EP3820331A1

EP3820331A1 - Thermally conductive cushion

Info

Publication number: EP3820331A1
Application number: EP19745462.2A
Authority: EP
Inventors: Mansour Abdulbaki; Arnab KHAN; Don SALISBURY; Vinoo SHARMA
Original assignee: Invista Textiles UK Ltd
Current assignee: Invista Textiles UK Ltd
Priority date: 2018-07-09
Filing date: 2019-07-08
Publication date: 2021-05-19
Also published as: WO2020014095A1; JP2021530282A; CN112566531A; JP7119198B2; US20210120965A1

Abstract

A product and process for reducing discomfort due to heat and moisture evolved during a period of contact between living skin and a cushioning material, using a thermally conductive cushioning device (10), having a first layer (20) of a moisture management fabric (22), a second layer (30) of a thermally conductive web (32), and a third layer (40) of a thermally insulative cushioning material (42).

Description

THERMALLY CONDUCTIVE CUSHION

[0001 ] This application claims priority to U.S. Provisional Application No. 62/695,362, filed on July 09, 2018. which is incorporated herein by reference in it s entirety.

[0002] Disclosed is a thermally conductive cushioning device, which conducts heat away from a point of contact thereof with the human body.

[0003] The human body releases heat in a number of ways to help regulate its temperature. An important way of releasing heat to control body temperature is through releasing moisture. The human body can release anywhere from 0.5 liter of moisture to 8 liters per day depending on the individual and their level of activity. Moisture may be released through various mechanisms, such as breathing, bodily waste functions, and perspiration.

[0004] Perspiration may occur when the body tries to rid itself of enough heat (i.e., cool itself) that it employs the help of convective heat transfer and starts to sweat. How much the body perspires depends upon a number of factors, such as the temperature and air movement within the surrounding environment, a person's metabolic state, and the amount of heat trapping and moisture retaining material near the body. However, moisture produced by the body during perspiration can collect in clothing, bedding, and other materials kept dose to the body, which can cause discomfort and/or impede the cooling process.

[0005] To reduce the discomfort caused by perspiration and to assist cooling the body, manufacturers have produced materials that generate a cooling effect. For example, mattresses have been developed which use active cooling to reduce surface temperatures, the active cooling being provided by blowers or the like. However, such systems suffer from various drawbacks, such as initial cost, the cost of operation and mechanical or electrical breakdowns. Tims, a passive cooling mechanism is more advantageous.

[0006] The transfer of heat can come about primarily as a result of heat conduction through solid material, convective heat transfer by air currents for example, radiation energy from a heated source to a cooler object, and mass transport such as through the evaporation of moisture. Some of these phenomena can come about through active exchange of heat such as an electrically driven air conditioner or a fan moving air around a heated object or passively where heat is exchanged without any external energy input.

[0007] Some passive ways to move energy in bedding articles is through a phase change of material (PCM) and moisture transport. A passive cooling effect is generated using one of two common mechanisms. The first mechanism includes the use of phase change materials (PCMs), which rapidly absorb heat to undergo a phase change at skin temperature and produce a sensation of cooling as a result. However, PCMs act as heat reservoirs that can only capture so much heat before the heat needs to be transferred away for the PCM to continue cooling in addition, encapsulated PCM on fabric often last a few minutes and then cannot trap more heat into the reservoir. Thus, the applicability PCMs in bedding materials to provide a cooling effect is limited.

[0008] The other mechanism for reducing discomfort by passive cooling may include the use of a fabric that wicks away moisture. Hydrophilic finishes have been used for fabric effects to wick away moisture. For example, non-silicone finishes that have some slickness have been used in fiberfili and can be hydrophilic. Rut while fabrics with hydrophilic finishes can wick away moisture, the cooling effect is somewhat limited.

[0009] It would be advantageous to provide a fabric-containing device that not only moves heat through moisture wicking, but also provides a passive cooling, by more effective conduction and convection from the point of contact with the human body.

SUMMARY

[0010] Presented herein is a thermally conductive cushioning device, comprising a first layer of a moisture management fabric, a second layer of a thermally conductive web, and a third layer of a thermally insulative cushioning material, wherein the thermal conductivity of the thermally conductive web is greater than or equal to the thermal conductivity of the cushioning material.

[0011] Advantageously, the moisture management fabric is formed of profiled cross- section polyester or polyamide fibers or other moisture management materials.

