Abstract:
A non-inflatable resting device used for heating and cooling is provided with a plurality of interconnected channels located close to an external surface of the resting device. Each channel substantially occupies the space between two support beams and the interior of said external surface. The comfort level of the resting devices is considerably increased while maintaining adequate structural integrity of the channels when the support beams are constructed with a cushion material having layers of different hardness levels. The top layer is a cushion material with high initial softness ratio. The arrangement of the channels and beams allows a non-pressurized conditioned fluid to flow underneath of the external surface providing a resting device with a heating and cooling system with unmatched energy efficiency. The high energy efficiency of the proposed resting device is due to the elimination of the compressor motor and the thick cushion layer used on the top surface as required by the competition. In addition, the ambient comfort level is improved by the elimination of a noisy compressor motor.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority from, and incorporates by reference the entirety of U.S. Provisional Patent Application Ser. No. 61/226,712 filed on Jul. 18, 2009. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    This invention relates generally to fluid flow within the body of non-inflatable resting devices, and more particularly, to temperature control systems for non-inflatable resting devices such as cushion mattresses and seating devices. 
         [0004]    2. Prior Art 
         [0005]    People spend several hours of each day sitting or laying down on a surface, including a bed (e.g., mattress, mattress pad, etc.) or a seat (e.g., office chair, sofa, seating pad, seating cushion, etc.) Since it is often desirable to manage and control the temperature of the surface that contacts the person (e.g., to remove the heat trapped in the contact area), several existing solutions attempt to cool or heat the contact surface or the person to improve personal comfort. 
         [0006]    For example, sofas and other pieces of furniture incorporate electrical and mechanical equipment inside the furniture and below the surface to be heated or cooled. Similarly, thermal blankets and mattress pads incorporate electrical heating elements to heat the contact surface. In addition to increasing the cost and complexity of the mattress or seat, these systems also increase the risks of hazardous conditions such as fire and electric shock. 
         [0007]    Other prior art solutions for heating and cooling of non-inflatable resting devices include the use of cushioned mattresses, pads, and seats with a plurality of hoses through which a conditioned fluid (i.e. water, air) is circulated under a relative thick cushion layer. The contact surface of the resting device is required to provide the users with sufficient comfort and to have thermal conductivity to allow adequate heating or cooling of the users resting on these devices. However, an acceptable trade-off between the mattress comfortability and the energy efficiency of the heating and/or cooling system has proven to be a difficult goal to obtain. Among others, the main drawbacks of these solutions are one or more of the following, 1) the conditioned fluid must be pressurized through the use of motor driven compressors because of the requirement of the conditioned fluid to support the users&#39; weight, making these solutions less energy efficient and more expensive due to the use of special sealed-tight hoses and connections, 2) the contact surface is made relatively thick due to the comfort level requirement, which in turn, adversely affects the thermal conductivity between the user and the conditioned fluid, 3) typically, the materials from which the contact surface is made of do not satisfactorily comply with the required thermal conductivity and mechanical strength, 4) the above performance deficiencies of the system imply that if air is used as the conditioned fluid, it needs to be blown onto the users through a multiplicity of holes located in the contact surface, and as a consequence, the system cannot be configured to work in a closed loop, and finally 5) when the heating and cooling system is configured as a closed loop, a more thermally efficient conditioned fluid is usually used, i.e., water. The mentioned drawbacks can be found on today&#39;s most popular heating and cooling mattress and pads such as the “ChilliPad”, “ChilliBed” and “CoolorHeat”. 
         [0008]    Consequently, there still is a market need for a non-inflatable resting device which can provides the users with a low-cost efficient heating and cooling while maintaining high comfort level. 
       DEFINITIONS 
       [0009]    “Hardness” is defined as the resistance against pressure. 
         [0010]    “Density” is the mass per unit volume. When density increases, hardness tends to increase. 
         [0011]    “Tensile strength” is the resistance against stretching. 
         [0012]    “Indentation Load Deflection” (ILD) factor is a hardness measurement defined in the ISO 2439 standard as the force that is required to compress a material a percentage of its original thickness, e.g., 25%, 40%, and 60% from its original thickness. And, these ILD&#39;s are designated as ILD 25% , ILD 40% , and ILD 60% , respectively. 
