Note: Descriptions are shown in the official language in which they were submitted.
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TEMPERATURE CONTROL MATTRESS WITH THERMOELECTRIC FABRIC
BACKGROUND
[0001] The present disclosure generally relates to mattress assemblies,
specifically to
temperature control mattress assemblies using thermoelectric fabric.
[0002] In order to maintain homeostasis the human body produces thermal energy
during sleep that is dissipated to the environment. This energy is transferred
to the sleep
surface which stores the energy and subsequently increases in temperature. As
temperatures
of the bed sleeping surface increase beyond the thermo-neutral zone
(approximately 82 to 85
degrees Fahrenheit) the sleep environment becomes uncomfortable and the
sleeper often
begins to perspire. Several mechanisms for cooling the surface of a mattress
have been
developed, but these systems suffer from a variety of limitations.
[0003] For example, fluid-based systems (both gas and liquid) have been
employed to
reduce sleep surface temperature. These systems typically require a pump to
circulate cooled
fluid through a mattress. These systems generate significant amounts of noise
as they pump
fluid through manifolds or radiators in the mattress. Additionally, these
systems come at
significant cost.
[0004] Alternatively, standard thermoelectric systems have been employed.
These
systems typically use rigid components spaced about a mattress to utilize the
Peltier effect
and transfer heat from the surface of the mattress. These systems are
localized about the
components resulting in a surface with non-uniform temperature distribution.
Additionally,
the rigid components limit their placement within the mattress assembly and
can cause
discomfort for sleepers. In some existing designs, multiple thermoelectric
components are
spaced about the interior of a mattress in order to cool a sleep surface. The
separation
between components decreases effectivity, as the cooling mechanisms do not
treat the sleep
surface uniformly. This generates hot and cold spots on the surface of the
mattress. An
increase in the number of components would decrease mattress comfort as the
components
are inflexible.
[0005] Accordingly, there remains a need for improved systems, devices, and
methods of reducing sleep surface temperature in mattress assemblies.
SUMMARY
[0006] A temperature control mattress is disclosed herein. The temperature
control
mattress can include a body support having a proximal surface that is
configured to support a
human body and a flexible thermoelectric fabric disposed along at least a
portion of the body
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support. The flexible thermoelectric fabric can be in thermal communication
with the
proximal surface of the body support and such that the flexible thermoelectric
fabric is
configured to cool the proximal surface of the body support.
[0007] In other aspects, a temperature control mattress can include a body
support
having a proximal surface that is configured to support a sleeper and a
flexible thermoelectric
fabric comprising at least one p-type layer coupled to at least one n-type
layer to provide at
least one p-n junction. The flexible thermoelectric fabric can be disposed
along at least a
portion of the body support such that the flexible thermoelectric fabric is in
thermal
communication with the proximal surface of the body support and such that the
flexible
thermoelectric fabric is configured to cool the proximal surface of the body
support.
[0008] The above described and other features are exemplified by the
accompanying
drawings and detailed description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] This disclosure will be more fully understood from the following
detailed
description taken in conjunction with the accompanying drawings, in which:
[0010] Figure (FIG.) 1 is a side view of an expanded thermoelectric apparatus
that
can form a flexible thermoelectric fabric;
[0011] FIG. 2 is an exemplary thermoelectric apparatus;
[0012] FIG. 3 is a side view of an exemplary flexible thermoelectric fabric;
[0013] FIG. 4 is a perspective cut-away view of an exemplary mattress assembly
that
includes a flexible thermoelectric fabric;
[0014] FIG. 5 is a cut-away view of an exemplary mattress assembly that
includes a
flexible thermoelectric fabric;
[0015] FIG. 6 is a perspective view of an exemplary flexible thermoelectric
fabric;
[0016] FIG. 7 is a diagram of a Peltier effect with respect to a flexible
thermoelectric
fabric; and
[0017] FIG. 8 is a diagram of a Seebeck effect with respect to a flexible
thermoelectric fabric.
