BACKGROUND

Field

[0001] Embodiments presented in this disclosure relate generally to body support products formed from foam materials and, in particular, to a customizable sleep system for accommodating the needed or desired degree of support and cooling of users.

Description of the Related Art

[0002] Conventional body supports can be found in a wide variety of shapes and sizes, and are often adapted for supporting one or more parts of a user's body. Examples of body supports include mattresses, mattress toppers, pillows, and other cushion-type products. Many body supports are constructed out of foam materials, such as polyurethane foam. The foam materials may include visco-elastic properties, and such foam materials being known in the art as "memory foam," which provides the body support with an increased ability to conform to a user and thereby distribute the weight of the user.

[0003] Although there are a multitude of foam materials that exhibit various properties and different degrees of support, e.g. some foam materials being soft and others firm, many body supports are constructed entirely out of a single piece of foam material. Conventional body supports are therefore not adjustable for use by multiple users who have different needed or desired degrees of support or comfort levels. Based on the limitations of existing body supports and the high consumer demand for body supports, there is a continuous need for new and improved adjustable body support products.

SUMMARY

[0004] One embodiment provides a customizable mattress for accommodating the needed or desired body support and cooling of users. The mattress includes one or more upper support members, each upper support member including a plurality of foam layers having at least one of different thermal conductivity characteristics and different glass transition temperature (Tg) characteristics. The mattress further includes one or more lower support members, each lower support member including a plurality of foam layers having different support characteristics.

[0005] Another embodiment provides a customizable sleep system for accommodating the needed or desired body support and cooling of users. The customizable sleep system includes the aforementioned mattress having one or more upper supports member, each upper support member indcluing a plurality of foam layers having at least one of different thermal conductivity characteristics and different Tg characteristics, and one or more lower support members, each lower support member including a plurality of foam layers having different support characteristics. The customizable sleep system further includes one or more pillows which each include a plurality of distinct foam layers having at least one of different support characteristics, different thermal conductivity characteristics, and different Tg characteristics.

[0006] Yet another embodiment provides a customizable sleep system which includes the aforementioned one or more pillows which each include a plurality of distinct foam layers differing in at least one of a support characteristic, a thermal conductivity characteristic, and a Tg characteristic. In addition, the customizable sleep system includes a mattress topper including one or more support members which each include a plurality of foam layers differing in at least one of a support characteristic, a thermal conductivity characteristic, and a Tg characteristic.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] So that the manner in which the above recited aspects are attained and can be understood in detail, a more particular description of aspects of this disclosure, briefly summarized above, may be had by reference to the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical aspects of this disclosure and are therefore not to be considered limiting of its scope, for this disclosure may admit to other equally effective aspects. [0008] Figure 1 is a perspective view of a customizable sleep system, according to one embodiment.

[0009] Figure 2 is a perspective view of a mattress of the customizable sleep system of Figure 1 , according to one embodiment.

[0010] Figure 3 is a perspective view of a mattress topper of the customizable sleep system of Figure 1 , according to one embodiment.

[0011] Figure 4 is a cross-section view of two pillows and a back view of a pillow case of the customizable sleep system of Figure 1 , according to one embodiment.

DETAILED DESCRIPTION

[0012] Embodiments presented herein provide a customizable sleep system for accommodating the needed or desired degree of body support and cooling of users.

[0013] In one embodiment, the customizable sleep system includes a mattress comprising one or more upper support members, each including multiple foam layers having at least one of different thermal conductivity characteristics and different glass transition temperature (Tg) characteristics, and one or more lower support members, each having multiple foam layers with different support characteristics. As used herein, support characteristics of foam include support factor (also referred to as sag factor or compression modulus), density, indention load deflection (ILD), firmness, softness, material type, and the like. The upper support members may be placed adjacent to each other to form a substantially continuous surface on top of the mattress, while the lower support members may be placed adjacent to each other to form a substantially continuous upper surface on which the upper support members rest. By reorienting the upper and/or lower support members and securing the support members in an enclosure, the system is customizable to the desired body support and cooling of one or more users.

[0014] In another embodiment, the customizable sleep system may also include one or more pillows, each having foam layers which differ in at least one of a support characteristic, a thermal conductivity characteristic, and a Tg characteristic. By removing or replacing one or more of the foam layers and/or reorienting the pillow, the system is customizable to the desired head support and cooling of one or more users.

[0015] In yet another embodiment, the customizable sleep system may further include a mattress topper with one or more support members which each include a plurality of foam layers that differ in at least one of a support characteristic, a thermal conductivity characteristic, and a Tg characteristic. The support members of may also be reoriented, either together or separately, to customize the mattress topper to provide the desired body support and cooling of one or more users.

