Bedding products having flexible gel panels

Abstract

A bedding product, such as a mattress, mattress topper, or pillow, includes a flexible gel panel having a gel layer with a top surface and a bottom surface, a flexible top layer overlying the top surface of the gel layer, and a flexible bottom layer overlying the bottom surface of the gel layer. The bedding product has a major surface and the flexible gel panel is integrated into the bedding product so that the flexible top layer of the flexible gel panel is juxtaposed with the major surface of the bedding product. The flexible gel panel removes body heat during use.

Claims

1. A bedding product comprising: a flexible gel panel having a length and a width defining a perimeter, said flexible gel panel including a gel layer having a top surface and a bottom surface, a flexible top layer overlying said top surface of said gel layer to form a top surface of said flexible gel panel, and a flexible bottom layer overlying said bottom surface of said gel layer to form a bottom surface of said flexible gel panel, wherein said gel layer has a wave configuration including thicker gel sections that are connected to one another by thinner gel filled valleys, wherein said thicker gel sections and said thinner gel filled valleys cooperate to form a continuous gel layer that extends continuously within the perimeter of said flexible gel panel, and wherein said flexible top layer and said flexible bottom layer are continuously separated from one another by said continuous gel layer that extends continuously within the perimeter of said flexible gel panel; and said bedding product having a major surface, wherein said flexible gel panel is integrated into said bedding product so that said flexible top layer of said flexible gel panel is juxtaposed with said major surface of said bedding product.

2. The bedding product as claimed in claim 1, wherein said gel layer comprises a cured gel layer.

3. The bedding product as claimed in claim 1, wherein said flexible top layer is bonded to said top surface of said gel layer, and said flexible bottom layer is bonded to said bottom surface of said gel layer.

4. The bedding product as claimed in claim 1, wherein said flexible top layer is selected from the group consisting of a clear film, a polyurethane film, and a TPU film.

5. The bedding product as claimed in claim 1, wherein said flexible bottom layer is selected from the group consisting of a flexible fabric, stretchable fabric, a phase change fabric, lightweight fabric, and a mesh fabric.

6. The bedding product as claimed in claim 1, wherein said gel layer spaces said flexible top layer from said flexible bottom layer at said gel filled valleys.

7. The bedding product as claimed in claim 1, wherein said flexible top layer overlying said top surface of said gel layer extends continuously within the perimeter of said flexible gel panel and said flexible bottom layer overlying said bottom surface of said gel layer extends continuously within the perimeter of said flexible gel panel, wherein said thicker gel sections comprise gel tubes that are connected to one another by said gel filled valleys that extend between said gel tubes to cooperatively form said continuous gel layer having the wave configuration.

8. The bedding product as claimed in claim 1, wherein said bedding product is selected from the group consisting of a pillow, a memory foam pillow, a mattress, a memory foam mattress, a mattress topper, a memory foam mattress topper, a pillowcase, a flat sheet, a fitted sheet, and a mattress protector.

9. The bedding product as claimed in claim 1, wherein said bedding product comprises a memory foam pillow having a major surface, and wherein said flexible gel panel is juxtaposed with said major surface of said memory foam pillow.

10. The bedding product as claimed in claim 1, wherein said flexible gel panel overlies a major surface of a pillow case.

11. The bedding product as claimed in claim 1, wherein said bedding product comprises a mattress topper having a major surface and said flexible gel panel is juxtaposed with said major surface of said mattress topper.

12. The bedding product as claimed in claim 1, wherein said bedding product comprises a memory foam mattress having a major surface, and wherein said flexible gel panel is juxtaposed with said major surface of said memory foam mattress.

13. The bedding product as claimed in claim 1, wherein said thicker gel sections of said gel layer comprise an array of geometric shapes selected from the group consisting of tubes, squares, circles, and triangles.

14. A bedding product comprising: a flexible gel panel having a length and a width defining a perimeter, said flexible gel panel including a gel layer having a top surface and a bottom surface, a flexible top layer overlying said top surface of said gel layer to form a top surface of said flexible gel panel, and a flexible bottom layer overlying said bottom surface of said gel layer to form a bottom surface of said flexible gel panel, wherein said gel layer has a wave configuration including thicker gel sections that are connected to one another by thinner gel filled valleys, wherein said thicker gel sections and said thinner gel filled valleys cooperate so that said gel layer extends continuously within the perimeter of said flexible gel panel for separating said flexible top layer and said flexible bottom layer; said bedding product having a major face, wherein said flexible top layer of said flexible gel panel is juxtaposed with said major face of said bedding product.

