Progressive slow pressure fill layer and mattress

Abstract

The utility model discloses a kind of progressive slow pressure filling layer and mattress, the progressive slow pressure filling layer is sequentially stacked from top to bottom with first sponge layer, second sponge layer and 3D material layer, wherein the hardness of first sponge layer is less than the hardness of second sponge layer, 3D material layer has warp-knitted spacer fabric;Through the hardness gradient design of first sponge layer, second sponge layer, in combination with the structural characteristics of 3D material layer warp-knitted spacer fabric, filling layer can gradually undertake and disperse pressure, realizes progressive slow pressure.This application realizes accurate fitting to human curve and progressive decomposition of pressure by the structural design, provides core filling structure with both comfortable fitting and stable support for mattress product, can realize accurate fitting to human curve, progressive decomposition of pressure and final effective support, effectively improve the comfort in sleep use.

Description

Technical Field

[0001] This utility model relates to the field of furniture technology, and in particular to a progressive pressure-relieving filling layer and mattress. Background Technology

[0002] As living standards improve, people have higher and higher requirements for sleep quality. As a key home furnishing product directly affecting sleep quality, the mattress's ability to balance comfort and support has become a core user need. Traditional mattresses have significant limitations in structural design, typically using only a single type of foam or spring system as the core support structure. This single-material design cannot simultaneously meet the body's multiple needs for mattress conformation, pressure relief, and stable support. If the mattress material is too soft, although it may provide some comfort initially, the lack of sufficient support can lead to an unnatural physiological state of the spine over time, increasing the risk of spinal deformities. If the mattress material is too firm, it cannot effectively conform to the body's curves, causing excessive pressure on certain areas (such as the shoulders and hips), hindering blood circulation, and ultimately affecting sleep comfort and health. To address these issues, some existing mattresses attempt to optimize their design by using multi-layered filling structures or combinations of springs with varying firmness. However, these solutions still have significant drawbacks. The pressure transmission between layers lacks smoothness, resulting in stiff transitions in support and uneven pressure distribution, failing to achieve a proper transition from precise conformation to the body's curves to providing stable support. Other mattresses employ horizontally zoned designs (such as three-, five-, or seven-zone designs), achieving zoned support by altering spring wire diameters. However, these mattresses only meet basic support needs and cannot simultaneously address pressure relief and body wrapping, making it difficult to comprehensively improve the sleep experience. In summary, mattresses currently on the market generally suffer from the technical challenge of simultaneously achieving precise conformation, effective pressure relief, and stable support. Utility Model Content

[0003] The present invention provides a progressive pressure-relieving filling layer and mattress, which aims to solve the problem of uneven transition and poor comfort in existing mattresses from conforming to supporting.

[0004] In a first aspect, the present invention provides a progressive pressure-relieving filling layer, comprising: a first sponge layer, a second sponge layer and a 3D material layer, wherein the first sponge layer, the second sponge layer and the 3D material layer are stacked sequentially from top to bottom, wherein the hardness of the first sponge layer is less than the hardness of the second sponge layer, and the 3D material layer has a warp-knitted spacer fabric.

[0005] Furthermore, the first sponge layer is a soft sponge layer.

[0006] Furthermore, the soft sponge layer is a zero-pressure sponge layer, and the surface hardness of the zero-pressure sponge layer is 0-10N; or, the soft sponge layer is an ordinary sponge layer, and the 40% indentation hardness of the ordinary sponge layer is 10-40N.

[0007] Furthermore, the soft sponge layer is made of slow-rebound polyurethane foam, and the density of the slow-rebound polyurethane foam is 40-60 kg / m³. 3 .

[0008] Furthermore, the second sponge layer is a high-elasticity sponge layer, and the 40% indentation hardness of the high-elasticity sponge layer is 40-100N.

[0009] Furthermore, the high-elasticity sponge layer is made of high-resilience polyurethane foam material, and the density of the high-resilience polyurethane foam material is ≥30kg / m³. 3 Rebound rate >60%.

[0010] Furthermore, the warp-knitted spacer fabric is a three-dimensional mesh structure composed of double-sided mesh fabric and intermediate connecting yarns.

