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Bed With Integrated Climate Control

20260041250 ยท 2026-02-12

    Inventors

    Cpc classification

    International classification

    Abstract

    Some aspects of this disclosure include a bed system with integrated climate control. In some examples, the bed system includes an integrated fan assembly for directing airflow around and/or in a mattress to adjust a temperature of the mattress.

    Claims

    1. A mattress system comprising: a first layer having a first layer top and a first layer bottom; a head rail attached to the first layer bottom; a foot rail attached to the first layer bottom and defining a first recessed portion and a second recessed portion; a first side rail attached to each of the first layer bottom, the head rail and the foot rail; a second side rail attached to each of the first layer bottom, the head rail and the foot rail; a first air module configured to create airflow between a first side of the first layer top and the first layer bottom via a first airflow insert pad, the first air module being positioned in the first recessed portion of the foot rail; a second air module configured to create airflow between a second side of the first layer top and the first layer bottom via a second airflow insert, the second air module being positioned in the second recessed portion of the foot rail; and one or more support layers including a first recessed portion and a second recessed portion, wherein the first airflow insert is positioned in the first recessed portion and the second airflow insert is positioned in the second recessed portion.

    2. A bed system comprising: a top foam layer having a top surface and a bottom surface; one or more support layers positioned below the bottom surface of the top foam layer; an inflatable chamber positioned below the one or more support layers; a foam rail structure including a head rail, a foot rail, a left rail, and a right rail, the foam rail structure being attached to a bottom side of the top foam layer and configured to surround the support layer and the inflatable chamber; a mattress bottom that covers the inflatable chamber; and an air module configured to create airflow and positioned within the foot rail and connected to an airflow insert positioned within a recessed portion of the one or more support layers.

    3. The bed system of claim 2, wherein the air module is configured to draw air from the top foam layer and direct exhaust air toward a foot side of the bed system.

    4. The bed system of claim 2, wherein the air module includes: a housing that defines an air inlet and an air outlet; and a fan assembly enclosed in the housing and configured to suction air through the air inlet and supply exhaust air through the air outlet.

    5. A mattress comprising: a first side rail and a second side rail; a top layer attached to the first side rail and the second side rail; an airflow insert; an air module in fluid communication with the airflow insert to create airflow through the top layer of the mattress; and a support layer positioned under the top layer and between the first side rail and the second side rail, wherein the support layer includes a recessed portion and the airflow insert is positioned in the recessed portion.

    6. The mattress of claim 5, wherein the recessed portion is on a bottom side of the support layer.

    7. The mattress of claim 5, wherein the mattress further comprises: a head rail and a foot rail, wherein the support layer is further positioned between the head rail and the foot rail.

    8. The mattress of claim 7, wherein the foot rail includes an air module recess and the air module is configured to be positioned in the air module recess.

    9. The mattress of claim 5, wherein the airflow insert is attached to the support layer using one or more fasteners.

    10. The mattress of claim 9, wherein the one or more fasteners include one or more hook and loop fasteners.

    11. The mattress of claim 5, wherein the airflow insert is positioned in the support layer without the use of fasteners.

    12. The mattress of claim 5, wherein the air module is configured to draw air from the top layer.

    13. The mattress of claim 5, wherein the air module is configured to push air through the top layer.

    14. The mattress of claim 5, wherein the air module includes: a housing that defines an air inlet and an air outlet; and a fan assembly enclosed in the housing and configured to suction air through the air inlet and supply exhaust air through the air outlet.

    15. The mattress of claim 14, wherein the airflow insert is connected to the air inlet.

    16. The mattress of claim 14, wherein the air module includes: wiring that is electrically connected to the fan assembly and extending from the housing, the wiring configured to electrically connect to a power source external to the mattress and supply electrical power to the fan assembly.

    17. The mattress of claim 5, wherein the air module includes a module to heat air.

    18. The mattress of claim 5, further comprising: a sleeve made of a fire resistant material and being sized and shaped to at least partially cover the airflow insert.

    19. The mattress of claim 18, wherein the airflow insert includes material that is configured to block the airflow from the air module when melted; and wherein when a burn occurs the sleeve is configured to direct heat from the burn towards the airflow insert, thereby melting material included in the airflow insert pad and blocking the airflow by the air module.

    20. The mattress of claim 18, wherein the mattress further comprises a cover surrounding at least the support layer, the airflow insert, the first side rail, the second side rail, and the top layer.

    Description

    BRIEF DESCRIPTION OF THE DRAWINGS

    [0028] FIG. 1 illustrates an example bed system having an integrated fan assembly as described herein.

    [0029] FIG. 2 is a bottom perspective view of a mattress system, illustrating the mattress system upside down.

    [0030] FIG. 3 is a partial exploded view of the mattress system of FIG. 2, illustrating a top layer, an intermediate layer, an example air chamber assembly, and the integrated fan assembly.

    [0031] FIG. 4 illustrates a bottom perspective view of the mattress system of FIG. 2 with a set of reinforcement straps removed and the integrated fan assembly in place.

    [0032] FIG. 5 is a perspective view of the integrated fan assembly.

    [0033] FIG. 6 illustrates a recessed view of airflow through the mattress system.

    [0034] FIG. 7 illustrates a side cross sectional view of airflow through the mattress system of FIG. 6.

    [0035] FIG. 8 is a bottom view of an example mattress system having the integrated fan assembly.

    [0036] FIG. 9 is another bottom view of the example mattress system of FIG. 8 having the integrated fan assembly.

    [0037] FIG. 10 is another bottom view of the example mattress system of FIG. 8 having the integrated fan assembly.

    [0038] FIG. 11 is a bottom view of another example mattress system having the integrated fan assembly.

    [0039] FIG. 12 is a bottom view of another example mattress system having the integrated fan assembly.

    [0040] FIG. 13A is a perspective view of the integrated fan assembly in the mattress system.

    [0041] FIG. 13B is a top view of the integrated fan assembly in the mattress system of FIG. 13A.

    [0042] FIG. 13C is a side perspective view of the integrated fan assembly in the mattress system of FIG. 13A.

    [0043] FIG. 14 illustrates an example bed system for providing a quality sleep experience with an example local bed system.

    [0044] FIG. 15 illustrates another fan assembly integrated into another example mattress system.

    [0045] FIG. 16 is a bottom perspective view of the mattress system of FIG. 15, illustrating the mattress system upside down.

    [0046] FIG. 17 is a partial exploded view of the mattress system of FIG. 16.

    [0047] FIG. 18 illustrates a bottom perspective view of the mattress system of FIG. 16.

    [0048] FIG. 19 is a perspective view of the integrated fan assembly of FIG. 15.

    [0049] FIG. 20 illustrates a recessed view of airflow through the mattress system of FIG. 16.

    [0050] FIG. 21 illustrates a side cross sectional view of airflow through the mattress system of FIG. 20.

    [0051] FIG. 22 is a bottom view of an example mattress system having the integrated fan assembly of FIG. 15.

    [0052] FIG. 23 is another bottom view of the example mattress system of FIG. 22 having the integrated fan assembly.

    [0053] FIGS. 24A-B illustrate a bottom view of a bottom layer of an example mattress system having the integrated fan assembly of FIG. 15.

    [0054] FIG. 25 illustrates an example mattress system.

    [0055] FIG. 26A is a bottom perspective view of the mattress system of FIG. 25, illustrating the mattress system upside down.

    [0056] FIG. 26B is a bottom perspective partially exploded view of the intermediate layer and the air flow insert of the mattress system of FIG. 25, illustrating the intermediate layer and the air flow insert upside down.

    [0057] FIG. 27 is a partial exploded view of the mattress system of FIGS. 25 and 26.

    [0058] FIG. 28A illustrates a view of the fan assembly of FIG. 25.

    [0059] FIG. 28B illustrates a view of the airflow insert pad of FIG. 25.

    [0060] FIGS. 28C-D illustrate the connection between the fan assembly and airflow insert pad of FIG. 25.

    [0061] FIG. 29 illustrates a cross sectional view of airflow through the mattress system of FIG. 25, taken along a cross sectional line shown in FIG. 31.

    [0062] FIG. 30 illustrates a side cross sectional view of the mattress system of FIG. 25, taken along a cross sectional line shown in FIG. 31.

    [0063] FIG. 31 is a bottom view of an example mattress system having the integrated fan assembly of FIG. 25.

    [0064] FIG. 32 is another bottom view of the example mattress system of FIG. 25 having the integrated fan assembly.

    [0065] FIGS. 33A-B illustrate a bottom view of a bottom layer of an example mattress system having the integrated fan assembly of FIG. 25.

    [0066] FIG. 34A illustrates an example air distribution layer.

    [0067] FIG. 34B illustrates an example sleeve made of a fire resistant material covering the example air distribution layer of FIG. 34A.

    [0068] FIGS. 35A and 35B illustrates an example process for constructing the air distribution layer with the sleeve made of a fire resistant material.

    [0069] FIG. 36 illustrates another perspective of the example sleeve made of a fire resistant material covering the example distribution layer of FIGS. 34A and 34B.

    [0070] FIG. 37 illustrates an example bed system with an integrated fan assembly.

    DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

    [0071] This document generally pertains to a bed system with climate control. In some examples, the bed system includes an integrated fan assembly for directing airflow around and/or in a mattress to adjust a temperature of the mattress.

    [0072] FIG. 1 illustrates an example bed system 100 having an integrated fan assembly 110 as described herein. In this example, the bed system 100 includes a mattress 101 and a foundation 103, which can be configured to be identical or similar to the mattresses and the foundations described herein. The mattress 101 can have a mattress core, which is configured to support a user resting on the mattress 101. In some implementations, the mattress core can have one or more inflatable air chambers. In some implementations, the mattress 101 can be configured as a climate-controlled mattress.

    [0073] As depicted, the mattress 101 can include a top layer 102, a rail structure 106, a bottom layer 108, and air chambers 124. In at least some embodiments, the mattress 101 may not have a rail structure and/or an air chamber 124. The integrated fan assembly 110 depicted and described herein can be attached or configured to a portion of the rail structure 106. For example, the fan assembly 110 can be disposed (e.g., positioned) at opposing left and right sides of the rail structure 106. As described herein, the fan assembly 110 can be received in a recessed portion of each of the opposing left and right sides of the rail structure 106. As a result, the fan assembly 110 may not interfere with other components of the mattress 101, such as the bottom layer 108, the air chambers 124, and/or the top layer 102. The fan assembly 110 can also be mounted to an air duct hose 111, as shown in FIG. 1. The fan assembly 110 can connect to the air duct hose 111 using one or more different fastening means, such as snaps, zipper, adhesive, and/or buttons. For example, as shown in FIG. 1, the fan assembly 110 can be snap fitted to a top opening of the air duct hose 111. As described herein, the air duct hose 111 can extend from an airflow insert pads 122 in the mattress 101. In some implementations, at least a portion of the hose 111 can be made of a silicon material and configured to be fitted around an air opening (e.g., an air inlet 710 in FIG. 5) of the fan assembly 110. As shown, the fan assembly 110 mounted to the air duct hose 111 can be positioned closer to a head side or a foot side of the mattress 101. The fan assembly 110 and the hose 111 may be offset from a midpoint of the mattress 101. In other embodiments not including the rail structure, the integrated fan assembly 110 may be located at another suitable position, including but not limited to being attached to a frame of the bed system, integrated within one or more foam layers of the mattress, or within a recess made within a mattress core. In some embodiments, the recess can be made in any suitable location for the fan assembly 110 and or the air duct hose 111.

    [0074] In some embodiments, the mattress core may comprise multiple coils, where the coils define a recess to receive the fan assembly 110. In some of these embodiments, the mattress core includes multiple coils and foam material which provides support to house the fan assembly 110, with or without the rail structure 106. In other embodiments, the mattress core may be comprised of foam, memory foam, gel, and/or a pocketed structure, which may or may not include a rail structure 106. In embodiments without a rail structure, the mattress may still include one or more recesses to receive the fan assembly 110 and one or more air flow pathways or air duct hoses 111 between the recess and the top surface 102.

    [0075] The fan assembly 110 can be configured to cool a top surface of the mattress 101 by, for example, drawing air from a top of the mattress and discharging it at a bottom of the mattress. In additional or alternatively, the fan assembly 110 can be configured to circulate ambient air or conditioned air (e.g., heated or cooled air) around or through one or more of the components in the mattress 101 to control a microclimate (e.g., increase or decrease a temperature or humidity) at the top surface of the mattress 101.

    [0076] In other words, the mattress 101 can include a first layer (e.g., the top layer 102) having a first layer top (e.g., a top surface) and a first layer bottom (e.g., a bottom surface) and extending from a first edge to a second edge. In at least some embodiments, as depicted in FIG. 1, the mattress 101 can also include a first side rail attached to the first layer bottom proximate the first edge and a second side rail attached to the first layer bottom proximate the second edge (e.g., opposing left and right sides of the rail structure 106). A core (e.g., inflatable air chamber 124) can be positioned under the first layer bottom between the first side rail and the second side rail. A first air module (e.g., the fan assembly 110, an air conditioning module) can also be included in the mattress 101 and configured to create airflow. The first air module can be disposed between the first side rail and the core under the first layer bottom. A second layer (e.g., the bottom layer 108) can also be disposed under the core and covering the core between the first side rail and the second side rail. The first air module can be configured to draw air from the first layer and direct exhaust air between the first side rail and the second layer. The first air module can also be configured to draw air from the first layer and direct exhaust air towards a head side of the mattress 101 and/or a foot side of the mattress 101. In some examples, the first air module is configured to push air through the first layer.

    [0077] In other implementations, the first air module can be configured to direct exhaust air towards an interior of the mattress 101. One or more interior components (e.g., layers) of the mattress 101 can be made of a breathable material allowing for the exhausted air to circulate through the mattress 101. A channel can also be integrated into one or more of the interior components such that the exhausted air can be routed towards a middle portion of the mattress 101 and away from the first air module. In other implementations, the first air module can be configured to direct exhaust air towards a foundation that supports the bottom of the mattress 101. For example, the first air module can pull air from a top surface of the mattress 101 and push the air out an opening that is defined at the foundation that supports the bottom of the mattress 101. In other implementations, the first air module can be configured to direct exhaust air out sides of the mattress 101 (e.g., through the side rails 234, 236 and through a mattress cover 140 of the mattress 101). For example, the exhaust air can be directed towards the side rails. A portion of each side rail can be made of a breathable material through which the exhaust air can pass through. Alternatively or in addition, the side rails can also have holes or openings integrated therein and proximate the first air module. Therefore, the exhaust air can be routed through the holes or openings. As described further below, the first air module can be mounted onto a first duct that is configured to permit air to flow to inflate an air chamber 124 of the core. The first air module and the first duct can be positioned offset from a midpoint of the mattress 101. In other implementations, the first air module can be positioned offset from the first duct.

    [0078] Further, the mattress 101 includes a mattress cover 140 having a top surface, a bottom surface, and side surfaces, which are configured to at least partially cover the top layer 102, the rail structure 106, the bottom layer 108, the air chambers 124, and the fan assembly 110. In some implementations, the fan assembly 110 can be configured to draw air from a top of the mattress 101, into the mattress 101 through the mattress cover 140, through the top layer 102, into an inlet of the fan assembly 110, out an outlet of the fan assembly 110, and out through the mattress cover 140 or some other exhaust outlet to a space outside of the mattress 1010. In some implementations, the fan assembly can be configured to blow air from the fan assembly 110 through the top layer 102 and out through the mattress cover 140 to a location at a top of the mattress 101. As a result, a temperature of a top surface of the mattress 101 can be cooled quicker and more efficiently.

    [0079] One or more of the top layer 102, the rail structure 106, and the bottom layer 108 can be made of foam materials. Alternatively or in addition, the top layer 102 can be surface-treated with one or more gel materials that have different heat capacities to provide prolonged coolness through the mattress when the bed is in a cooled air supply mode. In some implementations, one or more gel materials can be incorporated into the top layer 102 by surface-infusion. Moreover, in some implementations, the top layer 102 and the rail structure 106 can be part of an upside-down foam tub. The upside-down foam tub can further include a foot rail and a head rail, in addition to first and second side rails.

    [0080] FIG. 2 is a bottom perspective view of a mattress system 200, illustrating the mattress system 200 upside down. The mattress system 200 can be the mattress as depicted and described throughout this disclosure (e.g., refer to the mattress 101 in FIG. 1). The mattress system 200 can include a top layer (e.g., a first layer) 202, an intermediate layer (e.g., a second layer) 204, a rail structure 206, and a bottom layer (e.g., a third layer) 208. The mattress system 200 also has a top surface 212 (e.g., a top surface of the top layer 202). The intermediate layer 204 can include one or more airflow insert pads 122, as shown in FIG. 1.

    [0081] In some implementations, the top layer 202, the intermediate layer 204, and the bottom layer 208 are arranged in order from the top to the bottom of the mattress system 200. The rail structure 206 is arranged around a periphery of the mattress system 200 and configured to at least partially surround an air chamber assembly or mattress core. For example, the air chamber assembly can include one or more inflatable air chambers (e.g., refer to FIG. 3). As illustrated in FIG. 2, the bottom layer 208 can be disposed to be at least partially surrounded by the rail structure 206. The bottom layer 208 can be configured to close a space 211 (e.g., refer to FIG. 3) defined by the rail structure 206. In other implementations, the bottom layer 208 can be disposed above the rail structure 206.

    [0082] The mattress system 200 can also include fan assemblies 110 as described throughout this disclosure (e.g., refer to FIG. 1). As depicted, the mattress system 200 can have two fan assemblies 110 disposed in opposing left and right sides of the rail structure 206, and configured and operable to control microclimates of two separate zones (left and right sides) at the top of the mattress. In some implementations, the fan assembly 110 can be disposed in a head side of the rail structure 206 and/or a foot side of the rail structure 206. In yet other implementations, the mattress system 200 can have fewer or more integrated fan assemblies.

    [0083] FIG. 3 is a partial exploded view of the mattress system 200 of FIG. 2, illustrating the top layer 202, the intermediate layer 204, an example air chamber assembly 220, and the integrated fan assemblies 110. The top layer 202 can have the top surface 212 on which a user's body can be rested either directly, or indirectly through a mattress cover and/or one or more additional layers disposed on the top surface. The intermediate layer 204 can be disposed opposite to the top surface 212 of the top layer 202. The intermediate layer 204 can be attached to the top layer 202 in various ways. For example, the intermediate layer 204 can be glued to the top layer 202, or attached to the top layer 202 using fasteners, such as hook-and-loop fasteners (e.g., VELCRO), zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners.

    [0084] Moreover, the mattress system 200 can include the air chamber assembly 220. In the illustrated example, the air chamber assembly 220 includes a pair of air chambers 222 disposed between the top layer 202 and the bottom layer 208. The air chambers 222 can be inflatable air chambers. The air chamber assembly 220 depicted can be for a king or queen size mattress 200. Other mattresses, such as twin and full size mattresses, can have an air chamber assembly having only one air chamber. In yet other examples (not depicted), the air chamber assembly can be merely a mattress core that is not inflatable or filled with air. In some embodiments, the mattress core includes multiple coils to provide support to the mattress. In some examples, the coils are designed to flex in response to pressure to provide progressively firmer support as pressure is placed on the mattress. In some examples, the coils are metal springs. The coils can be made of other materials, such as a plastic material. In some examples, the mattress core includes a water bladder that provides support to the mattress when it is filled with water. In some examples, the mattress core is filled with foam material. The mattress core can be filed with other types of material including rubber, or gel. In some examples, the core made with various combinations of foam, rubber, gel, and coils.

