US20220346562A1

US20220346562A1 - Mattress

Info

Publication number: US20220346562A1
Application number: US17/726,599
Authority: US
Inventors: Zachariah Clarence Holtquist
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-04-29
Filing date: 2022-04-22
Publication date: 2022-11-03
Also published as: WO2022231953A1

Abstract

A mattress includes a mattress body, a control unit at the mattress body, a plurality of air conduits defined at the mattress body, and a plurality of air passages extending within the mattress body. The plurality of air conduits is in fluid communication with the control unit and the plurality of air passages such that the plurality of air conduits is configured to convey pressurized air from the control unit to the plurality of air passages. The plurality of air passages can each have an air passage end open at a surface of the mattress body such that pressurized air received from the air conduits is output by the air passages at the surface of the mattress body.

Description

RELATED APPLICATION

This application claims priority to U.S. provisional patent application No. 63/181,285 filed on Apr. 29, 2021.

TECHNICAL FIELD

This disclosure generally relates to mattresses as well as related mattress systems and methods.

BACKGROUND

A mattress is used to provide a sleeping support surface. However, currently available mattresses can be inefficient in that such mattresses can generally be relatively expensive yet uncomfortable. In particular, many such mattresses can be uncomfortable because the composition of these mattresses can reduce and/or prevent air flow at these mattresses, resulting in uncomfortable temperatures for the user sleeping at these mattresses. Moreover, many of these currently available mattresses can suffer with cleanliness issues.

SUMMARY

In general, various embodiments relating to mattresses as well as related systems and methods are disclosed herein. Mattress embodiments, and related systems and methods, disclosed herein can be useful in providing an enhanced experience for a user sleeping on the mattress. For example, mattress embodiments disclosed herein can facilitate improved air flow at the mattress providing a more comfortable and, in some cases, temperature-controlled experience for the user. In addition, such mattress embodiments disclosed herein that can facilitate improved air flow at the mattress (e.g., via one or more air passages extending within the mattress body and having an air outlet at an exterior surface of the mattress body) can also be useful in reducing instances of sudden infant death syndrome (SIDS) since this improved airflow at the sleeping surface of the mattress can reduce instances of suffocation at the sleeping surface of the mattress. As another example, mattress embodiments disclosed herein can facilitate an improved mattress body composition which can provide a more comfortable sleeping support surface for the user. As a further example, mattress embodiments disclosed herein can increase the sanitary condition of the mattress by resisting the presence of bacteria and other microorganisms at the mattress and resisting the permeation of fluids at the mattress. As a final example, mattress embodiments disclosed herein can be manufactured in a cost-effective and repeatable manner thereby increasing consistency of the mattress while, at the same time, allowing for cost reductions in manufacturing.
One embodiment includes a mattress. This mattress embodiment includes a mattress body, a control unit at the mattress body, a plurality of air conduits defined at the mattress body, and a plurality of air passages extending within the mattress body. The plurality of air conduits is in fluid communication with the control unit. Each one of the plurality of air passages includes an air passage open end at a surface (e.g., external surface, such as a top external surface) of the mattress body, and each one of the plurality of air passages is in fluid communication with at least one of the plurality of air conduits such that the plurality of air conduits are configured to convey pressurized air from the control unit to the plurality of air passages and the plurality of air passages is configured to output the pressurized air from the plurality of air conduits at the surface of the mattress body via the air passage open end at each one of the plurality of air passages.
In a further embodiment of this mattress, the surface of the mattress body at which the plurality of air passages is configured to output the pressurized air is a top surface of the mattress body at which a user would lay when using the mattress.
In a further embodiment of this mattress, the mattress can additionally include a valve. The valve can include a valve inlet portion, a valve outlet portion, and a valve actuator. The valve inlet portion can be in fluid communication with at least one of the plurality of air conduits and the valve outlet portion can be in fluid communication, via the valve actuator, with at least one of the plurality of air passages. The valve actuator can be configured, when actuated, to move between an air retention configuration and an air release configuration. In the air release configuration, the valve actuator is configured to increase an opening at the valve outlet portion, relative to a size of the opening at the valve outlet portion when the valve actuator is in the air retention configuration, to cause an increase in a volume of pressurized air that passes from the valve outlet portion to the at least one of the plurality of air passages. The valve outlet portion is in in fluid communication, via the valve actuator, with a first air passage of the plurality of air passages and a second air passage of the plurality of air passages, and the valve outlet portion is configured to output the pressurized air in a first direction to the first air passage of the plurality of air passages and in a second, different direction to the second air passage of the plurality of air passages. In some such embodiments, the mattress can further include a first air passage connector and a second air passage connector. The first air passage connector fluidly connects the valve outlet portion to the first air passage of the plurality of air passages, and the first air passage connector extends, from the valve outlet portion toward the first air passage of the plurality of air passages, in a direction toward a top surface of the mattress body at which a user would lay when using the mattress. The second air passage connector fluidly connects the valve outlet portion to the second air passage of the plurality of air passages, and the second air passage connector extends, from the valve outlet portion toward the second air passage of the plurality of air passages, in a direction toward the top surface of the mattress body.
In a further embodiment of this mattress, each one of the plurality of air passages includes the air passage open end at a top surface of the mattress body and a second air passage open end at a bottom surface of the mattress body.
In a further embodiment of this mattress, a volumetric ratio of the plurality of air passages to the mattress body is 1.1:1 or more.
In a further embodiment of this mattress, an area defined at a top surface of the mattress body defines a top surface area, and wherein the top surface area has 75% or less of the top surface area made up of the mattress body and 25% or more of the top surface area made up of the plurality of air passages.
In a further embodiment of this mattress, the plurality of air conduits extend from the control unit along a perimeter portion of the mattress body and into a more central region of the mattress body between two or more of the plurality of air passages.
In a further embodiment of this mattress, the mattress body includes a perimeter portion that is more rigid than a more central portion of the mattress body. This perimeter portion can include a plurality of perimeter air passages in fluid communication with at least one of the plurality of air conduits, and the plurality of perimeter air passages can have a smaller cross-sectional area than the plurality of air passages located at the more central portion of the mattress body. In some such embodiments, the plurality of perimeter air passages can be spaced closer to one another than the plurality of air passages located at the more central portion of the mattress body, and the mattress body can make up a greater percentage of a top surface area at the perimeter portion than the plurality of perimeter air passages at the perimeter portion.
In a further embodiment of this mattress, the mattress body is a single, integral piece that includes a fluid impermeable polymer material. In some such embodiments, the singe, integral piece mattress body further includes an antimicrobial additive.
In a further embodiment of this mattress, the mattress body includes a first layer and a second layer integrated with the first layer, and the first layer has a different rigidity than the second layer. In some such embodiments, the first layer is at a top surface of the mattress body and the second layer is located inward within the mattress body and extends from the first layer toward a bottom surface of the mattress body, and this second layer is more rigid than the first layer.
In a further embodiment of this mattress, the mattress further includes a sheet attachment member at the mattress body. The sheet attachment member includes a coupling that projects out from the mattress body and is configured to received and hold a sheet over a top surface of the mattress body.
In a further embodiment of this mattress, the mattress further includes a first sensor type at the mattress body and in communication with the control unit, a second sensor type at the mattress body and in communication with the control unit, a third sensor type at the mattress body and in communication with the control unit, and a fourth sensor type at the mattress body and in communication with the control unit. Each of the first sensor type, the second sensor type, the third sensor type, and the fourth sensor type is configured to sense a different condition. The first sensor type, the second sensor type, and the third sensor type are located adjacent one another at a common region of the mattress body while the fourth sensor type is spaced apart from this common region.
The details of one or more examples are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are illustrative of particular embodiments of the present invention and, therefore, do not limit the scope of the invention. The drawings are intended for use in conjunction with the explanations in the following description. Embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements. The features illustrated in the drawings are not necessarily to scale, though embodiments within the scope of the present invention can include one or more of the illustrated features (e.g., each of the illustrated features) at the scale shown.