[0016] Figure 1 is a perspective view of a customizable sleep system 100, according to one embodiment. As shown, the system 100 includes a mattress 1 10, a mattress topper 120, and two pillows 130 _1-2 . The mattress 1 10, the mattress topper 120, and the pillows 130 _1-2 can be used alone or in any combination with each other and/or with other existing body support products to provide a truly customizable sleep system for one or more users. The mattress topper 120 and/or the pillows 130 _1-2 may be used with and placed on top of an existing mattress to provide additional comfort and/or support. Although shown as being rectangular in shape, the mattress 1 10, mattress topper 120, and pillows 130 _1-2 can be formed in numerous shapes and sizes.

[0017] The mattress 1 10 includes four distinct pieces, specifically, two lower support members 1 12 _1-2 and two upper support members 1 15 _1-2 . Each of the support members 1 12 _1-2 and 1 15 _1-2 includes a plurality of foam layers having different support characteristics, thermal conductivity characteristics, and/or Tg characteristics. A user may orient and reorient the support members 1 12 _1-2 and 1 15 _1-2 within an enclosure 140 (shown in Figure 2) to adjust the mattress 1 10 so that the side of the mattress 1 10 that the user sleeps on provides the needed or desired body support and cooling characteristics. The enclosure 140 or portions thereof may be formed from a flexible cloth or sheet-type material, a woven fabric material, and/or a pre-shrunk quilted fabric material, or other types of bedding materials known in the art. When the support members 1 12 _1-2 and 1 15 _1-2 are secured in the enclosure 140, the lower support members 1 12 _1-2 are disposed adjacent to each other such that they jointly form a substantially flat and continuous top surface on which the upper support members 1 15 _1-2 , which themselves jointly form a substantially flat and continuous top surface on which users may lay, are positioned. In an alternative embodiment, the upper support members 1 15 _1-2 may be a single support member that forms a continuous top surface and provides the structural support of a single mattress.

[0018] As further described herein, the upper support members 1 15 _1-2 may each include multiple foam layers having at least one of different thermal conductivity characteristics and different Tg characteristics, such as a regular polyurethane foam layer and a gel-infused memory foam layer, or a memory foam layer with a gel glaze on top. The gel that is infused within or glazed on top of a foam layer effectively removes or absorbs the body heat of a user, thereby providing a cool or colder temperature support than a foam layer without gel. Accordingly, a user desiring a cooler surface to lie on may orient the upper support member 1 15 _{1 -2} that he/she lays above so that the gel-infused memory foam layer or memory foam layer with a gel glaze is on top. It should be understood that the foam layers having different thermal conductivity characteristics and/or different Tg characteristics may also have different support characteristics. The lower support members 1 12 _1-2 each include multiple foam layers with different support characteristics, such as different support factors, densities, indention load deflections (ILDs), firmness, softness, and material type. A user desiring to lie on a firmer or softer surface may orient one or both of the lower support members 1 12 _1-2 accordingly to achieve the desired body support.

[0019] The mattress topper 120 includes two distinct support members 122^ 2, each of which includes multiple foam layers. The foam layers of the mattress topper 120 may have different support characteristics, thermal conductivity characteristics, and/or Tg characteristics, so that the support members 122 _1-2 can be oriented to provide the needed or desired body support and cooling of one or more users. In one embodiment, the mattress topper 120 may be secured in an enclosure (similar to the enclosure 140 of the mattress 1 10 as shown in Figure 2) where the support members 122 _1-2 are disposed adjacent to each other such that they jointly form a substantially flat and continuous top and bottom surfaces. The support members 122 _1-2 can be separately removed from the enclosure and reoriented as desired by the users sleeping on either side. The mattress topper 120 can be positioned on an existing mattress or the mattress 120. In an alternative embodiment, the mattress topper 120 may include only one support member.

[0020] The pillows 130 _1-2 likewise include multiple foam layers. Each of the pillows 130 _1-2 may itself be placed inside a pillowcase. The foam layers of the pillows 130 _{1 -2} may each include a contour-shaped upper foam layer and one or more flat lower foam layers (shown as pillow 150 in Figure 4). The upper foam layer may include memory foam or gel-infused memory foam, and may further have a gel glaze layer on top, while the lower foam layers may include polyurethane foam having the same or different support characteristics. By adding or removing the lower foam layers, the firmness of the pillow and the pillow height may be adjusted (e.g. increased or reduced).

