A MATTRESS OR TOPPER WITH HEAT DISSIPATION CONFIGURATION

AND METHOD OF MANUFACTURE

FIELD OF THE INVENTION

This invention relates to mattress configurations and methods of manufacture of mattress configurations.

BACKGROUND

Various types of mattress and mattress cores are known. One common type is an 'inner-sprung' mattress that comprises an assembly of interlinked metal compression springs arranged inside the mattress to provide the appropriate resilience when housed within appropriate coverings. A 'pocket spring' mattress is another type of mattress core that addresses some of the problems associated with the inner-sprung mattress core. In a pocket spring mattress, the springs sit independently of each other in individual textile pockets. Another type of mattress core is known as a 'foam spring type' mattress core such as that described in New Zealand patent 330983. A foam spring type mattress core comprises a resilient member such as a foam blank or core having a plurality of apertures or bores therein which house metal compression springs.

Typically, the mattress cores are provided on a bed base or framework, such as a slat- bed framework. Additionally, most mattresses are provided with one or more integrally formed toppers or comfort layers. Often these toppers or comfort layers comprise textile and/or foam layers having desired characteristics in terms of density and/or hardness to enhance user comfort and/or to provide for different customer preferences.

A common issue in beds is management of body heat dissipation. Heat can build up in the mattress comfort layers and/or core and can lead to discomfort to the user and/or their bed partner.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art. SUMMARY OF THE INVENTION

It is an object of this invention to provide an improved mattress or mattress topper and/or method of manufacture, or to at least provide the public with a useful choice.

In a first aspect, the invention broadly comprises a mattress or mattress topper extending between head and foot ends, wherein at least a portion or portions of the mattress or mattress topper comprise: a laminated portion or panel, the laminated portion or panel comprising a laminated series of resilient elongate elements, wherein the laminated portion or panel comprises at least two different types of elongate elements.

In an embodiment, the type of elongate element is defined by the dimension of, characteristics of, and/or materials forming the elongate element.

In an embodiment, each elongate element is formed of a respective type of resilient material, and wherein the laminated panel or portion comprises elongate elements of at least two different types of resilient materials.

In an embodiment, at least a portion of the elongate elements are formed of a first resilient material and a portion of the elongate elements are formed of a second resilient material.

In an embodiment, the at least first resilient material has heat transferal properties and acts to transfer thermal energy from areas of high thermal energy to areas of lower thermal energy.

In an embodiment, the at least second resilient material has heat storage properties and acts to absorb thermal energy from an area of high thermal energy in contact with it.

In an embodiment, the first resilient material and the second resilient material act in combination to absorb and dissipate thermal energy away from an area of the mattress or topper having high thermal energy.

In an embodiment, the elongate elements in the laminated panel or portion are configured in a series arrangement such that each elongate element is adjacent another elongate element of a different type. In some embodiments, the series arrangement may be a repeating pattern of elongate elements with respect to type. In other embodiments, the series arrangement may be a semi-repeating pattern, customised arrangement, or random or arbitrary pattern, or other sequence or ordering of the different types of elongate elements with respect to each other across the width of the laminated panel.

In an embodiment, the series arrangement of elongate elements may be symmetrical with respect to the center of the laminated panel or portion.

In an embodiment, the elongate elements are arranged in a repeating pattern.

In an embodiment, the first resilient material is a foam.

In an embodiment, the first resilient material has high porosity relative to the second or other resilient materials used in the panel.

In an embodiment, the first resilient material is polyurethane foam or polyethylene foam or foamed latex rubber.

In an embodiment, the laminated panel further comprises a portion of elongate elements formed of a third resilient material.

In an embodiment, the elongate elements of the third resilient material are arranged in a repeating pattern with respect to the elongate elements of the first resilient material and the second resilient material.

In an embodiment, the second resilient material and/or the third resilient material is a foam having different properties to the first resilient material.

In an embodiment, the second or third resilient material is a viscoelastic foam. In an embodiment, the viscoelastic foam comprises an additive material, such as gel beads, carbon elements, and/or industrial diamonds.

In an embodiment, the second resilient material and/or the third resilient material is a gel or graphene-based foam.

In an embodiment, the elongate elements have an adhesive fixing or laminating them together in a side-by-side relationship. In an embodiment, the elongate elements are fixed together along their lengths.

In one embodiment, the adhesive fixing the elongate elements together is able to store thermal energy. In such embodiments, the adhesive may comprise an additive phase change material (PCM) or phase change composition.

In another embodiment, the adhesive fixing the elongate elements together may be any suitable adhesive, regardless of its thermal energy storage or transfer capacity.

In an embodiment, the mattress or topper further comprises a backing substrate of resilient material that is fixed to the laminated panel. In one configuration, the backing substrate comprises a complementary recess portion for receiving and retaining the laminated panel. In an embodiment, the backing substrate is larger in surface area than the laminated panel and defines the overall length and width dimensions of the mattress or topper. In an embodiment, the laminated panel is provided centrally on the backing substrate. In an embodiment, the mattress is configured such that the upper or contact surface of the mattress or topper is provided with a central zone surface provided by the laminated panel, and head and foot zone surfaces provided by the backing substrate above and below the central zone surface respectively. In an embodiment, the upper or contact surface of the laminated panel is flush or co-incident with the surrounding upper or contact surfaces of the backing substrate.

In an embodiment, at least a portion of the backing substrate contacts or is fixed to the underside surface of the laminated panel.

In an embodiment, the backing substrate is formed of the same material as the first resilient material of the elongate elements of the laminated panel.

In an embodiment, the upper or contact surface of the laminated panel may comprise a coating with thermal transfer properties. In one configuration, the coating may be a phase change material (PCM) coating, and may comprise a phase change material (PCM) component or composition or additive, for example the coating may be a PCM solution in liquid-form that is sprayed or rolled or otherwise applied to the upper or contact surface of the laminated panel. In one configuration, the PCM coating may be formed in any desired colour or appearance, including by way of example but not exclusively any one of the following : translucent, white, or blue. In some configurations, the PCM coating may further comprise one or more additive particles or granular materials, including but not limited to any one or more of the following : copper particles, silver particles, graphene particles, gel particles, carbon particles, and/or industrial diamond particles.

In one embodiment, the PCM solution is applied to the laminated panel at a surface or area density in the range of approximately 100 to approximately 200 grams/square meter, or approximately 125 to approximately 175 grams/square meter, or preferably approximately 150 grams/square meter.

In an embodiment, the laminated portion or panel is located at or towards the centre of the mattress or mattress topper.

In an embodiment, the laminated portion or panel is located in a central third or central half of the mattress or topper.

In an embodiment, the elongate elements of the laminated panel have substantially the same widths.

In an embodiment the elongate elements of the laminated panel have substantially the same lengths.

In an embodiment, the elongate elements have substantially the same thicknesses.

In some embodiments, the upper surface area of the laminated panel may be in the range of between 25%-75% of the mattress upper surface area, or more preferably between approximately 40-60% of the mattress surface area, or even more preferably about 50% of the mattress surface area. In other embodiments, the upper surface area of the laminated panel may be about 33% of the mattress upper surface area.

In an embodiment, the laminated portion or panel is configured to absorb and dissipate heat or thermal energy.

In an embodiment, the laminated portion or panel is defined by upper and lower edges that are parallel or co-incident with the head and foot ends of the mattress or topper, and side edges that extend between the upper and lower edges of the panel and which are parallel or co-incident with the side edges of the mattress or topper.

In an embodiment, the laminated portion or panel is further defined by an upper surface that faces toward or is co-incident with the contact surface of the mattress or topper, and a lower or underside surface that faces toward or is co-incident with the underside of the mattress or topper.

In an embodiment, the laminated portion or panel has a length defined between the upper and lower edges, a width defined between its side edges, and a depth or thickness defined between its upper and lower surfaces.

In an embodiment, the longitudinal axis of the elongate elements is parallel or co- incident with the side edges of the laminated panel such that the elongate elements extend in the lengthwise direction of the panel between its upper and lower edges.

In an embodiment, each of the elongate elements of the laminated panel may extend in a lengthwise direction of the mattress or topper defined between the head and foot ends of the mattress or topper.

In an embodiment, the longitudinal axes of the elongate elements of the laminted panel are parallel or co-incident with the upper and lower edges of the laminated panel such that the elongate elements extend in a lateral direction of the panel between its side edges.

In an embodiment, each of the elongate elements of the laminated panel extend in a lateral direction of the mattress or topper defined between the sides of the mattress or topper.

In an embodiment, the laminated panel is configured to absorb heat or thermal energy from at least its upper surface and dissipate at least some of that heat or thermal energy in lengthwise directions toward its upper a nd/or lower edges.

In an embodiment, the laminated panel is configured to absorb heat or thermal energy from at least its upper surface and dissipate at least some of that heat or thermal energy in lateral directions towa rd its side edges.