[0012] Alternatively, the moisture management fabric is formed of round or oval cross- section polyester or polyamide fibers, or other cross-sections that may channel moisture, which are treated to improve moisture wicking.

[0013] Alternatively, the moisture management fabric is formed of round or oval cross- section polyester or polyamide fibers, which are chemically treated with by plasma etching.

[0014] Alternatively, the moisture management fabric is formed of at least one selected from natural fibers, and profiled cross-section synthetic fibers.

[0015] In one form, the moisture management fabric is formed of a blend of natural fibers and profiled cross-section polyester or polyamide fibers, or it can be formed of a blend of natural fibers and round or oval cross-section polyester or polyamide fibers, which are chemically treated with a moisture wicking compound or plasma treated.

[0016] In another form, the thermally conductive web comprises metal selected from Groups 3 to 13 of the Periodic Table of the elements, and alloys thereof, such as a copper mesh, or thermally conductive forms of carbon, such as carbon fibers.

[0017] Advantageously, the thermally conductive web has a thermal conductivity of from about 0.1 to about 100 W/m-K, as measured from 20 C to 50 C and is dependent upon the construction of the thermally conductive fabric. For a single layer fabric one construction herein is of about 10-20 W/m-K.

[0018] Importantly, the thermally insulative material is not a heat sink, and can be a polyethylene terephthalate fiberfill insulation or any other cushioning layer of foam, fibers, feathers, down, polymer beads, buckwheat hulls, other common cushion stuffing materials, or combinations thereof. In one embodiment, the thermally insulative material can be a fiberfill that spreads moisture throughout its volume while retaining an acceptably slick hand.

[0019] In one form, of the thermally conductive cushioning device, the first layer is immediately adjacent the second layer.

[0020] In another form, the first layer is a woven, nonwoven or knitted fabric having a basis weight of from about 16 to about 300 g/m².

[0021] In yet another form, the second layer is a fine denier web having a force required for deflection which is substantially the same as a force required for deflection of the first layer. For example, the force required for deflection of the first layer is within ten percent (10%) of the force required for deflection of the second layer.

[0022] In another form, the third layer is a cushioning layer of foam or fibers, or a blend therefrom.

[0023] In some forms, the thermally conductive cushioning device is a pillow, a pillow case, a mattress cover, or a seat cushion.

[0024] Also presented is a process for providing a cooling effect to cushioning devices for contact with living skin, comprising (i) providing a thermally conductive cushioning device, comprising a first layer of a moisture management fabric, a second layer of a thermally conductive web, and a third layer of a thermally insulative cushioning material, (ii) contacting the cushioning device with skin to establish a temperature T i on the first layer of the cushioning device, and a first moisture level, (iii) extracting heat from the first layer of the cushioning device into the second layer of the cushioning device and reducing the temperature of the first layer to a temperature of T₂, (iv) wicking moisture away from the skin through the moisture management fabric of the first layer, and (v) distributing the heat and moisture toward edges of the first and second layers and away from the skin.

[0025] In one form, the thermally insulative material of the third layer delays transfer of heat from second layer into the third layer, thereby enhancing the distribution of heat toward the edges of the second layer

[0026] In one form, the“cushioning material” or fiberfill or other material resists heat flow. In this embodiment, the“cushioning material” is a thermal insulator.

[0027] In another form, the cushioning material is modified to improve its moisture wicking and thermal conduction properties.

[0028] Advantageously, temperature T₂ is from about 1 - 10° C less than temperature T i over a period of about 8 hours.

[0029] In an embodiment, heat dissipation is from 1 to 10 Watts, for example, 5W, and the difference between Ti and T₂ is maintained for more than 8 hours, for example 12 hours or 24 hours.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present disclosure is susceptible to various modifications and alternative forms, specific exemplary implementations thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific exemplary implementations is not intended to limit the disclosure to the particular forms disclosed herein.

[0031] FIG. 1A shows a schematic sectional view of a three layer cushioning fabric according to the disclosure herein.

[0032] FIG. 1B shows a cross-sectional view of a three layer cushioning fabric according to the disclosure herein, along section B-B of FIG. 1 A.

[0033] FIG. 2A shows a schematic view of a profiled cross-section fiber or filament, useful in the presently disclosed fabrics.