[0021] In an alternative embodiment, the pillows 130 _1-2 may each include two outer foam layers and one or more inner foam layers (shown as pillow 160 in Figure 4). The outer foam layers may comprise memory foam or gel-infused memory foam, and the inner foam layers may comprise polyurethane foam having the same or different support characteristics. One or both of the outer foam layers may further have a gel glaze layer on top. By adding or removing the inner foam layers, the firmness of the pillow and the pillow height may be adjusted (e.g. increased or reduced).

[0022] Figure 2 is a perspective view of the mattress 1 10 of the customizable sleep system 100 of Figure 1 , according to one embodiment. As discussed above, the mattress 1 10 includes four distinct support members 1 12 _1-2 and 1 15 _1-2 , which each includes two foam layers. The lower support members 1 12i. ₂ and the upper support members 1 15 _1-2 when placed together in the enclosure 140 form the size of a full, queen, and/or king size mattress. Alternatively, a single lower support member may instead be used and/or a single upper support member may be used. As shown in Figure 2, the thickness of the upper support members 1 15 _1-2 is less than the thickness of the lower support members 1 12 _1-2 . According to one example, the upper support members 1 15 _1-2 may each be about 3-5 inches thick, while the lower support members 1 12 _1-2 may each be about 7 inches thick.

[0023] As shown, the lower support member 1 12i comprises foam layers 1 13 _! and 1 14i having different support characteristics. For example, the foam layer 1 13 _! may be relatively soft and have an ILD rating within a range of about 6-13 Ibf, while the foam layer 1 14i may be relatively firm and have an ILD rating within a range of about 18-30 Ibf. In one embodiment, the relatively soft foam layer 1 13 _! may have an ILD rating about 2-3 Ibf less than that of the relatively firm foam layer 1 14i . The foam layers 1 13i and 1 14i may have the same thickness, such as about 3.5 inches thick. Further, the foam layers 1 13i and 1 14i may be secured together by laminating the foam layers 1 13i and 1 14i together, or by any other way known by one of ordinary skill in the art. The foam layers 1 13 ₂ and 1 14 ₂ of the support member 1 12 ₂ may be similarly situated and secured together. The foam layers 1 13 ₂ and 1 14 ₂ may have the same or different support characteristics as either of the foam layers 1 13 _! and

[0024] Each of the support members 1 12 _1-2 may be oriented and inserted into the enclosure 140 to provide a desired level of support to the user laying on the mattress 1 10. For example, a user desiring firmer support may orient the support member 1 12 _! or 1 12 ₂ that he/she is laying above so that the relatively firm foam layer 1 14 _! is on top and just below the upper support member 1 15i . Conversely, if the user desires a softer support, he/she may orient the support member 1 12i or 1 12 ₂ so that the relatively soft foam layer 1 13i is on top and just below the upper support member 1 15i . By reorienting the support members 1 12i _-2 , each side of the mattress 1 10 may be adjusted to provide a desired firmer or softer support for the user laying on that side.

[0025] As shown, the upper support member 1 15 _! includes distinct foam layers 1 16 1 17i having at least one of different support characteristics, different thermal conductivity characteristics, and different Tg characteristics. The foam layers 1 16 1 17i may be secured together by, e.g., laminating the support layers 1 16 1 17i or any other way known by one of ordinary skill in the art. The foam layers 1 16 1 17i may include a memory foam layer 1 16 _! and a regular foam layer 1 17i . The memory foam layer 1 16 _! may be about 2-4 inches thick, while the regular foam layer 1 17i may be about 1 inch thick. As the memory and regular foam layers 1 16i and 1 17i have different support characteristics, thermal conductivity characteristics, and/or Tg characteristics, the upper support member 1 15 _! may be reoriented by the user such that either the regular or memory foam layer is on top to provide the needed or desired body support and cooling. The foam layers 1 16 ₂ and 1 17 ₂ of the upper support member 1 15 ₂ may be similarly situated and secured together as the 1 16 _! and 1 17i of the upper support member 1 15i . The foam layers 1 16 ₂ and 1 17 ₂ may have the same or different support characteristics as either of the foam layers

