Cross Reference to Related Applications

[0001] This application claims the benefit of U.S. Patent Provisional No. 62/463,149, filed on February 24, 2017, which is hereby incorporated by reference in its entirety.

BACKGROUND

Statement of the Technical Field

[0002] The technical field of this disclosure comprises self- inflating mattresses, and more particularly self-inflating mattresses which are adjustable for improved comfort.

Description of the Related Art

[0003] The related art concerns methods and systems pertaining to self- inflating mattresses. United States Patent No. 6,190,486 issued Feb. 20, 2001 and entitled "Method For Making Self- Inflating Mattresses and Cushions concerns a method for making a self- inflating mattress. United States Patent No. 6,397,417, issued on June 4, 2002, and entitled "Self-Inflatable Apparatus concerns a self- inflatable mattress formed from an open pore foam core and one or more layers of dual melt film. United States Patent No. 6,494,243, issued on Dec. 17, 2002 and entitled Apparatus For Making Self-Inflatable Apparatus concerns a system for making a self- inflatable device, such as a mattress.

[0004] The above-referenced patents concern various aspects of open cell foam structures and methods of making same. Briefly, the manufacturing process consists of sealing the surface of an open-cell foam structure with a specifically developed air or gas impermeable elastomeric coating and then installing a valve in the sealed surface coating. In this way a self- inflatable structure or device that is further capable of being pressurized while retaining the original shape of the unsealed piece of foam. The process permits the sealing of virtually any shape that can be cut or molded in open-cell foam. Inflatable shapes with either flat sides or square edges, or complex, irregular, convoluted surfaces not normally or easily obtainable with traditional inflatable shell structure technology, can be created. SUMMARY

[0005] According to one aspect, this disclosure concerns a sealed foam, self- inflating mattress system. The system is comprised of a mattress core formed of open-cell foam. The mattress core can include first and second major sleeping surfaces on opposing sides of the mattress and at least one side wall which extends between the two major sleeping surfaces. An elastomeric coating encloses the mattress core to define an airtight mattress chamber. A vacuum pump is operatively coupled to the airtight mattress chamber and configured to selectively establish a negative PSIG internal operation pressure within the airtight mattress chamber. The negative PSIG internal operation pressure improves a comfort of the self- inflating mattress.

[0006] An air inlet of the vacuum pump is coupled to the airtight mattress chamber through an airtight control chamber. A check valve is provided between the air inlet of the vacuum pump and the airtight control chamber. The check valve is configured to create an airtight seal between the airtight control chamber and the air inlet of the vacuum pump when the vacuum pump is not activated. Further, an override valve is configured to selectively allow air to enter or exit the airtight control chamber and hence also the airtight mattress chamber.

[0007] In some scenarios, the sealed foam, self- inflating mattress includes a recess formed in the mattress core. In some scenarios described herein, the recess is disposed in the at least one side wall of the mattress. Further, the vacuum pump can be disposed in the recess. In such scenarios, a three-dimensional construct which defines a complex geometry sealing membrane (CGSM) can be included as part of the mattress. The CGSM is formed from two or more panels of elastomeric material which are arranged to correspond with or replicate a panel geometry of the recess. The two or more panels are heat fused together at adjacent edges to define one or more seams of the CGSM. For example radio frequency (RF) heating can be used to facilitate the heat fusing process. The CGSM is advantageously heat fused within the recess, whereby corners of the recess are sealed to form the airtight mattress chamber.

[0008] The disclosure also concerns a method for controlling a comfort of a sealed foam, self- inflating mattress. The method involves causing an airtight mattress chamber which is formed of open-cell foam and enclosed by an elastomeric coating to automatically self-fill with air by utilizing a resilience associated with the open-cell foam to expand the airtight mattress chamber. Thereafter, the airtight mattress chamber is permitted to be filled with air to an ambient air pressure comprising 0 PSIG. A vacuum pump is selectively operated to establish a negative PSIG internal operation pressure within the airtight mattress chamber for improving a comfort of the self- inflating mattress. The airtight mattress chamber is automatically sealed using a check valve after the negative PSIG internal operation pressure has been established.

[0009] According to one aspect, the operation of the vacuum pump can involve drawing air from the airtight mattress chamber through an airtight control chamber which is coupled to an air inlet of the vacuum pump. An airtight seal is automatically formed with the check valve to seal the airtight mattress chamber when the vacuum pump is not activated. An override valve coupled to the airtight control chamber can be used to selectively allow air to enter or exit the airtight control chamber and the airtight mattress chamber. In some scenarios, the method can further involve positioning a vacuum pump and the airtight control chamber in a recess formed in the mattress core.

