Mattress with integrated stiffening struts

Abstract

The invention relates to a mattress with integrated stiffening struts, wherein the stiffening struts are spaced apart from each other on a common plane within a mattress core and the mattress core has at least two foam layers arranged directly above one another and bonded together, the stiffening struts are clamped between the foam layers and each has a fiber-reinforced, rigid plastic rod extending in the longitudinal direction of the stiffening struts.

Description

[0001] The present invention relates to a mattress with integrated stiffening struts, wherein the stiffening struts are spaced apart from each other and arranged on a common plane within a mattress core.

[0002] Mattresses are known from the state of the art in which the firmness of the mattress core can be varied by inserting stiffening struts.

[0003] A two-layer mattress with variable firmness is known from US patent 3,110,042. Each layer of the mattress is encased in its own fabric cover. The layers are placed one on top of the other, and the fabric covers are sewn together at the contact point between the two layers. The fabric covers are sewn together in such a way that pockets for stiffening struts run perpendicular to the mattress. Different stiffening struts can be inserted into these pockets to vary the firmness of the mattress. In other words, the firmness of the sleeping surface can be adjusted as needed by means of the stiffening struts, resulting in a firmer sleeping surface into which a body lying on it sinks less deeply compared to an un-stiffened sleeping surface.

[0004] A disadvantage of mattresses known from the prior art is their rather complex construction, and the familiar stiffening struts are used only to vary the firmness of the mattress. In any case, this type of mattress requires a supporting base.

[0005] It is therefore the object of the present invention to propose a mattress that overcomes at least one disadvantage known from the prior art. In particular, a mattress is to be proposed that is simpler in construction and easier to handle.

[0006] In particular, the mattress should be designed so that it can be used self-supporting without an additional stable substructure or support.

[0007] The problem is solved by a mattress with the features of the main claim. Advantageous further developments of the mattress are specified in the dependent claims.

[0008] The mattress according to the invention has integrated stiffening struts which are arranged at a distance from each other on a common plane within a mattress core.

[0009] The mattress according to the invention has a particularly simple construction because the mattress core comprises at least two layers of foam arranged directly on top of each other and bonded together, with the stiffening struts being clamped directly between the foam layers. This provides a particularly simple and durable integration of the stiffening struts into the mattress core. Therefore, the need for complex insertion pockets for the stiffening struts within the mattress core is eliminated.

[0010] The stiffening struts run from one edge of the mattress to the opposite edge. The stiffening struts are spaced apart and arranged in the same plane, for example, running parallel to each other.

[0011] The stiffening struts each have a fiber-reinforced plastic rod running lengthwise along the stiffening struts.

[0012] The stiffening struts are either each made from a single fiber-reinforced, rigid plastic rod, or the stiffening struts consist of an elongated, rigid strut that is additionally reinforced with a fiber-reinforced, rigid plastic rod.

[0013] A single rigid plastic rod represents a particularly cost-effective and weight-optimized stiffening strut and can even be retrofitted into designated recesses, such as holes drilled in the mattress perpendicular to the sleeping surface. A stiffening strut reinforced with a rigid plastic rod has a wider surface area compared to the rod itself, resulting in improved flexural rigidity, better weight distribution, and improved integration of the stiffening strut into the mattress core. The stiffening strut can be made of materials such as wood, plywood, aluminum sheet, steel sheet, plastic, or laminate, into which the plastic rod is either embedded or attached.

[0014] In both cases, the fiber-reinforced, rigid plastic rod provides exceptional reinforcement to the mattress core, thereby specifically influencing the mattress's self-supporting capacity and comfort. The flexural rigidity can be improved in a directional manner simply by adjusting the cross-sectional shape of the plastic rod, for example, by using an oval cross-section. Only with this type of reinforcement is the mattress equipped with rigid, fiber-reinforced plastic rods strong enough to function as a self-supporting mattress, even when loaded with a person's weight.

[0015] This means that a mattress propped up at its edges, where the stiffening struts reinforced with the fiber-reinforced, rigid plastic rod run from one propped-up edge to an opposite edge of the mattress, is stable enough to support the weight of the mattress including the weight of one or more people lying on the mattress, without any noticeable sagging of the mattress.

[0016] The stiffening struts with fiber-reinforced plastic rods, which are integrated directly into the mattress core, form a soft sleeping surface with high lying comfort according to the invention.

[0017] At the same time, the mattress is so rigid due to the stiffening struts integrated directly into the mattress core that it does not require the support of a slatted frame like conventional mattresses. It is self-supporting and can be raised solely by two supportive pads at the edges.

