Patent Publication Number: US-9888782-B1

Title: Temperature controlled mattress system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit and priority to U.S. Provisional Application No. 62/451,488 filed Jan. 27, 2017, the disclosure of which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     The present disclosure relates generally to the field of mattresses, and more particularly to mattresses with temperature controlled systems. 
     Heating and cooling systems may be employed in foam mattresses to adjust a temperature of a sleeping area. The heating and cooling systems may rely on convective air heating or cooling through foam of the mattress. Circulation of hot or cold air through the foam of the mattress presents challenges for even distribution of the hot and cold air over the entire mattress. For example, the foam may prevent conditioned air from reaching a surface of the mattress such that the effects of the conditioned air are felt at a sleeping surface of the mattress. Further, achieving a uniform temperature of the sleeping area or portions of the sleeping area may also be difficult due to the nature of the foam of the mattress. 
     Additionally, a fire retardant sock, which is generally included around a mattress for the mattress to meet upholstered furniture fire safety standards, may also affect the distribution of hot and cold air to the sleeping area of a mattress. For example, the fire retardant sock typically includes at least one layer of a fire retardant foam. In a manner similar to the foam of the mattress, the fire retardant foam of the fire retardant sock may prevent circulation of hot and cold air to the sleeping surface of the mattress. 
     SUMMARY 
     The disclosed embodiments provide details regarding temperature controlled mattresses. In accordance with an embodiment, a mattress assembly includes at least one core layer. The at least one core layer includes a top surface and a bottom surface. Additionally, the mattress assembly includes at least one channel running through the at least one core layer from the bottom surface to the top surface. In operation, the at least one channel receives temperature conditioned air flow at the bottom surface of the at least one core layer. Further, the mattress assembly includes a fluid permeable surface layer coupled to the top surface of the at least one core layer. A fluid dispersal region is positioned between the top surface of the at least one core layer and the fluid permeable surface layer. Also provided in the mattress assembly is a fire retardant quilted panel surrounding the at least one core layer and the fluid permeable surface layer. The fire retardant quilted panel includes a plurality of layers made from fiber material. 
     In accordance with another illustrative embodiment, a temperature controlled cushion system includes at least one core layer. The at least one core layer has a top surface and a bottom surface. Additionally, the system includes at least one channel running through the at least one core layer from the bottom surface to the top surface of the at least one core layer. Also provided in the system is at least one thermoelectric fan coupled to the at least one channel at the bottom surface of the at least one core layer. In operation, the at least one thermoelectric fan provides temperature conditioned air flow to the at least one channel. Further, the system includes a fluid permeable surface layer coupled to the top surface of the at least one core layer and a fluid dispersal region positioned between the top surface of the at least one core layer and the fluid permeable surface layer. Furthermore, a fire retardant quilted panel surrounding the at least one core layer and the fluid permeable surface layer is included in the system. The fire retardant quilted panel includes a plurality of layers made from fiber material. 
     In accordance with another illustrative embodiment, a temperature controlled mattress system includes at least one core layer. The at least one core layer includes a top surface and a bottom surface. The system also includes at least two channels running through the at least one core layer from the bottom surface to the top surface of the at least one core layer. Further, at least two thermoelectric fans are coupled individually to the at least two channels at the bottom surface of the at least one core layer. In operation, the at least two thermoelectric fans provide temperature conditioned air flow to the at least two channels, and the at least two thermoelectric fans and the at least two channels are controllable to generate at least two temperature control zones in the temperature controlled mattress system. Additionally, the system includes a fluid permeable surface layer coupled to the top surface of the at least one core layer and at least one fluid dispersal region positioned between the top surface of the at least one core layer and the fluid permeable surface layer. A fire retardant quilted panel surrounding the at least one core layer and the fluid permeable surface layer is also included in the system, and the fire retardant quilted panel includes a plurality of layers made from fiber material. 
     Additional details of the disclosed embodiments are provided below in the detailed description and corresponding drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Illustrative embodiments of the presently disclosed subject matter are described in detail below with reference to the attached figures, which are incorporated by reference herein, and wherein: 
         FIG. 1  is a cross section perspective view of a temperature controlled mattress system, in accordance with an embodiment; 
         FIG. 2  is a schematic view of the temperature controlled mattress system of  FIG. 1 , in accordance with an embodiment; 
         FIG. 3  is a cross section perspective view of a temperature controlled mattress system including a phase change material, in accordance with an embodiment; 
         FIG. 4  is a schematic view of the temperature controlled mattress system of  FIG. 3 , in accordance with an embodiment; 
         FIG. 5  is a top view of a quilted panel, in accordance with an embodiment; and 
         FIG. 6  is a side cross section view of the quilted panel of  FIG. 5 , in accordance with an embodiment. 