[0010] The disclosure also concerns a method for manufacturing a sealed foam, self- inflating mattress system. The method involves forming a mattress core comprised of open cell foam. The mattress core can be formed to include first and second major sleeping surfaces on opposing sides of the mattress core and at least one side wall which extends between the two major sleeping surfaces. The method continues by forming a recess in the mattress core. For example, the recess can be formed in the at least one side wall. The entire mattress core is coated with a layer of a first elastomeric coating material to form an enclosure around the mattress core and define a mattress air chamber. The method continues with the assembly or formation of a three- dimensional construct. The three-dimensional construct defines a complex geometry sealing membrane (CGSM) comprised of two or more panels of a second elastomeric material. The second elastomeric material can be the same as the first elastomeric material. The panels are arranged to correspond with or replicate a panel geometry of the recess. The two or more panels are heat fused together at adjacent edges to define one or more seams of the CGSM. The CGSM is then heat fused within the recess to seal one or more corners of the recess, whereby the mattress air chamber is made airtight.

[0011] According to one aspect, a vacuum pump is disposed within the recess. The vacuum pump can have at least one air inlet which is coupled to the mattress air chamber. The mattress air chamber can be allowed to be filled with air to an ambient air pressure comprising 0 PSIG. The vacuum pump can then be selectively operated to establish a negative PSIG internal operation pressure within the airtight mattress chamber for improving a comfort of the self- inflating mattress. The method continues by automatically sealing the airtight mattress chamber using a check valve after the negative PSIG internal operation pressure has been established.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] This disclosure is facilitated by reference to the following drawing figures, in which like numerals represent like items throughout the figures, and in which:

[0013] FIG. 1 is a drawing which is useful for understanding a sealed foam, self- inflating mattress system in a first operating condition.

[0014] FIG. 2 is a drawing which is useful for understanding the sealed foam, self- inflating mattress system of FIG. 1, in a second operating condition.

[0015] FIG. 3A is a drawing which is useful for understanding certain recess features of a sealed foam, self- inflating mattress system when the mattress is inflated to 0 PSIG.

[0016] FIG. 3B is a drawing which is useful for understanding the effect of reducing a pressure in the self- inflating mattress system by using a vacuum pump.

[0017] FIG. 4 is a drawing that is useful for understanding a method of manufacturing a self- inflating mattress system with a recess formed therein.

DETAILED DESCRIPTION

[0018] It will be readily understood that the components of the systems and/or methods as generally described herein and illustrated in the appended figures could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description, as represented in the figures, is not intended to limit the scope of the present disclosure, but is merely representative of certain implementations in various different scenarios. While the various aspects are presented in the drawings, the drawings are not necessarily drawn to scale unless specifically indicated. [0019] This document concerns methods and systems for improving the comfort of certain types of open cell foam structures. As is known, a manufacturing process for an open cell foam structure can involve sealing the surface of an open-cell foam structure with an air or gas impermeable elastomeric coating and then installing a valve in the sealed surface coating. In this way a self- inflatable structure or device that is further capable of being pressurized while retaining the original shape of the unsealed piece of foam. The process permits the sealing of virtually any shape that can be cut or molded in open-cell foam. Inflatable shapes with either flat sides or square edges, or complex, irregular, convoluted surfaces not normally or easily obtainable with traditional inflatable shell structure technology, can be created. The apparatus, methods and manufacturing systems associated with this technology are described in detail in several U.S. Patents, including U.S. Patent Nos. 6,190,486, 6,397,417 and 6,494,243, all of which are expressly incorporated herein by reference. For ease of reference, the types of structures described in these patents are sometimes referred to herein as open-cell foam with elastomeric coating (OCFEC) structures.

[0020] This disclosure concerns an improvement to conventional OCFEC structures, particularly those OCFEC structures which are configured as a cushion or a mattress. Utilizing the techniques detailed in U.S. Patent Nos. 6,190,486, 6,397,417 and 6,494,243 an OCFEC can provide a cushion or mattress which is capable of self-inflating to 0 PSIG. As is known, PSIG (Pounds per Square Inch Gauge) represents the pressure differential between the pressure in an airtight chamber (such as an airtight mattress chamber defined by an OCFEC) and the pressure of the ambient atmospheric pressure.

