Layer assembly for a bed to distribute air

Patent metadata

Field	Value
Publication number	US-12279698-B2
Application number	US-202418619474-A
Country	US
Kind code	B2
Filing date	Mar 28, 2024
Priority date	Aug 23, 2017
Publication date	Apr 22, 2025
Grant date	Apr 22, 2025

Abstract

An air system for a bed can include a layer assembly having a head end, a foot end, and first and second sides, with a head portion near the head end, a foot portion near the foot end, and a middle portion between the head portion and the foot portion, the layer assembly. The layer assembly can have a spacer layer comprising spacer material configured to allow for air flow through the spacer material and a cover comprising a cover top layer and a cover bottom layer. The air system can have a distribution manifold that is substantially fan-shaped with a plurality of ribs defining channels and/or is positioned above the cover bottom layer and under the spacer layer. The air system can have first and second flaps with first and second retention features extending from the head and foot ends of the air layer.

First claim

What is claimed is:

1. An air system for a bed, comprising:
a layer assembly having a head end, a foot end, and first and second sides, wherein the layer assembly has a head portion near the head end, a foot portion near the foot end, and a middle portion between the head portion and the foot portion, the layer assembly having:
a first layer configured to allow airflow laterally and vertically therethrough;
a second layer configured to allow airflow therethrough and positioned under the first layer, the second layer comprising spacer material having one or more monofilament strands configured to allow for air flow through the spacer material, wherein the second layer has an edge with a concave curved portion; and
a cover comprising a cover top layer and a cover bottom layer, wherein the cover substantially encloses the first and second layers with the cover top layer above the first layer and the cover bottom layer below the second layer; and

a distribution manifold positioned inside the cover, wherein the distribution manifold is positioned above the cover bottom layer and under the cover top layer, wherein the distribution manifold defines an outlet which has a convex portion that is open and configured for air to escape the distribution manifold, wherein the convex portion of the outlet is positioned and configured to direct air laterally into the concave curved portion of the edge of the second layer which is positioned under the first layer so as to flow air from the outlet of the distribution manifold to a space occupied at least partially by the second layer under the first layer, from the space occupied at least partially by the second layer under the first layer into the first layer, and from the first layer out through the cover top layer.

2. The air system of claim 1 , wherein the air system is configured to be positioned on a top of a mattress of the bed.

3. The air system of claim 1 , wherein the outlet of the distribution manifold is shaped as an arc with the convex portion having a convex curvature when viewed from above at an angle perpendicular to the layer assembly.

4. The air system of claim 1 , wherein the distribution manifold comprises:
a manifold bottom surface that is substantially flat and positioned against the cover bottom layer; and
first and second vertically extending portions that extend upwards from the manifold bottom surface such that the manifold bottom surface and the first and second vertically extending portions combine to define a flow path to direct air flow through the outlet of the distribution manifold.

5. The air system of claim 4 , wherein the manifold bottom surface is substantially sealed and wherein a top of the distribution manifold is at least partially open opposite of the manifold bottom surface.

6. The air system of claim 1 , wherein the distribution manifold comprises:
a manifold bottom surface that is substantially flat and positioned against the cover bottom layer; and
first and second vertically extending portions that extend cantilevered upward from the manifold bottom surface and extend fully to a perimeter of the outlet of the distribution manifold.

7. The air system of claim 1 , wherein the second layer is stiffer and thinner than the first layer.

8. The air system of claim 1 , and further comprising:
a blower connected to the distribution manifold and configured to blow air through the distribution manifold and into the second layer.

9. The air system of claim 1 , and further comprising:
a blower positioned exterior to the cover.

10. The air system of claim 1 , and further comprising:
a hose assembly connected to the distribution manifold.

11. The air system of claim 1 , wherein the second layer is substantially rectangular when viewed from above at an angle perpendicular to the layer assembly.

12. The air system of claim 1 , and further comprising:
means to connect the layer assembly to a mattress.

13. A layer assembly configured to be positioned on top of a mattress to distribute air, the layer assembly comprising:
a cover;
a first layer configured to allow airflow therethrough positioned inside the cover proximate a top of the cover;
a second layer configured to allow airflow therethrough and positioned inside the cover under the first layer, wherein the second layer defines a concave curved portion at an edge; and
a distribution manifold positioned inside the cover, wherein the distribution manifold defines a convex curved outlet which is a portion of the distribution manifold that is open for air to escape the distribution manifold, wherein the convex curved outlet is positioned adjacent to the concave curved portion of the second layer so as to direct air into the concave curved portion of the second layer, through various portions of the second layer, up from the second layer into the first layer, and up from the first layer out through a top of the cover.

14. The layer assembly of claim 13 , wherein the distribution manifold comprises:
a manifold bottom surface that is substantially flat and positioned against a cover bottom layer; and
first and second vertically extending portions that extend upwards from the manifold bottom surface such that the manifold bottom surface and the first and second vertically extending portions combine to define a flow path to direct air flow through the convex curved outlet of the distribution manifold.

15. The layer assembly of claim 14 , wherein the manifold bottom surface is substantially sealed and wherein a top of the distribution manifold is at least partially open opposite of the manifold bottom surface.

16. The layer assembly of claim 13 , wherein the distribution manifold comprises:
a manifold bottom surface that is substantially flat and positioned against a cover bottom layer; and
first and second vertically extending portions that extend cantilevered upward from the manifold bottom surface and extend fully to a perimeter of the convex curved outlet of the distribution manifold.

17. The layer assembly of claim 13 , wherein the second layer is stiffer than the first layer.

18. The layer assembly of claim 13 , wherein one or more of the first and second layers comprises one or more monofilament strands randomly or substantially randomly placed to provide structural support for one or more of the first and second layers.

19. An air system for a bed, comprising:
a layer assembly having a head end, a foot end, and first and second sides, wherein the layer assembly is configured to be positioned on top of a mattress to distribute air, the layer assembly having:
a first layer comprising a spacer material having a thickness between a top and a bottom of the first layer and having a plurality of flow paths configured to allow airflow vertically and horizontally through the first layer;
a second layer configured to allow airflow therethrough and positioned under the first layer, the second layer comprising spacer material having one or more monofilament strands configured to allow for air flow through the spacer material; and
a cover comprising a cover top layer and a cover bottom layer, wherein the cover substantially encloses the first and second layers with the cover top layer above the first layer and the cover bottom layer below the second layer; and

an air distributor positioned inside the cover, wherein the air distributor is positioned above the cover bottom layer and under the cover top layer, wherein the air distributor defines an outlet with an outlet width greater than an outlet height, wher

Assignees

• Sleep Number Corp

Inventors

• Griffith Matthew
• Negus Natalie
• Rose Eric
• Karschnik Kody Lee

Classifications

• A47C27/18

  in combination with inflatable bodies · CPC title

• A47C27/083

  with pressure control, e.g. with pressure sensors · CPC title

• A47C27/06

  Spring inlays or spring units therefor · CPC title

• A47C21/048

  for heating · CPC title

• A47C20/04

  with adjustable inclination (A47C20/08 takes precedence) · CPC title