Body support device with inflatable air core

Abstract

A body support device (1) for supporting a person while resting or sleeping, such as a mattress, topper, or box spring, the device comprising a core (2) with at least two layers (4), each layer comprising a plurality of inflatable air cells (3), each air cell being in fluid communication with at least one adjacent air cell (3), and being adapted to be connected to and inflated by one or more air pumps (9); the core being divided into a plurality of pressure zones (6); and the layers of the inflatable air core being attached to one another in a vertically stacked configuration.

Description

FIELD OF THE INVENTIONThe present invention relates to the field of body support systems and, more particularly, to an inflatable support device for rest or sleep purposes.BACKGROUNDModern bedding solutions have developed significantly since the times of simple, evenly padded mattresses or of pure spring designs. Traditional mattress structures, which previously contained only curled metal springs or natural fillings such as straw and cotton, have been fitted with a variety of innovative materials such as foams, gels, water and air bubbles over time. Among these more recent developments, the use of air chambers or inflatable sections has gained importance because of the attendant advantages of adjustable strength, potential for pressure relief and individual adjustment options. However, many available designs are inadequate in one or more respects, often lacking in extensive modular design, sufficient zone divisions, or reliable methods for ensuring long term durability and ease of maintenance.Among the frequently observed limitations of conventional inflatable body support devices is the tendency for the pressure to spread unevenly over the entire bed or mattress surface if the chambers are not carefully structured or partitioned. For example, a single large air bubble typically results in a "hammock" effect in which the most severe part of the user's body sinks deeper and the surrounding areas may become excessively dense as a result, resulting in uneven pressure distribution. Likewise, in certain multi-chamber designs, proper fluid communication between the chambers is not assured, or there is no possibility of dividing the entire support surface into multiple zones, whereby each zone could be pressurized or depressurized independently. This shortcoming can limit the ability to conform the mattress to the body shape and comfort preferences of the user. Moreover, many of these designs disregard the possibility of providing multilayer inflatable structures, whereby the overall stability of the mattress can be improved and at the same time its flexibility can be maintained.Moreover, existing solutions often lack reliable methods for joining several layers of inflatable air cells together in a coherent whole. If two inflatable layers are simply placed one upon the other, without secure bonding by welding, adhesives, or other forms of permanent attachment, problems may arise with alignment and slippage, as well as possible long term wear phenomena. The individual layers may wear or misalign over time due to repeated inflation and deflation as well as lateral displacements by the sleeping user, thereby resulting in inconsistent comfort and possibly product failure. Therefore, there remains a need for a uniform, multi-layered approach that takes into account vertical alignment, structural integrity, ease of production, and custom customization capabilities.In addition to the purely structural aspects, new and more sophisticated methods for adjusting the strength or pressure of an inflatable bed or cushion have become more and more desirable. Although each zone can be manually inflated or deflated, it is impractical for most users, especially if it is a large number of zones or if the bed is to be fitted to the user's body in real time. Automated systems employing pressure sensing sensors and controls to interpret and respond to these measurements can dramatically improve the user experience and make the device from a static bedroom furniture a responsive system that can personalize comfort throughout the user's rest period.Accordingly, the invention described herein is directed to overcoming at least some of the problems described above.SUMMARY OF THE INVENTIONIn a first aspect, the invention relates to a body support device which may be configured as a mattress, box spring, topper, pillow or similar structure to support a user while resting or sleeping. According to claim 1, the apparatus comprises a core having at least two layers, each layer comprising a plurality of inflatable air cells arranged such that each air cell is in fluid communication with at least one adjacent cell within the same layer.Further preferred embodiments of the body support device are set out in claims 2 to 17.In a second aspect, the invention relates to a bed comprising a body support device according to claim 18.In a third aspect, the invention relates to the use of the bed or the body support device for supporting a human body.DESCRIPTION OF THE FIGURESThe following description of the figures of specific embodiments of the invention is merely exemplary in nature and is not intended to limit the present teachings, application, or uses thereof. FIG. 1 shows a schematic view of a body support device according to an embodiment of the invention. FIG. 2 shows a detailed view of a module according to an embodiment of the invention. FIG. 3 is a plan view of a body support device according to an embodiment of the invention. FIG. 4 shows sectional views