In an embodiment, the length of the elongate elements defines the length (with respect to the mattress) of the laminated panel or portion, and the number and width (with respect to the mattress) of the elongate elements defines the width of the laminated panel or portion .

In another embodiment, the length of the elongate elements defines the width (with respect to the mattress) of the laminated panel or portion, and the number and width of the elongate elements defines the length (with respect to the mattress) of the laminated panel or portion.

In an embodiment, the laminated portion or panel is configured to absorb and dissipate heat in a radiator-like fashion.

In an embodiment, the laminated portion or panel is configured to operate in a bellows- like manner to assist in heat transport or channelling when, in use, pressure, force, movement or compression is applied or exerted on the laminated panel or mattress or topper associated with the laminated panel. For example, any such pressure, force, movement or compression may enhance air movement through the laminated panel thereby enhancing heat dissipation in directions parallel or co-incident to the longitudinal axes of the elongate elements of the laminated panel.

In an embodiment, the laminated portion is comprised of different types of elongate elements, some of which are configured primarily to absorb heat or thermal energy and some of which are configured primarily to transport, channel or dissipate heat of thermal energy.

In an embodiment, the laminated panel is located or provided at (e.g. co-incident) or near the contact or upper surface of the mattress or topper.

In an embodiment, the laminated panel is a resilient foam panel or foam-type panel, or formed predominantly of resilient foam or foamed materials.

In a second aspect, the invention broadly comprises a mattress or mattress topper extending between head and foot ends, wherein at least a portion or portions of the mattress or mattress topper comprise: a laminated portion or panel, the laminated portion or panel comprising a laminated series of resilient elongate elements each extending in the lengthwise direction of the mattress or topper defined between the head and foot ends of the mattress or topper, wherein the laminated portion or panel comprises at least two different types of elongate elements.

In a third aspect, the invention broadly comprises a mattress or mattress topper extending between head and foot ends, wherein at least a portion or portions of the mattress or mattress topper comprise: a laminated portion or panel, the laminated portion or panel comprising a laminated series of resilient elongate elements each extending in a lateral direction of the mattress or topper defined between the sides of the mattress or topper, wherein the laminated portion or panel comprises at least two different types of elongate elements.

The second and third aspects of the invention may have any one or more of the features mentioned in respect of the first aspect of the invention.

In a fourth aspect, the invention broadly comprises a resilient laminated portion or panel for use in or as a mattress or mattress topper, the laminated portion of panel comprising a laminated series of resilient elongate elements, wherein the laminated portion or panel comprises at least two different types of elongate elements.

In an embodiment, the type of elongate element is defined by the dimension of, characteristics of, and/or the materials forming the elongate element.

The laminated panel may have any one or more of the features of the laminated panel described with respect to any of the first-third aspects of the invention.

In a fifth aspect, the invention broadly comprises a method of manufacturing or producing a laminated portion or panel for use in a mattress or mattress topper, the method comprising :

cutting or slicing at least two slabs or blocks of different types of resilient materials into multiple sheets;

interleaving and laminating together at least a portion of the sheets of each type into a laminated block comprising a series of different types of sheets; and

cutting or slicing the laminated block into multiple sheets of laminated portions or panels, each laminated panel comprising a laminated series of elongate elements formed of the at least two different types of resilient materials.

In an embodiment, interleaving and laminating together at least a portion of the sheets into a laminated block, comprises laminating a sufficient number of sheets together to form an elongate laminated block having a longitudinal axis.

In an embodiment, interleaving and laminating together at least a portion of the sheets into a laminated block comprising adhering or fixing the sheets together at their respective predominant surfaces.

In an embodiment, the sheets have a similar width and length. In an embodiment, the thickness of the sheets may be uniform or vary based on the type of resilient material. In an embodiment, cutting or slicing the laminated block into multiple sheets of laminated portions or panels comprises cutting or slicing the laminated block in cutting planes that are parallel or aligned with the longitudinal axis of the laminated block.

In an embodiment, cutting or slicing the laminated block into multiple sheets of laminated portions or panels comprises cutting or slicing the laminated block in cutting planes that extend through the block in a direction that is transverse or perpendicular to the adhering surfaces of the sheets.

In an embodiment, the at least two slabs or blocks are elongate, and each have a longitudinal axis.

In an embodiment, cutting or slicing each of the at least two slabs or blocks into sheets occurs transverse to the longitudinal axis of each slab or block.

In an embodiment, the laminated block is elongate and has a longitudinal axis.

In an embodiment, cutting or slicing the elongate laminated block into sheets of laminated portions or panels occurs transverse to the longitudinal axis of the elongate laminated block.

In an embodiment, the method may further comprise applying a coating to the intended upper or contact surface of each laminated panel. In one configuration, the coating may be a phase change material (PCM) coating, and may comprise a phase change material (PCM) component or composition or additive. In one embodiment, the PCM coating may be a PCM solution in liquid form, and the method may comprise spraying, rolling or otherwise applying the PCM solution to the upper or contact surface of the laminated panel. In an embodiment, the method may further comprise allowing the applied PCM solution to set, cure or dry, to generate the final laminated panels with applied top coating.

In one configuration, the PCM coating may be formed in any desired colour or appearance, including by way of example but not exclusively any one of the following: translucent, white, or blue. In some configurations, the PCM coating may further comprise one or more additive particles or granular materials, including but not limited to any one or more of the following : copper particles, silver particles, graphene particles, gel particles, carbon particles, and/or industrial diamond particles. In one embodiment, the method may comprise applying the PCM solution to the intended upper or contact surface of each laminated panel at a surface or area density in the range of approximately 100 to approximately 200 grams/square meter, or approximately 125 to approximately 175 grams/square meter, or approximately 150 grams/square meter.

The laminated panels produced by the method of any embodiment of the fifth aspect may further have any one or more of the features mentioned in respect of the previous first-fourth aspects of the invention.

In a sixth aspect, the invention broadly comprises a method of manufacturing a laminated portion or panel for use in a mattress or mattress topper, the method comprising :

interleaving and laminating together multiple sheets of different resilient materials into a laminated block; and

cutting or slicing the laminated block into multiple sheets of laminated panels, each laminated panel comprising a laminated series of elongate elements formed of the at least two different resilient materials.

In an embodiment, the method may further comprise applying a coating to the intended upper or contact surface of each laminated panel, in accordance with any one or more of the aspects described above with respect to the method of the fifth aspect of the invention.

The method of the sixth aspect of the invention may further comprise any one or more features mentioned in respect of the method of the fifth aspect of the invention.

The laminated panels produced by the method of any embodiment of the sixth aspect may further have any one or more of the features mentioned in respect of the previous first-fourth aspects of the invention.

Each aspect of the invention above may further comprise any one or more of the features of any of the other aspects of the invention.

The term 'comprising' as used in this specification and claims means 'consisting at least in part of'. When interpreting statements in this specification and claims which include the term 'comprising', other features besides the features prefaced by this term in each statement can also be present. Related terms such as 'comprise' and 'comprised' are to be interpreted in a similar manner.

The phrase 'contact surface' as used in this specification and claims is intended to mean, unless the context suggests otherwise, a surface that is the outermost surface or is substantially at or toward the outermost surface of a mattress or mattress topper in ordinary/intended use and which is typically the upper surface of the mattress or topper upon which the end-user lays either directly or indirectly via bedding layers or sheets for example, or alternatively may be a relative term in the context of an individual component of the mattress or topper which is intended to mean the upper surface or surface of a component that is closest to the outermost surface contacted by an end user of the mattress or mattress topper in ordinary/intended use, such as for example the contact surface of the laminated panel component may be the upper surface of the panel that will be closest to the end user during use of the mattress or mattress topper compared to the lower or underside surface of the laminated panel, regardless of whether the upper surface of the laminated panel is or directly forms the outermost surface of the mattress or is close to the outermost surface via one or more other mattress layers.

Terms such as 'first', 'second', 'third' or the like as used in this specification and claims in relation to components or features, unless the context suggests otherwise, are not intended to relate to order or priority or preference, but rather are generally intended as descriptive references to differentiate components relative to each other.

It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range (for example, 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and, therefore, all sub-ranges of all ranges expressly disclosed herein are hereby expressly disclosed. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

As used herein the term '(s)' following a noun means the plural and/or singular form of that noun.

