light, sound control before,
during, and after sleep) to improve sleep with biometric sensing in
the mattress as a feedback mechanism to tailor therapies.
[0089] The present devices may use independent temperature control
at the torso and feet through the night to try to improve sleep. A
naive temperature profile delivered by a control device might
provide warmth as the user is falling asleep, cool the user while
they're asleep to prevent night-time wakes, and warm the user up
before wakeup.
[0090] The algorithm uses biometrics data to improve on this naive
temperature control profile. Application of a temperature profile
(heating feet, for instance) is intended to aid the body's normal
thermoregulatory process during the night. This includes cooling
down core body temperature during sleep onset, maintaining lowered
core body temperature through the night, and increasing core body
temperature before wake.
[0091] There is evidence that poor thermoregulation is implicated
in poor sleep for diabetics, the obese, patients who suffer from
Raynaud's disorder, and other circulatory and sleep issues. There
is evidence that normal sleepers thermoregulatory process can be
impacted by food and alcohol consumption before bed, or by hormonal
cycles. Users whose thermoregulatory function is changed may need a
temperature intervention to assist in falling asleep, staying
asleep and waking up.
[0092] This thermoregulatory process can be tracked by watching a
user's heart rate. As core body temperature decreases at the
beginning of the night and increases at the end of the night
(corresponding to metabolism rate decrease and increase), heart
rate also increases and decreases. Heart rate data can be used to
measure the impact of the temperature intervention and to adjust
the temperature accordingly in real time.
[0093] Sleep staging data teased out from heart rate, respiration
rate, motion, EEG, or eye movement detection can be used to assess
quality or depth of sleep night for night, and use machine learning
to optimize sleeping temperatures per user.
[0094] To help users fall asleep, foot warming or other temperature
profiles may be used. In real time, the profiles watch their heart
rate to make sure it is dropping as expected (corresponding to core
body temperature decline).
[0095] Once the heart rate, respiration rate, and motion tracker
detect that the user has fallen asleep, the next phase of
temperature therapy begins.
[0096] While the user is asleep, the heart rate, respiration rate,
and motion are used to predict when a user may wake up during the
night. The same foot warming or other falling-asleep therapy
applied to the user to help lull them back to sleep can be
used.
[0097] Temperature profiles during the night that increase slow
wave and REM sleep may be used. The algorithm measures how much
slow wave and REM sleep was experienced per night and optimize
sleep temperature profile night for night to increase this deeper
sleep.
[0098] Finally, the heart rate may be used to track increasing core
body temperature through full body warming in the time before the
user has to wake up. The sleep stage is monitored to ensure the
user is nudged out of deep or slow wave sleep.
[0099] This same concept of tracking heart rate, respiration rate,
and motion through the night, tying them to core body temperature
and sleep stage through the night, and tuning interventions like
temperature during the night, can be applied to all products
intended to help sleep. This includes light therapy, sound masking,
and various mattress and blanket product choices (firmness,
ergonomics, thermal and humidity performance of bedding). All of
these products can be adjusted to improve sleep depth and quality,
with biometric sensing as a feedback mechanism.
[0100] Biometric and other data that might be relevant as a marker
for sleep quality (phone use, light exposure, diet, alcohol
consumption) can be collected from an ecosystem of sleep sensors,
as well. Interventions from a sleep ecosystem could include (in
additional to temperature, light, and sound interventions) sleep
coaching, diet recommendations, bedding recommendations. In this
way a platform for sleep might be created amongst a wide variety of
devices and data sources.
[0101] While various embodiments discussed herein show wireless and
wired functionality in specific areas, any wired connection may
function via a wireless connection and vice versa. In addition, any
discussion of Bluetooth may include any other wireless protocol
(including Wi-Fi), whether existing now or in the future. Further,
any Bluetooth (or other wireless) node shown herein may operate as
either a master or slave as appropriate.
[0102] In addition, the mattresses discussed herein may be of any
size, including without limitation: twin, full, queen, king,
California king and extra-long (of any size).
[0103] In addition, for a 2-user mattress, the features described
herein may be independently adjusted to provide different
experiences for each user.
[0104] Turning to a more detailed description, the various features
of this temperature-regulating mattress may be classified into
seven overall categories: System, Sensor, Cover, Base, Airbox,
Airflow and Remote. Each will be discussed in turn.
II. System
[0105] The scope and functionality of the temperature-regulating
mattress system taken in the aggregate is described herein.
[0106] Turning to FIG. 1A, shown us a functional diagram of the
temperature-regulating mattress system 100. A legend 112 shows the
various parts of this system: processor, radio/comms, input/sensor,
output/actuator, remote, comfort layer and base layer.
[0107] A main board 108 comprises a system microcontroller unit
(MCU) that provides overall governance of the system and
communicates with other components through a Wi-Fi or Bluetooth
radio. Two high voltage control boards 110 (HVCBs) comprise a
control MCU that provides governance of the control boards and
connects to the system MCU. The control MCU also interfaces with a
plurality of relative humidity (RHT) sensors and current and
voltage (I/V) sensing systems associated with either a heater or a
fan. Two biometric sensors 102 comprise a biometric sensor and a
biometric MCU that provides governance of the biometric sensor and
connects to the system MCU. A plurality of surface sensors 104
comprise a sensors MCU that provides governance of a plurality of
RHT sensors and presence sensors. Two remote systems 106 comprise a
remote MCU that provides governance of the remote and communicates
with the rest of the system via a Bluetooth radio. The remote MCU
has inputs comprising a proximity sensor, button, rotary encoder
and light sensor. The remote MCU outputs to a haptic actuator and a
LED controller that drives LEDs.
[0108] Turning to FIG. 1B, shown is a block diagram of the
temperature-regulating mattress system 150. A mattress 156
coordinates via Bluetooth with two mobile devices 152a, 152b, a
cloud platform/backed 154 and two remotes 158a, 158b.
[0109] Although these figures show specific numbers of devices and
specific types of radio communication, any number of devices and
radio communication types may be used.
[0110] Turning to FIG. 2, shown is a thermal model 200 the
temperature-regulating mattress system. At the top of the thermal
model 200 is the atmosphere 205 followed by the
resistance/capacitance a of blanket 210. This combined with the
heat added by a user comprises a microclimate 240 that sits above
the mattress and below the blanket. Additional
resistance/capacitance 215 of the cover and fitted sheet below the
user is associated with a temperature control unit 220 (airbox).
Surface sensors 230 sit in between the matter and mattress
cover.
[0111] The capacitor/resistor pair 225 models the thermal
relationship between the airbox (temperature control unit 220) and
the location of the surface sensors 230. In other words, how is the
temperature of air coming out of the airbox affecting the
temperature at the surface sensors due to
convection/conduction/radiation between them?
[0112] The capacitor/resistor pair 235 models the thermal
relationship between the temperature in the micro-climate (air
under the covers that the user is in) and the temperature at the
surface sensors (which are separated from the micro-climate by
several layers of fabric, and therefore do not read the
micro-climate temperature directly). Determining the parameters for
these interfaces (e.g. how much does the temperature change between
the two environments, or in other words how much thermal resistance
is there between them) enables a good estimate of the micro-climate
temperature from the temperature measured at the location of the
surface sensors.
[0113] Turning to FIG. 3, shows a temperature-regulating mattress
system having integrated sensors 300. This comprises a mattress 308
having a hidden base layer 310 on the bottom and a transparent
mattress cover 311 on the top. Surface sensors 304a-304h and
ventilation cuts 306a-306d are incorporated within the mattress
308. The surface sensors 304a-304h may include temperature,
humidity and user presence sensors that are integrated into the
mattress cover and are designed to be roll-packed. The ventilation
cuts 306a-306d cut through the comfort layer near the torso and fee
to allow air to distribute through the mattress.
[0114] The hidden base layer 310 is hidden by a fabric cap on a
comfort layer and may be of any relevant size and shape. The
transparent mattress cover 311 may have varying levels of
opacity.
[0115] Turning to FIG. 4A, shown is a wireless communication path
diagram 400 of a temperature-regulating mattress system. The
mattress 422 is divided into two parts, side A 410a and side B
410b. Two consoles/remotes/user input devices 405a, 405b
communicate with an electronics module 412 via Bluetooth. The
electronics module 412 communicates through the cloud to wirelessly
store and retrieve temperature profiles 450. The electronics module
412 may include fans, heaters, coolers, printed circuit boards and
may be removable for servicing.
[0116] Based on the input of the console/remotes/user input devices
405a, 405b and the temperature profiles 450, the electronics module
412 interfaces with foot sensor groups 410a, 410b and torso sensor
groups 408a, 408b. Each of the sensor groups communicates via
Bluetooth with the appropriate temperature, relative humidity and
pressure sensors. The sensors also may measure movement, presence,
heart rate and breathing rate.
[0117] Although this FIG. 4A shows a wireless system, one or more
portions of the system may be wired. Additional sensors may be
placed within the mattress 422 as warranted. And although the
electronics module 412 is shown at the foot of the bed 422,
airboxes may be integrated in the foot and torso portions of the
bed 422 (or other portions).
[0118] Turning to FIG. 4B, shown is a wireless communication path
diagram of an app controlling a mattress system 4600. Comfort
profile storage 4622 interfaces with cloud storage 4650, a remote
4604, an onboarding portal 4632 and a feedback portal 4634 and a
mattress hub 4630.