[0034] FIG. 2B shows a schematic view of a round cross-section fiber or filament, useful in the presently disclosed fabrics.

[0035] FIG. 3A is an illustration showing the construction of the measuring apparatus and the articles for temperature measurement.

[0036] FIG. 3B is a photographic representation of the article and weight upon the thermally conductive cushion.

[0037] FIGS. 4 A and 4B show the temperature profile of the cushioning article through 20 minutes with temperature measurements at various distances from the simulated head heat source. In FIG. 4B, the top temperature profile is with an article without any conductive material. The bottom layer has conductive material.

[0038] FIG. 5A shows the measured infrared temperature of the cushioning surface without the weight. The cushioning pillow, P6212-B, is a DACRON MEMORELLE™ polyester fiberfill of type SSF08. Curves showing temperatures with and without thermally conductive layer.

[0039] FIG. 5B shows the measured thermistor temperature between first layer fabric and the heat source. The cushioning pillow, P6212-B, is a DACRON MEMORELLE™ polyester fiberfill of type SSF08. Curves showing temperatures with and without thermally conductive layer.

[0040] FIG. 5C shows infrared temperature of the cushioning surface without the weight showing the temperature differences with and without the thermally conductive layer. The cushioning pillow, P6212-B, is a DACRON MEMORELLE™ polyester fiberfill of type SSF08. [0041] FIG. 5D shows the thermistor temperature between first layer fabric and the heat source showing the temperature differences with and without the thermally conductive layer. The cushioning pillow, P6212-B, is a DACRON MEMORELLE™ polyester fiberfill of type SSF08.

[0042] FIG. 5E show the two infrared temperature images of the test in FIG 5A-D after 7 hours. The top image is without the thermally conductive layer and the bottom image includes the thermally conductive layer.

[0043] FIG 6A shows the infrared temperature of the cushioning surface without the weight. The cushioning pillow P4550, is Therapedic Memory Foam. Curves showing temperatures with and without thermally conductive layer.

[0044] FIG. 6B shows the thermistor temperature between first layer fabric and the heat source. The cushioning pillow P4550, is Therapedic Memory Foam. Curves showing temperatures with and without thermally conductive layer.

[0045] FIG. 6C shows infrared temperature of the cushioning surface without the weight showing the temperature differences with and without the thermally conductive layer. Pillow P4550, is a Therapedic Memory Foam cushioning pillow.

[0046] FIG. 6D. shows the thermistor temperature between first layer fabric and the heat source showing the temperature differences with and without the thermally conductive layer. Pillow P4550, is a Therapedic Memory Foam cushioning pillow.

[0047] FIG. 6E. show the two infrared temperature images of the test in FIG 6A-D after 7 hours. The top image is without the thermally conductive layer and the bottom image includes the thermally conductive layer.

DETAILED DESCRIPTION

[0048] There is an increased interest in developing bedding materials having a cooling effect over the course of a sleep cycle. The present disclosure is directed towards a thermally conductive cushioning material which can be used in bedding materials.

Definitions

[0049] The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than the broadest meaning understood by skilled artisans, such a special or clarifying definition will be expressly set forth in the specification in a definitional manner that provides the special or clarifying definition for the term or phrase.

[0050] For example, the following discussion contains a non-exhaustive list of definitions of several specific terms used in this disclosure (other terms may be defined or clarified in a definitional manner elsewhere herein). These definitions are intended to clarify the meanings of the terms used herein. It is believed that the terms are used in a manner consistent with their ordinary meaning, but the definitions are nonetheless specified here for clarity.

[0051] A/an: The articles "a" and "an" as used herein mean one or more when applied to any feature in embodiments and implementations of the present invention described in the specification and claims. The use of "a" and "an" does not limit the meaning to a single feature unless such a limit is specifically stated. The term "a" or "an" entity refers to one or more of that entity. As such, the terms "a" (or "an"), "one or more" and "at least one" can be used interchangeably herein.

[0052] About: As used herein, "about" refers to a degree of deviation based on experimental error typical for the particular property identified. The latitude provided the term "about" will depend on the specific context and particular property and can be readily discerned by those skilled in the art. The term "about" is not intended to either expand or limit the degree of equivalents which may otherwise be afforded a particular value. Further, unless otherwise stated, the term "about" shall expressly include "exactly," consistent with the discussion below regarding ranges and numerical data.