15. The bedding product as claimed in claim 14, wherein said bedding product is selected from the group consisting of a pillow, a memory foam pillow, a mattress, a memory foam mattress, a mattress topper, a memory foam mattress topper, a pillowcase, a flat sheet, a fitted sheet, and a mattress protector.

16. The bedding product as claimed in claim 14, wherein said gel layer is cured, and wherein said flexible top layer is bonded with said top surface of said cured gel layer and said flexible bottom layer is bonded with said bottom surface of said cured gel layer.

17. The bedding product as claimed in claim 1, wherein said thicker gel sections of said gel layer comprise an array of geometric shapes selected from the group consisting of tubes, squares, circles, and triangles.

18. A bedding product comprising: a flexible gel panel having a length and a width defining a perimeter, said flexible gel panel including a gel layer having a top surface and a bottom surface, a flexible top layer overlying said top surface of said gel layer, and a flexible bottom layer overlying said bottom surface of said gel layer, wherein said gel layer has a wave configuration including thicker gel sections that are connected to one another by thinner gel filled valleys, wherein said thicker gel sections and said thinner gel filled valleys cooperate so that said gel layer extends continuously within the perimeter of said flexible gel panel for separating said flexible top layer and said flexible bottom layer; said bedding product having a major face, wherein said flexible top layer of said flexible gel panel is juxtaposed with said major face of said bedding product.

19. The bedding product as claimed in claim 18, wherein said bedding product is selected from the group consisting of a pillow, a memory foam pillow, a mattress, a memory foam mattress, a mattress topper, a memory foam mattress topper, a pillowcase, a flat sheet, a fitted sheet, and a mattress protector.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a top plan view of a first mold part used for making a flexible gel panel, in accordance with one embodiment of the present invention.

(2) FIGS. 2A-2F show a method of making a flexible gel panel, in accordance with one embodiment of the present invention.

(3) FIG. 3 shows a cross-sectional view of a flexible gel panel, in accordance with one embodiment of the present invention.

(4) FIG. 4A shows a perspective view of a first surface of a flexible gel panel, in accordance with one embodiment of the present invention.

(5) FIG. 4B shows a magnified view of the first surface of the flexible gel panel shown in FIG. 4A.

(6) FIG. 4C shows a flexible gel panel sewn into a bedding product, in accordance with one embodiment of the present invention.

(7) FIG. 5A shows a perspective view of a second surface of a flexible gel panel, in accordance with one embodiment of the present invention.

(8) FIG. 5B shows a magnified view of a second surface of the flexible gel panel shown in FIG. 5A.

(9) FIG. 5C shows a flexible gel panel sewn into a bedding product, in accordance with one embodiment of the present invention.

(10) FIG. 6 shows a bedding product including a flexible gel panel that covers 100% of the top surface of a mattress, in accordance with one embodiment of the present invention.

(11) FIG. 7 shows a bedding product including a flexible gel panel that covers 50% of the top surface of a mattress, in accordance with one embodiment of the present invention.

(12) FIG. 8 shows a bedding product including a pair of flexible gel panels that cover about 70% of a top surface of a mattress, in accordance with one embodiment of the present invention.

(13) FIG. 9 shows a bedding product including a flexible gel panel that covers one half of a mattress, in accordance with one embodiment of the present invention.

(14) FIGS. 10A-10C show a pillow case having a flexible gel panel incorporated into one of the major panels of the pillow case, in accordance with one embodiment of the present invention.

(15) FIG. 11 shows a pillow insertable into the pillow case of FIGS. 10A-10C, in accordance with one embodiment of the present invention.

(16) FIGS. 12A-12D show a method of placing the pillow of FIG. 11 inside the pillow case with the flexible gel panel of the FIGS. 10A-10C, in accordance with one embodiment of the present invention.

(17) FIG. 12E shows a magnified view of a major face of the pillow case of FIG. 12D including a flexible gel layer incorporated into a major panel of the pillow case, in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION

(18) Referring to FIG. 1, in one embodiment, a mold for making a flexible gel panel for sleep products preferably includes a first mold part 20 having a first end 22, a second end 24, and a length L.sub.1 extending between the first and second ends. The first mold part 20 also has side edges 26, 28 that define a width W.sub.1. In one embodiment, the length L.sub.1 is about 4-10 feet and the width W.sub.1 is about 3-6 feet.

(19) Referring to FIGS. 1 and 2A, the first mold part 20 includes a plurality of grooves 30 that extend along the length of the mold. In one embodiment, the grooves 30 have a semi-circular shape. The first mold part 20 also has flat surfaces 32 disposed between the grooves 30. The flat surfaces 32 are preferably co-planar and extend along the length L.sub.1 of the first mold part 20.