     
    
    
     The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which different embodiments may be implemented. 
     DETAILED DESCRIPTION 
     In the following detailed description of several illustrative embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments are defined only by the appended claims. 
     Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Further, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements includes items integrally formed together without the aid of extraneous fasteners or joining devices. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to”. Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity. 
     The subject matter disclosed in the present application provides an assembly for a temperature controlled mattress. In specific applications, it is desirable for a mattress to include one or more controllable temperature zones. Accordingly, the mattress is designed to receive cooling or heating airflow and to disperse the cooling or heating airflow and the cooling or heating effects of the airflow across a sleeping surface of the mattress. Further, the mattress includes a quilted panel secured around the mattress that provides a fire retardant barrier and is made from layers of fiber material without any foam layers that may interfere with the cooling or heating airflow to the sleeping surface of the mattress. While the figures are generally directed to mattress systems, it may be appreciated that other cushioning systems are also contemplated using the same heating and cooling airflow technology. For example, couches, chairs, and other upholstered furniture may also be designed using the heating and cooling techniques described herein. 
       FIG. 1  is a cross section perspective view of a temperature controlled mattress system  100 . In an embodiment, the temperature controlled mattress system  100  includes a core layer  102  of high density foam. A top surface  104  and a bottom surface  106  of the core layer  102  are also illustrated. A number of channels  108 A and  108 B run through the core layer  102  from the bottom surface  106  to the top surface  104 . While only two channels  108 A and  108 B are depicted in  FIG. 1 , it may be appreciated that the temperature controlled mattress system  100  may include a single channel  108 , or the temperature controlled mattress system  100  may include 3, 4, or more channels  108  while still falling within the scope of the presently disclosed subject matter. Further, while the figures depict the core layer  102  of high density foam, the core layer  102  may also include an innerspring mattress. In such an embodiment, the channels  108 A and  108 B may run through the core layer  102  between spring components of the innerspring mattress. 
     The channels  108 A and  108 B receive temperature conditioned airflow at the bottom surface  106  of the core layer  102  from thermoelectric fans  110 A and  110 B. In an embodiment, each of the channels  108 A and  108 B are coupled to an individual thermoelectric fan  110 A and  110 B, respectively, to provide the temperature conditioned airflow to a sleeping surface  111  of the temperature controlled mattress system  100 . In another embodiment, each of the thermoelectric fans  110 A and  110 B may provide the temperature conditioned airflow to all of the channels  108  that are included within a temperature control zone to which the thermoelectric fans  110 A and  110 B are assigned. The temperature control zones, as used herein, may refer to zones of the temperature controlled mattress system  100  that are individually controllable to vary the temperature at the sleeping surface  111  at the individual temperature control zones. The thermoelectric fans  110 A and  110 B may be disposed within a box spring (not shown) or a mattress frame (not shown) positioned beneath and in physical contact with the temperature controlled mattress system  100 . 
     Also included in the temperature controlled mattress system  100  is a fluid permeable surface layer  112  coupled to the top surface  104  of the core layer  102 . The fluid permeable surface layer  112  may be made from a slow response gel foam or any other slow response foam that is capable of receiving and dispersing the air flow from the channels  108  to the sleeping surface  111 . By way of example, the fluid permeable surface layer  112  may be made from a foam with a large cell structure. Further, the foam of the fluid permeable surface layer  112  may be at least one inch thick. 