[0053] And/or: The term "and/or" placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple elements listed with "and/or" should be construed in the same fashion, i.e., "one or more" of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the "and/or" clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and/or B", when used in conjunction with open-ended language such as "comprising" can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements). As used herein in the specification and in the claims, "or" should be understood to have the same meaning as "and/or" as defined above. For example, when separating items in a list, "or" or "and/or" shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as "only one of' or "exactly one of," or, when used in the claims, "consisting of," will refer to the inclusion of exactly one element of a number or list of elements. In general, the term "or" as used herein shall only be interpreted as indicating exclusive alternatives (i.e. "one or the other but not both") when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of'.

[0054] Comprising: In the claims, as well as in the specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases "consisting of' and "consisting essentially of' shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03. Any device or method or system described herein can be comprised of, can consist of, or can consist essentially of any one or more of the described elements.

[0055] Ranges: Concentrations, dimensions, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of about 1 to about 200 should be interpreted to include not only the explicitly recited limits of 1 and about 200, but also to include individual sizes such as 2, 3, 4, etc. and sub-ranges such as 10 to 50, 20 to 100, etc. Similarly, it should be understood that when numerical ranges are provided, such ranges are to be construed as providing literal support for claim limitations that only recite the lower value of the range as well as claims limitation that only recite the upper value of the range. For example, a disclosed numerical range of 10 to 100 provides literal support for a claim reciting "greater than 10" (with no upper bounds) and a claim reciting "less than 100" (with no lower bounds). In the figures, like numerals denote like, or similar, structures and/or features; and each of the illustrated structures and/or features may not be discussed in detail herein with reference to the figures. Similarly, each structure and/or feature may not be explicitly labeled in the figures; and any structure and/or feature that is discussed herein with reference to the figures may be utilized with any other structure and/or feature without departing from the scope of the present disclosure.

[0056] The terms fibers and filaments are generally used interchangeably throughout this disclosure, unless otherwise defined. The term yarns should be understood to represent a collection of fibers or filaments which are twisted or otherwise combined into a larger structure.

[0057] One purpose of the presently disclosed device is to provide a cooling effect to living skin which comes into contact with certain cushioning materials, such as pillows, mattress covers, or seat cushions and the like. During the course of a sleep cycle, a person’s head emits a great deal of heat and sometimes perspiration, largely due to the thermal insulative properties of pillow core materials, such as foam, fiberfill, feathers or other similar cushioning fillers.

[0058] In one form, illustrated in FIGs. 1A and IB, the presently disclosed device is a thermally conductive cushioning device 10, comprising a first layer 20 of a moisture management fabric or a non-moisture management fabric 22, a second layer 30 of a thermally conductive web 32, and a third layer 40 of a thermally insulative cushioning material 42.

[0059] The moisture management fabric 22 of the first layer 20 can be formed of profiled cross-section polyester or polyamide fibers, such as the tri-lobal fiber 22a illustrated in FIG. 2A. However, other such profiled cross-section fibers, such as quadri-lobal fibers can be used. Without being bound by theory, it is believed that moisture management, i.e. wicking, is enhanced by an increased void volume within fabric due to the voids between adjacent fibers in the weave or knit, caused by the indentations between the lobes of the fibers. Moisture can more readily be wicked away from the site of skin contact through the voids. Wicking may also be achieved at the level of the individual filament when the filaments are profiled such that the physical dimensions provide a surface tension conducive to wicking.

[0060] Alternatively, the moisture management fabric is formed of round or oval cross- section polyester or polyamide fibers 22b (FIG. 2B), which are treated with a moisture wicking compound 23. The moisture wicking compound 23 can be deposited onto the surface of fiber 22b, or incorporated into the fiber during spinning. The moisture wicking compound can be applied to the fibers at levels of about 0.01 to about 0.40 wt%, relative to the fiber weight, or even from about 0.01 to about 0.70 wt%. Alternatively, the moisture management fabric can be formed of round or oval cross-section polyester or polyamide fibers, which are chemically treated with by plasma etching.

[0061] Nonlimiting examples of such fibers include fibers made from polyesters, including polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polylactie acid (PLA), polyhydroxybutyrafe (PHB), and blends or copolymers thereof. In one form, the fibers may be made of polyethylene terephthalate. In other forms, the fibers may he made of polyamides, including nylon 5,6; nylon 6/6; nylon 6; nylon 7; nylon 11; nylon 12; nylon 6/10; nylon 6/12; nylon DT; nylon 6T; nylon 61; and blends or copolymers or terpolymers thereof.

