Comfort product

Abstract

An improved comfort product that uses an airflow through a heat exchanger and into the comfort product to selectively heat or cool an occupant has a support layer contacting and supporting a channel layer. The channel layer has at least one channel with an opening to accept air. The channel layer contacts and supports an engineered distribution layer that has numerous small holes making it air permeable. The engineered distribution layer contacts and supports an air permeable comfort layer that is of such size and shape to support an occupant of the comfort product. The comfort product also has a heat exchanger assembly for supplying heated or cooled air to the opening in the channel. The heat exchanger assembly includes an air intake having an intake fan, an exhaust outlet and a heat exchanger for selectively heating or cooling air flowing through the heat exchanger resulting in selectively heated or cooled supply air and exhaust air. The intake fan forces air through the heat exchanger where some of the air is selectively heated or cooled to be supplied to the comfort product and some air is used as exhaust air (to remove the unwanted heat if the supplied air is cooled or to warm the exhaust side of the heat exchanger if the supply air is warmed.). The selectively heated or cooled supply air then moves through the channels in the channel layer and the exhaust air exits through the exhaust vent. The selectively heated or cooled supply air then moves through the engineered distribution layer where the numerous small holes diffuse the air and then the selectively heated or cooled air then moves through the comfort layer where the air is further diffused and where the selectively heated or cooled air can selectively heat or cool an occupant of the comfort product.

1 . A comfort product having means to distribute air through the comfort product comprising: 
 a support layer;    a channel layer;    the channel layer being in contact with and supported by the support layer;    the channel layer having at least one channel formed therein;    the channel layer having an opening connecting to the channel;    an engineered distribution layer;    the engineered distribution layer being in contact with and supported by the channel layer;    the engineered distribution layer having numerous small holes making it air permeable;    a comfort layer;    the comfort layer being in contact with and supported by the top engineered distribution layer;    the comfort layer being of such size and shape to receive and support an occupant of the comfort product;    the comfort layer being air permeable;    a fan assembly for supplying air consisting of an air intake having an intake fan;    whereby; the intake fan can force air into and through the channels in the channel layer;    the air can then move through the engineered distribution layer where the numerous small holes diffuse the air; and    the air can then move through the comfort layer where the air is further diffused and where the air can comfort an occupant.    
   
   
       2 . A comfort product having means to distribute temperature conditioned air through the comfort product comprising: 
 a support layer;    a channel layer;    the channel layer being in contact with and supported by the support layer;    the channel layer having at least one channel formed therein;    the channel layer having an opening connecting to the channel;    an engineered distribution layer;    the engineered distribution layer being in contact with and supported by the channel layer;    the engineered distribution layer having numerous small holes making it air permeable;    a comfort layer;    the comfort layer being in contact with and supported by the top engineered distribution layer;    the comfort layer being of such size and shape to receive and support an occupant of the comfort product;    the comfort layer being air permeable;    a heat exchanger assembly for supplying heated or cooled air consisting of:    an air intake having an intake fan;    an exhaust outlet;    a heat exchanger for selectively heating or cooling air flowing through the heat exchanger thereby providing selectively heated or cooled air and exhaust air;    whereby; the intake fan can force air through the heat exchanger;    the heat exchanger selectively heats or cools the air;    the selectively heated or cooled air can then move through the channels in the channel layer;    the selectively heated or cooled air can then move through the engineered distribution layer where the numerous small holes diffuse the air; and    the selectively heated or cooled air can then move through the comfort layer where the air is further diffused and where the selectively heated or cooled air can selectively heat or cool an occupant.    
   
   
       3 . A comfort product as in  claim 2  wherein the heat exchanger includes a Peltier circuit.  
   
   
       4 . A comfort product as in  claim 2  wherein the support layer is made of high density foam.  
   
   
       5 . A comfort product as in  claim 2  wherein the support layer is made of low density foam.  
   
   
       6 . A comfort product as in  claim 2  wherein the channel layer is made of high density foam.  
   
   
       7 . A comfort product as in  claim 2  wherein the engineered distribution layer is made of low density foam.  
   
   
       8 . A comfort product as in  claim 2  wherein the engineered distribution layer is made of fiber paper.  
   
   
       9 . A comfort product as in  claim 2  wherein the comfort layer is made of low density foam.  
   
   
       10 . A comfort product as in  claim 2  wherein the comfort layer is made of blown fiber in a bag.  
   