(20) In one embodiment, the grooves 30 of the mold may have other shapes such as square, circular, triangular, or other geometric shapes or patterns. In one embodiment, the grooves 30 of the mold may be multi-dimensional.

(21) Referring to FIG. 2B, in one embodiment, a TPU film 34 is disposed over the flat surfaces 32 of the first mold part 20. Referring to FIG. 2C, heat and/or vacuum may be applied for collapsing the TPU film 34 into the grooves 30 of the first mold part 20 so that the TPU film conforms to the shape of the grooved face of the first mold part 20.

(22) Referring to FIG. 2D, a second mold part 20 is juxtaposed with the first mold part 20. The second mold part 20 preferably mirrors the first mold part 20. In one embodiment, the second mold part 20 includes a plurality of elongated grooves 30 and flat surfaces 32 that extend between the elongated grooves 30. A flexible fabric sheet 36, such as a four way stretchable sheet of fabric, is preferably disposed between the opposing grooved faces of the first and second mold parts 20, 20.

(23) Referring to FIG. 2E, in one embodiment, a layer of a curable gel 38, such as a polyether gel, is provided over the TPU film 34. In one embodiment, the curable gel is dispensed over the first mold part 20. In another embodiment, the curable gel may be injection molded between the first and second mold parts 20, 20.

(24) In one embodiment, the first and second mold parts 20, 20 are closed, whereby the fabric sheet 36 conforms to the shape of the grooved face of the second mold part 20. Heat and pressure are preferably applied to the laminate through the first and second mold parts 20, 20 to form a flexible gel panel 40 including a TPU film 34, a gel layer 38, and a flexible fabric layer 36. The flexible gel panel 40 preferably has a first surface 42 that conforms to the grooved face of the first mold part 20 and a second surface 44 that conforms to the grooved face of the second mold part 20.

(25) In one embodiment, the second mold part 20 is not used. After the gel is dispensed atop the first mold part 20, the fabric layer 36 is placed over the top surface of the gel material and the gel is cured, whereby the fabric layer 36 is bonded to the top surface of the gel layer. The fabric layer 36 preferably conforms to the shape of the cured gel layer for mirroring the shape of the cured gel layer.

(26) Referring to FIG. 2F, after sufficient levels of heat and pressure have been applied to the laminate, the first and second mold parts 20, 20 may move away from one another for opening the mold. Referring to FIGS. 2F and 3, the flexible gel panel 40 including the TPU film 34, the gel layer 38, and the fabric layer 36 is removed from the mold. The first surface 42 of the gel panel 40 is covered by the TPU film 34 and the second surface 44 of the gel panel 40 is covered by the flexible fabric 36.

(27) Referring to FIGS. 3 and 4A, the gel layer 38 of the flexible gel panel 40 includes a plurality of elongated gel tubes 50 that extend along the length L.sub.2 of the panel. The gel tubes 50 are connected to one another by gel filled valleys 52 that extend between the gel tubes 50. The gel tubes 50 and gel valleys 52 cooperate to form the continuous gel panel 40 having a wave configuration. When the flexible gel panel 40 is positioned atop a mattress, the first surface 42 that is covered by the TPU film 34 preferably faces upward for being contacted by an individual sleeping on the mattress. In the embodiment shown in FIG. 4A, the TPU film 34 is transparent.

(28) FIG. 4B shows a magnified view of the flexible gel panel 40 shown in FIG. 4A. The flexible gel panel 40 includes a transparent TPU film 34 covering the gel tubes 50 and the gel depressions 52 between the gel tubes. The transparent TPU film desirably covers the first surface 42 of the gel panel 40, which desirably faces individuals lying atop the bed for providing a cool sleeping surface.

(29) One embodiment of the present invention discloses gel that is arrayed as elongated gel tubes. In other embodiments, however, the gel of the gel panel may have a different pattern or shape, such as a square pattern or shape, a circular pattern or shape, a multi-dimensional pattern or shape, or other geometric patterns or shapes (e.g. triangular).

(30) Referring to FIG. 4C, in one embodiment, the flexible gel panel 40 is sewn to a sheet of fabric 54 having and outer edge 56 with a zipper 58. The flexible gel panel 40 may be inserted into a sleep product, such as a mattress topper. The zipper 58 may be closed for securing the gel panel 40 to the mattress topper. If the mattress topper needs laundering, the zipper 58 may be opened for removing the gel panel 40 from the mattress topper.