[0011] Secondly, this utility model also provides a mattress, comprising: a quilted layer, a filling layer and a support layer stacked sequentially from top to bottom, wherein the filling layer is the aforementioned progressive pressure-relieving filling layer.

[0012] Furthermore, the support layer includes several springs arranged in an array, the elastic stiffness of which gradually increases from top to bottom.

[0013] Furthermore, the spring includes a contact section, a pressure-relieving section, and a support section connected sequentially from top to bottom. The elastic stiffness of the contact section is less than that of the pressure-relieving section, and the elastic stiffness of the pressure-relieving section is less than that of the support section.

[0014] Furthermore, the diameter of the bonding section is 55-65mm and the pitch is 10-20mm; the diameter of the pressure-relieving section is 50-60mm and the pitch is 20-30mm; and the diameter of the support section is 45-55mm and the pitch is 30-50mm.

[0015] Furthermore, the bonding section, the pressure-relieving section, and the support section are connected into one piece by adhesive bonding or ultrasonic welding.

[0016] Furthermore, the quilted layer comprises phase change fabric, moisture-wicking and quick-drying fiber, anti-mite sponge and non-woven fabric stacked sequentially from top to bottom.

[0017] This invention provides a progressive pressure-relieving filling layer and mattress. The progressive pressure-relieving filling layer includes a first sponge layer, a second sponge layer, and a 3D material layer, which are stacked sequentially from top to bottom. The first sponge layer has a lower hardness than the second sponge layer, and the 3D material layer has warp-knitted spacer fabric. This application employs a structural design where the first sponge layer, the second sponge layer, and the 3D material layer with warp-knitted spacer fabric are stacked sequentially from top to bottom. This design allows human body pressure to experience the gradual contact and initial dispersion of the first sponge layer, the rapid response and secondary buffering of the second sponge layer, and the multi-point precise support and impact absorption of the 3D material layer during transmission. This creates a progressive pressure relief channel from gentle contact to stable support, achieving progressive pressure relief. This avoids the pressure concentration and abrupt support issues caused by the single material properties or abrupt transitions between layers in traditional mattresses, ultimately achieving uniform distribution of human body pressure, natural spinal support, and a significant improvement in sleep comfort. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 An exploded view of the progressive pressure-reducing filling layer and mattress according to an embodiment of the present invention is shown. Figure 2 A schematic diagram of the springs in a mattress according to an embodiment of the present invention is shown; Figure label: 1. Quilted layer; 11. Phase change fabric; 12. Moisture-wicking and quick-drying fiber; 13. Anti-mite sponge; 14. Non-woven fabric; 2. Filling layer; 21. First sponge layer; 22. Second sponge layer; 23. 3D material layer; 3. Support layer; 31. Adhesive section; 32. Pressure-relieving section; 33. Support section; 4. Edge protector; 5. Anti-slip bottom. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0021] The directional terms used in this invention, such as "up," "down," "front," "back," "left," "right," "inner," "outer," and "side," are merely for reference to the accompanying drawings. Therefore, the directional terms used are for explanation and understanding of this invention, and not for limiting it. Furthermore, in the accompanying drawings, structures that are similar or identical are indicated by the same reference numerals.

[0022] As people's demands for sleep quality increase, the comfort and support of mattresses become increasingly crucial. However, existing mattresses have significant shortcomings in the transition from conforming to support: traditional mattresses mostly use a single type of foam or spring, which is too soft and easily leads to insufficient support, or too firm and makes it difficult to conform to the body's curves; some improved mattresses have tried multi-layer filling or zoned design, but due to the uneven pressure transmission between layers and the stiff transition of support, they cannot achieve a smooth transition from precise conforming to stable support. This ultimately leads to localized pressure concentration on the body and a poor sleep comfort experience. There is an urgent need for a mattress filling structure that can solve this problem of an uneven transition.

[0023] Therefore, this utility model provides a progressive pressure-relieving filling layer and mattress. By setting a first sponge layer, a second sponge layer and a 3D material layer with warp-knitted interleaved fabric stacked sequentially from top to bottom with a gradient distribution of hardness, it achieves precise fit to the human body curve and progressive decomposition of pressure, solving the problem of uneven transition from fit to support in existing mattresses, and effectively improving the comfort of the mattress.