         [0013]    “Compression Load Deflection” (CLD) factor is a hardness measurement defined in the ISO 3386 standard as the counter pressure (force per surface) when the core material is pressed in 25% of its original thickness. 
         [0014]    “Compression Modulus” (CM) or Sag Factor is defined by ISO 2439 standard as the ratio of ILD 65%  to ILD 25% . The Compression Modulus (CM) somewhat correlates with the perception of a person to whether the mattress supports a person&#39;s body with more uniform alignment. 
         [0015]    “Initial Softness Ratio” (ISR) factor is a hardness measurement defined as the ratio of ILD 65%  to ILD 5% . The Initial Softness Ratio (ISR) somewhat correlates to the initial perception of a person about the comfort of the mattress. 
         [0016]    “Human Two-Point Discrimination Threshold” is measured on a person&#39;s back when lying down on a resting device, and it is the minimum separation distance at which two objects may be distinguished when coming into contact with the skin. In the medical field that distance is recognized as approximately equals to 1 inch maximum. 
         [0017]    The “Comfort Layer” is defined as a layer with high Initial Softness Ratio (ISR). The comfort layers are represented on the figures by a lower density hatch with a honey comb like pattern. 
         [0018]    The “Support Layer” is defined as a foam layer with high Compression Load Deflection (CLD) factor. The support layers are represented on the figures by a higher density hatch with a honey comb like pattern. 
         [0019]    “Bottoming out” refers to the collapse of a structure such that the top part of the structure substantially comes close or into contact with the bottom part as a response to an applied force. 
         [0020]    The “Contact Surface” refers to any external surface of a resting device on which users rest. In this document the contact surface is referred to as the top surface. 
       SUMMARY 
       [0021]    The requirement of a resting device made of a non-inflatable cushioned material for using pressurized conditioned fluid or a thick comfort layer through which heating and cooling is provided, is eliminated by configuring the resting device to have a plurality of interconnected channels through which a conditioned fluid flows substantially close to the contact surface of the resting device, where each of said channels substantially occupies the space between two support beams. The support beams provide structural strength to prevent the adjacent channels from bottoming out when subjected to weight loads. Additional strength and comfort are provided when each support beam is made out of a cushion material with non-uniform hardness levels. The top layer of the support beams is a comfort layer substantially close to the contact surface while the lower or bottom layers can have higher hardness levels in order to increase the structural strength of the support beams preventing the channels from bottoming out. In addition, the conditioned fluid can be configured to flow in a close loop without the need for motor driven compressors and special sealed tight connectors because the conditioned fluid flowing through the channels is not required to be pressurized. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a partial sectional view illustrating a channel limited by an external surface and two support beams having a single support layer. 
           [0023]      FIG. 2  is a partial sectional view illustrating a channel limited by an external surface and two support beams having a multiple support layers. 
           [0024]      FIG. 3  is a partial sectional view illustrating a channel limited by an external surface and two support beams having gradual change in hardness level. 
           [0025]      FIG. 4  is a partial sectional view illustrating a duct with sidewalls having a single support layer. 
           [0026]      FIG. 5  is a partial sectional view illustrating a duct with sidewalls having multiple support layers. 
           [0027]      FIG. 6  is a partial sectional view illustrating a duct with sidewalls having gradual change in hardness level. 
           [0028]      FIG. 7  is a perspective view of a mattress showing the connection with the supply and return hoses. 
           [0029]      FIG. 8  is a sectional view illustrating an embodiment of the heating and cooling unit. 
           [0030]      FIG. 9  is a sectional view of another embodiment of a heating and cooling unit attached to the mattress. 
           [0031]      FIG. 10  is a sectional view of an embodiment illustrating a ventilation unit attached to the mattress. 
           [0032]      FIG. 11  is a sectional view of an embodiment illustrating an embodiment of a heating unit attached to the mattress. 
           [0033]      FIG. 12  illustrates a top view of a mattress with the top surface removed and the channels connected to allow a single fluid flow. 
           [0034]      FIG. 13  is a sectional view of the mattress shown in  FIG. 12  along axis  FIG. 13-FIG .  13  illustrating a single support layer. 