FIG. 1 is a top plan view of a portion of an embodiment of a mattress.

FIG. 2 is a side elevational view of the mattress embodiment of FIG. 1.

FIG. 3 is a close-up, top plan view of a perimeter portion of the mattress embodiment of FIG. 1.

FIG. 4 is a side elevational view of the mattress embodiment of FIG. 1 including sheet attachment members and a support base.

FIG. 5 is a top plan view of an embodiment of a support base including multiple support base members.

FIG. 6 is a schematic diagram of exemplary air conduits at the mattress embodiment of FIG. 1.

FIG. 7 is a schematic diagram, shown in a longitudinal cross-sectional view, of exemplary air conduits and valves at the mattress embodiment of FIG. 1.

FIG. 8 is a schematic diagram, shown in a longitudinal cross-sectional view, of further exemplary air conduits and valves at the mattress embodiment of FIG. 1.

FIG. 9 is an elevational view of an embodiment of a valve at an air conduit of the mattress embodiment of FIG. 1.

FIG. 10 is a schematic diagram, shown in a longitudinal cross-sectional view, of exemplary sensors at the mattress embodiment of FIG. 1.

DETAILED DESCRIPTION

The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations for implementing embodiments of the present invention. Examples of constructions, materials, and/or dimensions are provided for selected elements. Those skilled in the art will recognize that many of the noted examples have a variety of suitable alternatives.
FIGS. 1 and 2 illustrate an embodiment of a mattress 100. Specifically, FIG. 1 shows a top plan view of a portion of the mattress 100, and FIG. 2 shows a side elevational view of the mattress 100.
The mattress 100 can include a mattress body 105. In some examples, the mattress body 105 can be a single, integral piece. For example, the mattress body 105 can be made as a single, integral piece via a casting (e.g., injection molding) or additive (e.g., three-dimensional printing) manufacturing process. The mattress body 105 can be made of one or more of a variety of materials. For example, the mattress body 105 can be a single, integral piece that includes a polymer material (e.g., an elastomer, such as silicone, in some cases a transparent or translucent silicone material). The polymer material included at the mattress body 105 can be a fluid impermeable polymer material (e.g., silicone). For instance, to form the single, integral piece mattress body 105, a polymer material can be poured into a mold and cured to form the mattress body 105, or a polymer material can be used as a feedstock material that is additively fused together during an additive manufacturing process. The mattress body 105 can be made in a variety of sizes, including, as one example, a full-size crib bed typically having a width of 26-30 inches and a length of 50-54 inches.
In certain embodiments, such as that shown in FIG. 2, the mattress body 105 can be formed as a single, integral piece from two or more integrated layers. The two or more integrated layers can have different rigidities, for instance because the two or more integrated layers are made up of a different material (e.g., differing polymer materials). For example, in these embodiments, the mattress body 105 can include a first layer 109 a and a second layer 109 b. The first layer 109 a can have a different rigidity than the second layer 109 b. For instance, the first layer 109 a can be at the top surface 106 and extend inward from the top surface 106 (e.g., the surface at which a user lays), and the second layer 109 b can be located inward within the mattress body 105 and extend from the first layer 109 a toward the bottom surface 107. In this arrangement, the first layer 109 a can be less rigid than the second layer 109 b. In a further embodiment, as shown in FIG. 2, the mattress body can additionally include a third layer 109 c. The third layer 109 c can have a different rigidity than each of the first and second layers 109 a, 109 b. As shown here, the first layer 109 a can be at the top surface 106 and extend inward from the top surface 106 (e.g., the surface at which a user lays), the second layer 109 b can be located inward within the mattress body 105 and extend from the first layer 109 a toward the bottom surface 107, and the third layer 109 c can be at the bottom surface 107 and extend inward from the bottom surface 107 (e.g., the surface opposite the top surface 106 at which the user lays) to the second layer 109 b. In this arrangement, the first layer 109 a can be less rigid than the second layer 109 b, and the second layer 109 b can be less rigid than the third layer 109 c such that the layers increase in rigidity moving from the tip surface 106 to the bottom surface 107 such that the most rigid layer—the third layer 109 c—is at the bottom of the mattress body 105. As noted, the layers 109 a, 109 b, 109 c can have differing rigidities, for instance, resulting from different polymer compositions of each of the layers 109 a, 109 b, 109 c.
In some embodiments, to help improve sanitation at the mattress 100, the mattress body 105 can have an antimicrobial function. In particular, the mattress body 105 can include one or more antimicrobial additives. For example, the mattress body 105 can include both a polymer material and an antimicrobial additive. For instance, when included, the antimicrobial additive can be an antimicrobial metal present at the mattress body 105 along with the polymer material (e.g., silicone). The antimicrobial metal could be one or more of silver, copper, and nickel. The presence of an antimicrobial additive at the mattress body 105 can help to resist the presence of bacteria or other microorganisms at the mattress body 105. Moreover, when the mattress body 105 also includes a fluid impermeable polymer material, the mattress body 105 can resist the permeation of fluids into the mattress body 105 and instead cause such fluid to run off of the surface of the mattress body 105. This fluid impermeability of the mattress body 105 may also be useful to resist the presence of one or more pests (e.g., bed bugs, ring worms) at the mattress body 105 since the fluid impermeability of the mattress body 105 can act to prevent such pests from penetrating into the interior of the mattress body 105. Thus, the mattress body 105 can help to improve sanitary conditions at the mattress 100 by resisting the presence of bacteria or other microorganisms and reducing fluid and/or pest permeation at the mattress body 105.