[0024] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0025] Please see Figures 1-2 This utility model embodiment shows a progressive pressure-relieving filling layer 2, including: a first sponge layer 21, a second sponge layer 22 and a 3D material layer 23, wherein the first sponge layer 21, the second sponge layer 22 and the 3D material layer 23 are stacked sequentially from top to bottom, wherein the hardness of the first sponge layer 21 is less than the hardness of the second sponge layer 22, and the 3D material layer 23 has a warp-knitted spacer fabric.

[0026] Specifically, in the progressive pressure-relieving filling layer 2 of this application, the first sponge layer 21 is a flexible layer with basic fit and initial pressure dispersion functions, the second sponge layer 22 is a flexible layer with secondary cushioning and support functions, both of which are layered structures. The 3D material layer 23 is a three-dimensional layer with support and breathability functions, and its warp-knitted spacer fabric is a fabric with a three-dimensional spacer structure formed by warp knitting of yarns. The three layers are stacked sequentially from top to bottom and closely fitted to form a complete filling structure. The first sponge layer 21 is less hard than the second sponge layer 22, ensuring that the pressure transmission transitions from soft fit to stable support. The warp-knitted spacer fabric of the 3D material layer 23 provides structural support and a breathable foundation for the whole. In particular, existing mattress filling structures often result in a stiff transition from fit to support due to the lack of a hardness gradient or an unreasonable structure of the support layer 3. This embodiment solves the problem of an uneven transition by setting a hardness gradient between the first and second sponge layers 22 and combining it with the warp-knitted spacer fabric of the 3D material layer 23 to construct a progressive structure of fit-cushioning-support. This structural design enables the filling layer 2 to initially conform to the curves of the human body and initially disperse pressure, laying the foundation for further performance optimization, while ensuring the basic support and breathability of the filling layer 2.

[0027] In this embodiment, by setting a first sponge layer 21, a second sponge layer 22, and a 3D material layer 23 stacked sequentially from top to bottom in the progressive pressure-reducing filling layer 2, and specifying that the hardness of the first sponge layer 21 is less than that of the second sponge layer 22 and that the 3D material layer 23 has warp-knitted spacer fabric, the lower hardness of the first sponge layer 21 is utilized to allow it to easily deform upon contact with the human body to conform to the body's curves, initially dispersing pressure on key areas such as the shoulders and hips, and avoiding localized pressure concentration. Then, the higher hardness of the second sponge layer 22 absorbs the pressure transmitted by the first sponge layer 21, providing secondary cushioning and rapid response, preventing excessive sinking of the body, and achieving a smooth transition from initial pressure dispersion to cushioning and support. Then, with the help of the three-dimensional mesh structure of the warp-knitted spacer fabric in the 3D material layer 23, it provides a solid and stable support foundation for the upper sponge layer on the one hand, avoiding sudden changes in support force, and on the other hand, its multi-point support characteristics can further disperse pressure, ensuring a smooth transition of pressure from cushioning support to stable support. The hardness gradient and functional synergistic design of this three-layer structure fundamentally solves the problem of uneven transition from fit to support caused by existing mattresses due to single materials or unreasonable multi-layer design. At the same time, each layer structure improves the user experience from the perspectives of fit, cushioning, and support, ultimately achieving precise fit of the filling layer 2 to the human body curve and gradual decomposition of pressure, providing the core pressure-relieving filling structure for the mattress product, effectively improving comfort and support reliability during sleep.

[0028] In one embodiment, the first sponge layer 21 is a soft sponge layer. Specifically, the soft sponge layer is a layered, slow-rebound flexible layer with a soft and easily deformable structural characteristic. Its function is to closely conform to the curves of the human body through its slow rebound properties, maximizing the dispersion of local pressure. This soft sponge layer maintains a top-to-bottom layered fit with the second sponge layer 22 and the 3D material layer 23, forming the top flexible structure of the filling layer 2. When the human body comes into contact with the soft sponge, it does not immediately rebound and exert a reaction force on the body like an ordinary sponge. Instead, it slowly conforms to the curves of the human body, expanding the support area and evenly distributing the pressure from several key points (such as the shoulders and hips) to the entire contact surface, conforming to every part of the body, making the local pressure approach zero, so that we do not feel pressure, achieving initial fit and pressure dispersion. Specifically, the first sponge layer 21 is set as a soft sponge layer, its slow rebound and fit properties are defined, the problem of poor fit of the first sponge layer 21 is solved, the top layer of the filling layer 2 can fit the curve of the human body more accurately, the pressure distribution effect is further optimized, and the initial fit comfort of the filling layer 2 is improved.

