Patent Publication Number: US-2021177166-A1

Title: Apparatus for bedding climate control system and method to use the same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present patent application claims the benefits of priority of U.S. Patent Application No. 62/720,582, entitled “Apparatus for bedding climate control system and method to use the same”, and filed at the U.S. Patent Office on Aug. 21, 2018, the content of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a home appliance, in particular an apparatus that provides air and/or heated air to a bedding control system. 
     BACKGROUND 
     The inventor has developed a self-making bedding system including a climate control system for the automation and ventilation of an existing duvet, comforter or blanket, as disclosed in international patent application no. WO 2018/064776 (Lemieux), the content of which is incorporated herein by reference. The bedding system comprises an inflatable lining configured to be inserted and affixed into a cover of a duvet together with the duvet. The inflatable lining comprises a network of pneumatic chambers defining a plurality of openings extending through the lining allowing air to circulate through the lining. The bedding system also comprises an apparatus operatively connected to the inflatable lining for blowing air into the network of pneumatic chambers, so as in use, the inflatable lining is inflated to allow for the duvet and its cover to be straightened back into position after every use of the duvet. The inflatable lining may define a second network of pneumatic chambers configured to circulate and distribute hot or cold air towards a user laid in a bed under the duvet so as to regulate the temperature of the duvet. The second network may comprise more than one separate sub-networks, for instance two or four, for distributing air with different temperatures in specific regions of the bed. The lower layer of the inflating lining may comprise a plurality of holes in connection with the second network for distributing the temperature-controlled air. 
     There is thus a need for a new apparatus allowing to simultaneously (1) providing air to the lining to allow for the duvet and its cover to be straightened back into position after every use of the duvet, and (2) controlling the temperature in the bedding system by providing heated air to the different networks and sub-networks of the bedding system. 
     SUMMARY 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     The invention is directed to an apparatus as described herein allowing to simultaneously providing air to a bedding system, and controlling the temperature of the bedding system. 
     According to a first aspect, the invention is directed to an apparatus for producing controlled air flows with different temperatures, the apparatus comprising: a blower unit having at least one air moving unit to generate air flow; an outlet unit comprising at least two air outlets fluidly connected to the blower unit and configured for providing the air flow outside the apparatus, each outlet comprising a valve for controllably closing the outlet to control the air flow going through the outlet; a heating unit comprising at least one heating element operatively connected to at least one of the outlets for heating the air flow circulating through the outlet; and a control unit operatively connected to the at least one air moving unit, to the valves and to the at least one heating element, for selectively controlling the air flow and temperature exiting each of the at least two outlets. Preferably, the air moving unit consists of a single centrifugal fan. 
     According to a preferred embodiment, the apparatus comprises three air outlets, wherein two of said three air outlets are equipped with one of the at least one heating element. With this configuration, the outlet not equipped of a heating system will be only used to inflate the bedding system where the two other outlets equipped with a heating element will be used to climate the bedding system. In that sense, the heating elements are preferably independently controlled one to the other allowing controlling the temperature of each side of the bed independently. 
     According to a preferred embodiment, the apparatus further comprises a longitudinal distribution pipe for connecting the outlets to the blower unit defining a longitudinal direction, the outlets being fluidly connected along the distributions pipe and perpendicularly oriented to the longitudinal direction of the distribution pipe. 
     According to a preferred embodiment, each air outlet comprises: a first chamber in fluid communication with the blower unit, and a second chamber in fluid communication with the first chamber and configured for providing the air flow outside the apparatus; and wherein the valve is configured to controllably close the first chamber to avoid the air flow generated by the blower unit to enter the second chamber. Preferably, the first and second chamber of each outlet form a continuous tubular element defining a tubular section with a cylindrical surface, each valve comprising a revolving disc fitting in size with the tubular section of the first chamber. The disc can be maintained inside the first chamber by a vertical pivot allowing the disc to rotate inside the first chamber between a closed position, when the disc closes the first chamber and blocks the air flow, and a full open position, when the disc is parallel to a direction of the air flow, the disc being maintained according to an operative position between the close and full open positions, the operative position being controllably modified by the control unit for modulating the air flow. Preferably, the at least one heating element is located around the cylindrical surface of the second chamber. 
     According to a preferred embodiment, each disc of each valve is rotated via an actuator comprising a micro-motorized element operatively controlled by the control unit and acting on the vertical pivot of the disc via a cable, each of the motorized element being independent one to the other. 
