Controlling a Mattress Climate-Control System Based on Thermal Event Gradient

This application claims benefit of U.S. Provisional Application No. 63/573,684, filed on Apr. 3, 2024. The disclosure of the prior application is hereby incorporated by reference in its entirety.

The present document relates to bed systems, and more particularly to techniques and components for controlling bed systems.

In general, a bed is a piece of furniture used as a location to sleep or relax. Many modern beds include a soft mattress on a bed frame. The mattress may include springs, foam material, and/or an air chamber to support the weight of one or more occupants. Various features and systems have been used in conjunction with beds, including heating and cooling systems for heating and cooling a user of a bed. A thermal event such as a fire in the mattress may warrant a mechanism for controlling various mattress components such as climate-control systems for heating and cooling the mattress in reliable, secured, and efficient ways in response to the thermal event occurring at the mattress.

Some embodiments described herein include a bed system with fire protection capabilities. The bed system can include a mattress climate-control system configured to supply conditioned air (e.g., heated or cooled air) to a mattress to achieve a desired temperature of the mattress. A thermal sensor and a controller can be used to detect a thermal event (such as a fire, including an incipient fire, a free burning fire, a smoldering fire, or other potentially dangerous thermal event) at the mattress and operate the mattress climate-control system based on the thermal event. Any thermal event that has a temperature gradient greater than or equal to a threshold temperature gradient will be detected by the thermal sensor. For example, the thermal sensor can be positioned in the mattress, in a mattress foundation on which the mattress rests, or in the climate-control system. A condition of the thermal sensor can change in response to the thermal event at the mattress. The controller detects the condition of the thermal sensor. Based on the condition of the thermal sensor, the controller operates the mattress climate-control system to disable one or more functions or components of the mattress climate-control system.

Some embodiments described herein include a bed system having a mattress, a mattress climate-control system, a thermal sensor, and a controller. The mattress climate-control system controls a climate at the mattress. The thermal sensor is positioned at the mattress. A condition of the thermal sensor changes in response to a thermal event at the mattress. The controller is connected to the mattress climate-control system. The controller performs operations including detecting the condition of the thermal sensor and operating the mattress climate-control system based on the condition of the thermal sensor.

Embodiments described herein can include one or more optional features. For example, the mattress climate-control system can include a heater coupled to the mattress to heat at least a portion of the mattress. For example, the mattress climate-control system can include a fan coupled to the mattress to supply or draw air to a top of the mattress.

In one aspect, a bed system includes a mattress, a mattress climate-control system to control a climate at the mattress, a thermal sensor positioned in the mattress climate-control system, and a controller connected to the mattress climate-control system. A condition of the thermal sensor changes in response to a thermal event proximate the mattress climate-control system. The controller performs operations including detecting the condition of the thermal sensor indicating the thermal event; and based on the condition of the thermal sensor, operating the mattress climate-control system. The thermal event includes a change in temperature with respect to time equal to or greater than a threshold change in temperature with respect to time.

In another aspect combinable with any other aspect, the threshold change in temperature with respect to time is 0.5 Fahrenheit per second (° F./s).

In another aspect combinable with any other aspect, the thermal sensor is positioned in an exhaust air flow of the mattress climate-control system.

In another aspect combinable with any other aspect, the thermal sensor includes at least one of a thermocouple, a resistance temperature device, or a thermistor.

In another aspect combinable with any other aspect, the mattress climate-control system includes a fan coupled to the mattress to draw air from a top of the mattress.

In another aspect combinable with any other aspect, operating the mattress climate-control system includes disabling the fan.

In another aspect combinable with any other aspect, the mattress climate-control system defines an air flow path.

In another aspect combinable with any other aspect, the air flow path passes from a core of the mattress to a thermal layer positioned above the core and out the thermal layer.

In another aspect combinable with any other aspect, the mattress further includes a core to pass a flow of air.

In another aspect combinable with any other aspect, the mattress climate-control system includes a thermal layer, an extended thermal layer, and a fan housing. The thermal layer is coupled to the core. The thermal layer receives the flow of air from the core and conducts the flow of air. The extended thermal layer is coupled to the thermal layer. The extended thermal layer receives the flow of air from the thermal layer and conducts the flow of air. The fan housing has a fan inlet, a fan, and a fan outlet. The fan inlet is coupled to the extended thermal layer. The fan draws air from a space outside the mattress into the core, through the thermal layer, through the extended thermal layer, through the fan inlet, through the fan housing, and out the fan outlet back into another space outside the mattress away from the core.

