Support core and mattress with thermoplastic foam edge protection structure
Patent Information
- Application Number
- CN202522715539.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-19
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-12-19
AI Technical Summary
[0003]但是，弹簧床芯转角为圆弧状，常规的直角状的海绵框架护边结构(通常由四块直线状海绵装配而成)难以与弹簧床芯紧密贴合，存在贴合空隙，并造成支撑缺失，影响用户体验
[0024]本实用新型的支撑芯体的有益效果是：包括弹簧芯体和包围弹簧芯体的护边结构，护边结构包括采用热塑性发泡材料的环状热塑性弹性体，环状热塑性弹性体具有四个圆弧弯曲，护边结构内侧可以更紧密地与弹簧芯体贴合，减小护边结构和弹簧芯体之间的空隙；热塑性发泡材料在运动鞋行业中广泛应用于鞋底(中底)材料，以此提高鞋的轻便性、支撑性和舒适回弹性。
Smart Images
Figure CN224892229U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of mattress technology, specifically relating to a support core and mattress with a thermoplastic foam edge protection structure. Background Technology
[0002] The existing mattresses have an edge protection structure, which improves the support of the mattress edges, making it less likely for people to slip off when sitting on the edge; on the other hand, it improves the elasticity of the mattress edges, so that different people will not feel a strong foreign object sensation when sitting on the edge of the mattress.
[0003] However, the corners of the spring mattress core are rounded, making it difficult for the conventional right-angled foam frame edge structure (usually composed of four straight pieces of foam) to fit tightly against the spring mattress core. This results in gaps and a lack of support, affecting the user experience. Furthermore, the foam edge provides insufficient support, increasing the risk of slippage. Using metal wire support springs, on the other hand, presents poor fatigue resistance and a risk of wire breakage and protrusion. Utility Model Content
[0004] This invention addresses the deficiency of existing mattresses where there is a gap between the edge protection structure and the inner support springs. It provides a support core with a thermoplastic foam edge protection structure to reduce the gap between the edge protection structure and the inner support springs. This invention also provides a mattress using this support core.
[0005] To achieve the above objectives, this utility model adopts the following technical solution: a support core with a thermoplastic foamed material edge protection structure, comprising:
[0006] Spring core;
[0007] The edge protection structure comprises a ring-shaped thermoplastic elastomer with four circular arc bends.
[0008] Among them, the cyclic thermoplastic elastomer is made by bending thermoplastic foam sheets;
[0009] The inner side of the annular thermoplastic elastomer is attached to the spring core.
[0010] The supporting core of this utility model includes a spring core and a protective edge structure surrounding the spring core. The protective edge structure includes an annular thermoplastic elastomer made of thermoplastic foam material. The annular thermoplastic elastomer has four circular arc bends. The inner side of the protective edge structure can fit more tightly with the spring core, reducing the gap between the protective edge structure and the spring core.
[0011] As an improvement, the end faces of thermoplastic foam sheets are heat-fused together.
[0012] As an improvement, the thermoplastic foam sheet is a single strip; or...
[0013] There are two identical thermoplastic foam sheets.
[0014] As an improvement, the spring core can be a pocket spring or a full-web spring.
[0015] As an improvement, the upper and lower edges of the edge protection structure are fixed to the spring at the edge of the spring core by means of a nail; or,
[0016] The spring core has edging steel around its upper and lower edges, and the upper and lower edges of the edging structure are fixed to the edging steel with nails. As an improvement, the thermoplastic foam material is foamed EVA, foamed TPU, foamed TPEE, or foamed PA; and / or,
[0017] The thickness of thermoplastic foam sheets is 2-10cm.
[0018] As an improvement, ventilation slots are provided on the thermoplastic foam sheet; and / or,
[0019] Deformation grooves are formed on the upper and / or lower surfaces of the thermoplastic foam sheet.
[0020] As an improvement, wiring channels are provided on the thermoplastic foam sheet; and / or,
[0021] Tubing grooves are cut into thermoplastic foam sheets.
[0022] The mattress includes a support core, which is the aforementioned support core with a thermoplastic foam edge protection structure.