     According to a preferred embodiment, the control unit comprises an electronic control system having a printed circuit board (PCB) operatively connected to: the blower unit for controlling a power of the least one air moving unit (on/off) and optionally the air flow; each actuator of the valve for controlling and maintaining the operative position of the valve, and as such control the air flow in each second chamber independently one to the other; and to each heating element for heating or not the air going through the second chamber. Preferably, the electronic control system is operated using at least one of the followings: an interface located on an outside surface of the apparatus; a smartphone, a tablet, an intelligent virtual/personal assistant, or computer including an application or software adapted for wirelessly sending instructions to the apparatus; and a remote control. More preferably, the instructions are wirelessly sent using Bluetooth or Wi-Fi. 
     According to a preferred embodiment, the apparatus further comprises: a casing for supporting the blower unit, the outlet unit, the heating unit and the control unit; and a grid element extending from a first side of the casing adjacent to the outlet unit, the grid element having at least one air flow opening for allowing air entering the casing; wherein a second side of the casing opposite to the first side is located adjacent to the blower unit, the air entering the casing of the apparatus through the first grid element being then forced to flow above or below the outlets before reaching the blower unit, in order to reduce noise propagation when the apparatus is running. Preferably, the casing is compact enough to be placed under a bed. For instance, the dimensions of the casing can be 3.25 inches (or 8.25 cm), 17.5 inches (or 44.45 cm) and 10.5 inches (or 26.67 cm). 
     According to a first aspect, the invention is directed to a method for producing controlled air flows with different temperatures, the method comprising:
         a) generating an air flow with at least one air moving unit (preferably with one air moving unit consisting of a single centrifugal fan);   b) conducting the air flow generated in step a) outside the apparatus through at least two air outlets, each outlet comprising a valve for controllably closing the outlet to control the air flow going through the outlet, and at least one heating element operatively connected to at least one of the outlets for heating the air flow circulating through the outlet; and   c) selectively and independently controlling the air flow and temperature exiting each of the at least two outlets by controlling the at least one air moving unit, the valves and the at least one heating element.       

     The invention is particularly useful for disabled persons for self-making their bed by directly controlling the apparatus via the application, with the possibility to use a voice control system combined with the application, or to have the apparatus daily programmed for making the bed or controlling the temperature at specific time of the day. 
     Other and further aspects and advantages of the present invention will be better understood upon the reading of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features and exemplary advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the appended drawings, in which: 
         FIG. 1  is a top perspective view of an apparatus in accordance with a preferred embodiment; 
         FIG. 2  is plan side view of the apparatus illustrated on  FIG. 1 ; 
         FIG. 3  is a top plan view of the apparatus illustrated on  FIG. 1 ; 
         FIG. 4  is a front plan view of the apparatus illustrated on  FIG. 1 ; 
         FIG. 5  is a top perspective view of the apparatus in accordance with a preferred embodiment including pipe connectors; 
         FIG. 6A  is a top open view of the apparatus according to a preferred embodiment; 
         FIG. 6B  is another top open view of the apparatus according to a preferred embodiment; 
         FIG. 6C  is yet another top open view of the apparatus according to a preferred embodiment; 
         FIG. 6D  is a further top open view of the apparatus according to a preferred embodiment; 
         FIG. 7A  is picture illustrating the front face of the honeycomb grid with air flow orifices according to a preferred embodiment; 
         FIG. 7B  is picture illustrating the back face of the honeycomb grid with air flow orifices according to a preferred embodiment; 
         FIG. 8A  is picture illustrating the front face of the honeycomb grid without air flow orifices according to a preferred embodiment; 
         FIG. 8B  is picture illustrating the back face of the honeycomb grid without air flow orifices according to a preferred embodiment; 
         FIG. 9  schematizes a bed having a blower in accordance with a preferred embodiment connected to a bedding climate system; 
         FIG. 10  illustrates a first interface of an application of a smartphone for controlling the bedding climate system; 
         FIG. 11  illustrates a second interface of an application of a smartphone for controlling the bedding climate system; 
         FIG. 12  illustrates a third interface of an application of a smartphone for controlling the bedding climate system; 
         FIG. 13  illustrates a fourth interface of an application of a smartphone for controlling the bedding climate system. 
