Partitioned bag spring and flexible filling coupled mattress without hard isolating layer

Abstract

The invention relates to the technical field of mattresses, and particularly discloses a partition bag spring and flexible filling coupling mattress without a hard isolation layer, a spring layer is composed of a plurality of independent bag springs arranged according to rows and columns, and the independent bag springs are arranged in a partition mode according to different specifications; the waist area is located in the middle, the shoulder area is adjacent to the waist area and is in front-back symmetry about the waist area, and the head area is adjacent to the shoulder area and is in front-back symmetry about the waist area; the non-hard isolating layer with certain tensile property wraps the spring layer, the flexible filling layer wraps the non-hard isolating layer and is fixedly connected with the non-hard isolating layer through a hook-and-loop fastener, and the fabric layer wraps the flexible filling layer. When the mattress is used in cooperation with a proper pillow, dynamic spine fitting can be achieved, and when a user lies on the back, the mattress adapts to the S-shaped curve of the spine, so that the cervical vertebra, the thoracic vertebra, the lumbar vertebra, the sacral vertebra and all joints of the tail bone spine are naturally relaxed and free of extrusion stress; when lying on the side, the spine is kept parallel to the mattress and prevented from being twisted, and it is ensured that the spine is always stretched without pressure during sleeping.

Description

Technical Field

[0001] This invention relates to the field of mattress technology, and is particularly applicable to protecting the spine and improving spinal health. Specifically, it refers to a mattress with zoned pocket springs and flexible filling coupled without a rigid insulating layer. Background Technology

[0002] Currently, traditional mattresses on the market have the following drawbacks:

[0003] 1. Rigid isolation layer: Rigid non-woven fabric, cotton felt, coconut fiber board, etc. are commonly used to block the dynamic response of the spring to the weight of the human body.

[0004] 2. Misleading filling layer: Hard materials (palm, jute, hard foam) are mistakenly considered to be "supportive," but in reality, they reduce the fit between the human spine and the mattress, and at the same time block the mechanical transmission of the mattress from top to bottom.

[0005] 3. Failure of spring zone design: The spring stiffness in the shoulder area is too high, and the support in the lumbar area is too sufficient or too high. The overall transition is not smooth and does not conform to the S-shaped curve characteristics of the human spine.

[0006] 4. Hard mattresses are directly associated with spinal diseases such as neck and shoulder pain and lumbar disc herniation.

[0007] Therefore, a mattress with zoned pocket springs and flexible filling coupled without rigid isolation layers has become an urgent problem to be solved. Summary of the Invention

[0008] The purpose of this invention is to provide a mattress with a combination of partitioned pocket springs and flexible filling without a rigid insulating layer, which solves the problem of traditional mattresses violating ergonomic principles due to the design defects of rigid insulating layers and partitioned independent pocket springs, as well as the use of rigid materials in the filling layer.

[0009] To solve the above-mentioned technical problems, the technical solution provided by the present invention is: a zoned pocket spring and flexible filling coupled mattress without a rigid isolation layer, comprising a spring layer, a rigid isolation layer, a flexible filling layer and a fabric layer;

[0010] The spring layer consists of several individually pocketed springs arranged in rows and columns, and the individually pocketed springs are arranged in different sections according to different specifications; the sections of the individually pocketed springs include a shoulder section and a waist section, the waist section is in the middle, the shoulder section is adjacent to the waist section and is symmetrical about the front and back of the waist section, and the head section is adjacent to the shoulder section and is symmetrical about the front and back of the waist section.

[0011] The rigid insulating layer encloses the spring layer, the flexible filling layer encloses the rigid insulating layer and is fixed by hook and loop fasteners, and the fabric layer encloses the flexible filling layer.

[0012] Furthermore, the specifications of the independent pocket springs in the head area are as follows: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10; the length of the head area in the mattress direction is 315-350mm.

[0013] The specifications of the individually pocketed springs in the shoulder area are: wire diameter: 1.6-2.0mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10; the dimension of the shoulder area in the length direction of the mattress is: 315-350mm.

[0014] The specifications of the independent pocket springs in the lumbar region are as follows: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10; the dimension of the lumbar region in the length direction of the mattress is 570-630mm.

[0015] Furthermore, the head area and shoulder area are merged into a single edge area, which is symmetrically arranged about the waist area, forming a three-zone independent pocket spring system.

