A cushioning insert

Abstract

A kind of pad inner core, including the pad inner core body made of elastic material, multiple springs embedded in the inside of the pad inner core body and multiple air-permeable channels arranged through the thickness direction of the pad inner core body;The air-permeable channel includes the first air-permeable channel located in upper layer and the second air-permeable channel located in lower layer, the aperture of the first air-permeable channel is smaller than the aperture of the second air-permeable channel;The air-permeable channel is located in the spring middle. By setting gradient air-permeable hole structure of small in upper layer and large in lower layer, the reasonable distribution of different aperture, the noise generated in the process of air flow is effectively reduced, and the excessive compression caused by uneven pressure of local material is avoided.Simultaneously, cooperate with the support frame set in bottom, gradient aperture structure design guides the hot and humid airflow along the preset path orderly to the bottom cavity, and is naturally discharged through the outer edge of frame, realizes the quick dehumidification effect of "moisture does not accumulate, inner core is not stuffy".

Description

Technical Field

[0001] This utility model belongs to the field of pad technology, specifically, it relates to a pad inner core. Background Technology

[0002] Mattress pads are a type of assistive device used for human support, cushioning, and enhanced comfort, widely used in various settings including homes, offices, transportation, medical facilities, and outdoor environments. Depending on the area of ​​use and function, mattress pads mainly include the following categories: mattresses, seat cushions, back cushions, and pillows. Finished mattress pads typically consist of a surface fabric layer, a comfort layer with filling underneath, and a support / core layer. The support layer is the core component, providing the main support and determining the pad's firmness and durability. The core layer is generally made of springs combined with filling materials such as high-density foam, memory foam, natural latex, coconut fiber, and palm fiber.

[0003] Current mattress cores still have significant room for improvement. For example, poor breathability leads to moisture buildup, causing material aging, mold growth, or reduced resilience. Furthermore, installing the springs after the filling material is molded results in some springs being exposed on the outside of the core, not fully encased. The mattress cores also lack a clean and simple appearance, posing potential safety risks. Therefore, a new type of mattress core is urgently needed to address these issues. Summary of the Invention

[0004] The purpose of this utility model is to provide a pad inner core, mainly addressing issues such as breathability, prevention of rebound performance attenuation, and avoiding spring exposure on the outer side of the inner core, while also improving the aesthetic appearance of the pad inner core. To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0005] A pad core includes a pad core body made of elastic material, a plurality of springs embedded inside the pad core body, and a plurality of ventilation channels extending through the thickness direction of the pad core body; the ventilation channels include a first ventilation channel located in the upper layer and a second ventilation channel located in the lower layer, wherein the aperture of the first ventilation channel is smaller than the aperture of the second ventilation channel; the ventilation channels are located in the middle of the springs.

[0006] Furthermore, the first ventilated channel has a pore size of 3mm to 15mm and is distributed in the top contact area of ​​the inner core body, serving as an air intake control layer to slow down the release of humid and hot airflow and reduce airflow noise; the second ventilated channel has a pore size of 20mm to 70mm and is located in the middle and lower layers of the inner core body, serving as a high-efficiency flow guiding layer to accelerate air circulation and moisture discharge; the first ventilated channel and the second ventilated channel are longitudinally connected to form a gradient ventilated channel.

[0007] A buffer layer is provided between the spring and the air vent to prevent the air vent from collapsing and closing when compressed.

[0008] The spring is made of 72# carbon steel, and its inner diameter is larger than the maximum outer diameter of the ventilation channel. The spring has 8 coils.

[0009] The number of air vents formed by the first air vent and the second air vent is equal to the number of springs, and each air vent runs longitudinally through the spring and is correspondingly located at the central axis of the spring, forming an array-like distribution structure.

[0010] The inner core of the pad includes a support frame, which is a ring-shaped micro-convex structure with a height of 2mm to 8mm. It is set around the bottom of the inner core of the pad and naturally encloses the bottom plane of the inner core of the pad to form a ring-shaped or fully continuous bottom cavity structure.

[0011] The memory foam cushioning layer is located between the spring and the ventilation channel, and has a thickness of 2mm to 5mm.

[0012] The inner core of the pad is made of polyurethane memory foam material and manufactured through an integrated molding foaming process.

[0013] The inner core of the pad includes a bending groove for guiding the inner core of the pad to bend along a preset direction.