[0018] This makes the mattress according to the invention versatile: It can be used like an ordinary mattress and, for example, on a bed frame with a slatted base; it can be placed directly on the floor or loading area of ​​a van or camper; for a raised sleeping surface, the mattress can, for example, be propped up on boxes. The mattress according to the invention is particularly suitable for equipping motorhomes and campervans. For equipping a campervan or motorhome, it is sufficient if its interior has two opposing beams or benches on which the mattress according to the invention can be placed with its edges. In this way, the mattress creates a raised, self-supporting sleeping surface.

[0019] Suitable fibers for the fiber-reinforced, rigid plastic rod include all synthetic and natural fibers with low elongation, such as glass fibers, carbon fibers, aramid fibers or basalt fibers.

[0020] The fibers are embedded in a plastic matrix, either as staple fibers, but preferably as long fibers or continuous filaments. Due to the low elongation of the fibers, a particularly rigid plastic rod is produced.

[0021] The fiber-reinforced plastic rod, for example, has a round cross-section with a diameter of, for instance, 6 to 20 mm, 8 to 16 mm, or 10 to 14 mm. For additional strength, the fiber-reinforced plastic rod can be encased in a plastic sheath. This additional sheathing prevents fibers from being released from the plastic matrix when the rod is bent.

[0022] In one embodiment of the mattress, the stiffening struts each have a plastic lamella into which the fiber-reinforced, rigid plastic rod is embedded.

[0023] For example, the stiffening struts consist of a plastic lamella in the longitudinal direction of which a fiber-reinforced, rigid plastic rod, such as a glass fiber-reinforced, rigid plastic rod, is centrally embedded, with the plastic lamella completely encasing the plastic rod. In cross-section, this embodiment of the stiffening strut has, for example, the following structure: In the center, the fiber-reinforced, rigid plastic rod forms a core, which itself may be encased by an additional plastic sheath. This core is in turn enclosed in another rigid lamella, which is bulged in a lens shape in the center and tapers to a flat band on opposite sides of the core. It is also possible to insert a plastic rod with an oval cross-section into this lamella in such a way that its longest dimension is positioned at a right angle to the sleeping surface of the mattress.

[0024] Because the plastic rod is embedded in a plastic lamella, a band-shaped stiffening strut is formed, which integrates very well between the two foam layers of the mattress core by simply being wedged between the two bonded foam layers. The band-shaped stiffening strut is very securely fixed between the foam layers and cannot twist between them. A stiffening strut designed in this way also provides optimal force transmission to the fiber-reinforced plastic rod.

[0025] In this context, it proves particularly advantageous if the rigid plastic lamella has a ribbed cross-section. For example, the plastic lamella has grooves and / or raised ribs running longitudinally, parallel to the embedded rigid plastic rod. Such a profile further improves the integration of the stiffening struts into the mattress core, thus ensuring its flexural rigidity.

[0026] In one embodiment of the invention, the stiffening struts are clamped between a first foam layer and a second foam layer, the first foam layer having a higher density than the second. This results in a mattress with different lying properties, depending on which of the foam layers is on top. The first foam layer has a higher density than the second foam layer and thus forms a firmer support surface.

[0027] The comfort of the mattress can be further varied by adding a third layer of foam. In this design, the mattress has a third foam layer that lies directly against the second foam layer and has a higher or lower firmness than the second foam layer.

[0028] The possible uses of the mattress according to the invention can be further increased by dividing the mattress into individual mattress segments that can be pushed together to form a sleeping surface. For example, the mattress is divided into two or three mattress segments, each of which is provided with integrated, rigid stiffening struts.This means that each of the mattress segments has integrated, rigid stiffening struts that are arranged at intervals from each other on a common plane within a mattress core or in different planes of the respective mattress segment relative to the other mattress segments, wherein the mattress cores have at least two foam layers arranged directly on top of each other and bonded together, the stiffening struts are clamped between the foam layers or bonded to them, and each stiffening strut has a fiber-reinforced, rigid plastic rod extending in the longitudinal direction of the stiffening struts.

[0029] It is also possible that the stiffening struts are arranged interchangeably in the foam layer or between a first and second foam layer in intermediately arranged receiving pockets.

[0030] The individual mattress segments can be stored separately to save space and, when needed, pushed together to form a single mattress, i.e., a single sleeping surface. The individual mattress segments can also be combined to create seating furniture, such as a sofa. Thanks to the rigid reinforcing struts, this type of seating furniture also provides a self-supporting surface that only requires support at its edges.