DETAILED DE S CRIPTION
[0018] Certain exemplary aspects will now be described to provide an overall
understanding of the principles of the structure, function, manufacture, and
use of the
devices, systems, methods, and/or kits disclosed herein. One or more examples
of these
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aspects are illustrated in the accompanying drawings. Those skilled in the art
will understand
that the devices, systems, methods, and/or kits disclosed herein and
illustrated in the
accompanying drawings are non-limiting and exemplary in nature and that the
scope of the
present invention is defined solely by the claims. The features illustrated or
described in
connection with any one aspect described may be combined with the features of
other
aspects. Such modification and variations are intended to be included within
the scope of the
present disclosure.
[0019] Further in the present disclosure, like-numbered components generally
have
similar features, and thus each feature of each like-numbered component is not
necessarily
fully elaborated upon. Additionally, to the extent that linear or circular
dimensions are used
in the description of the disclosed systems, devices, and methods, such
dimensions are not
intended to limit the types of shapes that can be used in conjunction with
such systems,
devices, and methods. A person skilled in the art will recognize that an
equivalent to such
linear and circular dimensions can be determined for any geometric shape.
Sizes and shapes
of the systems and devices, and the components thereof, can depend at least on
the size and
shape of the components with which the systems and devices will be used, and
the methods
and procedures in which the systems and devices will be used.
[0020] Flexible thermoelectric fabrics have been developed for use in various
applications. For example and without limitation, thermoelectric fabrics are
disclosed in U.S.
Publication No. 2013/0312806, which is titled "Thermoelectric Apparatus and
Applications
Thereof' and is hereby incorporated by reference in its entirety. These
flexible
thermoelectric fabrics can employ a layered p-n junction material to generate
temperature
gradients from electricity. Modules of the material may be arranged in series,
parallel or a
combination in order to achieve the desired temperature distribution. The
thermoelectric
fabric remains flexible due to its polymeric construction. This allows for
retained comfort
when placing the layers closer to the surface of the mattress where the body
is generating
heat. Thermoelectric fabrics can also cover an entire sleep surface if needed.
This can
decrease the positional requirements of the sleeper allowing them to move
freely in the
mattress while still experiencing uniform temperature distribution.
[0021] Flexible, polymer-based thermoelectric fabrics can be constructed
through the
lamination of doped p- and n- junction polymers separated by an insulating
material. These
laminated modules can be stacked and arranged in series, parallel or a
combination in order to
achieve the desired temperature distribution. Polymer based thermoelectric
fabrics can be
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placed nearer the surface of a mattress to increase efficiency of the cooling
or heating
process.
[0022] As is explained in greater detail in U.S. Publication No. 2013/0312806,
FIG. 1
illustrates an expanded side view of a thermoelectric apparatus that forms
example flexible
thermoelectric fabrics. The thermoelectric apparatus illustrated in HG, 1
comprises two p-
type layers I coupled to an n-type layer 2 in an altetnating fashion. The
alternating coupling
of p-type 1 and n-type 2 layers provides the thermoelectric apparatus a z-type
configuration
having p-n junctions 4 on opposite sides of the apparatus. Insulating layers 3
are disposed
between interfaces of the p-type layers 1 and the n-type layer 2 as the p-type
1 and n-type 2
layers are in a stacked configuration. As shown, the thermoelectric apparatus
provided.
in FIG. 1 is in an expanded state to facilitate illustration and understanding
of the various
components of the apparatus. In some aspects, however, the thermoelectric
apparatus is not
in an expanded state such that the insulating layers 3 are in contact with a p-
type layer I and
an n-type layer 2.
[0023] FIG. 1 additionally illustrates the current flow through the
thermoelectric
apparatus ind-uced by exposing one side of the apparatus to a heat source.
:Electrical contacts
X are provided to the thermoelectric apparatus for application of the
thermally generated
current to an external load.
[0024] Again, as is explained in greater detail in U.S. Publication No.
2013/0312806,
FIG. 2 illustrates an exemplary thermoelectric apparatus 200, wherein the p-
type lavers 201
and the n-type layers 202 are in a stacked configuration. The p-type layers
201 and the n-
type layers 202 can be separated by insulating layers 207 in the stacked
configuration. The
thermoelectric apparatus 200 can be connected to an external load by
electrical contacts
204,205.