[0023] As an improvement to the mattress, the mattress also includes an upper layer of heat-fused cotton and a lower layer of heat-fused cotton. The upper and lower layers of heat-fused cotton are fixed to the support core by ultrasonic heat fusion bonding, or the upper and lower layers of heat-fused cotton are fixed to the support core by nail guns.
[0024] The beneficial effects of the support core of this utility model are: it includes a spring core and a protective edge structure surrounding the spring core. The protective edge structure includes a ring-shaped thermoplastic elastomer made of thermoplastic foam material. The ring-shaped thermoplastic elastomer has four circular arc bends. The inner side of the protective edge structure can fit more tightly with the spring core, reducing the gap between the protective edge structure and the spring core. Thermoplastic foam material is widely used in the sports shoe industry for shoe sole (midsole) materials to improve the shoe's lightness, support, and comfortable rebound.
[0025] The mattress of this invention uses the support core of this invention and has all the beneficial effects of the support core of this invention. Attached Figure Description
[0026] Figure 1 This is an exploded view of the mattress according to Embodiment 1 of this utility model.
[0027] Figure 2 This is a schematic diagram of the support core of the mattress according to Embodiment 1 of this utility model.
[0028] Figure 3 This is a schematic diagram of the spring core of the mattress support core according to Embodiment 1 of this utility model.
[0029] Figure 4 This is a schematic diagram of the edge protection structure of the mattress support core according to Embodiment 1 of this utility model.
[0030] Figure 5 This is a schematic diagram of another edge protection structure of the mattress support core according to Embodiment 1 of this utility model.
[0031] Figure 6 This is a schematic diagram of the structure of the annular thermoplastic elastomer of the mattress support core before assembly, according to Embodiment 1 of this utility model.
[0032] Figure 7 This is a structural diagram illustrating one connection method between the mattress support core and the edge protection structure according to Embodiment 1 of this utility model.
[0033] Figure 8 This is a schematic diagram of another connection method between the support core and the edge protection structure of the mattress according to Embodiment 1 of this utility model.
[0034] Figure 9 This is a schematic diagram of the connection structure between the edge protection structure and the upper and lower layers of hot melt cotton in the mattress according to Embodiment 1 of this utility model.
[0035] Figure 10 This is a schematic diagram of the thermoplastic foam sheet material of the mattress according to Embodiment 2 of this utility model (only a partial view is shown).
[0036] Figure 11 This is a schematic diagram of the thermoplastic foam sheet material of the mattress according to Embodiment 3 of this utility model (only a partial view is shown).
[0037] In the diagram, 01 is the supporting core; 02 is the upper layer of hot melt cotton; 03 is the lower layer of hot melt cotton; and 04 is the nail gun.
[0038] 1. Annular thermoplastic elastomer; 10. Thermoplastic foam sheet; 11. Hot melt bonding surface; 12. Deformation groove; 13. Ventilation groove;
[0039] 2. Spring core; 20. Pocket spring; 21. Edge steel; 22. Ultrasonic welded surface. Detailed Implementation
[0040] The technical solutions of the embodiments of this utility model are explained and described below. However, the following embodiments are only preferred embodiments of this utility model and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments in the implementation methods without creative effort are all within the protection scope of this utility model.
[0041] See Figures 1 to 11 The support core with thermoplastic foamed material edge protection structure in this embodiment of the utility model includes:
[0042] Spring core;
[0043] The edge protection structure comprises a ring-shaped thermoplastic elastomer with four circular arc bends.
[0044] Among them, the cyclic thermoplastic elastomer is made by bending thermoplastic foam sheets;
[0045] The inner side of the annular thermoplastic elastomer is attached to the spring core.
[0046] The supporting core of this utility model includes a spring core and a protective edge structure surrounding the spring core. The protective edge structure includes an annular thermoplastic elastomer made of thermoplastic foam material. The annular thermoplastic elastomer has four circular arc bends. The inner side of the protective edge structure can fit more tightly with the spring core, reducing the gap between the protective edge structure and the spring core.
[0047] Example 1
[0048] See Figures 1 to 9 The mattress of Embodiment 1 of this utility model includes a support core 01, which comprises:
[0049] Spring core 2;
[0050] The edge protection structure includes a ring-shaped thermoplastic elastomer 1 with four circular arc bends.