of a body support device according to an embodiment of the invention.DETAILED DESCRIPTION OF THE INVENTIONThe present invention relates to a body support device which may be configured as a mattress, box spring, topper, pillow or similar structure to support a user while resting or sleeping. The apparatus comprises a core having at least two layers, each layer comprising a plurality of inflatable air cells arranged such that each air cell is in fluid communication with at least one adjacent cell within the same layer. Each of these at least two layers is further divided into a plurality of pressure zones, each pressure zone being independently pressurized or depressurized by suitable means known in the art, such as one or more air pumps for pressurization and / or one or more dump valves for pressure reduction.Unless otherwise defined, all terms used to disclose the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. As a further aid, term definitions are provided to better convey the teachings of the present invention.The following terms used herein have the following meanings:As used herein, the singular forms "a," "an," and "the" also include the plural, unless the context clearly indicates otherwise. The term "a compartment" refers to, for example, one or more compartments.As used herein, the term "about" referring to a measurable value such as a parameter, amount, duration of time, and the like is intended to include deviations of + / -20% or less, preferably + / -10% or less, more preferably + / -5% or less, even more preferably + / -1% or less, and even more preferably + / -0.1% or less from the stated value, so long as such deviations are suitable for practicing the disclosed invention. It should be understood, however, that the value to which the modifier "about" refers is also specifically disclosed.As used herein, the terms "comprise," "comprising," and "has... have" are synonymous with "comprise," "including," "include," or "include," and are inclusive or open terms that specify the presence of the following element, e.g., a component, and do not exclude the presence of additional, non-mentioned components, features, elements, members, steps known in the art or disclosed therein.Moreover, the terms "first", "second", "third" and similar terms are used in the specification and claims to distinguish similar elements and not necessarily to describe a sequential or chronological order unless otherwise stated. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein may function in orders other than as described or illustrated herein.The specification of numerical ranges with end points comprises all numbers and fractions which fall under this range, and the end points mentioned.The term "wt %", "weight percent", "wt %" or "wt %" as used herein and throughout the specification refers, unless otherwise defined, to the relative weight of the respective component based on the total weight of the formulation.While the terms "one or more" or "at least one", such as one or more or at least one member(s) of a group of members, are per se clear, it is further explained herein that the term includes, among other things, a reference to any one of these members or to two or more of these members, such as both ≥3, ≥4, ≥5, ≥6 or ≥7 etc. of these members and up to all of these members.Unless otherwise defined, all terms used to disclose the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. As a further aid, definitions for the terms used in the specification are provided to better convey the teachings of the present invention. The terms or definitions used here are used merely for better understanding of the invention.Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, when the term "in one embodiment" occurs in various places throughout this specification, it need not refer to, but may always refer to, the same embodiment. Moreover, the individual features, structures, or characteristics may be combined in any suitable manner in one or more embodiments, as will be apparent to one skilled in the art from this disclosure. Although some of the embodiments described herein include some features of other embodiments, but other features are not, combinations of features of various embodiments are to be considered within the scope of the invention and form various embodiments according to the understanding of those skilled in the art. In the following claims, for example, any of the claimed embodiments may be used in any combination.In a first aspect, the invention relates to a body support device for supporting a person while resting or sleeping, such as a mattress, a topper or a box spring, the device comprising a core having at least two layers, each layer comprising a plurality of inflatable air cells, each air cell being in fluid communication with at least one adjacent air cell, and being adapted to be connected to and inflated by one or more air pumps. The core is divided into a plurality of compression zones and the at least two layers of the inflatable air core are secured together in a vertically stacked configuration.The support device disclosed here with at least two cell layers improves the load distribution, reduces pressure points and increases comfort compared to a single-layer structure. It allows more precise settings of the zones and better adaptation to the user's body. The second or further layer increases the wear resistance by distributing the mechanical load uniformly, minimizing material fatigue and extending the service life.Moreover, the multilayer air cell structure increases stability because it prevents uncontrolled air displacement