     Spaces formed between the fluid permeable surface layer  112  and the top surface  104  of the core layer  102  may be used as fluid dispersal regions  114 A and  114 B. The fluid dispersal regions  114 A and  114 B may be confined to areas immediately surrounding the channels  108 A and  108 B, respectively, at the top surface  104  of the core layer  102 . In another embodiment, the fluid dispersal regions  114 A and  114 B may extend through an entire temperature control zone and be positioned over several of the channels  108  positioned along the temperature control zone. Further, the fluid dispersal regions  114  may be in direct contact with the channels  108 , the core layer  102  and the fluid permeable surface layer  112 . That is, the fluid dispersal regions  114  may be entirely defined by the space between the core layer  102  and the fluid permeable surface layer  112  without any intervening materials. Accordingly, the airflow from the channels  108  is free to enter the fluid permeable surface layer  112  directly from the fluid dispersal regions  114 . Further, in an embodiment, a density of the foam that makes up the fluid permeable surface layer  112  may be less than a density of the material that makes up the top surface  104  of the core layer  102 . In this manner, the airflow is prevented from entering the core layer  102  and is encouraged to flow through the fluid permeable surface layer  112  to the sleeping surface  111 . 
     In an embodiment, a quilted panel  116  is provided on the sleeping surface  111 . The quilted panel  116  may also extend around the entire temperature controlled mattress system  100  to provide a fire retardant barrier around the temperature controlled mattress system  100 . As discussed in detail below with reference to  FIG. 6 , the quilted panel  116  includes a plurality of fire retardant layers made from fiber material. Additionally, the quilted panel  116  is made without any layers of foam. Avoiding foam layers in the quilted panel  116  may limit an airflow dampening effect provided by foam used in a fire retardant layer. Accordingly, the layers made from fiber material (e.g., rayon and polyester) provide an easier path for the airflow to travel to the sleeping surface  111  than through a fire retardant barrier with one more layers of foam. 
     The thermoelectric fans  110 A and  110 B are capable of providing either hot or cold airflow to the channels  108  of the temperature controlled mattress system  100 . The thermoelectric fans  110  operate by either venting away hot air to introduce cold air into the channels  108  or venting away cold air to introduce hot air into the channels  108 . As depicted in  FIG. 1 , arrows  118 A and  118 B represent ambient airflow that enters the thermoelectric fans  110 A and  110 B, respectively. Within the thermoelectric fans  110 A and  110 B, the ambient airflow is conditioned to output cold airflow  120 A or hot airflow  120 B into the channels  108 A and  108 B, respectively. The cold airflow  120 A and the hot airflow  120 B then disperse into the fluid dispersal regions  114 A and  114 B, as indicated by arrows  122 A and  122 B. As the fluid dispersal regions  114 A and  114 B fill with the cold airflow  120 A and the hot airflow  120 B, respectively, the cold airflow  120 A and the hot airflow  120 B passes through the fluid permeable surface layer  112  and the quilted panel  116  to provide a cooling or heating effect on the sleeping surface  111 , as indicated by the arrows  124 A and  124 B, respectively. 
     It may be appreciated that the core layer  102  may include several layers of foam that represent a base portion of the temperature controlled mattress system  100 . As illustrated, the core layer  102  includes three layers  126 ,  128 , and  130 . As an example, the layer  126  may include a high density base foam, which functions as a foundation layer for the temperature controlled mattress system  100 . Further, the layer  128  may be a support layer of less dense foam than the layer  126 , but the support layer may include a foam that is denser than the layer  130 . The layer  130 , for example, may generally include a slow response memory foam layer that is less dense than the layers  128  and  126 . In this manner, as the layers  126 ,  128 , and  130  approach the sleeping surface  111 , the density of the layers  126 ,  128 , and  130  become less dense in relation to one another. Further, the top surface  104  of the core layer  102  (i.e., the top surface  104  of the layer  130 ) may be coated to prevent back flow of conditioned air into the core layer  102 , which encourages the conditioned air from the channels  108  to flow through the fluid permeable surface layer  112 . In another embodiment, the density of the foam in the layer  130  may be sufficiently greater than the density of the foam in the fluid permeable surface layer  112  such that the flow of conditioned fluid travels through the fluid permeable surface layer  112  without a significant amount of the conditioned fluid traveling into the layer  130 . 