[0031] Embodiments of the mattress according to the invention are explained in more detail below with reference to the figures. These show: Fig. 1 Schematic representation of a longitudinal section through a first embodiment of the mattress according to the invention; Fig. 2. Schematic representation of a cross-section through the mattress made of Fig. 1; Fig. 3 Schematic representation of a longitudinal section through a second embodiment of the mattress according to the invention; Fig. 4. Schematic representation of a cross-section through an embodiment of a stiffening strut; and Fig. 5 Schematic representation of an embodiment of a mattress consisting of two mattress segments.

[0032] The depictions in the Fig. Figures 1 to 5 are greatly simplified and not to scale. Furthermore, some details are omitted from the figures to allow an unobstructed view of the essential features of the invention.

[0033] Fig. Figure 1 schematically shows a first embodiment of the mattress 10 according to the invention in a longitudinal section. The mattress 10 has a mattress core with a first foam layer 1 and a second foam layer 2. The first foam layer 1 is arranged directly on the second foam layer 2 and bonded to it. The mattress 10 has integrated stiffening struts 4 which are clamped between the bonded foam layers 1 and 2.

[0034] The stiffening struts 4 run from one edge area of ​​the mattress 10 to an edge area opposite this edge area.

[0035] The stiffening struts 4 are arranged within the mattress core in a common plane. They are spaced apart from each other and, in this case, run parallel to each other.

[0036] In the illustrated embodiment, the stiffening struts 4 are arranged sandwich-like between the first foam layer 1 and the second foam layer 2. They are wedged between the first foam layer 1 and the second foam layer 2 without being glued to them. It is also possible to glue the stiffening struts 4 between the foam layers 1 and 2 to increase their integration into the mattress core.

[0037] The first and second foam layers 1, 2 are thermally bonded together or with an additional adhesive.

[0038] The first foam layer 1 has in Fig. In the embodiment shown in 1, the foam layer has a higher strength and a lower thickness than the second foam layer 2. Depending on which of the two foam layers 1, 2 is on top. The position of the person lying on the ground results in a softer or harder surface and a correspondingly different level of comfort.

[0039] As in Fig. As can be seen in Figure 2, the stiffening struts 4 run in a transverse direction perpendicular to the longitudinal direction of the mattress 10, i.e. parallel to the lying surface from one edge area of ​​the mattress 10 to an edge area of ​​the mattress 10 opposite it.

[0040] The stiffening strut 4 each have a fiber-reinforced, bending-resistant plastic rod 5 extending in the longitudinal direction of the stiffening struts 4.

[0041] The fiber-reinforced plastic rod 5 consists of natural or synthetic fibers, such as glass, carbon, aramid or basalt fibers, which are incorporated into a plastic matrix.

[0042] Thanks to the low-stretch reinforcing fibers, the plastic rod 5 is particularly resilient and rigid.

[0043] Fig. Figure 2 schematically shows a cross-section through mattress 10. Fig. 1. Due to the rigid plastic rod 5, the stiffening strut 4 is so stable that it is sufficient to support the mattress 10 only at its edges, between which the stiffening struts 4 extend. As shown in Fig. As shown in Figure 2, the mattress 10 is supported only at two opposite edges by a support beam 8. Instead of a support beam 8, the mattress 10 can also be propped up on chairs, boxes, or beverage crates placed on either side. In all cases, the rigid stiffening struts 4 provide sufficiently rigid reinforcement to create a self-supporting lying surface that can bear the weight of one or more persons without significant deflection.

[0044] Fig. Figure 3 shows a longitudinal section through a second embodiment of the mattress 10 according to the invention with an additional third foam layer 3.

[0045] The stiffening struts 4 are clamped between the first foam layer 1 and the second foam layer 2, with the first foam layer 1 having a higher density than the second foam layer 2. The third foam layer 3 lies directly on top of the second foam layer 2 and is bonded to it. In this case, the third foam layer 3 has a higher density than the second foam layer 2. It could just as easily have a lower density than the second foam layer 2. By varying the foam thicknesses and densities of the foam layers 1, 2, and 3, different lying properties can be achieved. Furthermore, different lying properties result depending on which side of the mattress 10 is facing up.

[0046] Fig. Figure 4 shows a cross-section of an embodiment of a stiffening strut 4 of the mattress 10 according to the invention.

[0047] In this embodiment, the stiffening struts 4 each have a similarly rigid plastic lamella 7 into which the fiber-reinforced rigid plastic rod 5 is embedded.

[0048] At the in Fig. The embodiment shown in Figure 4 is a glass fiber reinforced plastic rod 5.