[0025] FIG. 3 illustrates an exemplary flexible thermoelectric fabric 300. The
flexible thermoelectric fabric 300 can comprise a thermoelectric apparatus as
described above
with respect to FIGS. 1-2 such that the apparatus forms a fabric that is
capable of bending
easily without breaking the circuits. As such, in some aspects, the flexible
thermoelectric
fabric can comprise at least one p-type layer coupled to at least one n-
typela.yer to provide a
p-n junction, and an insulating layer at least partially disposed between the
p-type layer and
the n-type layer, the p-type layer comprising a plurality of carbon
nanoparticles and the n-
type layer comprising a plurality of n-doped carbon nanoparticles. In some
aspects, carbon
nanoparticles of the p-type layer are p-doped and carbon nanoparticles of the
n-type layer are
n-doped. in some aspects, a p-type layer of a flexible thermoelectric fabric
or apparatus can
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further comprise a polymer matrix in which the carbon nanoparticles are
disposed. In some
aspects, an n-type layer further comprises a polymer matrix in which the n-
doped carbon
nanoparticles are disposed. In some aspects, p-type layers and n-type layers
of a flexible
thermoelectric fabric or apparatus described herein are in a stacked
configuration.
[0026] In some aspects, carbon nanoparticles of a p-type layer comprise
fullerenes,
carbon nanotubes, or mixtures thereof In some aspects, carbon nanotubes can
comprise
single-walled carbon nanotubes (SWNT), multi-walled carbon nanotubes (MWNT),
as well
as p-doped single-walled carbon nanotubes, p-doped multi-walled carbon
nanotubes or
mixtures thereof N-doped carbon nanoparticles can comprise fiillerenes, carbon
nanotubes,
or mixtures thereof. In some aspects, n-doped carbon nanotubes can also
comprise single-
walled carbon nanotubes, multi-walled carbon nanotubes or mixtures thereof.
[0027] In some aspects, a p-type layer and/or n-type layer can further
comprise a
polymeric matrix in which the carbon nanoparticles are disposed. Any polymeric
material
not inconsistent with the objectives of the present invention can be used in
the production of a
polymeric matrix. In some aspects, a polymeric matrix comprises a
fluoropolymer including,
but not limited to, polyvinyl fluoride (PVF), polyvinylidene fluoride (PV10),
polytetrafluoroethylene (PTFE), or mixtures or copolymers thereof. In some
aspects, a
polymer matrix comprises polyacrylic acid (PAA), polymethacrylate (PMA),
polymethylmethacrylate (PNLMA) or mixtures or copolymers thereof. In some
aspects, a
polymer matrix comprises a polyolefin including, but not limited to
polyethylene,
polypropylene, polybutylene or mixtures or copolymers thereof. A polymeric
matrix can also
comprise one or more conjugated polymers and can comprise one or more
semiconducting
polymers.
[0028] As a person of ordinary skill will understand, the "Seebeck
coefficient" of a
material is a measure of the magnitude of an induced thermoelectric voltage in
response to a
temperature difference across that material. A p-type layer, in some aspects,
can have a
Seebeck coefficient of at least about 3 OA at a temperature of 290" K. In some
aspects, a
p-type layer has a Seebeck coefficient of at least about 5 ii.V/K at a
temperature of 290 K. In
some aspects, a p-type layer has a Seebeck coefficient of at least about 10
itV/K at a
temperature of 290 K. In some aspects, a p-type layer has a Seebeck
coefficient of at least
about 15 iiV/K or at least about 20 tiV/K at a temperature of 290 K. In some
aspects, a p-
type layer has a Seebeck coefficient of at least about 30 1.1V/K at a
temperature of 290 K. A
p-type layer, in some aspects, has a Seebeck coefficient ranging from about 3
ti.V/K to about
35 ii.V/K at a temperature of 290 K. A p-type layer, in some aspects, has a
Seebeck
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coefficient ranging from about 5 V/K to about 35 AUK at a temperature of 290
K. In some
aspects, a p-type layer has Seebeck coefficient ranging from about 10 iiV/K to
about 30 ItV/K
at a temperature of 2900 K. As described herein, in some aspects, the Seebeck
coefficient of
a p-type layer can be varied according to carbon nanoparticle identity and
loading. In some
aspects, for example, the Seebeck coefficient of a p-type layer is inversely
proportional to the
single-walled carbon nanotube loading of the p-type layer.