[0014] The distance between the centers of the multiple ventilation channels is 50mm to 120mm.

[0015] Compared with the prior art, the present invention has at least the following beneficial effects:

[0016] 1. By designing a gradient ventilation hole structure with smaller holes at the top and larger holes at the bottom, the reasonable distribution of different hole sizes effectively reduces noise generated during airflow and avoids excessive compression of local materials due to uneven pressure. Simultaneously, in conjunction with the support frame at the bottom, the gradient hole structure guides the humid and hot airflow along a preset path to the bottom cavity, and then naturally discharges it through the outer edge of the frame. This achieves a rapid dehumidification effect, preventing moisture accumulation and stuffiness, significantly improving the dryness and hygiene performance during prolonged use, and preventing material aging, mold growth, or odor development caused by moisture accumulation.

[0017] 2. To further enhance the dynamic support and rebound response speed of the pad's inner core, springs are installed at corresponding positions in each ventilation channel to effectively disperse local pressure and prevent the ventilation channels from collapsing and closing due to local stress concentration when under pressure, achieving the dual technical effect of "elastic support + breathable shape preservation". The springs are completely wrapped in the polyurethane memory foam matrix through an integrated molding foaming process, forming "suspended elastic support points", which not only ensures structural safety and eliminates exposed metal parts, but also maintains a simple and beautiful appearance, improving user experience and product lifespan.

[0018] 3. The inner core of the mat has a bending groove structure at the bottom, allowing users to bend the inner core in a directional manner along the guiding direction of the bending groove. This quickly adapts to different support angles, curvatures, or height requirements, thus accurately matching the personalized support requirements of different body types, sitting or lying postures, or medical rehabilitation scenarios. This significantly improves the product's functional adaptability and user comfort, meeting the application needs of multiple scenarios such as office, vehicle, rehabilitation, and home use. Attached Figure Description

[0019] Figure 1 This is a structural diagram of the inner core of the pad of this utility model;

[0020] Figure 2 This is a structural diagram of the other side of the inner core of the pad of this utility model;

[0021] Figure 3 This is a cross-sectional view of the inner core of the pad of this utility model;

[0022] Figure 4 This utility model Figure 3 A magnified view of a portion of point A in the middle.

[0023] Figure 5 This is an exploded view of the inner core structure of the pad of this utility model;

[0024] Figure 6 This is a schematic diagram of the transparent state of the inner core structure of the pad of this utility model;

[0025] Figure 7 This utility model Figure 6 A magnified view of a section at point B in the middle;

[0026] Figure 8 This is a structural diagram of another embodiment of the present invention.

[0027] The numbering in the attached diagram is explained as follows:

[0028] 1. Inner core of the pad; 2. First ventilation channel; 3. Second ventilation channel; 4. Bending groove; 5. Spring; 6. Support frame. Detailed Implementation

[0029] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the specific implementation methods of this utility model will be described below with reference to the accompanying drawings. Obviously, the drawings described below are merely some embodiments of this utility model. For those skilled in the art, other drawings and other implementation methods can be obtained based on these drawings without any creative effort.

[0030] like Figures 1 to 7 As shown, the inner core 1 of the mat is made of polyurethane memory foam, which has temperature-sensitive properties and slow rebound properties, allowing it to deform and adapt to body temperature and pressure, providing personalized support. To improve the breathability of the mat, several breathable channels are provided on the inner core 1, including a first breathable channel 2 and a second breathable channel 3. The first breathable channel 2 and the second breathable channel 3 are connected and run through the inner core 1 along the thickness direction. The first breathable channel 2 and the second breathable channel 3 adopt a gradient pore size design, with the pore size of the first breathable channel 2 being smaller than that of the second breathable channel 3, and the first breathable channel 2 being located on top of the second breathable channel 3.

[0031] The first ventilation channel 2 has a smaller pore size, preferably Φ3mm~Φ15mm, and is distributed on the top contact surface of the inner core 1 of the pad. It serves as an "air intake control layer" to slowly release the hot and humid airflow emitted by the human body, avoid airflow impact and noise interference, and prevent dust or foreign objects from quickly intruding into the inner core structure. The second ventilation channel (3) has a larger pore size, preferably Φ20mm~Φ70mm, and is located in the middle and lower layers of the inner core of the pad. It serves as a "high-efficiency conduction layer" and undertakes the main functions of air circulation and moisture exhaust, accelerating airflow diffusion and heat and moisture discharge. The two layers have a gradient distribution of pore size, with the larger pore size at the top and the smaller pore size at the bottom, constructing an orderly airflow path of "slow entry - fast conduction - concentrated exhaust", which significantly improves the breathability efficiency, while reducing airflow noise and optimizing the quiet experience.

