Mattress with integrated stiffening struts

Abstract

Mattress with integrated stiffening struts, wherein the stiffening struts are spaced apart from each other on a common plane within a mattress core, characterized in that the mattress core has at least two foam layers arranged directly on top of each other and bonded together, the stiffening struts are clamped between the foam layers and each of which, as rigid stiffening struts, 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 one another and arranged on a common plane within a mattress core.

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

[0003] For example, US Pat. No. 3,110,042 discloses a two-layer mattress with variable firmness. Each layer of the mattress is covered with its own fabric cover. The layers are placed on top of each other, and the fabric covers are sewn together at a contact point between the two layers. The fabric covers are sewn together in such a way that pockets for stiffening struts run transversely to the mattress. Different stiffening struts can be inserted into these pockets to vary the firmness of the mattress. In other words, the stiffening struts allow the firmness of the sleeping surface to be adjusted as needed, resulting in a harder sleeping surface into which a body sinks less deeply than with a non-stiffened sleeping surface.

[0004] The disadvantage of current mattresses is their rather complicated construction, and the familiar stiffening struts are used only to vary the firmness of the mattress. In any case, this mattress requires a supporting base.

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

[0006] In particular, the mattress should be designed in such a way that it can be used self-supporting without any additional stable substructure or support.

[0007] This object is achieved by a mattress having the features of the main claim. Advantageous further developments of the mattress are specified in the subclaims.

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

[0009] A particularly simple construction of the mattress according to the invention results from the fact that the mattress core comprises at least two foam layers arranged directly above one another and glued together, and the stiffening struts are clamped directly between the foam layers. This represents a particularly simple and at the same time durable integration of the stiffening struts into the mattress core. A complex design of insertion pockets for the stiffening struts within the mattress core is thus unnecessary.

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

[0011] The stiffening struts each have a fiber-reinforced plastic rod running in the longitudinal direction of the stiffening struts.

[0012] The stiffening struts are either made of 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 also be subsequently inserted into designated recesses, such as holes in the mattress, perpendicular to the sleeping surface. A rigid strut reinforced with a rigid plastic rod has a wider surface than a plastic rod, which ensures better flexural rigidity and weight distribution, as well as better integration of the stiffening strut into the mattress core. The rigid strut can be made of wood, plywood, aluminum sheet, steel sheet, plastic, or laminate, for example, into which the plastic rod is embedded or attached.

[0014] In both cases, the fiber-reinforced, rigid plastic rod provides special reinforcement for the mattress core, which can be used to specifically influence the mattress's self-supporting capacity and lying properties. The cross-sectional shape of the plastic rod, for example, with an oval cross-section, can improve flexural rigidity in a specific direction. Only with this type of reinforcement is the mattress equipped with rigid fiber-reinforced plastic rods strong enough to be self-supporting, even when loaded with a person's weight.

[0015] This means that a mattress that is propped up at its edges, with the stiffening struts reinforced with the fiber-reinforced, rigid plastic rod running from one propped up edge area to an opposite edge area of ​​the mattress, is stable enough to bear 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] Thanks to the stiffening struts with fiber-reinforced plastic rods, which are directly integrated into the mattress core, the mattress according to the invention forms a soft sleeping surface with a high level of comfort.

[0017] At the same time, the mattress is so rigid thanks to the stiffening struts integrated directly into the mattress core that it doesn't require the support of a slatted frame like conventional mattresses. It is self-supporting and can be propped up using just two supportive pads at the edges.

[0018] This makes the mattress according to the invention versatile: It can be used like a conventional mattress, for example, on a bed frame with a slatted frame; it can be placed directly on the floor or the loading area of ​​a van or camper; for a raised sleeping surface, the mattress can be jacked up on boxes, for example. The mattress according to the invention is particularly suitable for equipping mobile homes and campers. To equip a camper or mobile home, it is sufficient if the interior has two opposing posts or benches on which the mattress according to the invention can be placed with its edges. The mattress thus creates a raised, self-supporting sleeping surface.

[0019] All synthetic and natural fibers with only low elongation, such as glass fibers, carbon fibers, aramid fibers or basalt fibers, are suitable as fibers for the fiber-reinforced, rigid plastic rod.

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

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

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

[0023] For example, the stiffening struts consist of a plastic lamella in whose longitudinal direction the fiber-reinforced, rigid plastic rod, for example a glass-fiber-reinforced, rigid plastic rod, is embedded centrally, whereby the plastic lamella completely encloses the plastic rod. In cross-section, this embodiment of the stiffening strut has the following structure: In the center, the fiber-reinforced, rigid plastic rod forms a core, which can itself be encased in an additional plastic sheath. This core is in turn enclosed in a rigid lamella, which is also bulged in a lens-shaped manner 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 so that its longest dimension is inserted into the mattress at a right angle to the lying surface.

[0024] Because the plastic rod is embedded in a plastic slat, a band-shaped stiffening strut is formed, which can be easily integrated between the two foam layers of the mattress core by simply clamping it between the two glued foam layers. The band-shaped stiffening strut is securely fixed between the foam layers and cannot twist between them. A stiffening strut designed in this way also ensures optimal force transmission into the fiber-reinforced plastic rod.

[0025] In this context, it proves particularly advantageous if the rigid plastic slat has a ribbed cross-section. For example, the plastic slat 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, ensuring its flexural rigidity.

