Honeycomb fabric core layer and mattress

Abstract

The honeycomb fabric core layer comprises a corrugated supporting layer, the corrugated supporting layer is provided with a plurality of supporting parts which are adjacently connected, every two adjacent supporting parts are provided with a wave crest arranged to a high point and a wave trough arranged to a low point on a plane, and a honeycomb space is formed between every two wave crests or two wave troughs; the leveling layer is connected to the two sides of the corrugated supporting layer; wherein the corrugated supporting layer and the leveling layers are each of a woven structure formed by weaving a plurality of warps and wefts, one leveling layer is connected with all the wave crests, the other leveling layer is connected with all the wave troughs to limit the distance between every two adjacent wave crests or the distance between every two adjacent wave troughs, and the corrugated supporting layer is shaped by combining the corrugated supporting layer with the leveling layers. And meanwhile, the leveling layers are arranged on the two sides of the corrugated supporting layer to serve as contact surfaces, so that the sharpness caused by single contact between wave crests and wave troughs is reduced, the comfort is improved, the loading force can be shared, and the integrity is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mattress, in particular to a honeycomb fabric core layer and mattress. BACKGROUND

[0002] The core layer of the common mattress is mostly whole latex or memory foam material, such core layer has certain comfort, but the air permeability is relatively poor. CONTENT

[0003] In order to improve the air permeability of the mattress, the first purpose of the present application provides a honeycomb fabric core layer.

[0004] The honeycomb fabric core layer provided by the present application adopts the following technical scheme:

[0005] A honeycomb fabric core layer comprises:

[0006] A corrugated support layer has a plurality of adjacent support portions, adjacent two support portions have a wave crest placed at a high point and a wave trough placed at a low point on a plane, and a honeycomb space is formed between two wave crests or two wave troughs; and

[0007] A leveling layer is connected to both sides of the corrugated support layer.

[0008] The corrugated support layer and the leveling layer are both woven structures woven by a plurality of warp and weft, one leveling layer connects all the wave crests, and the other leveling layer connects all the wave troughs to limit the distance between adjacent two wave crests or adjacent two wave troughs.

[0009] By adopting the above technical scheme, the corrugated support layer is used as the main part of the elastic support, a plurality of honeycomb spaces provide paths for the flow of air, and the woven structure is arranged to make the entire leveling layer and the corrugated support layer have certain porosity, the porosity is in communication with the honeycomb space to accelerate the flow of air, thereby improving the air permeability of the core layer. Secondly, the leveling layer is connected to both sides of the corrugated support layer, which can first distribute the external force to the core layer, improve the overall strength of the core layer, and reduce the sharp feeling of the human body when contacting the corrugated support layer, thereby improving the comfort when contacting.

[0010] Preferably, the connection between the leveling layer and the corrugated support layer is a hot melt connection to form a hot melt woven part.

[0011] By adopting the above technical scheme, the distance between the adjacent two wave crests and the wave troughs on the corrugated support layer after hot melt connection is better limited, so that the entire corrugated support layer is shaped, and the overall performance and structural strength of the entire core layer are better improved.

[0012] The honeycomb fabric core layer provided by the present application adopts the following technical scheme:

[0013] A honeycomb fabric core layer comprises:

[0014] At least two corrugated support layers, each corrugated support layer having a plurality of adjacent support portions, each adjacent support portion having a wave crest disposed at a highest point and a wave trough disposed at a lowest point on a plane, a honeycomb space being formed between two wave crests or two wave troughs;

[0015] A shaping layer connecting two adjacent corrugated support layers, and

[0016] A leveling layer connecting two outer corrugated support layers;

[0017] Wherein, the corrugated support layers and the leveling layers are each a woven structure woven by a plurality of warp threads and weft threads, the shaping layer is a sandwich layer composed of a plurality of warp threads and / or weft threads, the wave crest and the wave trough of each adjacent corrugated support layer are connected, one leveling layer connects all wave crests of one outer corrugated support layer, and the other leveling layer connects all wave troughs of the other outer corrugated support layer.

