Mattress supporting layer structure and mattress

Abstract

The utility model belongs to the field of home furnishing, and particularly relates to a mattress supporting layer structure and a mattress. The mattress supporting layer structure comprises a first supporting layer and a second supporting layer, wherein multiple groups of through grooves are formed in the lower surface of the first supporting layer; the through groove is provided with a downward opening end and a closed end with an arch-shaped outline; a shaping groove is formed in the center area of the upper surface of the second supporting layer, and the shaping groove is provided with an inner contour matched with the outer contour of the first supporting layer; the first supporting layer is embedded into the shaping groove, and the shaping groove forms a pressure bearing structure located in the lateral direction of the first supporting layer. According to the scheme, material-saving design is carried out on the first supporting layer from the thickness and the area, meanwhile, the second supporting layer is used for stabilizing the structure of the first supporting layer, and comfortable sleep experience is provided. The first supporting layer in the mattress is modularly designed, so that the production cost is reduced, and the mattress is adaptive to ergonomics.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the field of home, more particularly to a mattress support layer structure and mattress. BACKGROUND

[0002] The main structure of the mattress is usually composed of a comfort layer, a buffer layer and a support layer, wherein the support layer is the core part of the mattress and is responsible for providing support for the human body. In recent years, with the increasing emphasis of consumers on sleep quality, the mattress industry has increasingly high requirements for material performance. High molecular materials have gradually become the mainstream choice of support layer materials due to their good resilience and high durability, and are widely used in various mattress products. However, although high molecular materials perform well in performance, many mattresses made of new or high-quality high molecular materials are difficult to popularize in the market due to the high cost of the materials. SUMMARY

[0003] Therefore, the utility model provides a mattress support layer structure and a corresponding mattress, which reduces the material cost through reasonable structure design and promotes comfortable high-performance mattresses.

[0004] The utility model realizes the following technical scheme:

[0005] A mattress support layer structure comprises:

[0006] A first support layer has a plurality of through grooves on the lower surface; the through grooves have downward opening ends and closed ends with an arc shape;

[0007] A second support layer has a shaped groove on the upper surface of the central area; the shaped groove has an inner contour that is matched with the outer contour of the first support layer;

[0008] The first support layer is embedded in the shaped groove, and the shaped groove constitutes a pressure-bearing structure on the side of the first support layer.

[0009] The present scheme provides a mattress support layer structure, wherein the first support layer is suitable for materials with better performance and higher price cost, such as ETPU material, which is the upper layer of the support layer and has good cushioning performance, making it convenient for users to directly experience the material performance; the second support layer is suitable for materials with relatively low price cost, such as EPP material, which is the lower layer of the support layer and provides better support effect.

[0010] For the first support layer, the scheme is designed to save material in thickness and area, and at the same time to ensure that the sleep experience provided by the first support layer does not decrease due to the saving of material. In terms of thickness design, the scheme reduces the use of the first support layer by opening a through slot at the bottom of the first support layer. However, after opening the through slot, the lower surface of the first support layer forms an arch structure, which will convert the vertical stress into lateral pressure, so a pressure-bearing structure needs to be configured on the side of the first support layer to prevent the first support layer from collapsing. In terms of area design, since the human sleep position is concentrated in the central area of the mattress, the use of first support layer material in the central area of the mattress and second support layer material in the edge area is considered. Accordingly, the scheme further designs the second support layer, while solving the two problems of lateral pressure-bearing structure and material partitioning. Specifically, the upper surface of the second support layer is provided with a shaped slot, and the specification of the first support layer is smaller than that of the second support layer to fit the shaped slot; the first support layer is sunkenly embedded in the shaped slot, and the lateral pressure is shared by the shaped slot to stabilize the structure of the first support layer.

[0011] As a preferred, the upper surface of the first support layer is provided with a plurality of partition grooves; the plurality of partition grooves are staggered with each other and enclose a plurality of independent support blocks.

[0012] The design of the partition groove can first save the material of the first support layer; secondly, the partition groove divides the upper surface of the first support layer into a plurality of support blocks, which will deform to different degrees when a human body lies down, and the partition groove can provide space for the deformation of the support blocks, improve the adaptability of the first support layer to the human body contour, and provide a more comfortable use experience.