In another aspect combinable with any other aspect, the fan is positioned proximate a foot portion of the bed system. The extended thermal layer extends from the thermal layer to the foot portion.

In another aspect combinable with any other aspect, the controller samples the condition of the thermal sensor at a rate of between 1 and 5 Hz.

In another aspect combinable with any other aspect, operating the mattress climate-control system includes generating an alarm notifying a user of the thermal event.

In another aspect, a mattress climate-control system includes a thermal layer, a fan, a temperature sensor, and a controller. The fan draws air from the thermal layer.

The temperature sensor is positioned in an exhaust of the fan. The temperature sensor senses a condition of the air in the exhaust. The temperature sensor transmits a signal representing the condition of the air in the exhaust to the controller. The condition includes a change in temperature with respect to time equal to or greater than a threshold change in temperature with respect to time. The controller performs operations including receiving the signal representing the condition of the air in the exhaust; comparing the condition of the air in the exhaust to a threshold condition of the air in the exhaust to obtain a comparison result; and based on the comparison result, operating the mattress climate-control system.

In another aspect, a mattress assembly includes a thermal sensor and a controller. The thermal sensor senses a condition of air in an exhaust of a fan to cool the mattress assembly. The thermal sensor transmits a signal representing the condition of the air in the exhaust. The condition of the air includes a change in temperature with respect to time equal to or greater than a threshold change in temperature with respect to time. The controller performs operations including receiving the signal representing the condition of the air in the exhaust; comparing the condition of air in the exhaust to a threshold condition of the air in the exhaust to obtain a comparison result; and based on the comparison result, operating the mattress assembly.

In another aspect, a method includes detecting a thermal event in a mattress with a thermal sensor, where the thermal event includes a change in temperature with respect to time equal to or greater than a threshold change in temperature with respect to time; and based on detecting the thermal event, disabling a mattress climate-control system positioned in the mattress.

In another aspect combinable with any other aspect, the method includes transmitting a signal indicating an occurrence of thermal event to a user computing device.

In another aspect combinable with any other aspect, disabling the mattress climate-control system includes disabling at least a fan of the mattress climate-control system.

In another aspect combinable with any other aspect, disabling the mattress climate-control system includes disabling at least a fan and a heater of the mattress climate-control system.

In another aspect combinable with any other aspect, disabling the mattress climate-control system includes disabling all of the mattress climate-control system.

In another aspect a mattress includes a fan, a temperature sensor, and a controller. The fan moves air through the mattress. The controller is in communication with the fan and the temperature sensor. The controller detects a fire as a function of a temperature gradient and reduces speed of the fan in response to detecting the fire.

In another aspect combinable with any other aspect, the temperature gradient includes a change in temperature with respect to time equal to or greater than a threshold change in temperature with respect to time.

In another aspect combinable with any other aspect, the fan, the temperature sensor, and the controller are positioned in a common housing.

The devices, system, and techniques described herein may provide one or more of the following advantages. Some embodiments described herein include a mattress with one or more thermal sensors to detect a thermal event and a controller to operate a climate-control system based on detecting the thermal event.

The time to detect a thermal event can be decreased. For example, by positioning one or more thermal sensor in the mattress in the exhaust air flow downstream from where the thermal event may occur, the time to detect the thermal event can be decreased.

The time to operate the climate-control system in response to the thermal event can be decreased. For example, by positioning one or more thermal sensor in the mattress in the exhaust air flow downstream from where the thermal event may occur, the thermal event can be detected sooner, reducing the time to operate the climate-control system responsive to the controller detecting the change in condition of the thermal sensor.

User safety can be improved. For example, when the user is on the mattress and the thermal event occurs on the mattress, the climate-control system can be transitioned to an OFF state, reducing an air flow or a heat input into the mattress, reducing a condition or a magnitude of the thermal event.

Damage to the mattress as a result of the thermal event can be reduced. For example, by positioning one or more thermal sensors in the mattress in the exhaust air flow downstream from where the thermal event may occur, the time to detect the thermal event can be decreased.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects and potential advantages will be apparent from the accompanying description and figures.