[0018] By adopting the above technical solution, when there are a plurality of corrugated support layers, the height of the entire core layer is greater, and the elastic deformation capacity is also improved accordingly. The shaping layer connecting the adjacent two corrugated support layers and the leveling layer are arranged to effectively limit the spacing between the two adjacent wave crests and wave troughs of the corrugated support layer, thereby improving the shaping capacity of the corrugated support layer. In addition, the pores of the weft-woven corrugated support layer and the leveling layer are in communication with the honeycomb space to provide a path for air flow, thereby ensuring air permeability and providing a better elastic support effect.

[0019] The application also provides a honeycomb fabric core layer adopting the following technical solution:

[0020] A honeycomb fabric core layer comprises:

[0021] At least two corrugated support layers, each corrugated support layer having a plurality of adjacent support portions, each adjacent support portion having a wave crest disposed at a highest point and a wave trough disposed at a lowest point on a plane, a honeycomb space being formed between two wave crests or two wave troughs;

[0022] A shaping layer connecting two corrugated support layers, and

[0023] A leveling layer connecting two outer corrugated support layers;

[0024] The corrugated support layer and the leveling layer are both woven structures woven by a plurality of warp and weft, the setting layer is a sandwich composed of a plurality of warp and / or weft, the wave crests and wave troughs of the adjacent two corrugated support layers are staggered, one leveling layer is connected to all the wave crests of one outer corrugated support layer, and the other leveling layer is connected to all the wave troughs of the other outer corrugated support layer.

[0025] By adopting the above technical scheme, when there are a plurality of corrugated support layers, the height of the entire core layer is larger, and the corresponding elastic deformation capacity is also improved, and the wave crests and wave troughs of the adjacent two corrugated support layers are staggered to increase the elastic stiffness to adapt to people who are used to sleeping on a mattress with large stiffness. Secondly, the setting layer connected between the adjacent two corrugated support layers, in combination with the arrangement of the leveling layer, effectively limits the spacing between the adjacent two wave crests and wave troughs of the corrugated support layer, and improves the setting capacity of the corrugated support layer. Thirdly, the honeycomb space of the weft-woven corrugated support layer and the leveling layer is connected in communication, providing a path for air flow, ensuring air permeability while providing better elastic support effect.

[0026] Preferably, the connection between the leveling layer and the corrugated support layer and the connection between the setting layer and the corrugated support layer are hot melt connections to form a hot melt woven part.

[0027] By adopting the above technical scheme, the spacing between the adjacent two wave crests and wave troughs on the corrugated support layer is better limited after hot melt connection, so that the entire corrugated support layer is set, and the overall performance and structural strength of the entire core layer are better improved.

[0028] Preferably, it further comprises:

[0029] A flexible member is used to connect the corrugated support layer and the leveling layer, the flexible member comprises a fixed end and a free end, the fixed end is connected to one of the leveling layers, and the free end passes through a leveling layer and a corrugated support layer and is fixed to another leveling layer.

[0030] By adopting the above technical scheme, the increase of the flexible member further improves the overall performance of the core layer.

[0031] In order to improve the air permeability of the mattress, the second object of the application provides a mattress.

[0032] The mattress provided by the application adopts the following technical scheme:

[0033] A mattress comprises two interconnected comfort units, and each comfort unit comprises a plurality of stacked core layers of the honeycomb fabric.

[0034] By adopting the technical scheme, each comfort unit comprises a plurality of honeycomb fabric core layers stacked and connected, and the woven structure and the structure of the corrugated support layer form a path for air flow, thereby improving the air permeability of the whole mattress.

[0035] Preferably, the first cloth cover has a first cavity for accommodating the comfort unit, and a surrounding enclosure is arranged inwardly at the outer edge of the first cavity, and a mesh cloth for closing the first cavity is connected to the surrounding enclosure.

[0036] By adopting the technical scheme, the two first cloth covers accommodate the comfort unit and improve the integrity, and the zipper connection can quickly realize disassembly and assembly. The surrounding enclosure can reduce the possibility of the comfort unit being separated after being accommodated in the first cavity, and the mesh cloth is used to close the first cavity, thereby ensuring good air flow and air permeability.