     Also illustrated are temperature control zones  132  and  134 . As illustrated, the temperature controlled mattress system  100  includes the two temperature control zones  132  and  134 . The thermoelectric fan  110 A provides the temperature control zone  132  with the cold airflow  120 A, while the thermoelectric fan  110 B provides the temperature control zone  134  with the hot airflow  120 B. The temperature control zones  132  and  134  may be split in such a manner to provide individualized temperature control for two users of the same mattress. In another embodiment, the temperature control zones  132  and  134  may be split in such a manner to provide different temperature control for a head and body of a user than the temperature control for a leg region of the user. While only two temperature control zones  132  and  134  are illustrated in  FIG. 1 , it may be appreciated that the temperature controlled mattress system  100  may include as many temperature control zones  132  and  134  as there are thermoelectric fans  110  providing conditioned airflow to the channels  108  of the temperature controlled mattress system  100 . For example, in an embodiment with four thermoelectric fans  110  providing conditioned airflow to four or more channels  108 , the temperature controlled mattress system  100  may include four different temperature control zones. 
     Turning to  FIG. 2 , a schematic view the temperature controlled mattress system  100  is depicted. In an embodiment, the temperature controlled mattress system  100  includes a controller  202  that controls application of conditioned air to the channels  108 A,  108 B,  108 C, and  108 D. The controller  202  includes at least one memory element  204  and at least one processor  206 . Instructions are stored in the memory element  204  and carried out by the processor  206  to control the thermoelectric fans  110  coupled to each of the channels  108 A,  108 B,  108 C, and  108 D. In particular, the processor  206 , when executing the instruction of the memory element  204 , instructs the controller  202  to provide signals along signal lines  208  that control operation of the thermoelectric fans  110 A,  110 B,  110 C, and  110 D. For example, the controller  202  may provide on/off signals and temperature control signals to the thermoelectric fans  110 A- 110 D along the signal lines  208 . 
     The controller  202  may be controlled by a remote control  210 . The remote control  210  enables a user of the temperature controlled mattress system  100  to control the temperature control zones  132  and  134  remotely via the controller  202 . In some embodiments, the remote control  210  may be a smart device (e.g., a phone or tablet device) with an application that communicatively connects with the controller  202  wirelessly for the user to control operation of the thermoelectric fans  110 A- 110 D. 
     Further, while  FIG. 1  depicts the two temperature control zones  132  and  134 ,  FIG. 2  depicts an embodiment with four different temperature control zones  212 A,  212 B,  212 C, and  212 D. By way of example, temperature control zones  212 B and  212 C may represent a head and body region of two separate users of the temperature controlled mattress system  100 , while temperature control zones  212 A and  212 D represent a leg region of the two separate users of the temperature controlled mattress system  100 . In the illustrated embodiment, the controller  202  provides signals to the thermoelectric fans  110 A- 110 D individually. Accordingly, as an example, a user may control the thermoelectric fan  110 C to provide cold airflow to the temperature control zone  212 C and the thermoelectric fan  110 D to provide hot airflow to the temperature control zone  212 D. At the same time, a separate user may control the thermoelectric fans  110 B and  110 A to both provide cold airflows to the temperature control zones  212 B and  212 A. Further, any other combination of hot and cold airflow may be provided by the thermoelectric fans  110 A- 110 D to the temperature control zones  212 A- 212 D based on user inputs to the remote control  210 . 
       FIG. 3  is a cross section perspective view of the temperature controlled mattress system  100  including a phase change material layer  302 . When the temperature controlled mattress system  100  includes multiple temperature control zones, such as the temperature control zones  132  and  134 , a portion  304  of the temperature controlled mattress system  100  may not be in contact with the fluid dispersal regions  114 A and  114 B. Accordingly, when hot airflow or cold airflow is supplied to the fluid dispersal regions  114 A and  114 B, the portion  304  of the temperature controlled mattress system  100  may not provide as significant of a heating or cooling effect as a remainder of the temperature controlled mattress system  100 . Such an effect may be particularly noticeable when the thermoelectric fans  110  are in a cooling mode due to a general difficulty of producing a cooling effect in the temperature controlled mattress system  100  when compared to producing a heating effect in the temperature controlled mattress system  100 . 
     To combat the reduced effectiveness of the cooling function across the portion  304  of the temperature controlled mattress system  100 , the phase change material layer  302  may be applied within a portion of the fluid permeable surface layer  112 . The phase change material layer  302  assists in dissipating heat when the thermoelectric fans  110  are in the cooling mode. Additionally, the phase change material layer  302  may prove particularly effective when both of the temperature control zones  132  and  134  are in a cooling mode. The phase change material layer  302  may absorb heat generated by a user in contact with the phase change material layer  302 . Because the phase change material layer  302  absorbs heat, a surface of the phase change material layer  302  feels cool to the touch when a user is in contact with the surface. 