which would otherwise lead to dips or uneven pressure distribution in single layer constructions. Instead, the air is more evenly distributed in the cells, thereby reducing peak loads and improving local pressure resistance.Moreover, the design allows for a more rapid and perceptible adjustment in which less air is needed for inflation, which allows for a more rapid and effective adjustment to the user's preferences. The system can be optimized based on predefined airflow and pressure requirements and provides efficient air regulation per minute for consistent and reliable performance.Each layer includes a plurality of air cells in fluid communication with at least one adjacent air cell. The interconnected air cells may translate air from compressed cells into adjacent cells when a user applies pressure, thereby passively balancing the load before the air pump adjusts the pressure. This natural redistribution helps the support device to respond immediately to movements. The apparatus disclosed herein builds upon this natural balance by further dividing each layer into multiple print zones which can be actively controlled. A "zone" used in the present disclosure includes a plurality of air cells that are in fluid communication with each other but are sealed or isolated from other zones to ensure that pressure changes in one zone do not inadvertently affect another. This is especially important in situations where a user requires a stronger lumbar support but a softer support under the shoulders, or in dual beds where each partner has different preferences or weight.The apparatus disclosed herein ensures that the layers of the air cells are aligned in a vertical plane and ensure uniform support and pressure distribution. This alignment prevents uneven load transfer and ensures that each print zone functions as intended. In addition, strength and stability can be controlled precisely as a result, since the settings in one layer directly correspond to those in the other.In some embodiments, the body support device 2 has layers. In other embodiments, the body support device has more than 2 layers, such as 3, 4, 5, or 6 layers of air cells stacked in a vertical arrangement.In an embodiment of the body support device disclosed herein, the core includes non-inflatable portions, wherein at least a portion of the non-inflatable portions are disposed between the air cells. The layers are secured to each other at the level of the non-inflatable portions. At least a portion of the non-inflatable portions are disposed corresponding to or aligned with the air cells. Some non-inflatable areas may conform to cell walls or edges to enhance structural integrity. The non-inflatable portions are disposed between the inflatable air cells, but do not necessarily provide a complete separation. In some embodiments, the non-inflatable portions serve as structural limitations while maintaining fluid communication between adjacent air cells. In other embodiments, the non-inflatable portions function as barriers that prevent fluid exchange between air cells. Alternatively, the non-inflatable portions may be arranged in a pattern that alternately permits or restricts fluid communication.Securing the layers in a vertically stacked configuration is of critical importance to prevent misalignment and performance degradation over time. Without reliable bonding, the stacked layers shift, especially during repeated inflation and deflation cycles or prolonged use. The invention solves this problem by including non-inflatable portions which serve as anchoring points. The alignment and joining of these non-inflatable portions by welding or bonding ensures that the layers remain stable and properly positioned, thus ensuring consistent performance.The approach of only requiring certain non-inflatable portions to be joined avoids having to properly align each inner air cell. Instead, these strategic anchor points ensure stability and macrolevel alignment without having to attempt to weld each inner seam across two entire layers at a time. This also ensures that each air cell or module retains a certain amount of independent movement, which allows the device to adapt better to the body shape or body weight distribution of the user.In some embodiments of the body support device disclosed herein, the non-inflatable portions include perforations and / or openings. The perforations and / or openings are preferably located in the non-inflatable portions located corresponding or aligned with the air cells. The perforations and / or openings are preferably located in the middle of the non-inflatable portions. The perforations provide structural alignment, mechanical stress distribution and flexibility of the material. They provide accurate positioning of the layers during manufacturing and reduce the risk of alignment errors. The perforations, which serve as pressure relief points, prevent tearing of the material, particularly in areas subjected to repeated inflation and deflation cycles. Additionally, strategic perforations improve air circulation and moisture control, thereby increasing user comfort and increasing the wear resistance of the body support device.The perforations in the non-inflatable portions may take various forms depending on their intended function. In some embodiments, the perforations are linear, cruciform, circular, elliptical, and / or polygonal. Cross-shaped perforations are particularly well suited for joining the air cell layers, since they allow a web of material forming a first layer to fold upwards, while the corresponding material of a second layer folds downwards, and meet