As used herein the term 'and/or' means 'and' or 'or', or where the context allows both. The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only and with reference to the accompanying drawings in which:

Figure 1 is a top view of a mattress or mattress topper in accordance with an embodiment;

Figure 2 is a top view of a mattress or mattress topper in accordance with another embodiment;

Figure 3 is a side view of the mattress or mattress topper shown in Figure 1 or 2;

Figure 3A is a schematic view depicting the topper with laminated panel as a comfort layer on top of a mattress core supported by a bedframe or bed base;

Figure 4 is a perspective view of the mattress or topper shown in Figure 2;

Figure 5 is a perspective view showing a cross section of the mattress or topper in Figure 4 viewed through line AA;

Figure 6 is a perspective view of the mattress or topper shown in accordance with another embodiment;

Figure 7 is a perspective view of a mattress or topper in accordance with another embodiment;

Figures 8A-8F are perspective views of the fabrication process or manufacturing method of a laminated portion or panel of the types shown in Figures 2-6, in accordance with an embodiment;

Figure 9 is a flow chart detailing the method of producing the laminated portion or panel of the types shown in Figures 2-6 following the stages shown in Figures 8A - 8F, in accordance with an embodiment;

Figures lOa-lOm are different views of the fabrication process or manufacturing method of a laminated portion or panel using three different materials as per the panel types shown in Figures 2-6, in accordance with an embodiment;

Figure 11 is a partial sectional view of a laminated portion or panel for a mattress or topper in accordance with another embodiment, the laminated panel shown on an optional foam backing substrate by way of example; and

Figures 12A and 12B show top and perspective views respectively of a mattress or mattress topper in accordance with another embodiment. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Overview

This disclosure relates to a mattress or mattress topper that includes one or more resilient laminated portion or panels, which are configured to assist in body heat dissipation or management of a person or people laying on it. Typically, the person or people are in close contact with the upper surface of the mattress or topper for example with a fitted sheet or comforter between the person or people and the mattress or topper, or the person can be laying directly in contact with the upper surface of the mattress or topper.

The laminated portion or panel(s) may form part of any type of mattress, mattress core, mattress topper or mattress comfort layer. The laminated portion panel(s) may be provided or formed into or onto any type of mattress or mattress core, whether 'inner- sprung', 'pocket spring', foam spring type, or a standard foam type mattress. The laminated panels may also be used as a mattress in their own right if dimensioned accordingly or be provided as a separate product for retro-fitting or laying on top of a mattress.

Typically, a mattress or topper is defined between a head end for receiving the head of a user and a foot end for receiving the feet of a user. The laminated portion or panel(s) are made up of a series of laminated elongate elements. In some embodiments, the elongate elements of the panel each extend in the lengthwise direction of the mattress or topper defined between its head and foot ends. In other embodiments, the elongate elements of the panel each extend in the lateral direction of the mattress between its side edges. In general, the laminated panel may be provided/oriented in a mattress such that elongate elements of the laminated panel may be oriented in any desired direction relative to the longitudinal axis or lengthwise direction of the mattress between its head and foot ends, whether parallel (lengthwise direction), transverse or perpendicular (lateral direction), or any other angular orientation such as, diagonal or otherwise.

The laminate panel(s) are provided where there is need for heat dissipation on or in the mattress or mattress topper. The laminate panel(s) act to absorb and dissipate thermal energy away from an area of the mattress or topper having high thermal energy. Typically, the laminated portion or panel(s) are made up of a series of elongate elements of at least two different types, defined by material properties and/or dimension. In some embodiments, at least a portion or some of the elongate elements are formed of or made from a first resilient material having heat transferal properties which acts to transfer thermal energy from areas of high thermal energy to areas of lower thermal energy, and at least a portion of the elongate elements are formed of or made from second resilient material having heat storage properties and acts to absorb thermal energy from an area of high thermal energy in contact with it. In other embodiments, the laminated panels may be formed of elongate elements of multiple different types, whether three, four, or more different types.

The laminated panels or portions comprise a series arrangement of elongate elements across the panel such that the elongate elements are typically laminated to adjacent elongate elements of different types. Multiple elongate elements are provided across the width of the laminated panel, and the series arrangement may be defined by an alternating, repeating pattern, symmetrical arrangement or other arrangement that produces the desired heat dissipation properties. The series arrangement of elongate elements is intended to create a co-operating relationship between the different types of elements of heat absorption, storage and transport or channelling of the heat toward the upper and/or lower ends or edges of the panel. The laminated arrangement of the panel may operate in a radiator-like manner with one or more persons laying on the mattress, and may also undergo enhanced thermal transport or dissipation when undergoing compression or movement caused by persons moving on the mattress due to a bellows- like effect of enhanced air movement through at least some of the elongate elements, such as those with higher porosity.

In embodiments in which the laminated panel or panel(s) are provided as an integral component of a mattress or topper, the laminated panels are typically provided at or toward the upper or contact surface of the mattress or topper, so as to be proximate to the source of thermal energy in use, namely body heat. In some embodiments, a single laminated panel may be provided in a central portion of the mattress or topper with respect to the length direction of the mattress or topper, which is generally co-incident with a person's core region in use, which tends to generate the most body heat. In other embodiments, two or more laminated panels may be provided in various arrangements relative to each other depending on the desired requirements or user preferences.

In some embodiments, the dimensions of the laminated panels in terms of length and width defining its surface area relative to the contact or upper surface area of the overall mattress or topper may be varied depending on the heat dissipation requirements. In some embodiments, the surface area of the laminated panel may be in the range of between 25%-75% of the mattress surface area, or more preferably between approximately 40-60% of the mattress surface area, or even more preferably about 50% of the mattress surface area. In other embodiments, the surface area of the laminated panel may be about 33% of the mattress surface area. In some embodiments, the width of the laminated panel extends substantially across the entire width of the mattress between its side edges, but may alternatively terminate prior to the side edges in other embodiments.

In some embodiments, the laminated panel or panels may be integrally formed or fixed onto or into a backing substrate. Typically, the backing substrate may be a foam-type substrate. The foam backing substrate may comprise a recess portion or portions for receiving and retaining a respective laminated panel or panels, to form the mattress or mattress component or topper. Typically, the dimensions of the backing substrate and laminated panel are such that the upper or contact surface of the backing substrate is substantially flush with the upper of contact surface of the laminated panel.

In some embodiments, the laminated panel may be or form the upper or outermost surface of the mattress or topper, but in other embodiments the laminated panel may be covered or below one or more other upper layers of material of the mattress or topper such that the laminated panel surface is displaced from or offset below the upper or outermost surface of the mattress or topper. Typically, in many embodiments, the closer the laminated panel is to the upper or outermost surface upon which the end user lays, the better the heat absorption and transferral performance of the laminated panel within the mattress or topper, in ordinary use.

Various example embodiments of the mattress or topper with laminated panel will now be described by way of example only.

First example embodiment of a mattress or topper

In a first embodiment, referring to Figures 1 and 3, the mattress component or topper 10 comprises a first portion or backing or base substrate 12 of resilient material, which, for the purposes of explanation is divided into a first zone 12a, a second zone 12b, and a third zone 12c. Each of these zones are in this embodiment formed from the same piece of resilient material, such as a foam block. By way of example only, the foam block may be foamed polyurethane or polyethylene or foamed latex rubber, and forms a backing substrate for one or more laminated panel 14 inserts. The mattress or topper 10 is defined between an upper or head end or edge 30a and a lower of foot end or edge 30b, and side edges 30c, 30d that extend between the head and foot ends, as shown in Figure 1. The mattress or topper 10 is further defined by an upper or contact surface 30e and an underside surface 30f. The length (LI) dimension of the mattress 10 in the longitudinal direction is defined by the distance between the head and foot ends 30a, 30b, the width (Wl) dimension of the mattress 10 in the latitudinal direction is defined between the side edges 30c, 30d, and the thickness (Tl) of the mattress or topper 10 is defined by the distance between the upper and underside surfaces 30e,30f.

As seen in Figure 3, in this embodiment, a laminate panel or portion 14 of the mattress or topper is positioned intermediate the first zone 12a and the second zone 12b, and above the third zone 12c of the first portion 12 relative to the length or longitudinal dimension of the mattress or topper defined between the head 30a and foot 30b ends. In this embodiment the laminated panel 14 is positioned so as to extend substantially across a central third region or zone of the mattress or topper 10. Alternatively, the laminated panel or panels 14 may be positioned anywhere on the mattress or topper 10 requiring dissipation or management of body heat.

The laminated panel or portion 14 is defined between upper 40a and lower 40b edges or ends, and side edges 40c, 40d that extend between the upper and lower ends of the panel, as shown in Figure 1. The laminated panel 14 is further defined by an upper or contact surface 40e and a lower or underside surface 40f. The length (L2) dimension of the panel 14 in the longitudinal direction is defined by the distance between the head and foot ends 40a, 40b, the width (W2) dimension of the panel 14 in the latitudinal direction is defined between the side edges 40c, 40d, and the thickness (T2) of the panel 14 is defined by the distance between the upper and underside surfaces 40e,40f.

In this embodiment, the laminated panel or portion 14 runs substantially across the width of the mattress or topper 10, such that the width of the laminated panel or portion 14 is substantially the same as the width of the mattress or topper 10. Alternatively, the width of the laminated panel or portion 14 may be less than the width of the mattress or topper 10 in alternative embodiments.