     In the illustrated embodiment, the phase change material layer  302  is provided over a middle third of the temperature controlled mattress system  100 . In this manner, the phase change material layer  302  may cover the portion  304  of the temperature controlled mattress system  100  and overlap portions of the fluid dispersal regions  114 A and  114 B. In the cooling mode, such an arrangement may provide a continuous cooling effect over the entire temperature controlled mattress system  100 . 
       FIG. 4  is a schematic view of the temperature controlled mattress system  100  and the phase change material layer  302 . As discussed above with reference to  FIG. 4 , the phase change material layer  302  absorbs heat, as indicated by arrows  402 . Accordingly, extra heat generated by a user over the phase change membrane layer  302  is dissipated from a surface of the phase change membrane layer  302 . Dissipation of the extra heat from the surface results in a cooling sensation at the surface of the phase change membrane layer  302 . The cooling effect may be particularly useful over the portion  304  of the temperature controlled mattress system  100  between the temperature control zones  132  and  134  when the temperature control zones  132  and  134  are both in the cooling mode. 
     Turning to  FIG. 5 , a top view of the quilted panel  116  is depicted. In an embodiment, the quilted panel  116  is made entirely from fibrous materials. The quilted panel  116  may reduce a restriction of airflow from the fluid dispersal regions  114  as compared to a fire retardant layer that is not made entirely from fibrous materials (e.g., a fire retardant layer that includes a fire retardant foam layer). The quilted panel  116  may surround the entire temperature controlled mattress system  100  to meet fire retardant regulations associated with furniture. 
       FIG. 6  is a cross section view of the quilted panel  116 . In an embodiment, the quilted panel  116  includes a breathable top fabric  602 . The breathable top fabric  602  assists in enabling airflow from the fluid dispersal regions  114  to travel to the sleeping surface  111  of the temperature controlled mattress system  100  due to the breathable nature of the fabric. That is, the breathable top fabric  602  provides a negligible resistance to the airflow from the fluid dispersal regions  114  to the sleeping surface  111 . 
     The quilted panel  116  also includes a fire retardant layer of rayon  604  directly beneath the breathable top fabric  602  and layers  606  and  608  of polyester beneath the fire retardant layer of rayon  604 . The layers  606  and  608  of polyester may be a high loft Dacron polyester (i.e., polyethylene terephthalate). The high loft of the layers  606  and  608  provides the quilted panel  116  with the visible quilted height. Further, the fire retardant layer of rayon  604  prevents a flame from travelling from the sleeping surface  111  of the temperature controlled mattress system  100  to the foam layers of the temperature controlled mattress system  100 . 
     As mentioned above, the quilted panel  116  is positioned above the fluid permeable surface layer  112  to create the sleeping surface  111 . Further, in an embodiment, the quilted panel  116  is also positioned around sides of the core layer  102  and around a bottom surface  106  of the core layer  102  to create a fire retardant layer of the quilted panel  116  around the entire temperature controlled mattress system  100 . Further, it may be appreciated that while  FIG. 6  depicts a layer of rayon  604  and two layers  606  and  608  of polyester, more or fewer layers of fire retardant and non-fire retardant fibrous material may also be deployed to make up the quilted panel  116 . Further, as the quilted panel  116  is composed entirely of fibrous materials, no foam layers are provided in the quilted panel  116  that would interfere with the airflow from the fluid dispersal regions  114  to the sleeping surface  111 . 
     While this specification provides specific details related to certain components of the temperature controlled mattress system  100 , it may be appreciated that the list of components is illustrative only and is not intended to be exhaustive or limited to the forms disclosed. Other components of the temperature controlled mattress system  100  will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. Further, the scope of the claims is intended to broadly cover the disclosed components and any such components that are apparent to those of ordinary skill in the art. 
     The above disclosed embodiments have been presented for purposes of illustration and to enable one of ordinary skill in the art to practice the disclosed embodiments, but is not intended to be exhaustive or limited to the forms disclosed. Many insubstantial modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The scope of the claims is intended to broadly cover the disclosed embodiments and any such modification. 
     It should be apparent from the foregoing disclosure of illustrative embodiments that significant advantages have been provided. The illustrative embodiments are not limited solely to the descriptions and illustrations included herein and are instead capable of various changes and modifications without departing from the spirit of the disclosure.