[0029] In this embodiment, the soft sponge layer is a zero-compression sponge layer, and the surface hardness of the zero-compression sponge layer is 0-10N. Alternatively, the soft sponge layer is a regular sponge layer, and the 40% indentation hardness of the regular sponge layer is 10-40N. Specifically, the zero-compression sponge layer is one type of soft sponge layer, which is a layered structure with a soft surface and no obvious reaction force after deformation. The surface hardness of 0-10N refers to the force required to resist deformation when the surface is subjected to external force. The regular sponge layer is another type of soft sponge layer, which is a layered layer with basic softness. The 40% indentation hardness of 10-40N refers to the force required when it is compressed to 40% of its thickness. One of the two sponge layers is selected as the soft sponge layer, and it is laminated and bonded to the second sponge layer 22 and the 3D material layer 23. Specifically, by limiting the hardness range of zero-pressure sponge (0-10N) or ordinary sponge (10-40N), the soft sponge layer is ensured to have sufficient softness for adhesion, while also having basic hardness to avoid excessive sagging, thus solving the problem of unstable performance of the soft sponge layer. By limiting this parameter, the adhesion effect and pressure dispersion ability of the soft sponge layer are more controllable, ensuring that different types of soft sponge layers can achieve the expected gradual pressure relief effect.

[0030] In this embodiment, the soft sponge layer is made of slow-rebound polyurethane foam, and the density of the slow-rebound polyurethane foam is 40-60 kg / m³. 3 Specifically, slow-rebound polyurethane foam is a polymer material with viscoelastic properties. Its porous structure gradually deforms under pressure, and its density is 40-60 kg / m³. 3Ensuring material durability. This material absorbs energy through the slow movement of molecular chains. Specifically, it uses a slow-rebound material with a specific density range, which maintains the softness of the soft layer while preventing collapse and deformation after long-term use through material density control. This makes the slow-rebound characteristics of the soft sponge layer more durable, while ensuring its structural strength and durability, extending the service life of the filling layer 2, and maintaining stable adhesion and pressure dispersion effects.

[0031] In one embodiment, the second sponge layer 22 is a high-elasticity sponge layer, and the 40% indentation hardness of the high-elasticity sponge layer is 40-100N. Specifically, the high-elasticity sponge layer is a layered, highly resilient, flexible layer with the structural characteristic of quickly recovering its original shape after deformation. The 40% indentation hardness of 40-100N refers to the force required when it is compressed to 40% of its thickness, which determines its cushioning and support capabilities. This high-elasticity sponge layer is located between the first sponge layer 21 and the 3D material layer 23, maintaining a layered and close fit, and becoming the intermediate buffer structure of the filling layer 2. The high-elasticity sponge layer has high resilience and high comfort properties, providing rapid response and secondary cushioning. When the user makes movements such as turning over during sleep, the high-elasticity sponge will quickly rebound to its original shape, which, together with the upper soft sponge, will quickly respond and support the human body, reducing the energy consumption of movements when turning over, thereby reducing the number of awakenings during sleep and ensuring sleep quality. Specifically, by setting a medium-hardness, high-elasticity sponge layer, it is ensured that it can withstand the pressure of the first sponge layer 21 and rebound quickly, solving the problems of insufficient buffering and uneven pressure transmission, making the intermediate buffering link of the filling layer 2 more reliable, realizing the smooth transmission of pressure from the first sponge layer 21 to the 3D material layer 23, and avoiding pressure concentration or sudden support changes.