The laminated panel or portion 14 in this embodiment comprises a series of resilient elongate elements, each being made from one of at least two different materials 16 and 18, such that the laminated panel comprises some elongate elements of a first resilient material 16 and some elongate elements formed of a second resilient material. As shown, in this embodiment, the laminated panel 14 is oriented with respect to the mattress or topper 10 such that series of elongate elements extend in the lengthwise direction of the mattress or topper defined between the head and foot ends 30a, 30b of the mattress or topper, as seen in Figures 1 and 2. In particular, the longitudinal axes of the elongate elements 16,18 (defined between their respective ends) are oriented to be parallel to the side edges 30c, 30d or longitudinal axis of the mattress or topper extending between its head and foot ends 30a, 30b.

The laminated series arrangement of resilient elongate elements of different types in the laminated panel 14 is configured to transport or channel heat along the longitudinal axes of at least some of the elongate elements to thereby dissipate thermal energy toward the periphery of the laminated panel toward its upper 40a and lower 40b edges (which are co-incident with and/or defined by the ends of the elongate elements). In use, this transports or dissipates heat away from the user's core, which is the primary body heat source of most intensity.

In this embodiment, the elongate elements of the panel 14 all have a substantially rectangular or square cross-sectional profile along their length, but this profile or shape may be varied in alternative configurations as will be appreciated by a skilled person.

In this embodiment, the elongate elements each have a uniform width (co-incident with the width dimension W2 of the panel) and length (co-incident with the length dimension L2 of the panel) and thickness (co-incident with the thickness dimension T2 of the panel), and thus form a substantially consistent rectangular structure, as seen in Figures 1 and 2. However, it will be appreciated that the elongate elements in the laminate panel may be configured with varying or non-uniform dimensions in any of the length, width and/or thickness dimensions, to create alternative shaped panels and/or to vary the heat dissipation or performance of the panel. Varying the dimensions of one type of elongate element relative to the other elements enables the overall material composition of the panel to be varied and/or the interaction between the elements of the panel.

In some alternative examples, an aspect or aspects of dimension of one type of elongate element may be selectively varied relative to the other type or types of elongate elements to control the nature of the heat dissipation or performance characteristics of the panel. By way of example only, the width of one type of the elongate elements might be configured to be different to the width of another type of the elongate elements in the panel to create a particular heat absorption and dissipation characteristic for the laminated panel. It will be appreciated that the upper 40a, lower 40b, and side edges 40c, 40d of the laminated panel may be straight as shown, or alternatively may be curvilinear, profiled, stepped, curved, undulating or any other desired edge profile by cutting the panel edges as desired and/or forming the panel with varied length elongate elements. Likewise, the contact and/or underside surface of the panel may be uniform or flat, or alternatively may be undulating or non-uniform across the surface or portions of the surface if desired, via cutting or varying the thickness dimensions of selected elongate elements as desired.

Referring to Figure 3A, in this embodiment, the laminate panel 14 forms part of a topper or comfort layer 10 provided or integrally fixed on the upper surface of a mattress core 11, which is typically in use installed or placed on a bedframe or bed base 13. The mattress core 11 may be of any type, which may be inner-sprung, pocket-spring, foam spring type, or foam mattress with single or multi-layered foam. The topper or comfort layer 10 may have one or more additional comfort layers above or below it, as will be appreciated. Typically, the laminated panel 14 is provided at or near the contact or outermost surface of the finished mattress product comprising the core and one or more comfort layers or toppers, so that it is close to the body heat source in us, although this is not essential in all embodiments.

As mentioned, it will be appreciated that the laminated panel may be provided as a mattress itself if made of sufficient dimensions, or the topper 10 comprising the resilient backing substrate in combination with the laminate panel may be used or provided as a mattress for lying on in its own right.

Elongate element arrangement

As seen in Figure 1, in this embodiment the series of elongate elements are arranged in a repeating or alternating pattern, with an elongate element of a first material 16 followed by at least an elongate element of a second different material 18. This pattern repeats along the width of the mattress or topper 10 from one edge to the other to form the series across the width W2 of the laminated panel 14. In this embodiment the series along the width W2 of the laminated panel allows for the different characteristics of the elements of the first material 16 and the elements of the second different material 18 to work together to transfer heat away from the core of the body of a user who is laying on the mattress or topper 10, as will be explained further below. It will be appreciated that in alternative arrangements, the series arrangement need not be a repeating pattern of different types of elongate elements, but could be a randomised series, symmetrical series relative to the center of the panel, or some other arrangement, sequence or ordering that provides for dissipation of heat when the elongate elements synergistically work or interact together. Typically, the series arrangement provides that each elongate element is adjacent an elongate element or elements (e.g. on both sides) of a different type, the type typically defined by the material of the element but could additionally or alternatively be defined with respect to its dimension or shape.

In this embodiment, and referring to Figure 3, the thickness T2 of the laminated portion or panel 14, and therefore the thickness of each elongate element in the panel is such that the combined thickness of the laminated portion or panel 14 combined with the thickness of third zone 12c (receiving recess) of the base substrate 12 is such that the upper surface 40e of the laminated panel is substantially flush with the surrounding upper surface 30e of the base substrate in zones 12a and 12b.

Function of different materials

In this embodiment, the arrangement of the first material 16 and the at least a second different material 18 in a series arrangement to form the laminated portion or panel 14 acts to absorb thermal energy from the core of a body of a person or bodies of people laying (directly or indirectly via bedding) on the mattress or topper 10, and to transfer this thermal energy away from the core of the body or bodies and towards the extremities or peripheral upper and lower edges of the panel in a radiator like function. The series arrangement of the elongate elements within the laminated portion or panel 14 as well as the structures of the different materials making up the laminated portion or panel 14 allow for thermal energy to be dissipated, as will be explained below. As shown the laminated panel is configured such that the heat is transported to and dissipated at the upper and lower edges 40a, 40b of the laminated panel into or toward the head 12a and foot 12c regions or zones of the mattress surface. For example, the laminated panel is configured within the mattress to draw or transport heat away from a person's body core toward their head and/or feet when a person is laying on the mattress.

In this embodiment, the elongate elements in the laminated portion or panel 14 formed from the second material 18 function to absorb thermal energy from an area of high thermal energy in direct or close contact with it. Thus, when a body of a person is in close or direct contact with the mattress or topper 10, for example through a fitted sheet or other bedding or additional layer, the elongate elements in the laminate portion or panel formed from the second material 18 act to draw thermal energy away from the body of a person as the body has a higher amount of thermal energy. In this embodiment the elongate elements of the second material 18 are made from a resilient material with specific characteristics for absorbing and storing thermal energy. These characteristics allow the elongate elements of the second material 18 to absorb and store thermal energy, drawing it away from the core of the body of the user. By way of example only, the second material 18 may be a viscoelastic and/or low response foam. Optionally the viscoelastic and/or low response foams may comprise an additive material or materials such as, but not limited to, gel beads, carbon elements, and/or industrial diamonds.

In this embodiment, the elongate elements in the laminated portion or panel formed from the first material 16 act to dissipate, move, channel and/or transport thermal energy from areas of high thermal energy to areas of lower thermal energy in the material or elongate element. Therefore, the elongate elements of the first material 16 act to transfer thermal energy that has been drawn away from the body of a person or bodies of people on the mattress or topper by the adjacent elongate elements of the second different material 18, and dissipate this thermal energy towards the head and/or feet of the mattress or topper 10. This allows the thermal energy collected by each of the elongate elements of the second material 18 to be channelled or funnelled through each of the elongate elements of the first material 16 towards areas of lower thermal energy in the mattress or topper such as first zone 12a and second zone 12b of the base substrate, which are located at the head and foot of the user when in a traditional sleeping position. By way of example only, the first material 16 may be a foamed polyurethane or polyethylene or foamed latex rubber. In some embodiments, the base substrate 12 may be of the same material as the first material 16.

In this embodiment, the elongate elements 18 of the second material can be considered primarily heat absorption elements and the elongate elements 16 of the first material can be considered primarily heat transport elements. The laminated configuration effectively forms clusters of heat absorbing and dissipating formations, whereby each heat transport element 16 draws and transports heat away (toward the upper and lower edges of the panel and/or toward the underside surface of the panel) from its adjacent heat absorbing elements 18 on either side.

The elongate elements in the laminate portion or panel formed from the first material 16 act to transfer thermal energy along the length of each elongate element and away from the core or high thermal energy portion of the body of a person laying on the mattress or topper 10. In some embodiments the elongate elements of the first material 16 act to transfer heat out of the laminated portion or panel 14 of the mattress or topper 10 and into the backing substrate 12. Additionally or alternatively, in some embodiments the elongate elements of the first material 16 act to transfer heat to areas of lower thermal energy within the laminated portion or panel 14 itself. This transfer of heat can be along the length of each elongate element of the first material 16, towards the first zone 12a and/or the second zone 12b, and/or downwards towards the third zone 12c. In this embodiment each of the elongate elements of the first material 16 is made from the same resilient material as the base substrate 12 of the mattress or topper 10, although this is not essential. The first resilient material 16 in this embodiment has good or higher (relative to the other types of elements in the panel) porosity which allows heat to move easily from areas of higher temperature in the material to areas of lower temperature. Alternatively, each of the elongate elements of the first material 16 is made from a different resilient material as the base substrate 12, but still having a structure or properties allowing thermal energy to be dissipated within it.