           [0035]      FIG. 14  is a sectional view of the mattress in  FIG. 12  along axis  FIG. 14-FIG .  14  illustrating a duct. 
           [0036]      FIG. 15  is a sectional view of the mattress in  FIG. 12  along axis  FIG. 15-FIG .  15  illustrating a channel. 
           [0037]      FIG. 16  is a sectional view of the mattress in  FIG. 12  along axis  FIG. 16-FIG .  16  illustrating a support beam. 
           [0038]      FIG. 17  is a sectional view of the mattress in  FIG. 12  along axis  FIG. 17-FIG .  17  illustrating another support beam. 
           [0039]      FIG. 18  is a top view of a mattress with the top surface removed illustrating another embodiment of the support beams and the channels connected to allow a single fluid flow. 
           [0040]      FIG. 19  is a sectional view of the mattress shown in  FIG. 18  along axis  FIG. 19-Fig .  19  illustrating a support beam comprising rectangular support columns. 
           [0041]      FIG. 20  is an enlargement of a typical air pocket between two rectangular support columns. 
           [0042]      FIG. 21  is a top view of a mattress with the top surface removed illustrating another embodiment of the support beams and the channels connected to allow a single fluid flow. 
           [0043]      FIG. 22  is a sectional view of the mattress shown in  FIG. 21  along axis  FIG. 22-FIG .  22 , illustrating a support beam comprising cylindrical support columns. 
           [0044]      FIG. 23  is a top view of an embodiment of a ductless mattress with the top surface removed illustrating the channels connected to allow a single fluid flow. 
           [0045]      FIG. 24  is a sectional view of the mattress shown in  FIG. 23  along axis  FIG. 24-FIG .  24 . 
           [0046]      FIG. 25  is a top view of an embodiment of a mattress with the top surface removed illustrating the channels connected to allow multiple fluid flows. 
           [0047]      FIG. 26  is a sectional view of the mattress shown in  FIG. 25  along axis  FIG. 26-FIG .  26 , illustrating a channel and two ducts. 
           [0048]      FIG. 27  is a sectional view of the mattress shown in  FIG. 25  along axis  FIG. 27-FIG .  27 , illustrating a support beam and two ducts. 
           [0049]      FIG. 28  is a sectional view of a support beam illustrating a continuous support layer sandwiched between two comfort layers. 
           [0050]      FIG. 29  illustrates the support beam of  FIG. 28  subjected to weight loads. 
           [0051]      FIG. 30  is a sectional view of a support beam illustrating a segmented support layer. 
           [0052]      FIG. 31  illustrates the support beam of  FIG. 30  subjected to weight loads. 
           [0053]      FIG. 32  is a sectional view of a support beam illustrating another embodiment of a segmented support layer. 
           [0054]      FIG. 33  illustrates the support beam of  FIG. 32  subjected to weight loads. 
           [0055]      FIG. 34  shows a section of a support beam illustrating a support layer embedded into the comfort layer. 
           [0056]      FIG. 35  shows a section of support beam illustrating a non-embedded support layer. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0057]      FIG. 1 ,  FIG. 2 , and  FIG. 3  are sectional views illustrating three embodiments of the support beams  103 , while  FIG. 4 ,  FIG. 5 , and  FIG. 6  are sectional views illustrating three embodiments of the duct  107  ( 108 ). The weight of a user lying down on the top surface  112  can be supported by the support beams  103 . When properly designed, the support beams  103  can behave like a spring and react to the applied weight in such a way as to prevent the channels  102  from bottoming out. The support beams  103 , the channels  102  and duct  107  ( 108 ) can be constructed out of a foam material with uniform hardness level. The problem of a mattress  100  having support beams  103  made of a foam having uniform hardness level, is that, if the foam material has low density or is too soft, the support beams  103  can collapse allowing the bottoming-out of the channels  102 , and substantially blocking the flow of the conditioned air  101 . On the contrary, if the hardness level of the foam material is increased to make it less compressible, the body pressure points increase making it more difficult for users to rest comfortably. As a result, a satisfactory trade-off between comfortability of the mattress  100  and structural integrity of the support beams  103  is more difficult to obtain by using support beams  103  having uniform hardness level. 