(31) FIGS. 5A and 5B show the second surface 44 (FIG. 3) of the gel panel 40. The flexible fabric 36, accessible at the second surface 44, conforms to the shape of the gel tubes 50 and the gel valleys 52 that interconnect the gel tubes 50. The gel tubes 50 and the gel valleys 52 preferably extend along the length L.sub.2 of the flexible gel panel 40. When the gel panel 40 is positioned atop a mattress, the second surface 44 of the gel panel 40 desirably faces toward the mattress.

(32) Referring to FIG. 5C, in one embodiment, the flexible gel panel 40 is sewn to the sheet of fabric 54 having the outer edge 56 with the zipper 58. The flexible gel panel 40 may be inserted into a sleep product, such as a mattress topper. The zipper 58 may be closed for securing the gel panel 40 to the mattress topper. As described above, if the mattress topper needs laundering, the zipper 58 may be opened for removing the gel panel 40 from the mattress topper. The gel panel 40 may be re-inserted into the mattress topper after laundering.

(33) Referring to FIG. 6, in one embodiment, a sleep product 60, such as a mattress topper, may include a flexible gel panel 40 that covers 100% of the surface area of a mattress 62.

(34) Referring to FIG. 7, in one embodiment, a sleep product 160, such as a mattress topper, may have three zones whereby one of the zones of a mattress 162 is covered by a flexible gel panel 140.

(35) Referring to FIG. 8, in one embodiment, a sleep product 260, such as a mattress topper, may have four zones whereby two of the zones of a mattress 262 are covered by a pair of flexible gel panels 240A, 240B.

(36) Referring to FIG. 9, in one embodiment, a sleep product 360, such as a mattress topper, may have two zones (e.g. his/her) whereby only one of the zones of a mattress 362 is covered by a flexible gel panel 340.

(37) In FIGS. 6-9, the mattresses are not shown to scale, and the mattresses are not inclined mattresses as they may appear to be in FIGS. 6-9. In the embodiments of FIGS. 6-9, the flexible gel panels may be incorporated into bedding products that are positioned over mattresses, such as flat sheets, fitted sheets, mattress toppers and mattress protectors.

(38) Referring to FIGS. 10A-10C, in one embodiment, a pillow case 460 has a flexible gel panel 440 incorporated into at least one of the major panels of the pillow case. The flexible gel panel 440 is manufactured and has similar properties as the flexible gel panels disclosed herein.

(39) Referring to FIG. 10B, in one embodiment, the pillow case 460 has a first major panel 462 and a second major panel 464, which are sewn together around three sides of the respective first and second major panels. The fourth sides of the respective first and second major panels 462, 464 are not sewn together to define a pillow case opening, which may be closed using a fastener such as a zipper 466. Although a zipper 466 is shown, other fastening elements may be used, such as buttons, hook and loop fasteners, etc. In one embodiment, a flexible gel panel 440 is preferably incorporated (e.g., sewn) into the second major panel 464 of the pillow case 460. In one embodiment, a first flexible gel panel is incorporated into the first major panel 462 of the pillow case 460 and a second flexible gel panel is incorporated into the second major panel 464 of the pillow case 460.

(40) FIG. 10C shows a magnified view of the flexible gel panel 440 incorporated into the second major panel 464 of the pillow case 460. The pillow case 460 has an opening 468 that extends between the first major panel 462 and the second major panel 464. A pillow may be passed through the opening 468 for placing the pillow inside the pillow case 460. The zipper 466 may be closed for securing the pillow inside the pillow case 460.

(41) Referring to FIG. 11, in one embodiment, a pillow 470, such as a memory foam pillow, may be inserted into the pillow case 460 shown and described above in FIGS. 10A-10C. The pillow 470 may be made of a wide range of materials conventionally used for making pillows. In one embodiment, the pillow 470 may comprise memory foam. In one embodiment, the pillow may comprise memory foam and gel, such as a gel layer accessible at a major face of the pillow.

(42) Referring to FIG. 12A, in one embodiment, the pillow 470 is passed through the opening 468 of the pillow case 460. FIG. 12B shows the pillow 470 after it has been further inserted into the pillow case 460.

(43) Referring to FIG. 12C, after the pillow 470 has been fully inserted into the opening 468 between the first and second major panels 462, 464, the zipper 466 may be pulled closed for closing the pillow case opening 468 and securing the pillow within the pillow case 460. As shown in FIG. 12C, the flexible gel panel 440 that is incorporated into the second major panel 464 of the pillow case 460 is juxtaposed with a major face of the pillow 470 (FIG. 12B).

(44) FIG. 12D shows pillow case 460 after the zipper 466 has been fully closed. FIG. 12E shows a magnified view of a section of the pillow case with the pillow secured within the pillow case. The flexible gel layer 440 incorporated into the second major panel 464 of the pillow case 460 overlies a major face of the pillow. In use, an individual places his or her head atop the flexible gel panel to obtain the cooling effect provided by the flexible gel panel 440.