at the vertical middle where the two layers are joined together. Circular perforations located at the ends of the cross-shaped perforations prevent tearing of the material by more evenly distributing the load and reducing local stress during inflation and deflation cycles as well as the movement of the user.The layers of the body support device disclosed herein are secured together by any methods known in the art, such as, but not limited to, welding, or with an adhesive. Possible welding methods include radio frequency welding, RF (radio frequency) welding, ultrasonic welding or heat sealing, all of which are common in the manufacture of thermoplastics. Specific adhesion promoters which are compatible with TPU or the particular polymer used and which have the required tensile, shear and peel strength properties can be selected as adhesives. The result is a unitary two or more layer structure that acts as a single part and yet maintains the internal multi-zone architecture that provides flexibility and comfort.In one embodiment of the body support device disclosed herein, the core has between 2 and 12 pressure zones, although the invention is not strictly limited to this number. The reason for selecting 2 to 12 print zones per layer is the balance between complexity and practical benefit. Fewer than 2 zones are substantially equivalent to a single bubble arrangement that offers only minimal adjustment possibilities. In many cases, 5 zones are sufficient to address the various major regions of the human body: head, shoulders, lumbar spine, thigh, and legs / feet. In more specific products, extended differentiation may be required, and therefore the invention provides for extension or reduction of zone number, depending on what is appropriate for the intended application.Alternatively, the body support device has between 2 and 3 pressure zones, 2 and 4 pressure zones, 2 and 5 pressure zones, 2 and 6 pressure zones, 2 and 7 pressure zones, 2 and 8 pressure zones, 2 and 9 pressure zones, 2 and 10 pressure zones or 2 and 12 pressure zones.In some embodiments, the pressure in a print zone of a first layer corresponds to the pressure in a vertically oriented print zone of a second or further layer, thereby ensuring uniform pressure distribution across multiple layers.In other embodiments, the pressure in vertically oriented pressure zones in different layers may be controlled independently of each other, such that differential pressure adjustments between the layers are possible. This allows for individual support in which one layer may provide a softer or stronger feel compared to another to optimize comfort and compliance depending on the user's weight, position or sleep preferences.Moreover, in some embodiments, the print zones of different layers may be connected to each other, allowing dynamic redistribution of the air between the layers based on the real-time load conditions. In contrast, in other embodiments, each layer may maintain isolated print zones, preventing air exchange between the layers and allowing targeted adjustments per layer.In some embodiments of the body support device disclosed herein, the air cells are organized into modules within a layer. The air cells within a module are in fluid communication with each other through channels. A single module, within the scope of the present invention, consists of an array of inflatable air cells interconnected by channels that allow fluid flow between the cells within the module. The channels may be integrated into the material or manufactured by an assembly process in which edges and seams are carefully joined according to a pattern.In some embodiments, the air cells are equipped with vent valves (exhaust or exhaust valves) to allow controlled venting of the air so that excess air can be vented as needed. This function helps to regulate pressure, prevents over-inflation and provides optimum comfort. In certain embodiments, the vent valves are arranged at the module level, thereby allowing for selective air venting for precise adjustments within certain pressure zones. In one embodiment, each pressure zone is equipped with an exhaust or drain valve. In a further embodiment, a central discharge valve may also be present, which is controlled by the control unit. To release pressure, both the pressure zone valves and the central release valve are opened.The modular system contributes to load distribution, but its main advantage is reliability. Each module functions as a closed system in which air cells within the module are in fluid communication with each other through channels, thereby ensuring that failure of an air cell in a module does not affect the entire structure in the layer or zone. The modules may be interconnected via hoses or ducts, allowing a controlled flow of air between them and simultaneously maintaining insulation in the event of leaks or malfunctions. Moreover, the modular construction simplifies manufacturing and assembly and enables the production of standardized components that can be efficiently integrated, thereby reducing material waste and complexity of production.In some embodiments, each module in a layer is in fluid communication with the corresponding module in the layer directly above or below, thereby ensuring vertical air communication between the layers. This configuration allows synchronized pressure adjustments across multiple layers.In other embodiments, however, cross-layer connections between non-vertically oriented modules are also possible. In this arrangement, fluidic connection of a module in one layer to a module in another layer may be established that is not