    [0085] The air chambers 222 can be arranged to be surrounded by the rail structure 206. The air chamber assembly 220 can further include a pump system configured to inflate and/or deflate the air chambers 222. The pump system can be disposed outside the mattress and fluidly connected to the air chambers 222 via fluid delivery components. For example, the mattress 200 further includes an air chamber hose 226 connected to the air chambers 222 for inflating or deflating the air chambers 222. For example, one end of the air chamber hose 226 can be connected to the air chamber 222 to be in fluid communication with the interior of the air chamber 222, and the other end of the air chamber hose 226 can be fluidly connected to the pump system. In the illustrated implementations, the air chamber hoses 226 are routed at the side locations of the mattress system 200, at a middle axis of the mattress system 200. In alternative implementations, the air chamber hoses 226 can be routed at different locations of the mattress system 200, such as the head or foot of the mattress system 200, or other suitable locations of the mattress system 200.

    [0086] As depicted, the rail structure 206 can be disposed on the intermediate layer 204, or on the top layer 202 where there is no intermediate layer, to define the space 211 for at least partially receiving the air chamber assembly 220. The bottom layer 208 can be disposed at least partially within the space 211 to at least partially cover the space 211 and the air chamber assembly 220 within the space 211. The space 211 can be a single, integral solid layer. The space 211 can be made of a same or different material as the top layer 202, the intermediate layer 204, and/or the rail structure 206. Some embodiments, the mattress system 200 does not include a rail structure 206 but instead houses or mounts the fan assembly with a recess and/or to a support structure.

    [0087] The mattress system 200 can also include an airflow insert pad 122 (e.g., thermal insert) that can be included in the mattress 200 and configured to circulate ambient or conditioned air through the mattress 200 under the user at rest. The airflow insert pad 122 can be positioned under the top layer 202. In some implementations, the intermediate layer 204 defines a cutout section or recess to receive the airflow insert pad 122 therein. The airflow insert pad 122 can include a material having a higher air permeability than the top layer 202, the intermediate layer 204 and/or other adjacent layers, thereby promoting airflow through the airflow insert pad 122 as opposed to its adjacent layer(s) such as the top layer 202 and the intermediate layer 204. In the illustrated example, the mattress includes two airflow insert pads 122. A single airflow insert pad, or more than two airflow insert pads can be included in other implementations of the mattress. The airflow insert pad 122 can be arranged at various locations in the mattress 200. In the illustrated example, the airflow insert pad 122 is disposed between the head and foot of the mattress 200 (e.g., in the middle of the mattress). The pad 122 can also be disposed closer to the head of the mattress 200 or the foot of the mattress 200 to optimize positioning without needing to rely on a foundation hole pass-through. In some implementations, the pad 122 can be laminated in place using adhesive. The pad 122 can also be held in place using one or more other attaching means, such as hook and loop fasteners, buttons, Velcro, and/or zippers.

    [0088] The fan assemblies 110 can be connected to or mounted on the air duct hose 111. The fan assemblies 110 can also be disposed at least partially in the rail structure 206. As depicted, the fan assemblies 110 are offset from a middle axis of the mattress system 200. The middle axis can extend along a center between the head end and the foot end of the mattress. The fan assemblies 110 can be positioned closer to a head side of the rail structure 206 or a foot side of the rail structure 206. Positioning the fan assemblies 110 closer to the head side of the rail structure 206 can be advantageous to exhaust or provide more airflow to a head portion of the top surface 212 of the mattress system 200 than other portions of the mattress system. Positioning the fan assemblies 110 closer to the foot side of the rail structure 206 can be advantageous to provide or exhaust more airflow to a foot portion of the top surface 212 of the mattress system 200 than other portions of the mattress system. Offsetting the fan assemblies 110 from the middle axis of the mattress system 200 can be beneficial so that the fan assemblies 110 do not interfere with configuration and operation of the air chamber hoses 111 that are located at or around the middle axis of the mattress system 200. Moreover, the fan assemblies 110 can be positioned in the rail structure 206 relative to the air chamber hoses 111 based on where the air chamber hoses 111 are disposed in the mattress system 200 (e.g., if the hoses 111 are positioned closer to a head portion of the mattress system 200, then the fan assemblies 110 can be positioned at the middle axis of the mattress system 200 or any other suitable location. In some implementations, where the mattress system 200 does not have the air chamber assembly 220, the fan assemblies 110 can be positioned at the middle axis of the mattress system 200.

    [0089] The top layer 202, the intermediate layer 204, the rail structure 206, and the bottom layer 208 can be made of various materials. For example, at least one of the top layer 202, the intermediate layer 204, the rail structure 206, and the bottom layer 208 can be made of foam, which may be closed-cell, open-cell, or a combination thereof. Additionally, the top layer 202, the intermediate layer 204, and/or the rail structure 206 can form a foam tub in which the air chamber assembly 220 is housed. Other materials, such as one or more coil springs, air chambers, spacer materials, and/or other suitable materials, can be used for at least one of the top layer 202, the intermediate layer 204, the rail structure 206, and the bottom layer 208.

    [0090] FIG. 4 illustrates a bottom perspective view of the mattress system 200 of FIG. 2 with a set of reinforcement straps 250A-B removed and the integrated fan assembly 110 in place. The reinforcement straps 250A-B can be used to hold the mattress system 200 in place and keep it from bowing outwards when used. For example, the straps 250A-B can be used to keep the bottom layer 208 (e.g., refer to FIGS. 2-3) in place inside the rail structure 206 and over one or more components of the mattress system 200 (e.g., the air chamber assembly 220 in FIG. 3 disposed inside the space 211). Therefore, the one or more components can be retained inside the mattress system 200 when the mattress system 200 is flipped over and positioned on top of a foundation or other mattress support system.

    [0091] In some implementations, the mattress system 200 can be configured to include a core of various types, such as one or more inflatable air chambers, foams, and/or spring assemblies, that can be received in the space 211 defined by the rail structure 206 in the same or similar manner as described herein.

    [0092] The rail structure 206 can include a foot rail 230, a head rail 232, and opposite side rails 234, 236 extending between the foot rail 230 and the head rail 232. In some implementations, the rail structure 206 can be made of one or more foam materials. In this example, the rail structure 206 is attached to the intermediate layer 204. The rail structure 206 has a top rail side, a bottom rail side, a rail inner side, and a rail outer side. In other words, each of the foot rail 230, the head rail 232, and the opposite side rails 234, 236 has a top rail side, a bottom rail side, a rail inner side, and a rail outer side. In the illustrated example, the top rail side can be attached to the intermediate layer 204, while the bottom rail side that is opposite to the top rail side is exposed and defines a perimeter of the rail structure 206 in the view of FIG. 4. The rail inner side faces an interior of the mattress, while the rail outer side that is opposite to the rail inner side faces outwards and defines a side exterior of the mattress.

    [0093] When attached to the intermediate layer 204, the rail structure 206 may be also engaged with, or attached to, the air chamber assembly 220 that is positioned in the space 211 of the mattress and abutted with the intermediate layer 204. For example, the foot rail 230 is attached to a bottom of the intermediate layer 204 at (or proximate) a foot edge of the intermediate layer 204, and the head rail 232 is attached to the bottom of the intermediate layer 204 at (or proximate) a head edge of the intermediate layer 204 (opposite to the foot edge of the intermediate layer 204). The side rails 234, 236 are attached to the bottom of the intermediate layer 204 at (or proximate) opposite sides of the intermediate layer 204. The rail structure 206 also forms an upside-down foam tub, along with the layers (e.g., the intermediate layer 204 and/or the top layer 202). For example, the rail structure 206 defines the space 211 for receiving a mattress core or air chamber assembly 220, such as one or more inflatable air chambers, foams, and/or spring assemblies (e.g., refer to FIG. 3). In implementations where no intermediate layer 204 is provided, the rail structure 206 can be attached to the top layer 202 in a similar manner.

    [0094] The first reinforcement strap 250A can be connected to the opposite side rails 234, 236 so as to extend under the mattress core or air chamber assembly 220 between bottoms of the side rails 234, 236. For example, one end of the first strap 250A can be connected to a first connection point 242A located on a bottom of a first side rail (e.g., the side rail 234), and the other end of the first strap 250A can be connected to a second connection point 240A located on a bottom of a second side rail (e.g., the side rail 236). The first strap 250A can be attached to the opposite side rails 234, 236 at predetermined connection locations 240A, 242A. Thus, the first strap 250A can extend under a core from a bottom of the first side rail to a bottom of the second side rail. Similarly, the second strap 250B can be connected to the opposite side rails 234, 236 so as to extend under the mattress core or air chamber assembly 220 between bottoms of the side rails 234, 236. For example, one end of the second strap 250B can be connected to a third connection point 242B located on a bottom of the first side rail (e.g., the side rail 234), and the other end of the second strap 250B can be connected to a fourth connection point 240B located on a bottom of the second side rail (e.g., the side rail 236). The second strap 250B can be attached to the opposite side rails 234, 236 at predetermined connection locations 240B, 242B.

    [0095] The straps 250A-B can be attached to the rail structure 206 using one or more fastening elements 238. The fastening elements 238 can be of various types. For example, the fastening elements 238 include adhesive tapes. Alternatively or in addition, the fastening elements 238 can be hook-and-loop fasteners (e.g., VELCRO), zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners. The fastening elements 238 can be applied at the connection locations 240A-B and/or 242A-B, or at desired locations (e.g., the ends) of the straps 250A-B, so that such desired location of the straps 250A-B are attached to the connection points 240A-B and/or 242A-B of the rail structure 206. For example, adhesive tapes can be applied between the connection locations 240A-B and 242A-B of the rail structure 206 and the ends of the straps 250A-B.

    [0096] The reinforcement straps 250A-B can be used with pieces of hook materials (e.g., 3M hook materials) with adhesive backing (e.g., the fastening elements 238). The hook materials can be placed along the bottom side of the perimeter side rails 234 and 236. In some implementations, the reinforcement straps 250A-B can include a scrim material and attach to the hook materials and extend from one side of the mattress system 200 to the other side. The straps 250A-B can be removable to allow other components (e.g., the air chambers, layers, etc.) to be assembled without interference. The straps 250A-B can be adjustable to accommodate for stretch or changes over time, varying tolerances of a foam tub and its cover, or general aesthetic preference impact. The straps 250A-B can also have a width of varying sizes, such as a width ranging between about 1 inch and about 7 inches.

    [0097] In some implementations, the first strap 250A and the second strap 250B are positioned in a longitudinal middle section of the mattress system 200. The first strap 250A can extend to be parallel with the second strap 250B and spaced at a predetermined distance from the second strap 250B.

    [0098] Other configurations of the straps 250A-B can be possible. In some implementations, the straps 250A-B can be routed to cross each other. For example, the first strap 250A and the second strap 250B are connected to the opposite side rails 234, 236 to extend under the mattress core or air chamber assembly 220 between the bottoms of the side rails 234, 236. The first strap 250A can be routed to cross the second strap 250B by connecting one end of the first strap 250A to one of the side rails 234, 236 between the head rail 232 and the second strap 250B, and connecting the other end of the first strap 250A to the other side rail 234, 236 between the foot rail 230 and the second strap 250B.

    [0099] In other configurations, one or more of the straps 250A-B can extend to one or both of the foot rail 230 and the head rail 232. In one example, one or more of the straps 250A-B can extend from the foot rail 230 to the head rail 232 rather than extending between the opposite side rails 234, 236. In another example, one or more of the straps 250A-B can extend from the foot rail 230 to the head rail 232 in addition to having one or more of the straps 250A-B extending between the opposite side rails 234 and 236. In yet other configurations, fewer or additional reinforcement straps can be included in the mattress system 200.

    [0100] As depicted, the fan assembly 110 can be disposed at least partially in the rail structure 206. The straps 250A-B can be attached to the rail structure 206 on opposite sides of the fan assemblies 110, thereby reinforcing or maintaining the rail structure 206 at or around the fan assemblies 110. For example, in the illustrated example, the fan assemblies 110 are provided in the opposite side rails 234, 236, and the first strap 250A and/or the second strap 250B are connected to the opposite side rails 234, 236 proximate the fan assemblies 110. The rail structure 206 can also include one or more recessed portions proximate to the fan assembly 110 and/or the connection points of the straps 250A-B to receive other components (e.g., air passages, air chamber hoses, electronic wires, etc.) of the mattress system 200. In alternative implementations, the mattress system 200 does not include the straps 250A-B and their associated elements.

    [0101] Other configurations of the fan assemblies 110 are possible. For example, the fan assemblies 110 can be positioned closer to the foot rail 230 and/or closer to the head rail 232. The fan assemblies 110 can also be positioned on outer sides of the connection locations 240A-B and 242A-B. In other words, the fan reinforcement straps 250A-B need not be positioned around the fan assemblies 110. In some implementations, the mattress system 200 may not include the reinforcement straps 250A-B, as depicted and described further in reference to FIG. 18.

    [0102] FIG. 5 is a perspective view of the integrated fan assembly 110. As depicted, the fan assembly 110 includes an external housing 700 configured to receive a fan and electronics that can control operation of the fan. The fan assembly 110 can include an air duct 708 (e.g., plenum) that is fluidly connected to the housing 700 and configured for airflow into or from the housing 700. The housing 700 and the air duct 708 can define an air inlets and an air outlets. In embodiments where the fan assembly 110 operates to draw air, the air duct 708 defines an air inlet 710, and the housing 700 defines an air outlet 702. In embodiments where the fan assembly 110 operates to blow air, the air inlet 710 of the air duct 708 works as an air outlet, and the air outlet 702 of the housing 700 works as an air inlet.

    [0103] The air inlet 710 of the air duct 708 is positioned toward the top of the mattress to thereby effectively draw air from the top of the mattress. As described herein, the air outlet 702 of the housing 700 is oriented toward the foot side or the head side of the mattress at the bottom of the mattress. For example, the housing 700 can be positioned between a bottom layer (e.g., the bottom layer 208) and a corresponding side rail (e.g., one of the side rails 234, 236) of the mattress, and the air outlet 702 is oriented toward a channel defined between the bottom layer and the corresponding side rail (i.e., a side surface of the bottom layer and a side surface of the side rail that faces the side surface of the bottom layer), as shown and described in reference to FIGS. 2-3.

    [0104] In some implementations, the air duct 708 of the fan assembly 110 can also function as a base portion of the fan assembly 110. For example, the air duct 708 can be attached to the rail structure of the mattress using one or more fastening elements (e.g., screws, bolts, adhesive, etc.). In some implementations, the air duct 708 is configured to fit the recessed portion (e.g., the recessed portions 306, 406, 506) defined at the rail structure. The air duct 708 can be received into and fit in the recessed portion with or without additional fastening elements (e.g., screws, bolts, adhesives, etc.). Moreover, when the mattress is manufactured, the fan assembly 110 can be integrated into or attached to the mattress during production. In some implementations, the air duct 708 (together with the housing 700) can be removed from the mattress when the fan assembly 110 needs to be serviced and/or replaced. Therefore, fastening the air duct 708 to the rail structure can provide for easier servicing of the fan assembly 110.

    [0105] FIG. 6 illustrates a cross sectional view of the mattress system 200, taken along a cross sectional line shown in FIG. 8. FIG. 6 illustrates an example airflow 800 (e.g., exhaust air) through the mattress system 200. As depicted, the mattress 200 includes the mattress cover 140, the top layer 202, the intermediate layer 204, the rail structure 206, air chambers 222, an optional airflow layer 223, airflow insert pad 122 (e.g., thermal insert), and the bottom layer 208 (e.g., refer to FIGS. 1-3). The airflow insert pad 122 can be stitched together or attached together as one piece. The view of FIG. 6 depicts the opposite side rails 234 and 236 of the rail structure 206. The fan assemblies 110 are positioned within the opposing side rails 234 and 236 of the rail structure 206. In some implementations, the optional airflow layer 223 can be positioned to be flushed with the intermediate layer 204 and configured to promote air circulation and distribution toward and from the top layer 202. The airflow layer 223 can include a material that provides a higher airflow rate than the intermediate layer 204 and/or the top layer 202. The airflow layer 223 can promote and guide the airflow 800 from the mattress top into the air ducts 708 of the fan assemblies 110.

    [0106] The fan assemblies 110 are positioned such that the air duct 708 is fluidly connected to the air duct hose 111 that is fluidly connected to the airflow layer 223 in the intermediate layer 204, and such that an air opening (e.g., the air outlet 702 shown and described in FIG. 5) of the housing 700 is oriented towards the head portion or the foot portion of the mattress 200. As depicted in FIG. 6, the airflow 800 is directed from the top of the mattress, through the air duct hose 111, into the air duct 708 of the fan assembly 110 and routed into the housing 700 of the fan assembly 110. The airflow 800 can also flow through one or more layers of the mattress 200 to provide for air circulation at the top layer 202. In addition, the airflow 800 can be directed through the intermediate layer 204, the airflow layer 223, and/or through the top layer 202 of the mattress 200. As a result, the fan assemblies 110 can cause the airflow 800 at the top surface of the mattress cover 140 to lower or moderate a temperature of the mattress 200.

    [0107] FIG. 7 illustrates a side cross sectional view of the mattress 200, taken along a cross sectional line shown in FIG. 8. FIG. 7 depicts the airflow 800 that is drawn into the fan assembly 110 and further depicts exhaust air 801 from the fan assembly 110. This side cross sectional view of the mattress 200 depicts a longer side of the mattress 200, such as a left or right side. The mattress 200 includes the rail structure 206 having the head rail 232, the foot rail 230, and one side rail 234. Moreover, the fan assembly 110 is disposed in the side rail 234 of the rail structure 206, closer to the head rail 232 or the head portion of the mattress 200. As depicted, the fan assembly 110 is offset from a middle axis of the mattress 200. In the illustrated example, the fan assembly 110 is oriented towards the head rail 232. As a result, the airflow 801 is discharged from the fan assembly 110 towards the head portion of the mattress 200 to thereby lower a temperature of a top surface of the mattress 200. Alternatively, the fan assembly 110 is oriented towards the foot rail 230.

    [0108] As described herein, the exhaust air 801 can be directed through a channel or recessed portion (e.g., the channel or recessed portion 308, 408, 508, 604) that is defined between a side of the bottom layer 208 and an adjacent side rail of the rail structure (e.g., the rail structure 206). The channel or recessed portion can extend toward the head portion or the foot portion of the mattress 200. This provides for more direct and efficient exhaust of air from the fan assembly 110 to thereby quickly lower the temperature of the top surface of the mattress 200. Moreover, the airflow 800 can be drawn from a top surface of the mattress 200 through the airflow insert pad 122 (e.g., thermal insert), where the airflow 800 can be collected, and then directed through the air duct hose 111 into the air duct 708 and the fan assembly 110.