EXAMPLE 1

(45) Various sleep products were tested to determine how long it took for the products to warm to certain temperature levels and to record the maximum temperature for each of the sleep products. As documented below, during use, sleep products having flexible gels or flexible gel pads incorporated therein take longer to warm, and may take up to 5.5 times longer to warm to certain temperature levels when compared to sleep products in which gels are not utilized.

(46) Each of eight submitted samples was subjected to a temperature monitoring test. The eight submitted samples were as follows:

(47) TABLE-US-00001 Key Sample Description Sample 1 Foam/Gel Pillow (blue side up) Sample 2 Cool Foam Pillow (blue side up) Sample 3 Foam w/o Ventilation Pillow Sample 4 Foam w/Ventilation Pillow Sample 5 Latex Pillow Sample 6 Fiber Pillow Sample 7 Down Pillow Sample 8 Gel Infused Memory Foam

(48) Each sample was subjected to a temperature monitoring test whereby a thermocouple was placed in the following locations of the samples: the center of the top surface, at the point of heat application; the center of the bottom surface; the center of the interior (embedded in filling); and the outer edge. An electronic heating pad was placed in the center of each sample. The electronic heating pad was made in China and was distributed by Kaz, Inc. model number HP750. The heating pad was set to the temperature setting that maintained a temperature of 90 F.+/5 (32 C.+/3). A weight of 20 lbs. was placed on the heating pad. The temperature at each thermocouple was monitored for 90 minutes, with a reading taken every 30 seconds. The electronic heating pad was removed for the last 30 minutes of the test. During the test, a thermal image of each sample was taken at 10 minute intervals. The test results for each sample are provided in the charts below.

(49) Results of Temperature Readings at Top of Samples

(50) TABLE-US-00002 Sam- Sam- Sam- Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4 ple 5 ple 6 ple 7 ple 8 Maximum 40.7 46.2 47.1 49.2 47.4 48.1 48.4 49.6 Temp ( C.) Time To Max 60.0 11.5 11.5 11.5 11.0 9.5 11.0 11.5 Temp (min) Minimum 24.4 24.6 23.3 23.2 24.3 22.9 23.5 23.7 Temp ( C.) Average 35.0 37.0 35.9 38.8 36.5 37.0 37.3 36.4 Temp ( C.)

(51) Results of Temperature Readings at Bottom of Samples

(52) TABLE-US-00003 Sam- Sam- Sam- Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4 ple 5 ple 6 ple 7 ple 8 Maximum 24.2 24.9 25.3 24.9 26.1 25.4 27.4 24.2 Temp ( C.) Minimum 22.1 23.8 23.7 23.8 23.7 23.1 23.7 22.5 Temp ( C.) Average 23.3 24.3 24.6 24.4 25.0 24.7 26.4 23.6 Temp ( C.)

(53) Results of Temperature Readings at Interior of Samples

(54) TABLE-US-00004 Sam- Sam- Sam- Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4 ple 5 ple 6 ple 7 ple 8 Maximum 27.7 25.3 27.4 25.8 28.6 31.8 30.0 28.4 Temp ( C.) Minimum 22.4 23.6 23.1 22.8 24.0 22.6 23.0 22.4 Temp ( C.) Average 26.3 24.6 26.0 24.7 27.4 29.6 28.3 26.6 Temp ( C.)

(55) Results of Temperature Readings at Interior of Samples

(56) TABLE-US-00005 Sam- Sam- Sam- Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4 ple 5 ple 6 ple 7 ple 8 Maximum 24.2 24.2 24.0 24.4 24.1 24.3 24.1 23.8 Temp ( C.) Minimum 22.5 22.3 22.0 22.4 22.6 22.4 22.6 22.5 Temp ( C.) Average 23.1 22.9 23.0 23.2 23.1 22.8 23.2 23.2 Temp ( C.)

(57) Based on the resting results, Sample 1the Foam/Gel Pillow sample, exhibited the lowest thermal conductivity properties compared to all of the other samples evaluated. Under the same heat load conditions (which simulated actual use), it took the Foam/Gel Pillow (gel side up) approximately 5.5 times longer to reach its maximum temperature, and its maximum temperature, was on average, 7 C. lower than the other samples evaluated.

(58) While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, which is only limited by the scope of the claims that follow. For example, the present invention contemplates that any of the features shown in any of the embodiments described herein, or incorporated by reference herein, may be incorporated with any of the features shown in any of the other embodiments described herein, or incorporated by reference herein, and still fall within the scope of the present invention.