         [0058]    The solution for designing the support beams  103  with structural integrity while having a foam mattress  100  with high comfort level is to provide the support beams  103  with a foam material with non-uniform hardness levels. As shown in  FIG. 1 , the top of the support beams  105  comprises a comfort layer  104  while a support layer  105  is added below. The comfort layer  104  has a higher Initial Softness Ratio (ISR) in order to provide users with comfort while the support layer  105  below provides the support beams  103  with structural integrity preventing the channels  102  from bottoming-out. If bottoming-out occurs, the channels  102  can be substantially blocked greatly decreasing the flow of the conditioned air  101  and the performance of the heating and cooling system. Bottoming-out of the channels  102  is a condition to be avoided and accounted for in the mattress design stage. 
         [0059]      FIG. 1  illustrates a channel  102  conveniently located below the top surface  112  on which users lie down to rest, and between two support beams  103  having a foam material with a support layer  105  sandwiched between two comfort layers  104 . This embodiment follows the criteria of having a top layer with high Initial Softness Ratio (ISR) while the layer below has higher hardness level preventing the support layers  105  from collapsing and avoiding bottoming-out of the channels  102 .  FIG. 2  and  FIG. 3  illustrate additional embodiments of the support beams  103 .  FIG. 2  illustrates the support beams  103  comprising multiple support layers  105 .  FIG. 3  illustrates the support beams  103  made of a foam material having gradual change in hardness level. The top of the support beams  103  is a foam material having high Initial Softness Ratio (ISR) while the deeper foam has gradual increase in hardness levels. 
         [0060]      FIG. 4 ,  FIG. 5 , and  FIG. 6  show embodiments of a duct  107  ( 108 ). The duct  107  ( 108 ) connects with the channels  102  and is used to transport the conditioned air  101  within the interior of the mattress  100 . As opposed to the channels  102 , a duct  107  ( 108 ) is located away from the external surfaces of the mattress  100 . The sidewalls of the duct  107  ( 108 ) counteract the weight applied on the top surface  112  preventing the ducts from bottoming out.  FIG. 4  illustrates a duct  107  ( 108 ) with sidewalls constructed out of a foam material having a support layer  105  sandwiched between two comfort layers  104 .  FIG. 5  illustrates another embodiment of a duct  107  ( 108 ) with sidewalls made of a foam material having multiple support layers  105 . While  FIG. 6  shows another embodiment of a duct  107  ( 108 ) with sidewalls built with a foam material having gradual change in hardness levels. 
         [0061]    Even though the description of the figures depicts the cushion material from which the mattress  100  is made as being of the polymer type foam, other types of cushion materials can also be used and are within the scope of the invention. For instance, cushion materials used for the construction of the resting devices can be one or more thermoplastic polymers, natural or synthetic fibers such as polyurethane, vinyl PVC (polyvinyl chloride), latex, polyethylene, nylon, rubber, neoprene rubber, cotton, wool, etc., and similar materials used in cushion mattresses. The top surface  112  can be made of Nylon, Lycra, Cotton, Polyester or similar materials with small thickness (approximately between 5 mils and 20 mils) so as to promote heat transfer. In addition to a smaller thickness, the heat transfer characteristic of the top surface  112  can be improved by using materials made of heat-conductive polymers. Adding conductive fillers increases the thermal conductivity of these polymers. For instance, some compounds used as conductive fillers are graphite fibers and silver, among others. In one embodiment (not shown) the top surface  112  can be made detachable for washing purposes. A flocking material made of, e.g., cotton, rayon, nylon, etc., can also be applied to the top surface  112  to provide additional comfort. Although the embodiments disclosed in the application use air as the conditioned fluid, a person of ordinary skill in the art would understand that a variety of other gases or liquids can be used to perform this function and they are within the intent and scope of the invention. 
         [0062]    The technique for making foam materials with different hardness levels is known prior art and it is not covered in this document. The required hardness levels of the support layer  105  and the Initial Softness Ratio (ISR) of the comfort layer  104  can be determined based on factors such as the height, width, and comfortability of the support beams  103 , and the channels  102  minimum unobstructed crossed-sectional area to be maintained under a user&#39;s maximum weight, etc. 