[0029] Similarly, an n-type layer can have a Seebeck coefficient of at least
about -3
[tV/K at a temperature of 290 K. In some aspects, an n-type layer has a
Seebeck coefficient
at least about -5 tiV/K at a temperature of 290 K. In some aspects, an n-type
layer has a
Seebeck coefficient at least about -10 p.V/K at a temperature of 290 K. In
some aspects, an
n-type layer has a Seebeck coefficient of at least about -15 V/K or at least
about -20 1.tV/K.
at a temperature of 290 K. In some aspects, an n-type layer has a Seebeck
coefficient of at
least about -30 tiV/K at a temperature of 290 K. An n-type layer, in some
aspects, has a
Seebeck coefficient ranging from about -3 V/K to about -35 V/K at a
temperature of 290
K. In some aspects, an n-type layer has Seebeck coefficient ranging from about
-5 V/K to
about -35 V/K at a temperature of 290 K. In some aspects, an n-type layer
has Seebeck
coefficient ranging from about -10 tiV/K to about -30 tiV/K at a temperature
of 290 K. In
some aspects, the Seebeck coefficient of an n-type layer can be varied
according to n-doped
carbon nanoparticle identity and loading. In some aspects, for example, the
Seebeck
coefficient of an n-type layer is inversely proportional to the carbon
nanoparticle loading of
the n-type layer.
[0030] As described herein and in U.S. Publication No. 2013/0312806, in some
aspects the flexible thermoelectric fabric can include an insulating layer. An
insulating layer
can comprise one or more polymeric materials. Any polymeric material not
inconsistent with
the objectives of the present invention can be used in the production of an
insulating layer. In
some aspects, an insulating layer comprises polyacrylic acid (PAA),
polymethacrylate
(PMA), polymethylmethacrylate (PMMA) or mixtures or copolymers thereof. In
some
aspects, an insulating layer comprises a polyolefin including, but not limited
to polyethylene,
polypropylene, polybutylene or mixtures or copolymers thereof. In some
aspects, an
insulating layer comprises PVDF. An insulating layer can have any desired
thickness not
inconsistent with the objectives of the present invention. In some aspects, an
insulating layer
has a thickness of at least about 50 nm. In some aspects, an insulating layer
has a thickness
ranging from about 5 nm to about 50 p.m. Additionally, an insulating layer can
have any
desired length not inconsistent with the objectives of the present invention.
In some aspects,
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an insulating layer has a length substantially consistent with the lengths of
the p-type and n-
type layers between which the insulating layer is disposed. That is, in some
aspects, an
insulating layer, p-type layer, andlor n-type layer can have a length of at
least about 1 lArn. In
some aspects, an insulating layer, p-type layer, andlor n-type layer can have
a length ranging
from about 1 pm to about 500 mm.
[0031] In use, the flexible thermoelectric fabric can be incorporated into a
mattress
assembly. In so doing, the mattress assembly can be configured to be a
temperature control
mattress and, additionally or alternatively, can be configured to produce an
electric charge.
FIG. 4 illustrates an example mattress assembly 400 having a body support 402.
The body
support 402 has a proximal surface 404 that can support a body 406. The body
406, as
shown, can be a human body and the body support 402 can be configured to
support the body
in a prone, supine, semi-supine, sitting, or any other position so long as the
body support 402
supports some portion of the body.
[0032] FIG. 5 illustrates an example mattress assembly 500. As shown, the
mattress
assembly 500 can have an inner support 502 and a body support surface 504. In
some
aspects, the inner support 502 can be any of a spring, foam, air, or any other
core support
structure known in the art. The body support surface 504 can, as shown,
include a variety of
layers 506, 508, 510, 512, 514. The layers can be formed of any support
material including
foams, gels, fabrics, down feathers, or any other known support material.