    [0109] FIG. 8 is a bottom view of an example mattress system 300 having the integrated fan assembly 110. As depicted, the mattress system 300 is flipped upside down so that a top surface of the mattress system 300 is facing down. The depicted mattress system 300 has a rail structure 302 and a bottom layer 304, as described throughout this disclosure (e.g., refer to the rail structure 206 and the bottom layer 208 in FIG. 2). The mattress system 300 can have one or more additional components described herein, such as a top layer, an intermediate layer, and/or an air chamber assembly. Moreover, in some implementations, the bottom layer 304 disposed inside the rail structure 302 can be retained or held in place using one or more reinforcement straps, as described in reference to FIG. 4.

    [0110] The rail structure 302 has recessed portions 306. The recessed portions 306 are configured to receive the fan assemblies 110. In other words, a first side rail (e.g., a left or ride side rail of the rail structure 302) can define a first rail recessed portion (e.g., the recessed portion 306) configured to at least partially receive a first air module (e.g., the fan assembly 110). The recessed portions 306 can be any appropriate size to fit a size of the fan assemblies 110. Therefore, the fan assemblies 110 can be disposed inside the rail structure 302 so that the fan assemblies 110 do not interfere with one or more other components of the mattress system 300. Additionally, as depicted, the recessed portions 306 can be offset from a middle axis 310 of the mattress system 300. This configuration can also be beneficial to prevent interference of the fan assemblies 110 placement with one or more other components of the mattress system 300 that are disposed at or around the middle axis 310. The middle axis 310 can be an axis that extends between the opposite side rails and divides the mattress system 300 into two halves. Alternatively, the middle axis 310 can be offset from the axis that divides the mattress system 300 into two halves.

    [0111] The recessed portions 306 can have a predetermined width W1 that is suitable for receiving at least part of the fan assemblies 110. The predetermined width W1 can be big enough to maintain sufficient air flow and room for installation of the fan assembly 110 while also being minimal in size to minimize discomfort that may occur from an opening that is too wide. Too large of an opening may be felt by the user laying on top of the mattress system 300, thereby reducing comfortability. By way of example, the width W1 can be 9.5 inches. This width can be advantageous to provide sufficient air flow without compromising comfortability of the mattress system 300 to users. In other implementations, the width W1 of the recessed portion 306 can range from 4 inches to 10 inches. Other ranges of the width W1 are also possible for various configurations of the mattress.

    [0112] Moreover, the bottom layer 304 can have recessed portions 308. The recessed portions 308 can have various dimensions (widths, lengths, and depths). In some implementations, a width W2 of the recessed portion 308 can be smaller than 1 inch. In other example implementations, the width W2 can range from 1 inches to 6 inches. In some implementations, as illustrated in FIG. 8, a length L2 of the recessed portion 308 can extend between opposite head and foot rail portions 314 and 316. As illustrated in FIG. 8, the length L2 of the recessed portion 308 can extend an entire distance between the opposite head and foot rail portions 314 and 316. The distance L2 of the recessed portion 308 can range in size depending on the size of the mattress system 300. In other implementations, the length L2 of the recessed portion 308 can be smaller than the distance between the opposite head and foot rail portions 314 and 316, as further described in more detail with respect to FIG. 12. Various other sizes of the recessed portions 308 can be realized (e.g., refer to FIGS. 9-12). The various different sizes of the recessed portions 308 can be advantageous to ensure that the bottom layer 304 remains positioned in a center of the mattress system 300 without shifting to one of the sides of the system 300 and eliminating or compromising airflow 312A-B through the recessed portions 308. For example, the bottom layer 304 can have the recessed portions 308 positioned at the head portion 314 and/or the foot portion 316 of the mattress system 300. Moreover, as described herein, instead of having the recessed portion 308, the bottom layer 304 can be made of a breathable material to allow air to flow directly through the bottom layer 304.

    [0113] The recessed portions 308 can be configured to facilitate or direct airflows 312A-B (e.g., exhaust air) from the fan assemblies 110. For example, the recessed portions 308 can create one or more different flow paths to direct exhaust air from the fan assemblies 110. A first flow path can be bound by a side surface of a first side rail (e.g., the side rails) and a corresponding side surface of at least one additional layer (e.g., the bottom layer 304). The bottom layer 304 can cover a core between the first and second side rails. The mattress 300 can also include a mattress cover having a top panel, a bottom panel, and opposing side panels. The first flow path can further be bound by a bottom surface of the core and a top surface of the bottom panel of the mattress cover. In some implementations, the core can include an air chamber. A width of the first flow path between the side surface of the first side rail and the corresponding side surface of the bottom layer 304 can vary in a longitudinal direction along the first side rail. The corresponding side surface of the bottom layer 304 can include a tapered surface (not shown) that is angled relative to the side surface 303 of the first side rail that faces the corresponding side surface of the bottom layer 304. The width of the first flow path can decrease from a location at which the fan assembly 110 is positioned, toward either a head side of the mattress 300 or a foot side of the mattress 300. The width of the first flow path can also vary along an entire length of the bottom layer 304. The first flow path can extend to a corner of the bottom layer 304. The first flow path can also extend vertically along at least part of the sides of the mattress 300. The first flow path can be defined at least through the air duct 708 of the fan assembly 110. The first flow path can be defined along at least one foam layer between a mattress top and a mattress bottom. The mattress top can include a mattress cover and the mattress bottom can include a bottom layer.

    [0114] The recessed portions 308 can also be angled (e.g., tapering) so as to better direct and exhaust the airflows 312A-B towards either the head portion 314 or the foot portion 316 of the mattress system 300. As depicted in FIG. 8, the recessed portions 308 of the bottom layer 304 are symmetrical from the middle axis 310 of the mattress system 300. Therefore, it does not matter how the bottom layer 304 is oriented or directed when assembled to other parts of the mattress system 300 (e.g., when disposed in the rail structure 302). In other words, the symmetrical recessed portions 308 of the bottom layer 304 allow easy assembling of the bottom layer 304 to other parts of the mattress system 200 because the bottom layer 304 provides the same configuration of the mattress system 200 regardless of the orientation of the bottom layer 304 attaching to the rest of the mattress system 200. In one example, an angle A of the tapered recessed portion 308 with respect to the middle axis 310 can range from 60 degrees to 85 degrees. Another example of the angle A can range from 65 degrees to 80 degrees. Yet another example of the angle A can range from 70 degrees to 75 degrees. Other ranges of the angle A are also possible.

    [0115] In one example, the fan assemblies 110 in the mattress system 300 are oriented towards the head portion 314 of the mattress system 300. In another example, the fan assemblies 110 can also be oriented towards the foot portion 316 of the mattress system 300. Regardless of whether the fan assemblies 110 are oriented towards the head portion 314 or the foot portion 316, the symmetrical recessed portions 308 provide for uniform airflow in whichever direction that the fan assemblies 110 are oriented.

    [0116] The recessed portions 308 create air ducts or channels for which the airflows 312A-B are exhausted out of the fan assembly 110.

    [0117] For example, the mattress 300 can define a first channel (e.g., the recessed portion 308) between the first side rail (e.g., the rail structure 302) and a second layer (e.g., a layer, such as the inflatable air chamber, above the bottom layer 304). The first channel is configured to permit for airflow between the first side rail and the second layer. The second layer can also define a layer recessed portion (e.g., the recessed portion 308) defining the first channel between the first side rail and the second layer. The layer recessed portion can extend at least partially along a length of the second layer.

    [0118] Directing the airflows 312A-B around components of the mattress system 300, such as along edges or sides of the components, can provide for a more effective cooling effect of a top surface of the mattress system 300. For example, the airflows 312A-B promote air draw from the mattress top through the fan assemblies 110, thereby causing more effective cooling effect at the mattress top.

    [0119] The recessed portions 306 and/or 308 can prevent the fan assemblies 110 from interfering with one or more other components integrated in the mattress system 300. For example, electric wires and/or air chamber hoses can be disposed along sides of the bottom layer 304 and/or the rail structure 302. Placing the fan assemblies 110 in the recessed portions 306 and/or 308 can keep the fan assemblies 110 separate from these additional components and prevent interference of configuration or operation of such components.

    [0120] In some implementations, the mattress system 300 can have fewer or additional fan assemblies 110. For example, the mattress system 300 can have one fan assembly 110 along a longer side of the rail structure 302. In another example, the bed system 300 can have one fan assembly 110 along the head portion 314 or the foot portion 316. As yet another example, the mattress system 300 can have two fan assemblies 110 on each of the longer sides of the rail structure 302. In yet another example, the mattress system 300 can have a fan assembly 110 disposed on each of the longer sides of the rail structure 302 and the head portion 314 and the foot portion 316. As described herein, each of the fan assemblies 110 can be oriented in any direction when disposed in the recessed portions 306 and 308.

    [0121] FIG. 9 is another bottom view of the example mattress system 300 of FIG. 8 having the integrated fan assembly 110. In comparison to FIG. 8, FIG. 9 depicts the airflows 312A-B (e.g., exhaust air) directed towards the foot portion 316 of the mattress system 300. Thus, the fan assemblies 110 are disposed and oriented towards the foot portion 316 of the mattress system 300. In this example, the fan assemblies 110 are arranged on the left side of the middle axis 310 so that the fan assemblies 110 are disposed closer to the head portion 314 than the foot portion 316. Alternatively, the fan assemblies 110 can be arranged the right side of the middle axis 310 so that the fan assemblies 110 are disposed closer to the foot portion 316 than the head portion 314, and thus increase airflow toward the foot portion 316 compared to the head portion 314.

    [0122] The recessed portions 308 of the bottom layer 304 are symmetrical and proportional along the length of the mattress system 300. Therefore, orientation of the bottom layer 304 does not matter when assembled with other parts of the mattress system 300, thereby improving convenience of assembling and servicing the mattress system 300. The airflows 312A-B can be directed along the channels created by the recessed portions 308 such that air can flow along sides of the components of the mattress system 300 and cool the top surface of the mattress system 300.

    [0123] Similarly to those of FIG. 8, the recessed portions 306 can have a predetermined width W3 that is suitable for receiving at least part of the fan assemblies 110. The width W3 of the recessed portion 306 can range from 2 inches to 10 inches. In other implementations, the width W3 of the recessed portions 306 can range from 3 inches to 9 inches. In other implementations, the width W3 of the recessed portions 306 can range from 4 inches to 8 inches. Moreover, the recessed portions 308 can have various dimensions (widths, lengths, and depths). In some implementations, a width W4 of the recessed portion 308 can be smaller than 1 inch. In other implementations, the width W4 can range from 1 inches to 6 inches. In other implementations, the width W4 of the recessed portions 308 can range from 2 inches to 5 inches. In other implementations, the width W4 of the recessed portions 308 can range from 3 inches to 4 inches. In some implementations, as illustrated in FIG. 8, a length L3 of the recessed portion 308 can extend between opposite head and foot rail portions 314 and 316. The length L3 of the recessed portion 308 can extend an entire distance between the opposite head and foot rail portions 314 and 316. The distance L3 of the recessed portion 308 can range in size depending on the size of the mattress system 300, as described above.

    [0124] FIG. 10 is another bottom view of the example mattress system 300 of FIG. 8 having the integrated fan assembly 110. In comparison to FIGS. 8 and 9, FIG. 10 depicts the airflows 312A-B (e.g., exhaust air) going in different or opposite directions. For example, the airflow 312A is directed towards the head portion 314 of the mattress system 300. The airflow 312B is directed towards the foot portion 316 of the mattress system 300. Directing air towards both the head portion 314 and the foot portion 316 of the mattress system 300 can be advantageous to cool or lower temperatures of two different zones at a top surface of the mattress system 300 at different rates. Directing air towards both the head portion 314 and the foot portion 316 of the mattress system 300 can also be advantageous to allow for a common fan assembly 110 to be used, regardless of whether the fan assembly is positioned on a right side or a left side of the mattress system 300. Regardless of fan assembly orientation, the airflows 312A-B can be directed along the channels created by the recessed portions 308 such that air can flow along sides of the components of the mattress system 300 and cool the top surface of the mattress system 300.

    [0125] Similarly to those of FIGS. 8-9, the recessed portions 306 can have a predetermined width W5 that is suitable for receiving at least part of the fan assemblies 110. Moreover, the recessed portions 308 can have various dimensions (widths, lengths, and depths). For example, the recessed portions 308 can have a width W6, as described in reference to FIGS. 8-9. In some implementations, as illustrated in FIGS. 8-9, a length L4 of the recessed portion 308 can extend between opposite head and foot rail portions 314 and 316.

    [0126] FIG. 11 is a bottom view of another example mattress system 400 having the integrated fan assembly 110. The mattress system 400 can be similar to the mattress system 300 depicted and described in reference to FIGS. 8-10. For example, the mattress system 400 is flipped upside down so that a top surface of the mattress system 400 is facing down. The depicted mattress system 400 has a rail structure 402 and a bottom layer 404, as described throughout this disclosure. The bottom layer 404 disposed inside the rail structure 402 can be retained or held in place using one or more reinforcement straps, as described in reference to FIG. 4. For example, a reinforcement strap can be placed across a middle axis 410 of the mattress system 400, thereby connected to opposing longer sides of the rail structure 402.

    [0127] The rail structure 402 has recessed portions 406, as described in reference to FIGS. 8-10. The fan assemblies 110 are disposed at least partially in the recessed portions 406 of the rail structure 402. As depicted, the recessed portions 406 are offset from the middle axis 410 of the mattress system 400. This configuration can be beneficial to prevent interference of the fan assemblies 110 placement with one or more other components of the mattress system 400.

    [0128] Moreover, the bottom layer 404 has recessed portions 408 to facilitate or direct airflows 412A-B (e.g., exhaust air) from the fan assemblies 110. The recessed portions 408 can also be angled so as to better direct the airflows 412A-B. In comparison to the recessed portions 308 in FIGS. 8-10, the recessed portions 408 in FIG. 11 begin at the middle axis 410 of the mattress system 400 and taper towards a head portion 414 of the mattress system 400. In other implementations, the recessed portions 408 can begin at the middle axis 410 and taper towards a foot portion 416 of the mattress system 400.

    [0129] The configuration of the recessed portions 408 in FIG. 4 provides for the fan assemblies 110 to be oriented towards the head portion 414 of the mattress system 400. As a result, the airflows 412A-B can be directed towards one or more layers of the mattress system 400 proximate to the head portion 414 of the mattress system 400. This configuration can be advantageous to exhaust the air and direct it toward the head portion 414 of the mattress system 400. In other implementations where the recessed portions 408 are disposed towards the foot portion 416, the fan assemblies 110 can be oriented towards the foot portion 416 such that the airflows 412A-B are exhausted and directed towards the foot portion 416 of the mattress system 400.

    [0130] The configuration of the recessed portions 406 and/or 408 are also advantageous to prevent the fan assemblies 110 from interfering with one or more other components integrated in the mattress system 400. For example, electric wires and/or air chamber hoses can be disposed along sides of the bottom layer 404 and/or the rail structure 402, such as at the middle axis 410. Placing the fan assemblies 110 in the recessed portions 406 and/or 408 can keep the fan assemblies 110 separate from these additional components and prevent interference of configuration or operation of such components.

    [0131] Similarly to those of FIGS. 8-10, the recessed portions 406 can have a predetermined width W7 that is suitable for receiving at least part of the fan assemblies 110. The width W7 of the recessed portion 406 can range from 2 inches to 10 inches. One or more other ranges can be used for the width W7. Moreover, the recessed portions 408 can have various dimensions (widths, lengths, and depths). In some implementations, a width W8 of the recessed portion 408 can be smaller than 1 inch. In other implementations, the width W8 can range from 1 inches to 6 inches. One or more other ranges can be used for the width W8. In some implementations, a length L5 of the recessed portion 408 can extend between the head portion 414 and the middle axis 410. In other implementations, the length L5 can extend between the foot portion 416 and the middle axis 410. The distance L5 of the recessed portion 408 can range in size depending on the size of the mattress system 400.

    [0132] FIG. 12 is a bottom view of another example mattress system 500 having the integrated fan assembly 110. The mattress system 500 can be similar to the mattress systems 300 and 400 depicted and described in reference to FIGS. 8-11. For example, the mattress system 500 is flipped upside down so that a top surface of the mattress system 500 is facing down. The depicted mattress system 500 has a rail structure 502 and a bottom layer 504, as described throughout this disclosure. The bottom layer 504 disposed inside the rail structure 502 can be retained or held in place using one or more reinforcement straps, as described in reference to FIG. 4. For example, a reinforcement strap can be placed across a middle axis 510 of the mattress system 500, thereby connected to opposing longer sides of the rail structure 502.

    [0133] The rail structure 502 has recessed portions 506, as described in reference to FIGS. 8-11. The fan assemblies 110 are disposed in the recessed portions 506 of the rail structure 502. As depicted, the recessed portions 506 are offset from the middle axis 510 of the mattress system 500. This configuration can be beneficial to prevent interference of the fan assemblies 110 placement with one or more other components of the mattress system 500 that are disposed at or around the middle axis 510 of the mattress system 500.

    [0134] Moreover, the bottom layer 504 has recessed portions 508 to facilitate or direct airflows 512A-B (e.g., exhaust air) from the fan assemblies 110. The recessed portions 508 can also be angled or tapered so as to better direct the airflows 512A-B. Like the recessed portions 308 in FIGS. 8-11, the recessed portions 508 in FIG. 12 are symmetrical from the middle axis 510 of the mattress 500. The recessed portions 508 taper symmetrically from the middle axis 510 to corners of a head portion 514 and a foot portion 516 of the mattress system 500. The recessed portions 508 are also narrower in width (e.g., refer to width W10) than the recessed portions 308 in FIGS. 8-11. The width of the recessed portions 508 and 308 can be different based on a configuration of a mattress system. In some implementations, a larger width may enable better air flow, thereby circulating air more efficiently and/or quickly throughout the mattress 500. In some implementations, a smaller width can maintain comfortability of a user on the mattress 500. The smaller width can also maintain surface stability of the mattress 500.

    [0135] As depicted in FIG. 12, the airflows 512A-B (e.g., exhaust air) are directed through the channels of the recessed portions 508 towards the head portion 514 of the mattress system 500. In other implementations, one or more of the airflows 512A-B can be directed through the channels of the recessed portions 508 towards the foot portion 516 of the mattress system 500. Because the recessed portions 508 are symmetrical from the middle axis 510, the fan assemblies 110 can be oriented in either direction towards the head portion 514 or the foot portion 516 of the mattress system 500 without compromising on an effectiveness of cooling the top surface of the mattress system 500. Moreover, the symmetrical recessed portions 508 of the bottom layer 504 allow easy assembling of the bottom layer 504 to other parts of the mattress system 500 because the bottom layer 504 provides the same configuration of the mattress system 500 regardless of the orientation of the bottom layer 504 attaching to the rest of the mattress system 500. In one example, an angle B of the tapered recessed portion 508 with respect to the middle axis 510 can range from 60 degrees to 85 degrees. Another example of the angle B can range from 50-65 degrees. Other ranges of the angle B are also possible.