[0049] The glass fiber reinforced plastic rod 5 has a round cross-section with a diameter of 8 mm. The plastic rod is encased in a plastic sheath 6. The plastic sheath 6 enhances the bending stiffness of the plastic rod 5 and prevents the potential release of fibers from its plastic matrix.

[0050] The plastic lamella 7 completely encases the plastic rod 5. That is, the rigid, fiber-reinforced plastic rod 5 forms a core in the center, which is encased by the plastic sheath 6. The plastic rod 5 with its plastic sheath 6 is in turn enclosed by a lens-shaped, bulging plastic lamella. The centrally lenticularly widened plastic lamella 7 tapers on opposite sides of the core to a flat, wing-like band.

[0051] Overall, the following results from the in Fig. The structure shown in Figure 4 comprises a band-shaped, rigid stiffening strut 4, with an integrated stiffening rib in the form of a glass fiber reinforced, rigid plastic rod 5 embedded in the plastic lamella 7.

[0052] The band-shaped stiffening strut 4 according to Fig. 4 can be easily integrated between the foam layers 1 and 2 of the mattress core by simply clamping it between the two bonded foam layers 1 and 2. The band-shaped stiffening strut 4 cannot twist between the foam layers 1 and 2. Furthermore, it ensures optimal force transmission and distribution into the fiber-reinforced plastic rod 5.

[0053] The in Fig. The plastic lamella 7 shown in Figure 4 has a ribbed cross-section. The plastic lamella 7 has grooves and raised ribs running lengthwise, parallel to the embedded plastic rod. The ribbed cross-section improves the integration of the stiffening struts 4 into the mattress core and provides the stiffening strut 4 with additional stability.

[0054] It is also possible that the in Fig. 4. The lamellar shape shown is made from other materials, such as an aluminum profile.

[0055] Fig. Figure 5 shows an embodiment of the mattress 10 according to the invention, which is divided into two individual mattress segments 11. Both mattress segments 11 can be pushed together to form a lying surface.

[0056] Each of the mattress segments 11 has integrated stiffening struts 4, which are spaced apart from each other on a common plane within a mattress core of the respective mattress segment 11, wherein the mattress cores have at least two foam layers 1, 2 arranged directly on top of each other and bonded together, the stiffening struts 4 are clamped between the foam layers 1, 2 and the stiffening struts 4 each have a fiber-reinforced plastic rod 5 extending in the longitudinal direction of the stiffening struts 4.

[0057] The individual mattress segments 11 can be stored separately to save space and, if required, pushed together to form a mattress 10, i.e., a single sleeping surface. The individual mattress segments 11 can also be assembled to form a sofa with a seat and backrest. Thanks to the rigid stiffening struts 4, the seat of such a sofa is also self-supporting, and it is sufficient to support the seat only at its edges. Reference symbol list 10 11 Mattress Mattress segment 1 first foam layer 2 second foam layer 3 third foam layer 4 stiffening struts 5 fiber-reinforced plastic rods 6 plastic sheath 7 plastic slats 8 support beam QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 3 110 042

[0003]

Claims

[1] Mattress with integrated stiffening struts, wherein the stiffening struts are spaced apart from each other on a common plane within a mattress core, characterized by that the mattress core has at least two layers of foam arranged directly on top of each other and glued together, the stiffening struts are clamped between the foam layers and each has a fiber-reinforced, rigid plastic rod running in the longitudinal direction of the stiffening struts. [2] Mattress according to claim 1, characterized by , that the rigid stiffening struts have a similarly rigid plastic lamella into which the fiber-reinforced rigid plastic rod is embedded and which is always positioned parallel to the lying surface in the mattress with its longest cross-sectional dimension. [3] Mattress according to claim 2, characterized bythat the rigid plastic lamella has a ribbed lamella cross-section that increases the stability of the plastic lamella. [4] Mattress according to any one of the preceding claims, characterized by that the rigid stiffening struts are clamped between a first foam layer and a second foam layer, the first foam layer having a higher strength than the second foam layer. [5] Mattress according to any one of the preceding claims, characterized by , that the rigid stiffening struts are interchangeably arranged in intermediate receiving pockets between a first foam layer and a second foam layer. [6] Mattress according to claims 4 and 5, characterized by that the mattress has a third foam layer that lies directly against the second foam layer and has a higher / lower firmness than the second foam layer. [7] Mattress according to any one of the preceding claims, characterized by , that the mattress is divided into individual mattress segments which can be pushed together to form a lying surface, with the rigid stiffening struts always arranged perpendicular to the lying surface.

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