[0032] In this embodiment, the high-elasticity sponge layer is made of high-resilience polyurethane foam material, and the density of the high-resilience polyurethane foam material is ≥30kg / m³. 3 The resilience rate is >60%. Specifically, high-resilience polyurethane foam is the core material of the high-elasticity sponge layer. It is a porous foam structure with high resilience and a density ≥30kg / m³. 3 The material's weight is no less than 30 kg per cubic meter, determining its structural stability. A rebound rate >60% means that more than 60% of the material recovers to its original thickness after deformation, determining its rebound speed. The high-elasticity sponge layer made of this material is layered and bonded to the first sponge layer 21 and the 3D material layer 23, with a porous structure ensuring breathability. Specifically, by limiting the material density and rebound rate parameters, the problems of uncontrollable performance and unstable cushioning and support effects of the high-elasticity sponge layer are solved, making the rebound speed and support capacity of the high-elasticity sponge layer more stable. This ensures that the filling layer 2 can respond quickly during movements such as turning over, reducing energy consumption and extending the service life of the high-elasticity sponge layer.

[0033] In one embodiment, the warp-knitted spacer fabric is a three-dimensional mesh structure composed of double-sided mesh fabric and intermediate connecting yarns. Specifically, the double-sided mesh fabric is the upper and lower surface layers of the warp-knitted spacer fabric, a layered fabric with uniform mesh openings, used for breathability and structural support. The intermediate connecting yarn is a filamentous structure connecting the upper and lower surface layers, used to maintain the three-dimensional spacing of the fabric. Together, they constitute the three-dimensional mesh structure of the warp-knitted spacer fabric, which is a layered three-dimensional layer. This warp-knitted spacer fabric is layered and adhered to the first and second sponge layers 22, forming the core structure of the 3D material layer 23. The warp-knitted spacer fabric has extremely high breathability and a certain degree of elasticity. At the same time, the abundant stretchable elastic yarns provide multi-point precise support for the body, provide a solid foundation for the upper layer, and ensure air circulation. The layered structure of the spacer fabric can effectively absorb the impact force, and rapidly expand the range of pressure dispersion upon contact. Specifically, by defining the specific structure of the warp-knitted spacer fabric, it is clarified that the 3D material layer 23 simultaneously possesses multiple physical properties such as breathability, elasticity, and support, enabling the 3D material layer 23 to provide multi-point support more efficiently, while ensuring air circulation inside the filling layer 2, thereby improving the support stability and breathability comfort of the filling layer 2.

[0034] Reference Figure 1 and Figure 2 This utility model embodiment also provides a mattress, comprising: a quilted layer 1, a filling layer 2, and a support layer 3 stacked sequentially from top to bottom, wherein the filling layer 2 is the progressive pressure-relieving filling layer 2 of the above embodiment. The progressive pressure-relieving filling layer 2 has been described in detail in the above embodiment, and for the sake of brevity, it will not be described again here.

[0035] Specifically, the quilted layer 1 is the top functional layer of the mattress, a multi-layered structure composed of multiple materials, with functions of temperature regulation, moisture absorption, and mite prevention; the filling layer 2 is the middle pressure-relieving layer of the mattress, providing conformability, cushioning, and support; and the support layer 3 is the bottom support layer of the mattress, a structural layer with stable support performance. These three layers are stacked sequentially from top to bottom and closely fitted. The quilted layer 1 is in direct contact with the body, the filling layer 2 bears pressure in the middle, and the support layer 3 provides basic support at the bottom, together forming the complete mattress structure. Specifically, by integrating the specific structure of the filling layer 2 into the complete mattress system, the "softness-firmness mismatch" problem caused by the mismatch in performance between the filling layer 2 and the support layer 3 in traditional mattresses is solved. Through the systematic integration of the three functions, conformability, pressure relief, support, and environmental control functions are organically integrated, achieving optimized and improved overall mattress performance and enhancing overall mattress comfort.