[0119] The onboarding portal 4632 is designed to collect data about
the user before the user goes to sleep. The data may include the
user's gender, age, weight, sleep pattern, sleep location, desired
temperature, desired relative humidity and the like. The onboarding
portal 4632 may be used to control sleep parameters through the
sleeping process. The remote 4604 may also be used during the sleep
period to adjust sleep parameters through the sleep process. The
advantage of the remote 4604 over the outboarding portal 4632 is
that the remote 4604 only requires simple actions such as a push,
twist or gesture to control the sleep parameters. This allows the
user to easily and quietly adjust parameters throughout the sleep
period without having to boot up an onboarding portal 4632 on a
phone, tablet or other portable device.
[0120] At the end of a sleep period, a user may use a feedback
portal 4634 to report on the quality of sleep, the temperature, the
humidity and other parameters during the sleep period. This data is
reported to the comfort profile storage 4622 to update the user
profiles as appropriate.
[0121] The hub 4630 may also interface wirelessly with sensor
groups 4605, 4606 having temperature, relative humidity and
pressure sensors. The hub 4630 may interface with heaters 4612 and
fans 4614 in the mattress system and their related exhaust
temperature and humidity sensors 4610.
[0122] Although both onboarding portal 4632 and feedback portal
4634 are shown routing through cloud, one or both of portals may
connect directly to a mattress control main board via
Bluetooth/Wi-Fi/wireless or wired connection.
[0123] FIGS. 5, 6, 7 and 8 show exploded views of a
temperature-regulating mattress system.
[0124] Turning to FIG. 5, shown is an exploded views of a
temperature-regulating mattress system 500. On the left is an
unexploded mattress view. On the right side, an exploded view shows
a comfort layer 510 on the top, followed by comfort layer stiffness
adjusters 512, followed by a base layer 514. The comfort layer
stiffness adjusters 512 may be flexible structures made from foam,
rubber, gel or other flexible materials. They may also be air
permeable to aid in air distribution. The base may form protrusions
from air paths between the mattress and bed frame or
foundation.
[0125] Sandwiched between the comfort layer 510 and the base layer
514 is an electronics module 516. The electronics module 516 may
include fans, heaters, printed circuit boards and may be removable
for servicing.
[0126] A side view of a cross-section of a mattress system shows
the electronics module 516 and an air distribution system 518 for
distributing the air throughout the mattress. The system may be
either incorporated into foam as molded or cut channels or a
separately molded part that is inserted into a cavity under the
comfort layers.
[0127] Turning to FIG. 6, shown are various views of a
temperature-regulating mattress system 600. On the left is a
complete mattress view 604a with the air intake module 606a jutting
out. On the top right, the complete mattress view 604b is shown
with the combined electronics module 608a and air intake module
606d. This may include fans, heaters, printed circuit boards and
may be removable for servicing.
[0128] On the middle right and bottom right shown is a
semi-transparent mattress in a perspective view 604c and side view
604d with the combined electronics module 608b, 608c and air intake
module 606b, 606c in its place on the bottom of the mattress 604c,
604d.
[0129] The views also show comfort and diffusion materials 610a,
610b along with a distribution layer 612 below those materials. The
comfort and diffusion materials 610a, 610b may be air permeable
materials diffuses and distributes air delivered by the
distribution layer 612. The distribution layer 612 may be either
incorporated into foam as molded or cut channels or a separate part
that is inserted into cavity under comfort layers.
[0130] Turning to FIG. 7, shown are various views of a
temperature-regulating mattress system 700. On the left is a
complete mattress with a comfort cover top 705 and an air permeable
cover top 708. On the bottom shown is the placement of electronics
module 714.
[0131] This may include fans, heaters, printed circuit boards and
may be removable for servicing.
[0132] On the right shown is the placement of air intake 712 and
diffusion materials 710 that may be air permeable material that
diffuses and distributes air.
[0133] Turning to FIG. 8, shown is a complete mattress exploded
view 800. The top layer is a cover top 802, followed by a series of
comfort layers 804, followed by a distribution layer 806, followed
by an intake layer 808 and followed by a cover bottom 812.
Installed on the intake layer 808 are electronic modules 810 that
may include fans, heaters, printed circuit boards and may be
removable for servicing.
[0134] The cover top 802 may be comfortable and air permeable. The
distribution layer 806 may be either incorporated into foam as
molded or cut channels or, alternatively, be a separate part that
is inserted into a cavity under comfort layers. The intake layer
808 may be about 2 inches in height and consist of flexible,
structural impermeable materials with air channels. The cover
bottom 812 may have air permeability and be durable.
[0135] FIGS. 9,10 and 11 show cross-sections of a
temperature-regulating mattress system.
[0136] Turning to FIG. 9, shown is a mattress cross-section first
embodiment 900 consisting of a comfort layer cross-section 901 and
a base layer cross-section 951. The comfort layer cross-section 901
includes a mattress cover top panel 905 over a top panel foam
insert 906 that are joined at a stitch seam 908. On the side is a
mattress cover outer border 910 and a mattress cover inner border
912 that are joined with the base via a mattress cover to base
cover zipper 920. On the top are embedded surface sensors 903 and
surface sensor patches 904.
[0137] The comfort layer 901 is partially surrounded by a mattress
fire sock 914. A mattress cover zipper 916 secures a mattress cover
base panel 918 and a mattress cover to base cover zipper 820. A
surface sensor plug 926 provides power to the system.
[0138] Within the mattress itself are foam comfort layers 924 with
an embedded ergonomic gel matrix 922. Cut vertically through the
mattress are air-impermeable surfaces 902 for air passage.
[0139] The base layer 951 cross-section includes a base top panel
958 and a base cover zipper 960 that secures a base cover border
962. A mattress cover to base cover zipper 966 secures a base cover
base panel 968. On the top is a biometric sensor 956. On the side
is a surface sensor socket 952. On the bottom is an AC power socket
972 and AC power cord 970.
[0140] Across the base layer cross-section 951 are a series of
expanded polypropylene (EPP) segments 976. A torso airbox 974 and
feet air box 984 are integrated within the EPP segments 976. Each
airbox includes a fan 978a, 978b and a heater 980a, 980b. Air ducts
982a, 982b allow air to circulate throughout the height of the base
layer 951.
[0141] The EPP Segments 976 shown in this figure and elsewhere in
the application consist of expanded polypropylene chosen because of
its lightweight and strong properties. It may be easily molded in
various shapes including molding including nuts that for screws to
be inserted thereto. These segments may also comprise expanded
polyethylene (EPE) expanded polystyrene (EPS) and be injection
molded, blow molded, rotationally molded, pressure formed or vacuum
formed.
[0142] Turning to FIG. 10, shown is a mattress cross-section second
embodiment 1000 consisting of a comfort layer cross-section 1001
and a base layer cross-section 1051. The comfort layer
cross-section 1001 includes a mattress cover outer top panel 1005
over a top panel foam insert 1007 that are joined at a stitch seam
1008. On the side is a mattress cover outer border 1011 and a
mattress cover inner border 1012 held together by an inner cover to
outer cover snap 1010. The mattress cover inner border 1012 is also
the mattress cover inner top panel 1006 at the top of the
mattress.
[0143] On the top are embedded surface sensors 1003 and surface
sensor patches 1004.
[0144] The comfort layer 1001 is partially surrounded by a mattress
fire sock 1014. A mattress cover zipper 1016 secures a mattress
cover base panel 1018 and a mattress cover to base cover zipper
1020. A surface sensor plug 1026 provides power to the system.
[0145] Within the mattress itself are foam comfort layers 1024 with
an embedded ergonomic gel matrix 1022. Cut vertically through the
mattress are air-impermeable surfaces 1002 for air passage.
[0146] The base layer 1051 cross-section includes a base top panel
1058 and a base cover zipper 1060 that secures a base cover border
1062. A mattress cover to base cover zipper 1066 secures a base
cover base panel 1068. On the top is a biometric sensor 1056. On
the side is a surface sensor socket 1052. On the bottom is an AC
power socket 1072 and AC power cord 1070.
[0147] Across the base layer cross-section 1051 are a series of
expanded polypropylene (EPP) segments 1076. A torso airbox 1074 and
torso air box 1084 are integrated within the EPP segments 1076.
Each airbox includes a fan 1078a, 1078b and a heater 1080a, 1080b.
Air ducts 1082a, 1082b allow air to circulate throughout the height
of the base layer 1051.
[0148] Turning to FIG. 11, shown is a mattress cross-section third
embodiment 1100 consisting of a comfort layer 1101 cross-section,
an airbox layer 1106 cross-section, an intake layer 1103
cross-section and an adjustable base 1104 cross-section. The
adjustable base may be folded about the gaps shown.
[0149] The comfort layer 1101 may be about 11.5 inches comprises a
plurality of temperature, humidity, motion sensors 1102a-1102e
below the mattress cover and is surrounded by a comfort layer fire
sock 1122. On the top is a comfort layer cover 1120 and within are
comfort foam layers 1124. Vertical sealed inside surfaces 1110
allow for air distribution through the comfort layer 1101 while
prevented lateral airflow.
[0150] The airbox layer 1106 may be 2 inches and includes a
biometric sensor 1112, and 2 airboxes 1130a, 1130b (one torso, one
foot, each having a heater and fan that are not shown) surrounded
by an airbox chassis 1128a, 1128b. The biometric sensor 1112 may
measure heart rate, breathing rate and presence sensing.
[0151] Between each airbox chassis 1128, 1128b and the airbox cover
1126a, 1126b is thermoformed foam 1118a, 1118b. Also incorporated
are temperature and humidity sensor downstream of the heater 1114a,
1114b and temperature and humidity sensor upstream of the fan
1116a, 1116b.
[0152] The intake layer 1103 may be about 2 inches comprises intake
layer foam 1132 and surrounded by an intake layer fire sock
1134.