The mattress 100 can also include a plurality of air passages 110. The air passages 110 can be defined at the mattress body 105. For instance, as illustrated, the air passages 110 can be spaced apart by the mattress body 105 which can extend between the air passages 110. In the illustrated embodiment of the mattress 100, the air passages 110 can extend through the mattress body 105, such as seen in FIG. 2. For example, as seen best in FIG. 2, the mattress body 105 can include a top surface 106 and an opposite bottom surface 107. One or more (e.g., all) of the plurality of air passages 110 can extend through the mattress body 105 from the top surface 106 to the bottom surface 107. In such an example, the plurality of air passages 110 can have a first air passage end 111 defined at the top surface 106 of the mattress body 105 and a second, opposite air passage end 112 defined at the bottom surface 107. Thus, in this example, the mattress body 105 can extend between the air passages 110 along the top surface 106, along the bottom surface 107, and along a height 108 of the mattress body 105 from the top surface 106 to the bottom surface 107. The height 108 of the mattress body 105 can vary in different embodiments, ranging, in some embodiments, from two inches to thirty six inches, four inches to twenty four inches, four inches to twenty inches, four inches to fifteen inches, and four inches to ten inches. In embodiments where the mattress body 105 is made up of layers (e.g., the layers 109 a, 109 b, and/or 109 c), each layer can define a respective portion of the air passages 110 such that the integrated layers together align the respective portions of the air passages 110 and together form a height 113 of the air passages 110.
In the illustrated embodiment of the mattress 100, the air passages 110 can define a cross-section width of 0.1 inch to 10 inches, 0.5 inch to 5 inches, 0.75 inch to 2.5 inch, or 1 to 2 inches. Also in the illustrated embodiment, the air passages 110 are defined by the mattress body 105 in a generally hexagon cross-sectional shape. Also in the illustrated embodiment, each air passage 110 can have a uniform hexagon cross-sectional shape along the height 113 of the air passage 110. Though, in other embodiments, the air passages 110 can take a variety of shapes, including other polygon shapes, at the first and second air passage ends 111, 112 and/or along the height 113 of the air passage 110 (e.g., a varying cross-sectional shape and/or cross-sectional diameter of the air passage 110 along the height 113).
The presence of the air passages 110 at the mattress body 105 can act to reduce the volume of the mattress body 106 making up the mattress 100. For example, in some embodiments of the mattress 100, the volumetric ratio of the air passages 110 to the mattress body 105 at the mattress 100 can be 1:1; 1.1:1; 1.2:1; 1.3:1; 1.4:1; 1.5:1; 1.6:1; 1.7:1; 1.8:1; 1.9:1; or 2:1 or more. The noted volumetric ratios of the air passages 110 to the mattress body 105 at the mattress 100 can be measured when the mattress 100 is in an unloaded state (e.g., when a user is not applying force at (e.g., laying on) the mattress 100).
More specifically, the presence of the air passages 110 at the mattress body 105 can reduce the surface area of the mattress body 105 at the top surface 106 of the mattress body 105. For example, for an area 104 defined at the top surface 106 of the mattress body 105: the mattress body 105 can make up 75% or less of the area 104 at the top surface 106 and air (via the air passages 110) can make up 25% or more of the area 104 at the top surface 106; the mattress body 105 can make up 60% or less of the area 104 at the top surface 106 and air (via the air passages 110) can make up 40% or more of the area 104 at the top surface 106; the mattress body 105 can make up 50% or less of the area 104 at the top surface 106 and air (via the air passages 110) can make up 50% or more of the area 104 at the top surface 106; the mattress body 105 can make up 40% or less of the area 104 at the top surface 106 and air (via the air passages 110) can make up 60% or more of the area 104 at the top surface 106; the mattress body 105 can make up 30% or less of the area 104 at the top surface 106 and air (via the air passages 110) can make up 70% or more of the area 104 at the top surface 106; the mattress body 105 can make up 25% or less of the area 104 at the top surface 106 and air (via the air passages 110) can make up 75% or more of the area 104 at the top surface 106. Thus, the air passages 110 at the top surface 106 of the mattress body 105 can act to reduce the area at the top surface 106 made up by the mattress body 105. The area 104 can be a non-perimeter area at the top surface 106 of the mattress body 105.
The mattress 100 can further include a control unit 115. As described elsewhere herein, the control unit 115 can be configured to control one or more functions of one or more components of the mattress 100. As such, the control unit 115 can include, for instance, a non-transitory computer readable storage article having computer executable instructions, a programmable processor coupled to the non-transitory computer readable storage article and configured to execute the computer executable instructions, a pump, a power source (e.g., rechargeable battery), and/or a transceiver (e.g., wireless transceiver) for signal communication with a remote device. The control unit 115 can be included, at least in part, at the mattress body 105. For example, the mattress body 105 can define a recess 116 and the control unit 115 can be embedded within the mattress body 105 at the recess 116 defined at the mattress body 105. In the illustrated embodiment of the mattress 100, the control unit 115 is embedded within the mattress body 105 adjacent the bottom surface 107 of the mattress body 105 and adjacent a foot end of the mattress body 105 (e.g., generally opposite a head end of the mattress body 105).
FIG. 3 shows a close-up, top plan view of a perimeter portion 120 of the mattress 100. The perimeter portion 120 can be defined at an edge end 121 of the mattress body 105 and extend inward a predetermined distance from that edge end 121 of the mattress body 105. For instance, the perimeter portion 120 can extend inward one inch, two inches, three inches, four inches, five inches, six inches, or one to twelve, or more, inches from the edge end 121 of the mattress body 105.