         [0063]    The width of the conditioned air channels  102  is limited by the maximum separation distance between two adjacent support beams  103  for which a person may feel uncomfortable. If the support beams  103  are placed at a distance equal or greater than the “human two-point discrimination threshold”, then, the pressure points at each support beam  103  increase making the mattress  100  uncomfortable. However, the top surface  112  aids in the supporting role of a person&#39;s body, significantly increasing the minimum threshold distance. 
         [0064]      FIG. 7  is a perspective view of the mattress  100  connected to the return and supply hoses  138 ,  139  respectively. The hoses  138 ,  139  can be constructed of flexible thermoplastic polymers and should possess sufficient structural strength to maintain an open cross section. In addition, the materials used for the hoses  138 ,  139  have poor heat transfer characteristic (i.e., low thermal conductivity) to minimize the heat losses between the conditioned air  101  (flowing through the hoses) and the environment. 
         [0065]      FIG. 8  illustrates one embodiment of the heating and cooling unit  130 . The heating and cooling unit comprises a thermoelectric heat pump  144  also known as a Peltier module, which is widely used as a solid state heat pump for mattress heating and cooling applications. The thermoelectric heat pump  130  can comprise two air chambers  131 ,  132  each including a heat exchanger  140 ,  141  respectively. The air chambers  131 ,  132  can each be provided with a pair of ventilation fans  133 ,  134 . The fans can also be integrated with the thermoelectric heat pump unit similar to model number MAA150T-24 as manufactured by Melcor. In one embodiment (not shown), the air cambers  131 ,  132  each can be provided with just a fan similar to model number AA-150-24-22 as manufactured by Melcor. 
         [0066]    When a DC current passes through the thermoelectric heat pump  144 , the conditioned air heat exchanger  140  cools down while the ambient air heat exchanger  141  heats up. On the contrary, if the DC current reverses polarity, the conditioned air heat exchanger  140  heats up while ambient air heat exchanger  141  cools down. In a cooling operation, when the conditioned air  101  passes through the conditioned air chamber  131 , heat is transferred from the conditioned air  101  to a lower temperature heat exchanger  140 , thereby cooling the conditioned air  101 . As the ambient air  135  passes through the air chamber  132 , heat is transferred from a higher temperature heat exchanger  141  to the ambient air  135 , thereby cooling the heat exchanger  141 . On the other hand, the heating operation is performed by reversing the polarity of the voltage applied to the thermoelectric heat pump  144 . The temperature of the conditioned air heat exchanger  140  increases and the temperature of the ambient air heat exchanger  141  decreases. In an embodiment (not shown), the addition of a heating device in the air chamber can provide additional heating as well as humidity and moisture control functions. Water reservoir  145  can be provided for collecting the moisture due to condensation in the air chambers. 
         [0067]    In another embodiment of the heating and cooling unit  130  shown in  FIG. 9 , the hoses  138 ,  139  are not used as the heating and cooling unit  130  is attached directly to the mattress  100  via the openings  109 ,  110 . This embodiment can also be provided with an external power supply to make the heating and cooling unit  130  more compact. 
         [0068]      FIG. 10  illustrates another embodiment using a ventilation fan unit  142  connected directly to the mattress  100  via the openings  109 ,  110 . The embodiment shown in  FIG. 10  can be used in environments where the ambient air can provide some level of cooling. The ambient air can be used to provide cooling of the top surface  112  by removing the trapped body heat through the top surface  112 . In the embodiment depicted in  FIG. 10 , ambient air is drawn into the supply opening  109  by the ventilation fan unit  142 , circulates through the mattress  100  and returns out of the mattress as exhaust air  146  through the exhaust air hose  136  in an open-loop configuration. This embodiment can also be used for removing moisture from the channels  102  after use. 
         [0069]      FIG. 11  illustrates another embodiment where a simpler heating unit  143  is used. This embodiment is similar to the embodiment of  FIG. 10  except that a heating device (not shown) is enclosed within the heating unit  143 . This embodiment can also be used in a closed-loop air flow configuration by connecting a jumper  111  that reroutes exhaust air  146  back into the mattress  100 . Such an embodiment requires minimal power consumption during heating operation. 