[0032] It should be noted that the number, distribution density, and pore shape (such as round, elliptical, honeycomb, etc.) of the ventilation channels can be customized according to the size of the pad and the usage scenario (such as children's pads, gaming pads, medical pads) to achieve a unity of function and aesthetics.

[0033] The specific air circulation process is as follows: When a person lies on the inner core 1 of the mattress, the body temperature and pressure cause the polyurethane memory foam material to deform. At the same time, the heat and moisture emitted by the body slowly seep into the inner core of the mattress through the first ventilation channel 2. Because the pore size of the first ventilation channel 2 is small, it can control the air intake and avoid excessive airflow and airflow noise from causing discomfort to the human body. The incoming air flows and diffuses inside the inner core of the mattress, and through the large pore size of the second ventilation channel 3, it achieves rapid conduction and high-flow processing, undertaking the main air circulation function. Finally, the moisture and heat carried by the air are concentrated and discharged through the bottom of the inner core 1, completing the complete cycle of "small hole air intake → large hole conduction → bottom discharge". This layered and progressive ventilation system not only ensures excellent breathability, but also effectively regulates the temperature and humidity environment of the inner core of the mattress, avoiding material aging, mildew, or loss of resilience due to moisture accumulation, maintaining the optimal performance state of the polyurethane memory foam material, and improving the overall user comfort.

[0034] To further enhance the dynamic support and rebound response speed of the pad core, several independent spring units 5 are uniformly embedded inside the pad core 1. The springs 5 ​​are made of high carbon steel or memory alloy and are completely wrapped in polyurethane memory foam matrix through integrated molding foaming process to form "suspended elastic support points", which not only ensures structural safety (no exposed metal parts) but also maintains a simple and beautiful appearance.

[0035] To avoid interference from the spring structure on the ventilation path, the inner diameter of spring 5 is designed to be larger than the maximum outer diameter of the ventilation channel, allowing the first ventilation channel 2 and the second ventilation channel 3 to be precisely positioned in the central area of ​​each spring 5. A 2mm to 5mm thick memory foam buffer layer is maintained between spring 5 and the ventilation channel to ensure that the two are functionally independent and structurally non-interfering. This ensures both a uniform distribution of the ventilation network and prevents the ventilation channels from collapsing and closing due to localized stress concentration under pressure, achieving a dual technical effect of "elastic support + ventilation and shape preservation".

[0036] Spring 5 is preferably made of 72# carbon steel, which has excellent elastic properties and fatigue strength, providing durable and stable support. Spring 6 is made of galvanized steel wire with electroplating surface treatment, heat treatment temperature not lower than 300°C, spring wire diameter of 2.0mm (international tolerance-free), spring inner diameter must be larger than the maximum outer diameter of the vent channel, spring height is 140mm ± 3mm, spring coils are 8 ± 0.5 coils, and spring weight is 36g ± 2g.

[0037] This cushion core structure allows for customization of different sizes to meet various usage scenarios, such as sofa cushions and mattresses. Simply adjust the size and the number of springs and ventilation channels.

[0038] To meet the personalized needs of different usage scenarios for the shape of the mat, the bottom of the inner core 1 of the mat is provided with a flexible bending groove 4. The bending groove 4 can be arranged in parallel as a single line or multiple lines, or set horizontally or vertically. It can also be designed as a wave-shaped, sawtooth-shaped or stepped trajectory according to the mechanical performance requirements, so as to achieve a mechanical balance of "local flexibility and overall stability" in a specific area.

[0039] This design is particularly suitable for applications requiring external support structures such as brackets, backrests, and ramps, including rehabilitation training, post-operative care, office sitting support, in-vehicle rest, and outdoor camping. Guided by the bending groove 4, the inner core of the pad can quickly adapt to different tilt angles, curvatures, or support heights, thereby precisely matching users with different body types, postures, or medical rehabilitation requirements, significantly improving comfort and functionality.