Like reference symbols in the various drawings indicate like elements.

shows an example air bed systemthat includes a bed, a climate-control systemwith fans, a thermal sensor, and a controller. The climate-control systemcontrols a climate of the air bed systemmoving air through channelsin the mattresswith the fansto cool the bed. One or more thermal sensorsare positioned at the bed(a mattress). A condition of the thermal sensorchanges in response to a thermal event at the mattress. For example, the thermal event can be a change or an increase in a temperature of the air bed systemwhich changes the condition of the thermal sensor. The controlleris operatively coupled to the climate-control system. The controllerdetects the condition of the thermal sensorand based on the condition of the thermal sensor, operates the climate-control system, for example, by selectively operating or disabling one or more features or components of the climate-control system. While the climate-control systemis shown and described as part of an air bed system (the air bed system) with air chambers, the climate-control systemcan also be used with non-air bed systems (e.g., systems without inflatable air chambers). Accordingly, the air bed systemcould be modified to be a non-air bed system that includes none, one, or several of the features and components described with respect to the air bed system. The climate-control system, the thermal sensor, and the controllerare described in more detail in reference to.

The bedcan be a mattress that includes at least one air chambersurrounded by a resilient borderand encapsulated by bed ticking. The resilient bordercan include any suitable material, such as foam. In some embodiments, the resilient bordercan combine with a top layer or layers of foam (not shown in) to form an upside-down foam tub (a foam tubshown in). In other embodiments, mattress structure can be varied as suitable for the application.

As illustrated in, the bedcan be a two chamber design having first and second fluid chambers, such as a first air chamberA and a second air chamberB. Sometimes, the bedcan include chambers for use with fluids other than air that are suitable for the application. For example, the fluids can include liquid. In some embodiments, such as single beds or children's beds, the bedcan include a single air chamberA orB or multiple air chambersA andB. Although not depicted, sometimes the bedcan include additional air chambers.

The first and second air chambersA andB can be in fluid communication with a pump. The pumpcan be in electrical communication with a remote controlvia control box. The control boxcan include a wired or wireless communications interface for communicating with one or more devices, including the remote control. The control boxcan be configured to operate the pumpto cause increases and decreases in the fluid pressure of the first and second air chambersA andB based upon commands input by a user using the remote control. In some implementations, the control boxis integrated into a housing of the pump. Moreover, sometimes, the pumpcan be in wireless communication (e.g., via a home network, WiFi, Bluetooth, or other wireless network) with a mobile device via the control box. The mobile device can include, but is not limited to, the user's smartphone, cell phone, laptop, tablet, computer, wearable device, home automation device, or other computing device. A mobile application can be presented at the mobile device and provide functionality for the user to control the bedand view information about the bed. The user can input commands in the mobile application presented at the mobile device. The inputted commands can be transmitted to the control box, which can operate the pumpbased upon the commands.

The remote controlcan include a display, an output selecting mechanism, a pressure increase button, and a pressure decrease button. The remote controlcan include one or more additional output selecting mechanisms and/or buttons. The displaycan present information to the user about settings of the bed. For example, the displaycan present pressure settings of both the first and second air chambersA andB or one of the first and second air chambersA andB. Sometimes, the displaycan be a touch screen, and can receive input from the user indicating one or more commands to control pressure in the first and second air chambersA andB and/or other settings of the bed. The remote controlcan control the climate-control systemby operating the fans. For example, the remote controlcan, based on the user inputs, turn on, turn off, increase a speed, or decrease the speed of the fans.

The output selecting mechanismcan allow the user to switch air flow generated by the pumpbetween the first and second air chambersA andB, thus enabling control of multiple air chambers with a single remote controland a single pump. For example, the output selecting mechanismcan be a physical control (e.g., switch or button) or an input control presented on the display. Alternatively, separate remote control units can be provided for each air chamberA andB and can each include the ability to control multiple air chambers. Pressure increase and decrease buttonsandcan allow the user to increase or decrease the pressure, respectively, in the air chamber selected with the output selecting mechanism. Adjusting the pressure within the selected air chamber can cause a corresponding adjustment to the firmness of the respective air chamber. In some embodiments, the remote controlcan be omitted or modified as appropriate for an application.

is a block diagram of an example of various components of an air bed system. These components can be used in the example air bed system. The control boxcan include a power supply, a processor, a memory, a switching mechanism, and an analog to digital (A/D) converter. The switching mechanismcan be, for example, a relay or a solid state switch. In some implementations, the switching mechanismcan be located in the pumprather than the control box. The pumpand the remote controlcan be in two-way communication with the control box. The pumpincludes a motor, a pump manifold, a relief valve, a first control valveA, a second control valveB, and a pressure transducer. The pumpis fluidly connected with the first air chamberA and the second air chamberB via a first tubeA and a second tubeB, respectively. The first and second control valvesA andB can be controlled by switching mechanism, and are operable to regulate the flow of fluid between the pumpand first and second air chambersA andB, respectively.