[0036] In one embodiment, the support layer 3 includes a plurality of springs arranged in an array, the elastic stiffness of which gradually increases from top to bottom. Specifically, the plurality of springs arranged in an array are the core supporting components of the support layer 3, and are helical elastic structures. Elastic stiffness refers to the ability of a spring to resist deformation, and the gradual increase in elastic stiffness from top to bottom means that the ability of the spring to resist deformation gradually increases from top to bottom. These springs are evenly arranged to form a spring matrix, which together constitute the main body of the support layer 3, and the elastic stiffness of each spring increases from top to bottom along its own axis, maintaining a stacked correspondence with the quilted layer 1 and the filling layer 2 above. Specifically, existing support layer 3 springs often have no gradient change in elastic stiffness, resulting in a stiff support transition and failing to adapt to the gradual pressure relief of the filling layer 2. This embodiment solves the problem of poor coordination between the support layer 3 and the filling layer 2 and an uneven support transition by setting the elastic stiffness of the springs to increase from top to bottom, so that the support layer 3 can gradually bear the pressure transmitted by the filling layer 2. This design allows the support layer 3 to increase its support as pressure increases, matching the pressure-relieving logic of the filling layer 2, further optimizing the transition effect of the mattress from conforming to supporting, and improving overall support stability.

[0037] Reference Figure 2In this embodiment, the spring includes a fitting section 31, a pressure-relieving section 32, and a support section 33 connected sequentially from top to bottom. The elastic stiffness of the fitting section 31 is less than that of the pressure-relieving section 32, and the elastic stiffness of the pressure-relieving section 32 is less than that of the support section 33. Specifically, the fitting section 31 is the upper section of the spring, with a spiral structure and the lowest elastic stiffness, functioning to conform to the subtle curves of the human body; the pressure-relieving section 32 is the middle section of the spring, with a spiral structure and moderate elastic stiffness, functioning to gently distribute pressure; the support section 33 is the lower section of the spring, with a spiral structure and the highest elastic stiffness, functioning to provide rigid support. The three sections are connected sequentially from top to bottom along the spring axis to form a complete spring structure, and the elastic stiffness of the fitting section 31 < the elastic stiffness of the pressure-relieving section 32 < the elastic stiffness of the support section 33, consistent with the array arrangement of the support layer 3. In this embodiment, the spring has at least eight coils, and its structural parameters gradually change from top to bottom along the central axis: the first few coils, i.e., the contact section 31, have a gradually increasing spring diameter and a smaller pitch, making the spring tip soft and sensitive, easy to deform, and closely conforming to the subtle curves of the human body; the middle few coils, i.e., the pressure-relieving section 32, have a moderate spring diameter and a moderate pitch, beginning to provide stronger support and gently dispersing the pressure from the upper layer; the last few coils, i.e., the support section 33, have a gradually decreasing spring diameter and a larger pitch, providing rigid support and ensuring the overall stability of the mattress and strong support for heavier areas such as the waist and hips. This unique three-section spring structure together constitutes a progressive pressure relief structure of contact-pressure relief-support. Specifically, if existing springs are not designed in segments, their elastic stiffness changes irregularly, making it difficult to accurately adapt to the needs of fitting, pressure relief, and support. This embodiment divides the spring into three segments and defines the stiffness relationship, enabling the spring to bear pressure in stages, solving the problems of unclear functional zoning and poor targeted support and pressure relief of the spring. Through this segmented design, the spring can accurately respond to the pressure needs of different parts of the human body, further refining the progressive support effect of support layer 3 and improving the mattress's adaptability to the human body's curves.

[0038] In specific implementation, the diameter of the bonding section 31 is 55-65mm, and the pitch is 10-20mm; the diameter of the pressure-relieving section 32 is 50-60mm, and the pitch is 20-30mm; the diameter of the support section 33 is 45-55mm, and the pitch is 30-50mm. Specifically, the diameter refers to the outer diameter of the spring coil, and the pitch refers to the distance between two adjacent coils. The bonding section 31 has a diameter of 55-65mm and a pitch of 10-20mm, making its coils thicker and the spacing between them smaller, resulting in a more flexible structure; the pressure-relieving section 32 has a diameter of 50-60mm and a pitch of 20-30mm, making its coil thickness and spacing moderate, resulting in moderate elastic stiffness; the support section 33 has a diameter of 45-55mm and a pitch of 30-50mm, making its coils thinner and the spacing between them larger, resulting in a more stable structure. The diameter and pitch parameters of the three segments jointly determine the elastic stiffness of each segment, ensuring that the stiffness gradient of the fitting segment 31, the pressure-relieving segment 32, and the support segment 33 meets the design requirements, while maintaining the top-to-bottom connection relationship among the three segments. Specifically, if the diameter and pitch parameters of existing segmented springs are not clearly defined, it is easy to cause the stiffness gradient to be unpredictable and the support effect to be unstable. This embodiment ensures that the spring stiffness gradient is achievable and replicable by limiting the specific parameters of each segment, thus solving the problem of unclear spring performance parameters and uncontrollable support effect. By limiting the parameters of decreasing diameter and increasing pitch, the function of each segment of the spring is made more precise, ensuring that the support layer 3 can stably and progressively support the mattress through fitting, pressure-relieving, and support, thus ensuring the consistency of the mattress's support performance.