directly above or below it, but is offset. This allows for more complex air distribution patterns.In one embodiment, each layer has between 2 and 12 modules, although the invention is not strictly limited to this number. Alternatively, the body support device comprises between 2 and 3 modules, 2 and 4 modules, 2 and 5 modules, 2 and 6 modules, 2 and 7 modules, 2 and 8 modules, 2 and 9 modules, or 2 and 10 modules.In one embodiment of the body support device disclosed herein, at least one pressure zone per layer is formed by a module. In another or further embodiment, at least one print zone per layer is formed by a plurality of modules, the modules within a zone being in fluid communication with one another by hoses or channels. In some embodiments, the tubes are welded to the modules. A print zone can thus be formed from 1, 2, 3, 4 or 5 modules.Hoses welded or otherwise connected to the modules may be used to connect multiple modules within the same zone to ensure that air can flow between the modules but not outside the zone. In a non-limiting embodiment, each layer has nine modules distributed among five targeted support zones. The head zone has one module, the shoulder zone has two modules, the back zone has one module, the lower body zone has two modules and the foot zone has three modules. Each zone is connected to its own outlet controlled by an air pump, so that the pressure can be adjusted independently according to the user's preferences or by means of automatic regulation. This zone configuration provides for individual comfort, optimized weight distribution and improved ergonomic support.In some embodiments, the inflatable air core of the body support device is made of a material selected to balance durability, flexibility, and comfort while providing long term air tightness. The material must have high resistance to the penetration of moisture and body fluids to prevent microbial growth and wear over time. It should be resistant to cycling, i.e., be able to withstand repeated inflation and deflation as well as partial pressure adjustments while supporting the weight of different users. To ensure reliability, the material must be air tight for extended periods of time and must be able to withstand a continuous compressive load of up to 0.35 bar for extended periods of time and a peak pressure of up to 0.45 bar for short periods of time. Moreover, it must have a long-term durability, i.e., maintain its structural integrity at room temperature for at least ten years. Because the body support device may be transported and stored, the material should be wear resistant, able to withstand temperatures from -20°C to 80°C, and able to withstand packaging operations such as stacking and rolling without sacrificing performance. The material must also allow a secure connection by heat welding in order to ensure a robust and leak-proof integration of channels and hoses into the air core.Materials which meet these requirements are, for example, polyether-TPU (thermoplastic polyurethane), PVC and copolyester. However, polyether TPU is particularly well suited due to its balance of durability, processability and functional longevity.In one embodiment, the air cells are inflated to their maximum capacity. However, in a more preferred embodiment, the air cells are only partially inflated to increase user comfort. For example, each individual air cell may be inflated to less than 50% of its full capacity, preferably to less than 45% and more preferably to less than 40%. In another embodiment, the air cells are inflated to a capacity of from 20% to 50%, preferably from 20% to 40%, and more preferably from 25% to 35% (e.g., about 33%).The present construction with several interconnected cells is different from prior art constructions using large rectangular parallelepiped inflatable blocks. In the present construction, less air is required for full functionality. In one embodiment, the structure consumes between one third and half less air than the prior art cuboid structures.In some embodiments, the body support device further includes padding. Such padding may be arranged directly on the core, under the core and / or laterally of the core or embedding the core.The cushioning materials may be synthetic foams such as memory foam, latex foam and gels. Any padding known in the art may be used with the body support device disclosed herein, such as foam, latex, polyester fiber filling, memory gel, natural fibers, synthetic fibers, air-filled materials, gel-added polymers, viscoelastic materials, hollow fibers, microbeads, buckwheat shells, coco fibers, wool, cotton, capok, bamboo fibers, hemp fibers, algal-based foams, encapsulated air chambers, or a combination thereof.In a further embodiment, the upholstery has a pocket spring layer. The pocket spring layer consists of individually sheathed spiral springs, which offer local support and reduce a transmission of movement between different regions of the support device. Each spring functions independently to conform to the body shape of the user while maintaining durability and structural integrity. The bagspring layer may be placed above the inflatable air core to improve conformability, or below the core to provide a stronger backing, or integrated between multiple layers of foam or fibrous padding to provide a balanced comfort system.In another embodiment, the padding is made of felt. Felt serves as a protective and stabilizing layer which helps to distribute the pressure evenly over the bearing surface. It also reduces noise and vibration resulting from the air cell adjustments or the movement of the springs and acts