         FIG. 14  illustrates a fifth interface of an application of a smartphone for controlling the bedding climate system; 
         FIG. 15  illustrates a sixth interface of an application of a smartphone for controlling the bedding climate system; 
         FIG. 16  illustrates a seventh interface of an application of a smartphone for controlling the bedding climate system; and 
         FIG. 17  is a flowchart for illustrating the method according to a preferred embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 to 4  illustrate an apparatus  1  that provides air and/or heated air to a bedding control system according to a preferred embodiment. The apparatus  1  comprises a casing  3  for encasing and supporting an electrically powered blower unit as the one detailed in  FIGS. 6A to 6D . 
     The casing  3  defines a top flat surface  5 , a bottom flat surface  7  and a front wall  9  connecting the top and bottom surfaces. The front wall  9  defines an aperture  11  configured to nest up to 3 air flow outlets  13  of the blower unit. 
     The casing  3  also defines lateral walls  15  and  16  extending from the top to the bottom surfaces. Each of the lateral walls comprises a grid element. The functionality of the grid elements will be better described herein after in reference to  FIGS. 7A, 7B, 8A and 8B . The grid elements are generally made of a translucent plastic material and the apparatus may include LED lights located inside the casing and adjacent to the grid elements to produce light of different colors and intensity when the apparatus is working. 
     As illustrated on  FIG. 3 , the casing  3  also defines a back wall  17  extending from the top to the bottom surfaces, and from which may extend an electrical cable for powering the apparatus (not illustrated). The apparatus may also have feet  19 , such as anti-slip rubber feet, extending from the bottom surface  7 , or from the back wall  17  allowing the apparatus  1  to stand on the back wall. 
     As illustrated on  FIGS. 5 and 6A , the apparatus  1  may further comprise a connecting element  21  that is configured to be inserted and maintained into the aperture  11  of the front wall  9 , for instance by clipping. The connecting element comprises tubular portions  23  for matching and aligning with the air flow outlets  13 . The tubular portions are each sized to operatively connect with a respective pipe  25  for distributing air and/or heat to the device in need of said air and/or heat. 
       FIG. 6A  shows an open casing  3  detailing the internal electrically powered blower unit, and in particular the grid elements  27  and  28  forming the lateral walls  15  and  16  respectively. 
     The grid elements  27 ,  28  are generally made of a one-piece molded plastic material and are configured to be maintained by the casing, for instance by clipping. According to a preferred embodiment illustrated in  FIGS. 7A to 8B , the first and second grid element  27 ,  28  have a 3-D honeycomb pattern.  FIG. 7A  shows the external face of the first grid element  27  having a flat central portion  271  of closed honeycomb cells surrounded by an upper and lower row  272  of open honeycomb cells forming vertical openings  273  for allowing air to flow inside the apparatus  1 . In this regard, the first grid element  27  having air flow openings is located adjacent to the air outlets  311 ,  312 ,  313  whereas the opposite second grid element  28 , as illustrated in  FIGS. 8A and 8B , and which is adjacent to the blower unit  29 , is made of closed honeycomb cells  281  which does not comprise air flow openings. The air entering the casing  3  of the apparatus  1  through the first grid element  27  is forced to flow above or below the outlets before reaching the blower unit  29 . This configuration of the grid elements  27 ,  28  allows reducing noise propagation when the apparatus is running. 
     As illustrated in  FIG. 6A , the apparatus  1  also comprises a filtering element  51  comprising a case  511  embedding a filter (not visible). The filter is facing the grid element  27  and thus allows filtering the air entering the casing when the apparatus is running for removing dust or the like. The case  511  comprises a handle portion  512  allowing to remove the case  511  from the casing  3  when the filter needs to be changed. 
       FIG. 6B  shows an open casing  3  detailing the internal electrically powered blower unit, and in particular a centrifugal blower unit  29 , electrically powered, to generate air flow. The centrifugal blower unit  29  is operatively connected to a main air conduit  31  having one inlet  310  in fluid communication with the blower unit  29  and a plurality of outlets  311 ,  312 ,  313 . 
     As illustrated on  FIG. 6C , each of the outlets  311 ,  312 ,  313  define a chamber  33  in fluid communication with the main conduit  31 . Each of the chambers  33  comprises a valve  35  which, in its closed position, closes the chamber to avoid air to enter the outlets. As illustrated, each valve  35  may comprise a revolving disc  37  fitting in size with the tubular section of the chamber  33 . The disc is maintained inside the chamber by a vertical pivot  39  allowing the disc to rotate inside the chamber between a closed position when the disc  37  closes the chamber  33 , and an full open position where the disc is parallel to the air flow. The position of the disc between the close and full open positions can be modified and maintained in its position to modulate the air flow. The disc can be moved via an actuator comprising a (micro-) motorized element  41  acting on the pivot of the disc via a cable  43 . Each of the motorized element is independent one to the other. 