[0039] Furthermore, the bonding section 31, the pressure-relieving section 32, and the support section 33 are connected into a single unit by adhesive bonding or ultrasonic welding. Specifically, adhesive bonding is a process of connecting the spring segments using an adhesive, while ultrasonic welding is a process of fusing the metal contact surfaces of the springs using ultrasonic vibration. One of these two processes is used for the axial connection of the spring bonding section 31, pressure-relieving section 32, and support section 33, forming an inseparable integral spring structure. After connection, the springs remain arrayed within the support layer 3, working in conjunction with the filling layer 2 and the quilted layer 1. Specifically, if the existing spring segments are not securely connected, they are prone to loosening and displacement during long-term use, leading to a decrease in support performance. By defining two reliable connection methods, the connection of the three spring segments is ensured to be stable, solving the problems of loose spring structure and unstable support performance. This connection process makes the overall spring structure more durable, avoids support breaks due to segment separation, extends the service life of the mattress support layer 3, and maintains a stable, progressive support effect. In one embodiment, the quilted layer 1 comprises, from top to bottom, a phase change fabric 11, a moisture-wicking and quick-drying fiber 12, an anti-mite sponge 13, and a non-woven fabric 14, stacked sequentially. Specifically, the phase change fabric 11 is the top layer material of the quilted layer 1, a knitted fabric containing phase change microcapsules, capable of absorbing or releasing heat; the moisture-wicking and quick-drying fiber 12 is a fiber layer located below the phase change fabric 11, with an irregular groove structure in cross-section, capable of quickly wicking away moisture; the anti-mite sponge 13 is a sponge layer located below the moisture-wicking and quick-drying fiber 12, with the function of inhibiting mite growth; and the non-woven fabric 14 is the bottom layer material of the quilted layer 1, a layered structure formed by interwoven fibers, serving a fixing and insulating function. The four layers are stacked sequentially from top to bottom and quilted together by machine to form a complete quilted layer 1, located on the top layer of the mattress, in direct contact with the human body. Specifically, existing quilted layers 1 often fail to simultaneously achieve temperature regulation, moisture absorption, and mite prevention functions due to their limited material composition or unreasonable combination, resulting in poor comfort of the sleep microenvironment. This embodiment, by limiting the four layers of materials and their layering relationship, makes the quilted layer 1 more functional, solving the problems of limited functionality and poor sleep microenvironment. It should be noted that the phase change fabric 11 in this embodiment is produced by thoroughly mixing phase change microcapsules with spinning polymers (such as melt or solution of polyester or polypropylene) and using traditional spinning processes (melt spinning or solution spinning) to create temperature-controlled fibers containing PCM. These fibers are then spun and knitted to produce knitted fabrics with a weight >300g. Fabrics produced using this process have more durable and long-lasting temperature control. The moisture-wicking fibers in this embodiment employ physical structure modification technology, resulting in irregular cross-sections designed with grooves such as cross-shaped or Y-shaped fibers. The moisture-wicking fibers produced using this process have permanent moisture-wicking properties and are more durable. Through this multi-layered composite material design, the quilted layer 1 can maintain a stable temperature and humidity environment for sleep, inhibit the growth of mites, provide users with a drier and healthier surface contact experience, and further improve the overall comfort of the mattress.

[0040] In other embodiments, the mattress is further provided with edge protectors 4 made of high-density foam or hard cotton to increase edge support and prevent slippage. An anti-slip bottom surface 5 is also provided below the support layer 3.