         [0070]      FIG. 12  shows a mattress  100  with the top surface  112  removed.  FIG. 12  illustrates an embodiment of the inventive concept with the channels  102  interconnected to allow a single flow of the conditioned fluid  101 .  FIG. 13  and  FIG. 14  are sectional views of the mattress  100  shown in  FIG. 12 . These figures show the support layer  105  as part of the sidewalls of the channels  102  and the duct  107 .  FIG. 15  is a sectional view illustrating a channel  102 .  FIG. 16  and  FIG. 17  are sectional views illustrating support beams  103 . 
         [0071]    In accordance with the inventive concept, interconnected channels  102  are formed next to the top surface  112  of the mattress  100  and substantially extend between two sides defining the perimeter of the external surface. The conditioned air  101  can be supplied to the mattress  100  through the supply opening  109  (see  FIG. 14 ), then through the supply duct  107 , through which the conditioned air  101  passes up through the interior opening  114  (see  FIG. 12 ) and into the channels  102 . Similarly, the conditioned air  101  can return (or exit) from the mattress  100  through the channels  102  and discharged out through the return opening  110 . The configuration of the interior opening, ducts, and channels allows the conditioned air  101  to be received into the mattress  100  by the supply opening  109  and discharged from the return opening  110 . The volume of each channel  102  and each duct  107  ( 108 ) has a geometric ratio such that its length divided by the equivalent of the diameter of its cross-sectional area is greater than three. A person of ordinary skill in the art will understand that a variety of supply and return channel and duct configurations are within the spirit and scope of the invention. For instance, the mattress  100  shown in  FIG. 12  can have two separate comfort zones (not shown) to simultaneously enable two users to adjust for two different temperature levels of the top surface  112 . The latter can be implemented by furnishing each half of the mattress  100  with a separate plurality of channels  102  and beams  103 , and each plurality having its own conditioned air  101 . 
         [0072]    Although the embodiments have been described with the conditioned air  101  being supplied to the foam mattress  100 , via the supply hose, ducts, and openings and returning using the return hose, ducts, and openings, the system can instead be configured to supply conditioned air  101  via the described return path and return via the described supply path. As the conditioned air  101  travels from the supply opening  109  through the mattress  100 , by the time it returns to the return opening  110 , it will be less cool (or less hot) compared to when it entered the resting mattress  100  due to the heat transfer process. This difference in temperature results in a top surface  112  having areas with significantly different temperature levels. In one embodiment, this situation is mitigated by periodically (i.e., after the expiration of a predetermined time interval) reversing the flow direction of the conditioned air  101 . 
         [0073]    The supply and return hoses  109 ,  110  can be attached to the supply and return openings  109 ,  110 , respectively. The other ends of the supply and return hoses connect to the heating and cooling unit  130 . 
         [0074]      FIG. 18  and  FIG. 21  show single-flow mattresses  100  illustrating additional embodiments of the support beams  103  formed by a plurality of support columns  123  and air pockets  115 . The support columns  123  can be of any shape. For instance,  FIG. 18  illustrates rectangular support columns  123  while  FIG. 21  illustrates cylindrical support columns  123 . Each support column  123  is separated from the next by an air pocket  115 . As shown  FIG. 20 , two bridging films  113  connect the sidewalls of the adjacent support columns  123  making the channels  102  continuous and preventing the conditioned air  101  from moving through the air pockets  115 . 
         [0075]      FIG. 23  shows a single-flow ductless mattress  100  with the channels  102  and support beams  103  oriented along the longest axis of the mattress. The connecting jumper  111  completes the flow path of the condition air  101  and allows the hoses  109 ,  110  to be located on the same side of the mattress. 
         [0076]      FIG. 25  shows another embodiment of the mattress  100  where the channels  102  and ducts  107 ,  108  are interconnected to allow multiple flows of the conditioned air  101  below the top surface  112 . If the conditioned air  101  enters through the supply opening  109 , the supply duct  107 , and the channels  102 , then, it returns through the channels  102 , the return duct  108 , and exits through the return opening  110 , and vice versa.  FIG. 26  illustrates a channel  102  connected to a return duct  108 .  FIG. 27  illustrates a support beam  103  formed by a support layer  105  located between two comfort layers  104 . 