[0026] The regular foam layer 1 17 may include a polyurethane foam, such as a ventilated polyurethane foam that permits air to flow through the foam layer 1 17i . The memory foam layer 1 16 _! may include any viscoelastic foam, such as those typically produced by reaction of special visco-polyol and isocyanate compounds, which results in a polyurethane foam having viscoelastic properties. The memory foam layer 1 16i may also be a ventilated foam and infused with a gel material, such as a polyurethane based gel, forming a so- called gel-infused memory foam. The gel material may comprise polyether polyol or polyol in short. The gel material may be formed by reacting a polyol with an isocyanate in the presence of a catalyst. The gel material may be in the form of particles or beads embedded in the foam layer 1 16i . The gel material may be a polymer such as an elastomeric polymer, thermosetting polymer, thermoplastic elastomer, natural oil polyol (NOP), and a combination thereof. Suitable gels include polyurethane gels, silicone gels, PVC gels, polyorganosiloxane gels, polyol gels, polyisocyanate gels, and combinations thereof. For example, the gel material may provide additional support and/or increase the thermal conductivity of the foam layer 1 16i to effectively remove or absorb the body heat of a user, thereby providing a cool or colder temperature support than a non-gel-infused layer. [0027] Additional cooling may be provided by optionally wrapping the upper support members 1 15 _1-2 in a cooling fabric, and/or adding a gel glaze layer on top of the support members 1 15 _1-2 . The cooling fabric may be constructed from cooling yarn, polyester, spandex, a combination thereof, or any other material known by one of ordinary skill in the art. The gel glaze layer may include a polyurethane based gel material, such as polyether or polyol.

[0028] The enclosure 140 may be made from any sheeting material such as cotton, polyester, microfiber, lyocell, and the like. A zipper 1 18 is provided across the sides of the enclosure 140 to open and close the enclosure 140. The zipper 1 18 permits access into the enclosure 140 so that the support members 1 12 _1-2 and 1 15 _1-2 can be placed into and removed from within the enclosure 140. Other fastening mechanisms may be used in lieu of the zipper 1 18.

[0029] Figure 3 is a perspective view of the mattress topper 120 of the customizable sleep system 100 of Figure 1 , according to one embodiment. The mattress topper 120 may be placed on top of an existing mattress for additional comfort. As shown, the mattress topper 120 includes two support members 122 _1-2 for users laying on either side of the mattress topper 120. The support members 122 _1-2 may be positioned adjacent to each other within an enclosure (such as enclosure 140 shown in Figure 2) to form a full, queen, and/or king size mattress. The support members 122 _1-2 when in use are placed adjacent to each other such that they form a substantially continuous and flat top surface on which one or more users may sleep. Alternatively, a single support member may also be used.

[0030] Each of the support members 122 _1-2 itself includes two foam layers ^* \ 24 and ^* \ 26 for support member 122^ and two foam layers 124 ₂ and 126 ₂ for support member 122 ₂ . Similar to the foam layers of the mattress 1 10, the foam layers 124 _1-2 and 126 _1-2 may be laminated or secured together in any way known by one of ordinary skill in the art. The foam layers 124 ₂ and 126 ₂ may have the same or different support and/or cooling characteristics as either of the foam layers ^* \ 24 and 126 _! . The foam layers 124 _1-2 may include ventilated memory foam or gel-infused memory foam, and the foam layers 125 _1-2 may include ventilated polyurethane foam. The memory foam layers 124 _1-2 may be about 1 .5-2.5 inches thick, while the polyurethane foam layers 125 _1-2 may be about 0.5-1 inch thick.

[0031] By reorienting the support members 122 _1-2 of the mattress topper 120, the user can get the needed or desired support and cooling characteristics. For example, a user desiring a cooler and softer support may reorient the support member 122 _1-2 that he/she is laying on so that the softer/cooler foam layer (e.g. gel-infused memory foam layer) is on top. The support members 122 _1-2 of the mattress topper 120 may each be reoriented separately, allowing users on either side of the mattress topper 120 to adjust their respective support member 122 _1-2 as desired.

[0032] Additional cooling may be provided for the mattress topper 120 by optionally wrapping the mattress topper 120 in a cooling fabric, and/or adding a gel glaze layer on top of one or both foam layers 124 _1-2 . The cooling fabric may be constructed from cooling yarn, polyester, spandex, a combination thereof, or any other material known by one of ordinary skill in the art. The gel glaze layer may include a polyurethane based gel material, such as polyether or polyol.

[0033] Figure 4 is a cross-section view of two different pillows (pillow 150 shown in Panel A, and pillow 160 shown in Panel B) and a back view of a pillow case 170 (shown in Panel C) of the customizable sleep system 100 of Figure 1 , according to one embodiment. As shown in panel A, the pillow 150 includes an upper foam layer 151 formed in a contour shape and two flat, lower foam layers 152-153 which are placed beneath the upper foam layer 151 . Although only two lower foam layers 152-153 are shown, any number of lower foam layers can be included. The upper foam layer 151 may include ventilated memory foam or a gel-infused memory foam, while the lower foam layers 152-153 may include polyurethane foams having the same or different support characteristics. The upper foam layer 151 may be placed in an inner enclosure, such as a mesh inner cover, which is distinct from the pillow case 170 enclosing the entire pillow 150. The upper foam layer 151 may be about 3-4 inches thick, while the lower foam layers 152-153 may each be about 0.5 inches thick. The upper and lower foam layers 151 -153 of the pillow 150 are not secured together and can be added and removed from the pillow case 170 to customize the support and cooling characteristics to the need or desire of the user.