    [0136] Additionally, as described throughout this disclosure, the configuration of the recessed portions 506 and/or 508 are advantageous to prevent the fan assemblies 110 from interfering with one or more other components integrated in the mattress system 500. For example, electric wires and/or air chamber hoses can be disposed along sides of the bottom layer 504 and/or the rail structure 502, such as at the middle axis 510. Placing the fan assemblies 110 in the recessed portions 506 and/or 508 can keep the fan assemblies 110 separate from these additional components and prevent interference of configuration or operation of such components.

    [0137] Similarly and as described in reference to those of FIGS. 8-11, the recessed portions 506 can have a predetermined width W9 that is suitable for receiving at least part of the fan assemblies 110. The recessed portions 508 can also have various dimensions (widths, lengths, and depths), such as a width W10 and a length L6 of the recessed portion 508 that can extend between opposite head and foot rail portions 514 and 516.

    [0138] FIG. 13A is a perspective view of the integrated fan assembly 110 in the mattress system 600. As depicted, the fan assembly 110 is placed inside/positioned within a recessed portion 601 of the rail structure 206. The positioning of the fan assembly 110 inside the recessed portion 601 is advantageous because it keeps the fan assembly 110 hidden from view. Moreover, this configuration prevents the fan assembly 110 from obstructing access or functioning of other components of the mattress system 600.

    [0139] The recessed portion 601 is offset from a middle axis 602 of the mattress system 600. This configuration is advantageous because it allows existing ports in the mattress system 600 to function normally. For example, the recessed portion 601 may not intrude with functioning or placement of ports that are used for inflating and deflating inflatable air chambers of the mattress system 600.

    [0140] The fan assembly 110 protrudes out from the recessed portion 601 and into a recessed portion 604 of the bottom layer 208 of the mattress system 600. As depicted, the recessed portion 604 is angled such that it has a bigger width closer to the middle axis 602 and a smaller or narrower width closer to corners of the rail structure 206. For example, as depicted in FIG. 13A, the fan assembly 110 is positioned such that an airflow 606 (e.g., exhaust air) is directed towards a foot end of the mattress 600. In other implementations, the fan assembly 110 can be positioned such that the airflow 606 is directed towards a head end of the mattress 600.

    [0141] FIG. 13B is a top view of the integrated fan assembly 110 in the mattress system 600 of FIG. 13A. The fan assembly 110 includes wires 608. The wires 608 can connect the fan assembly 110 to a power source in the mattress system 600. The wires 608 can also provide a connection of the fan assembly 110 to a power source external to the mattress system 600. Thus, the wires 608 can supply electrical power to the fan assembly 110. As depicted in FIG. 13B, the wires 608 can be positioned inside the recessed portion 601 of the rail structure 206. Therefore, the wires 608 can be kept out of sight. This placement of the wires 608 can also be beneficial because it may not obstruct other components of the mattress system 600, such as the bottom layer 208, the fan assembly 110 itself, and/or other layers of the mattress system 600 as depicted and described herein. In some implementations, the fan assembly 110 can be placed inside of an enclosure that has a fan guard, a printed circuit board (PCB) to help with controlling the fan assembly 110, and indicator lights. The wires 608 can be organized inside the enclosure and routed out, as described herein.

    [0142] FIG. 13C is a side perspective view of the integrated fan assembly 110 in the mattress system 600 of FIG. 13A. Fan assemblies 110 are positioned within recessed portions 601 on opposing sides of the rail structure 206 (e.g., left and right sides). Both sides of the bottom layer 208 can also have symmetrical recessed portions 604 to facilitate for airflow in whatever direction the fan assemblies are oriented. Moreover, the fan assemblies 110 are offset from the middle axis 602 such that additional components of the mattress system 600, such as air chamber ports, can still function as they normally would. For example, placement of the fan assemblies 110 that is offset from the middle axis 602 does not require reconfiguring or moving inflatable air chamber ports that are positioned at the middle axis 602 of the mattress system 600. In some implementations, where the mattress system 600 does not include air chamber ports or inflatable air chambers, the fan assembly 110 can be positioned at the middle axis 602 of the mattress system 600.

    [0143] FIG. 14 illustrates an example bed system 900 for providing a quality sleep experience with an example local bed system 901. The local bed system 901 can include a bed 902 and a bed control system 910 used in conjunction with the bed 902 and configured to control one or more user comfort features of the bed 902. The local bed system 901 can be any one of the bed systems described throughout this disclosure.

    [0144] The bed 902 can include a mattress 904 and a foundation 906. In some embodiments, the mattress 904 can be an air mattress having an inflatable air chamber and a controller for controlling inflation of the inflatable air chamber, as described herein. In other embodiments, the mattress 904 does not include an air chamber. For example, the mattress 904 may include foam and/or springs instead of or in addition to an inflatable air chamber. The mattress 904 can be sized and shaped as a twin mattress, full mattress, queen mattress, king mattress, California king mattress, split king mattresses, partially split mattress (e.g. a mattress that is split at the head and/or foot ends and joined in the middle), and/or other mattress as suitable for the application. The foundation 906 is positioned under the mattress 904 to support the mattress 904. In some embodiments, the foundation 906 can be an adjustable foundation with one or more articulable sections, such as for raising the head and foot of the foundation 906 and the mattress 904. In other embodiments, the foundation 906 can be a stationary foundation.

    [0145] The bed 902 can be configured to provide a microclimate control of the mattress 904. In some implementations, as described herein, the bed 902 can be configured to provide a cooling function. For example, the bed 902 can include a fan assembly 905 (e.g., refer to the fan assembly 110 described throughout this disclosure) that can be included in the mattress 904. The fan assembly 905 can be configured to circulate ambient air through the mattress 904 to reduce a top surface temperature of the mattress 904.

    [0146] In addition or alternatively, the bed 902 provides a foot warming function. For example, the bed 902 can include a foot warming device 920 which is disposed on the mattress 904 or incorporated in the mattress 904 and at a foot side of the bed 902. The foot warming device 920 can be disposed on a top of the mattress 904, included in the mattress 904, or disposed at other locations of the bed 902 and/or in other configurations. The foot warming device 920 can include an electronic heating element in some implementations. The foot warming device 920 can include an air circulation element through which heating air is circulated in other implementations. Other configurations are also possible.

    [0147] In addition or alternatively, the bed 902 can include an airflow insert pad 922 that can be included in the mattress 904 and configured to circulate ambient or conditioned air through the mattress under the user at rest. The airflow insert pad 922 can be arranged at various locations in the mattress 904. In the illustrated example, the airflow insert pad 922 is disposed between the head and foot of the mattress 904 (e.g., in the middle of the mattress 904).

    [0148] The bed control system 910 operates to control features available for the bed 902. In some implementations, the bed control system 910 includes a bed articulation system 912, an air chamber control system 914, a foot warming control system 916, an airflow insert pad control system 918, and a fan control system 919.

    [0149] The bed articulation system 912 operates to articulate the foundation 906 and/or the mattress 904. For example, the bed articulation system 912 can adjust one or more articulable sections of the foundation 906 to raise the head and foot of the foundation 906 and/or the mattress 904. The bed articulation system 912 can include a controller and an actuator (e.g., a motor) operated by the controller and coupled to the articulable sections of the foundation 906 so that the sections of the foundation 906 are automatically adjusted to desired positions. Alternatively or in addition, the articulable sections of the foundation 906 can be manually adjusted.

    [0150] The air chamber control system 914 operates to control the air chamber of the mattress 904. The air chamber control system 914 can include a controller and an actuator (e.g., a pump) operated by the controller and fluidly connected to the air chamber. The actuator is controlled to inflate or deflate the air chamber to provide and maintain a desired pressure in the air chamber, thereby providing a desired firmness of the air chamber.

    [0151] The foot warming control system 916 operates to control the foot warming device 920 disposed in the mattress 904. The foot warming control system 916 can include a controller configured to activate a heating element of the foot warming device 920 and maintain a desired temperature of the heating element.

    [0152] The airflow insert pad control system 918 operates to control the airflow insert pad 922 disposed in the mattress 904. The airflow insert pad control system 918 can include an air controller configured to cause ambient or conditioned air to flow into or out of the airflow insert pad 922 so that a top layer of the mattress above or adjacent the airflow insert pad 922 have a desired temperature and/or humidity. The airflow insert pad control system 918 can determine an airflow based on one or more temperature and/or humidity sensor readings at the top layer of the mattress 904 and/or of the user's body.

    [0153] The fan control system 919 operates to control the fan assembly 905. The fan control system 919 can include an air controller configured to cause ambient air to be expelled from the fan assembly 905 so that the top layer of the mattress can reach a desired, cooled temperature and/or humidity level. The fan control system 919 can determine an airflow based on one or more temperature and/or humidity sensor readings at the top layer of the mattress 904 and/or the user's body. In other implementations, the fan control system 919 can operate the fan assembly 905 to circulate air through the mattress by drawing ambient air into the fan assembly 905.

    [0154] In some implementations, the bed articulation system 912, the air chamber control system 914, the foot warming control system 916, the airflow insert pad control system 918, and the fan control system 919 can be independently configured and operated. In other implementations, some or all of the bed articulation system 912, the air chamber control system 914, the foot warming control system 916, the airflow insert pad control system 918, and the fan control system 919 are at least partially combined so that they share at least part of their components such as actuators (e.g., motors, pumps, etc.) and/or controllers (e.g., control circuits, processors, memory, network interfaces, etc.).

    [0155] The bed control system 910 can be accessed by a user via one or more control devices 930, such as a bed-side controller 932 and a mobile computing device 934. The bed-side controller 932 is wired to, or wirelessly connected to, the bed control system 910 to enable the user to at least partially control the bed control system 910. The bed-side controller 932 includes an input device (e.g., a keypad, buttons, switches, etc.) for receiving a user input of controlling various settings of the bed control system 910, such as articulation positions, temperature settings, air chamber pressure settings, etc. The bed-side controller 932 can further include an output device (e.g., a display, a speaker, etc.) for outputting the statuses and conditions of the bed control system 910 and other information useful to the user, such as articulation positions, temperature settings, air chamber pressure settings, sleep analysis results, etc. The same or similar functionalities can be implemented with the mobile computing device 934, such as a mobile device running a dedicated software application. For example, the user can use a mobile device as an input device to control various settings of the bed control system 910, such as articulation positions, temperature settings, air chamber pressure settings, etc., and further use the mobile device as an output device to see the statuses and conditions of the bed control system 910 and other useful information, such as articulation positions, temperature settings, air chamber pressure settings, sleep analysis results, etc.

    [0156] Referring still to FIG. 14, the system 900 can include a server system 940 connected to the local bed system 901 and configured to provide one or more services associated with the bed 902. The server system 940 can be connected to the local bed system 901, such as the bed 902, the bed control system 910, and/or the control devices 930, via a network 942. The server system 940 can be of various forms, such as a local server system with one or more computing devices dedicated to one or more beds, or a cloud server. The network 942 is an electronic communication network that facilitates communication between the local bed system 901 and the server system 940. An electronic communication network is a set of computing devices and links between the computing devices. The computing devices in the network use the links to enable communication among the computing devices in the network. The network 942 can include routers, switches, mobile access points, bridges, hubs, intrusion detection devices, storage devices, standalone server devices, blade server devices, sensors, desktop computers, firewall devices, laptop computers, handheld computers, mobile telephones, and other types of computing devices. In various embodiments, the network 942 includes various types of links. For example, the network 942 includes wired and/or wireless links. Furthermore, in various embodiments, the network 942 is implemented at various scales. For example, the network 942 can be implemented as one or more local area networks (LANs), metropolitan area networks, subnets, wide area networks (such as the Internet), or can be implemented at another scale.

    [0157] In some implementations, the server system 940 can provide a bed data service that can be used in a data processing system associated with the local bed system 901. The server system 940 can be configured to collect sensor data and sleep data from a particular bed, and match the sensor and sleep data with one or more users that use the bed when the sensor and sleep data were generated. The sensor and sleep data, and the matching data, can be stored as bed data 950 in a database. The bed data 950 can include user identification data usable to identify users of beds. The users can include customers, owners, or other users registered with the server system 940 or another service. Each user can have, for example, a unique identifier, user credentials, contact information, billing information, demographic information, or any other technologically appropriate information. The bed data 950 can include management data usable to identify data related to beds or other products associated with data processing systems. For example, the beds can include products sold or registered with a system associated with the server system 940. Each bed can have, for example, a unique identifier, model and/or serial number, sales information, geographic information, delivery information, a listing of associated sensors and control peripherals, etc. Additionally, an index or indexes stored in the bed data 950 can identify users that are associated with beds. For example, this index can record sales of a bed to a user, users that sleep in a bed, etc.

    [0158] The bed data 950 can include sensor data that record raw or condensed sensor data recorded by beds with associated data processing systems. For example, a bed's data processing system can have a temperature sensor, humidity sensor, pressure sensor, and light sensor. Readings from these sensors, either in raw form or in a format generated from the raw data (e.g. sleep metrics) of the sensors, can be communicated by the bed's data processing system to the server system 940 for storage in the bed data 950. Additionally, an index or indexes stored by the server system 940 can identify users and/or beds that are associated with the sensor data. In some implementations, the server system 940 can use any of its available data to generate advanced sleep data. The advanced sleep data includes sleep metrics and other data generated from sensor readings.

    [0159] For example, the advanced sleep data can include sensed mattress surface temperature values and/or sensed mattress surface humidity values. Using these values, the server system 940 can determine an amount of ambient and/or conditioned air to deliver through the mattress 904 to maintain an optimal or desired temperature for the mattress 904 (e.g., the desired temperature can be determined by the user, by the server system 940, and/or by any one of the other systems described in reference to FIG. 14). The server system 940 can also determine/estimate a body temperature of the user based on sensed mattress surface temperature values and/or humidity values. One or more of these calculations can be performed locally on the bed's data processing system. Performing such calculations in the server system 940, however, can be advantageous because the calculations can be computationally complex or require a large amount of memory space or processor power that is not available on the bed's data processing system. This can help allow a bed system to operate with a relatively simple controller and still be part of a system that performs relatively complex tasks and computations.

    [0160] The sensed temperature values and/or airflow adjustment determinations can also be transmitted to the bed-side controller 932 and/or the mobile computing device 934. Based on these values and airflow adjustment determinations, the user can selectively moderate, adjust, and/or change an airflow through the mattress 904 or a desired temperature.

    [0161] In addition or alternatively, the server system 940 can provide a sleep data service that can be used in a data processing system that can be associated with the local bed system 901. In this example, the server system 940 is configured to record data related to users' sleep experience and store the data as sleep data 952. The sleep data 952 can include pressure sensor data related to the configuration and operation of pressure sensors in beds. For example, the pressure sensor data can include an identifier of the types of sensors in a particular bed, their settings and calibration data, etc. The sleep data 952 can include pressure based sleep data which can be calculated based on raw pressure sensor data and represent sleep metrics specifically tied to the pressure sensor data. For example, user presence, movements, weight change, heart rate, and breathing rate can be determined from raw pressure sensor data. Additionally, an index or indexes stored by the server system 940 can identify users that are associated with pressure sensors, raw pressure sensor data, and/or pressure based sleep data. The sleep data 952 can include non-pressure sleep data which can be calculated based on other sources of data and represent sleep metrics obtained from such other sources of data. For example, user entered preferences, light sensor readings, and sound sensor readings can all be used to track sleep data 952. Additionally, an index or indexes stored by the server system 940 can identify users that are associated with other sensors and/or non-pressure sleep data 952.

    [0162] In addition or alternatively, the server system 940 can provide a user account service that can be used in a data processing system associated with the local bed system 901. For example, the server system 940 can record a list of users and to identify other data related to those users, and store such data as user account data 954. The user account data 954 are related to users of beds with associated data processing systems. For example, the users can include customers, owners, or other users registered with the server system 940 or another service. Each user can have, for example, a unique identifier, user credentials, demographic information, or any other technologically appropriate information. The user account data 954 can include engagement data usable to track user interactions with the manufacturer, vendor, and/or manager of the bed and/or cloud services. This engagement data can include communications (e.g., emails, service calls), data from sales (e.g., sales receipts, configuration logs), and social network interactions. The user account data 954 can include usage history data related to user interactions with one or more applications and/or remote controls of a bed. For example, a monitoring and configuration application can be distributed to run on, for example, the control devices 930. This application can log and report user interactions for storage. Additionally, an index or indexes stored by the server system 940 can identify users that are associated with each log entry.

    [0163] In addition or alternatively, the server system 940 can provide an environment service that can be used in a data processing system associated with the local bed system 901. For example, the server system 940 can record data related to users' home environment, and store such data as environment data 956. The environment data 956 can be obtained using one or more sensors installed in or around the bed. Such sensors can be of various types that can detect environmental variables, such as light sensors, noise sensors, vibration sensors, thermostats, etc. The environment data 956 can include historical readings or reports from those sensors. By way of example, a light sensor is used to collect data indicative of the frequency and duration of instances of increased lighting when the user is asleep.

    [0164] FIG. 15 illustrates another fan assembly 1110 integrated into another example mattress system 1500. The mattress system 1500 can be part of the bed system 100 described in reference to FIG. 1. For example, components 1106, 1122, and 1110 can replace components 106, 110, and 122 in the mattress 101 in FIG. 1. The mattress system 1500 can be similarly configured as other examples of the mattress system described herein. Further, the fan assembly 1110 can be similarly configured as other examples of the fan assembly described herein. More particularly, the mattress system 1500 can include the top layer 102, rail structure 1106, the bottom layer 108, and air chambers. In this example, the integrated fan assembly 1110 can be disposed (e.g., positioned) at a foot end of the rail structure 1106. As described herein, the fan assembly 1110 can be received in a recessed portion of the foot end of the rail structure 1106. As a result, the fan assembly 1110 may not interfere with other components of the mattress system 1500, such as the bottom layer 108, the air chambers, and/or the top layer 102. The fan assembly 1110 can also be mounted to the air duct hose 111 (e.g., FIG. 16). As described herein, the air duct hose 111 can extend from airflow insert pads 1122 in the mattress system 1500. In some implementations, at least a portion of the hose 111 can be made of a silicon material and configured to be fitted around an air opening (e.g., an air inlet 1710 in FIG. 19) of the fan assembly 1110. The fan assembly 1110 can then draw air out of the airflow insert pads 1122 and exhaust the drawn air into the foot end of the rail structure 1106.

    [0165] The fan assembly 1110 can be similar (e.g., in terms of functionality) to the fan assembly 110 described throughout this disclosure. For example, the fan assembly 1110 can be configured to pull or draw air from the mattress system 1500. In other examples, the fan assembly 1110 can also be configured to push air into the mattress system 1500 (such as ambient air or cooled/conditioned air), which can be beneficial to cool a top surface of the mattress system 1500. In yet other examples, the fan assembly 1110 can be configured to push heated air into the mattress system 1500 to warm a top surface of the mattress system 1500. Therefore, the fan assembly 1110 can be arranged to draw air into the mattress system 1500 and circulate the air therein to help control a microclimate at the top surface of the mattress system 1500.