[0051] Among them, the annular thermoplastic elastomer 1 is obtained by bending the thermoplastic foam sheet 10;
[0052] The inner side of the annular thermoplastic elastomer 1 is attached to the spring core 2.
[0053] See Figure 1 and Figure 2 The thermoplastic foam sheet 10 is bent and shaped to form four arc bends, which match and fit the arc-shaped sides of the four springs at the edge corners of the spring core 2. The edge protection structure and the spring core 2 can be arc-shaped and fitted at the edge corners, reducing the gap between them. The edge protection structure and the spring core 2 fit tightly, resulting in good support performance at the corners.
[0054] See Figure 1In this embodiment, the mattress also includes a comfort layer and a fabric layer. The comfort layer is typically made of latex or foam, and can be used in combination or individually to enhance lying comfort. The upper fabric layer, the bottom fabric layer, and the edge fabric layer are connected by a rolling or binding process to form an outer cover that encloses the support core 01 and the comfort layer.
[0055] In this embodiment, the mattress also includes an upper layer of hot melt cotton 02 and a lower layer of hot melt cotton 03.
[0056] See Figure 2 In this embodiment, the support core 01 also includes non-woven fabric.
[0057] See Figure 3 In this embodiment, the upper and lower edges of the spring core 2 are provided with edging steel 21.
[0058] In this embodiment, the spring core 2 is a pocket spring 20. The upper and lower edges of the pocket spring core 20 are provided with edging steel 21. The edging steel 21 and the edge of the pocket spring 20 are fixed together by nails 04, ensuring the edging steel 21 is firmly fixed to the upper and lower edges of the pocket spring core 20. A layer of non-woven fabric is laid on both the upper and lower surfaces of the pocket spring core 20. Figure 3 The edge of the non-woven fabric layer is fixed to the edge steel 21 by the nail gun 04, so that the bag spring 20 is firmly fixed to the edge of the non-woven fabric layer.
[0059] In other embodiments, the spring core 2 may also be a coil spring, such as a Bonnell spring, which includes coil springs and string springs that connect adjacent coil springs in series.
[0060] See Figure 4 The thermoplastic foam sheet 10 can be a single piece. After being heated, softened, and bent, the single thermoplastic foam sheet 10 forms a ring-shaped thermoplastic elastomer 1 (end-face bonding is not considered for now). The thermoplastic foam sheet 10 is bent by preheating to form an arc bend. An edge protection structure is obtained by continuously bending a long strip of thermoplastic foam sheet 10 at a pre-set size position. This edge protection structure provides the ring structure and the inner cavity in the middle of the ring structure for placing the spring core 2. It also avoids the problem of low processing efficiency caused by the need to glue or heat-melt the end faces of multiple sheets when splicing them together. Alternatively, see [link to other documentation]. Figure 5There are two identical thermoplastic foam sheets 10. After being heated, softened, and bent, the thermoplastic foam sheets 10 form a U-shape. Having two thermoplastic foam sheets 10 reduces the overall length of the sheets before heating and bending, improving storage, handling, and processing efficiency. By controlling the heating and bending position, the thermoplastic foam sheets 10 are also bent into a U-shape, with the end faces to be joined located at the middle of the edge of the spring core 2.
[0061] See Figure 6 The upper and lower edges of the edge protection structure are fixed to the edging steel 21 by nails 04. Alternatively, see... Figure 7 The spring core 2 uses a whole-net spring, and the upper and lower edges of the edge protection structure are fixed to the spring edge of the spring core 2 by the gun nail 04.
[0062] See Figure 8 The upper hot melt cotton 02, the lower hot melt cotton 03, and the support core 01 are fixed together by ultrasonic hot melt bonding. The upper and lower surfaces of the annular thermoplastic elastomer 1 of the support core 01, the lower surface of the upper hot melt cotton 02, and the upper surface of the lower hot melt cotton 03 all form ultrasonic welding surfaces 22.
[0063] In other embodiments, the upper hot melt cotton 02, the lower hot melt cotton 03 and the support core 01 can also be fixed by nail gun 04.
[0064] In other embodiments, the upper hot melt cotton 02, the lower hot melt cotton 03 and the support core 01 can also be bonded together with adhesive. In this case, the upper hot melt cotton 02 and the lower hot melt cotton 03 do not need to be made of hot melt material.