[0013] As a preferred, in the horizontal projection direction, the opening positions of the partition grooves and the through slots are staggered with each other.

[0014] The material thickness of the first support layer is reduced at the opening positions of the partition grooves and the through slots; the scheme staggered the opening positions of the partition grooves and the through slots to avoid the local support thickness being too low. Further preferably, the material thickness of the first support layer at any position in the vertical direction is not less than the depth of the partition groove or the through slot, to avoid the situation of insufficient support strength.

[0015] As a preferred, the plurality of through slots are staggered with each other; the through slots form a plurality of multidirectional ventilation parts at the staggered positions.

[0016] The through slots form a grid-shaped multidirectional ventilation structure, so that the mattress has good moisture removal and ventilation performance, and improves the user experience comfort.

[0017] As a preferred, each of the plurality of multidirectional ventilation parts is located below the support block.

[0018] The position of the multi-directional ventilation part accommodates the ventilation channel, so the points providing supporting force are also dispersed. The multi-directional ventilation part is arranged below the supporting block, the pressure of the human body is concentrated through the supporting block and then is evenly distributed to each part of the multi-directional ventilation part, so that the supporting force of each point is kept balanced.

[0019] Preferably, the first supporting layer comprises a plurality of supporting units, each of which comprises one supporting block and one or more multi-directional ventilation parts.

[0020] By adjusting the quantity relationship between the supporting block and the multi-directional ventilation part, supporting units with different supporting force degrees are formed, on the basis of which the mattress can be ergonomically designed to provide different supporting force degrees for different parts of the human body.

[0021] Preferably, a convex massage block is arranged above the supporting block.

[0022] Preferably, the side surface of the first supporting layer is provided with a surrounding edge; the surrounding edge forms a limiting structure for the first supporting layer.

[0023] The surrounding edge can further limit the shaking of the first supporting layer in the shaping groove, and also make the side surfaces of the first supporting layer and the second supporting layer continuously and smoothly connect, and the upper surfaces of the first supporting layer and the second supporting layer fill the gap, so that a better use experience is obtained.

[0024] The utility model also includes a mattress, the mattress contains preceding mattress supporting layer structure.

[0025] Preferably, the first supporting layer comprises a plurality of first supporting modules, each of which comprises an I-shaped supporting area, the I-shaped supporting area comprises a plurality of I-shaped supporting units, each of which comprises one supporting block and a plurality of multi-directional ventilation parts; each of the first supporting modules also comprises a II-shaped supporting area, the II-shaped supporting area comprises a plurality of II-shaped supporting units, each of which comprises one supporting block and one multi-directional ventilation part.

[0026] In actual production, if the overall mold is opened in units of single mattress, the processing difficulty is high and the loss rate is large, therefore, the mattress supporting layer structure is modularly split in the scheme, and the first supporting module is taken as the production unit of the first supporting layer. When the human body is in a lying position, different parts such as head, shoulder, neck, trunk and leg need different supporting force degrees, so the first supporting module is designed in zones, so that the supporting force provided by the first supporting module has gradient difference. The scheme can reduce the processing cost on the one hand, and can realize more abundant mattress supporting zoning through different splicing schemes on the other hand.

[0027] As preferred, a plurality of the shaping grooves are formed on the second support layer, and the shaping grooves are adapted to the profile of the first support module or the profile after the first support module is cut.

[0028] The first support module is cut and spliced to form a complete mattress, and each first support module or cut piece is fixed by an independent shaping groove. The shaping groove plays a role of first partitioning for the support area, and the gradient partition of the first support module plays a role of second partitioning, which is more in line with ergonomics.

[0029] The utility model provides a mattress support layer structure, through layered design and modularization optimization, realize the effect of saving material cost, adaptation ergonomics and promotion comfort. The first support layer is located in the upper layer of mattress structure, is made of high performance, high cost material, its lower surface sets up arch shaped through groove to reduce material, simultaneously forms multidirectional ventilation structure through staggered design, promotes the air permeability, its upper surface sets up the separation groove, divides the first support layer into independent support block, improves the adaptability to human profile. The second support layer is located in the lower layer of mattress structure, is made of low cost material, through setting up shaping groove fixes the first support layer and shares the lateral pressure of arch shaped through groove, prevents the collapse. In addition, the modularization design allows the first support layer to be partitioned and optimized, provides gradient support force according to the needs of different human parts, while reducing processing difficulty and loss rate. The overall structure is fixed by partitioning through shaping groove, combines modularization partition design, further improves ergonomics performance and use experience. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 It is a first perspective view of the first support module.