         [0077]      FIG. 28  illustrates a support beam  103  having a continuous support layer  105  when no weight is applied on the top surface  112 . As shown in  FIG. 29 , when a support beam  103  with a continuous support layer  105  is subjected to weight loads, compression forces  118  and tensile forces  119  are generated within the continuous support layer  105  creating body pressure points which in turn decrease the comfort level of the mattress  100 . The comfort level of the mattress can be improved if the support layer  105  is divided in segments  120 . The relative movement of the segments  120  with respect to each other minimizes the stiffness of the support layer  105  by minimizing the compression and tensile forces  118 ,  119  respectively. 
         [0078]      FIG. 30  illustrates an embodiment of the segments  120  of the support layer  105 . This embodiment can be implemented by attaching the top surface of each segment  120  to a flexible film (not shown) located between the support layer  105  and the upper comfort layer  104 . The film can be made of a flexible thermoplastic or fiber type materials. As shown in  FIG. 31 , the function of this film is to work as a hinge between two adjacent segments  120  to mitigate the effects of the tearing forces on the upper comfort layer  104 .  FIG. 32  illustrates another embodiment where the support layer  105  is partitioned and attached to the top and bottom comfort layers  104 .  FIG. 33  illustrates the vertical shifting of the segments  120  when the top surface  112  is subjected to weight loads. 
         [0079]    The tearing forces exerted on the comfort layers  104  due to the relative movement among the segments  120  are also mitigated by providing small incisions  121  on the comfort layers  104 .  FIG. 30  and  FIG. 31  show the incisions  121  being made into the bottom comfort layer  104  to allow the segments  120  to swing open at the bottom. While  FIG. 32  and  FIG. 33  show the incisions  121  made at the top and bottom comfort layers  104  to ease the vertical shifting of the segments  120 .  FIG. 34  illustrates an embodiment of a support layer  105  embedded into the comfort layer  104 , while  FIG. 35  illustrates the support layer  105  attached to the top and bottom comfort layers  104 . 
         [0080]    A film can be attached to each sidewall of the support beam  103  shown in  FIG. 35  to prevent the conditioned air  101  from moving across the openings created by the swinging of two adjacent segments  120 , making the channels  102  continuous. 
         [0081]    As opposed to providing heating and cooling through a thick comfort layer on top of the mattress  100 , the heat transfer of the mattress  100  occurs through a thin top surface  112  allowing for higher thermal efficiencies. The conditioned air  101  flowing through the channels  102  can provide an efficient comfort zone a few inches above the top surface  112 . The comfort zone is proportional to the temperature of the top surface  112 . The conditioned air  101  flowing in the channels  102  provides this comfort zone by conducting heat toward (when using heated conditioned air  101 ) or away (when using cooled conditioned air  101 ) from the top surface  112 , thereby heating or cooling the immediate vicinity or any user resting on the top surface  112 . A desirable range for a comfort zone where most persons feel comfortable lies in the range between 25° C. and 30° C. 
         [0082]    The described embodiments of the mattress  100  incorporate an impermeable top surface  112  to keep the conditioned air  101  from escaping the channels  102 . The top surface  112  creates a comfort zone largely in the form of convection heat moving through the top surface  112 . In other embodiments (not shown) employing a porous top surface  112 , the conditioned air  101  can be allowed to leak from the channels  102  through the top surface  112  providing additional cooling or heating of the comfort zone. Compared to an impermeable top surface  112 , a system with a porous top surface can provide higher rate of heat transfer but at the cost of lower energy efficiency as it allows the conditioned air  101  to escape. 
         [0083]    The channels  102  can be made smoother by applying a coating or using a film to cover the sidewalls of the support beams  103 . A smooth sidewall minimizes flow turbulences and pressure drop losses. In addition, the described figures show the channels  102  with rectangular form, but, they can also have other shapes such as elliptical, circular, triangular, etc. 
         [0084]    The design simplicity of mattress  100  lends itself for high productivity manufacturing process lowering production costs per mattress unit. The mattress  100  can be constructed from a single foam piece with dimensions equal to the mattress, and then, the channels  102  can be made by a cut out process. The mattress  100  can also be constructed by using a lower height foam piece, and then, the support beam  103  can be attached on top. 
         [0085]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other embodiments that are evident to those skilled in the art. Such other embodiments are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural/functional elements with insubstantial differences from the inventive concept being claimed.