    [0166] FIG. 16 is a bottom perspective view of a mattress system 1600, illustrating the mattress system 1600 upside down. The mattress system 1600 can be the mattress system 1500 as depicted and described in reference to FIG. 15. The mattress system 1600 can also include some similar or same components as the mattress system 200 depicted and described in FIG. 2. For example, the mattress system 1600 can include the top layer (e.g., a first layer) 202, the intermediate layer (e.g., a second layer) 204, and the bottom layer (e.g., a third layer) 208, which is not shown in FIG. 16. The intermediate layer 204 can include the airflow insert pads 1122, as shown in FIG. 15. The airflow insert pads 1122 can each extend some length from a foot end 1207 of the rail structure 1206 towards a head end 1209 of the rail structure 1206. The airflow insert pads 1122 can be inset some distance from the foot end 1207 of the rail structure 1206 as well as respective right and left sides of the rail structure 1206.

    [0167] A bottom layer (e.g., the bottom layer 108 as shown in FIG. 15) can cover an entire bottom of the mattress system 1600, from one rail edge to another rail edge (e.g., from a head end edge to a foot end edge of the rail structure 1206 and from a right side edge to a left side edge of the rail structure 1206). In some implementations, the bottom layer can also cover the rail structure. In other implementations, the bottom layer is inserted into a space defined (surrounded) by the rail structure.

    [0168] The mattress system 1600 can also include the rail structure 1206, as shown in FIG. 15. The rail structure 1206 is arranged around a periphery of the mattress system 1600 and configured to at least partially surround an air chamber assembly or mattress core. For example, the air chamber assembly can include one or more inflatable air chambers (e.g., refer to FIG. 17). The foot end 1207 of the rail structure 1206 can have a wider width than the head end 1209 opposite the foot end and left and right sides of the rail structure 1206. In some implementations, the combined width of the foot end 1207 and head end 1209 of the rail structure 1206 is the same as the combined width of the foot rail 230 and the head rail 232 of the mattress 200 (FIG. 4). The foot end 1207 can be wider in order to accommodate placement of the fan assemblies 1110 thereto. As described in reference to FIG. 15, the fan assemblies 1110 can be disposed inside the foot end 1207 of the rail structure 1206 and configured to draw air through the air duct hoses 111 from the airflow insert pads 1122 and out along the inside of the rail structure 1206 (e.g., along the foot end 1207 of the rail structure 1206). For example, the foot end 1207 defines a recessed portion 1306 (e.g., cavity) configured to receive the fan assembly 1110. Referring also to FIG. 19, the recessed portion 1306 is configured to entirely receive an external housing 1700 of the fan assembly 1110. The recessed portion 1306 is open toward the interior of the mattress so that an air duct 1708 of the fan assembly 1110 extends therethrough. An air inlet 1710 at the end of the air duct 1708 is exposed out of the recessed portion 1306 in the foot end 1207 and configured to couple to the air duct hose 111. The fan assemblies 1110 can be positioned at the foot end 1207 of the rail structure 1206 to prevent the fan assemblies 1110 from protruding out from the mattress system 1600 due to connection to the air duct hoses 111. Moreover, the fan assemblies 1110 are positioned farther away from a head of a user of the mattress system 1600 so that the fan assemblies 1110 are quieter when operating. As a result, sounds from the fan assemblies 1110 may not disturb the user's sleep.

    [0169] As depicted, the mattress system 1600 can have two fan assemblies 1110 disposed in the foot end 1207 of the rail structure 1206, and configured and operable to control microclimates of two separate zones (left and right sides) at the top of the mattress system 1500. In yet other implementations, the mattress system 1500 can have fewer or more integrated fan assemblies.

    [0170] FIG. 17 is a partial exploded view of the mattress system 1600 of FIG. 16, illustrating the top layer 202, the intermediate layer 204, the example air chambers 222, and the integrated fan assemblies 1110. The air chambers 222 can be arranged to be surrounded by the rail structure 1206.

    [0171] As depicted, the rail structure 1206 can be disposed on the intermediate layer 204, or on the top layer 202 where there is no intermediate layer, to define the space 211 for at least partially receiving the air chambers 222. As described in reference to FIG. 16, the bottom layer 208 can be disposed within the space 211 to cover the entire space 211 and the air chambers 222 within the space 211.

    [0172] The mattress system 1600 can also include the airflow insert pads 1122 (e.g., thermal insert), which can be positioned under the top layer 202. In some implementations, the intermediate layer 204 can define a cutout section or recess to receive the airflow insert pads 1122 therein. The airflow insert pads 1122 can be similar to the airflow insert pad 122 described throughout this disclosure. In the illustrated example, the airflow insert pads 1122 are disposed between the head and foot of the mattress 1600, partially along a length of the mattress 1600 from the head to the foot. The pads 1122 are disposed closer to the foot of the mattress 1600 than the head of the mattress 1600 to optimize positioning without needing to rely on a foundation hole pass-through. For example, as described herein, the fan assembly can be embedded in the foam. The fan assembly can operate to draw air from the top of the mattress, and the fan assembly is designed to have enough power to expel the air out of the rail structure of the mattress. This design allows the mattress assembly to not rely on a single foundation and to be used with any type of foundation. In one example, a portion of the rail structure can be thickened in order to accept the fan assembly and main structural integrity of the foam mattress assembly. In some implementations, the fan assembly is placed in the foot of the bed (e.g., in the foot rail of the mattress), and the air chamber is shifted up towards the head of the bed, reducing the thickness of the head rail. By placing the fan assembly in the foot rail as opposed to the head rail can provide additional benefits. For example, the sound of the fan is further away from the head reducing perceived sound levels. The chamber is shifted to the more comfort sensitive areas of the body (core, head) rather than the feet. In addition, where the fan assembly is a cooling-only module, the fan assembly can have a relatively small form factor so as to fit within the bounds of the mattress.

    [0173] The airflow insert pads 1122 can be attached to a surface of the space 211 using one or more attachment mechanisms. For example, each corner of the airflow insert pad 1122 can include a hook or loop configured to mate with a respective loop or hook on the space 211. Such hook and loop fasteners can provide for easy and secure attachment of the airflow insert pad 1122 in the space 211. One or more other attachment mechanisms can be used, including but not limited to adhesives. In other examples, the airflow insert pads 1122 can be interference fit to the cutout section or recess in the intermediate layer 204, or received within the cutout section or recess in the intermediate layer 204 without attachment mechanisms. In some implementations, the airflow insert pads 1122 can be positioned to be flush with the intermediate layer 204.

    [0174] The fan assemblies 1110 can be connected to or mounted on the air duct hoses 111. The fan assemblies 1110 can also be disposed at least partially in the rail structure 1206 at the foot end, as described in reference to FIGS. 15-16. In some implementations, the intermediate layer 204 defines a cutout section or recess configured to receive the air duct hoses 111. The air duct hoses 111 can be received in the cutout section or recess to be flush with the intermediate layer 204.

    [0175] FIG. 18 illustrates a bottom perspective view of the mattress system 1600 of FIG. 16. Unlike the mattress system 200 depicted and described in FIG. 4, the mattress system 1600 depicted and described in FIG. 18 does not include reinforcement straps (e.g., the reinforcement straps 250A-B in FIG. 4). Instead, a foot rail 1230 of the rail structure 1206 is thicker than a head rail 1232 and the opposite side rails 234 and 236. The thicker foot rail 1230 can provide additional support for the rail structure 1206 to hold a shape of the mattress system 1600. The thicker foot rail 1230 can also provide additional support for maintaining the fan assemblies 1110 in place so that the rail structure 1206 does not bend and/or the fan assemblies 1110 do not protrude from a general shape of the mattress system 1600. By thickening the foot rail 1230, the head rail 1232 and the opposite side rails 234 and 236 can be adjusted in width such that an existing air chamber assembly can be positioned in the mattress system 1600. For example, the head rail 1232 may be thinned/thinner in width. Therefore, an air chamber assembly may not have to be modified in size and/or shape in order to fit within a space (e.g., the space 211 in FIG. 17) defined by and between the foot rail 1230, the head rail 1232, and the opposite side rails 234 and 236 of the rail structure 1206. For example, the air chamber assembly 220 described in FIG. 3 can be used with both the mattress system 200 and the mattress system 1600, even though the rail structure 206 of the mattress system 200 has rails of equal width and the rail structure 1206 of the mattress system 1600 has rails of different widths. In one example, the width of the foot rail can range between 4 inches and 7 inches, and the head rail can range between 1 inches and 4 inches, so that the total width of the foot and head rails can be around 8 inches. In this example, each of the side rails can be maintained at 4 inches of width.

    [0176] In some implementations, the foot rail 1230 can have a largest width, the head rail 1232 can have a smallest width, and the opposite side rails 324 and 236 can have a same width that is less than the width of the foot rail 1230 and greater than the width of the head rail 1232. As mentioned above, the rail structure 1206 can be sized in such a way that still allows an existing air chamber assembly to be positioned in the mattress system 1600 without having to be replaced by a differently sized air chamber assembly. In some implementations, the opposite side rails 234 and 236 can be increased in width to provide additional support and maintain the rail structure 1206 in the shape of the mattress system 1600.

    [0177] FIG. 19 is a perspective view of the integrated fan assembly 1110 of FIG. 15. As depicted, the fan assembly 1110 includes an external housing 1700 configured to receive a fan and electronics that can control operation of the fan. The fan can be positioned in the external housing 1700. The electronics can include a printed circuit board positioned proximate to the fan and/or near an air outlet 1702 of the fan assembly 1110. The electronics can connect (e.g., wired and/or wireless) to a controller of a bed system (e.g., the bed system 100 in FIG. 1) and can be configured to control operation of the fan assembly 1110. In some implementations, the electronics can include one or more sensors for measuring temperature, humidity, and/or smoke detection in the fan assembly 1110 and/or near the fan assembly 1110 when positioned in the mattress system 1500 and/or 1600.

    [0178] The fan assembly 1110 can include an air duct 1708 (e.g., plenum) that is fluidly connected to the housing 1700 and configured for airflow into or from the housing 1700. The housing 1700 and the air duct 1708 can define air inlets and air outlets. For example, where the fan assembly 110 operates to draw air, the air duct 1708 defines an air inlet 1710, and the housing 1700 defines an air outlet 1702. In embodiments where the fan assembly 1110 operates to blow air, the air inlet 1710 of the air duct 1708 works as an air outlet, and the air outlet 1702 of the housing 1700 works as an air inlet. One or more components of the fan assembly 1110 depicted and described in FIG. 19 can be similar to one or more components of the fan assembly 110 depicted and described in FIG. 5.

    [0179] FIG. 20 illustrates a cross sectional view of airflow through the mattress system 1600 of FIG. 16, taken along a cross sectional line shown in FIG. 22. FIG. 20 illustrates an example airflow 1800 (e.g., exhaust air) through the mattress system 1600. The mattress system 1600 can be similar to the mattress system 200 depicted and described in reference to FIG. 6. The view of FIG. 20 depicts the head rail 1232 and the foot rail 1230 of the rail structure 1206. The fan assemblies 1110 are positioned within the foot rail 1230 of the rail structure 1206, as described throughout FIGS. 15-19.

    [0180] As shown in FIG. 20, the airflow 1800 is directed from the top surface of the mattress system 1600, through the airflow insert pad 1122, and into the fan assembly 1110 via the air duct 1708. The airflow 1800 can then be routed into the housing 1700 of the fan assembly 1110. In some implementations, the airflow 1800 can also flow through one or more layers of the mattress 1600 to provide for air circulation at the top layer 202. By circulating the airflow 1800, the fan assembly 1110 can cause the airflow 1800 at the top surface of the mattress cover 140 to lower or moderate a temperature of the mattress 1600.

    [0181] FIG. 21 illustrates a side cross sectional view of the mattress system 1600, taken along a cross sectional line shown in FIG. 22. FIG. 21 depicts the airflow 1800 that is drawn into the fan assembly 1110 and further depicts exhaust air 1801 from the fan assembly 1110. This side cross sectional view of the mattress 1600 depicts a shorter foot side of the mattress 1600. The mattress 1600 includes the rail structure 1206 having the side rails 234 and 236. The fan assemblies 1110 are disposed in the foot rail 1230 of the rail structure 1206 (not shown). In the illustrated example, the fan assemblies 1110 are oriented towards the side rail 234 of the rail structure 1206. As a result, the airflow 1801 is discharged from the fan assemblies 1110 towards the same side portion of the mattress 1600 to thereby lower a temperature of a top surface of the mattress 1600. Alternatively, the fan assemblies 1110 can be oriented towards the side rail 236 of the rail structure 1206.

    [0182] As shown in FIG. 21, the fan assemblies 1110 can exhaust the airflow 1801 in the same direction. In some implementations, the fan assemblies 1110 can exhaust the airflow 1801 in different directions (e.g., the fan assembly 1110 closest to the side rail 234 can exhaust the airflow 1801 towards the side rail 234 and the fan assembly 1110 closest to the side rail 236 can exhaust the airflow 1801 towards the opposite side rail 236). Regardless of an orientation/direction of the fan assemblies 1110, the airflow 1801 can be directed into and/or around the rail structure 1206 to effectively adjust a microclimate of a top surface of the mattress 1600 as described throughout this disclosure.

    [0183] FIG. 22 is a bottom view of the example mattress system 1600 having the integrated fan assembly (e.g., the fan assembly 1110 shown in FIG. 15). As depicted, the mattress system 1600 is flipped upside down so that a top surface of the mattress system 1600 is facing down. The depicted mattress system 1600 has a rail structure 1302 and the bottom layer 304, as described throughout this disclosure (e.g., refer to the rail structure 1206 in FIG. 16 and the bottom layer 208 in FIG. 2). In some implementations, as described in reference to FIGS. 24A-B, the mattress system 1600 can have a bottom layer 1900.

    [0184] FIG. 23 is another bottom view of the example mattress system 1600 of FIG. 22 having the integrated fan assembly 1110. In FIG. 23, the bottom layer 304 is removed to show detail of the rail structure 1302. The rail structure 1302 has recessed portions 1306. The recessed portions 1306 are configured to receive the fan assemblies 1110. A foot rail 1304 can include recessed portions 1306 configured to at least partially receive each of the fan assemblies 1110. The recessed portions 1306 can be any appropriate size to fit a size of the fan assemblies 1110. Therefore, the fan assemblies 1110 can be disposed inside the rail structure 1302 so that the fan assemblies 1110 do not interfere with one or more other components of the mattress system 1600. This configuration can also be beneficial to prevent interference of the fan assemblies 1110 placement with one or more other components of the mattress system 1600 that are disposed at or around a middle axis of the mattress system 1600 (e.g., refer to the middle axis 310 described in reference to FIGS. 8-10.

    [0185] The recessed portions 1306 can have a predetermined width W1 that is suitable for receiving at least part of the fan assemblies 1110. The predetermined width W1 can be big enough to maintain sufficient airflow and room for installation of the fan assembly 1110 while also being minimal in size to minimize discomfort that may occur from an opening that is too wide. The width W1 can depend on the length of the thermal module. For example, the width W1 can be greater (e.g., by 1 inch or more) than the length of the thermal module. In some implementations, where the length of the thermal module is 8.5 inches, the width W1 can be 9.5 inches or larger.

    [0186] In some implementations, the recessed portions 1306 can be arranged in one or more different configurations to facilitate or direct airflow (e.g., exhaust air) from the fan assemblies 1110. As shown in FIG. 23, the recessed portions 1306 can be arranged such that the fan assemblies 1110 can direct air towards a same side rail of the rail structure 1302. As another example, the recessed portions 1306 can be arranged in an opposite direction such that both fan assemblies 1110 direct air towards the opposite side rail of the rail structure 1302. In some implementations, each of the recessed portions 1306 can be arranged in opposite configurations such that the fan assembly 1110 on a right side of the mattress system 1600 can direct air towards a right side rail of the rail structure 1302 and the fan assembly 1110 on a left side of the mattress system 1600 can direct air towards a left side rail of the rail structure 1302. In some implementations, each of the recessed portions 1306 can be arranged towards each other such that both fan assemblies 1110 direct air inwards towards a midpoint of the foot rail 1304 of the rail structure 1302. In yet some implementations, at least one of the recessed portions 1306 can be arranged inwards, towards the midpoint of the foot rail 1304 of the rail structure 1302. Moreover, in some implementations, an air duct of the fan assemblies 1110 (e.g., the air duct 1708 in FIG. 19) can extend out from the foot rail 1304 of the rail structure 1302.

    [0187] FIGS. 24A-B illustrate a bottom view of a bottom layer 1900 of an example mattress system 1901 having the integrated fan assembly of FIG. 15. The mattress system 1901 can be the same as or similar to the mattress systems 1500 and 1600. In some implementations, the bottom layer 1900 can be part of the mattress system 200 described herein.

    [0188] Referring to both FIGS. 24A-B, the bottom layer 1900 (e.g., base pad) can cover an entire bottom of the mattress system 1901, including a top layer (e.g., a first layer, such as the top layer 202) 1902, an intermediate layer (e.g., a second layer, such as the layer 204) 1904, a rail structure 1906 (e.g., such as the rail structure 206 and/or 1206). The bottom layer 1900 can be made of a material that has some permeability to provide a sufficient airflow rate for adjusting a microclimate at a top surface of the mattress system 1901. The fan assemblies described herein (e.g., the fan assembly 110 and the fan assembly 1110) can also route airflow throughout the mattress system 1901 sufficiently to overcome features of the bottom layer 1900 that may otherwise impede ability to adjust the microclimate and achieve a desired cooling at the top surface of the mattress system 1901. The foot of the bed is configured to be permeable enough to discharge the air through the foot rail without a need for any permeability of the base. Therefore, for example, the bottom layer 1900 can be made of various types of material (e.g., not breathable, having minimum breathability, etc.) In some implementations, the bottom layer is made to little breathability so that the air exits the vertical surface at the foot of the bed. Moreover, the fan assemblies described herein can sufficiently route airflow through/around the rail structure 1906 and the bottom layer 1900 without requiring exhaust openings (e.g., the recessed portions 1306) to extend out from the rail structure 1906 and into a surrounding environment.

    [0189] Still referring to both FIGS. 24A-B, the bottom layer 1900 can be formed with multiple pieces. For example, the bottom layer 1900 can be split longitudinally down a midpoint of the bottom layer 1900, thereby having first and second flaps 1900A and 1900B, respectively. Each of the flaps 1900A and 1900B can be individually opened/folded back from a midpoint of the mattress system 1901 to access components of the mattress system 1901 described throughout this disclosure. This construction can be beneficial to allow for opening the mattress system 1901 for assembly, maintenance, and/or fixing/replacing one or more components of the mattress system 1901. Each of the flaps 1900A and 1900B can also be attached (e.g., laminated, adhered) to respective side rails of the rail structure 1906. In some implementations, the flaps are attached to the rails using foam lamination. For example, for laminating to the head and foot rails, glue (e.g., 3-4 inches) would be present following the glue path created by the side rails. This makes the head/foot rails have a partial lamination with the base pads. The flaps 1900A and 1900B of the bottom layer 1900 may not be laminated or otherwise attached to head and foot rails of the rail structure 1906 to ensure that the flaps 1900A and 1900B can be individually opened or closed.