[0016] The specifications of the individually pocketed springs in the edge area are: wire diameter: 1.6-2.0mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10, and the length of the edge area along the mattress is 630-700mm. The specifications of the individually pocketed springs in the lumbar area are: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10, and the length of the lumbar area along the mattress is 570-630mm.

[0017] Furthermore, the upper and lower sides of the spring layer are provided with metal frames reinforced at the four corners, and the spring layer is surrounded by edge-supporting rigid foam.

[0018] Alternatively, the edge support foam surrounding the spring layer could be replaced with springs extending to all four sides of the mattress, and then reinforced with edge springs.

[0019] Furthermore, the flexible filling layer includes an upper filler, a lower filler, and a surrounding filler. The upper filler is fixed to the top of the non-rigid isolation layer by hook and fastener, the lower filler is fixed to the bottom of the non-rigid isolation layer by hook and fastener, and the surrounding filler surrounds the non-rigid isolation layer, with its upper edge connected to the upper filler and its lower edge connected to the lower filler.

[0020] Furthermore, the top, bottom, and sides of the non-rigid isolation layer are provided with hook and loop fasteners, and the hook and loop fasteners at the top and bottom are connected by a pull cord.

[0021] Furthermore, the non-rigid isolation layer uses a mesh fabric with the following specifications: weight: 350-440g / m², thickness: 1.2-2.5mm, elongation: 20%±5, and breathability: open area ≥50%. The mesh fabric can be used in different specifications of weight, thickness, elongation, and breathability, which will alter the overall performance of the mattress.

[0022] Furthermore, the upper filling material, from the inner layer to the outer layer, consists of corrugated fabric, a first nonwoven fabric, a high-hardness ultra-soft sponge, a low-hardness ultra-soft sponge, silicone mixed fibers, and a second nonwoven fabric.

[0023] Furthermore, the materials of the upper and lower fillers are arranged in the same way from the inner to the outer layer, or the silicone-mixed fibers can be replaced with / added to other materials. Other flexible materials such as natural latex, high-elasticity sponge, and hydrophilic cotton can be used in the upper and lower fillers to replace high-hardness or low-hardness ultra-soft sponges.

[0024] Furthermore, the surrounding filling material, from the inner layer to the outer layer, consists of corrugated fabric, a first nonwoven fabric, foam, silicone mixed fiber, and a second nonwoven fabric.

[0025] The advantages of this invention compared to the prior art are:

[0026] When used with a suitable pillow, this invention can achieve dynamic spinal conformation. When lying on your back: the mattress adapts to the S-curve of the human spine, with the upper back slightly sinking and the lumbar region in a soft support state. At the same time, the cervical, thoracic, lumbar, sacral, and coccygeal vertebrae are naturally relaxed without compression or pressure. When lying on your side: the spine is kept parallel to the mattress, avoiding lateral bending and twisting, and ensuring that the spine is always stretched and pressure-free during sleep.

[0027] The invention features zoned, independently pocketed springs that provide differentiated support. The shoulder area uses thin-diameter springs for flexible and downward support, allowing the upper back to sink slightly when lying on your back and reducing shoulder resistance when lying on your side (reducing the risk of frozen shoulder caused by long-term shoulder contact with a hard bed). The lumbar area uses thick-diameter springs for strong and resilient support, conforming to and maintaining the physiological curvature of the human spine.

[0028] This invention optimizes the support structure, guiding a natural transition to a non-crossing posture when lying on one's side, avoiding asymmetrical load on the spine, and reducing spinal torsion caused by crossing the legs when lying on one's side.

[0029] The partitioned pocket spring without rigid isolation layer and the flexible filling coupling design of this invention reduce the thickness of the filling layer and replace redundant materials with scientific support. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of a mattress with a partitioned pocket spring and flexible filling coupled without a rigid insulating layer, according to the present invention. Figure 1 .

[0031] Figure 2 This is a schematic diagram of the structure of a mattress with a partitioned pocket spring and flexible filling coupled without a rigid insulating layer, according to the present invention. Figure 2 .

[0032] Figure 3 This is a schematic diagram of the partitioning of the spring layer.

[0033] Figure 4 This is a schematic diagram of the connection structure of an independently pocketed spring, without a rigid insulating layer and with hook and loop fasteners.

[0034] Figure 5 It is a cross-sectional view of an individually pocketed spring, without a rigid insulating layer, and with a hook and loop fastener connection.

[0035] As shown in the figure: 1. Spring layer, 2. Non-rigid isolation layer, 3. Flexible filling layer, 4. Fabric layer, 5. Head area, 6. Shoulder area, 7. Waist area, 8. Individually pocketed springs, 9. Edge-supporting rigid foam, 10. Hook and loop fasteners, 11. Drawstring, 12. Corrugated fabric, 13. First nonwoven fabric, 14. High-hardness ultra-soft sponge, 15. Low-hardness ultra-soft sponge, 16. Silicone-blended fiber, 17. Second nonwoven fabric, 18. Foam. Detailed Implementation

[0036] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer", "vertical", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0037] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] The following is a detailed description of a zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to the present invention, with reference to the accompanying drawings.

[0039] Combined with appendix Figure 1-5 The specific implementation process of the present invention, a zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer, is as follows:

[0040] A modular pocket spring and flexible filling mattress without a rigid insulating layer includes a spring layer 1, a rigid insulating layer 2, a flexible filling layer 3, and a fabric layer 4. The rigid insulating layer 2 encloses the spring layer 1, the flexible filling layer 3 encloses the rigid insulating layer 2 and is fixed by hook and loop fasteners 10, and the fabric layer 4 encloses the flexible filling layer 3, forming a multi-layer structure. The layers are coupled to each other, providing the human body with a natural relaxation of the spine without compression or pressure between the vertebrae. At the same time, it naturally corrects poor sleeping postures caused by the mattress (such as spinal twisting caused by sleeping on one's side with legs crossed), thereby repairing fatigue and damage to the spine caused by poor work and life postures, and protecting and improving spinal health.

[0041] Spring layer 1 consists of several individually pocketed springs 8 arranged in rows and columns, and these pocketed springs 8 are arranged in different zones according to their specifications. These zones include a head zone 5, a shoulder zone 6, and a waist zone 7. The waist zone 7 is located in the middle, the shoulder zone 6 is adjacent to the waist zone 7 and symmetrically positioned front-to-back about the waist zone 7, and the head zone 5 is adjacent to the shoulder zone 6 and symmetrically positioned front-to-back about the waist zone 7. This zoned arrangement can provide targeted support according to the weight and pressure distribution of different parts of the body, better conforming to the curve of the human spine.

[0042] The specifications of the individually pocketed springs 8 in the head area 5 are as follows: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10. This specification of spring provides adequate support for the head and relieves head pressure.

[0043] The specifications of the individually pocketed springs 8 in the shoulder area 6 are as follows: wire diameter: 1.6-2.0mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10. The relatively fine wire diameter and the number of coils make the springs in the shoulder area 6 softer, better adapting to the characteristics of the shoulder and back, and reducing shoulder pressure.

[0044] The specifications of the individually pocketed springs 8 in the lumbar region 7 are as follows: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10. Further optimizations have been made based on ergonomic requirements to provide appropriate support and maintain the natural physiological curve of the spine.

[0045] The top and bottom sides of spring layer 1 are reinforced with metal frames at the four corners to enhance the stability of spring layer 1 and prevent the springs from shifting or deforming during mattress transportation and use. Spring layer 1 is surrounded by edge-supporting rigid foam 9, which provides a smooth transition between the mattress spring area and the mattress edge, while also increasing edge support and providing a soft and comfortable feel when sitting on the edge of the mattress.

[0046] The rigid isolation layer 2 encloses the spring layer 1, which serves to isolate the spring from the flexible filling layer 3, preventing the spring from directly contacting the flexible filling layer 3 and causing penetration and wear. It also reduces the noise generated when the spring moves.

[0047] The mattress without a rigid insulating layer 2 uses a mesh fabric with the following specifications: weight 350-440g / m², thickness 1.2-2.5mm, elongation 20%±5, and breathability: open area ≥50%. The mesh fabric has good flexibility and breathability, ensuring air circulation while isolating the spring layer 1 from the flexible filling layer 3. This effectively removes moisture and heat generated during sleep, maintaining a dry and comfortable sleeping environment. Simultaneously, its moderate elongation can accommodate the deformation of the spring layer 1 without restricting the normal operation of the springs. The mesh fabric can also be available in different weights, thicknesses, elongations, and breathability specifications, which will alter the overall performance of the mattress.

[0048] The top, bottom, and sides of the non-rigid isolation layer 2 are equipped with hook and loop fasteners 10, and the hook and loop fasteners 10 at the top and bottom are connected by a pull cord 11. The connection between the hook and loop fasteners 10 and the flexible filling layer 3 uses the hook side of Velcro, which can be well bonded to the corrugated fabric 12 of the flexible filling layer 3, increasing the connection and fixing effect while avoiding the use of glue.

[0049] This design makes the connection between the rigid insulating layer 2 and the flexible filling layer 3 more secure, avoiding the use of glue to affect the sleeping experience and premature aging that would affect the lifespan of the mattress.

[0050] The flexible filler layer 3 encloses the non-rigid isolation layer 2 and includes an upper filler, a lower filler, and surrounding fillers.

[0051] The upper filler is connected and fixed to the top of the non-rigid isolation layer 2 by hook and fastener 10, and the lower filler is connected and fixed to the bottom of the non-rigid isolation layer 2 by hook and fastener 10. The filler surrounds the non-rigid isolation layer 2, with its upper edge connected to the upper filler and its lower edge connected to the lower filler, forming a complete wrapping structure.

[0052] The upper filling, from the innermost layer to the outermost layer, consists of corrugated fabric 12, a first non-woven fabric 13, a high-firm ultra-soft sponge 14, a low-firm ultra-soft sponge 15, silicone-blended fibers 16 (or replacing / adding other materials to silicone-blended fibers 16), and a second non-woven fabric 17. This multi-layered structure design fully utilizes the advantages of each layer of materials. The corrugated fabric 12 can be securely connected to the hook and loop fasteners 10 while maintaining the mattress's breathability. The combination of high-firm ultra-soft sponge 14 and low-firm ultra-soft sponge 15 provides appropriate support and cushioning, meeting the support and comfort needs of different parts of the body. The silicone-blended fibers 16 have excellent breathability, moisture wicking, and durable support performance, and also have antibacterial and anti-mite functions, improving the mattress's hygiene. Both the first non-woven fabric 13 and the second non-woven fabric 17 are made of ultra-soft, high-density, breathable non-woven fabric, further enhancing the breathability of the filling and maintaining a fresh sleeping environment.

[0053] The upper and lower filler materials are arranged in the same way from the inner to the outer layer, or the silicone-fiber mixture 16 can be replaced / added with other materials. This design can be flexibly adjusted according to different usage requirements and cost considerations to meet the diverse needs of the market.

[0054] The upper and lower fillings create a dual-sided design for the mattress. Depending on the needs, different materials can be used for some layers of the upper and lower fillings. For example, to adapt to the transition between winter and summer use, silk / raw cotton can be used instead of silicone-blended fiber 16 or a combination thereof in the upper filling, while wool / cashmere / camel hair can be used instead of silicone-blended fiber 16 or a combination thereof in the lower filling. Other flexible materials such as natural latex, high-elasticity sponge, and hydrophilic cotton can also be used in the filling layers. The most important factor of the dual-sided design is that it provides the necessary elasticity (support) recovery period for the mattress filling materials, ensuring effective support and preventing localized sagging while significantly increasing the mattress's lifespan.

[0055] The surrounding filling, from the innermost layer to the outermost layer, consists of corrugated fabric 12, first non-woven fabric 13, foam 18, silicone-blended fiber 16, and second non-woven fabric 17. This surrounding filling design enhances the softness and comfort of the mattress edges, provides some protection, and prevents the mattress edges from making hard contact with the body.

[0056] In one embodiment of the invention, the four vertical surfaces of the mattress edge are bonded to a rigid foam frame with hot melt adhesive, thus eliminating the need for corrugated fabric in this connection method.

[0057] In another embodiment of the invention, the fabric, silicone-blended fiber 16, and ultra-soft, breathable non-woven fabric are quilted together and then bonded to the mesh fabric without a rigid insulating layer 2, the high-hardness ultra-soft sponge 14, and the low-hardness ultra-soft sponge 15, which encase the individually pocketed springs 8, using a conventional spray adhesive method. Mattresses made using this process have slightly less effective spinal health protection, but represent a significant improvement over mattresses made using traditional methods.

[0058] Fabric layer 4 encases the flexible filling layer 3 and is made of high-quality fabric material, offering excellent touch and breathability to provide a comfortable sleeping surface. Furthermore, fabric layer 4 can be treated with antibacterial, anti-mite, and waterproof agents as needed, further improving the mattress's hygiene and lifespan.

[0059] The present invention and its embodiments are described above. This description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if a person skilled in the art is inspired by this and, without departing from the purpose of the present invention, designs structures and embodiments similar to this technical solution without inventiveness, they shall fall within the scope of protection of the present invention.

Claims

1. A mattress with zoned pocket springs and flexible filling coupled together without a rigid insulating layer, characterized in that: It includes a spring layer (1), a non-rigid isolation layer (2), a flexible filling layer (3), and a fabric layer (4); The spring layer (1) is composed of several independent pocket springs (8) arranged in rows and columns, and the independent pocket springs (8) are arranged in different sections according to different specifications; the sections of the independent pocket springs (8) include a shoulder section (6) and a waist section (7), the waist section (7) is in the middle, the shoulder section (6) is adjacent to the waist section (7) and is symmetrically arranged about the front and back of the waist section (7), and the head section (5) is adjacent to the shoulder section (6) and is symmetrically arranged about the front and back of the waist section (7); The non-rigid isolation layer (2) encloses the spring layer (1), the flexible filling layer (3) encloses the non-rigid isolation layer (2) and is fixed by hook and loop fastener (10), and the fabric layer (4) encloses the flexible filling layer (3).

2. The five-zone pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 1, characterized in that: The specifications of the independent pocket springs (8) in the head area (5) are: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10; the dimensions of the head area (5) in the length direction of the mattress are: 315-350mm. The specifications of the independent pocket springs (8) in the shoulder area (6) are: wire diameter: 1.6-2.0mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10; the dimensions of the shoulder area (6) in the length direction of the mattress are: 315-350mm. The specifications of the independent pocket springs (8) in the lumbar region (7) are as follows: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10; the dimensions of the lumbar region (7) in the length direction of the mattress are: 570-630mm.

3. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 1, characterized in that: The head area (5) and the shoulder area (6) are merged into an edge area, which is symmetrically arranged about the waist area (7) to form a three-zone independent pocket spring system. The specifications of the independent pocket springs (8) in the edge area are: wire diameter: 1.6-2.0mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10, and the length of the edge area in the mattress direction is 630-700mm. The specifications of the independent pocket springs (8) in the lumbar area (7) are: wire diameter: 1.8-2.2mm, diameter: 35-60mm, height: 100-200mm, number of coils: 5-10, and the length of the lumbar area (7) in the mattress direction is 570-630mm.

4. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 2 or 3, characterized in that: The spring layer (1) is provided with metal frames reinforced at the four corners on both the upper and lower sides, and the spring layer (1) is provided with edge support rigid foam (9) around it.

5. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 4, characterized in that: The flexible filling layer (3) includes an upper filling material, a lower filling material, and a surrounding filling material. The upper filling material is connected and fixed to the top of the non-rigid isolation layer (2) by hook and fastener (10). The lower filling material is connected and fixed to the bottom of the non-rigid isolation layer (2) by hook and fastener (10). The surrounding filling material surrounds the non-rigid isolation layer (2), and its upper edge is connected to the upper filling material and its lower edge is connected to the lower filling material.

6. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 5, characterized in that: The top, bottom and sides of the non-rigid isolation layer (2) are provided with hook and loop fasteners (10), and the hook and loop fasteners (10) at the top and bottom are connected by a pull rope (11).

7. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 6, characterized in that: The non-rigid isolation layer (2) is made of mesh fabric with the following specifications: weight: 350-440g / m², thickness: 1.2-2.5mm, elongation: 20%±5, and breathability: open area ≥50%.

8. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 7, characterized in that: The upper filling material consists of, from the inner layer to the outer layer, corrugated fabric (12), first nonwoven fabric (13), high-hardness ultra-soft sponge (14), low-hardness ultra-soft sponge (15), silicone mixed fiber (16), and second nonwoven fabric (17).

9. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 8, characterized in that: The materials of the upper and lower fillers are arranged in the same way from the inner to the outer layer, or the silicone mixed fiber (16) can be replaced with / added with other materials.

10. A zoned pocket spring and flexible filling coupled mattress without a rigid insulating layer according to claim 9, characterized in that: The surrounding filling materials, from the inner layer to the outer layer, are corrugated fabric (12), first nonwoven fabric (13), foam (18), silicone mixed fiber (16), and second nonwoven fabric (17).

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