[0031] Figure 2 It is a second perspective view of the first support module.

[0032] Figure 3 It is a first perspective view of the cooperation of the first support layer and the second support layer.

[0033] Figure 4 It is a second perspective view of the cooperation of the first support layer and the second support layer.

[0034] Figure 5 It is a third perspective view of the first support module.

[0035] Figure 6 It is a third perspective view of the cooperation of the first support layer and the second support layer.

[0036] Figure 7 It is a support unit schematic view.

[0037] LEGEND:

[0038] 1 first support layer, 101 first support module, 102 first block, 103 second block, 110 through slot, 120 support block, 130 massage block, 140 type I support unit, 150 type II support unit, 160 air hole, 170 type I support area, 180 type II support area, 190 separation groove

[0039] 2 second support layer, 210 shaping groove, 211 first shaping groove, 212 second shaping groove, 213 third shaping groove 3 surrounding edge. DETAILED DESCRIPTION

[0040] The utility model will be further described below in conjunction with the drawings and specific embodiments. Those skilled in the art will be able to realize the utility model based on these descriptions. In addition, the embodiments of the utility model involved in the following description are generally only a part of the embodiments of the utility model, not all embodiments. Therefore, based on the embodiments in the utility model, all other embodiments obtained by those skilled in the art without creative labor shall belong to the scope of protection of the utility model.

[0041] Embodiment 1

[0042] The embodiment is a mattress support layer structure.

[0043] With the development of material science, there are many high polymer materials on the market that perform well in resilience, ventilation, support, and silence. However, due to high material costs, they cannot be popularized and applied in the sleep and home field. Therefore, the inventors hope to propose a mattress support layer structure that can reduce material costs while providing users with a good sleep experience.

[0044] Please refer to Figure 3 、 Figure 4 、 Figure 5 The mattress support layer structure includes a second support layer 2 as the lower layer and a first support layer 1 as the upper layer. The second support layer 2 is suitable for materials with lower price costs, and the first support layer 1 is suitable for materials with better performance and higher price costs. In this embodiment, the second support layer 2 is made of EPP material, and the first support layer 1 is made of ETPU material. ETPU material has excellent resilience, strong durability, and can maintain softness and elasticity in low-temperature environments.

[0045] The center area of the upper surface of the second support layer 2 is provided with a shaped groove 210, and the specification size of the second support layer 2 is the specification size of the finished mattress. The specification size of the shaped groove 210 is smaller than that of the second support layer 2. The specification size and the outer contour of the first support layer 1 are adapted to the shaped groove 210, and the lower part of the first support layer 1 is embedded in the shaped groove 210. The shaped groove 210 is a closed groove with four lateral inner walls and forms a surrounding structure for the lower part of the first support layer 1, and the first support layer 1 can be stably clamped in the shaped groove 210. From the material use area, the human sleep position is concentrated in the central area of the mattress, so the first support layer 1 material is used in the central area of the mattress and the second support layer 2 material is used in the edge area in this embodiment, which realizes material saving while ensuring human sleep experience.

[0046] Please refer to Figure 7 , the lower surface of the first support layer 1 is provided with a plurality of through grooves 110, the opening end of the through groove 110 faces downward, and the closed end is arc-shaped. The plurality of through grooves 110 are staggered to form a ventilation network of the first support layer 1, and the intersection of two through grooves 110 forms a multidirectional ventilation part. The through groove 110 forms a plurality of arc-shaped structures on the lower surface of the first support layer 1, and the arc-shaped structure converts the vertical stress into lateral pressure. At this time, the shaped groove 210 acts as a lateral pressure bearing structure to prevent the first support layer 1 from collapsing.