   
       11 . A comfort product as in  claim 2  which includes a backrest.  
   
   
       12 . A comfort product as in  claim 11  wherein the backrest is comprised mainly of low density foam.  
   
   
       13 . A comfort product as in  claim 2  wherein the channel is spiral shaped.  
   
   
       14 . A comfort product as in  claim 2  wherein the channel is vein-like.  
   
   
       15  . A comfort product as in  claim 14  wherein the vein-line channel has at least one connection opening and wherein the connection opening can make an air-tight connection with a second connection opening in another like comfort product.  
   
   
       16 . A comfort product having means to distribute temperature conditioned air through the comfort product comprising: 
 a support layer of either high density foam or low density foam;    a channel layer of high density foam;    the channel layer being in contact with and supported by the support layer;    the channel layer having channels formed therein;    the channel layer having an opening connecting to the channels;    an engineered distribution layer fiber paper or low density foam;    the engineered distribution layer being in contact with and supported by the channel layer;    the engineered distribution layer having numerous small holes making it air permeable;    a comfort layer of low density foam, layered fiber paper or blown fiber in a bag;    the comfort layer being in contact with and supported by the top engineered distribution layer;    the comfort layer the comfort layer being of such size and shape to receive and support an occupant of the comfort product;    the comfort layer being air permeable;    a heat exchanger assembly for supplying heated or cooled air consisting of:    an air intake having an intake fan;    an exhaust outlet;    a heat exchanger for selectively heating or cooling air flowing through the heat exchanger thereby providing selectively heated or cooled air and exhaust air;    the heat exchanger including a Peltier circuit whereby:    the intake fan can force air through the heat exchanger;    the heat exchanger selectively heats or cools the air;    the selectively heated or cooled air can then move through the channels in the channel layer;    the selectively heated or cooled air can then move through the engineered distribution layer where the numerous small holes diffuse the air; and    the selectively heated or cooled air can then move through the comfort layer where the air is further diffused and where the selectively heated or cooled air can selectively heat or cool an occupant.    
   
   
       17 . A comfort product as in  claim 16  wherein: 
 the support layer has a top side;    the channel layer has a top side, a bottom side and at least one lateral side;    the bottom side of the channel layer being in contact with and supported by the top side of the support layer;    the engineered distribution layer has a top side and a bottom side;    the bottom side of the engineered distribution layer being in contact with and supported by the top side of the channel layer;    the comfort layer having a top side and a bottom side;    the bottom side of the comfort layer being in contact with and supported by the top side of the engineered distribution layer;    the top side of the comfort layer supporting an occupant of the comfort product;.    
   
   
       18 . A comfort product as in  claim 17  wherein: 
 the channels in the channel layer are formed in the top side of the channel layer; and    the opening in the channel layer connecting to the channels is in the lateral side of the channel layer.    
   
   
       19 . A comfort product as in  claim 17  wherein: 
 the channels in the channel layer are formed in the top side of the channel layer; and    the opening in the channel layer connecting to the channels is in the bottom of the channel layer.    
   
   
       20 . A comfort product as in  claim 17  wherein the channel in the channel layer is spiral shaped.  
   
   
       21 . A comfort product as in  claim 20  wherein the spiral shaped channel extends from the top side of the channel layer through the channel layer to the bottom side of the channel layer.  
   
   
       22 . A comfort product as in  claim 16  wherein the channel is vein-like.  
   
   
       23 . A comfort product as in  claim 22  wherein the vein-line channel has at least connection opening and wherein the connection opening can make an air-tight connection with a second connection opening another like comfort product.  
   
   
       24 . A comfort product as in  claim 16  which includes a backrest.  
   