as an insulating barrier between the various layers, thereby improving durability. The felt padding may be placed directly above the air core to provide additional cushioning, below the core to increase stability, or between a pocket spring layer and a foam padding to balance the transitions between the layers.In some embodiments, the body support device includes a combination of multiple cushioning materials to achieve an optimum of comfort, wear resistance, and pressure distribution. One embodiment includes a bag spring layer disposed above the air core and a layer of memory foam thereover for body and comfort adaptation. Another embodiment consists of a felt layer disposed between the air core and a viscoelastic foam layer with encapsulated air chambers that allow dynamic pressure adjustment. In another embodiment, a combination of latex foam is used for elasticity, wool for temperature regulation, and a pocket spring layer for targeted support. Alternatively, a two-sided support system may be provided, one side being gel-added memory foam for cooling comfort, while the other side has a stronger felt and bag spring structure so that users can choose their preferred strength. These various configurations are not limiting.Memory foam is highly appreciated, for example, because of its property of conforming to the body as well as its ability to reduce pressure spots, while gel-loaded foams can assist in heat dissipation to users who quickly become too warm during sleep. Latex foam is often estimated because of its natural origin, breathability, and elasticity, thereby providing a conformable, yet supportive feel.In one embodiment of the body support device disclosed herein, the device includes at least one pump and each pressure zone is in fluid communication with at least one pump. In some embodiments, the body support device disclosed herein includes one or more air pumps, preferably at least 1, 2, 3, 4, or 5 pumps. The air pump in the body support device is configured to precisely regulate the air flow and thus ensure efficient inflation of the air core and air deflation of the air core while maintaining an optimal pressure level. The pump operating at a noise level below 30 dB, preferably below 25 dB, more preferably below 20 dB, most preferably below 15 dB, supports PWM control for adjustable power and uses little current to reduce heat generation and thus extend its life. It is designed in such a way that it resists static pressure of more than 0.3 bar, preferably more than 0.35 bar.In one embodiment, the apparatus includes quiet air pumps specifically designed for operation with lower acoustic emissions with consistent efficiency. Moreover, a sound absorbing housing encloses critical components, thereby effectively absorbing and reducing vibrations that contribute to operating noises. A sound attenuation mechanism additionally attenuates the airflow noise level, thus providing a smoother user experience. Moreover, the system is designed to require a lower volume of air in the cells, which means that fewer inflation adjustments are required and thus the frequency and intensity of pump activation is reduced.In another or further embodiment, the body support device includes a manifold to connect the pressure zones to the one or more air pumps via hoses. The manifold in the body support device is configured to efficiently regulate the flow of air between the air pump and the inflatable air core and to provide precise pressure adjustment across multiple zones. It includes solenoid valves that operate within a controlled voltage range, have low current consumption, and withstand a high cycle count to ensure long durability. The manifold is optimized for minimum heat generation, low noise levels and high airflow capacity, thereby allowing reliable inflation of the air cells and air vents from the air cells while maintaining user comfort and long term performance.In another embodiment, the body support device disclosed herein includes a controller configured to regulate the air pressure in the pressure zones. In a further embodiment, the support device has sensors which are designed to detect pressure changes within the inflatable air core. These sensors may be located on the controller or in the device itself.In some embodiments, the controller is a printed circuit board (PCB).In one embodiment, the controller in the body support device is responsible for regulating the air pressure within the inflatable air core by controlling the flow of air between the air pump, the manifold, and the pressure zones.In one embodiment, it can process real-time data from multiple embedded sensors, such as pressure sensors, strategicly placed in each print zone, either near the center or at spatially distributed points, to monitor local air pressure. When a user changes position and thereby causes a pressure spike in a particular zone, the corresponding sensor detects the deviation from its target set point. Then, the controller activates an air pump or a bleed valve to regulate the amount of air until equilibrium is restored.In another or further embodiment, the sensors are located in the controller. In a preferred embodiment, the sensors are arranged in the controller and are connected to the hose lines which inflate the pressure zone and / or exhaust the air therefrom, whereby the pressure in the pressure zone can be detected.Beyond local adjustments, the controller may be programmed with advanced algorithms to interpret data across multiple zones, thus ensuring a balanced and adaptive support profile. In some embodiments, their mode may be adjusted, e.g., in terms of firmness