[0037] The application also provides a mattress adopting the following technical scheme:

[0038] A mattress comprises

[0039] A comfort unit comprises a plurality of stacked and connected honeycomb fabric core layers, and

[0040] An elastic unit is connected to the comfort unit, and the elastic unit comprises a plurality of stacked and connected corrugated support layers.

[0041] By adopting the technical scheme, the comfort unit provides a contact unit for human sleep, reduces the sharp feeling during contact, and the elastic unit improves the elastic support capacity of the whole mattress. Each comfort unit and elastic unit comprises a plurality of stacked and connected honeycomb fabric core layers, and the woven structure and the structure of the corrugated support layer form a path for air flow, thereby improving the air permeability of the whole mattress.

[0042] Preferably, the first cloth cover has a first cavity for accommodating the comfort unit, and the second cloth cover has a second cavity for accommodating the elastic unit, and a surrounding enclosure is arranged inwardly at the outer edge of the first cavity and the second cavity, and a mesh cloth for closing the first cavity is connected to the surrounding enclosure. The first cloth cover and the second cloth cover are connected by a zipper.

[0043] By adopting the technical scheme, the first cloth cover and the second cloth cover correspondingly accommodate the comfort unit and the elastic unit to improve the integrity, and the connection by the zipper can realize the disassembly and assembly more quickly. The setting of the enclosure can reduce the possibility of disengagement after the comfort unit and the elastic unit are accommodated into the first cavity and the second cavity, and the mesh cloth is used to seal the first cavity and the second cavity, and good air flow is ensured to ensure the air permeability.

[0044] In summary, the present application includes at least one of the following beneficial technical effects:

[0045] 1. The corrugated support layer is shaped by the corrugated support layer combined with the leveling layer, the leveling layer is arranged on both sides of the corrugated support layer as a contact surface to reduce the sharp feeling caused by single contact of the wave crest and the wave trough, improve the comfort, and can share the load to improve the integrity;

[0046] 2. The comfort unit and the elastic unit are accommodated by the cloth cover, and the connection between the two cloth covers is realized by the zipper, and the combination adjustment can be adaptively made according to the requirements of different people for the rigidity of the mattress. BRIEF DESCRIPTION OF DRAWINGS

[0047] Figure 1 The structure diagram of the honeycomb fabric core layer in the first embodiment;

[0048] Figure 2 The structure diagram of the corrugated support layer in the first embodiment;

[0049] Figure 3 The cross-sectional view of the honeycomb fabric core layer in the first embodiment;

[0050] Figure 4 The connection diagram of the leveling layer and the corrugated support layer in the first embodiment;

[0051] Figure 5 The connection diagram of the elastic element, the leveling layer and the corrugated support layer in the first embodiment;

[0052] Figure 6 The structure diagram of the honeycomb fabric core layer in the second embodiment;

[0053] Figure 7 The cross-sectional view of the honeycomb fabric core layer in the second embodiment;

[0054] Figure 8 The connection diagram of the shaping layer and the corrugated support layer in the second embodiment;

[0055] Figure 9 The cross-sectional view of the honeycomb fabric core layer in the third embodiment;

[0056] Figure 10A schematic view of the structure of the mattress in Example Four;

[0057] Figure 11 A schematic view of the first cloth cover in Example Four when unfolded;

[0058] Figure 12 A schematic view of the structure of the comfort unit in Example Four;

[0059] Figure 13 A schematic view of the connection of the comfort unit and the elastic unit in Example Five.

[0060] BRIEF DESCRIPTION OF DRAWINGS 1, corrugated support layer; 11, support part; 111, wave crest; 112, wave trough; 12, honeycomb space; 2, leveling layer; 3, elastic member; 31, fixed end; 32, free end; 4, hot melt woven part; 5, shaping layer; 10, first cloth cover; 101, enclosure; 102, mesh cloth; 20, comfort unit; 30, elastic unit. DETAILED DESCRIPTION

[0061] The application will be further described below in conjunction with the drawings.