    [0190] In some implementations, the bottom layer 1900 can also include openings 1908A and 1908B (e.g., cutouts, chamber ports, etc.) on respective flaps 1900A and 1900B. The openings 1908A and 1908B can be positioned towards a midpoint of the mattress system 1901 (e.g., a hip of the bed). The openings 1908A and 1908B can be offset some predetermined distance from the midpoint of the mattress system 1901, in some implementations. Moreover, the openings 1908A and 1908B can be positioned at locations where air duct hoses may attach to air chambers of the mattress system 1901 such that all or some wiring/cables can be maintained together in a centralized location and routed therefrom to a power source and/or a controller for the mattress system 1901 and/or the bed system. The openings 1908A and 1908B can therefore be configured to receive wires/cables that are routed to and from components (e.g., the fan assemblies, air chambers, etc.) in the mattress system 1901. For example, wiring/cables connected to an external housing of a fan assembly can be routed (e.g., in a wire harness or without a hardness) from the foot rail of the rail structure 1906 to the midpoint of the mattress system 1901 (e.g., the hip of the bed) along the foot rail and at least one of the side rails of the rail structure 1906.

    [0191] The wiring can be routed, as an illustrative example, along the foot rail to a location where the flap 1900B folds back from the respective side rail of the rail structure 1906. The wiring can be secured along one or more portions of the rail structure 1906 using one or more wire management loops. The loops can keep the wiring from shifting out of its intended location inside the mattress system 1901 when the mattress system 1901 is transported (e.g., to a user's home), when a user sits on edges of the mattress system 1901, and/or when the mattress system 1901 is lifted off a base/foundation of a bed system. The loops can be secured to the respective side rails of the rail structure 1906 (and/or portions of the foot rail of the rail structure 1906) using adhesive (e.g., foam glue between the bottom layer 1900 and the respective side rail of the rail structure 1906) and/or hook and loop fasteners (e.g., micro-hooks adhered to the respective side rail and fabric attached to the micro-hooks). One or more other attachment mechanisms may also be used to attach the wire management loops to the mattress system 1901.

    [0192] One or more wire management loops can be attached to each side of the mattress system 1901. For example, a loop can be configured at a corner where the foot rail means a right side rail (and where the foot rail meets a left side rail) of the rail structure 1906. This location can be beneficial to ensure the wiring does not shift or move towards a center of the mattress system 1901 and thus interfere with other components therein. Moreover, this location can be beneficial to ensure stress experienced on the fan assembly from using and/or moving the mattress system 1901 may be relieved. One or more additional wire management loops can be placed along a length of the side rail up to the respective opening 1908A or 1908B. In some implementations, wire management loops may not be used. Instead, the wiring can be attached directly to the mattress system 1901 with adhesives, hook and loop fasteners, and/or one or more other types of attachment mechanisms.

    [0193] The wiring can then be tucked between the respective side rail of the rail structure 1906 and the flap 1900B of the bottom layer 1900 up to the respective opening 1908B. The wiring can then be routed through the respective opening 1908B. As a result, the wiring may be consolidated and maintained in one location, thereby providing an aesthetically pleasing look and also ease to a user of the mattress system 1901 and/or a technician when setting up and maintaining the mattress system 1901. In other words, when the mattress system 1901 is manufactured and before it is delivered to a user, wires from the fan assemblies can be routed along the side rails of the rail structure 1906 and out through the respective openings 1908A and 1908B. Maintaining the wires in one location can be beneficial to ensure ease of setting up the mattress system 1901 in a home of the user. A delivery technician or the user may not be required to connect wiring between/amongst one or more components of the mattress system 1901. Instead, the wires may already be connected to the components and thus maintained in a centralized location (e.g., at the openings 1908A and 1908B). The wires can also be maintained at the openings 1908A and 1908B such that they do not protrude through a cover of the mattress system 1901 or otherwise interfere with comfortability of the user of the mattress system 1901 or an aesthetic appearance of the mattress system 1901 when it is in use in the user's home.

    [0194] FIGS. 25-33B illustrate an example mattress system 2500. In the example shown the mattress system 2500 includes an integrated fan assembly 2510. The cover (not shown) of the mattress system 2500 has been removed for clarity to show internal components of the mattress system 2500. In the example mattress system 2500, a top layer 2502 (e.g., a comfort layer) attaches to a rail structure 2506. In some examples, the top layer 2502 is attached to the rail structure 2506 using an adhesive (e.g., a hot melt adhesive or laminate). One or more support layers (e.g., the intermediate layer 2504) are positioned within the rail structure 2506. Attaching the top layer 2502 to the rail structure 2506 and positioning the one or more support layers can streamline the construction of the mattress system 2500 and reduces the thickness of the mattress system 2500 because only the single top layer 2502 is attached to a top portion of the rail structure 2506. Further this construction allows for the fan assembly 2510 to be positioned in the foot rail 2530 without interfering with the intermediate layer 2504. The mattress system 2500 can be constructed with a continuous lamination process of the top layer 2502 to the rail structure 2506 without needing to move the rail structure 2506 multiple times.

    [0195] The mattress system 2500 includes an integrated fan assembly 2510. In some implementations, the integrated fan assembly 2510 is integrated completely within the mattress system 2500. In some implementations, the integrated fan assembly 2510 is controlled by a thermal module controller (not shown). In other implementations, the integrated fan assembly 2510 is controlled by a general controller (not shown) of a bed system. For example, a controller that also controls the air chambers (e.g., a controller further configured to inflate or deflate the air chambers, receive sensor data from sensors in the mattress system, and other processes for operating/managing components of the mattress system.

    [0196] The example mattress system 2500 includes a fan assembly 2510. Other examples can include other types of air modules or fluid modules. In some implementations, the fan assembly 2510, or other air or fluid module, includes a module to heat air. In some implementations, the fan assembly 2510, or other air or fluid module, includes a module to cool (e.g., condition) air. In some of these implementations, the mattress system 2500 includes a sleeve made of a fire resistant material and being sized and shaped to at least partially cover the airflow insert 2522. Examples of such a sleeve are illustrated and described in reference to FIGS. 34A-36.

    [0197] FIG. 25 illustrates a fan assembly 2510 integrated into an example mattress system 2500. The mattress system 2500 can be part of a bed system and may include some or all of the components of the bed system 100 described in reference to FIG. 1. For example, components 2506, 2522, and 2510 can replace components 106, 110, and 122 in the mattress 101 in FIG. 1. The mattress system 2500 can be similarly configured as other examples of the mattress system described herein. Further, the fan assembly 2510 can be similarly configured as other examples of the fan assembly/air module described herein. The mattress system 2500 includes a top layer 2502 (sometimes referred to as a first layer and/or a comfort layer), rail structure 2506, the bottom layer 2508, an intermediate layer 2504 (sometimes referred to as a support layer) and air chambers 2622. The intermediate layer 2504 includes recessed portions 2550 configured to house an air flow insert 2522. In this example, the fan assembly 2510 can be disposed (e.g., positioned) at a foot end of the rail structure 2506. As described herein, the fan assembly 2510 can be received in a recessed portion of the foot end of the rail structure 2506. As a result, the fan assembly 2510 may not interfere (or reduce interference) with other components of the mattress system 2500, such as the bottom layer 2508, the air chambers 2622, and/or the top layer 2502. In the embodiment shown, the fan assembly 2510 is directly connected to an airflow insert 2522. The fan assembly 2510 can draw air out of the airflow insert 2522 and exhaust the drawn air into the foot end of the rail structure 2506.

    [0198] The fan assembly 2510 can be similar (e.g., in terms of structure and/or functionality) to the fan assembly 110 described throughout this disclosure. For example, the fan assembly 2510 can be configured to pull or draw air from the mattress system 2500. In other examples, the fan assembly 2510 can also be configured to push air into the mattress system 2500 (such as ambient air or cooled/conditioned air), which can be beneficial to cool a top surface of the mattress system 2500. In yet other examples, the fan assembly 2510 can be configured to push heated air into the mattress system 2500 to warm a top surface of the mattress system 2500. Therefore, the fan assembly 2510 can be arranged to draw air into the mattress system 2500 and circulate the air therein to help control a microclimate at the top surface of the mattress system 2500.

    [0199] As discussed above in some examples, the mattress system 2500 includes a top layer 2502 attached to the rail structure 2506 (e.g., including a first side rail 2534, second side rail 2536, head rail 2532, foot rail 2530). Each air module, such as the fan assembly 2510, is in fluid communication with a corresponding airflow insert 2522 to create airflow through the top layer 2502. The one or more support layers (e.g., the intermediate layer 2504) are positioned under the top layer 2502 and within the rail structure 2506. For example, the one or more support layers can be positioned between the first side rail 2534, the second side rail 2536, the head rail 2532, and/or the foot rail 2430. In some examples, top layer 2502, the intermediate layer 2504, the first side rail 2534, the second side rail 2536, the head rail 2532, and the foot rail 2530 comprise one or more foam materials.

    [0200] The one or more support layers (e.g., the intermediate layer 2504) can also include recessed portions 2550 where the airflow insert 2522 are each positioned within the corresponding recessed portion 2550. For example, as shown in FIG. 26B. In some implementations, the airflow insert pad 2522 (e.g., thermal insert, thermal insert pad, airflow insert, air distribution layer) are attached to the intermediate layer 2504 using one or more fasteners. Examples of fasteners include hook and loop fasteners (e.g., including corresponding hook and loop fasteners positioned at each corner on the top side of the airflow insert 2522 and the recessed portion 2550 on the bottom side of the intermediate layer 2504) and adhesive/laminate fasteners. In some example implementations, the intermediate layer 2504 and the airflow insert 2522 are at least partially laminated to attach the airflow insert 2522 to the intermediate layer 2504. In some examples, inflatable air chambers 2622 are positioned underneath the support layer and in between the first side rail 2534 and the second side rail 2536. In some implementations, the head rail 2532, the foot rail 2530, the first side rail 2534, and the second side rail 2536 of the rail structure 2506 with the top layer 2502 form part of an upside-down foam tub.

    [0201] In some implementations, the fan assembly 2510 includes one or more modules to heat and/or condition air. The fan assembly 2510 can be positioned with an air module recess (e.g., recessed portion 2606) in the foot rail 2530 and configured to draw air from the top layer 2502. In some examples, the fan assembly includes a housing that defines an air inlet and an air outlet and a fan assembly enclosed in the housing and configured to suction air through the air inlet and supply exhaust air through the air outlet. The airflow insert 2522 is configured to connect to the air inlet of the fan assembly 2510 via a connector. For example, the connector 3402, shown in FIG. 34A. The fan assembly 2510 can include wiring that is electrically connected to the fan assembly 2510 and extends from the housing, the wiring configured to electrically connect to a power source external to the mattress and supply electrical power to the fan assembly 2510.

    [0202] In some implementations, a sleeve made of a fire resistant material at least partially covers the airflow insert 2522. For example, as shown in FIGS. 34A-36. The sleeve is configured to resist transmission of fire through the sleeve. In some examples, the airflow insert 2522 includes material that is configured to block (or reduce/limits) the airflow from the fan assembly 2510 when melted and, when a burn occurs, the heat melts material included in the airflow insert 2522 and blocks (or reduces) the airflow from the fan assembly 2510.

    [0203] Some aspects include a process for assembling the mattress system 2500. The mattress system 2500 is assembled by first constructing a foam tub by applying an adhesive (e.g., a laminate) to connect the rails of the rail structure 2506 and the top layer 2502. In some examples, the bottom layer 2508 includes flaps that can be opened to access an interior space of the foam tub. In some of these examples, the base pad flaps are adhered to the side rails of the foam tub. Next, the intermediate layer 2504 is attached underneath the top layer 2502 and within the rail structure 2506. In some examples, the intermediate layer 2504 (which can include one or more support layers) is attached using connectors (e.g., hook and loop connectors, adhesives, laminates, etc.) The intermediate layer 2504 includes a recessed portions 2550, where the airflow inserts 2522 are placed. In some examples, the airflow insert 2522 are connected using hook and loop connectors that are placed in the corners of the recessed portion 2550 and on a top side of the airflow insert 2522. Prior to attaching the airflow insert 2522 to the recessed portion 2550 of the intermediate layer 2504, the air flow insert 2522 is connected to an air module (e.g., the fan assembly 2510). The airflow insert 2522 and fan assembly 2510 are placed together in the mattress with the fan assembly 2510 being placed within a recess in the foot rail. In some examples, the airflow insert 2522 is installed with a sleeve made of a fire resistant material. Next, the air chambers 2622 are positioned within the foam tub. After the air chambers 2622 are positioned the foam tub is closed by closing the flaps of the bottom layer 2508. In some examples, a wire harness connected to the air module is routed alongside a side rail before the bottom layer 2508 is closed. In some examples, a cover is placed over the foam tub. The cover may be made of a fire resistant material. In some examples, prior to placing the cover over the foam tub one or more sensors are positioned in the mattress including a temperature sensor strip, which can be placed on the top surface of the top layer 2502. In some examples, the cover is installed with a zipper to enclose the foam tub and the wires are routed together with a tie or hook and loop connector (e.g., Velcro loop) to hold the wires together.

    [0204] FIG. 26A is a bottom perspective view of the mattress system 2500 of FIG. 25, illustrating the mattress system 2500 upside down. The mattress system 2500 can also include some similar or same components as the mattress system 200 depicted and described in FIG. 2. The mattress system 2500 can include the top layer 2502 (e.g., a first layer, a comfort layer), the intermediate layer 2504 (e.g., a second layer, support layer), and the bottom layer (e.g., a third layer), which is not shown in FIG. 26A. The intermediate layer 2504 can include a recessed portion configured to receive the airflow insert 2522. The airflow insert 2522 can each extend some length from a foot end 2507 of the rail structure 2506 towards a head end 2509 of the rail structure 2506. The airflow insert 2522 can be adjacent from the foot end 2507 of the rail structure 2506 as well as inset from the respective right and left sides of the rail structure 2506.

    [0205] A bottom layer (e.g., the bottom layer 2508 as shown in FIG. 25) can cover an entire bottom of the mattress system 2500, from one rail edge to another rail edge (e.g., from a head end edge to a foot end edge of the rail structure 2506 and from a right side edge to a left side edge of the rail structure 2506). In some implementations, the bottom layer can also cover the rail structure. In other implementations, the bottom layer is inserted into a space defined (surrounded) by the rail structure.

    [0206] The mattress system 2500 can also include the rail structure 2506, as shown in FIG. 25. The rail structure 2506 is arranged around a periphery of the mattress system 2500 and is configured to at least partially surround an air chamber assembly or mattress core, and the intermediate layer 2504 containing the airflow insert 2522. For example, the air chamber assembly can include one or more inflatable air chambers (e.g., refer to FIG. 27). The foot end 2507 of the rail structure 2506 can have a wider width than the head end 2509 opposite the foot end and left and right sides of the rail structure 2506. For example, the foot rail 2530 can be 1.875 inches thicker than the head rail 2532. In some implementations, the combined width of the foot end 2507 and head end 2509 of the rail structure 2506 is the same as the combined width of the foot rail 230 and the head rail 232 of the mattress 200 (FIG. 4). The foot end 2507 can be wider in order to accommodate placement of the fan assemblies 2510. The fan assemblies 2510 can be disposed inside the foot end 2507 of the rail structure 2506 and configured to draw air from the airflow insert 2522 and out along the inside of the rail structure 2506 (e.g., along the foot end 2507 of the rail structure 2506). For example, the foot end 2507 defines a recessed portion 2606 configured to receive the fan assembly 2510. The recessed portion 2606 is configured to entirely (or in some cases, substantially) receive an external housing of the fan assembly 2510. The recessed portion 2606 (e.g., a cavity) is open toward the interior of the mattress so that an air duct of the fan assembly 2510 extends therethrough. An air inlet at the end of the air duct is exposed out of the cavity in the foot end 2507 and configured to couple to the air flow insert 2522. Directly connecting the fan assembly 2510 to the air flow inserts 2522 allows the fan assemblies 2510 to be placed closer to the air flow inserts 2522 to more quickly modulate the temperature at the top surface of the mattress. As shown, the fan assemblies 2510 are positioned at the foot end 2507 of the rail structure 2506. The fan assemblies 2510 are positioned farther away from a head of a user of the mattress system 2500 so that the fan assemblies 2510 are quieter when operating. As a result, sounds from the fan assemblies 2510 may not disturb the user's sleep.

    [0207] As depicted, the mattress system 2500 can have two fan assemblies 2510 disposed in the foot end 2507 of the rail structure 2506, and configured and operable to control microclimates of two separate zones (left and right sides) at the top of the mattress system 2500. In yet other implementations, the mattress system 2500 can have fewer or more fan assemblies.

    [0208] Unlike the mattress system 200 depicted and described in FIG. 4, the mattress system 2500 depicted and described in FIG. 26 does not include (or may not include) reinforcement straps (e.g., the reinforcement straps 250A-B in FIG. 4). Instead, a foot rail 2530 of the rail structure 2506 is thicker than a head rail 2532 and the opposite side rails 2534 and 2536. The thicker foot rail 2530 can provide additional support for the rail structure 2506 to hold a shape of the mattress system 2500. The thicker foot rail 2530 can also provide additional support for maintaining the fan assemblies 2510 in place so that the rail structure 2506 has little or no bend and/or the fan assemblies 2510 do not protrude (or protrudes little) from a general shape of the mattress system 2500. By thickening the foot rail 2530, the head rail 2532 and the opposite side rails 2534 and 2536 can be adjusted in width such that an existing air chamber assembly can be used. For example, the head rail 2532 may be thinned/thinner in width than the foot rail 2530 and the opposite side rails 2534 and 2536. Therefore, an air chamber assembly designed for a mattress having a less thick foot rail may not have to be modified in size and/or shape in order to fit within a space defined by and between the foot rail 2530, the head rail 2532, and the opposite side rails 2534 and 2536 of the rail structure 2506. For example, the air chamber assembly 220 described in FIG. 3 can be used with both the mattress system 200 and the mattress system 2500, even though the rail structure 206 of the mattress system 200 has rails of equal width and the rail structure 2506 of the mattress system 2500 has rails of different widths. In one example, the width of the foot rail can range between 4 inches and 7 inches, and the head rail can range between 1 inches and 4 inches, so that the total width of the foot and head rails can be around 8 inches. In this example, each of the side rails can be maintained at 4 inches of width. Other dimensions can also be used. For example, an alternative embodiment that omits side rails is shown and described below with respect to FIG. 37.

    [0209] In some implementations, the foot rail 2530 can have a largest width, the head rail 2532 can have a smallest width, and the opposite side rails 2524 and 2536 can have a same width that is less than the width of the foot rail 2530 and greater than the width of the head rail 2532. As mentioned above, the rail structure 2506 can be sized in such a way that still allows an existing air chamber assembly to be positioned in the mattress system 2500 without having to be replaced by a differently sized air chamber assembly. In some implementations, the opposite side rails 2534 and 2536 can be increased in width to provide additional support and maintain the rail structure 2506 in the shape of the mattress system 2500.