[0040] like Figure 8 As shown, in another embodiment, to further improve the breathability and moisture-wicking performance and structural stability of the pad's inner core, an annular micro-convex support frame 6 is integrally formed or embedded around the bottom perimeter of the pad's inner core. The height is preferably 2mm to 8mm. The support frame 6 and the bottom plane of the pad's inner core naturally enclose each other to form an annular or fully permeable bottom cavity structure. This cavity serves as a buffer channel for moisture guidance and air convection, forming a three-dimensional breathable system of "upward absorption and downward drainage" with the breathable channels distributed within the pad's inner core. When the user generates sweat or moisture during use, the moisture first permeates downward through the breathable channels on the surface of the pad, is then captured by the cavity and guided to the outer edge of the frame, and finally naturally discharged from the pad system by air convection or gravity. This achieves a rapid moisture-wicking effect of "no moisture accumulation and no stuffiness in the inner core," significantly improving the dryness and hygiene performance during prolonged use.

[0041] Furthermore, the support frame 6 structurally combines the functions of "positioning support" and "anti-displacement." When the inner core of the mat is assembled into the outer sleeve, shell, or matching bracket, the support frame 6 can form a fitting fit with the inner wall or limiting groove of the external structure, effectively preventing the inner core of the mat from lateral displacement, rotation, or sinking due to human movement, gravity compression, or vibration during use, ensuring precise support points, structural stability, and a consistent user experience. It is especially suitable for dynamic or tilting usage scenarios such as vehicles, wheelchairs, rehabilitation beds, and gaming chairs, greatly improving product safety and reliability.

[0042] The above embodiments are merely preferred embodiments of this utility model and are not intended to limit the scope of protection of this utility model. All changes made based on the design principles of this utility model, and any non-creative changes made thereon, shall fall within the scope of protection of this utility model.

Claims

1. A pad core, characterized in that, The device includes a core body made of elastic material, multiple springs embedded inside the core body, and multiple ventilation channels extending through the thickness of the core body. The ventilation channels include a first ventilation channel on the upper layer and a second ventilation channel on the lower layer, wherein the aperture of the first ventilation channel is smaller than the aperture of the second ventilation channel. The ventilation channels are located in the middle of the springs.

2. The pad core according to claim 1, characterized in that, The first ventilated channel has a pore size of 3mm to 15mm and is distributed in the top contact area of ​​the inner core body. It serves as an air intake control layer to slow down the release of humid and hot airflow and reduce airflow noise. The second ventilated channel has a pore size of 20mm to 70mm and is located in the middle and lower layers of the inner core body. It serves as a high-efficiency flow guiding layer to accelerate air circulation and moisture discharge. The first and second air-permeable channels are longitudinally connected to form a gradient air-permeable channel.

3. The pad core according to claim 1, characterized in that, The inner core of the pad includes a buffer layer to prevent the air passage from collapsing and closing under pressure.

4. The pad core according to claim 3, characterized in that, The spring is made of 72# carbon steel, and its inner diameter is larger than the maximum outer diameter of the venting channel. The spring has 8 coils.

5. The pad core according to claim 4, characterized in that, The number of air vents formed by the first air vent and the second air vent is equal to the number of springs, and each air vent runs longitudinally through the spring and is correspondingly located at the central axis of the spring, forming an array-like distribution structure.

6. The pad core according to claim 5, characterized in that, The inner core of the pad includes a support frame, which is a ring-shaped micro-convex structure with a height of 2mm to 8mm. It is set around the bottom of the inner core of the pad and naturally encloses the bottom plane of the inner core of the pad to form a ring-shaped or fully continuous bottom cavity structure.

7. The pad core according to claim 3, characterized in that, The buffer layer is located between the spring and the air vent, and has a thickness of 2mm to 5mm.

8. The pad core according to claim 1, characterized in that, The inner core of the pad is made of polyurethane memory foam material and manufactured through an integrated molding foaming process.

9. The pad core according to claim 8, characterized in that, The inner core of the pad includes a bending groove for guiding the inner core of the pad to bend along a preset direction.

10. The pad core according to claim 5, characterized in that, The center-to-center distance between adjacent ventilation channels in the plurality of ventilation channels is 50mm to 150mm.

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