[0021] An OCFEC is also capable of operating at an internal pressure which is less than an ambient atmospheric pressure. For convenience, this condition is sometimes referred to herein as "(-) PSIG". More particularly, an OCFEC can operate at (-) PSIG if air is removed (e.g., by means of a valve) from the internal air chamber defined by the OCFEC. Alternatively, an OCFEC can operate at an internal pressure which is higher than an ambient atmospheric pressure (a condition referred to herein as "(+) PSIG") if air is introduced to the internal air chamber by using a valve.

[0022] As shown in FIG. 1, a solution disclosed herein involves an OCFEC 114 in which the self- inflatable airtight mattress chamber 112 defined by the OCFEC is coupled to vacuum pump assembly (VPA) 102. For greater clarity in FIG. 1, the airtight mattress chamber 112 is shown as a void but it should be understood that in an OCFEC 114 the interior space defined by the airtight mattress chamber 112 will be filled with open cell foam material 123. An exterior wall fo the OCFEC 114 will be comprised of an elastomeric material. As such the OCFEC 114 can have a basic construction which is similar to that described in one or more of U.S. Patent Nos. 6,190,486, 6,397,417 and 6,494,243.

[0023] The VPA 102 can be comprised of a vacuum pump motor/fan subassembly 104, and an airtight enclosure subassembly (AES) 106. The vacuum pump motor/fan subassembly includes a vacuum pump 105. The AES 106 defines an airtight control chamber 108 which can be formed of a rigid material. In some scenarios, the rigid material can be selected to include a metal or polymer. In FIG. 1 the VPA is shown directly integrated with the AES 106. However this level of integration is not critical and other configurations are also possible. For example, in some scenarios, attachment of the VPA 102 to the AES 106 can be implemented by means of a press-fit fitting, quick disconnect fitting, hose fitting, or threaded fitting.

[0024] The airtight control chamber 108 is coupled to an airtight mattress chamber 112 defined by the OCFEC. In some scenarios, a chamber coupler 120 and an inlet fitting 121 can be used to facilitate this coupling. The chamber coupler 120 forms an opening to the interior of the airtight control chamber 108. The inlet fitting 121 is disposed in an elastomeric coating wall of the OCFEC 114 and forms an opening to the airtight mattress chamber 112. The chamber coupler 120 and the inlet fitting can be formed of a suitable material such as a metal or rigid plastic. In some scenarios, the chamber coupler 120 can be threaded onto the inlet fitting 121. However, other arrangements are also possible. For example, it can be advantageous in certain embodiments to select a quick disconnect airtight fitting for this purpose so that the VPA 102 can be more easily removed and attached to the OCFEC 114. In some scenarios, the chamber coupler 120 can be connected to the inlet fitting 121 indirectly by means of a hose (not shown). The combination of the chamber coupler 120 and the inlet fitting 121 provide an opening or air passageway between the airtight control chamber 108 and the airtight mattress chamber 112 so that the two chambers are always at the same air pressure. The chamber coupler 120 and inlet fitting 121 also allow for the VPA 102 to be affixed to the self- inflatable OCFEC 114 as shown. [0025] The AES is operatively coupled to the vacuum pump 105 so that the vacuum pump can pump air out of the airtight control chamber 108 when the vacuum pump is operated. The AES 106 includes a check valve 110 that prevents air from entering or exiting the airtight chambers 108, 112 when the vacuum pump 105 is not running. Upon activation of the vacuum pump 105, a reduction in pressure created by the vacuum pump 105 on one side of the check valve 110 will cause the check valve to open whereby air can be pumped out of the airtight control chamber 108. Since airtight control chamber 108 is also connected to airtight mattress chamber 112, this pumping operation has the effect of also removing air from the airtight mattress chamber 112. The pumping operation is indicated in FIG. 1 by arrows 118, 119

[0026] An override valve 116 in communication with the airtight control chamber 108 is configured to allow air to enter or exit the airtight chambers 108, 112 when the override valve is in its open condition. Accordingly, check valve 110 and the vacuum pump motor/fan subassembly 104 can be effectively bypassed when the override valve is open. This condition is illustrated in FIG. 2, which shows that in one scenario air (indicated by arrows 126, 128) can be allowed to enter airtight chambers 108, 112 when the override valve 116 is open.

[0027] The chamber coupler 120 and the inlet fitting 121 provide an opening or air passageway between the airtight control chamber 108 and the airtight mattress chamber 112 so that the two chambers are always at the same air pressure. The vacuum pump 105, when operated, can reduce the internal pressure of the airtight chambers 108, 112. Consequently, a (-) PSIG condition can be achieved in the OCFEC 114. It has been determined that when an OCFEC 114 which comprises a mattress or cushion is transitioned to a (-) PSIG condition, the comfort and feel of the OCFEC mattress or cushion is substantially improved.