In this embodiment, each of the elongate elements of the first material 16 and the second material 18 when formed in the series arrangement act in combination to absorb and dissipate thermal energy away from an area of the mattress or topper having high thermal energy, and to an area of the mattress or topper having a lower thermal energy. The properties of elongate elements of the second material 18 allow it to absorb thermal energy from a thermal source such as the body of a user who is in direct or close contact with the laminated portion or panel, specifically the core of the body of the user which is warmer than the other parts of the body and is prone to overheating. The properties of the second material 18 also allow it to store this thermal energy within its structure.

In this embodiment, each of the elongate elements of the first material 16 and second material 18 are in contact in an arrangement such as a series or pattern, extending in the lengthwise direction of the mattress or topper 10 defined between the head and foot ends of the mattress or topper 10. In this embodiment the properties of the second material 18 as described above allow it to draw thermal energy away from a body in direct or close contact with it, such as through an additional layer or bedding such as a fitted sheet. In this embodiment the elongate elements of the second material 18 are in physical contact with the elongate elements of the first material 16, and so as one or more elongate elements of the second material 18 absorb and store thermal energy, one or more of the elongate elements of the first material 16 in contact with the one or more elongate elements of the second material 18 begin to increase in thermal energy at the point of contact of the two elongate elements. The properties of the first material 16 allow it to transfer this thermal energy from the area of contact with the body of a user, which will have a higher level of thermal energy, to other areas along the length of the elongate element which have a lower thermal energy level. In this way, the thermal energy from the body of the user on the mattress or topper 10 is distributed away from the area of higher thermal energy and towards areas having a lower thermal energy level such as the head or the feet of the user which are located in the first zone 12a and second zone 12b of the first portion respectively. This helps to regulate body temperature for users sleeping on the mattress or topper 10.

In this embodiment, each of the elongate elements of the first material 16 and the second different material 18 comprising the laminated portion or panel are connected, fixed or laminated together. Each elongate element arranged in the series making up the laminated portion or panel is laminated in physical contact with the elongate element either side of it. In this embodiment, each of the elongate elements are fixed or laminated together with an adhesive.

In some embodiments each of the elongate elements are fixed or laminated together with an adhesive that optionally includes a phase change material (PCM) component or composition. PCM added to the adhesive may, in some configurations or embodiments, allow thermal energy to more effectively transfer from the elongate elements of the second material 18 to the elongate elements of the first material 16. In such embodiments, adhesive with added PCM may serve the function of storing and releasing large amounts of thermal energy, so that the thermal energy absorbed from the body of the user laying on the bed by the elongate elements of the second different material 18 is able to transfer into the elongate elements of the first material 16 in contact with the elongate elements of the second material 18 absorbing and storing thermal energy so that the heat can be dissipated as previously described. In an alternate embodiment, PCM-based elongate elements could be provided as additional elements between each of the elongate elements of the first and second materials, such that the series arrangement comprises three different types of elongate elements, in a repeating pattern across the panel.

In other embodiments, the elongate elements may be fixed or laminated together with any suitable adhesive. In some configurations, the connection or lamination can be achieved using thermal adhesives, or adhesives with specific thermal absorption or transferal properties, or any other standard or conventional or standard adhesives may also be used as will be appreciated by a skilled person.

In this embodiment the laminated portion or panel 14 is connected or laminated to the base substrate 12 on both the underside, where the second portion 14 contacts the third zone 12c, and at each upper 40a and lower 40b end where contact with the first 12a and second 12b zones occurs. In some embodiments, the laminated portion or panel 14 is connected or laminated to the first portion 12 at one or more of these points using the same adhesive used to laminate the elongate elements together, or alternatively any other suitable type of adhesive.

In this embodiment, the first zone 12a and the second zone 12b of the base substrate 12 have an equivalent surface area. In alternative embodiments, it will be appreciated that the first zone 12a and second zone 12b may alternatively be of different surface areas. It will also be appreciated that the first zone 12a, the second zone 12b and the third zone 12c of the base substrate 12 may alternatively be made from different types of resilient material and may be fixed or connected together using methods as described above relating to the connection of the first portion 12 to the laminated portion or panel 14 rather than being formed from a single piece or block of resilient material as described in the first embodiment.

In this embodiment the laminated panel 14 is positioned centrally or in a central region of the mattress or topper 10, for example the laminated panel may cover a central third of the upper surface area. Alternatively, the laminate panel 14 may be positioned and/or dimensioned as desired such that one or multiple laminated panels may be provided and the ratio of the surface area of the laminated panel relative to the surrounding base substrate may be varied to suit design and/or user requirements or preferences regarding cost and/or dissipation or management of body heat.

In one embodiment, the first zone 12a and second zone 12b of the first portion are made from a first resilient material such as that previously described, while the third zone 12c is made from a different material, having high or higher porosity relative to zones 12a, 12b. The material of the third zone 12c aids in air-flow beneath the elongate elements of the laminated portion or panel 14 and acts to vent the heat from the vertical layers or elongate elements of the panel and aid in facilitating the cooling action.

In an alternate embodiment, the third zone 12c or recess of the base substrate may not be present, and the first zone 12a and the second zone 12b may be physically separated by the laminated panel 14. By way of example, the first and second zones 12a, 12b may be connected or fixed to the laminated panel 14 at its upper and lower edges 40a, 40b, using adhesive as previously described or using any other suitable fixing method.

The width and length dimensions of the mattress or topper 10 may be selected to suit different typical sizes of beds. The length is typically approximately 2030mm but could be varied as desired, and the width could be any of the following standard widths or size chart:

• Long single - approximately 910mm

• King single - approximately 1070mm

• Double - approximately 1370mm

• Queen - approximately 1530mm

• King - approximately 1670mm

• Super King - approximately 1830mm

• California King - approximately 2000mm

In one embodiment, the width of each elongate element is preferably in the range of approximately 5mm to approximately 150mm, more preferably in the range of approximately 30mm to approximately 100mm, and even more preferably approximately 60mm. The thickness of the elongate elements is preferably in the range of approximately 5mm to approximately 150mm, more preferably in the range of approximately 30mm to approximately 100mm, and even more preferably approximately 50mm. The length of the elongate elements is preferably in the range of approximately 500mm to approximately 2100mm, for example in the embodiment relating to Figure 6, and is even more preferably approximately 1000mm in the embodiments relating to Figures 1-5 and 7. It will be appreciated that the width, height, and length of each elongate element in the laminated portion or part may be different.

Further examples of the laminated panel and/or mattress or topper will be explained below.

Second example embodiment of a mattress or topper

Figures 2-5 show another embodiment of the mattress or topper 10 having a laminated panel 14a formed of three different types of elongate elements, each element formed of one of three different materials. As will be appreciated, the various aspects and alternatives of the first example embodiment also apply to this embodiment, but have not been repeated for brevity.

In this embodiment the elongate elements of the first material 16 in the panel 14a are equivalent to the elongate elements of the first material 16 as defined in the panel 14 of the previous embodiment, in both function and structure. This first material 16 is a resilient material having good or higher relative porosity to dissipate and move thermal energy. The elongate elements of the first material 16 act to transfer thermal energy from areas of high thermal energy to areas of lower thermal energy along the length of each elongate element. The elongate elements of the first material 16 are therefore able to move heat away from the core of the body of a person laying in close or direct contact with the mattress or topper 10, towards their head and/or feet.

In this embodiment each of the elongate elements of the first material 16 is made from the same resilient material as the base substrate 12 of the mattress or topper 10. By way of example only, the resilient material of the first material 16 may be from a foam block, and may be a foam such as foamed polyurethane or polyethylene or foamed latex rubber. The resilient material in this embodiment may have high porosity which allows heat to move easily from areas of higher temperature within the material to areas of lower temperature, thus allowing optimal distribution of thermal energy away from the core of the user to areas of lower temperature within the mattress or topper.

The elongate elements of the first material 16 act to transfer thermal energy out of the laminated portion or panel 14a of the mattress or topper 10 and into the first portion 12. This transfer of thermal energy can be along the length of each vertical layer of the first material 16, towards the first zone 12a and/or the second zone 12b, and/or downwards towards the third zone 12c.

In this embodiment, similarly to the previous embodiment, the laminated portion or panel 14a also comprises elongate elements of a second material 20. However, this embodiment of the laminated panel 14a also includes further elongate elements of a third different material 22, having different properties to the first and second materials. The elongate elements of the second material 20 and elongate elements of the third material 22 function similarly to the elongate elements of the second material 18 in the first example panel 14 embodiment. By way of example, each of the elongate elements of the second material 20 and third material 22 are made from a resilient material with specific characteristics for absorbing and storing thermal energy. These characteristics allow the elongate elements of the second material 20 and elongate elements of the third material 22 to absorb thermal energy from an area of high thermal energy in close or direct contact with it and then store this thermal energy. This allows the elongate elements to draw heat away from the body of the user who is laying on the mattress or topper, and store this heat.

By way of example, the elongate elements of the second material 20 or the third material 22 may be a viscoelastic and/or low response foam. The viscoelastic and/or low response foams may optionally further comprise an additive material or materials such as, but not limited to, gel beads, carbon elements, and/or industrial diamonds. By way of example, the second and third materials may be selected from foams of any of the following brand types:

• Graphene

• Fusion Gel

• Fusion Gel ⁺

• LR Foam

• Memory Foam

• Genius

• Energex

As noted above, in this embodiment the elongate elements of the second material 20 are formed from a different material than the elongate elements of the third material 22, such that the laminated panel 14a in this second example embodiment comprises a mixture of three different elongate element material types.

As will be appreciated by the above, in this embodiment the elongate elements of the first material 16, the elongate elements of the second material 20, and the elongate elements of the third material 22 when formed in a side-by-side laminated series arrangement such as that described above, function similarly to as that described in the first example embodiment. The elongate elements of the first material 16, second material 20, and third material 22 when formed in a series arrangement act in combination to absorb and dissipate thermal energy away from an area of the mattress or topper having high thermal energy, and to an area of the mattress or topper having a lower thermal energy. The properties of the second material 20 and the third material 22 allow these materials to absorb thermal energy from a thermal source such as the body of a user who is in close or direct contact with the elongate elements, or specifically the core of the body of the user which is warmer than the other parts of the body and is prone to overheating. The properties of the second material 20 and the third material 22 also allow it to store this thermal energy within its structure.

As seen in Figures 2-5, in this embodiment the series of elongate elements are arranged in a repeating pattern, with an elongate element of a first material 16 followed by at least an elongate element of a second different material 20, which is then followed by at least an elongate element of a third different material 22. This pattern repeats along the width of the mattress or topper 10 from one edge to the other to form the series. In this embodiment the series along the width of the mattress or topper allows for the different characteristics of the first material 16 and the second different material 20 and third different material 22 to work together to transfer heat away from the core of the body of a user who is laying on the mattress or topper 10, as explained in regard to the previous embodiment. It will be appreciated that in alternative embodiments the series arrangement may be non-repeating, symmetrical or some other sequence or ordering of the different type of elongate elements with respect to each other across the width of the laminated panel. The frequency of occurrence or pattern density of each different type of elongate element across the laminated panel may also be uniform or different. For example, one or more different types of elements may be present in the pattern at a higher frequency that other types of elements.

In this embodiment elongate elements of the first material 16, elongate elements of the second material 20, and elongate elements of the third material 22 are in contact in a series arrangement in the laminated panel 14a. The properties of the second material 20 and third material 22 as described above allow them to draw thermal energy away from a body in contact with it. The second material 20 and third material 22 are in physical contact with the first material 16, and so as the second material 20 and third material 22 absorbs and stores thermal energy, the first material 16 begins to heat at the point of contact with the second material 20 and the third material 22. The properties of the first material 16 allow it to transfer this thermal energy from the area of contact, which will have a higher level of thermal energy, to other areas along its length which have a lower thermal energy level. In this way, the thermal energy from the body of the user on the mattress or topper 10 is distributed away and towards areas having a lower thermal energy level such as the head or the feet of the user. This helps to regulate body temperature for users sleeping on the mattress or topper 10.

In this embodiment in the series arrangement as described, the elongate elements of the first material 16 and the elongate elements of the second different material 20 and third different material 22 are connected or laminated together as per the previous embodiment with an adhesive. In one embodiment, the adhesive may optionally comprise a phase change material (PCM) or composition to enhance heat transfer between the laminated elongate elements. Alternatively, any suitable conventional or other adhesive for laminating or fixing foam materials together may be used. The laminated portion or panel 14a is also connected or attached to the first portion 12 of the mattress or topper as per the previous first example embodiment.

Further example embodiments and/or alternative configurations of the laminated panel and/or mattress or topper In some embodiments, the laminated panels of the previous embodiments are provided with an optional top coating on the upper or contact surface of the laminated panels. In one configuration, the coating is a phase change material (PCM) coating, such as a coating comprising a phase change material (PCM) component or composition or additive. In one embodiment, the PCM coating may be a PCM solution in liquid form that is sprayed, rolled or otherwise applied to the upper or contact surface of the laminated panel, and which is then allowed to set, cure or dry or is otherwise actively cured or dried using heating, fans or similar, to complete or finish the panel.

The PCM coating applied to the laminated panel may be or have any desired colour or appearance, including by way of example but not limited to any one of the following: translucent, white, or blue. In some configurations, the PCM coating or solution may further comprise one or more additive particles or granular materials, including but not limited to any one or more of the following : copper particles, silver particles, graphene particles, gel particles, carbon particles, and/or industrial diamond particles.

In one embodiment, the PCM solution is applied to the intended upper or contact surface of the laminated panel at a surface or area density in the range of approximately 100 to approximately 200 grams/square meter, or approximately 125 to approximately 175 grams/square meter, or approximately 150 grams/square meter.

It will be appreciated that the PCM solution or coating may be applied either before the laminated panel is assembled into the mattress or topper, or when it is in situ within the mattress or topper of the embodiments shown in Figures 1-5. Likewise, the PCM solution may either be exclusively or primarily applied to the contact surface of the laminated panel only or additionally also applied to surrounding surface areas of the contract surface of the mattress or topper such as in the 12a, 12b zones.

In the configuration of Figure 6, which shows a full-length laminated panel 14b, the PCM solution or coating may be applied to the entire contact surface or at least a portion of the contact surface, such as a central region of the contact surface that is likely to be aligned with an end user's core region when in use.

It will be appreciated that the PCM solution or coating may also be applied to other surfaces of the panel such as, for example, the underside surface and/or side and end peripheral surfaces if desired. The PCM solution or coating on the upper or contact surface of the laminated panel, in some embodiments, further assists or enhances the heat transferal from the end user into the elongate elements of the laminated panel, which further function to absorb and dissipate the heat as previously described.

Laminated panel formed with two different types of elongate elements

Reverting to the embodiment of Figure 1, the laminated portion or panel 14 may comprise elongate elements of only a first material 16 and a second different material 18, as previously described. As described, the first material 16 is equivalent to the resilient material such as polyurethane foam or any of the examples described in the previous example embodiments. Additionally, it will be appreciated that the second material 18 may be equivalent to either the second material 20 or the third material 22 as defined in the second example embodiment relating to Figures 2-5. The elongate elements of the second material 18 in this embodiment act to draw thermal energy away from the core of a user and store it within the material. The elongate elements of the first material 16 in this embodiment act to move the thermal energy stored within the second material away from the core of the user to areas of lower temperature within the mattress or topper. The elongate elements of the first and second material may be arranged in a repeating pattern as described and shown with respect to the first example embodiment. A PCM adhesive may connect or adhere the elongate elements together.

In a further embodiment or configuration, the elongate elements 16,18 of the laminated portion or panel 14 are laminated together using a standard adhesive or glue, which may have little or no thermal energy storage or dispersal properties. The elongate elements of the first material 16 and the elongate elements of the second different material 18 are connected or laminated together such that each layer is in physical contact with the elongate elements on either side of it. Alternatively, it will be appreciated that other forms of connection means are possible for attaching or fixing the elongate elements of the different materials together. It will also be appreciated that in some alternative embodiments no attachment means may be necessary, and the elongate elements of the different materials may be held in place by an over sheet, or a solid or fabric sleeve or casing surrounding either the whole of the mattress or topper, or just the laminated portion or panel 14. As a further alternative, the elongate elements maybe provided adjacent each other in an abutting arrangement, and each fixed in place in the panel structure via an adhesive that fixes each element to a common backing substrate 12, without any additional adhesive required between the abutting surfaces of the elongate elements, i.e. each elongate element is fixed or adhered to a common backing substrate 12 without being adhered to each other. Laminated panel forming entire mattress or topper

Referring to Figure 6, in another further example embodiment, the elongate elements of the laminated portion or panel 14b may run the whole length of the bed, such that a base substrate or first portion 12 as shown in the first and second example embodiments of Figures 1-5 is not necessary and does not form part of the embodiment. In effect therefore, the elongate elements of the laminated portion or panel 14b in the embodiment of Figure 6 run the full length of the mattress or topper, from the top/head end to the bottom/foot end of the bed or mattress. Figure 6 shows a full-length laminated panel 14b of the type shown in the embodiment of Figures 2-5 which is formed by a pattern of three different types of elongate elements, although it will be appreciated that full-length laminated panel 14b of the type shown in Figure 6 may be formed from two or more different types of elongate elements.