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

[0027] The mattress's comfort can be further varied by adding a third foam layer. In this version, the mattress features a third foam layer that lies directly against the second foam layer and is either firmer or firmer 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 single sleeping surface. For example, the mattress is divided into two or three mattress segments, with each mattress segment being equipped with integrated, rigid stiffening struts.This means that each of the mattress segments has integrated rigid stiffening struts which are arranged at a distance from one another 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 above one another and glued to one another, the stiffening struts are clamped between the foam layers or glued to them, and the stiffening struts each have a fiber-reinforced, rigid plastic rod running in the longitudinal direction of the stiffening struts.

[0029] It is also possible for the stiffening struts to be arranged interchangeably in the foam layer or between a first and second foam layer in receiving pockets arranged therebetween.

[0030] The individual mattress segments can be stored individually to save space and, if necessary, pushed together to form a single mattress, i.e., a single sleeping surface. The individual mattress segments can also be combined to form a seating unit, such as a sofa. Thanks to the rigid stiffening struts, this type of seating unit also provides a self-supporting seating 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. They 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 from 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 representations in the Fig. Figures 1 to 5 are highly simplified and not to scale. Some details have also been omitted from the figures to provide an unobstructed view of 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 glued to it. The mattress 10 has integrated stiffening struts 4, which are clamped between the glued foam layers 1, 2.

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

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

[0036] In the embodiment shown, the stiffening struts 4 are sandwiched between the first foam layer 1 and the second foam layer 2. They are clamped 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, 2 to increase their integration into the mattress core.

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

[0038] The first foam layer 1 has Fig. 1 has a higher strength and a lower layer thickness than the second foam layer 2. Depending on which of the two foam layers 1, 2 is on top, the result is a softer or harder support surface and a correspondingly different lying comfort.

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

[0040] The stiffening struts 4 each have a fiber-reinforced, rigid plastic rod 5 running in the longitudinal direction of the stiffening struts 4.

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

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

[0043] Fig. 2 shows schematically a cross section through the mattress 10 from 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 in its edge areas, between which the stiffening struts 4 extend. As in Fig. 2, the mattress 10 is supported only in two opposite edge areas 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 form a sufficiently rigid reinforcement to create a self-supporting lying surface that can bear the weight of one or more people without significant deflection.

[0044] Fig. 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 strength than the second foam layer 2. The third foam layer 3 lies directly on the second foam layer 2 and is glued to it. In this case, the third foam layer 3 has a higher strength than the second foam layer 2. It could just as easily have a lower strength than the second foam layer 2. By varying the foam thicknesses and the strengths 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 on top.

[0046] Fig. 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 likewise rigid plastic lamella 7 into which the fiber-reinforced rigid plastic rod 5 is embedded.

[0048] At the Fig. The embodiment shown in Figure 4 is a glass fibre 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 coated with a plastic sheath 6. The plastic sheath 6 supports the flexural rigidity of the plastic rod 5 and the possible release of fibers from its plastic matrix.

[0050] The plastic lamella 7 completely encloses the plastic rod 5. This means that the rigid, fiber-reinforced plastic rod 5 forms a core in the center, which is covered 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 lens-shaped, widened plastic lamella 7 tapers on opposite sides of the core to form a flat, wing-like band.

[0051] Overall, the Fig. 4, 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, 2 of the mattress core by simply clamping it between the two glued foam layers 1, 2. The band-shaped stiffening strut 4 cannot twist between the foam layers 1, 2. Furthermore, it provides optimal force introduction and distribution into the fiber-reinforced plastic rod 5.

[0053] The Fig. The plastic slat 7 shown in Figure 4 has a ribbed cross-section. The plastic slat 7 has grooves and raised ribs running longitudinally 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 Fig. 4 shown slat shape is made of 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 single sleeping surface.

[0056] Each of the mattress segments 11 has integrated stiffening struts 4, which are arranged at a distance from one another 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 above one another and glued to one another, 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 running in the longitudinal direction of the stiffening struts 4.

[0057] The individual mattress segments 11 can be stored individually to save space and, if necessary, pushed together to form a single mattress 10, i.e., a single sleeping surface. The individual mattress segments 11 can also be combined 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. List of reference symbols 10 mattress 11 mattress segment 1 first foam layer 2 second foam layer 3 third foam layer 4 stiffening struts 5 fiber-reinforced plastic rod 6 plastic sheath 7 plastic slats 8 support beam QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes 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 arranged at a distance from each other on a common plane within a mattress core, characterized by that the mattress core has at least two foam layers arranged directly one above the other and glued together, the stiffening struts are clamped between the foam layers and each have a fiber-reinforced, rigid plastic rod running in the longitudinal direction of the stiffening struts as rigid stiffening struts. [2] Mattress according to claim 1, characterized by that the rigid stiffening struts have a likewise rigid plastic lamella into which the fiber-reinforced rigid plastic rod is embedded and which is always arranged in the mattress with the longest cross-sectional dimension parallel to the lying surface. [3] Mattress according to claim 2, characterized bythat the rigid plastic slat has a ribbed slat cross-section which increases the stability of the plastic slat. [4] Mattress according to one of the preceding claims, characterized by that the rigid stiffening struts are clamped between a first foam layer and a second foam layer, wherein the first foam layer has a higher strength than the second foam layer. [5] Mattress according to one of the preceding claims, characterized by that the rigid stiffening struts are arranged interchangeably between a first foam layer and a second foam layer in receiving pockets arranged therebetween. [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 one of the preceding claims, characterized by that the mattress is divided into individual mattress segments that can be pushed together to form a lying surface, with the rigid stiffening struts always arranged transversely to the lying surface.

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