[0062] It should be noted that when an element is referred to as being "on" another element, it can be directly on the other element or intervening elements can also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements can also be present. The terms "vertical", "horizontal", "left", "right" and similar expressions as used herein are for illustration purposes only and are not intended to limit the embodiments.

[0063] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description of the application herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Example One

[0064] Figure 1 A structure of a honeycomb fabric core layer is shown, which includes a corrugated support layer 1 and leveling layers 2 connected on both sides of the corrugated support layer 1, the leveling layers 2 improving the flatness of the outer sides of the entire core layer.

[0065] In combination Figure 2, the corrugated support layer 1 comprises a plurality of support parts 11 connected in sequence, and adjacent two support parts 11 have a wave crest 111 placed at a highest point and a wave trough 112 placed at a lowest point on a plane, and a honeycomb space 12 is formed between the two wave crests 111 or the two wave troughs 112. In the embodiment, the cross-sectional shape of the corrugated support layer 1 presents a regular sinusoidal wave shape.

[0066] Referring to Figure 3 , the two leveling layers 2 correspond to connect a plurality of wave crests 111 and a plurality of wave troughs 112 on the same plane respectively to limit the spacing L between the two adjacent wave crests 111 or the two adjacent wave troughs 112, and the leveling layer 2 improves the integrity of the core layer after connecting the plurality of wave crests 111 and the plurality of wave troughs 112.

[0067] Referring to Figure 4 , the leveling layer 2 and the corrugated support layer 1 are both woven structures woven by warp and weft, and the warp and weft are both fiber lines, and the connection position of the leveling layer 2 and the corrugated support layer 1, i.e. the position where the leveling layer 2 connects with the plurality of wave crests 111 and the plurality of wave troughs 112, is a hot melt connection to form a hot melt woven part 4, which can further improve the shaping effect of the corrugated support layer 1.

[0068] Combined with Figure 1 and Figure 5 , the honeycomb fabric core layer further comprises a plurality of elastic members 3, in the embodiment, the elastic member 3 is an elastic rope, including a fixed end 31 and two free ends 32, the two free ends 32 are sewn through one of the leveling layers 2 and the corrugated support layer 1 by hand or machine, and the fixed end 31 is connected to the end face of one of the outer leveling layers 2, and the two free ends 32 are connected and abut on the other outer leveling layer 2, thereby further improving the integrity of the core layer through the elastic member 3.

[0069] In the embodiment, the leveling layer 2 and the corrugated support layer 1 have a plurality of pores on the surface due to the structural characteristics brought by the woven structure, the pores are communicated with the honeycomb space 12 to provide a path for air flow, so that the entire core layer has good air permeability. Embodiment two

[0070] Referring to Figure 6 and Figure 7 , a structure of a honeycomb fabric core layer, which is different from the first embodiment, comprises at least two corrugated support layers 1 and a shaping layer 5 connected between the adjacent two corrugated support layers 1. The wave crests 111 and the wave troughs 112 of the adjacent two corrugated support layers 1 are opposite and connected with the shaping layer 5.

[0071] Combined with Figure 8The shaping layer 5 is arranged between the adjacent two corrugated support layers 1, and is a sandwich layer composed of a plurality of warp threads and / or weft threads. In this embodiment, the shaping layer 5 is composed of a plurality of weft threads arranged at intervals, and the junctions of the weft threads and the wave crests 111 and the wave troughs 112 are also connected by hot melting to form the hot melting woven part 4.

[0072] Compared with the core layer in Embodiment One, the core layer in this embodiment has higher elastic stiffness, thereby having better weight effect. Embodiment Three

[0073] With reference to Figure 9 A structure of a honeycomb fabric core layer, which is different from that of Embodiment Two in that the wave crests 111 and the wave troughs 112 of the adjacent two corrugated support layers 1 are arranged in a staggered manner. In this combination, the core layer has greater elastic stiffness than the core layer in Embodiment Two. Embodiment Four

[0074] With reference to Figure 10 to Figure 12 A mattress, which comprises two comfort units 20 connected to each other, and each comfort unit 20 comprises a plurality of honeycomb fabric core layers according to any one of Embodiments One to Three connected in a stacked manner. In this embodiment, the honeycomb fabric core layers according to Embodiment Two are taken as an example, and the leveling layers 2 of the adjacent two core layers are in contact with each other.