[0041] In summary, this application achieves progressive pressure relief for the human body throughout the entire process from slight contact to heavy pressure support by combining a soft, high-elasticity, and 3D material filling layer 2 with a 33-section irregularly shaped spring support layer 3 (sensitive fit section 31, stable pressure relief section, and stable support section 33). This effectively avoids pressure concentration and sudden changes in support, solving the problem of excessive firmness in existing mattresses. At the same time, thanks to the zero-pressure upper layer and the small-pitch design of the spring top, it can sensitively respond to the curves of the human body, especially achieving a seamless and precise fit for the shoulders and hips, thus improving the comfort of body contact. Furthermore, the lower 3D material and the large pitch, small diameter structure of the spring bottom ensure strong overall support for the mattress, effectively supporting the lumbar spine and maintaining the natural physiological curve of the spine, thus guaranteeing reliable support. In addition, the high breathability of the 3D material layer 23 combined with the temperature regulation function of the quilted layer 1 of the phase change fabric 11 significantly improves the breathability of the mattress while regulating the temperature of the sleep microenvironment, providing users with a dry and comfortable sleep experience. Ultimately, the mattress performance is comprehensively optimized from multiple dimensions such as pressure relief, fit, support, and temperature and humidity control, significantly improving sleep comfort and user experience.

[0042] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this utility model, and these modifications or substitutions should all be covered within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A progressive pressure-reducing filler layer, characterized in that, include: The first sponge layer, the second sponge layer, and the 3D material layer are stacked sequentially from top to bottom. The hardness of the first sponge layer is less than that of the second sponge layer, and the 3D material layer has a warp-knitted spacer fabric.

2. The progressive pressure-reducing filling layer according to claim 1, characterized in that, The first sponge layer is a soft sponge layer.

3. The progressive pressure-reducing filling layer according to claim 2, characterized in that, The soft sponge layer is a zero-pressure sponge layer, and the surface hardness of the zero-pressure sponge layer is 0-10N; or... The soft sponge layer is a regular sponge layer, and the 40% indentation hardness of the regular sponge layer is 10-40N.

4. The progressive pressure-reducing filling layer according to claim 3, characterized in that, The soft sponge layer is made of slow-rebound polyurethane foam, and the density of the slow-rebound polyurethane foam is 40-60 kg / m³. 3 .

5. The progressive pressure-reducing filling layer according to claim 1, characterized in that, The second sponge layer is a high-elasticity sponge layer, and the 40% indentation hardness of the high-elasticity sponge layer is 40-100N.

6. The progressive pressure-reducing filling layer according to claim 5, characterized in that, The high-elasticity sponge layer is made of high-resilience polyurethane foam material, and the density of the high-resilience polyurethane foam material is ≥30kg / m³. 3 Rebound rate >60%.

7. The progressive pressure-reducing filler layer according to any one of claims 1-6, characterized in that, The warp-knitted spacer fabric is a three-dimensional mesh structure composed of double-sided mesh fabric and intermediate connecting yarns.

8. A mattress, characterized in that, include: The quilted layer, filling layer and support layer are stacked sequentially from top to bottom, wherein the filling layer is the progressive pressure-relieving filling layer as described in any one of claims 1-7.

9. The mattress according to claim 8, characterized in that, The support layer includes several springs arranged in an array, and the elastic stiffness of the springs gradually increases from top to bottom.

10. The mattress according to claim 9, characterized in that, The spring includes a contact section, a pressure-relieving section, and a support section connected sequentially from top to bottom. The elastic stiffness of the contact section is less than that of the pressure-relieving section, and the elastic stiffness of the pressure-relieving section is less than that of the support section.

11. The mattress according to claim 10, characterized in that, The diameter of the bonding section is 55-65mm and the pitch is 10-20mm; the diameter of the pressure-relieving section is 50-60mm and the pitch is 20-30mm; the diameter of the support section is 45-55mm and the pitch is 30-50mm.

12. The mattress according to claim 10, characterized in that, The bonding section, the pressure-relieving section, and the support section are connected into one piece by adhesive bonding or ultrasonic welding.

13. The mattress according to any one of claims 8-12, characterized in that, The quilted layer comprises, from top to bottom, phase change fabric, moisture-wicking and quick-drying fiber, mite-proof sponge and non-woven fabric stacked together.

Images