[0062] In another form, the moisture management fabric 22 can be formed of a blend of natural fibers and profiled cross-section polyester or polyamide fibers, or it can be formed of a blend of natural fibers and round or oval cross-section polyester or polyamide fibers, which are treated with a moisture wicking compound. In an embodiment, the moisture wicking fabric layer can be be made entirely of natural fibers that are inherently moisture wicking (such as viscose made from natural starting materials) or natural fibers treated to be hydrophilic and more moisture wicking (e.g. coated cotton). For example, the moisture management fabric can be formed of a blend of natural fibers and profiled cross-section polyester or polyamide fibers, or it can be formed of a blend of natural fibers and round or oval cross-section polyester or polyamide fibers, which are chemically treated with a moisture wicking compound or plasma treated.

[0063] The fibers in accordance with the present disclosure can have dpf values ranging from 0.04 dpf to 40 dpf. Non-limiting examples include dpf values ranging from 0.5 dpf to 30 dpf, from 0.5 dpf to 20 dpf, from 0.5 dpf to 10 dpf, from 0.5 dpf to 5 dpf, from 0.5 dpf to 2 dpf, from 0.5 dpf to 1.5 dpf, from 1 dpf to 10 dpf, from I dpf to 5 dpf, from 5 dpf to 30 dpf, from 5 dpf to 20 dpf, from 5 dpf to from 10 dpf, and from 5 dpf to 7 dpf. In certain embodiments, the fibers can dpf values of less than 10 dpf, such as less than 7 dpf, less than 5 dpf, less than 3 dpf, and less than 1.5 dpf. In an embodiment, the fibers have dpf values of from 0.5 to 3.

[0064] The first layer 20 can be a woven or knitted fabric having a basis weight of from about 16 to about 300 g/m². [0065] Suitable treatments to effect moisture wicking properties can include use of hydrophilic compounds known by those skilled in the art to impart hydrophilic properties to synthetic fibers. Suitable hydrophilic fibers are disclosed in U. S. Patent 6,656,586 column 8, lines 12-20, incorporated by reference as if set forth at length herein in an embodiment, the fabric is subject to certain pre- and post- scouring events. The pre-seouring can include putting fabric in a very hot bath (50-70°C) along with mild to strong caustic to removes all oils and waxes. The post-scouring treatment can add to the fabric a non-ionic wetting agent such as Permalose^;M from Croda in a 60°C bath for 20 minutes. These key steps impart the wicking behavior in polyester based fabrics.

[0066] The thermally conductive web 32 can be made from a metal. Suitable metals can include those from Groups 3 to 13 of the Periodic Table of the elements, and alloys thereof. In advantageous forms, the web can be a woven or knitted copper mesh, or a woven or knitted aluminum mesh, available from Edward J. Darby & Sons, Philadelphia, Pennsylvania, U.S.A. Highly conductive forms of carbon can also be suitable, as can boron nitride (BN) merely to name two examples. The mesh sizes can range from about 50 to about 325 mesh, with individual wire diameters of from about 0.001 inch to about 0.003 inch and mesh and oOpening widths of 0.005 inch to 0.015 inch.

[0067] In another form, the thermally conductive web 32 comprises thermally conductive carbon fibers that meet the flexibility needs as described herein.

[0068] Advantageously, the thermally conductive web 32 has a thermal conductivity of from about 0.1 to about 100 W/m-K, such as from about 1 to about 50 W/m-K, or even from 10 to about 20 W/m-K, and is dependent upon the construction of the thermally conductive fabric. For a single layer fabric one construction herein is of about 10-20 W/m-K. For another multilayer thermally conductive fabric the conductivity is about 60-100 W/m-K. See for reference: C. Li, G.P. Peterson / International Journal of Heat and Mass Transfer 49 (2006) 4095-4105.

[0069] The force required for deflection of the first layer 20 can be within ten percent (10%) of the force required for deflection of the second layer 30. In one form, the second layer 30 can be a fine denier web having a force required for deflection which is substantially the same as a force required for deflection of the first layer 20. Suitable tests of force required for deflection include ASTM D1388 and BS EN 9073, BS 5058, AFNOR G07-109. In one example using copper or brass, the fabric filament diameter must be less than 0.04mm and a thread per cm of < 50 in the warp and weft direction.