III. Sensors
[0153] The scope and functionality of sensors within a
temperature-regulating mattress system is described herein. Such
sensors may measure one or more of the following: temperature,
(relative) humidity, pressure/presence, movement, presence, heart
rate, breathing rate and other biometric parameters.
[0154] Turning to FIG. 12, shown is a schematic of a wireless
sensor system 1200. Within the system, there is a metal grille 1205
over electronics for temperature and humidity sensing 1210 powered
by a battery 1220. The sensor system 1200 communicates wirelessly
via an antenna 1230.
[0155] Turning to FIG. 13, shown is a cross-section of a
temperature-regulating mattress system 1300 with various integrated
or embedded sensors.
[0156] A user lies on the mattress 1340 along the dashed line 1325
with bedding 1310 above and a sheet 1330 and mattress protector
1335 below. Sensors may be integrated or embedded in all parts of
the system, including at foot sensor 1320, a top-of-sheet sensor
1345, an under-sheet sensor 1350 and an embedded sensor 1355.
Single or multiple sensors per user may be used.
[0157] Turning to FIG. 14, shown are sensors embedded in a comfort
layer mattress system 1400.
[0158] A series of sensors are wired into comfort layer at the foot
1410a and the torso 1410b. Wires 1420 run through the mattress
system 1400 that are installed in the comfort layer before the
cover is installed. The wires 1420 then are directed to a connector
1430 that interfaces with the base 1440. The power of the base
layer 1440 may also power the sensors 1410a, 1410b via the
connector 1430 and wires 1420.
[0159] Turning to FIG. 15, shown are sensors embedded in tethered
layers mattress system 1500. A sensor band 1510 wraps around a
comfort layer 1515 and is secured 1520 to the base layer 1525. The
sensor band 1510 may include multiple sensors of various functions
and includes an electric connection when secured 1520 so that the
power of the base layer 1525 may also power the sensor band
1510.
[0160] The sensor band 1510 is covered with sheeting by the
user.
[0161] There may also be wider bands or multiple bands in this
system. Or the band footprint may extend to any part of the
mattress and have multiple cutouts.
[0162] Turning to FIG. 16, shown are sensors embedded in a cover
mattress system 1600.
[0163] A series of sensors are wired into the cover layer 1615 at
the foot 1610a and the torso 1610b. The cover layer 1615 is
designed to be placed over the comfort layer 1640. Wires 1650 run
through the cover layer 1615. The wires 1615 are directed to a
connector wire 1620 that terminates at a snap connector 1623 that
interfaces with the base 1625. The power of the base layer 1625 may
also power the sensors 1610a, 1610b via the connector 1620 and
wires 1650.
IV. Cover
[0164] The scope and functionality of covers within a
temperature-regulating mattress system is described herein. The
cover may consist of any suitable materials, including latex,
memory foam, polyester blends, feathers, wool, cotton, flannel,
silk and bamboo. Connecting systems such as zippers may be replaced
by any other connector such hook and loop fasteners (Velcro.RTM.),
snaps, tape and the like.
[0165] Turning to FIG. 17, shown is an assembly of a cover over a
mattress system 1700. A mattress core 1710 is shown separated from
a base 1720. After being zipped, an assembled mattress core plus
base 1730 is shown.
[0166] Turning to FIG. 18A, shown is an exploded view 1800 of a
mattress cover. Shown staring from the top is a top panel 1802, a
foam insert 1804, an inner border 1806, a bottom panel 1808 and an
outer border 1810
[0167] Turning to FIG. 18B, shown shows an exploded view 1850 of a
base cover. Shown starting from the top is a top panel 1852, a
border 1854 and a bottom panel 1856.
[0168] Turning to FIG. 19, shown is a detailed view of a seams
within a mattress system 1900 with a cover mattress layer 1990
having lower zipper teeth 1985 and a cover base layer 1992 having
upper zipper teeth 1983.
[0169] On the top shown is a mattress cover outer border 1902 and a
mattress cover inner border 1906. In the top inset shown is a
mattress cover top panel 1908, an optional top panel foam insert
1910, a mattress cover outer border 1902 and a mattress cover inner
border 1906 all joined together by stitching 1930.
[0170] On the bottom shown is a base cover border 1904. In the
bottom inset shown is a mattress cover outer border 1902 and an
interchangeable reverse coil zipper 1980a joined together by
stitching 1957. Also shown is a base cover mesh fabric 1960 and an
interchangeable reverse coil zipper 1980b joined together by
stitching 1955. Also shown is lower zipper teeth 1985 and upper
zipper teeth 1983 joined together by stitching 1956 and zipper
1975. This zipper 1975 is designed to join the cover mattress layer
1990 and a cover base layer 1992.
[0171] Turning to FIG. 20 shown is further detail of the bottom
cover of a temperature-regulating mattress system. On left side,
shown is a spacer fabric sample 1 2050, a spacer fabric sample 2
2054, a fabric diagram 2052 and a spacer fabric sample 3 2056. The
fabric diagram 2502 shows a front surface, a back surface and
spacer yarn in between the front surface and back surface.
[0172] On the right side, shown is a mattress cross section detail
system 2000. Shown is a cover top 2010 that may be comfortable and
air permeable and a cover bottom 2025. The cover top 2010 and cover
bottom 2025 surround comfort layers 2015 (that may be about 10
inches in height) and an intake layer 2020. The intake layer 2020
may be about 2 inches in height and have a flexible impermeable
structure with air channels on the perimeter side 2060a and bottom
2060b, 2060c, 2060d, 2060e.
[0173] Airflow through the air channels 2060a, 2060b, 2060c, 2060d,
2060e are enabled because the cover bottom 2025 may be constructed
from spacer fabric or similar material (as shown on the left side
of FIG. 20). This fabric allows air to move freely through the
cover bottom 2025 in both the perpendicular and parallel
directions. In particular, airflow moves through the fabric
parallel to the surface when the underside and vertical sides of
the mattress are blocked by bedframe and bedding.
V. Base
[0174] The scope and functionality of bases within a
temperature-regulating mattress system is described herein. The
base may include components integrated within the base structure or
modular components affixed to the base structure (or a combination
of the two).
[0175] FIGS. 21 and 22 show schematics of an integrated base.
[0176] FIG. 21 shows a schematic of an integrated base 2100 have a
mattress 2110 and a base 2120 powered by wire 2140. Air
distribution may take place in the mattress 2110. Biometric sensors
2130 may be integrated within the base 2120. Such sensors may
include hear rate/breathing rate/presence sensing and other
biometrics.
[0177] Also shown is an integrated torso module 2150a and an
integrated foot module 2150b. These modules 2150a, 2150b may jut
out from base 2120 because of the airboxes contained therein or may
be level with the base 2120. The base 2120 may include electronics,
fans, heaters and air intake apparatuses.
[0178] Turning to FIG. 22, shown is a base system detail 2200 with
foam panels 2210, a fabric hinge 2220, thermoformed foam 2230 and
permeable fabrics 2240a, 2240b. As will be shown below, the fabric
hinge will allow the base 2120 to be folded in various
combinations.
[0179] FIGS. 23, 24A and 24B show schematics of a modular base.
[0180] Turning to FIG. 23, shown is a schematic of a modular base
system 2300.
[0181] Temperature, humidity and motion sensors 2302a-2302f are
incorporated below the mattress cover within the mattress 2306.
Modules 2304a, 2304b (each of which is split into 2 parts) that at
least contain airboxes (not shown) are installed on the base
2310.
[0182] Biometric sensors 2308 may be integrated within the base
2310. Such sensors may include hear rate/breathing rate/presence
sensing and other biometrics.
[0183] The modules 2304a, 2304b are normally assembled by the end
user and connected to the base 2310 electrically. This may produce
better packaging solutions with smaller boxes.
[0184] Turning to FIG. 24A, shown is a modular base system detail
2400 without the module installed. Shown is a permeable fabric 2420
and a thermoformed tray 2430 with a power cable storage 2410.
[0185] Turning to FIG. 24B, shown is a modular base system detail
2400 with the module 2480 installed. Shown is a permeable fabric
2470a, 2470b and a power connection 2460.
[0186] The system is designed so that the module 2480 is snapped
into a thermoformed tray 2430 where the power cable located in the
power cable storage 2410 is connected to the power connection 2460.
This provides power to the module 2480. Similar setups for 3 other
modules (not shown) may be implemented.
[0187] Turning to FIG. 25, shown is a schematic of a base layer
with cover 2500. The fabric cover 2510 (shown as transparent) may
be of any suitable material that is either opaque, translucent or
transparent. This allows the base layer components to be contained
in a fabric shell. The fabric cover 2510 may be permeable so as to
allow air to be distributed to holes in the mattress installed
above the base layer (not shown). A segmented structure 2530
comprising several segments that allow the base layer to fold for
shipment and flex for compatibility with adjustable bases.
[0188] Turning to FIG. 26, shown is a schematic of a base layer
without a cover 2600. A biometric sensor track 2610 is inlaid to
measure dynamic sleeping profiles for the mattress user, including
measuring breathing rate, heart rate and movement throughout the
night. Five rigid panels 2650a, 2650b, 2650c, 2650d, 2650e are
installed over five molded EPP segments 2640a, 2640b, 2640c, 2640d,
2640e. This segmented structure comprising several segments allows
the base layer to fold for shipment and flex for compatibility with
adjustable bases.
[0189] A torso airbox system 2602b is installed within rigid panel
2650c flush with the top of the base layer. Ramps 2630c, 2630d are
carved out of the rigid panel 2650c to allow for airflow. In the
alternative, the torso airbox system 2602b may include integrated
ramps on the left and right to allow for airflow.