The perimeter portion 120 can be more rigid than non-perimeter portions (e.g., a central portion, e.g., the area 104 of the mattress body bounded by the perimeter portion 120) of the mattress body 105. In particular, as shown in the example of FIG. 3, the perimeter portion 120 can have perimeter air passages 123 that have a smaller cross-sectional area than the air passages 110 located at a non-perimeter portion of the mattress body 105. And, in some such embodiments, adjacent perimeter air passages 123 can be spaced closer to one another as compared to the spacing between adjacent air passages 110. The presence of the smaller cross-sectional area perimeter air passages 123 at the perimeter portion 120 can result in the mattress body 105 making up a greater percentage of the area at the perimeter portion 120 than the perimeter air passages 123 make up at the perimeter portion 120. Also, the presence of the smaller cross-sectional area perimeter air passages 123 at the perimeter portion 120 can result in the mattress body 105 making up a greater percentage of the area at the perimeter portion 120 than at non-perimeter portions (e.g., than at the area 104). For instance, in one specific embodiment, the number of perimeter air passages 123 at the perimeter portion 120 can be 50%, 60%, 75%, 90%, 100%, 125%, 150%, 175%, or 200% more than the number of air passages 110 located at a non-perimeter portion of mattress body 105 having the same area as the area of perimeter portion 120. The smaller perimeter air passages 123 can facilitate the air conveyance function of the mattress 100 while at the same time making the perimeter portion 120 more rigid (e.g., due the increased proportion of the mattress body 105 at the perimeter portion 120) than non-perimeter portions (e.g., central portions, the area 104) of the mattress body 105. This increased rigidity at the perimeter portion 120 can be useful in providing a more stabilized region at the mattress 100 and, thereby, help to prevent a user from inadvertently leaving (e.g., rolling off of) the mattress 100. In other embodiments, the perimeter portion 120 may not include perimeter air passages 123 and instead can be a solid portion made up of the mattress body 105.
FIG. 4 shows a side elevational view of the mattress 100 including sheet attachment members 125. The sheet attachment members 125 can be defined at the mattress body 105. In some cases, the sheet attachment members 125 can be integral to the mattress body 105 (e.g., the sheet attachment members 125 are formed integral to the mattress body 106 during casting or additive manufacturing of the mattress body 105). For example, the sheet attachment members 125 can be formed, at least in part, as a recess within the mattress body 105. The sheet attachment member 125 can include a coupling 126 (e.g., a hook-type member) that projects out from the mattress body 105 and the sheet attachment member 125 and is configured to received and hold a sheet (e.g., placed over the top surface 106 of the mattress body 105). The sheet attachment members 125 can be included one or more side ends 121 of the mattress body 105 and spaced apart from the bottom surface 107. This configuration of the sheet attachment members 125 can facilitate secure placement of a sheet over the top surface 106 of the mattress body 105 while leaving the bottom surface 107 of the mattress body uncovered by the sheet. In this way, the air flow facilitated by the air passages 110 (and, when present the perimeter air passages 123) can be maintained because the sheet attachment members 125 allow the bottom surface 107, where openings of the air passages 110 (and, when present the perimeter air passages 123) are located, to be unobstructed by the sheet.
FIG. 4 also shows an embodiment of a support base 130. And, FIG. 5 shows a top plan view of the support base 130 including multiple support base members 131, 132, 133. The support base 130 can include a mattress interfacing side 134 and a ground surface interfacing side 135 opposite the side 134. The support base 130 can be configured to receive the mattress 100 at the side 134 and support the mattress 100 thereat. The support base 130 can be more rigid than the mattress body 105 (e.g., the support base 130 is made of a more rigid polymer material than the mattress body 105) so as to provide sufficient support and stability to the mattress body 105.
To help facilitate air flow at the mattress 100, the support body 130 can include support body air passages 136. In some embodiments, the support body 130 includes the support body air passages 136 in the same configuration as the air passages 110 defined at the mattress body 105. The support body 130 can be positioned relative to the mattress body 105 such that the air passages 110, defined by the mattress body 105, are aligned with the support body air passages 136. More specifically, the support body air passages 136 can have an end 137 defined at the side 134 and this end 137 can be generally aligned, and interface with, the respective end 112 of the air passage 110. In this way, the support body 130 can reduce obstruction of air flow via the air passages 110 and, thereby, can facilitate air flow within the mattress body 105. In addition, in some embodiments, the support body 130 can include support body air passages 136 at one or more side surfaces 138 of the support body 130.
The support base 130 can define a height 139 extending between the side 134 and the side 135. The height 139 of the support base 130 can vary in different embodiments, for example from two inches to sixty inches, four inches to forty inches, six inches to thirty-six inches. The height 139 of the support base 130 can be useful in creating sufficient air volume inside of the support base 130 to facilitate the air transfer function between the mattress body 105 and the support base 130. As such, a height 139 of the support base greater than approximately six inches may be sufficient, depending on the embodiment of the mattress 100, to provide this air transfer.