   
       25 . A comfort product having means to distribute temperature conditioned air through the comfort product comprising: 
 a support layer of high density foam or low density foam;    the support layer having a top side;    a channel layer of high density foam;    the channel layer having a top side, a bottom side and at least one lateral side;    the bottom side of the channel layer being in contact with and supported by the top side of the support layer;    the top side of the channel layer having channels formed therein;    the channel layer having an opening, the opening connecting to the channels;    an engineered distribution layer of fiber paper or low density foam;    the engineered distribution layer having a top side and a bottom side;    the bottom side of the engineered distribution layer being in contact with and supported by the top side of the channel layer;    the engineered distribution layer having numerous small holes making it air permeable;    a comfort layer of low density foam, layered fiber paper or blown fiber in a bag;    the comfort layer having a top side and a bottom side;    the bottom side of the comfort layer being in contact with and supported by the top side of the engineered distribution layer;    the top side of the comfort layer being of such size and shape to receive and support an occupant of the comfort product;    the comfort layer being air permeable;    a back rest foam of low cut density foam;    the back rest being in contact with and supported by the top side of the comfort layer;    a heat exchanger assembly for supplying heated or cooled air consisting of:    an air intake having an intake fan;    an exhaust outlet;    an air conduit having a first end and a second end;    the first end of the air conduit connected to the air intake;    the second end of the air conduit connected to a heat exchanger for selectively heating or cooling air flowing through the heat exchanger from the air conduit thereby providing selectively heated or cooled air and exhaust air;    the heat exchanger including a Peltier circuit;    an air supply tube connected to the heat exchanger at a first end receiving the selectively heated or cooled air;    the air supply connected to the opening in the channel layer;    whereby; the intake fan can force air through the air intake, into the air conduit and through the heat exchanger;    the heat exchanger selectively heats or cools the air;    the selectively heated or cooled air can move through the air supply tube;    the selectively heated or cooled air can then move through the channels in the channel layer;    the selectively heated or cooled air can then move through the engineered distribution layer where the numerous small holes diffuse the air; and    the selectively heated or cooled air can then move through the comfort layer where the air is further diffused and where the selectively heated or cooled air can selectively heat or cool an occupant.    
   
   
       26 . A comfort product as in  claim 25  wherein the channel in the channel layer is spiral shaped.  
   
   
       27 . A comfort product as in  claim 26  wherein the spiral shaped channel extends from the top side of the channel layer through the channel layer to the bottom side of the channel layer.  
   
   
       28 . A comfort product as in  claim 25  wherein the channel is vein-like.  
   
   
       29 . A comfort product as in  claim 28  wherein the vein-like channel has at least one connection opening and wherein the connection opening can make an air-tight connection with a second connection opening another like comfort product.  
   
   
       30 . A comfort product as in  claim 25  wherein the opening in the channel layer connecting to the channels is in the lateral side of the channel layer.  
   
   
       31 . A comfort product as in  claim 25  wherein the opening in the channel layer connecting to the channels is in the bottom of the channel layer.  
   
   
       32 . A comfort product as in  claim 25  wherein the heat exchanger assembly has a switch assembly to activate or deactivate the heat exchanger assembly.  
   
   
       33 . A comfort product as in  claim 32  wherein the switch assembly includes a pressure activated switch.  
   
   
       34 . A comfort product as in  claim 25  wherein the heat exchanger assembly is mounted in a space defined by an opening in the support layer, the channel layer and the scrim so the heat exchanger assembly fits in the interior of the comfort product.  
   
   
       35 . A comfort product as in  claim 25  wherein the heat exchanger assembly is mounted exterior of a space defined the support layer, the channel layer and the scrim so the heat exchanger assembly is exterior to the remainder of the comfort product.  
   
   
       36 . A comfort product having means to distribute temperature conditioned air through the comfort product manufactured by a process such that: 
 a support layer is die cut from high density foam or low density foam to form a structure having a top;    a channel layer is die cut from high density foam to form a structure having a top, bottom and at least one side;    the channel layer having channels formed in the top side of the channel layer;    an engineered distribution layer is die cut from fiber paper or low density foam to form a structure having a top and a bottom;    the engineered distribution layer having holes formed to allow the passage of air from the bottom side of the engineered distribution layer to the top side of the engineered distribution layer;    a comfort layer of such size and shape to receive and support an occupant of the comfort product is die cut from low density foam or is made of blown fiber collected in a bag to form a structure having a top side and a bottom side;    the bottom side of the channel layer being glued to the top side of the support layer using foam glue so that the channel layer is in contact with and supported by the support layer;    the bottom side of the engineered distribution layer being glued to the top side of the channel layer using foam glue so that the engineered distribution layer is in contact with and supported by the channel layer;    the bottom side of the comfort layer being glued to the top side of the engineered distribution layer using foam glue so that the comfort layer is in contact with and supported by the engineered distribution layer;    a heat exchanger assembly being connected to the channels of the channel layer to force selectively heated or cooled air through the channels, up through the holes in the engineered distribution layer where the air is diffused and through the comfort layer where the air is further diffused to heat or cool the top of the comfort layer.