[0070] In one form, of the thermally conductive cushioning device 10, the first layer 20 is immediately adjacent the second layer 30, such as in direct contact. In this way, heat from the first layer 20 is immediately conducted into the second layer 30, and distributed toward the edges of the layers and away from the point of contact between the cushioning device 10 and the living skin.

[0071] The thermally insulative material or cushion typical is much more insulative than the thermally conductive web. In one construction herein the polyethylene terephthalate cushioning material conductivity is about 0.03 to 0.06 W/m K. The cushioning material can be a polyethylene terephthalate fiberfill or any other cushioning layer of foam, fibers feathers, down, polymer beads, chopped straws, buckwheat hulls, other common cushion stuffing materials, or combinations thereof. According to the presently disclosed device, heat and moisture are conducted away from the user, instead of down into the cushioning material. The insulating nature of the cushioning material 42 redirects heat and moisture to the overlying first and second layers of the device. In this manner, the thermally conductive cushioning device can reduce temperatures at the contact surface (Head Cooling DT) from about 0.1° C to about 10° C over a typical 8 hour sleep cycle period, or from about 2° C to about 8° C, or from about 4° C to about 6° C, or even from about 4.5° C to about 5.5° C. The Head Cooling DT can be measured by conventional means using thermocouples, thermometers and/or thermistors. The thickness of the insulative cushioning material 42 should be at least about ¼ inch, advantageously at least about ½ inch, or more. The insulative cushioning material 42 can be a polyethylene terephthalate fiberfill insulation or any other cushioning layer of foam or fibers.

[0072] In an embodiment, the fill can be hydrophilic so that it too can draw moisture vapor away from the skin, into the pillow, and then out again through other parts of the fabric/cushion. While there is heat conduction into the volume it is significantly less with this device, which primarily conducts heat in a planar or radial way from the source heat (the head). Additionally, the fiberfill may or may not have additional moisture managing features that as disclosed in WO 2016/154012. Moisture from the body does contain some percentage of the total heat from the source. While suitable cushioning materials can be relatively resistant to heat flow, it is desirable in one embodiment to provide lower resistance to radial heat than tangential heat flow (into the cushion).

[0073] If the cush ion material is a fiberfill, the fiberfill may Slave any crimp shape suitable for use in finished bedding articles such as pillows, mattress pads comforters, duvets, quilts etc., furniture components, such as seat cushions and chair hackings; sleeping bags; animal blankets, and other apparel articles that have a non-woven or high-loft non-woven applications. Suitable crimp shapes include (1) mechanical crimp (i.e., a saw-tooth crimp), (2) a spiral conjugate, and (3) an omega conjugate (i.e., asymmetric or jet quench). In one nonlimiting form, the fiberfill is mechanically crimped. In another nonlimiting form, the fiberfil! has a conjugate crimp.

[0074] Also presented is a process for providing a cooling effect to cushioning devices for contact with living skin, comprising providing a thermally conductive cushioning device, having a first layer of a moisture management fabric, a second layer of a thermally conductive web, and a third layer of a thermally insulative cushioning material. The process includes contacting the cushioning device with skin to establish a temperature Ti on the first layer of the cushioning device, and a first moisture level, then extracting heat from the first layer of the cushioning device into the second layer of the cushioning device and reducing the temperature of the first layer to a temperature of T₂. Additionally, the process includes wicking moisture away from the skin through the moisture management fabric of the first layer, and distributing the heat and moisture toward edges of the first and second layers and away from the skin. In an embodiment, the thermal conductivity of the second layer exceeds that of the cushion, and heat preferentially flows toward the edges of the second layer, such that T₂ is from about 1-10° C less than Ti over a period of about 8 hours.

[0075] Non-limiting examples of the insulative cushioning material include: finished bedding products, such as pillows, pillow cases, duvets, quilts, and comforters; furniture components, such as seat cushions and chair backings; sleeping bags; animal blankets; and other apparel articles that have a non-woven or high-loft non-woven applications.

Examples

Example 1: Thermal Conduction

[0076] The following is a description of the testing procedure and setup.