Laminated panel with non-uniform pattern density

The laminated panels 14, 14a, 14b in the prior embodiments are configured with a substantially uniform pattern density in that each type of elongate element repeats with the substantially the same frequency across the laminated panel, i.e. there are approximately an equal number of different types of elements.

In other embodiments, the laminated panel may be configured with a varying pattern density with respect to the different types of elongate elements. For example, one or more of the different types of elements may occur more or less frequently in the panel than other types of elements, i.e. there may be more or less of some types of elements than other types of elements. By way of example, the embodiment of the laminated panel 14c in Figure 7 demonstrates this showing the first type of elongate element 16 has a higher frequency or pattern density relative to the two other types of elongate element 20,22. In particular, there are approximately double the elongate elements 16 relative to either of the other types of elements 20 or 22, with the elongate elements 16 having about twice the frequency of occurrence in the pattern relative to the other types of elements. As shown, in this particular configuration, elongate element 16 occurs every second element, whereas elongate elements 20 and 22 occur every fourth element in the pattern. These non-uniform pattern densities can be varied as desired to generate the desired laminated panel characteristics based on various factors including, but not limited to, heat dissipation characteristics, overall panel comfort or hardness or density characteristics, and/or cost requirements.

Laminated panel with 4 different types of elongate elements Figure 11 shows one example of a laminated panel 130 on a backing substrate 132, in a similar configuration to the embodiments described with respect to Figures 1-5. In this embodiment, the laminated panel is provided with more different types of elongate elements. In particular, the laminated panel 130 is provided with four different types of elongate elements 134,136,138,140.

Mattress or topper with laterally oriented laminated panel or panels

The previous embodiments described relate primarily to a laminated panel or panels that are configured with elongate elements that are intended to be oriented in the lengthwise direction of the mattress or topper or which extend in the longitudinal direction defined from the head end to the foot end of the mattress or topper.

Referring to Figures 12A and 12B an alternative embodiment of the laminated panel 14d is shown in which the elongate elements extend in a lateral direction across the mattress or topper between its sides. Like reference numerals represent like components. Laminated panel 14d is of similar construction to the previous embodiments, except its orientation with respect to the mattress is different. As shown the mattress or topper 10 is provided with a laminated panel 14d in which the series of laminated elongate elements 16,20,22 making up the panel each extend in a lateral or sideways direction (i.e. a direction that is transverse or perpendicular to the lengthwise direction between the head and foot ends) extending between the sides 30c, 30d of the mattress. In other words, the laminated panel 14d is laterally or horizontally oriented with respect to the mattress or topper 10 such that the longitudinal axis of each elongate element extends in a direction that is parallel or aligned with the upper 30a and lower 30b edges of the mattress 10.

In this embodiment, the laminated panel 14d operates in a similar manner to the other embodiments, although the direction of primary heat transfer or transportation or dissipation may differ. For example, this lateral configuration of the elongate elements causes at least some of the heat absorbed by the panel to be dissipated or transported in a lateral direction away from a person's core laying on the mattress toward the sides or side edges of the mattress. In particular, the lateral configuration of the panel is such that at least some heat or thermal energy is directed laterally along the longitudinal axes of at least some of the elongate elements toward their ends, which are located at or toward the side edges of the mattress.

It will be appreciated that the lateral orientation of the laminated panel 14d may be applied whether the panel is a part or component of a mattress or topper, such as forming a central or other zone of a mattress with respect to a backing substrate 12 as shown, or in the context of forming a full-length panel of the type shown and described with respect to Figure 6. It will also be appreciated that a mattress or topper may be provided with a combination of both one or more 'lengthwise' orientated laminated panels and one or more 'laterally' oriented laminated panels, in one or more zones or areas of the mattress, if desired.

It will be appreciated that any of the variations, features, materials, configurations or other aspects described with respect to the previous 'lengthwise' oriented laminated panels also either apply or may be adapted for the 'laterally' oriented laminated panel configurations. Likewise, the manufacturing methods and embodiments described below in respect of the laminated panels intended for a 'lengthwise' configuration also either apply or may be adapted to produce laminated panels intended for a laterally oriented configuration. As will be appreciated, the fundamental construction of the laminated panels is the same. However, the intended orientation of the panel with respect to the overall mattress or topper will dictate the dimensional aspects of the panel during manufacture.

Other example embodiment configurations

It will be appreciated that the various aspects, features, configurations and alternatives of the each of the above example embodiments may be applied or combined with any of the other described embodiments above or below. For example, it will be appreciated that the aspects, features and alternatives of the above embodiments may be applied to any type of laminated panel, whether it comprises elongate elements of two, three, four, more different types.

Example methods of manufacture of the laminated panels

Figures 8A-8F and Figures lOa-lOm detail embodiments of the different stages of fabrication for producing the laminated portion or panel 14a of the mattress or topper described in relation to the second example embodiment in Figures 2-5 above which comprises three different types of elongate elements, although it will be appreciated that a similar process or manufacturing principles may be adapted and/or applied to produce the laminated panels of the other example embodiments 14, 14b, 14c, 14d or the variations described. Figure 9 shows a flow chart of the process with reference to Figures 8A-8F and lOa-lOm.

First example manufacturina method Referring to Figures 8A-8F and the process shown in Figure 9, the first step 90 requires a slab or block of a resilient material, either the first, second or third material. Figure 8a shows a slab 80 of such material 82, which is in this example equivalent to the first material 16 in the embodiments above, such as foamed polyurethane or polyethylene or foamed latex rubber. The slab of first material 80 has a width 81, height 83, and length 87. Similar respective slabs of a second material and a third material, and any further materials making up the elongate elements of the desired laminated panel are also prepared or provided, but not shown. The slab 80 of first material 82 as shown in Figure 8a has a length 87 and a longitudinal axis AA running parallel to its length.

The slab 80 or block of resilient material is then sliced or cut into sheets transverse to its longitudinal axis AA at step 91. Each of the sheets having substantially the same thickness. The result of this is shown in Figure 8B, which shows the slab or block 80 from Figure 8A after being cut into sheets 84 transverse to the longitudinal axis AA. Each of the sheets has the same width 81 and height 83 as the block or slab 80 of resilient material. This process is repeated with the slabs or blocks of the second and third resilient materials and any further resilient materials making up the elongate elements of the laminated portion or panel. In this embodiment, the height and width of these further sheets of resilient material is the same as width 81 and height 83. The thickness of the sheets may be uniform across the different types of resilient material, or varied, depending on the dimension of the end elongate elements required within the laminated panels. The result of this slicing process is to generate three stacks of uniformly sized (with respect to at least width and height) sheets of the three different materials, i.e. three stacks of different types of foam sheets, in this embodiment.

The individual sheets 84 of the first resilient material are then interleaved with, layered or sequenced and then connected or adhered to the individual sheets 86,88 of the other second and third resilient material or materials in a repeating layered pattern as previously described at step 93, and with reference to Figures 8C and 8D, to form a new laminated slab or block 85. Figure 8C shows a partially formed laminated slab of sheets, and Figure 8D shows the full new laminated slab or block 85. The widths and lengths of the different individual sheets 84,86,88 being laminated, connected or adhered together are aligned to keep the orientation of the resilient materials consistent and thus preserve the properties of the material(s). The number of repetitions in the pattern is determined by the desired width of the final mattress or topper and/or the desired width of the laminate panels required, as the width of the mattress or topper and/or the laminated panel will be determined by the combined length of the individual sheets connected or adhered together in the newly formed laminated slab 85. As described above, the laminated sheets 84,86,88 of the different desired resilient materials forms a laminated slab or block 85 of layered sheets of resilient materials which are laminated together, as shown in Figure 8D. The laminated slab or block 85 has a length 89 and a longitudinal axis AA running parallel to its length. The laminated slab or block 85 is then cut or sliced into further sheets lengthways at step 95, in cutting planes that are co-incident, aligned or parallel to the longitudinal axis AA of the laminated slab 85 as shown in Figure 8E. The laminated slab or block 85 is cut or sliced into numerous individual sheets 97 which are in the sequence or pattern required of the desired end laminate portions or panels of the mattress or topper in the desired dimensions and pattern of materials as described in regard to the laminated panel 14a embodiment in Figures 2-5. For example, Figure 8F shows one of the laminated panels 97 or sheets sliced from the laminated block 85.

It will be appreciated that the thickness 92 of the laminated panels 97 sliced from the laminated block 85 may be uniform if being used for similar end mattress or topper products, or that different thickness laminated panels 97 may be sliced from the laminated block 85 if required or desired.

It will be appreciated that the laminated panels 97 may then be assembled or fixed to a backing substrate 12 as described and shown with respect to the embodiment of Figures 2-5, or otherwise assembled as a component into a mattress or topper. Additionally, an optional PCM coating may be applied to the laminated panels as previously described.

It will be appreciated that the manufacturing method above includes any of the materials described in respect of the embodiment of Figures 2-5 and other embodiments described, and can also be adapted to produce any of the alternative configurations of the laminated panels described.

Second example manufacturing method

Similar to the first example manufacturing method, Figures lOa-lOm further demonstrate the fabrication process or method of manufacture of a laminated panel 14a in relation to the second example embodiment of Figures 2-5 described above, which comprises a laminated panel 14a having three different types of elongate elements, although it will be appreciated that a similar process may be applied or adapted to produce the laminated panels of the first example embodiment which comprises two different types of elongate elements, or any of the other laminated panel embodiments of alternatives described. In this embodiment, a rectangular slab or block of a first resilient material 102 is shown in Figure 10a, this slab or block is then oriented as shown in Figure lOd to start the process. A slab or block of a second resilient material 106 is shown in Figure 10b, similarly, this slab or block is then oriented as shown in Figure lOe to start the process. A slab or block of a third resilient material 106 is shown in Figure 10c, this slab or block is also oriented as shown in Figure lOf to start the process.

Similar to the manufacturing embodiment described in relation to Figures 8a-8f, each slab or block of each material has a width, height, and length. The first block or slab 108 as shown in Figure lOd has a length 109 and a longitudinal axis AA running parallel to its length. The second block or slab 110 as shown in Figure lOe has a length 111 and a longitudinal axis AA running parallel to its length. The third block or slab 112 as shown in Figure lOf has a length 113 and a longitudinal axis AA running parallel to its length.

Each of the respective slabs or blocks of the first, second and third materials as shown in Figures lOd, lOe, and lOf are then cut or sliced into sheets having substantially the same thickness, as described in relation to the above first manufacturing embodiment. The cutting or slicing is done in cutting planes that run transverse to the longitudinal axis AA of each block or slab. The first block or slab 108 is cut or sliced into multiple sheets 114 as shown in Figure lOg, the second block or slab 110 is cut or sliced into multiple sheets 116 as shown in Figure lOh, and the third block or slab 112 is also cut or sliced into multiple sheets 118 as shown in Figure lOi. The thickness of the sheets from one slab are typically uniform, and may also be the same thickness as sheets from the other slabs. Alternatively, the thickness of the different types of sheets may vary between type, depending on the dimensional specifications of the individual elongate elements required for the end laminated panel.

The individual sheets 114 of the first material 114 are then interleaved, layered or sequenced into a laminated block or slab of sheets, with the individual sheets 116,118 of second material and the third material in the sequence or pattern required of the desired end laminated panels, to progressively generate a new laminated slab. Figures lOj and 10k show a partially formed laminated slab. The individual sheets of each resilient material are laminated, connected or adhered together using an adhesive as previously described in relation to the prior embodiments above. The adhesive may be a conventional adhesive suitable for fixing foam or resilient type materials together and may optionally comprise a PCM additive in some embodiments. The number of repetitions in the pattern is determined by the desired width of the final mattress or topper and/or laminated panel, as the width of laminated panel is determined by the combined length of the laminated slab formed by the individual sheets connected or adhered together.

As described above, the laminated sheets of the different desired resilient materials form a new slab or block 120 of layered sheets of resilient materials which are laminated together, as shown in Figure 101. This new laminated slab or block 120 has a length 121 and a longitudinal axis BB running parallel or co-incident to its length dimension. As shown the longitudinal axis BB of the laminated slab 120 extends in a direction that is transverse or perpendicular to the major surfaces of the layered sheets 114,116,118.

The laminated slab or block 120 is then cut or sliced lengthways into sheets 122, in cutting planes that are aligned, parallel or co-incident with to the longitudinal axis BB, as shown in Figure 10m. In this embodiment the laminated slab or block 120 is cut or sliced into numerous individual sheets 122 which are in the sequence or pattern required of the desired end laminate portions or panels of the mattress or topper in the desired dimensions and pattern of materials as described in regard to the embodiment in Figures 2-5. In particular, the individual sheets 122 represent the laminated panels 14a of the type previously described.

Similar to the first example manufacturing method, the laminated panels 122 may then have an optional coating (e.g. a PCM solution as previously described) applied, and may then be assembled with a backing substrate 12 to form the desired mattress or topper, or otherwise assembled as a component into a mattress or topper for example.

Further example configurations

The following describes further particular examples of the mattress or topper having different example configurations and specifications, by way of further non-limiting illustration.

Referring to Figure 1, the laminated portion or panel in this further example has a length L2 of approximately 1 metre from first edge 40a to second edge 40b. The width W1 of the laminated portion or panel from the third edge 40c to the fourth edge 40d will depend on the intended size of the mattress, for example a long single will be approximately 910mm, a king single will be approximately 1070mm, a double will be approximately 1370mm, a queen will be approximately 1530mm, a king will be approximately 1670mm, a super king will be approximately 1830mm, and a California king will be approximately 2000mm. The laminated portion or panel in this example has a thickness of between 20mm to 40mm.

The base substrate of the mattress or topper in the first zone 12a and the second zone 12b is in one embodiment a polyurethane foam having grade between 22-50. Alternatively, the base substrate in the first zone 12a and the second zone 12b is a polyurethane foam having a grade between 24-120.

The base substrate of the mattress or topper in the third zone 12c in this example is a layer of spacer-airflow material underneath the laminated portion or panel 14. The spacer-airflow material in this example has a thickness of between 20mm and 40mm. This material will aid in air-flow which vents the heat from the foams by facilitating the cooling action.

The laminated portion or panel is formed from a laminated series of elongate elements, each respective elongate element being formed from a respective type of resilient material, the laminated portion or panel formed from elongate elements of at least two different types of resilient materials. In this embodiment, the at least two or more resilient materials forming the elongate elements can be made from one of:

• Polyurethane foam, having a grade of between 20-100,

• Graphene having a grade of between 35-42,

• Fusion Gel having a grade of between 67-60,

• Fusion Gel ⁺ having a grade of between 34-90,

• LR Foam having a grade of between 38-40,

• Memory Foam having a grade of between 55-40,

• Memory Foam having a grade of between 55-60,

• Genius having a grade of between 50-50, or

• Energex having a grade of between 80-100.

The elongate elements in the laminated series are bonded together using an adhesive. In this example, the adhesive used may be a glue containing a PCM or a conventional glue without a PCM additive.

A first example configuration is a two-type laminated portion or panel, formed from a laminated series of elongate elements of two different types of resilient material. The first type of resilient material is in this example polyurethane foam having a grade between 20-100. The second material may be any one of the following materials:

• Graphene having a grade of between 35-42, • Fusion Gel having a grade of between 67-60,

• Fusion Gel ⁺ having a grade of between 34-90,

• LR Foam having a grade of between 38-40,

• Memory Foam having a grade of between 55-40,

• Memory Foam having a grade of between 55-60,

• Genius having a grade of between 50-50, or

• Energex having a grade of between 80-100

For example, the laminated portion or panel can be formed from elongate elements of a polyurethane foam having a hardness of between 20-100, and elongate elements of graphene based resilient material. Alternatively, the laminated portion or panel can be formed from elongate elements of a polyurethane foam having a hardness of between 20-100, and elongate elements of fusion gel based resilient material. Additional combinations of the polyurethane foam having a hardness of between 20-100 and the above materials will be appreciated.

The width of each elongate element in this example is 60mm. In another embodiment, the width of the elongate elements of the first material, being the polyurethane foam having a grade between 20-100 is 80mm, while the width of the elongate elements of the second material is 60mm. Alternatively the width of the elongate elements of the second material is 40mm.

A second example configuration is a three-type laminated portion or panel, formed from a laminated series of elongate elements of three different types of resilient material. The first type of resilient material is in this example polyurethane foam having a grade between 20-100. The second material may be any one of the following materials:

• Graphene having a grade of between 35-42,

• Fusion Gel having a grade of between 67-60,

• Fusion Gel ⁺ having a grade of between 34-90,

• LR (low resilience) Foam having a grade of between 38-40,

• Memory Foam having a grade of between 55-40,

• Memory Foam having a grade of between 55-60,

• Genius having a grade of between 50-50, or

• Energex having a grade of between 80-100

The third material, as will be appreciated, can be any one of the above materials, excluding the material used as the second material. For example, the laminated portion or panel can be formed from elongate elements of a polyurethane foam having a hardness of between 20-100, elongate elements of graphene based resilient material, and elongate elements of a fusion gel based resilient material. Alternatively, the laminated portion or panel can be formed from elongate elements of a polyurethane foam having a hardness of between 20-100, elongate elements of fusion gel based resilient material, and elongate elements of a Genius based resilient material. Additional combinations of the polyurethane foam having a hardness of between 20-100 and two of the above materials will be appreciated.

The width of each elongate element in this example is 60mm. In another embodiment, the width of the elongate elements of the first material, being the polyurethane foam having a grade between 20-100 is 80mm, while the width of the elongate elements of the second and third materials is 60mm. Alternatively the width of the elongate elements of the second and/or the third materials is 40mm.

Example embodiments of the invention have been described by way of example only and modifications may be made thereto without departing from the scope of the invention as defined by the accompanying claims.