    [0210] FIG. 26B is a bottom perspective partially exploded view of the intermediate layer 2504 and the air flow insert 2522 of the mattress system 2500 of FIG. 25, illustrating the intermediate layer 2504 and the air flow insert 2522 upside down. The recessed portions 2550 of the intermediate layer 2504 can be sized and shaped to securely fit the air flow insert 2522. The air flow inserts 2522 can be installed with a fire resistant sleeve covering the air flow inserts 2522. The air flow inserts 2522 can be attached to the recessed portion 2550 using hook and loop connectors, adhesives, laminates, or other connectors.

    [0211] FIG. 27 is a partial exploded view of the mattress system 2500 of FIGS. 25 and 26. FIG. 27 illustrates the top layer 2502, the intermediate layer 2504, the example air chambers 2622, and the integrated fan assemblies 2510. The air chambers 2622 and the intermediate layer 2504 can be arranged to be surrounded by the rail structure 2506.

    [0212] The rail structure 2506 is attached to the top layer 2502 using an adhesive where the intermediate layer 2504 is located within the rail structure 2506. Attaching the top layer 2502 directly to the rail structure 2506 can allow for a single lamination process to attach the top layer 2502 to the rail structure 2506.

    [0213] The mattress system 2500 can also include the airflow insert pad 2522 (e.g., thermal insert, thermal insert pad, airflow insert, air distribution layer), which can be positioned under the top layer 2502, above the air chambers 2622, and within the rail structure 2506. In some implementations, the intermediate layer 2504 can define a cutout section or recessed portion to receive the airflow inserts 2522 therein. The airflow inserts 2522 can be similar to the airflow insert pad 122 described throughout this disclosure. In the illustrated example, the airflow insert 2522 is disposed between the head and foot of the mattress system 2500, partially along a length of the mattress system 2500 from the head to the foot. The airflow insert 2522 is disposed closer to the foot of the mattress system 2500 than the head of the mattress system 2500 to optimize positioning without needing to rely on a foundation hole pass-through. For example, as described herein, the fan assembly can be embedded in the foam. In the example shown, the airflow inserts 2522 are configured to be positioned adjacent to the foot rail 2530 of the mattress system 2500 to connect with the fan assemblies 2510. The fan assembly 2510 can operate to draw air from the top of the mattress, and the fan assembly 2510 is designed to have enough power to expel the air out of the rail structure 2506 of the mattress. This design can allow the mattress assembly to not rely on a single purpose-built foundation and instead to be used with any type of foundation. In one example, a portion of the rail structure 2506 can be thickened in order to accept the fan assembly 2510 and maintain structural integrity of the foam mattress assembly. In some implementations, the fan assembly 2510 is placed in the foot of the bed (e.g., in the foot rail 2530 of the mattress), and the air chamber 2622 is shifted up towards the head of the bed, reducing the thickness of the head rail 2532. By placing the fan assembly 2510 in the foot rail 2530 as opposed to the head rail 2532 can provide additional benefits. For example, the sound of the fan is further away from the head of a sleeper, which can reduce perceived sound levels. The chamber is shifted to the more comfort sensitive areas of the body (core, head) rather than the feet. In addition, where the fan assembly is a cooling-only module that utilizes ambient air for cooling, the fan assembly can have a relatively small form factor so as to fit within the bounds of the mattress.

    [0214] The airflow insert 2522 can be attached to a recessed portion 2550 of the intermediate layer 2504 using one or more attachment mechanisms. For example, each corner of the airflow insert 2522 can include a hook or loop configured to mate with a respective hook or loop on the recessed portion 2550 of the intermediate layer 2504. Such hook and loop fasteners can provide for easy and secure attachment of the airflow insert 2522 in the recessed portion 2550 of the intermediate layer. One or more other attachment mechanisms can be used, including but not limited to adhesives and laminates.

    [0215] As discussed above, the airflow insert 2522 can be interference fit to the cutout section or recess (e.g., the recessed portion 2550) in the intermediate layer 2504, or received within the cutout section or recess in the intermediate layer 2504 without attachment mechanisms. In some implementations, the airflow insert 2522 can be positioned to be flush with the intermediate layer 2504.

    [0216] The fan assemblies 2510 can be connected to or mounted to the airflow insert 2522. The fan assemblies 2510 can also be disposed at least partially in the rail structure 2506 at the foot end. In some alternative implementations, the intermediate layer 2504 defines a cutout section or recess configured to receive an air duct hoses. In these implementations, the air duct hoses can be received in the cutout section or recess to be flush with the intermediate layer 2504.

    [0217] FIG. 28A illustrates a view of the fan assembly 2510 of FIG. 25. In some examples, the fan assembly 2510 is similar to the integrated fan assembly 1110 illustrated in FIG. 10. The example shown in FIG. 28A shows an air inlet 2082. FIG. 28B illustrates a view of the airflow insert 2522. The view shown includes a connector 2804 configured to receive the air inlet 2802 of the fan assembly 2510 to connect the airflow insert 2522 and the fan assembly 2510, as shown in FIGS. 28C and 28D.

    [0218] The airflow insert 2522 can include material 2810 contained within the airflow insert 2522. In some examples, the material 2810 is linear polyolefin (POE) material. The material 2810 can include properties which cause it to melt during thermal event (e.g. a fire, burn, smolder, or similar event), thereby, blocking (or reducing) airflow from the fan assembly 2510 to stop the access of moving air to the region impacted by the thermal event.

    [0219] FIG. 29 illustrates a cross sectional view of airflow through the mattress system 2500 of FIG. 25, taken along a cross sectional line shown in FIG. 31. FIG. 29 illustrates an example airflow 2700 (e.g., exhaust air) through the mattress system 2500. The mattress system 2500 can be similar to the mattress system 200 depicted and described in reference to FIG. 6. The view of FIG. 29 depicts the head rail 2532 and the foot rail 2530 of the rail structure 2506. The fan assemblies 2510 are positioned within the foot rail 2530 of the rail structure 2506.

    [0220] As shown in FIG. 29, the airflow 2700 is directed from the top surface of the mattress system 2500, through the airflow insert 2522, and into the fan assembly 2510 via the air inlet 2910. The airflow 2700 can then be routed into the housing 2900 of the fan assembly 2510. In some implementations, the airflow 2700 can also flow through one or more layers of the mattress system 2500 to provide for air circulation at the top layer 2502. By circulating the airflow 2700, the fan assembly 2510 can cause the airflow 2700 at the top surface of the mattress cover to a lower or higher temperature of the mattress system 2500.

    [0221] FIG. 30 illustrates a side cross sectional view of the mattress system 2500, taken along a cross sectional line shown in FIG. 31 and with the foot rail 2530 removed for clarity. FIG. 30 depicts the airflow 2700 that is drawn into the fan assembly 2510 and further depicts exhaust air 2701 exiting from the fan assembly 2510. The mattress system 2500 includes the rail structure 2506 having the first and second side rails 2534 and 2536. The fan assemblies 2510 are disposed in the foot rail 2530 of the rail structure 2506 (not shown). In the illustrated example, the fan assemblies 2510 are oriented towards the first side rail 2534 of the rail structure 2506. As a result, the airflow 2701 is discharged from the fan assemblies 2510 towards the same side portion of the mattress system 2500 to thereby lower a temperature of a top surface of the mattress system 2500. Alternatively, the fan assemblies 2510 can be oriented towards the side rail 2536 of the rail structure 2506.

    [0222] As shown in FIG. 30, the fan assemblies 2510 can exhaust the airflow 2701 in the same direction. In some implementations, the fan assemblies 2510 can exhaust the airflow 2701 in different directions (e.g., the fan assembly 2510 closest to the side rail 2534 can exhaust the airflow 2701 towards the side rail 3534 and the fan assembly 2510 closest to the side rail 2536 can exhaust the airflow 2701 towards the opposite side rail 2536). Regardless of an orientation/direction of the fan assemblies 2510, the airflow 2701 can be directed into and/or around the rail structure 2506 to effectively adjust a microclimate of a top surface of the mattress system 2500 as described throughout this disclosure.

    [0223] FIG. 31 is a bottom view of an example mattress system 2500 having the integrated fan assembly 2510 of FIG. 25. As depicted, the mattress system 2500 is flipped upside down so that a top surface of the mattress system 2500 is facing down. The depicted mattress system 2500 has a rail structure 2506 and the bottom layer 2508. In some implementations, as described in reference to FIGS. 33A-B, the mattress system 2500 can have a bottom layer 2508.

    [0224] FIG. 32 is another bottom view of the example mattress system 2500 of FIG. 25 having the integrated fan assembly 2510. In FIG. 32, the bottom layer 2508 is removed to show detail of the rail structure 2506. The rail structure 2506 includes foot rail 2530 that has recessed portions 2606. The recessed portions 2606 are configured to receive the fan assemblies 2510. A foot rail 2530 can include recessed portions 2606 configured to at least partially receive each of the fan assemblies 2510. The recessed portions 2606 can be any appropriate size to fit a size of the fan assemblies 2510. Therefore, the fan assemblies 2510 can be disposed inside the rail structure 2506 so that the fan assemblies 2510 do not interfere with one or more other components of the mattress system 2500. This configuration can also be beneficial to prevent interference of the fan assemblies 2510 placement with one or more other components of the mattress system 2500 that are disposed at or around a middle axis of the mattress system 2500 (e.g., refer to the middle axis 310 described in reference to FIGS. 8-10).

    [0225] The recessed portions 2606 can have a predetermined width W1 that is suitable for receiving at least part of the fan assemblies 2510. The predetermined width W1 can be big enough to maintain sufficient airflow and room for installation of the fan assembly 2510 while also being minimal in size to minimize discomfort that may occur from an opening that is too wide. The width W1 can depend on the length of the fan assembly 2510. For example, the width W1 can be greater (e.g., by 1 inch or more) than the length of the fan assembly 2510. In some implementations, where the length of the fan assembly 2510 is 8.5 inches, the width W1 can be 9.5 inches or larger.

    [0226] In some implementations, the recessed portions 2606 can be arranged in one or more different configurations to facilitate or direct airflow (e.g., exhaust air) from the fan assemblies 2510. As shown in FIG. 32, the recessed portions 2606 can be arranged such that the fan assemblies 2510 can direct air towards a same side rail of the rail structure 2506. As another example, the recessed portions 2606 can be arranged in an opposite direction such that both fan assemblies 2510 direct air towards the opposite side rail of the rail structure 2506. In some implementations, each of the recessed portions 2606 can be arranged in opposite configurations such that the fan assembly 2510 on a right side of the mattress system 2500 can direct air towards a right side rail of the rail structure 2506 and the fan assembly 2510 on a left side of the mattress system 2500 can direct air towards a left side rail of the rail structure 2506. In some implementations, each of the recessed portions 2606 can be arranged towards each other such that both fan assemblies 2510 direct air inwards towards a midpoint of the foot rail 2530 of the rail structure 2506. In some implementations, at least one of the recessed portions 2606 can be arranged inwards, towards the midpoint of the foot rail 2530 of the rail structure 2506. Moreover, in some implementations, an air duct of the fan assemblies 2510 can extend out from the foot rail 2530 of the rail structure 2506.

    [0227] FIGS. 33A-B illustrate a bottom view of a bottom layer 2508 of an example mattress system 2500 having the integrated fan assembly 2510 of FIG. 25. Referring to both FIGS. 33A-B, the bottom layer 2508 (e.g., base pad) can cover an entire bottom of the mattress system 2500, including a top layer (e.g., a first layer and/or comfort layer, such as the top layer 2502), a rail structure 2506, an intermediate layer (e.g., a second layer and/or support layer, such as the intermediate layer) 2504 positioned within the rail structure 2506. The bottom layer 2508 can be made of a material that has some permeability to provide a sufficient airflow rate for adjusting a microclimate at a top surface of the mattress system 2500. The fan assemblies 2510 can also route airflow throughout the mattress system 2500 sufficiently to overcome features of the bottom layer 2508 that may otherwise impede ability to adjust the microclimate and achieve a desired cooling at the top surface of the mattress system 2500. The foot of the bed is configured to be permeable enough to discharge the air through the foot rail 2530 without a need for any permeability of the base. Therefore, for example, the bottom layer 2508 can be made of various types of material (e.g., not breathable, having minimum breathability, etc.) In some implementations, the bottom layer 2508 is made to have little breathability so that the air exits the vertical surface at the foot of the bed. Moreover, the fan assemblies described herein can sufficiently route airflow through/around the rail structure 2506 and the bottom layer 2508 without requiring exhaust openings (e.g., the recessed portions 2606) to extend out from the rail structure 2506 and into a surrounding environment.

    [0228] Still referring to both FIGS. 33A-B, the bottom layer 2508 can be formed with multiple pieces. For example, the bottom layer 2508 can be split longitudinally down a midpoint of the bottom layer 2508, thereby having first and second flaps 2508A and 2508B, respectively. Each of the flaps 2508A and 2508B can be individually opened/folded back from a midpoint of the mattress system 2500 to access components of the mattress system 2500 described throughout this disclosure. This construction can be beneficial to allow for opening the mattress system 2500 for assembly, maintenance, and/or fixing/replacing one or more components of the mattress system 2500. Each of the flaps 2508A and 2508B can also be attached (e.g., laminated, adhered) to respective side rails of the rail structure 2506. In some implementations, the flaps are attached to the rails using foam lamination. For example, for laminating to the head and foot rails, glue (e.g., 3-4 inches) would be present following the glue path created by the side rails. This makes the head/foot rails have a partial lamination with the base pads. The flaps 2508A and 2508B of the bottom layer 2508 may not be laminated or otherwise attached to head and foot rails of the rail structure 2506 to ensure that the flaps 2508A and 2508B can be individually opened or closed.

    [0229] In some implementations, the bottom layer 2508 can also include openings 3308A and 3308B (e.g., cutouts, chamber ports, etc.) on respective flaps 2508A and 2508B. The openings 3308A and 3308B can be positioned towards a midpoint of the mattress system 2500 (e.g., a hip of the bed). The openings 3308A and 3308B can be offset some predetermined distance from the midpoint of the mattress system 2500, in some implementations. Moreover, the openings 3308A and 3308B can be positioned at locations where air duct hoses may attach to air chambers of the mattress system 2500 such that all or some wiring/cables can be maintained together in a centralized location and routed therefrom to a power source and/or a controller for the mattress system 2500 and/or the bed system. The openings 3308A and 3308B can therefore be configured to receive wires/cables that are routed to and from components (e.g., the fan assemblies, air chambers, etc.) in the mattress system 2500. For example, wiring/cables connected to an external housing of a fan assembly 2510 can be routed (e.g., in a wire harness or without a hardness) from the foot rail 2530 of the rail structure 2506 to the midpoint of the mattress system 2500 (e.g., the hip of the bed) along the foot rail 2530 and at least one of the side rails of the rail structure 2506.

    [0230] The wiring can be routed, as an illustrative example, along the foot rail 2530 to a location where the flap 2508B folds back from the respective side rail of the rail structure 2506. The wiring can be secured along one or more portions of the rail structure 2506 using one or more wire management loops (not shown). The loops can keep the wiring from shifting out of its intended location inside the mattress system 2500 when the mattress system 2500 is transported (e.g., to a user's home), when a user sits on edges of the mattress system 2500, and/or when the mattress system 2500 is lifted off a base/foundation of a bed system. The loops can be secured to the respective side rails of the rail structure 2506 (and/or portions of the foot rail 2530 of the rail structure 2506) using adhesive (e.g., foam glue between the bottom layer 2508 and the respective side rail of the rail structure 2506) and/or hook and loop fasteners (e.g., micro-hooks adhered to the respective side rail and fabric attached to the micro-hooks). One or more other attachment mechanisms may also be used to attach the wire management loops to the mattress system 2500.

    [0231] One or more wire management loops can be attached to each side of the mattress system 2500. For example, a loop can be configured at a corner where the foot rail 2530 means a right side rail (and where the foot rail meets a left side rail) of the rail structure 2506. This location can be beneficial to ensure the wiring does not shift or move towards a center of the mattress system 2500 and thus interfere with other components therein. Moreover, this location can be beneficial to ensure stress experienced on the fan assembly 2511 from using and/or moving the mattress system 2500 may be relieved. One or more additional wire management loops can be placed along a length of the side rail up to the respective opening 3308A or 3308B. In some implementations, wire management loops may not be used. Instead, the wiring can be attached directly to the mattress system 2500 with adhesives, hook and loop fasteners, and/or one or more other types of attachment mechanisms.

    [0232] The wiring can then be tucked between the respective side rail of the rail structure 2506 and the flap 2508B of the bottom layer 2508 up to the respective opening 3308B. The wiring can then be routed through the respective opening 3308B. As a result, the wiring may be consolidated and maintained in one location, thereby providing an aesthetically pleasing look and also ease to a user of the mattress system 2500 and/or a technician when setting up and maintaining the mattress system 2500. In other words, when the mattress system 2500 is manufactured and before it is delivered to a user, wires from the fan assemblies can be routed along the side the rails of the rail structure 2506 and out through the respective openings 3308A and 3308B. Maintaining the wires in one location can be beneficial to ensure ease of setting up the mattress system 2500 in a home of the user. A delivery technician or the user may not be required to connect wiring between/amongst one or more components of the mattress system 2500. Instead, the wires may already be connected to the components and thus maintained in a centralized location (e.g., at the openings 3308A and 3308B). The wires can also be maintained at the openings 3308A and 3308B such that they do not protrude through a cover of the mattress system 2500 or otherwise interfere with comfortability of the user of the mattress system 2500 or an aesthetic appearance of the mattress system 2500 when it is in use in the user's home.

    [0233] The features of the integrated fan assemblies and sleeves described herein can be applied to various types of mattress systems. In some implementations, the fan assemblies described herein can be integrated into a mattress that does not have air chambers. For example, the fan assemblies can be integrated into a mattress including spring assemblies, foam materials, or any suitable supporting materials, instead of inflatable air chambers. The fan assemblies can be installed inside such a mattress the same or similar ways described herein (e.g., by inserting the fan assemblies at least partially in cutout sections of the rail structure). In other implementations, the fan assemblies can be mounted to any suitable locations within a mattress other than the rail structure of the mattress. In some cases, a mattress system may not include a rail structure. Instead, the mattress system can include a material, such as springs, foam, or another supporting material that makes up a majority composition of the mattress. In such mattress systems, a fan assembly, such as the fan assembly 110, the fan assembly 1110, and or the fan assembly 2510 can be integrated into or otherwise housed in a recessed portion of the material of the mattress system. For example, a mattress system can be composed of foam materials. A recessed portion, such as an opening, can be cut into a foot end of the foam materials of the mattress system, near an edge of the foot end. The fan assembly can then be placed thereto to provide similar or same functionality to the mattress system as the fan assemblies described herein. As another example, a mattress system can be composed of springs. A recessed portion can be formed near a foot end of the mattress system in which a fan assembly can be placed to provide similar or same functionality to the mattress system as the fan assemblies described throughout this disclosure. One or more other configurations and/or placements of the fan assembly can be used to incorporate the fan assembly into mattress systems that do not include rail structures and/or air chambers.