[0077] Testing area is within a controlled environmental chamber. The temperature is controlled at 70°F ± l.5°F and relative humidity (RH%) at 60% ± 7%. The sample and apparatus are preconditioned for at least 12 hours inside the environmental chamber. [0078] The test configuration is shown in FIGs. 3A and 3B. It consists of a pillow with a variety of possible fill (polyester, foam, down, etc.) as a third layer which includes fabric Figure 1A and 1B (40). A certain layer of copper fabric or brass or other highly conductive material is used (30). A layer or two of fabric as a first layer (20). The fabric can be of cotton, polyester or other kinds material that may or may not be moisture wicking but is preferred to be moisture wicking.

[0079] A heat source and weight; simulating the area, the weight and heat output of an approximate human head is placed upon the pillow as illustrated in Figure 3A and pictured in Figure 3B.

[0080] The heat source is approximately 225 cm² and has a power output of approximately 4 W over given area. The power is measured and controlled.

[0081] There are at least four temperature measurements including ambient condition. An Infrared [IR] temperature of the surface of the pillow with the weight briefly removed to image the surface of the article. The surface temperature is used with a FLIR T450sc spectrometer. The other temperature measurements are with thermistors that have tighter measurements than thermocouples. Temperature measurement between the surface of the first fabric layer and the heat source simulating the temperature between the head and the pillow surface. Temperature measurement at the bottom of the pillow against an insulative surface.

[0082] Measurements are taken at the beginning of the test just prior to applying the heat source and periodically through 7 to 8 hours of testing. Typically, the temperatures are measured about every hour.

[0083] The example showing the results in Figure 4 was prepared as follows. The top infrared image and associated infrared temperature were constructed of the following: (40) an insulative cushion foam, no thermally conductive fabric was used, and a top layer of two moisture wicking fabrics of (80%) cotton, (20%) polyester blend that were approximately of 120 g/m² each (20). The bottom infrared image and associated temperature next to the image were constructed of the following: (40) an insulative cushioning foam (40), 4 layers of copper woven mesh of 200 inch-l and diameter of 0.002 inch wire (30) and a top layer of two moisture wicking fabrics of (80%) cotton, (20%) polyester blend that were approximately of 120 g/m² each (20). A controlled heater was applied, and continuous temperature measurements were taken using the infrared camera over a course of 20 minutes. Plots of surface temperature were taken from the edge of the heater to 5 inches. Examining the two plots shows that the surface where the“head” is located produced a temperature difference of approximately 6°C. Also it is observed that the heated region is much more concentrated around the“head” or where the heat source is located without the thermally conductive fabric versus the bottom image that has the thermally conductive fabric.

Example 2:

[0084] The example showing the results in Figure 5 was prepared as follows. The one example without the thermally conductive layer was a pillow of polyester type SSF08 which consisted of 26 oz of about 1 dpf siliconized fiber encased in a fabric shell (40), and a top layer of two moisture wicking fabrics of (80%) cotton, (20%) polyester blend that were approximately of 120 g/m2 each (20). The second article was constructed of a pillow of polyester type SSF08 which consisted of 26 oz of about 1 dpf siliconized fiber encased in a fabric shell (40), a second layer constructed of 8 layers of 100 mesh, copper woven fabric composed of wires of diameter of 0.0012 inches (30) and a top layer of two moisture wicking fabrics of (80%) cotton, (20%) polyester blend that were approximately of 120 g/m2 each (20).

[0085] Figure 5A shows the results of the infrared temperature for both samples over a period of more than 7 hours. Figure 5B shows the results of the thermistor that is between the heater simulated the heat output of the head and the top layer (20). In Figures 5C and 5D are the temperature difference results of Figures 5A and 5B respectively. The temperature difference was observed to be 3.5 to 4 °F for each of the infrared temperature and thermistor. We believe this value is quite significant.

Example 3:

[0086] The example showing the results in Figure 6 was prepared as follows. The one example without the thermally conductive layer was a pillow of brand Therapedic Memory Foam (40), and a top layer of two moisture wicking fabrics of (80%) cotton, (20%) polyester blend that were approximately of 120 g/m2 each (20). The second article was constructed of a pillow of brand Therapedic Memory Foam (40), a second layer constructed of 8 layers of 100 mesh, copper woven fabric composed of wires of diameter of 0.0012 inches (30) and a top layer of two moisture wicking fabrics of (80%) cotton, (20%) polyester blend that were approximately of 120 g/m2 each (20).