[0034] The lower foam layers 152-153 may provide firmness and/or height to the pillow 150. The upper foam layer 151 may be constructed from ventilated memory foam or gel-infused memory foam, while the lower foam layers 152-153 may be constructed from polyurethane foam and may be significantly thinner than the upper foam layer 151 . The upper and the lower foam layers 151 -153 may be housed together in an enclosure such as the pillow case 170. The firmness and/or height of the pillow 150 may then be adjusted, as desired, by removing or replacing one or both of the lower foam layers 152-153. For example, a user desiring a firmer and higher pillow may secure both lower foam layers 152-153 with the upper foam layer 151 in the pillow case 170, while a user desiring a softer and lower pillow may remove one or both of the lower foam layers 152-153 from the pillow case 170. Finally, the pillow 150 may further include a gel glaze layer formed on top of the upper foam layer 151 for further cooling effect.

[0035] As shown in panel B, the pillow 160 includes two outer foam layers 161 -162 and two inner foam layers 163-164 placed between the outer foam layers 161 -162. Although only two inner foam layers 163-164 are shown, any number of inner foam layers can be included. The outer foam layers 161 -162 may include a ventilated memory foam or gel-infused memory foam, and the inner foam layers 163-164 may include polyurethane foam pieces having the same or different support characteristics. The pillow 160 optionally includes a gel glaze layer 165 formed on top of the outer foam layer 161 for further cooling effect. The outer foam layers 161 -162 may each be about 2.5 inches thick, while the inner foam layers 163-164 may each be about 0.5 inches thick. The outer and inner foam layers 161 -164 of the pillow 160 are not secured together and can be added and removed from the pillow case 170 to customize the support and cooling characteristics to the need or desire of the user.

[0036] The inner foam layers 163-164 of the pillow 160 may provide firmness and/or height to the pillow 160. The outer foam layers 161 -162 may be constructed from ventilated memory foam or gel-infused memory foam, while the inner foam layers 163-164 may be constructed from polyurethane foam and be significantly thinner than the outer foam layers 161 -162. The outer and inner foam layers 161 -164 may be housed together in an enclosure such as the pillow case 170, and the firmness and/or height of the pillow 160 may be adjusted, as desired, by removing or replacing one or both of the inner foam layers 163-164. The outer foam layers 161 -162 may be re-oriented, as desired, so that either the outer foam layer 161 having the gel glaze layer 165 or the outer foam layer 162 without a gel glaze layer is on top.

[0037] Panel C illustrates the pillow case 170 as an example enclosure in which the customizable pillows 150 and 160 may be secured. As shown, the pillow case 170 includes a cover 171 and a zipper 172. The cover 171 may be constructed from any sheeting material such as cotton, polyester, microfiber, lyocell, and the like. The pillow 150 or the pillow 160 can be placed within the cover 171 , and the zipper 172 may then be fastened to secure the pillow 150, 160 in the pillow case 170. The zipper 172 is a three-sided zipper formed on a bottom surface of the cover 171 . The foam layers 151 -153 of the pillow 150 and the foam layers 161 -164 of the pillow 160 may be removed from and/or replaced in the pillow case 170 to provide a desired or required head support and cooling.

[0038] Advantageously, the embodiments presented herein provide a customizable sleep system for accommodating the needed or desired body support and cooling of one or more users. A mattress is disclosed having one or more upper support members, each upper support member including a plurality of foam layers having at least one of different thermal conductivity characteristics and different Tg characteristics and that jointly forms an upper surface of the mattress, as well as one or more lower support members each including foam layers having different support characteristics. By reorienting the upper and/or lower support members and securing the support members in an enclosure, the needed or desired body support and cooling may be provided for one or more users. Further, a mattress topper is disclosed which may be used in conjunction with any existing mattress, and which includes one or more support members, each having foam layers differing in at least one of different support characteristics, different thermal conductivity characteristics, and different Tg characteristics. The support members of the mattress topper may also be reoriented to provide the needed or desired body support and cooling for one or more users. Further still, one or more pillows are disclosed which each include multiple foam layers that differ in at least one of a support characteristic, a thermal conductivity characteristic, and a Tg characteristic. By removing or replacing one or more of the foam layers and/or reorienting the pillow, the needed or desired head support and cooling may be provided for one or more users.

[0039] While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.