[0190] A foot airbox system 2602a is installed within rigid panel
2650e flush with the top of the base layer. Ramps 2630a, 2630b are
carved out of the rigid panel 2650e to allow for airflow. In the
alternative, the foot airbox system 2602a may include integrated
ramps on the left and right to allow for airflow.
[0191] Turning to FIG. 27, shown is an internal wiring schematic of
a base layer 2700. Within the base layer 2700 are a wiring system
2710 that connects (among other possible devices) a biometric
sensor strip 2720, a torso airbox 2730, a feet airbox 2740 and a
surface sensor interconnect 2750. The torso airbox 2730 and feet
airbox 2740 each include two fans on the side and an electrical
component in the middle to control operation of the airboxes 2730,
2740. The surface sensor interconnect 2750 interfaces with other
sensors throughout the mattress system to providing inputs to the
airboxes 2730, 2740 and transmit outputs from the biometric sensor
strip 2720.
[0192] Turning to FIG. 28, shown are five external wiring
schematics within a base layer.
[0193] Schematic 12810 shows a wiring system sourced on the side of
the foot of the mattress. A top view, side flat view and side
folded view are shown.
[0194] Schematic 2 2820 shows a wiring system sourced on the bottom
of the middle of the mattress. A top view, side flat view and side
folded view are shown.
[0195] Schematic 3 2830 shows a wiring system sourced on the top of
the middle of the mattress. A top view, side flat view and side
folded view are shown.
[0196] Schematic 4 2840 shows a wiring system sourced on the bottom
of the head of the mattress. A top view, side flat view and side
folded view are shown.
[0197] Schematic 5 2850 shows a wiring system sourced on the top of
the head of the mattress. A top view, side flat view and side
folded view are shown.
[0198] The foregoing schemes may be adjusted such that the wiring
is sourced at any other position within the mattress.
[0199] Turning to FIG. 29A, shown are various schematics of an
adjustable base layer and its associated mattress. Making the base
layer adjustable allows the mattress system to be formed into
various configurations for additional user comfort and for easier
shipping.
[0200] On the top left, shown is an articulating mattress system
2910 with four segments in the base layer to allow for such
articulation. On the bottom left, shown is an internal view of the
same articulating mattress system 2920 with four segments: head
(the widest segment), torso (including an airbox), legs and feet
(including an airbox). On the top right, shown is an overhead
schematic view of the same articulating mattress system 2930 with
the same four segments. On the bottom right, the same articulating
mattress system 2940 with the same four segments is set in an
exemplary configuration. Here, the head segment is set at a
116-degree angle from the torso segment, the torso segment is set
at a 142-degree angle from the legs section and the legs section is
set at a 142-degree angle from the feet section.
[0201] The foregoing system may have a different number of layers
capable of being articulated in angles ranging from above 0 degrees
to 180 degrees.
[0202] Turning to FIG. 29B, shown is a partially exploded view of
schematic of a base of an articulating mattress system 2950. The
schematic shows five segments joined together with sixteen hinges
2975 shown in an exploded view. The first, second and fourth
segments 2942a, 2942b, 2942c include no visible electronic parts.
The third segment 2951a includes an integrated torso airbox system
2947a and the fifth segment 2951b includes an integrated feet
airbox system 2947b. The entire system is powered via a power cord
2971 and an internal wiring system (not shown).
[0203] Turning to FIG. 29C, shown is a detail view of an adjustable
base layer hinge 2990. On the left side, an overhead view shows the
hinge 2975 (which may be the same hinge as in FIG. 29B) joining two
segments 2924a, 2924b together. The cross section of hinge 2975 and
the two segments 2924a, 2924b at line A-A is shown on the right
side. Here it can be seen that the hinge 2975 flexibly joins the
two segments 2924a, 2924b because the hinge 2975 includes two
circular protrusions 2976a, 2976b that snap into two circular
receptacles 2980a, 2980b. The circular receptables 2980a, 2980b may
be carved out of the material that comprises the two segments
2924a, 2924b such that the circular protrusions 2976a, 2976b remain
ensconced in the two segments 2924a, 2924b at any angle the two
segments 2924a, 2924b may be set. These angles may include those
shown in FIG. 29A.
[0204] Turning to FIG. 29D, shown is a detail view of another
adjustable base layer hinge. A side view 2901 shows a double hinge
2904a, 2904b ensconced within two segments 2903a, 2903b. A top view
2902 shows the same double hinge 2904a, 2904b ensconced within two
segments 2903a, 2903b. The advantage of this embodiment is that the
hinge structure is reinforced in both directions so that
flexibility of the two segments 2903a, 2903b to bend in both
directions is enhanced.
[0205] Turning to FIG. 29E, shown is a foldable base layer system
2991. A folded base layer 2995 shows five segments folded on top of
one another on a bed frame 2993. The folded nature of these five
segments may be accomplished by using the hinges shown in either
FIG. 29C or 29D.
VI. Airbox
[0206] The scope and functionality of airboxes within a
temperature-regulating mattress system is described herein. The
airboxes may include components integrated within the base
structure or modular components affixed to the base structure (or a
combination of the two).
[0207] The general function of an airbox in the base layer is the
selective use of a fan and a heater to generate heated air or
cooled air that will be forcefully blown into areas of the mattress
installed above the base layer. Although positive temperature
coefficient (PTC) heaters are shown in this section, any suitable
convection heater or thermoelectric heater may be substituted.
[0208] In addition, an airbox may be used without the heater for
delivery of air at the ambient air temperature. In addition, an
airbox may be used with a cooler for delivery air cooler than the
ambient air temperature. In addition, an airbox may be coupled with
a humidifier or dehumidifier to adjust the relative humidity of the
delivered air.
[0209] In general, airboxes may be installed in the center of the
base layer (to provide air to the torso area of a mattress user)
and at the bottom of the base layer (to provide air to the feet
area of a mattress user).
[0210] FIGS. 30A, 30B, 31 and 32 show schematics of an airbox that
is integrated into the base layer.
[0211] Turning to FIG. 30A, shown is top view of an integrated
airbox 3000 with air exhausts 3002a, 3002b that may output warmed
air. The air exhausts 3002a, 3002b include ramps that allow for
enhanced air distribution to the rest of the mattress.
[0212] Turning to FIG. 30B, shown is bottom view of an integrated
airbox 3050 with air inlets 3004a, 3004b. The air inlets 3004a,
3004b may draw ambient air for possible heating and further
distribution with the mattress system.
[0213] Turning to FIG. 31, shown is a cross-section view of an
integrated airbox 3100. The ducting/enclosure top 3105 covers a
first blower 3110a and a PTC heater 3115a pair and a second blower
3110b and a PTC heater pair 3115b, both of which are installed on
an enclosure bottom 3125. Also included is logic board and wiring
3120 that controls the power and operation of each of the
blower/PTC heater pairs 3110a, 3115a, 3110b, 3115b.
[0214] Turning to FIG. 32, shown is an integrated airbox system
3200. Intake airflow 3245 enters a blower 3220, proceeds to a
heater 3210 and then is outputted via lateral airflow 3250 and
upward airflow 3260. Downstream sensors 3230 and upstream sensors
3240 may measure temperature and humidity of the passing air (where
downstream and upstream means downstream and upstream from the
blower 3220 and heater 3210). This data can be passed to the rest
of the mattress system to keep the mattress environment comfortable
for the user.
[0215] FIGS. 33A, 33B, 34 and 35 show schematics of a modular
airbox that is affixed to the base layer.
[0216] Turning to FIG. 33A, shown is top view of a modular airbox
3300 with air exhausts 3310a, 3310b that may output warmed air.
[0217] Turning to FIG. 33B, shown is bottom view of a modular
airbox 3350 with air inlets 3355a, 3355b. The air inlets 3355a,
3355b may draw ambient air for possible heating and further
distribution with the mattress system.
[0218] Turning to FIG. 34, shown is an exploded view of a modular
airbox 3400. The exterior comprises a ducting/enclosure mounting
frame 3410, endcaps 3405a, 3405b and an enclosure 3440. The
interior comprises a first blower 3402a and a PTC heater 3404a pair
and a second blower 3402b and a PTC heater pair 3404b and a logic
board and wiring 3450 that controls the power and operation of each
of the blower/PTC heater pairs 3402a, 3402b, 3404a, 3404b.
[0219] Turning to FIG. 35, shown is an integrated airbox system
3500. Intake airflow 3520 enters a blower 3504, proceeds to a
heater 3502 and then is outputted via lateral airflow 3510 and
upward airflow 3530 though the holes on top of the airbox.
Downstream sensors 3550 and upstream sensors 3560 may measure
temperature and humidity of the passing air (where downstream and
upstream means downstream and upstream from the blower 3504 and
heater 3502). This data can be passed to the rest of the mattress
system to keep the mattress environment comfortable for the
user.
[0220] Turning to FIG. 36 shows a cross-section of a mattress
system 3600 having air delivery channels. Here, the air entry 3630
passes through holes in the base or through a vertical perimeter or
through body of spacer fabric. The air then passes through the
electronics module 3640. The outputted air passes through
distribution ducts 3610 then exits the mattress via a series of
vertical exhausts 3620. The volume of the distribution ducts 3610
may vary along its length to affect air distribution patterns
across the surface area of the mattress. The electronics module
3640 may include a blower, heater and sensors on one or more
printed circuit boards (PCBs). There may be two or more electronics
modules 3640 in the mattress system 3600. The electronics module
3640 may be removable for servicing and upgrades.
[0221] FIGS. 37 and 38 show different air distribution patterns for
air exiting a mattress. Turning to FIG. 37, shown is a schematic of
air distribution patterns in a mattress system 3710 that primarily
provide torso and feet airflow through the mattress top. Turning to
FIG. 38, shown is a schematic of air distribution patterns in a
mattress system 3720 that primarily provides airflow throughout the
entirety of the mattress top.
VII. Airflow
[0222] The scope and functionality of devices that improve airflow
within a temperature-regulating mattress system is described
herein.
[0223] FIGS. 39A, 39B, 39C, 39D, 39E and 39F show various methods
for sealing surface of holes or slots in a mattress cut through the
foam comfort layers. Sealed holes prevent the fluid flow
horizontally into the foam through the walls of the cutout or from
the underside. These methods may be combined in a mattress system.
(The pointers in FIGS. 39A-39F are shown on the right side of the
slots, they may equally apply to the left side of the slots.)
[0224] Turning to FIG. 39A (liquid sealant solution), shown is a
sealant system 3900 with foam comfort layers 3902 adjacent to dried
sealant on the side 3904a and bottom 3904b. These sealants dry to
form an impermeable skin (made from, for example, gel, silicon,
rubber or adhesive). The sealant may be poured in the hole or
sprayed using a nozzle.
[0225] Turning to FIG. 39B (molded/self-skinning solution), shown
is a sealant system 3910 with foam comfort layers 3912 adjacent to
an impermeable foam on the side 3914a and bottom 3914b. Here the,
impermeable foam may be created in the hole by the comfort foam
layers 3912 poured sequentially into the mold. The surfaces
touching the side and bottom self-skin creating an impermeable
surface.
[0226] Turning to FIG. 39C (molded/insert), shown is a sealant
system 3920 with foam comfort layers 3922 adjacent to a single
impermeable foam insert 3924. Here the, impermeable foam insert
3924 may be molded from self-skinning or a pneumatic foam is
assembled into the comfort layers 3922 using adhesive.
[0227] Turning to FIG. 39D (flexible insert), shown is a sealant
system 3930 with foam comfort layers 3932 adjacent to a flexible
tube 3934. Here a thin-walled flexible tube 3934 is inserted into
the hole and is held into place by friction and/or adhesive. The
hole may be expanded during insertion to aid in installation.
Possible flexible tube 3934 materials include gel, silicone,
rubber, latex, polymers or a flexible duct hose.
[0228] Turning to FIG. 39E (flexible insert with flange), shown is
a sealant system 3940 with foam comfort layers 3942 adjacent to a
flexible tube with flange 3944. Here a thin-walled flexible tube
with flange 3944 is inserted into the hole and is held into place
by friction and/or adhesive. The hole may be expanded during
insertion to aid in installation. Possible flexible tube with
flange 3944 materials include gel, silicone, rubber, latex,
polymers or a flexible duct hose. The flange 3946 adds
impermeability to the underside of the mattress.
[0229] Turning to FIG. 39F (encapsulated spring insert), shown is a
sealant system 3950 with foam comfort layers 3952 adjacent to a low
stiffness coil spring 3954. The low stiffness coil spring 3954 is
encapsulated in a sealant such as: an impenetrable polyethylene
pocket or sleeve; over-molded rubber; pneumatic foam; or a flexible
duct hose. The spring holds the hole open while providing minimal
vertical stiffness.
[0230] Turning to FIG. 46A (flexible insert), shown is a sealant
system 4630 with foam comfort layers 4632 adjacent to a flexible
tube 4634. Here, a thin-walled flexible tube 4634 is inserted into
the angled hole and is held into place by friction and/or adhesive.
The hole may be expanded during insertion to aid in installation.
Possible flexible tube 4634 materials include gel, silicone,
rubber, latex, polymers or a flexible duct hose.
[0231] Turning to FIG. 46B (flexible insert with flange), shown is
a sealant system 4640 with foam comfort layers 4642 adjacent to a
flexible tube with a flange 4644, where the flange portion is
identified by reference numeral 4646. Here, a thin-walled flexible
tube with flange 4644 is inserted into the angled hole and is held
into place by friction and/or adhesive. The hole may be expanded
during insertion to aid in installation. Possible flexible tube
with flange 4644 materials include gel, silicone, rubber, latex,
polymers or a flexible duct hose. The flange 4646 adds
impermeability to the underside of the mattress.
[0232] Turning to FIG. 46C (encapsulated spring insert), shown is a
sealant system 4650 with foam comfort layers 4652 adjacent to a low
stiffness coil spring 4654. The low stiffness coil spring 4654 is
encapsulated in a sealant such as: an impenetrable polyethylene
pocket or sleeve; over-molded rubber; pneumatic foam; or a flexible
duct hose. The encapsulated low stiffness coils spring 4654 is
inserted into the angled hole. The spring holds the hole open while
providing minimal vertical stiffness.
[0233] FIGS. 47A and 47B show an additional embodiment of sealed
vertical holes or slots in a mattress. Turning to FIG. 47A
(sealant, or flexible insert with a flange and sealant), shown is a
sealant system 4740 with foam comfort layers 4742 adjacent to a
sealed vertical hole 4744. The hole 4744 is sealed either by a
sealant or via an insert as described above. The sealant system
4740 also includes flanges or sealant that extend across the top
and bottom surfaces of the mattress, to extend the sealed areas
around the hole(s). In the figure, the bottom flange or sealant is
identified by reference numeral 4746 and the top flange or sealant
is identified by reference numeral 4748. When using, a thin-walled
flexible tube, the tube is inserted into the hole and is held into
place by friction and/or adhesive. The hole may be expanded during
insertion to aid in installation. Possible flexible tube with
flange materials include gel, silicone, rubber, latex, polymers or
a flexible duct hose. The sealant or flange(s) 4746 and 4748 add
impermeability to the underside and the top of the mattress,
respectively.
[0234] Turning to FIG. 47B (sealant, or flexible insert with a
flange and sealant), shown is a sealant system 4750 with foam
comfort layers 4752 adjacent to a sealed angled hole 4754. The hole
4744 is sealed either by a sealant or via an insert as described
above. The sealant system 4750 also includes flanges or sealant
that extend across the top and bottom surfaces of the mattress, to
extend the sealed areas around the hole(s). In the figure, the
bottom flange or sealant is identified by reference numeral 4756
and the top flange or sealant is identified by reference numeral
4758. When using, a thin-walled flexible tube, the tube is inserted
into the hole and is held into place by friction and/or adhesive.
The hole may be expanded during insertion to aid in installation.
Possible flexible tube with flange materials include gel, silicone,
rubber, latex, polymers or a flexible duct hose. The sealant or
flange(s) 4756 and 4758 add impermeability to the underside and the
top of the mattress, respectively.
[0235] FIGS. 48A and 48B show an additional embodiment of sealed
vertical holes or slots in a mattress. Turning to FIG. 48A (a
vertical insert), shown is a sealant system 4840 with foam comfort
layers 4842 adjacent to a vertically oriented insert 4849, which
may be constructed from polymers rubber, fabric or foam, such as
reticulated foam. The outer surface 4844 of the insert 4849 is made
impermeable by an impermeable fabric, polymer, or applied flexible
sealant. Alternatively, the insert 4849 is placed within the
flexible impermeable tube, of the type described above. The sealant
system 4840 may also include optional flanges or sealant that
extend across the top and bottom surfaces of the mattress, to
extend the sealed areas around the holes. In the figure, the bottom
flange or sealant is identified by reference numeral 4846 and the
top flange or sealant is identified by reference numeral 4848. The
sealant or flange(s) 4746 and 4748 add impermeability to the
underside and the top of the mattress, respectively.
[0236] Turning to FIG. 48B (an angled insert), shown is a sealant
system 4850 with foam comfort layers 4852 adjacent to an angularly
oriented insert 4859, which may be constructed from polymers
rubber, fabric or foam, such as reticulated foam. The outer surface
4854 of the insert 4859 is made impermeable by an impermeable
fabric, polymer, or applied flexible sealant. Alternatively, the
insert 4859 is placed within the flexible impermeable tube, of the
type described above. The sealant system 4850 may also include
optional flanges or sealant that extend across the top and bottom
surfaces of the mattress, to extend the sealed areas around the
holes. In the figure, the bottom flange or sealant is identified by
reference numeral 4856 and the top flange or sealant is identified
by reference numeral 4858. The sealant or flange(s) 4756 and 4758
add impermeability to the underside and the top of the mattress,
respectively.
[0237] FIGS. 49A and 49B show an additional embodiment of sealed
vertical holes or slots in a mattress. Turning to FIG. 49A (a
vertical insert or applied sealant, with an additional layer),
shown is a sealant system 4940 with foam comfort layers 4942
adjacent to a vertically oriented insert 4944, which may be
constructed from polymers rubber, fabric, or foam, such as
reticulated foam. The sealant system 4840 includes flanges or
sealant that extend across the top and bottom surfaces of the foam
comfort core layers, to extend the sealed areas around the holes.
In the figure, the bottom flange or sealant is identified by
reference numeral 4946 and the top flange or sealant is identified
by reference numeral 4948. Each of the flanges or sealant 4946 and
4948 is secured by an additional layer 4947 and 4949, respectively,
that is added to the top and/or bottom of the foam comfort core.
The additional layer has holes in it to match the holes that run
through the comfort core layers. The additional layer may be made
from a permeable, semi-permeable, or impermeable material.
[0238] Turning to FIG. 49B (an angled insert or applied sealant,
with an additional layer), shown is a sealant system 4950 with foam
comfort layers 4952 adjacent to an angularly oriented insert 4954,
which may be constructed from polymers rubber, fabric, or foam,
such as reticulated foam. The sealant system 4840 includes flanges
or sealant that extend across the top and bottom surfaces of the
foam comfort core layers, to extend the sealed areas around the
holes. In the figure, the bottom flange or sealant is identified by
reference numeral 4956 and the top flange or sealant is identified
by reference numeral 4958. Each of the flanges or sealant 4956 and
4958 is secured by an additional layer 4957 and 4959, respectively,
that is added to the top and/or bottom of the foam comfort core.
The additional layer has holes in it to match the holes that run
through the comfort core layers. The additional layer may be made
from a permeable, semi-permeable, or impermeable material.
[0239] FIGS. 50A and 50B show an additional embodiment of sealed
vertical holes or slots in a mattress. Here, to maintain better
support to a user, the holes through the foam comfort core layers
are made relatively small. Turning to FIG. 50A (vertical insert or
applied sealant with an additional layer), shown a sealant system
5040 with foam comfort layers 5042 adjacent to a vertically
oriented insert 5044. Flanges or sealant extend across the bottom
face 5046 and the top face 5048 to extend the sealed areas around
the hole(s). An additional top layer 5049 and an additional bottom
layer 5047, each having a hole of larger diameter then the hole
through the comfort-core layers, are added to the top and bottom,
respectively. Due to the larger hole diameter in these additional
top and bottom layers, the area available to air passing through
the hole at the top and bottom surfaces is larger than that of the
hole through the foam comfort core layers 5042. As a result, air
passing through the fabric that is in contact with the top and
bottom of the foam core layers has a larger area to pass through
and therefore reduces resistance loss.
[0240] Turning to FIG. 50B (angular insert or applied sealant with
an additional layer), shown a sealant system 5050 with foam comfort
layers 5052 adjacent to an angularly oriented insert 5054. Flanges
or sealant extend across the bottom face 5056 and the bottom face
5048 to extend the sealed areas around the hole(s). An additional
top layer 5059 and an additional bottom layer 5057, each having a
hole of larger diameter then the hole through the comfort-core
layers, are added to the top and bottom, respectively. Due to the
larger hole diameter in these additional top and bottom layers, the
area available to air passing through the hole at the top and
bottom surfaces is larger than that of the hole through the foam
comfort layers 5052. As a result, air passing through the fabric
that is in contact with the top and bottom of the foam comfort
layers has a larger area to pass through and therefore reduces
resistance loss.
[0241] FIG. 51 shows the cross-section and top views of a mattress
system using inserts with holes or slots. In this embodiment, the
assembly 5100 includes comfort layers 5102 with two rows of
openings 5104 (e.g., pill-shaped slots). Inserts 5106 with dual
holes 5108 are located within the slotted openings 5104. Note, the
number of rows of slotted openings in the comfort layers and the
number of holes 5108, and their layout, in each insert 5106 could
be varied. The inserts 5106, which are assembled into the openings
5104, may be formed from molded or machined pieces of foam that
incorporate holes through them. The inserted pieces could be molded
from self-skinning foam, or have their surfaces sealed in other
ways, for example spraying with a liquid sealant. The holes in the
inserts can be of various shape, sizes, and angles. For example, in
some embodiments the angle could be such that one could see all the
way down through the hole when looking from above the insert. In
other embodiments, the angle could be large enough such that one
could not see all the way down through the hole when looking from
above the insert.
[0242] FIGS. 52A, 52B, 52C, 52D, 52E, and 52F show various
embodiments of the inserts in FIG. 51. Turning to FIG. 52A, shown
is an insert 5200 with two angularly running holes 5202 with sealed
surfaces. The topmost portion of the figure shows a cross-section
of the insert 5200. The next portion down in the FIG. 52A depicts
the insert from the bottom, along section A-A. Right below, FIG.
52A shows two side views of the insert 5200, from different
directions. Finally, the lowest portion of the figure depicts the
view of the insert from the top.
[0243] Turning to FIG. 52B, shown is a two-part insert 5220 having
two angularly running holes 5222 with sealed surfaces. The two
parts, constituting two halves of the insert, are joined together
to form the insert. The topmost portion of the figure shows a
cross-section of the insert 5220. The next portion down in the FIG.
52B depicts one half of the insert, when viewed from the bottom.
Right below, FIG. 52A shows two side views of the insert 5220, from
different directions. Right below that, FIG. 52B shows one half of
the insert, viewed from the top. Finally, the lowest portion of the
figure depicts the two halves of the insert joined together 5226,
forming the insert, viewed from the bottom.
[0244] Turning to FIG. 52C, shown is an insert 5230 with two
angularly running holes 5232 with sealed surfaces. The topmost
portion of the figure shows a cross-section of the insert 5230. As
can be seen from the cross-sectional view, each hole changes its
angle as it passes through the insert. The next portion down in the
FIG. 52C depicts the insert from the bottom, along section A-A.
Right below, FIG. 52C shows two side views of the insert 5230, from
different directions. Finally, the lowest portion of the figure
depicts the view of the insert from the top.
[0245] Turning to FIG. 52D, shown is a cross-sectional view of an
insert 5240 with a single hole having a conical shape. Turning to
FIG. 52E, shown is a cross-sectional view of an insert 5250 with a
single hole having a circular shape. Turning to FIG. 52F, shown is
a cross-sectional view of an insert 5260 with a single hole having
a circular shape that is narrower than in FIG. 52E, but that flares
out at top and bottom of the insert. In each of the embodiments,
the surfaces of the holes are sealed to prevent air loss.
[0246] FIG. 53 shows another embodiment of the mattress system
using inserts with holes or slots. The upper portion of FIG. 53
shows the top view of the mattress system and the lower portion of
the figure shows a cross-sectional view of the mattress system
along section A-A. From the top view, one can see the mattress
system 5300 includes five sections, 5301a, 5301b, 5301c, 5301d, and
5301e. Sections 5301b and 5301d are molded or machined insert
sections that are assembled in between the sections 5301a, 5301c,
and 5301e of regular foam comfort layers. The insert sections have
holes running through them. These holes can have various shapes,
e.g., circles, squares, rectangles, etc. and may be vertical or
angled. The cross-sectional view of the mattress system at the
bottom of FIG. 53 shows an angular hole 5304 in the insert 5301b
and also shows an angular hole 5306 in the insert 5301d. The foam
comfort layers are designated by reference numeral 5302.
[0247] FIG. 54 shows an embodiment of the mattress system 5400
using inserts for forming holes or slots in the system. The upper
portion of FIG. 54 shows the top view of the mattress system and
the lower portion of the figure shows a cross-sectional view of the
mattress system along section A-A. This embodiment differs from the
embodiment in FIG. 53 in that the molded or machined
insert-sections 5402 and 5404 are assembled in cutouts in the
regular foam comfort layers 5406. Once installed, the inserts form
one side of each hole. The cross-sectional view of the mattress
system at the bottom of FIG. 53 shows an angular hole formed by the
combination of the insert 5404 and the comfort layers 5406. These
holes can have various shapes, e.g., circles, squares, rectangles,
etc. and may be vertical or angled. Sealing may be achieved by
employing a self-skinning molded foam for the insert, or by
applying a liquid sealant to a permeable foam or foam layers.
[0248] FIG. 55 shows another embodiment of the mattress system 5500
with holes or slots. The upper portion of FIG. 55 shows the top
view of the mattress system and the lower portion of the figure
shows a cross-sectional view of the mattress system along section
A-A. From the top view, one can see the mattress system 5500
includes five sections, 5501a, 5501b, 5501c, 5501d, and 5501e, of
comfort layers that are either cut along cut lines 5504 and
separated or are formed along cut lines 5504. The cut face(s) of
each of the five sections, along the line(s) 5504, is then sealed.
Sealing may be achieved by, for example, applying liquid sealant to
the cut faces, or laminating an impermeable membrane to the cut
faces. The sections are then assembled together, forming sealed
vertical or angled holes withing the mattress system 5500. The
holes can have various shapes, e.g., circles, squares, rectangles,
triangular, etc. The cross-sectional view of the mattress system
5500 at the bottom of FIG. 55 shows the angular holes formed in the
comfort layers 5502.
[0249] FIG. 56 shows another embodiment of a mattress system with
vertical holes or slots. The left side of FIG. 56 shows a
cross-sectional view of the mattress system and the right side of
the figure shows a top view of the mattress system. As can be seen
from the cross-sectional view, the mattress system 5600 is composed
of seven layers (labeled L1 through L7), with L1 being the topmost
layer and L7 being the bottommost layer. The cross-sectional view
also shows two holes 5602 and 5604 cut through the layers. Hole
5602 is located in the middle of the mattress (torso zone) and hole
5604 is located at the right end of the mattress (foot zone). In
this embodiment, some of the mattress layers include multiple
sections of different materials, having different densities and ILD
characteristics, or may include similar materials having different
characteristics. For example, the topmost (first) layer L1 includes
two sections, left and right. In one preferred embodiment, the left
section could be hypersoft foam, labeled in the figure as L1A, and
the left section could be viscoelastic foam, labeled as L1B. The
third layer down, L3, for example, includes three sections (left,
middle, and right). In one embodiment, the middle section could be
hypersoft foam having one set of characteristics (labeled L3B), and
the right and left sections could be hypersoft foam having another
set of characteristics (labeled L3A). Some of the materials that
may be used in the various layers include hypersoft foam,
viscoelastic foam, high resiliency foam, convoluted foam, and
rubber.
[0250] Looking at the top view of the mattress system 5600 (right
side of FIG. 56), one can see the two sections of the first layer
L1. The top view also shows that the holes 5602 and 5604 have an
oval slotted shape. Each row of holes running across the mattress
is further divided into two groups (left and right), allowing the
mattress system 5600 to accommodate two occupants.