[0047] In some embodiments, the thickness of the first support layer 1 is adapted to the depth of the shaped groove 210, and at this time the first support layer 1 is completely embedded in the shaped groove 210. In another part of the embodiment, the thickness of the first support layer 1 exceeds the depth of the shaped groove 210, and the upper part of the first support layer 1 is exposed outside the second support layer 2. At this time, a surrounding edge 3 is arranged around the upper part of the first support layer 1. Specifically, the surrounding edge 3 is arranged at the four top corners of the first support layer 1. The horizontal projection of the surrounding edge 3 is L-shaped, and the thickness of the surrounding edge 3 is equivalent to the height difference between the first support layer 1 and the second support layer 2, and the width of the surrounding edge 3 is equivalent to the width of the edge of the shaped groove 210. The surrounding edge 3 can further limit the shaking of the first support layer 1 in the shaped groove 210, and can also make the side surfaces of the first support layer 1 and the second support layer 2 continuous and smooth, and the upper surfaces are filled and the gap is eliminated, so that a better use experience is obtained.

[0048] Please refer to Figure 1 、 Figure 2 、 Figure 6The upper surface of the first support layer 1 is provided with multiple sets of partition grooves 190; the multiple sets of partition grooves 190 are staggered with each other and surround to form multiple sets of independent support blocks 120. The design of the partition grooves 190 can first save the material of the first support layer 1, and secondly improve the adaptability of the first support layer 1 to the human body contour. When the human body lies down, the support blocks 120 are pressed and deformed to different degrees, and the partition grooves 190 can provide space for the deformation of the support blocks 120. Further, the upper surface of each support block 120 is provided with a convex massage block 130, which provides a massage touch and improves the user experience.

[0049] The material thickness of the first support layer 1 is reduced at the positions where the partition grooves 190 and the through grooves 110 are provided, so the positions where the partition grooves 190 and the through grooves 110 are provided are staggered with each other in the horizontal projection direction. In the preferred embodiment, the material thickness of the first support layer 1 at any position in the vertical direction is not less than the depth of the partition grooves 190 or the depth of the through grooves 110, so as to avoid the situation of insufficient support strength.

[0050] At the positions of the multi-directional ventilation parts, the support force points are dispersed due to the accommodation of the intersecting through grooves 110. In order to reasonably and uniformly distribute the pressure of the human body, each multi-directional ventilation part is located below the support block 120, so that the pressure of the human body is first concentrated by the support block 120 and then distributed, so that the support forces of the points are kept balanced.

[0051] In the preferred embodiment, the multi-directional ventilation parts are uniformly distributed on the lower surface of the first support layer. By changing the area of the support block 120 and the number matching relationship between the support block 120 and the multi-directional ventilation parts, support units with different support strengths can be formed. Please refer to Figure 7 The type I support unit 140 includes one support block 120 and four multi-directional ventilation parts, the four multi-directional ventilation parts are arranged in a 2x2 square array, the support block 120 is aligned with the center region of the square array; a plurality of type I support units 140 are arranged continuously to form a type I support area 170. The type II support unit 150 includes one support block 120 and one multi-directional ventilation part, the center regions of the support block 120 and the multi-directional ventilation part are aligned; a plurality of type II support units 150 are arranged continuously to form a type II support area 180. The support unit provides a structural basis for further ergonomic design.

[0052] Please refer to Figure 6The bed mattress support layer structure also has a ventilation hole 160. The ventilation hole 160 penetrates the first support layer 1 from top to bottom and further communicates to the upper surface of the second support layer 2. In the preferred embodiment, the ventilation hole 160 is located at the center of the support block 120 of the I-shaped support unit 140. The penetrating ventilation hole 160 is combined with the support layer to form a three-dimensional ventilation network. The ventilation hole 160 is located on the I-shaped support unit 140, which reduces the material while maintaining the support of the structure.

[0053] Embodiment 2

[0054] The bed mattress uses the bed mattress support layer structure in embodiment 1.

[0055] In the bed mattress support layer structure proposed in embodiment 1, the gradient difference of the support force between the I-shaped support unit and the II-shaped support unit can adapt to the differentiated needs of different areas of the human body for support force, so the distribution of the support unit can be designed in the finished bed mattress. In actual production, if the overall mold is opened in units of a single bed mattress, the processing difficulty is high and the loss rate is large, so the bed mattress support layer structure is considered to be modularized and decomposed to reduce the processing difficulty. For convenience of description, the direction from the head of the bed to the tail of the bed will be referred to as the "length direction" of the bed mattress, and the direction perpendicular to the length direction will be referred to as the "width direction" of the bed mattress.