     As illustrated on  FIG. 6D , each chambers  33  fluidly communicates with a longitudinal tubular portion  45  ended with the air flow outlets  13 . At least one of the tubular portions comprises a heating element  47  for heating the air flowing through the tubular portion. The heating element as illustrated can surround the tubular portion. Each of the heating element is independent one to the other. 
     The apparatus  1  further comprises an electronic control unit  49 , comprising for instance a printed circuit board (PCB), operatively connected to: 
     the blower unit for controlling the power of the blower (on/off) and eventually the air flow; 
     to each of the actuators of the valves  35  for controlling the opening and closing of the valve, and air flow; and 
     to each of said heating elements  47  for heating or not the air going through the longitudinal tubular portion  45 . 
     The electronic control unit can be operated using: 
     an interface located on an outside surface of the casing; and/or 
     a smartphone, tablet or computer including an application or software adapted for wirelessly sending instructions to the apparatus, the connection can be using Bluetooth or Wi-Fi; and/or 
     a remote control. 
       FIGS. 10 to 16  shows examples of different interfaces of the application for controlling the self-making bedding system and the bedding climate system illustrated on  FIG. 9 . 
       FIG. 17  illustrates the method for producing controlled air flows with different temperatures according to a preferred embodiment. The method  1000  comprises:
         a) generating an air flow with at least one air moving unit (preferably with one air moving unit consisting of a single centrifugal fan)  1100 ;   b) conducting the air flow generated in step a) outside the apparatus through at least two air outlets, each outlet comprising a valve for controllably closing the outlet to control the air flow going through the outlet, and at least one heating element operatively connected to at least one of the outlets for heating the air flow circulating through the outlet  1200 ; and   c) selectively and independently controlling the air flow and temperature exiting each of the at least two outlets by controlling the at least one air moving unit, the valves and the at least one heating element  1300 .       

     The apparatus and method as disclosed herein allow producing air flow to inflate an inflatable element, such as a self-making bedding system, via a first exhausting pipe while heating or not the air exiting the apparatus via a second, optionally a third, exhausting pipe, for controlling the temperature sent into the inflatable element. The invention cannot be limited in accordance with the number of exhausting pipes. 
     In the preferred embodiment illustrated herein, the apparatus comprises three air flow outlets. The central outlet  46  does not include a heating element and is generally used for inflating the self-making bed system when the apparatus  1  is used for self-making the bed as detailed in WO 2018/064776, the content of which is enclosed herewith. The two other outlets are used to send temperature controlled air in the second chambers of the bedding climate control system for independently controlling the temperature on each side of the bed (see  FIG. 9 ). 
     By using a smartphone, a tablet, an intelligent virtual/personal assistant, a remote control or the like, operatively connected with the apparatus  1 , one can modulate the temperature of the air sent to one side of the bed by modifying the air flow (opening of the valve) and/or the temperature of the heating elements. In that case, the central outlet is closed. When the user wants the self-making bedding system works and makes the bed, the central outlet is open while the two other outlets with the heating elements are closed to inject a maximum of air flow into the bedding system. The application controlling the apparatus may also be used for programming when the apparatus will start ( FIGS. 15 and 16 ). For instance, the bed may be heated during several minutes before bedtime. 
     The present invention in combination with the self-making bedding system of the Applicant (WO2018/064776) is useful not only for normal use at home but also in combination with medical beds at home or in hospitals. The invention may be particularly useful for disabled persons allowing them to self-make their bed by directly controlling the apparatus via the application, with the possibility to use a voice control system combined with the application, or to have the apparatus daily programmed for making the bed or controlling the temperature at specific time of the day. 
     A method is generally conceived to be a self-consistent sequence of steps leading to a desired result. These steps require physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic/electromagnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, parameters, items, elements, objects, symbols, characters, terms, numbers, or the like. It should be noted, however, that all of these terms and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. 
     The description of the present invention has been presented for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen to explain the principles of the invention and its practical applications and to enable others of ordinary skill in the art to understand the invention in order to implement various embodiments with various modifications as might be suited to other contemplated uses.