[0251] FIGS. 57A, 57B, 57C, and 57D show an embodiment of a
seven-layer mattress system that uses tubular inserts. FIG. 57A
shows a top view of the mattress system 5700, with two rows of
oval-shaped holes (slots) 5702 and 5704. FIG. 57B shows a
cross-sectional view of the mattress system 5700 along the line A-A
in FIG. 57A, illustrating the row of holes 5704 across the
mattress. FIG. 57C shows a detailed view of the mattress system
5700 in area B of FIG. 57B. Specifically, FIG. 57C shows two holes,
one labeled 5704a and another labeled 5704b, each passing through
the seven layers of the mattress system 5700. A plastic (or rubber)
insert 5706 is placed in each hole. The insert includes flanges on
top and bottom. Importantly, the flanges do not protrude all the
way to the top and/or bottom of the mattress system 5700. Instead,
the top mattress layer covers up the upper flanges from the top and
the bottom mattress layer covers up the lower flanges from the
bottom. This way, the upper flange of each insert is secured
between the first and second mattress layers and the lower flange
of each insert is secured between the sixth and seventh mattress
layers. Such a construction not only prevents the inserts from
separating from the mattress layers, but also provides
aesthetically pleasing design, as the insert flanges are not
visible to the user. In the preferred embodiment, the inserts have
an accordion type design, which allows them to contract and expand
together with the mattress layers in response to the different
forces applied to the mattress system 5700 by the occupants.
[0252] FIG. 57D shows a cross-sectional view of the mattress system
along the line C-C in FIG. 57A. It depicts the inserts 5706 in the
hole(s) 5702 in the middle of the mattress (torso zone) and in the
hole(s) 5704 at one end of the mattress (foot section). Similar to
the mattress system 5600 in FIG. 56, the cross-sectional view of
mattress system 5700 in FIG. 57D shows the mattress layers having
various sections of various materials.
[0253] FIGS. 58A, 58B, and 58C show cross-sectional views of
another set of embodiments of a mattress system with holes or
slots. Similar to the mattress system 5600 in FIG. 56, the
cross-sectional views in FIGS. 58A, 58B, and 58C show seven-layer
mattress systems where some of the layers are composed of various
sections of different material.
[0254] Turning to FIG. 58A, shown is a cross-sectional view of a
seven-layer mattress system 5800 with vertically placed rubber
inserts 5802.
[0255] Turning to FIG. 58B, shown is a cross-sectional view of a
seven-layer mattress system 5810 with rubber inserts 5814 placed in
the holes 5816 and 5818 that are running at a slight angle. At the
angle shown in FIG. 58B, when looking straight down from above the
insert 5814, one can see all the way through the hole to the bottom
of the mattress.
[0256] Turning to FIG. 58C, shown is a cross-sectional view of a
seven-layer mattress system 5820 with rubber inserts 5824 placed in
the holes 5826 and 5828 that are running at a greater angle then
the one in FIG. 58B. At the angle shown in FIG. 58C, when looking
straight down from above the insert 5824, one cannot see all the
way through the hole to the bottom of the mattress.
[0257] FIGS. 59A, 59B, and 59C show cross-sectional views of
another set of embodiments of a mattress system with holes or
slots. Similar to the mattress systems in FIGS. 58A, 58B, and 58C
the cross-sectional views in FIGS. 59A, 59B, and 59C also show
seven-layer mattress systems, 5900, 5910, and 5920 respectively,
where some of the layers are composed of various sections of
different materials. In contrast to the embodiments in FIGS. 58A,
58B, and 58C, however, the inserts 5902, 5912, and 5922 in the
FIGS. 59A, 59B, and 59C, respectively, are molded pneumatic inserts
that, when inserted, span layers two (L2) through six (L6) in both
the torso and foot zones of the mattress system. The top and bottom
layers (L1 and L7) have holes that line up with the holes in the
inserts. In FIG. 59A, the holes in the insert 5902 run vertically;
in FIG. 59B, the holes in the inserts 5912 run at a slight angle
off vertical; and in FIG. 59C, the holes in the inserts 5922 run at
a greater angle off vertical, such that when looking straight down
from above the insert, one cannot see all the way through the hole
to the bottom of the mattress. Because the walls of each hole
should be substantially impermeable to air, the inserts 5902, 5912,
and 5922 should either be made of substantially impermeable
material, self-skinning foam, or have liquid sealant applied to
them.
[0258] FIGS. 60A and 60B show cross-sectional views of another set
of embodiments of a mattress system with holes or slots. Similar to
the mattress systems in FIGS. 59A and 5B, the cross-sectional views
in FIGS. 60A and 60B also show seven-layer mattress systems, 6000
and 6010 respectively, where some of the layers are composed of
various sections of different materials. In contrast to the
embodiments in FIGS. 59A and 59B, however, the inserts 6002 and
6012 in the FIGS. 60A and 60B, respectively, are pneumatic
fabricated die cut inserts, which, when inserted, span layers two
(L2) through six (L6) in both the torso and foot zones of the
mattress system. The top and bottom layers (L1 and L7) have holes
that line up with the holes in the inserts. In FIG. 60A, the hole
in the insert 6002 runs vertically; and in FIG. 60B, the hole in
the insert 6012 runs at an angle. Because each insert is made up of
stacked, die cut material layers, the angularly running hole in the
insert 6012 appears to have stepped edges. Because the walls of
each hole should be substantially impermeable to air, the inserts
6002, and 6012 should either be made of substantially impermeable
material(s), self-skinning foam(s), or have liquid sealant applied
to them.
[0259] FIGS. 61A, 61B, and 61C show cross-sectional views of
another set of embodiments of a mattress system with holes. Similar
to the mattress systems in FIGS. 59A, 58B, and 58C the
cross-sectional views in FIGS. 61A, 61B, and 61C also show
seven-layer mattress systems, 6100, 6110, and 6120 respectively,
where some of the layers are composed of various sections of
various materials. In contrast to the embodiments in FIGS. 59A,
59B, and 59C, however, the mattress systems in the FIGS. 59A, 59B,
and 59C include inserts drilled holes. In FIG. 61A, the holes 6102
are drilled vertically; in FIG. 61B, the holes are drilled at a
slight angle off vertical; and in FIG. 61C, the holes are drilled
at a greater angle off vertical, such that when looking straight
down from above a hole, one cannot see all the way through it to
the bottom of the mattress. Because the walls of each hole should
be substantially impermeable to air the material in the sections of
the layers where the holes are locations should either be made of
substantially impermeable material, self-skinning foam, or have
liquid sealant applied to them.
[0260] Each of the methods of sealing the hole walls discussed
above can be applied to holes that are angled along their axis, and
of any cross-section, e.g., circular, elliptical, rectangular,
square, etc. For example, FIGS. 46A, 46B, and 46C, which correspond
to FIGS. 39D, 39E, and 39F, respectively, show holes that are
angled along their axis.
[0261] In addition, the various insert embodiments may be used
interchangeably or in combinations to achieve the required airflow
in the mattress.
[0262] As an example, the invented mattress may include a laterally
extending comfort layer, which itself may include a plurality of
layers, said comfort layer having a lower surface and an upper
surface, said comfort layer comprising an opening extending through
said comfort layer from the upper surface to the lower surface; a
tubular insert positioned within the opening of said comfort layer
and having an upper end and a lower end, said tubular insert having
an air-impermeable peripheral wall extending between the upper end
and the lower end of said tubular insert, said tubular insert
further comprising a first air-impermeable flange located at one of
the upper end and the lower end of said tubular insert and
extending around the opening at one of the upper surface and the
lower surface of said comfort layer; a laterally extending bottom
layer joined to the lower surface of said comfort layer, said
bottom layer having an aperture that is aligned with the opening at
the lower surface of said comfort layer, the aperture being equal
to or greater than the opening at the lower surface of said comfort
layer; a laterally extending top layer joined to the upper surface
of said comfort layer and having an aperture that is aligned with
the opening at the upper surface of said comfort layer, the
aperture being equal to or greater than the opening at the upper
surface of said comfort layer; wherein one of said top layer and
said bottom layer secures said first flange of said tubular insert
to said comfort layer. The tubular insert may comprise a second
air-impermeable flange located at the other one of the upper end
and the lower end of said tubular insert, said second flange
extending round the opening at the other one of the upper surface
of said comfort layer and the lower surface of said comfort layer;
and wherein the other one of said top layer and said bottom layer
secures said second flange of said tubular insert to said comfort
layer.
[0263] As another example, the invented mattress system may include
a plurality of laterally extending foam layers joined together,
said plurality of foam layers having an upper surface and a lower
surface, said plurality of foam layers further having at least one
opening extending between the upper surface and the lower surface
of said plurality of foam layers; an at least one foam insert
positioned within said at least one opening, said at least one foam
insert having an upper surface and a lower surface, said at least
one foam insert further comprising a hole running from the upper
surface of said at least one foam insert to the lower surface of
said at least one foam insert; and a fan located below said
plurality of foam layers, said fan configured to force air through
the hole in said foam insert toward the upper surface of said foam
insert; wherein the interior surface of said hole in the foam
insert in air-impermeable; wherein the upper surface of said at
least one foam insert is aligned with the upper surface of said
plurality of laterally extending foam layers; and wherein the lower
surface of said at least one foam insert is aligned with the lower
surface of said plurality of laterally extending foam layers. The
interior surface of the foam insert may be made air-impermeable due
to self-skinning property of the foam insert, such as use of a foam
having self-skinning property. Alternatively, the interior surface
of the foam insert may be made air-impermeable by applying a
sealant.