[0075] The mattress of this embodiment further comprises two first cloth covers 10, and each first cloth cover 10 has a first cavity for accommodating the comfort unit 20. The first cavity is provided with an annular enclosure 101 inwardly extending at the outer edge, which is used to reduce the possibility of the comfort unit 20 coming off the first cavity. The enclosure 101 is further connected with a mesh cloth 102 by sewing, and the mesh cloth 102 has apertures to provide a path for air flow, and at the same time, the mesh cloth 102 closes the opening of the first cavity to limit the comfort unit 20 from coming off the first cavity. At the same time, the two enclosures 101 are connected by a zipper, thereby realizing the detachable connection of the two first cloth covers 10. Embodiment Five

[0076] With reference to Figure 13 A mattress, which is different from Embodiment Four in that it comprises a comfort module and an elastic module connected to each other, and the elastic module comprises the corrugated support layers 1 according to any one of Embodiments One to Three connected in a stacked manner, and the wave crests 111 and the wave troughs 112 of the adjacent two corrugated support layers 1 are connected.

[0077] Meanwhile, the mattress in the embodiment further comprises a second cloth cover, the second cloth cover has a second accommodating cavity, the second accommodating cavity is used for accommodating the elastic unit 30, the second cloth cover also has the enclosing 101 and the mesh cloth 102 of the first cloth cover 10 for limiting the possibility of the elastic module escaping from the second accommodating cavity, and the first cloth cover 10 and the second cloth cover are also connected by using a zipper. Compared with the mattress in the fourth embodiment, the mattress in the embodiment has higher elasticity.

[0078] The above are preferred embodiments of the application, and do not limit the protection scope of the application, so: all equivalent changes made according to the structure, shape, principle of the application should be covered within the protection scope of the application.

Claims

1. A honeycomb fabric core layer, characterized by, It comprises: a corrugated support layer (1) having a plurality of adjacent support sections (11), each adjacent support section (11) having a wave crest (111) at a highest point and a wave trough (112) at a lowest point on a plane, and a honeycomb space (12) formed between two wave crests (111) or two wave troughs (112); and a leveling layer (2) connected to both sides of the corrugated support layer (1); wherein the corrugated support layer (1) and the leveling layer (2) are both woven structures woven by a plurality of warp and weft threads, one leveling layer (2) is connected to all wave crests (111), and the other leveling layer (2) is connected to all wave troughs (112) to limit the spacing between adjacent two wave crests (111) or adjacent two wave troughs (112).

2. A honeycomb core according to claim 1, wherein, It also comprises: a flexible member (3) for connecting the corrugated support layer (1) and the leveling layer (2), the flexible member (3) comprising a fixed end (31) and a free end (32), the fixed end (31) being connected to one of the leveling layers (2), and the free end (32) passing through a leveling layer (2) and the corrugated support layer (1) and being fixed to the other leveling layer (2).

3. A honeycomb core according to claim 1, wherein, It comprises: the connection between the leveling layer (2) and the corrugated support layer (1) is a hot melt connection to form a hot melt woven part (4).

4. A honeycomb fabric core layer characterized by, It comprises: at least two corrugated support layers (1) having a plurality of adjacent support sections (11), each adjacent support section (11) having a wave crest (111) at a highest point and a wave trough (112) at a lowest point on a plane, and a honeycomb space (12) formed between two wave crests (111) or two wave troughs (112); a shaping layer (5) connected to two adjacent corrugated support layers (1), and a leveling layer (2) connected to the corrugated support layers (1) on both outer sides; wherein the corrugated support layer (1) and the leveling layer (2) are both woven structures woven by a plurality of warp and weft threads, the shaping layer (5) is a sandwich layer composed of a plurality of warp and / or weft threads, the wave crests (111) and the wave troughs (112) in the adjacent two corrugated support layers (1) are connected, one leveling layer (2) is connected to all wave crests (111) on one outer corrugated support layer (1), and the other leveling layer (2) is connected to all wave troughs (112) on the other outer corrugated support layer (1).