[0065] In this embodiment, the thickness of the thermoplastic foam sheet 10 is 2-10cm.
[0066] In this embodiment, the thermoplastic foaming material is foamed EVA, foamed TPU, foamed TPEE, or foamed PA.
[0067] In this embodiment, the mattress processing procedure includes:
[0068] 1. Cut the thermoplastic foam board into 10 thermoplastic foam sheets according to the standard height requirements of the mattress core. The length of the sheet is referenced to the circumference of the mattress.
[0069] 2. Starting from the centerline of the headboard, at the first bend at the edge of the bed core, the long strip of thermoplastic foam elastomer is bent vertically by hot pressing, taking advantage of the thermoplastic properties of the thermoplastic foam material, while ensuring that the bending radius coincides with the rounding radius of the bed core.
[0070] 3. Starting from the first bending point, at the second bend of the bed core, the long strip of elastic body is bent vertically again by hot pressing. Finally, the long strip of elastic body is bent four times by hot pressing to form a frame structure that can surround the bed core.
[0071] 4. The strip-shaped thermoplastic foam material at the beginning and end of the center line of the bed is joined by end-face hot-melt bonding to form a ring-shaped thermoplastic elastomer 1 (edge protection structure). The ring-shaped thermoplastic elastomer 1 can completely cover the outer ring of the spring core 2.
[0072] 5. Place the edge protection structure on the outer ring of the spring core 2, and fix the upper layer hot melt cotton 02 and the lower layer hot melt cotton 03 of the mattress core to the edge steel 21 of the spring core 2 with C-shaped metal nails 04, thereby completing the assembly between the mattress support core 01 and the upper layer hot melt cotton 02 and the lower layer hot melt cotton 03.
[0073] In other mattress manufacturing processes, the edge protection structure can be fitted onto the outer ring of the spring core 2, and the surfaces of the upper hot melt cotton 02 and the lower hot melt cotton 03 that contact the edge protection structure can be fixed by adhesive. The adhesive can be applied by using additional glue or by using ultrasonic welding to soften the upper surface of the thermoplastic foam sheet 10, thereby fixing the surfaces of the upper hot melt cotton 02 and the lower hot melt cotton 03 that contact the edge protection structure.
[0074] In other mattress processing steps, the end faces of the thermoplastic foam sheet 10 are heat-fused together so that the edge protection structure forms a complete ring in front of the outer ring of the spring core 2, which facilitates handling and subsequent processing operations.
[0075] See Figures 7 to 9 There are three ways to assemble the edge protection structure and the spring core 2 into the support core 01:
[0076] The first type, see [link / reference] Figure 8 The edge protection structure is fixed to the spring at the edge of the spring core 2 by the gun nail 04;
[0077] The second type, see [link] Figure 7 The edge protection structure is fixed to the edge steel 21 along the edge of the spring core 2 by the gun nail 04;
[0078] The third type, see [link] Figure 9 The upper hot melt cotton 02 and the lower hot melt cotton 03 are bonded to the upper and lower surfaces of the edge protection structure, thus wrapping and limiting the spring core 2. At this time, it is not necessary to connect the edge protection structure and the spring core 2 separately.
[0079] In other embodiments, the upper hot melt cotton 02, the lower hot melt cotton 03, and the spring core 2 can be assembled into a solid whole by using multiple assembly methods simultaneously. For example, the edge protection structure is fixed to the edging steel 21 on the edge of the spring core 2 by nails 04, and the upper hot melt cotton 02, the lower hot melt cotton 03, and the support core 01 are fixed by ultrasonic hot melt composite fixation. The upper and lower surfaces of the annular thermoplastic elastomer 1 of the support core 01, the lower surface of the upper hot melt cotton 02, and the upper surface of the lower hot melt cotton 03 all form ultrasonic welding surfaces 22.