As noted, in the illustrated embodiment, the support base 130 can include multiple support base members 131, 132, 133 as shown in FIG. 5. The support base members 131, 132, 133 can be positioned in a side-by-side arrangement to create a support base 130 sized in a manner corresponding to the size of the particular mattress 100 that the support base 130 is to support. Each of the support base members 131, 132, 133 can include the noted support body air passages 136. In stances where the support base 130 is made up of multiple support base members 131, 132, 133, storing, shipping, and transporting the support base 130 can be more efficient and this may provide an enhanced modularity to the support base 130 that allows for easier tailoring of the support base to the size of the particular mattress 100 it is configured to support.
FIG. 6 shows a schematic diagram of exemplary air conduits 140 at the mattress 100. In the illustrated embodiment, the air conduits 140 are embedded within the mattress body 105. For example, the air conduits 140 can be located at a height 108 within the mattress body 105 closer to the top surface 106 of the mattress body 105 than the bottom surface 107 of the mattress body 105. As one particular such example, the air conduits 140 can be located within a top third of the height 108 of the mattress body 105 such that the distance between the air conduits 140 and the top surface 106 can be approximately half the distance between the air conduits 140 and the bottom surface 107.
As shown in the example of FIG. 6, one end of each of the air conduits 140 is fluidly connected to the control unit 115. The control unit 115 can include a pump, or other suitable mechanism, for conveying air (e.g., air pressurized greater than atmospheric pressure) into the air conduits 140. In the illustrated embodiment, the air conduits 140 extend from the respective end fluidly connected to the control unit 115 along the perimeter portion 120 of the mattress body 105. This configuration of the air conduits extending along the perimeter portion 120 can be useful, for instance, in embodiments where the perimeter portion 120 is generally solid and does not include perimeter air passages 123. As the air conduits 140 extend along the perimeter portion 120, the air conduits 140 can branch away from the perimeter portion 120 and into a more central region of the mattress body 105. The air conduits 140 can extend into the more central region of the mattress body 105 between the air passages 110. In this way, as will be described further below, the air conduits 140 can output air from the control unit 115 to one or more of the air passages 110.
FIG. 6 also shows one example of the mattress body 105 where a corner 103 of the mattress body 105 forms a generally linear surface. In particular, in the example shown here, the corner 103 of the mattress body 105 forms a generally forty-five degree angle between adjacent side surfaces of the mattress body 105 connected by the corner 103.
FIG. 7 is a schematic diagram shown in a longitudinal cross-sectional view taken at, and in a direction perpendicular to, the height 108 of the mattress body 105 where the air conduits 140 are located and shows features that can be included at the air conduits 140. Specifically, to help facilitate controlled output of air from the air conduits 140 to the air passages 110, one of more valves 150 can be included at the air conduits 140. As air passes from the control unit 115 through the air conduits 140 to a particular valve 150, the valve 150 can be configured to actuate (e.g., as a result of the pressure within the air conduit 140 exceeding a predetermined pressure) to an air release configuration in which the valve 150 outputs air from the air conduit 140 to one or more air passages 110 adjacent the valve 150. As shown in the example of FIG. 7, the valve 150, when actuated to the air release configuration, can output air from the air conduit 140 to multiple air passages 110 adjacent the valve 150. As illustrated in FIG. 7, the mattress body 105 can include a plurality of valves 150 to increase the area over which air is output into the air passages 110. The air output to the air passages 110 can pass to the top surface 106 of the mattress body 105 and, thereby, encounter a user laying at the top surface 106.
This air encountering the user at the top surface 106, via the air passages 110, can help to provide a controlled temperature experience for the user. For example, the control unit 115 can include a heating element and/or a cooling element. In operation, a user can provide temperature control input to the control unit 115. In response to the temperature control input, the control unit 115 can act to draw in ambient air, pass this ambient air through the heating element or cooling element (e.g., depending on the temperature control input relative to the temperature of the drawn-in ambient air), pressurize this ambient air via the pump at the control unit 115, and output the heated or cooled pressurized air to the air conduits 140 which in turn can deliver the heated or cooled pressurized air to the air passages 110 to thereby provide a controlled temperature experience corresponding to the temperature control input provided by the user.
To enhance the temperate controlled experience, the mattress body 105 can include multiple zones 160, 161. The zones 160, 161 can be spaced apart from one another along the mattress body 105. Each zone 160, 161 can include at least one air conduit 140 and at least one valve 150. Each zone 160, 161 can be independently controlled via the control unit 115. For example, a user can provide a first zone temperature control input to the control unit 115. In response to the first zone temperature control input, the control unit 115 can act to draw in ambient air, pass this ambient air through the heating element or cooling element (e.g., depending on the first zone temperature control input relative to the temperature of the drawn-in ambient air), pressurize this ambient air via the pump at the control unit 115, and output the heated or cooled pressurized air to the air conduit(s) 140 of the zone 160 which in turn can deliver the heated or cooled pressurized air to the air passage(s) 110 located at the zone 160. Similarly, the user can provide a second zone temperature control input to the control unit 115. The second zone temperature control input can specify a different output air temperature than the first zone temperature control input. In response to the second zone temperature control input, the control unit 115 can act to draw in ambient air, pass this ambient air through the heating element or cooling element (e.g., depending on the second zone temperature control input relative to the temperature of the drawn-in ambient air), pressurize this ambient air via the pump at the control unit 115, and output the heated or cooled pressurized air (e.g., at a different temperature than the output pressurized air at the zone 160) to the air conduit(s) 140 of the zone 161 which in turn can deliver the heated or cooled pressurized air to the air passage(s) 110 located at the zone 161. Thus, the zone control configuration can provide a user with a differential controlled temperature experience at separate zones spaced apart along the mattress body 105. In some embodiments, the control unit may include multiple pumps so that each zone can have a dedicated pump and, thereby, allow for the differential controlled temperature experience generally simultaneously at the different zones 160, 161.
To facilitate user control input at the mattress 100, the control unit 115 can be in communication (e.g., wireless communication) with a remote user device, such as a smart phone or tablet that executes, via a programmable processor, computer-executable instructions stored thereat in a non-transitory storage medium. This can allow the user to provide the user control input (e.g., the first and second zone temperature control inputs) at the remote user device which in turn can transmit a corresponding control signal to the control unit 115 instructing the control unit 115 to execute a control function corresponding to the user control input.
As another example, the mattress body 105 could include a speaker and/or one or more light elements. With respect to the speaker, when present, the user can likewise provide a user sound control input at the remote user device which in turn can transmit a corresponding control signal to the control unit 115 instructing the control unit 115 to execute a sound control function at the speaker (e.g., turn on/off the speaker, adjust the volume of the speaker, change the type of sound output at the speaker) corresponding to the user sound control input. Similarly, with respect to the one or more light elements, when present, the user can likewise provide a user light control input at the remote user device which in turn can transmit a corresponding control signal to the control unit 115 instructing the control unit 115 to execute a light control function at the one or more light elements (e.g., turn on/off one or more of the light elements, adjust the brightness of the one or more light elements, change a color of one or more of the light elements) corresponding to the user light control input.
FIG. 7 also illustrates an example where the mattress body 105 further includes one or more sensors 170. The sensors 170 can be located within the mattress body 105. The sensors 170 can include one or more of a movement sensor, a respiration sensor, an oxygen sensor, a pulse sensor, and a temperature sensor. The one or more sensors 170 can be in signal communication with the control unit 115 so as to convey data generated at the one or more sensors 170 to the control unit 115. In one such example, one or more of the sensors 170 can include a wireless transmitter and the control unit 115 can include a wireless receiver to facilitate wireless transmission of data generated at the one or more sensors 170 to the control unit 115.
In embodiments of the mattress 100 that includes different zones 160, 161, the sensors 170 can be located at each of the different zones 160, 161. In this way, the sensors 170 can collect data independently at the different zones 160, 161. For example, a first temperature sensor can be located at the first zone 160 and a second temperature sensor can be located at the second zone 161. The first temperature sensor can transmit temperature data relating to the first zone 160 to the control unit 115, and, in response, the control unit 115 can compare the temperature data relating to the first zone 160 to a preset temperature for the first zone 160 and, when the temperature data relating to the first zone 160 differs from the preset temperature for the first zone 160, act to adjust the temperature at the first zone 160 by delivering heated or cooled air to the first zone 160 via the air passages 110 located at the first zone 160. Similarly, the second temperature sensor can transmit temperature data relating to the second zone 161 to the control unit 115, and, in response, the control unit 115 can compare the temperature data relating to the second zone 161 to a preset temperature for the second zone 161 and, when the temperature data relating to the second zone 161 differs from the preset temperature for the second zone 161, act to adjust the temperature at the second zone 161 by delivering heated or cooled air to the second zone 161 via the air passages 110 located at the second zone 161. As such, in this embodiment, the control unit 115 can use data generated by the sensors 170 to perform one or more independent operations (e.g., temperature control operation) at a particular zone 160, 161 in an automated manner.
In the embodiment shown at FIG. 7, the sensors 170 are located at the air conduits 140. For example, the sensors 170 can be fixed to an exterior surface of the air conduits 140. In one such instance, the sensors 170 could be in the form of an electric circuit printed onto the exterior surface of the air conduit 140 as part of an additive manufacturing process in manufacturing the mattress body 105.
FIG. 8 is a schematic diagram, shown in a longitudinal cross-sectional view taken at, and in a direction perpendicular to, the height 108 of the mattress body 105 where the air conduits 140 are located, and shows another exemplary configuration of the air conduits 140 and valves 150. In particular, the air conduits 140 are in a closed loop configuration in the example of FIG. 8 in that the air conduits 140 are in fluid communication with one another. This air conduit 140 configuration can be present at a particular zone (e.g., a foot zone) of the mattress body 105.
As shown in FIG. 8, some of the air conduits 140 extend in a generally diagonal, approximately forty-five degree orientation parallel to one another. This exemplary configuration of the air conduits 140 can be useful, for instance, in providing a generally uniformly distributed air output function across the particular zone where this air conduit configuration is present.
FIG. 9 shows an elevational view of the valve 150 at the air conduit 140 of the mattress 100. The valve 150 can include a valve inlet portion 151, a valve outlet portion 152, and a valve actuator 153. The valve inlet portion 151 can be in fluid communication with the air conduit 140 and the valve outlet portion 152 can be in fluid communication, via the valve actuator 153, with one or more air passages 110.
The valve actuator 153 can be configured, when actuated, to move between an air retention configuration and an air release configuration. For example, when pressurized air enters the valve 150 at the valve inlet portion 151, this pressurized air flows into contact with the valve actuator 153 at the valve outlet portion 152. As sufficient pressurized air (e.g., a predetermined volume of air pressurized at or above a predetermined air pressure) contacts the valve actuator 153, this pressurized air can act to move the valve actuator 153 from the air retention configuration to the air release configuration. In the air release configuration, the valve actuator 153 can increase the opening at the valve outlet portion 152, relative to the size of the opening at the valve outlet portion 152 when the valve actuator 153 is in the air retention configuration, so as to increase the volume of pressurized air that passes from the valve outlet portion 152 to the one or more air passages 110. Similarly, when the volume and/or pressure of the air contacting the valve actuator 153 reduces below the predetermined volume and/or the predetermined air pressure, the valve actuator 153 can move from the air release configuration to the air retention configuration at which the valve actuator can decrease the opening at the valve outlet portion 152, relative to the size of the opening at the valve outlet portion 152 when the valve actuator 153 is in the air release configuration, so as to decrease the volume of pressurized air that passes from the valve outlet portion 152 to the one or more air passages 110. As such, the valve actuator 153 can be biased to the air retention configuration and moved from the air retention configuration to the air release configuration as a result of sufficient pressurized air (e.g., the predetermined volume of air pressurized at or above the predetermined air pressure) contacting the valve actuator 153.
In the illustrated embodiment, the valve outlet portion 152 is in fluid communication with each of multiple air passages 110 via a respective air passage connector 154. In some embodiments, the air passage connectors 154 can be configured to act as a diverter so as to distribute air output from the valve outlet portion 152 in one or more directions of the adjacent air passages 110. For example, the air passage connector 154 can extend from the valve outlet portion 152 to a respective air passage 110 and, thereby, serve to convey air output from the valve 150 to the respective air passage 110. In the embodiment shown, one or more of the air passage connectors 154 can extend from the valve outlet portion 152 to a respective air passage 110 in a direction toward the top surface 106 of the mattress body 105. For example, two of the air passage connectors 154 shown in FIG. 9 extend at an angle of approximately thirty to forty five degrees, relative to a central longitudinal axis 155 of the air conduit 140, upward toward the respective air passages 110 and the top surface 106. Another of the air passage connectors 154 shown in FIG. 9 extends generally perpendicular (e.g., vertically) to the central longitudinal axis 155 of the air conduit 140 upward toward the respective air passage 110 and the top surface 106.
FIG. 10 shows a schematic diagram, shown in a longitudinal cross-sectional view taken at, and in a direction perpendicular to, the height 108 of the mattress body 105 where the air conduits 140 are located, and shows exemplary sensors 170 at the mattress 100. The embodiment of FIG. 10 includes different sensor types—a first sensor type 170 a, a second sensor type 170 b, a third sensor type 170 c, a fourth sensor type 170 d, and a fifth sensor type 170 e. Each of the sensor types 170 a-170 e can be different from each of the other sensor types 170 a-170 e. As one example, the sensor types can be selected from the group consisting of: a movement sensor, a respiration sensor, an oxygen sensor, a pulse sensor, and a temperature sensor.
As FIG. 10 illustrates, some of the sensor types 170 a-170 e can be adjacent one another at a common region while others of the sensor types 170 a-170 e can be spaced apart from the common region where the adjacent sensor types are located. For instance, the first sensor type 170 a, the second sensor type 170 b, and the third sensor type 170 c can be adjacent one another at a common region 172 of the mattress body 105, while the fourth sensor type 170 d can be spaced apart from the common region 172 and the fifth sensor type 170 e can be spaced apart from the common region 172. Such a distribution of different sensor types can be useful in creating efficiencies in manufacturing and, at the same time, can help to locate different sensor types at a position that is appropriate for generating the particular type of data for which the sensor is configured. For instance, some sensor types (e.g., an oxygen sensor) may generate data more effectively if located close to the top surface 106 where a user lays. As described previously, one or more of the sensor types 170 a-170 e can be located at the air conduits 140. For example, one or more of the sensor types 170 a-170 e can be fixed to an exterior surface of the air conduits 140. In one such instance, such sensor types 170 a-170 e could be in the form of an electric circuit printed onto the exterior surface of the air conduit 140 as part of an additive manufacturing process in manufacturing the mattress body 105. And, as also described previously, the sensor types 170 a-170 e can be in signal communication with the control unit so as to convey data generated at each of the sensor types 1701-170 e to the control unit where such data can be processed in operation of the mattress 100.
Various non-limiting exemplary embodiments have been described. It will be appreciated that suitable alternatives are possible without departing from the scope of the examples described herein.

