Support cushions including a support insert with a bag for directing air flow, and methods for controlling surface temperature of same

1. A support cushion, comprising:

a body supporting layer formed of a first foam having a first surface and a second surface opposite the first surface, the body supporting layer having a plurality of airflow channels extending between the first surface and the second surface that deliver comfort air to the body supporting layer;

a base layer formed of a second foam different from said first foam positioned adjacent to and bonded to the second surface of the body supporting layer, the base layer defining a cavity with a support insert positioned within the cavity, the support insert including a bag defining an inlet hole and one or more outlet holes positioned adjacent to and in flow communication with the second surface of the body supporting layer;

an array of springs surrounded by the bag, or one or more layers of foam surrounded by the bag, wherein ambient air flow disperses through the bag and the one or more layers of foam or the array of springs before exiting through the one or more outlet holes of the bag and into the body supporting layer;

a fan operably connected to the inlet hole of the bag by a conduit wherein the conduit extends into the support cushion to the bag and wherein the conduit provides the ambient air flow directly into the inlet hole of the bag and out of the one or more outlet holes of the bag, wherein the ambient air flow spreads within the support cushion, and wherein the ambient air flow is solely said comfort air that exits only through said plurality of airflow channels.

2. The support cushion of claim 1 , the array of springs configured to support the body supporting layer.

3. The support cushion of claim 1 , wherein the support insert further comprises one or more foam layers substantially surrounded by the bag, the one or more foam layers configured to support the body supporting layer.

4. The support cushion of claim 1 , wherein the body supporting layer defines the plurality of airflow channels extending from the second surface to the first surface, the plurality of airflow channels substantially aligned with the one or more outlet holes of the bag.

5. The support cushion of claim 1 , wherein the base layer includes a bottom wall and a side wall positioned on top of the bottom wall, the side wall extending along a perimeter of the bottom wall.

6. The support cushion of claim 5 , wherein the bottom wall of the base layer defines a hole aligned with the inlet hole of the bag.

7. The support cushion of claim 1 , wherein the bag is comprised of an impermeable material.

8. The support cushion of claim 7 , wherein the bag is comprised of a plastic sheet.

9. The support cushion of claim 1 , wherein the body supporting layer, the base layer, or both the body supporting layer and the base layer are comprised of a visco-elastic foam.

10. The support cushion of claim 9 , wherein the body supporting layer is comprised of a porous visco-elastic foam.

11. The support cushion of claim 9 , wherein the visco-elastic foam comprising the body supporting layer has a porosity greater than that of the visco-elastic foam comprising the base layer.

12. The support cushion of claim 1 , further comprising a heating unit, a cooling unit, or both a heating unit and a cooling unit configured to provide thermally controlled air flow into the inlet hole of the bag and out of the one or more outlet holes of the bag.

13. The support cushion of claim 1 , wherein the fan is operably connected to the inlet hole of the bag by a conduit positioned a distance away from the support cushion.

14. The support cushion of claim 1 , wherein the fan is mounted to the base layer.

15. A mattress assembly, comprising:

a body supporting layer comprised of visco-elastic foam and having a first surface and a second surface opposite the first surface, the body supporting layer defining a plurality of channels extending from the second surface to the first surface;

a base layer positioned adjacent to and bonded to the second surface of the body supporting layer, the base layer defining a cavity with a support insert positioned within the cavity, the support insert including an impermeable material defining an inlet hole and one or more outlet holes, the one or more outlet holes positioned adjacent to and in flow communication with the second surface of the body supporting layer and aligned with the plurality of channels extending through the body supporting layer; and

an array of springs surrounded by the impermeable material, or one or more layers of foam surrounded by the impermeable material, wherein ambient air flow disperses through the impermeable material and the one or more layers of foam or the array of springs before exiting through the one or more outlet holes of the impermeable material and into the body supporting layer;

a fan operably connected to the inlet hole of the impermeable material by a conduit that extends into the base layer and is directly connected to the impermeable material to provide ambient air flow into the inlet hole of the impermeable material and out of the one or more outlet holes of the impermeable material, wherein the ambient air flow exits only through said plurality of channels and the ambient air flow is solely comfort air to comfort a user.

16. The mattress assembly of claim 15 , wherein the support insert further comprises an array of springs substantially surrounded by the impermeable material, the array of springs configured to support the body supporting layer.

17. The mattress assembly of claim 15 , wherein the support insert further comprises one or more foam layers substantially surrounded by the impermeable material, the one or more foam layers configured to support the body supporting layer.

18. The mattress assembly of claim 15 , wherein the fan is operably connected to the inlet hole of the impermeable material by a conduit positioned a distance away from the mattress assembly.

19. The mattress assembly of claim 15 , wherein the fan is mounted to the base layer.

20. A method of controlling air flow through a support cushion, comprising the steps of:

providing a support cushion having

a body supporting layer formed of a first foam having a first surface and a second surface opposite the first surface,

a base layer formed of a second foam different from said first foam positioned adjacent to the second surface of the body supporting layer, the base layer defining a cavity with a support insert positioned within the cavity, the support insert including a bag defining one or more outlet holes positioned adjacent to and in flow communication with the second surface of the body supporting layer and an inlet hole, and

a fan operably connected to a conduit that extends into the base layer, the conduit being directly connected to the inlet hole of the bag to provide ambient air flow into the inlet hole of the bag and out of the one or more outlet holes of the bag;

supplying an electrical current to the fan such that the fan pushes an amount of ambient air into the inlet hole of the bag; and

moving the amount of ambient air out of the one or more outlet holes of the bag, through the body supporting layer and solely out of the first surface of the body supporting layer as a comfort air which comforts a user.