[0264] As another example, the invented mattress system may include
a plurality of laterally extending foam layers joined together,
said plurality of foam layers having an at least one opening
therethrough, said opening located in a torso zone of said
mattress; a foam insert positioned withing the opening, said foam
insert comprising a hole therethrough for allowing airflow between
a top surface of said mattress and a bottom surface of said
mattress; wherein the interior surface of said hole in
air-impermeable; and wherein said foam insert increases support in
the torso zone of said mattress.
[0265] As a result, the invented insert not only functions to allow
airflow from the bottom to the top of the mattress, but it also
functions as a support element. Because the invented inserts may be
placed in areas other than the torso zone of the mattress (e.g.,
foot section, hip section, shoulder section, head section, etc.),
the present invention allows for mattress designs that are not only
provide better temperature regulation but are optimized to provide
increased support to a user human anatomy. The foam inserts
disclosed above may not have any air holes but could be used merely
for providing specific localized support in and across the various
mattress zones. For example, foam inserts in the torso zone might
provide greater support then the foam inserts in the foot zone. In
addition, insert provided support could also vary across a single
zone.
[0266] The invented foam insert may be formed by molding or by died
cutting. For example, an insert including a plurality of die cut
layers may have its hole created by a stacked combination of the
holes die cut in each of the layers. In such a situation, if the
insert hole is either slanted or has a cross-sectional area that
varies from the bottom to the top of the insert, the interior
surface of the resulting hole will have a stepped profile.
[0267] FIGS. 40A, 40B and 40C show various constructions that
improve airflow throughout a mattress system. They may be used
singly or in combination.
[0268] Turning to FIG. 40A, shown is a partial mattress system
cross-section 3960 where a mattress 3961 includes a plurality of
vertical cutouts 3962. A specially formed EPP segment 3966 has a
raised edge that increases the pressure around the duct outlet
perimeter. This compresses the bottom foam layer 3963 and creates a
better seal between the base layer and the mattress. Another
portion of the EPP segment 3965 (partially shown) also compresses
the bottom foam layer 3963. The blower/heater combination 3964 may
be inserted into the EPP segment as well to complete construction
of the base layer interfacing with the mattress.
[0269] Turning to FIG. 40B, shown is a partial mattress system
cross-section 3970 with a frame 3972 installed at the bottom of the
foam layers. As shown in the inset 3971 on the top left, the frame
3972 incorporates holes that lets air through from the base layer
to the mattress layer. The holes in the frame 3972 may "match up"
with the holes in the mattress. Alternatively, the frame 3972 may
have only edges with an open middle. The frame edges 3974a, 3974b
may consist of impermeable but flexible material (such as EPP) that
solidifies the installation of the frame 3972 within the
mattress.
[0270] One purpose of the frame 3972 is to create air space between
the mattress cover 3973 and the underside of the foam 3975. This
increases area that the air can flow through the mattress cover
3973 which results in lower pressure drop and less losses in
flow.
[0271] Turning to FIG. 40C, shown is a partial mattress
cross-section 3990 with a mattress having vertical air passages
3994a, 3994b, 3994c, 3994d taking air blown from airboxes 3992a,
3992b through ducts 3991a, 3991b. Underneath the airboxes 3992a,
3992b and their related EPP segments (not shown) is a permeable
base cover (also not shown) that allows the air to be drawn in by
the airboxes 3992a, 3992b. Surrounding the mattress on the top and
the sides is a permeable mattress cover (not shown) that allows the
air to be pushed out through the vertical air passages 3994a,
3994b, 3994c, 3994d. In contrast, portions of the top of the base
layer and the bottom of the mattress layer 3993a, 3993b and 3993c
may be made of an impermeable material such as rubber having
lamination. This material improves airflow throughout the mattress
by maximizing the amount of air drawn in by the airboxes 3992a,
3992b actually passing through ducts 3991a, 3991b.
VIII. Remote
[0272] The scope and functionality of remotes to allow the user to
control features within a temperature-regulating mattress system is
described herein. The purpose of these remotes includes allowing
users to make real-time adjustments to mattress parameters without
the user having to get out of bed. This is especially useful when
the user wants to make an adjustment in the midst of a sleep
cycle.
[0273] The properties of the remote discussed herein may be mixed
and varied as needed to provide various functions for the mattress
system.
[0274] In addition to these remotes, an app may be used to control
similar features of the mattress in addition to providing an
interface for more complex operations (such as those described
above in FIG. 4B).
[0275] Turning to FIG. 41A, shown is a schematic of a remote 4000
for a mattress system. The remote 4000 is generally puck-shaped and
incorporates a full surface tactile button 4002 and is capable of
recognizing gesture sensing 4004 performed on the remote 4000. The
remote 4000 is capable of rotations 4006 and has a haptic motor
4012. Alight indicator 4010 is installed on the top of the remote
4000. A gradient light indicator 4014 emanates from the bottom of
the remote 4000. Installed on the bottom of the remote 4000 is a
reset button 4008 and LED 4016.
[0276] Turning to FIG. 41B, shown is a cross-section of the remote
in FIG. 41A integrated with its base 4100 and a cross-section of
the remote separated from its base 4110. The rotating member 4112
is selectively separable and attachable from its base 4114 to allow
for battery access.
[0277] Turning to FIG. 41C, shown is an exploded view 4150 of the
remote in FIG. 41A. Moving from top to bottom, shown is a dial top
4152, a linear resonant actuator/haptic motor 4154, capacitive
touch sensor 4156, a PCB 4158, a light pipe/diffuser 4160, a
battery housing 4162, batteries 4164, a rotating plate 4166, a
bearing 4168 and a base with rubber grip 4170.
[0278] The PCB 4158 may contain an internal management unit,
accelerometer or gyroscope.
[0279] FIGS. 42, 43, 44 and 45 show schematics of alternative
remotes for mattress system.
[0280] Turning to FIG. 42, shown is a schematic of a log-shaped
remote system 4200. This log-shaped remote system 4200 includes a
touch and press surface 4210, an emanating light 4220 and a
re-charging port door 4230.
[0281] Turning to FIG. 43, shown is a schematic of a flip-over
remote system 4300. On the left, the remote 4310 is in profile
mode. Here the profile mode may show the remote is in standby mode
(represented by Z's in one color). A press on the remote 4320 may
be used by a user to cycle between desired features and a twist of
the remote 4330 may increase or decrease the temperature, airflow
or other feature parameter. When activated the color of the Z's may
change, telling the user that the status of the remote or parameter
has changed.
[0282] The remote may be flipped 4340 to enter basic mode 4350.
Here a press may turn the remote on or off 4360 and a twist 4370
may activate or adjust various features in the mattress system.
[0283] Turning to FIG. 44, shown is a schematic of a bounce-back
remote system 4400. This remote is constructed so a left or right
twist of the dial always springs back to the center. A press 4410
on the remote may start the system. A twist 4420 on the remote may
adjust various system parameters. A double press 4430 on the remote
may pause the system. Along press 4440 (such as 3 seconds) may turn
the system off.
[0284] Turning to FIG. 45, shown is a remote horizontal gesture
system 4510 and a remote vertical gesture system 4520 that may
control features of a mattress system. The gesture sensing module
in the remote detects mid-air horizontal and vertical gestures.
IX. Conclusion
[0285] In the foregoing specification, specific embodiments have
been described. However, one of ordinary skill in the art
appreciates that various modifications and changes can be made
without departing from the scope of the invention as set forth in
the claims below. Accordingly, the specification and figures are to
be regarded in an illustrative rather than a restrictive sense, and
all such modifications are intended to be included within the scope
of present teachings.
[0286] The benefits, advantages, solutions to problems, and any
element(s) that may cause any benefit, advantage, or solution to
occur or become more pronounced are not to be construed as a
critical, required, or essential features or elements of any or all
the claims. The invention is defined solely by the appended claims
including any amendments made during the pendency of this
application and all equivalents of those claims as issued.
[0287] Moreover, in this document, relational terms such as first
and second, top and bottom, and the like may be used solely to
distinguish one entity or action from another entity or action
without necessarily requiring or implying any actual such
relationship or order between such entities or actions. The terms
"comprises," "comprising," "has", "having," "includes",
"including," "contains", "containing" or any other variation
thereof, are intended to cover a non-exclusive inclusion, such that
a process, method, article, or apparatus that comprises, has,
includes, contains a list of elements does not include only those
elements but may include other elements not expressly listed or
inherent to such process, method, article, or apparatus. An element
proceeded by "comprises . . . a", "has . . . a", "includes . . .
a", "contains . . . a" does not, without more constraints, preclude
the existence of additional identical elements in the process,
method, article, or apparatus that comprises, has, includes,
contains the element. The terms "a" and "an" are defined as one or
more unless explicitly stated otherwise herein. The terms
"substantially", "essentially", "approximately", "about" or any
other version thereof, are defined as being close to as understood
by one of ordinary skill in the art. The term "coupled" as used
herein is defined as connected, although not necessarily directly
and not necessarily mechanically. A device or structure that is
"configured" in a certain way is configured in at least that way
but may also be configured in ways that are not listed.
[0288] The Abstract of the Disclosure is provided to allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. In addition,
in the foregoing Detailed Description, various features are grouped
together in various embodiments for streamlining the disclosure.
This method of disclosure is not to be interpreted as reflecting an
intention that the claimed embodiments require more features than
are expressly recited in each claim. Rather, as the following
claims reflect, inventive subject matter lies in less than all
features of a single disclosed embodiment. Thus, the following
claims are hereby incorporated into the Detailed Description, with
each claim standing on its own as a separately claimed subject
matter.
* * * * *