5. A honeycomb core according to claim 4, wherein, The connection between the leveling layer (2) and the corrugated support layer (1) and the connection between the shaping layer (5) and the corrugated support layer (1) are hot melt connections to form a hot melt woven part (4).

6. A honeycomb core according to claim 4, wherein, It also comprises: a flexible member (3) for connecting the corrugated support layer (1) and the leveling layer (2), the flexible member (3) comprising a fixed end (31) and a free end (32), the fixed end (31) being connected to one of the leveling layers (2), and the free end (32) passing through a leveling layer (2) and the corrugated support layer (1) and being fixed to the other leveling layer (2).

7. A honeycomb fabric core layer characterized by, It comprises: At least two corrugated support layers (1) having a plurality of adjacent support sections (11), each adjacent support section (11) having a wave crest (111) at a high point and a wave trough (112) at a low point in a plane, and a honeycomb space (12) formed between two wave crests (111) or two wave troughs (112); a shaping layer (5) connecting two adjacent corrugated support layers (1), and a leveling layer (2) connecting the corrugated support layers (1) on both sides. The corrugated support layers (1) and the leveling layers (2) are both woven structures woven by a plurality of warp and weft threads, the shaping layer (5) is a sandwich layer composed of a plurality of warp and / or weft threads, the wave crests (111) and the wave troughs (112) of the adjacent two corrugated support layers (1) are staggered, one leveling layer (2) connects all the wave crests (111) of one corrugated support layer (1) on one side, and the other leveling layer (2) connects all the wave troughs (112) of the other corrugated support layer (1) on the other side.

8. A honeycomb core according to claim 7, wherein, The connection between the leveling layer (2) and the corrugated support layer (1) and the connection between the shaping layer (5) and the corrugated support layer (1) are hot melt connections to form a hot melt woven part (4).

9. A honeycomb core according to claim 7, wherein, Further comprising: a flexible member (3) for connecting the corrugated support layers (1) and the leveling layers (2), the flexible member (3) comprising a fixed end (31) and a free end (32), the fixed end (31) being connected to one of the leveling layers (2), and the free end (32) penetrating through one of the leveling layers (2) and the corrugated support layer (1) and being fixed to the other leveling layer (2).

10. A mattress characterized in that, Comprising two interconnected comfort units (20), each comfort unit (20) comprising a plurality of superimposed honeycomb fabric core layers as claimed in claim 1 or 4 or 7.

11. A mattress according to claim 10, wherein, Further comprising two first cloth covers (10), each first cloth cover (10) having a first cavity for accommodating the comfort unit (20), and a surrounding enclosure (101) inwardly extending at the outer edge of the first cavity, and a mesh cloth (102) connected to the surrounding enclosure (101) for closing the first cavity; wherein the two first cloth covers (10) are connected by a zipper.

12. A mattress characterized in that, Comprising a comfort unit (20) comprising a plurality of superimposed honeycomb fabric core layers as claimed in claim 1 or 3 or 4, and an elastic unit (30) connected to the comfort unit (20), the elastic unit (30) comprising a plurality of superimposed corrugated support layers (1) as claimed in claim 1 or 4 or 7.

13. The mattress of claim 12, wherein, Further comprising a first cloth cover (10) and a second cloth cover, the first cloth cover (10) having a first cavity for accommodating the comfort unit (20), and the second cloth cover having a second cavity for accommodating the elastic unit (30), a surrounding enclosure (101) inwardly extending at the outer edge of the first cavity and the second cavity, and a mesh cloth (102) connected to the surrounding enclosure (101) for closing the first cavity; wherein the first cloth cover (10) and the second cloth cover are connected by a zipper.

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