In some implementations, the pumpand the control boxcan be provided and packaged as a single unit. In some implementations, the pumpand the control boxcan be provided as physically separate units. The control box, the pump, or both can be integrated within or otherwise contained within a bed frame, foundation, or bed support structure that supports the bed. Sometimes, the control box, the pump, or both can be located outside of a bed frame, foundation, or bed support structure (as shown in the example in).

The air bed systeminincludes the two air chambersA andB and the single pumpof the beddepicted in. However, other implementations can include an air bed system having two or more air chambers and one or more pumps incorporated into the air bed system to control the air chambers. For example, a separate pump can be associated with each air chamber. As another example, a pump can be associated with multiple chambers. A first pump can be associated with air chambers that extend longitudinally from a left side to a midpoint of the air bed systemand a second pump can be associated with air chambers that extend longitudinally from a right side to the midpoint of the air bed system. Separate pumps can allow each air chamber to be inflated or deflated independently and/or simultaneously. Additional pressure transducers can also be incorporated into the air bed systemsuch that a separate pressure transducer can be associated with each air chamber.

As an illustrative example, in use, the processorcan send a decrease pressure command to one of air chambersA orB, and the switching mechanismcan convert the low voltage command signals sent by the processorto higher operating voltages sufficient to operate the relief valveof the pumpand open the respective control valveA orB. Opening the relief valvecan allow air to escape from the air chamberA orB through the respective air tubeA orB. During deflation, the pressure transducercan send pressure readings to the processorvia the A/D converter. The A/D convertercan receive analog information from pressure transducerand can convert the analog information to digital information useable by the processor. The processorcan send the digital signal to the remote controlto update the displayto convey the pressure information to the user. The processorcan also send the digital signal to other devices in wired or wireless communication with the air bed system, including, but not limited to, mobile devices described herein. The user can then view pressure information associated with the air bed system at their device instead of at, or in addition to, the remote control.

As another example, the processorcan send an increase pressure command. The pump motorcan be energized in response to the increase pressure command and can send air to the designated one of the air chambersA orB through the air tubeA orB via electronically operating the corresponding control valveA orB. While air is being delivered to the designated air chamberA orB to increase the chamber firmness, the pressure transducercan sense pressure within the pump manifold. The pressure transducercan send pressure readings to the processorvia the A/D converter. The processorcan use the information received from the A/D converterto determine the difference between the actual pressure in air chamberA orB and the desired pressure. The processorcan send the digital signal to the remote controlto update a display.

Generally speaking, during an inflation or deflation process, the pressure sensed within the pump manifoldcan provide an approximation of the actual pressure within the respective air chamber that is in fluid communication with the pump manifold. An example method includes turning off the pump, allowing the pressure within the air chamberA orB and the pump manifoldto equalize, then sensing the pressure within the pump manifoldwith the pressure transducer. Providing a sufficient amount of time to allow the pressures within the pump manifoldand chamberA orB to equalize can result in pressure readings that are accurate approximations of actual pressure within air chamberA orB. In some implementations, the pressure of the air chambersA and/orB can be continuously monitored using multiple pressure sensors (not shown). The pressure sensors can be positioned within the air chambers. The pressure sensors can also be fluidly connected to the air chambers, such as along the air tubesA andB.

In some implementations, information collected by the pressure transducercan be analyzed to determine various states of a user laying on the bed. For example, the processorcan use information collected by the pressure transducerto determine a heartrate or a respiration rate for the user. As an illustrative example, the user can be laying on a side of the bedthat includes the chamberA. The pressure transducercan monitor fluctuations in pressure of the chamberA, and this information can be used to determine the user's heartrate and/or respiration rate. As another example, additional processing can be performed using the collected data to determine a sleep state of the user (e.g., awake, light sleep, deep sleep). For example, the processorcan determine when the user falls asleep and, while asleep, determine the various sleep states (e.g., sleep stages) of the user. Based on the determined heartrate, respiration rate, and/or sleep states of the user, the processorcan determine information about the user's sleep quality. The processorcan, for example, determine how well the user slept during a particular sleep cycle. The processorcan also determine user sleep cycle trends. Accordingly, the processorcan generate recommendations to improve the user's sleep quality and overall sleep cycle. Information that is determined about the user's sleep cycle (e.g., heartrate, respiration rate, sleep states, sleep quality, recommendations to improve sleep quality, etc.) can be transmitted to the user's mobile device and presented in a mobile application, as described above.