    [0234] FIGS. 34A-36 illustrate an example air distribution layer 3400 with a fire resistant sleeve 3410. In some examples, the sleeve 3410 improves the flammability test performance of a mattress system (e.g., the mattress systems 200, 1500, 1600, and 2500 described herein) in which it is installed in over an air distribution layer (e.g., an air flow insert pad). In some examples, incorporating the sleeve 3410 allows the mattress system to pass flammability test performance requirements without having to implement a fan shut down action.

    [0235] In some cases, a burn or other thermal event (e.g. a fire, burn, smolder, or similar event) can occur on or in a mattress system. In some examples, during the burn, the heat from a flame travels down through the foam and then melts linear polyolefin (POE) material within the air distribution layer 3400, which causes the air flow to/from the air module (e.g., fan) to close off and thus stops (or otherwise reduces or limits) the access of moving air to the flame.

    [0236] In some implementations, the sleeve 3410 is configured to resist transmission of heat through the sleeve 3410 to protect surrounding areas of the mattress. In some examples, the air distribution layer 3400 includes material (e.g. POE material or an intumescent material) that is configured to block the airflow from the at least one air module when melted or expanded and the sleeve 3410 is configured to allow enough heat to transfer from a burn through the air distribution layer to heat the material included in the air distribution layer and block the airflow from the at least one air module (e.g., by melting or expanding the material). For example, the sleeve 3410 can be designed to allow enough heat to transfer from a burn event through the sleeve 3410 to melt the POE material in the air distribution layer 3400 but not allow excessive heat/fire through the sleeve 3410 which would cause damage other portions of the mattress, such as the air chambers. In some examples, the sleeve 3410 can be designed to provide the optimal amount of a barrier to protect the other components/areas of the bed (such as the air chambers). In some examples, a tightly controlled insert wrap material is used to provide the optimal amount of barrier to allow the POE material to melt and protect the surrounding areas of the mattress. As may be appreciated, POE or intumescent material may be located in any suitable location that may stop or reduce air flow. For example, in some embodiments, intumescent material may be located in or around the fan assembly, in one or more location in one or more air ducts, or one or more locations in the air module(s).

    [0237] In some examples, the sleeve 3410 allows for air distribution layer 3400 protection with increased flexibility on the air distribution layer material specifications. For example, by allowing for the use of other materials because the POE material is no longer required to be the driving protection of flame/heat. In some examples, the air flow from the air module is low enough that no fan shutdown mechanism is necessary to prevent the spread of the burn/fire.

    [0238] In some examples, the mattress includes temperature sensors which are configured to send a signal to shut off the air module when a detected temperature exceeds a threshold. In some examples, the temperatures sense a spike in temperature which is indicative of a fire/burn event and sends a signal to shut off the air module (e.g., by shutting off the fan) in response to detecting the spike in temperature. In some examples, the signal is sent to a controller for the mattress and/or air module.

    [0239] In some examples, an expanding material which expands when heated to a certain temperature (e.g., an intumescent material) is used to block (or reduce) the airflow from the fan assembly. In these examples, the expanding material may be contained within air distribution layer 3400. In some embodiments, the expanding material can be placed at other locations. For example, the expanding material can be positioned in the fan assembly. For example, in reference to FIG. 5, the expanding material can be positioned within the housing 700 such as within the air duct 708. Similarly, in reference to FIG. 19, the expanding material can be contained in the fan assembly 1110, such as within the air duct 1708. In these examples, the expanding material may expand when heated to a certain temperature (e.g., when a burn event occurs at the mattress), thereby blocking (or reducing) airflow from the air inlet through the fan assembly. In reference to FIGS. 28A, 28C, and 28D, the expanding material can be placed, such that when it is expanded, to prevent (or reduce) air through the air inlet 2802. Alternatively, the expanding material may be positioned to block (or reduce) the air flow at the air outlet of the fan assembly. In some embodiments, the expanding material can be placed within the air chamber hose (e.g., the air chamber hose 226 or air chamber hose 111 illustrated in FIGS. 2, 3, 4, 6, 7), such that the expanding material expands when heated to a certain temperature, thereby blocking (or reducing) the airflow to the fan assembly. In some embodiments, the expanding material can be positioned within any combination of the air distribution layer, the air duct of the fan assembly, other locations in the fan assembly, and/or the air chamber/duct hose. In some embodiments, the POE material is used in the air distribution layer and the expanding material is used in any combination of the air duct of the fan assembly, other locations in the fan assembly, and/or the air chamber/duct hose.

    [0240] In still other examples, the POE material can be placed at other locations. For example, the POE material can be positioned in the fan assembly. For example, in reference to FIG. 5, the POE material can be positioned within the housing 700 such as within the air duct 708. Similarly, in reference to FIG. 19, the POE material can be contained in the fan assembly 1110, such as within the air duct 1708. In these examples, the material may contract (e.g., by melting) when heated to a certain temperature (e.g., when a burn event occurs at the mattress), thereby blocking airflow from the air inlet through the fan assembly. In reference to FIGS. 28A, 28C, and 28D, the POE material can be placed, such that when it is contracted, to prevent (or reduce) air through the air inlet 2802. Alternatively, the POE material may be positioned to block (or reduce) the air flow at the air outlet of the fan assembly. In some embodiments, the POE material can be placed within the air chamber hose (e.g., the air chamber hose 226 or air chamber hose 111 illustrated in FIGS. 2, 3, 4, 6, 7), such that the POE material contracts when heated to a certain temperature, thereby blocking (or reducing) the airflow to the fan assembly. In some embodiments, the POE material can be positioned within any combination of the air distribution layer, the air duct of the fan assembly, other locations in the fan assembly, and/or the air chamber/duct hose.

    [0241] In some examples, the sleeve 3410 is installed by pulling the sleeve 3410 around the air distribution layer 3400 (e.g., as shown in FIGS. 35A and 35B). In other examples, the sleeve 3410 can be laminated or stitched to the air distribution layer 3400.

    [0242] In some examples, a first sleeve and a second sleeve are configured to be attached within the recessed portions 2550 of the intermediate layer 2504 for each of the air flow inserts 2522, as shown in FIG. 25. For example, the sleeve may include a hook and loop connector in each corner that each are configured to attach to a corresponding hook and loop connector in the corners of the recessed portions 2550 of the intermediate layer 2504.

    [0243] FIG. 34A illustrates an example air distribution layer 3400. In the example shown, the air distribution layer 3400 includes an air permeable portion 3404, an air impermeable portion 3406, and a connector 3402.

    [0244] The air distribution layer 3400 is configured to allow air flow from a top surface of a mattress and/or direct air flow to the top surface of the mattress (e.g. when connected to an air module that draws or supplies air such as the fan assembly 110, the fan assembly 1110, and or the fan assembly 2510). Examples of the air distribution layer 3400 include the air flow insert pad 1122 shown in FIG. 15 and the air flow insert 2522 shown in FIG. 25. In some examples, the air distribution layer 3400 includes an airflow insert pad. In some examples, the air distribution layer 3400 includes linear polyolefin (POE) material contained within a cover that contains the air permeable portion 3404 and the air impermeable portion 3406. The POE may be highly breathable to allow airflow between the air permeable portion 3404 and the connector 3402. In some alterative implementations, the air distribution layer is sealed with an air impermeable material with holes punched through the air impermeable material at positions to direct the air flow.

    [0245] The air permeable portion 3404 of the air distribution layer 3400 may be made of a mesh material. The air permeable portion 3404 is on a top surface of the air distribution layer to direct air to or from the top surface. For example, as shown in FIG. 25 through the intermediate layer 2505 and the top layer 2502 in the mattress system 2500 (e.g., bed system), or as shown in FIG. 15 the top layer 102 and the intermediate layer of the mattress system 1500. The air impermeable portion 3406 of the air distribution layer 3400 surrounds the air permeable portion 3404 to create a cover for the air distribution layer, where the cover encloses POE material.

    [0246] The connector 3402 is configured to connect the air distribution layer 3400 to an air module (e.g., the fan assembly 2510 shown in FIG. 25 or the fan assembly 1110 shown in FIG. 15). The connector 3402 is used to put the air distribution layer 3400 in fluid communication with the air module. In some examples, the connector 3402 is configured to connect to a hose or includes a hose which is connected to the air module. In some examples, the connector is sewn to the air impermeable portion of the cover of the air distribution layer 3400.

    [0247] FIG. 34B illustrates an example sleeve 3410 made of a fire resistant material covering the example air distribution layer 3400 of FIG. 34A. In the example shown, the sleeve 3410 encloses the air distribution layer 3400 except for the connector 3402 to allow the air distribution layer 3400 to connect to an air module (e.g., the fan assembly 2510 shown in FIG. 25).

    [0248] In some implementations, The sleeve 3410 is configured to resist transmission of fire through the sleeve 3410 without stopping the airflow from the at least one air module. For example, the sleeve 3410 can be formed of a material and have a configuration (e.g. size and shape of holes) that resists transmission of fire through the sleeve 3410.

    [0249] In some implementations, the air distribution layer 3400 includes material that is configured to block (or reduce) the airflow from the at least one air module when melted. For example, when a burn occurs the sleeve 3410 is configured to direct heat from the burn towards the air distribution layer 3400, thereby melting the material included in the air distribution layer 3400 and blocking (or reducing) the airflow from the air module.

    [0250] The sleeve 3410 includes fabric sized and shaped to at least partially surround the air distribution layer 3400. The sleeve 3410 is made of a fire resistant material, such as flame resistant rayon. In some examples, the material that makes up the sleeve further includes polyester and fiberglass.

    [0251] In some examples, a top portion of the sleeve 3410 is made of a mesh fabric that is air permeable. In some examples, the sleeve 3410 is entirely made of fire resistant material. In some examples, the sleeve 3410 is constructed using ribbed knit construction of the fire resistant material. In some examples, the fire resistant material can be configured to resist burning at eight hundred degrees Fahrenheit. However, the material can be configured to resist burning at higher or lower temperatures in different examples and to meet a variety of different safety standards.

    [0252] In some examples, the air module includes components and or a module to direct heated air through the air distribution layer 3400 to heat a top surface of the mattress. The air module can also include components and or a module to direct condition (e.g., cooled) air through the air distribution layer to cool a top surface of the mattress.

    [0253] FIGS. 35A and 35B illustrates an example process for constructing the air distribution layer 3400 with the sleeve 3410 made of a fire resistant material. In the example shown, the sleeve 3410 is installed by sliding the sleeve 3410 over the air distribution layer 3400. In other implementations, the sleeve 3410 is laminated to the air distribution layer 3400.

    [0254] In some implementations, the sleeve 3410 is stitched to the air distribution layer 3400. In some of these examples, the sleeve 3410 includes a top portion and a bottom portion, where the top portion is stitched to a top side of the air distribution layer and the bottom portion is stitched to a bottom side of the air distribution layer.

    [0255] FIG. 36 illustrates another perspective of the example sleeve 3410 made of a fire resistant material covering the example air distribution layer 3400 of FIG. 34A. FIG. 36 illustrates the fire sleeve 3410 is configured to entirely cover the air distribution layer 3400 except the connector 3402, to allow the connector 3402 to connect with the air module.

    [0256] FIG. 37 illustrates an example, bed system 3700 with an integrated fan assembly 3710. The bed system 3700 includes a top layer 3702, an intermediate layer 3704, a mattress core layer 3706, and a bottom layer 3708. In the embodiment shown the intermediate layer includes recessed portions to receive the air flow insert 3722. The air flow insert 3722 is coupled to the fan assembly 3710. The bed system may include some of the components arranged in similar positions of the various bed and mattress systems described herein. The example system 3700 is configured such that a rail structure is not used. In some of these embodiments, the one or more fan assemblies 3710 are integrated within a mattress core 3706. The fan assembly 3710 can be configured to draw air from the surface of the top layer 3702 through the air flow insert 3722 and out the side or bottom of the bed system 3700. In some of these embodiments, the fan assemblies 3710 are mounted to a frame (not shown) of the bed system 3700 and connected to corresponding air flow inserts 3710 via a hose through the mattress core 3706.

    [0257] In some examples, the mattress core layer 3706 is made of a foam material. In other examples, coils (such as metal springs define the mattress core). In some embodiments, other materials are used such as gels or liquids. In some examples, the mattress core layer 3706 is made of foam and coils. In some examples, the mattress core layer 3706 is made of a combination of multiple materials.

    [0258] In some embodiments, the bed system 3700 does not include an intermediate layer 3704 and the mattress core includes a recess to house the airflow inserts 3710. In some embodiments, the be system 3700 includes only the mattress core layer 3706 housed within a cover (e.g., with a quilted foam on the top to provide comfort to a user on the mattress). In these embodiments, the mattress core layer 3706 is designed to act as the air distribution layer. For example, the mattress core layer 3706 is made of foam material it can include channels to allow air to flow from the mattress surface. In some examples, the mattress core includes coils which define channels that allow air to flow from the mattress surface. In some of these examples, the coils at certain portions of the mattress contain foam and the coils at other portions are open to define a space that allows air to flow from the mattress surface via the fan assembly.

    [0259] In some embodiments, the bed system 3700 does not include the bottom layer 3708. For example, in bed systems where the mattress core 3706 does not include air chambers can also not include the bottom layer 3708.

    [0260] Referring to FIGS. 1-37 generally, some embodiments include a bed system. The bed system includes a mattress with one or more layers, a first air module and a second air module configured to create airflow; a first airflow insert pad positioned at least partially within at least one of the one or more layers on a first side of the mattress, a second an airflow insert pad positioned at least partially within the at least one of the one or more layers on a second side of the mattress, and a first sleeve and a second sleeve made of a fire resistant material. The first an airflow insert pad being configured to circulate the airflow from the first air module through the first side of the mattress. The second an airflow insert pad being configured to circulate the airflow from the second air module through the second side of the mattress, and a first sleeve and a second sleeve made of a fire resistant material, wherein the first sleeve at least partially covers the first an airflow insert pad and the second sleeve at least partially covers the second an airflow insert pad.

    [0261] Another embodiment includes a bed system including a mattress. The mattress includes an air distribution layer, a second layer, and a sleeve made of a fire resistant material positioned to at least partially cover the air distribution layer but not cover the second layer. In some of these examples, the mattress also includes a second sleeve made of a second fire resistant material positioned to enclose at least the second layer, the sleeve, and the air distribution layer and a mattress cover positioned to enclose at least the second sleeve, the second layer, the sleeve, and the air distribution layer.

    [0262] Some examples, include a sleeve configured to be installed for an airflow insert pad of a bed system. The sleeve including fabric sized and shaped to at least partially surround an airflow insert pad configured to facilitate circulation of airflow through a mattress of a bed system. Where the fabric is at least partially constructed of a fire resistant material.

    [0263] Some embodiments include a bed system including a mattress including one or more layers, at least one air module configured to create airflow, an air distribution layer positioned within the mattress, the air distribution layer being configured to facilitate circulation of the airflow, and a sleeve made of a fire resistant material and being sized and shaped to at least partially cover the air distribution layer. In some examples, the at least one air module includes a fan assembly configured to draw air from the air distribution layer to the at least one air module. In some examples, the one or more layers comprises a first layer, a second layer, and air distribution layer. In some of these examples, the air distribution layer is positioned between the first and second layers, wherein the sleeve is positioned under the first layer and above the second layer. In some examples, the sleeve at least partially encloses the air distribution layer but not the first and second layers. In some examples, the sleeve is a first sleeve and wherein a second sleeve made of a second fire resistant material at least partially encloses the first layer, the second layer, the air distribution layer, and the first sleeve. The bed system can also include a mattress cover enclosing the second sleeve, the first layer, the second layer, the air distribution layer, the first sleeve, and in some cases one or more additional mattress components.

    [0264] Some embodiments include a mattress comprising a first side rail, a second side rail, a top layer attached to the first side rail and the second side rail, an airflow insert pad, an air module in fluid communication with the airflow insert pad to create airflow through the top layer of the mattress, and a support layer positioned under the top layer and between the first side rail and the second side rail, wherein the support layer includes a recessed portion and the airflow insert is positioned in the recessed portion. Some of these embodiments include a sleeve made of a fire resistant material and being sized and shaped to at least partially cover the airflow insert. The sleeve can be configured to resist transmission of fire through the sleeve stopping the airflow from the air module. In some of these examples, the airflow insert pad includes material that is configured to block (or reduce) the airflow from the air module when melted, where when a burn occurs the sleeve is configured to direct heat from the burn towards the airflow insert pad, thereby melting material included in the airflow insert pad and blocking the airflow from the air module.

    [0265] Some embodiments include a bed system comprising a first side rail and a second side rail, an airflow insert, a first air module in fluid communication with the airflow insert pad to create airflow through a top layer of a mattress of the bed system, and one or more layers positioned between the first side rail and the second side rail, the one or more layers a support layer, wherein the support layer includes a recessed portion and the airflow insert is positioned in the recessed portion. Some of these embodiments include a sleeve made of a fire resistant material and being sized and shaped to at least partially cover the airflow insert.

    [0266] Some embodiments include a bed system including a top foam layer having a top surface and a bottom surface, one or more support layers positioned below the bottom surface of the top foam layer, an inflatable chamber positioned below the support layer, a foam rail structure including a head rail, a foot rail, a left rail, and a right rail, the foam rail structure is attached to a bottom side of the top foam layer and configured to surround the support layer the inflatable chamber, a mattress bottom that covers the inflatable chamber, and an air module configured to create airflow and positioned within the foot rail and connected to an airflow insert positioned within a recessed portion of the one or more support layers. Some of these embodiments include a sleeve made of a fire resistant material and being sized and shaped to at least partially cover the airflow insert.

    [0267] Some embodiments include, a mattress comprising a first layer having a first layer top and a first layer bottom, a head rail attached to the first layer bottom, a foot rail attached to the first layer bottom and defining a first recessed portion and a second recessed portion, a first side rail attached to the first layer bottom, the head rail and the foot rail, a second side rail attached to the first layer bottom, the head rail and the foot rail, a first air module configured to create airflow between a first side of the first layer top and the first layer bottom via a first airflow insert pad, the first air module being positioned in the first recessed portion of the foot rail, a second air module configured to create airflow between a second side of the first layer top and the first layer bottom via a second airflow insert pad, the second air module being positioned in the second recessed portion of the foot rail, and one or more support layers including a first recessed portion and a second recessed portion, wherein the first airflow insert pad is positioned in the first recessed portion and the second airflow insert pad is positioned in the second recessed portion. Some of these embodiments include a first sleeve and a second sleeve made of a fire resistant material and being sized and shaped to at least partially cover the first airflow insert and the second airflow insert, respectively.

    [0268] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of the disclosed technology or of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of particular disclosed technologies. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment in part or in whole. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described herein as acting in certain combinations and/or initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations may be described in a particular order, this should not be understood as requiring that such operations be performed in the particular order or in sequential order, or that all operations be performed, to achieve desirable results. Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims.