Distribution pad for a temperature control system

Patent metadata

Field	Value
Publication number	US-10194752-B2
Application number	US-201514842177-A
Country	US
Kind code	B2
Filing date	Sep 1, 2015
Priority date	Dec 27, 2012
Publication date	Feb 5, 2019
Grant date	Feb 5, 2019

Abstract

An air distribution pad comprises an upper layer, a lower layer, and a spacer material located between the upper layer and the lower layer, the spacer material configured to allow air to pass therethrough. An air distributor is configured to distribute air to the spacer material, wherein the air distributor comprises a port configured to receive an air hose, wherein the port is directed laterally sideways from the air distributor. At least one joining structure is coupled to the upper layer and the lower layer, the at least one joining structure providing one or more channels formed through the spacer material in fluid communication with the air distributor. The one or more channels are configured to direct generally laterally flowing air from the port of the air distributor to a generally longitudinal direction along the at least one channel.

First claim

What is claimed is:

1. An air distribution pad, comprising:
an upper layer, a lower layer, and a spacer material located between the upper layer and the lower layer, the spacer material having a plurality of resilient support fibers configured to provide support in compression and configured to allow air to pass therethrough;
an air distributor configured to distribute air to the spacer material, wherein the air distributor comprises a port configured to receive an air hose, wherein the port is directed laterally sideways from the air distributor; and
at least one joining structure coupled to the upper layer and the lower layer and extending through the spacer material, the at least one joining structure providing one or more channels formed through the spacer material in fluid communication with the air distributor;
wherein the one or more channels are configured to direct generally laterally flowing air from the port of the air distributor to a generally longitudinal direction along the at least one channel,
wherein a first joining structure is on a first lateral side of the spacer material proximate the air distributor, and a second joining structure is on a second lateral side of the spacer material opposite the air distributor, wherein a portion of the first joining structure proximate a first longitudinal end of the spacer material proximate the air distributor forms an acute angle relative to a longitudinal axis of the spacer material and a portion of the second joining structure proximate the first longitudinal end of the spacer material forms an obtuse angle relative to a lateral axis of the spacer material.

2. The air distribution pad according to claim 1 , wherein at least one of the upper layer and the lower layer defines one or more openings in communication with the one or more channels.

3. The air distribution pad according to claim 1 , wherein the first joining structure forms a sinusoidal shape along the longitudinal direction and the second joining structure forms an arc shape along the longitudinal direction.

4. The air distribution pad according to claim 1 , wherein the at least one joining structure comprises stitching between the upper layer and the lower layer, the stitching extending through the spacer material.

5. The air distribution pad according to claim 1 , wherein a configuration of the upper layer is substantially a mirror image of a configuration of the lower layer.

6. The air distribution pad according to claim 1 , further comprising a comfort layer, wherein the combination of the comfort layer and the spacer material provides a cushion-neutral feel for a user.

7. The air distribution pad of claim 1 , wherein the stitching is in tension to pull the upper layer and lower layer at least partially together to at least partially compress the spacer material.

8. An air distribution pad, comprising:
an upper layer, a lower layer, and a spacer material located between the upper layer and the lower layer, the spacer material configured to allow air to pass therethrough;
an air distributor configured to distribute air to the spacer material, wherein the air distributor comprises a port configured to receive an air hose; and
stitching, coupling the upper layer and the lower layer and extending through the spacer material, the stitching being in tension configured to pull the upper layer and lower layer at least partially together to at least partially compress the spacer material and providing one or more channels formed through the spacer material in fluid communication with the air distributor, wherein at least one of the top layer and the bottom layer defines openings in communication with the one or more channels;
wherein the one or more channels are configured to direct air from the air distributor along the one or more channels and out of the openings.

9. The air distribution pad according to claim 8 , wherein the port in the air distributor is directed laterally sideways, and the one or more channels are configured to direct generally laterally flowing air from the port to a generally longitudinal direction along the at least one channel.

10. The air distribution pad according to claim 8 , wherein the stitching comprises a first line of stitching on a first lateral side of the spacer material proximate the air distributor, and a second line of stitching on a second lateral side of the spacer material opposite the air distributor, wherein a portion of the first line of stitching proximate a first longitudinal end of the spacer material proximate the air distributor forms an acute angle relative to a longitudinal axis of the spacer material and a portion of the second line of stitching proximate the first longitudinal end of the spacer material forms an obtuse angle relative to a lateral axis of the spacer material.

11. The air distribution pad according to claim 10 , wherein the first line of stitching forms a sinusoidal shape along the longitudinal direction and the second line of stitching forms an arc shape along the longitudinal direction.

12. The air distribution pad according to claim 8 , wherein a configuration of the upper layer is substantially a mirror image of a configuration of the lower layer.

13. The air distribution pad of claim 8 , wherein the spacer material has a plurality of resilient support fibers configured to provide support in compression.

14. An air distribution pad, comprising:
an upper layer, a lower layer, and a spacer material located between the upper layer and the lower layer, the spacer material configured to allow air to pass therethrough;
an air distributor configured to distribute air to the spacer material, wherein the air distributor comprises a port configured to receive an air hose; and
stitching, coupling the upper layer and the lower layer and extending through the spacer material, the stitching providing one or more channels formed through the spacer material in fluid communication with the air distributor, wherein at least one of the top layer and the bottom layer defines openings in communication with the one or more channels;
wherein the one or more channels are configured to direct air from the air distributor along the one or more channels and out of the openings,
wherein the air distribution pad has a head area near a head of the air distribution pad, a foot area near a foot of the distribution pad, and a central area between the head area and the foot area, wherein the air distributor is positioned at the central area of the air distribution pad, wherein the stitching comprises a first length of stitching extending from the central area to the head area and having a first curved shape, wherein the stitching comprises a second length of stitching extending from the central area to the foot area and having a second curved shape that curves differently than the first curved shape of the first length of stitching, and wherein at least part of the central area has no stitching between ends of the first length of stitching and the second length of stitching.

15. The air distribution pad of claim 14 , wherein the stitching is in tension to pull the upper layer and lower layer at least partially together to at least partially compress the spacer material.

16. The air distribution pad of claim 14 , wherein the spacer material has a plurality of resilient support fibers configured to provide support in compression.

17. An air distribution pad, comprising:
an upper layer, a lower layer, and a spacer material located between the upper layer and the lower layer, the spacer material configured to allow air to pass

Assignees

• Sleep Number Corp

Inventors

• Zaiss Vit
• Karschnik Kody Lee

Classifications

• A47C21/04

  Devices for ventilating, cooling or heating · CPC title

• A61G7/05792

  with low air loss function, e.g. in mattresses, overlays or beds · CPC title

• A47C21/044 Primary

  with active means, e.g. by using air blowers or liquid pumps · CPC title

• A47C27/14

  with foamed material inlays · CPC title

• A61G7/05784

  with ventilating means, e.g. mattress or cushion with ventilating holes or ventilators · CPC title