Claims

What is claimed is:

1. A mattress comprising:

a mattress body;

a control unit at the mattress body;

a plurality of air conduits defined at the mattress body, wherein the plurality of air conduits is in fluid communication with the control unit; and

a plurality of air passages extending within the mattress body, wherein each one of the plurality of air passages includes an air passage open end at a surface of the mattress body, wherein each one of the plurality of air passages is in fluid communication with at least one of the plurality of air conduits such that the plurality of air conduits are configured to convey pressurized air from the control unit to the plurality of air passages and the plurality of air passages is configured to output the pressurized air from the plurality of air conduits at the surface of the mattress body via the air passage open end at each one of the plurality of air passages.

2. The mattress of claim 1, wherein the surface of the mattress body at which the plurality of air passages is configured to output the pressurized air is a top surface of the mattress body at which a user would lay when using the mattress.

3. The mattress of claim 1, further comprising:

a valve, the valve including a valve inlet portion, a valve outlet portion, and a valve actuator, wherein the valve inlet portion is in fluid communication with at least one of the plurality of air conduits and the valve outlet portion is in fluid communication, via the valve actuator, with at least one of the plurality of air passages.

4. The mattress of claim 3, wherein the valve actuator is configured, when actuated, to move between an air retention configuration and an air release configuration, wherein, in the air release configuration, the valve actuator is configured to increase an opening at the valve outlet portion, relative to a size of the opening at the valve outlet portion when the valve actuator is in the air retention configuration, to cause an increase in a volume of pressurized air that passes from the valve outlet portion to the at least one of the plurality of air passages.

5. The mattress of claim 3, wherein the valve outlet portion is in in fluid communication, via the valve actuator, with a first air passage of the plurality of air passages and a second air passage of the plurality of air passages, and wherein the valve outlet portion is configured to output the pressurized air in a first direction to the first air passage of the plurality of air passages and in a second, different direction to the second air passage of the plurality of air passages.

6. The mattress of claim 5, further comprising:

a first air passage connector fluidly connecting the valve outlet portion to the first air passage of the plurality of air passages, the first air passage connector extending, from the valve outlet portion toward the first air passage of the plurality of air passages, in a direction toward a top surface of the mattress body at which a user would lay when using the mattress; and

a second air passage connector fluidly connecting the valve outlet portion to the second air passage of the plurality of air passages, the second air passage connector extending, from the valve outlet portion toward the second air passage of the plurality of air passages, in a direction toward the top surface of the mattress body.

7. The mattress of claim 1, wherein each one of the plurality of air passages includes the air passage open end at a top surface of the mattress body and a second air passage open end at a bottom surface of the mattress body.

8. The mattress of claim 1, wherein a volumetric ratio of the plurality of air passages to the mattress body is 1.1:1 or more.

9. The mattress of claim 1, wherein an area defined at a top surface of the mattress body defines a top surface area, and wherein the top surface area has 75% or less of the top surface area made up of the mattress body and 25% or more of the top surface area made up of the plurality of air passages.

10. The mattress of claim 1, wherein the plurality of air conduits extend from the control unit along a perimeter portion of the mattress body and into a more central region of the mattress body between two or more of the plurality of air passages.

11. The mattress of claim 1, wherein the mattress body includes a perimeter portion that is more rigid than a more central portion of the mattress body.

12. The mattress of claim 11, wherein the perimeter portion includes a plurality of perimeter air passages in fluid communication with at least one of the plurality of air conduits, and wherein the plurality of perimeter air passages have a smaller cross-sectional area than the plurality of air passages located at the more central portion of the mattress body.

13. The mattress of claim 12, wherein the plurality of perimeter air passages are spaced closer to one another than the plurality of air passages located at the more central portion of the mattress body.

14. The mattress of claim 13, wherein the mattress body makes up a greater percentage of a top surface area at the perimeter portion than the plurality of perimeter air passages at the perimeter portion.

15. The mattress of claim 1, wherein the mattress body is a single, integral piece that includes a fluid impermeable polymer material.

16. The mattress of claim 15, wherein the singe, integral piece mattress body further includes an antimicrobial additive.

17. The mattress of claim 1, wherein the mattress body includes a first layer and a second layer integrated with the first layer, wherein the first layer has a different rigidity than the second layer.

18. The mattress of claim 17, wherein the first layer is at a top surface of the mattress body and the second layer is located inward within the mattress body and extends from the first layer toward a bottom surface of the mattress body, and wherein the second layer is more rigid than the first layer.

19. The mattress of claim 1, further comprising:

a sheet attachment member at the mattress body, the sheet attachment member includes a coupling that projects out from the mattress body and is configured to received and hold a sheet over a top surface of the mattress body.

20. The mattress of claim 1, further comprising:

a first sensor type at the mattress body and in communication with the control unit;

a second sensor type at the mattress body and in communication with the control unit;

a third sensor type at the mattress body and in communication with the control unit; and

a fourth sensor type at the mattress body and in communication with the control unit,

wherein each of the first sensor type, the second sensor type, the third sensor type, and the fourth sensor type is configured to sense a different condition, and wherein the first sensor type, the second sensor type, and the third sensor type are located adjacent one another at a common region of the mattress body while the fourth sensor type is spaced apart from the common region.