[0087] Figure 6A shows the results of the infrared temperature for both samples over a period of more than 7 hours. Figure 6B shows the results of the thermistor that is between the heater simulating the heat output of the head and the top layer (20). In Figures 6C and 6D are the temperature difference results of Figures 6A and 6B respectively. The temperature difference was observed to be 4 to 6 °F for each of the infrared temperature and thermistor. The memory foam is more insulative an thus may illustrate the movement of heat outward on the surface relative to the less insulative polyester fiberfill.

[0088]

Industrial Applicability

[0154] The systems and methods disclosed herein are applicable to the bedding industry.

[0155] It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite“a” or“a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.

[0089] It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non- obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower, or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.

Claims

CLAIMS What is claimed is:

1. A thermally conductive cushioning device, comprising:

a first layer of a moisture management fabric;

a second layer of a thermally conductive web; and

a third layer of a cushioning material, wherein the thermal conductivity of the thermally conductive web is greater than or equal to the thermal conductivity of the cushioning material.

2. The thermally conductive cushioning device of claim 1, wherein the moisture management fabric is formed of profiled cross-section polyester or polyamide fibers or other moisture management materials.

3. The thermally conductive cushioning device of claim 1 or 2, wherein the moisture management fabric is formed of round or oval cross-section polyester or polyamide fibers or other cross-sections that may channel moisture, which are treated to improve moisture wicking.

4. The thermally conductive cushioning device of any preceding claim, wherein the moisture management fabric further comprises natural fibers.

5. The thermally conductive cushioning device of any preceding claim, wherein the moisture management fabric is formed of a blend of natural fibers and round or oval cross- section polyester or polyamide fibers, which are either chemically treated with a moisture wicking compound or plasma treated to improve moisture wicking.

6. The thermally conductive cushioning device of any preceding claim, wherein the thermally conductive web comprises at least one of:

(a) metal selected from Groups 3 to 13 of the Periodic Table of the elements;

(b) alloys comprising at least one metal of (a); and

(c) thermally conductive forms of carbon.

7. The thermally conductive cushioning device of any preceding claim, wherein the thermally conductive web comprises a copper mesh or thermally conductive carbon fibers.

8. The thermally conductive cushioning device of any preceding claim, wherein the thermally insulative cushioning material is not a heat sink, such as a polyethylene terephthalate fiberfill insulation.

9. The thermally conductive cushioning device of any preceding claim, wherein the thermally conductive web has a thermal conductivity of from about 0.1 to about 100 W/m-K, as measured from 20° C to 50° C.

10. The thermally conductive cushioning device of any preceding claim, wherein first layer is immediately adjacent the second layer.

11. The thermally conductive cushioning device of any preceding claim, wherein first layer is a woven or knitted fabric having a basis weight of from about 16 to about 300 g/m².

12. The thermally conductive cushioning device of any preceding claim, wherein second layer is a fine denier web having a force required for deflection that is substantially the same as a force required for deflection of the first layer, such as wherein the force required for deflection of the first layer is within ten percent (10%) of the force required for deflection of the second layer.

13. The thermally conductive cushioning device of any preceding claim, wherein the third layer is a cushioning layer of foam or fibers, or a blend therefrom.

14. The thermally conductive cushioning device of any preceding claim, which is a pillow or a pillow case.

15. The thermally conductive cushioning device of any preceding claim, which is a mattress cover.

16. The thermally conductive cushioning device of any preceding claim, which is a seat cushion.

17. A process for providing a cooling effect to cushioning devices for contact with living skin, comprising:

providing a thermally conductive cushioning device, comprising a first layer of a moisture management fabric, a second layer of a thermally conductive web, and a third layer of a thermally insulative cushioning material;

contacting said cushioning device with skin to establish a temperature T i on said first layer of the cushioning device, and a first moisture level;

extracting heat from said first layer of the cushioning device into said second layer of the cushioning device and reducing the temperature of said first layer to a temperature of T2; wicking moisture away from said skin through said moisture management fabric of the first layer; and

distributing said heat and moisture toward edges of said first and second layers and away from the skin.

18. The process of claim 21, wherein said thermally insulative material of said third layer delays entry heat from second layer into the third layer, thereby enhancing the distribution of heat toward the edges of the second layer.

19. The process of claim 21, wherein T2 is from about 0.5-10° C less than Ti over a period of about 8 hours.