[0028] When an OCFEC structure 114 (e.g., a mattress structure) is expanded to its baseline foam dimensions, the chamber's internal air pressure will be at 0 PSIG. Removal of any air from the chamber will yield, when the check valve 110 and override valve 120 are closed, a condition of negative internal pressure (-) PSIG in the airtight mattress chamber 112 and a softening of the structure from its baseline foam firmness.

[0029] This condition of negative internal pressure in the chamber is the result of the continuing tendency of the elastic, open celled foam to expand back to its original dimensions, thereby causing a suction effect on the sealed outer elastomeric skin or wall 124 of the OCFEC structure. In turn, this results in the automatic drawing in of air through the override valve 116 when the valve is subsequently re-opened.

[0030] With the arrangement shown in FIGs. 1 and 2, an OCFEC cushion or mattress made using the process described in one or more of U.S. Patent Nos. 6,190,486, 6,397,417 and 6,494,243 may be operated with adjustable firmness. The firmness can be adjusted from a pressurized (+) PSIG condition that is harder than the original foam firmness to a negative internal pressure (-) PSIG condition that is softer than the original foam firmness. Additional details of the system are provided below.

[0031] According to one aspect, the vacuum pump 105 is comprised of a fan or rotating vane attached to a motor. Vacuum pumps are well known in the art and therefore will not be described here in detail. However, it will be appreciated that the fan pulls air from the airtight chambers 108, 112 and exhausts it to ambient air as indicated by arrows 118, 119. When the fan is in motion, the vacuum pressure generated opens the check valve 110 allowing the air to pass through the check valve 110 and into an air inlet 109 of the vacuum pump motor/fan

subassembly 104. When the fan is not in motion, the check valve remains closed to seal air from entering or existing the inlet. The fan can be configured as an axial fan or as a centrifugal fan. Of course, other configurations of a vacuum pump are also possible. For example, in some scenarios, a the vacuum pump could be a diaphragm pump, a piston pump, or a scroll pump. A power supply (not shown) provides electric power to run the motor and fan subassembly.

Activation of the fan can be controlled by a button or switch mounted directly on the assembly, or the system can be remotely controlled by a control unit 130.

[0032] The control unit can be comprised of electronic circuitry which in some scenarios can include a processing element such as a microcontroller, microprocessor or application specific integrated circuity. In some scenarios the control unit can include a short range wireless communication capability to facilitate communications with a remote control or a smart phone (not shown). In such scenarios, activation of the fan and/or valves can be controlled by means of the remote control or smart phone. [0033] The check valve 110 creates an air tight seal when the vacuum pump 105 is not activated. The check valve 110 can be comprised of a spring-loaded poppet, a flapper, or a solenoid valve. These types of check valves are well-known and will not be described in detail. However, it should be understood that upon activation of the motor, the vacuum pressure generated will open the check valve, or the electronic control unit 130 will trigger a solenoid type of check valve to open. In some scenarios the check valve 110 can also operate as a pressure relief valve to vent excess pressure within the airtight enclosure subassembly and inflatable structure.

[0034] The override valve 116 can be comprised of a spring-loaded poppet, a flapper, or a solenoid valve. The override valve 116 allows for air to be drawn into the airtight control chamber 108 when the chamber is at a partial vacuum, and allows air to be expelled from the airtight control chamber 108 if the air pressure therein is at a pressure above ambient pressure. The override valve can be configured to operate manually or can be electronically controlled with a solenoid valve (not shown) responsive to signals from the electronic control unit 130.

[0035] This specific arrangement disclosed in FIGs. 1 and 2 allows for the pressure of an inflatable OCFEC structure 114 to be adjusted above or below ambient pressure and to maintain that pressure when connected to the pump assembly via the inlet.

[0036] Turning now to FIG. 3 A and 3B, there is shown an OCFEC mattress system 300 which is similar to the arrangement shown in FIGs. 1 and 2. As such, the mattress system 300 includes a VPA 302 coupled to an OCFEC mattress 314. The VPA 302 can be similar to the VPA 102 and can be coupled to the OCFEC mattress 314 in a similar manner. FIG 3A shows the OCFEC mattress 314 in its pressurized condition whereas FIG. 3B shows the mattress 314 in its softened condition having negative internal pressure.