[0056] Please refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 The first support layer 1 is composed of a plurality of first support modules 101. Each first support module 101 has an I-shaped support area 170 composed of I-shaped support units 140, an II-shaped support area 180 composed of II-shaped support units 150, and an I-shaped support area 170 composed of I-shaped support units 140 arranged in sequence in the length direction. The support block 120 in the I-shaped support area 170 has a larger area and better support effect; the support block 120 in the II-shaped support area 180 has a smaller area and is more suitable for the human body contour. The single first support module 101 includes differentiated zones with different support properties, and in actual production, the first support module 101 can be used as a production unit, and the first support module 101 can be assembled and spliced to obtain a bed mattress with more rich structure partitions.

[0057] Please refer to Figure 3 , Figure 4, take a first support module 101, cut along the width direction in the type II support area, obtain the first support module 101 first tile 102 and second tile 103. First tile 102 and second tile 103 both contain type I support area and type II support area, but there are differences in the number distribution of type I support area 170 and type II support area 180. The first support layer 1 is provided with three shaping grooves 210 along the length direction, the size of the first shaping groove 211 is adapted to the first tile 102, the size of the second shaping groove 212 is adapted to a complete first support module 101, and the size of the third shaping groove 213 is adapted to the second tile 103, and the first support module 101 and the two tiles are respectively embedded in the three shaping grooves 210. The mattress first forms three large partitions to support the head and neck, torso and foot of the human body; each partition has multiple different support areas, and the mattress contains seven small partitions in total, which finely adapt to the head, shoulder, back, waist, hip, thigh and calf of the human body.

Claims

1. A mattress support layer structure, characterized by, The bed mattress support layer structure comprises: a first support layer (1) having a plurality of groups of through grooves (110) formed on the lower surface; the through grooves (110) have downward opening ends and closed ends with an arc shape; a second support layer (2) having a plurality of shaped grooves (210) formed on the central area of the upper surface; the shaped grooves (210) have inner contours matching the outer contours of the first support layer (1); the first support layer (1) is embedded in the shaped grooves (210), and the shaped grooves (210) form pressure bearing structures on the lateral sides of the first support layer (1).

2. The mattress support layer structure of claim 1, wherein, The upper surface of the first support layer (1) has a plurality of groups of separation grooves (190); the groups of separation grooves (190) are staggered with each other and form a plurality of groups of independent support blocks (120).

3. The mattress support layer structure of claim 2, wherein, In the horizontal projection direction, the positions where the separation grooves (190) and the through grooves (110) are formed are staggered with each other.

4. The mattress support layer structure of claim 2, wherein, The groups of through grooves (110) are staggered with each other; the staggered positions of the through grooves (110) form a plurality of multidirectional ventilation parts.

5. The mattress support layer structure of claim 4, wherein, Each of the multidirectional ventilation parts is located below the support block (120).

6. The mattress support layer structure of claim 5, wherein, The first support layer (1) comprises a plurality of support units; each of the support units comprises one support block (120) and one or more multidirectional ventilation parts.

7. The mattress support layer structure of claim 1, wherein, The lateral surface of the first support layer (1) is provided with a surrounding edge (3); the surrounding edge (3) forms a limiting structure for the first support layer (1).

8. A mattress characterized by, The bed mattress support layer structure comprises:

9. The bed mattress according to claim 8, wherein the upper surface of the first support layer (1) has a plurality of groups of separation grooves (190); the groups of separation grooves (190) are staggered with each other and form a plurality of groups of independent support blocks (120); the groups of through grooves (110) are staggered with each other; the staggered positions of the through grooves (110) form a plurality of multidirectional ventilation parts; the first support layer (1) comprises a plurality of first support modules (101); each of the first support modules (101) comprises an I-shaped support area (170) comprising a plurality of I-shaped support units (140); each of the I-shaped support units (140) comprises one support block (120) and a plurality of multidirectional ventilation parts; each of the first support modules (101) further comprises a II-shaped support area (180) comprising a plurality of II-shaped support units (150); each of the II-shaped support units (150) comprises one support block (120) and one multidirectional ventilation part.

10. The mattress of claim 9, wherein, The second support layer (2) has a plurality of shaped grooves (210) formed thereon; the shapes of the shaped grooves (210) match the contours of the first support modules (101) or the contours obtained by cutting the first support modules (101).

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