Additionally, the
layers 506, 508, 510, 512, 514 can be configured to allow heat to transfer
from the proximal
surface or proximal most layer 506 to the distal most layer 514. As such, a
flexible
thermoelectric fabric can be disposed between any of layers 506, 508, 510,
512, 514.
Alternatively and/or additionally, any of the layers 506, 508, 510, 512, 514
can be formed of
an example flexible thermoelectric fabric in accordance with the disclosures
made herein.
For example, layer 506 can be a decorative quilt mattress topper. In some
aspects, the quilt
topper 506 can be formed of a flexible thermoelectric fabric.
[0033] As shown in FIG. 6, the flexible thermoelectric fabric 608 can be
formed of
stacked p-layers, n-layers, and insulation layers, as is described above. As
such, the flexible
thermoelectric fabric 608 can be configured to utilize the Peltier effect
and/or the Seebeck
effect. As used herein and as a person of ordinary skill will understand, the
"Peltier effect"
means the presence of heating or cooling at an electrified junction of two
different
conductors. Further, as a person of ordinary skill will understand, the
"Seebeck effect"
means an induced thermoelectric voltage in response to a temperature
differential across a
material.
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[0034] FIG. 7 illustrates an exemplary diagram of the Peltier effect, which
can result
in cooling of the body support surface when the flexible thermoelectric fabric
is disposed
such that it is in thermal communication with the proximal surface of the body
support. In
this manner, the top-most layer 702 of the fabric is cooled as charge moves
through the p-
layer 704 and n-layers 706 accordingly. As such, heat is dissipated along a
bottom-most
surface 708 of the fabric as the p-layer(s) and n-layer(s) are connected by a
circuit 710.
[0035] Fig. 8 illustrates a schematic diagram of the Seebeck effect, which can
result
in the generation of an electrical voltage when the flexible fabric is heated
at the proximal
surface of the body support, such as when a human lays on the body support and
transfers its
body heat into the proximal surface of the body support. As shown, the top-
most surface 802
of the fabric is exposed to a heat source¨i.e., a sleeper's body heat¨and the
bottom-most
surface 808 is at a temperature that is cooler than the top-most layer 802.
Voltage is
generated by the system when the p-layers 804 are connected to the n-layers
806 with a load
resistor 810.
[0036] Thus, in some aspects, either to maximize temperature regulation of the
sleeping surface (i.e., the proximal surface of the body support) or to
maximize a current
generated by the flexible fabric, the fabric can be disposed along an entire
proximal surface
of a mattress. As was described above, for example, a mattress topper can be
formed entirely
of flexible thermoelectric fabric. Alternatively, the fabric can be
strategically located along
portions of the fabric so as to maximize thermal communication between the
proximal
surface and the fabric. That is, the fabric can be placed in any manner that
is consistent with
absorbing a desired and/or optimal amount of body heat from a body.
Additionally, the
flexible nature of the example thermoelectric fabrics provide various
advantages as described
herein. For example, they are less costly to produce, more comfortable, more
easily
integrated and would provide more well distributed functionality on a large
surface such as a
mattress. The above disclosure solves positional and comfort issues by
allowing for uniform
thermal control decreasing hot spots or cold spots. This in turn also allows
the sleeper to
move freely without sensing changes in the cooling/heating system efficiency
and
furthermore, allows for the thermoelectric system to be near the surface of
the mattress for
greater efficiency.
[0037] With respect to the above description, it is to be realized that the
optimum
composition for the parts of the invention, to include variations in
components, materials,
size, shape, form, function, and manner of operation, assembly and use, are
deemed readily
apparent to one skilled in the art, and all equivalent relationships to those
illustrated in the
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examples and described in the specification are intended to be encompassed by
the present
invention. Therefore, the foregoing is considered as illustrative only of the
principles of the
invention. Further, various modifications may be made of the invention without
departing
from the scope thereof, and it is desired, therefore, that only such
limitations shall be placed
thereon as are set forth in the appended claims.
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