[0037] In its softened condition, an OCFEC mattress 314 will have a comfort feel which is similar to that of gelatin. The effect is similar to that which is achieved with viscoelastic foam, but has the added advantage of facilitating an ability to adjust the firmness. The internal suction effect associated with (-) PSIG operation of an OCFEC configured as a mattress gives the mattress a unique, extremely comfortable feel as a sleep surface. Full support of the body is provided along each contour of an individual, without hard spots that can disturb a pleasant sleep.

[0038] To achieve the (-) PSIG state in FIG. 3B while a person lies on an OCFEC mattress 314, the VPA 302 is advantageously incorporated into a portion of the OCFEC. For example, in some scenarios, a portion of the OCFEC mattress can formed with a cutout or recess 304 defined therein. In some scenarios, the recess 304 can be defined in or along a portion of a side wall 308 which extends between first and second opposing major sleeping surfaces 310, 312 of the mattress. The recess 304 can be formed in such a way as to form a shelf 306 which is spaced apart from each of the major sleeping surfaces 310, 312 so that the shelf is intermediate of the two major sleeping surfaces 310, 312. In some scenarios, the shelf can extend inwardly a distance from the side wall 308 in a direction which is generally parallel to the sleeping surfaces 310, 312. Of course other configurations of the cutout or recess or also possible. For example, a recess formed as a notch 316 in the open cell foam of the mattress could be used to accommodate the VPA 302. In some embodiments, a rigid or semi-rigid flange 318 can be used to define the contours and boundaries of the recess 304 or a notch 316. The flange can be made of a rigid or semi-rigid polymer, or from metal. As shown in FIG. 3 A, the flange 318 can be fitted into a portion of the mattress where the open cell foam has been cut away. Alternatively, the open cell foam can be injected and then allowed to cure around the exterior of the flange. All such configurations of the cutout, notch or recess are contemplated for use with the various embodiments. Also, it should be understood that the geometry of the recess is not critical and any suitable geometry can be used for this purpose. For example, instead of the rectangular geometry shown in FIGs. 3A and 3B, a cylindrical geometry could be used to form the recess.

[0039] Referring now to FIG. 4, the recess 304 can comprise a relatively complex open cell foam geometry. Accordingly, a special technique may be required in order to facilitate sealing portions of such complex geometries with the elastomeric coating. For example, interior corners 402, 404 of the recess 304 may have a tendency to leak air under negative or positive pressure differentials. These leaks are due to pleating of the elastomeric coating in these intricate portions of the structure.

[0040] To avoid such potential leaks a special sealing technique can be used. The sealing technique can involve the use of a three-dimensional construct in the form of a complex geometry sealing membrane (CGSM) 406. According to one aspect, the CGSM 406 can formed from one or more sheets of elastomeric material. In some scenarios the elastomeric material can be the same elastomeric coating material which is used to seal and form an outer surface 408 of the OCFEC mattress system 300. The elastomeric sheets or panels 410-413 can be pieced together and sealed at the seams 420 where the edges of the sheets are joined. For example, radio frequency heat sealing can be used to heat overlapping edge portions of adjacent sheets so that they are fused together at the seams.

[0041] The CGSM 406 can include complex three-dimensional contours comprising one or more elastomeric material panels (e.g., panels 410-413) disposed in different planes. The CGSM may further include outside and inside corners (e.g. corners 402, 404) to match or correspond to the contours of a recess (e.g., recess 304). After the CGSM 406 has been constructed as described herein, it can be positioned in the recess as shown by the arrows in FIG. 4. Once seated in position, the CGSM 406 can be sealed directly to the open-cell foam comprising the core of the mattress or to a layer of elastomeric coating which has been applied to the exterior of the open-cell foam. This sealing process can be accomplished by any suitable means.

According to one aspect, a heated die 416 can be used for this purpose. As shown in FIG. 4, the heated die 416 can be formed to have the same geometry as the CGSM 406. A layer of buffer material 418 can be disposed between the CGSM 406 and the heated die 416. As a result of the foregoing process, the CGSM 406 will become fused with the foam and/or layers of elastomeric coasting. The RF heat sealing applied to the seams of panels 410-413 maintains the airtight barrier in these sections that otherwise would form leaks due to pleating of the elastomeric coating. This technique allows for the sealing of a recess cut from the foam as well as sealing any inside or outside corner.

[0042] As used in this document, the singular form "a", "an", and "the" include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term "comprising" means "including, but not limited to".

[0043] Although the systems and methods have been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the disclosure herein should not be limited by any of the above descriptions. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.