[0080] The beneficial effects of the mattress in Embodiment 1 of this utility model are as follows: The mattress support core 01 includes a spring core 2 and an edge protection structure surrounding the spring core 2. The edge protection structure includes a ring-shaped thermoplastic elastomer 1 made of thermoplastic foam material. The ring-shaped thermoplastic elastomer 1 has four arc bends, allowing the inner side of the edge protection structure to fit more tightly with the spring core 2, reducing the gap between the edge protection structure and the spring core 2. Using hot water-based foam material instead of sponge provides better support. Furthermore, no glue is required during the processing and assembly of the edge protection structure. Thermoplastic foam material is widely used in the sports shoe industry for shoe sole (midsole) materials to improve the lightness, support, and comfortable rebound of shoes.
[0081] Example 2
[0082] join Figure 10 In this embodiment, deformation grooves 12 are formed on the upper and lower surfaces of the thermoplastic foam sheet 10. The deformation grooves 12 are notched and include a trapezoidal segment that is larger on the outside and smaller on the inside, and an arc-shaped segment at the inner end. By forming the deformation grooves 12, the edge protection structure can bend better to adapt to the movement of the electric bed. The edge protection structure has four long strips, and the deformation grooves 12 are only provided on two of the long strips in the length direction of the mattress. The long strips in the width direction of the mattress at the head and foot of the electric bed do not have deformation grooves 12.
[0083] In other embodiments, the deformation groove 12 is only provided in a portion of the long strip at the location where the electric bed is bent, that is, there are multiple deformation grooves 12 and they are distributed at intervals.
[0084] Example 3
[0085] See Figure 11 In this embodiment, the thermoplastic foam sheet 10 has ventilation slots 13 to improve air permeability. At the same time, the ventilation slots 13 also facilitate the bending of the thermoplastic foam sheet 10.
[0086] In other embodiments, wiring channels and conduit channels are provided on the thermoplastic foam sheet 10 to arrange wires and air pipes of components for the smart mattress, so as to meet the installation needs of the intelligent electrical components of the smart mattress.
[0087] The above description is merely a specific embodiment of this utility model, but the scope of protection of this utility model is not limited thereto. Those skilled in the art should understand that this utility model includes, but is not limited to, the content described in the above specific embodiments. Any modifications that do not depart from the functional and structural principles of this utility model will be included within the scope of the claims.
Claims
1. A support core with a thermoplastic foam edge protection structure, characterized in that: include: Spring core (2); The edge protection structure includes an annular thermoplastic elastomer (1) with four arc bends. Among them, the cyclic thermoplastic elastomer (1) is made by bending thermoplastic foam sheet (10); The inner side of the annular thermoplastic elastomer (1) is attached to the spring core (2).
2. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: The end faces of the thermoplastic foam sheet (10) are heat-fused together.
3. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: Thermoplastic foam sheet (10) is one piece; or, There are two identical thermoplastic foam sheets (10), and the thermoplastic foam sheets (10) are concave after bending.
4. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: The spring core (2) is a pocket spring (20) or a whole-net spring.
5. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: The upper and lower edges of the edge protection structure are fixed to the spring at the edge of the spring core (2) by means of a nail (04); or, The upper and lower edges of the spring core (2) are provided with edging steel (21), and the upper and lower edges of the edging structure are fixed to the edging steel (21) by gun nails (04).
6. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: The thermoplastic foam material is foamed EVA, foamed TPU, foamed TPEE, or foamed PA; and / or, The thickness of the thermoplastic foam sheet (10) is 2-10cm.
7. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: Ventilation slots (13) are formed in the thermoplastic foam sheet (10); and / or, Deformation grooves (12) are formed on the upper and / or lower surfaces of the thermoplastic foam sheet (10).
8. The support core with thermoplastic foamed material edge protection structure according to claim 1, characterized in that: Cable trays are provided on the thermoplastic foam sheet (10); and / or, A tube channel is opened on the thermoplastic foam sheet (10).
9. A mattress, including a support core (01), characterized in that: The support core (01) is the support core (01) with a thermoplastic foamed material edge protection structure as described in any one of claims 1 to 8.
10. The mattress according to claim 9, characterized in that: The mattress also includes an upper layer of hot melt cotton (02) and a lower layer of hot melt cotton (03). The upper layer of hot melt cotton (02), the lower layer of hot melt cotton (03) and the support core (01) are fixed together by ultrasonic hot melt bonding, or the upper layer of hot melt cotton (02), the lower layer of hot melt cotton (03) and the support core (01) are fixed together by nail gun (04).