or sleep position, and tailored to the user's preferences or medical needs. In addition, the body support device may have smart home or IoT connectivity so that external devices such as smart phones or voice assistants may control zone printing, store user profiles, or log print data over time. The controller may operate autonomously when integrated into the bed or wirelessly connect to an external device via Bluetooth or WLAN, thereby ensuring seamless remote settings while maintaining real-time responsiveness even at a connection termination.In some embodiments, the one or more air pumps, the controller, and the manifold are housed in a housing unit. In other embodiments, they are housed in independent units within the body support device.In some embodiments, the body support device disclosed herein is a mattress, a core of a box spring, a mattress toper, or a cushion. The invention is therefore not limited to typical household mattresses. It also includes the concept of a box spring or bed frame using inflatable technology, a topper which can be laid on an existing mattress when the user wishes to retrofit an existing bed with respect to individually adjustable comfort, or even special seat cushions for sofas, vehicles or medical chairs.The inflatable air core of the support apparatus disclosed herein may be manufactured by any method known in the art. In some embodiments of the invention disclosed herein, the inflatable air core is manufactured by a method comprising the following steps:providing TPU webs, preferably of polyether TPU;welding the TPU webs in a layer to a plurality of modules, each module having a plurality of air cells in fluid communication and a plurality of non-inflatable portions, and adjacent modules being structurally connected to the non-inflatable portions;establishing a fluid connection between at least two modules within the layer by means of hoses or integrated channels;stacking at least two layers and connecting these layers at the non-inflatable portions.The bonding between the layers is done by welding or bonding to the non-inflatable portions. The welding technique for the modules and layers is selected from radio frequency welding, hot welding, infrared welding, ultrasonic welding and laser welding.Pressure zones are formed by establishing fluid communication between modules. These modules are connected either by hoses or by integrated channels. When hoses are used, the hoses are welded to the modules. The hoses can be made from the same TPU material or from a complementary polymer. The diameter of each tube is designed to allow the amount of air flow required to inflate or deflate the air, but not so large as to compromise the comfort or structural arrangement of the modules.In a second aspect, the invention disclosed herein relates to a bed having a body support device as disclosed in one of the preceding embodiments.In one embodiment, a mattress for a queensize, kingsize, single, or infant bed has five pressure zones. Each zone corresponds to key anatomical regions such as head / neck, upper body, lumbar spine, pelvis / thigh, and lower leg / foot. The mattress may be divided into left and right sections so that independent control is possible for each sleeper. Each layer consists of 9 modules connected together by welded tubes directing the flow of air within the zones. A compact, low noise air pump is housed in a separate compartment with a plurality of pressure sensors monitoring variations. The bed is equipped with a digital interface that can be accessed via an on-bed device or a mobile app so that the user can accurately set the zone pressure. Embedded sensors allow pressure adjustments in real time and log sleep data.In a third aspect, the invention relates to the use of a support element or a bed as described in one of the preceding embodiments for supporting a human body.In a final aspect, the invention relates to a method for changing the pressure in a body support device or in a bed as disclosed in any of the preceding embodiments, the method comprising:independently detecting a pressure value within each pressure zone of the inflatable air core by means of one or more sensors;comparing the detected pressure value of each pressure zone with a corresponding target pressure value;determining whether adjustment is required based on the comparison; andadjusting the air pressure in each pressure zone by transmitting an adjustment command to an air pump, wherein the steps are performed by a controller.When a user hangs up, sensors register the pressure distribution and a controller processes the measured values and determines, using an algorithm, the correct strength levels in the various zones based on the characteristics of the user. When the pressure in a zone falls below the set point, the controller inflates the zone; when the pressure exceeds the set point, air is vented. This process is continuous or on a certain schedule, so that initially frequent adjustments are possible during use and activity is reduced as soon as the user comes to rest to minimize noise. In medical applications, continuous monitoring provides pressure relief for users prone to decubitus or other diseases requiring dynamic support.The system may also adapt to alternative parameters if a zone cannot meet its set point due to leaks, user movements, or changes in ambient temperature. If the pressure in a zone remains permanently below the set point, the controller initiates a re-inflation cycle. If multiple cycles fail, the system may notify the user or caregiver for verification.In some embodiments, the body support device may automatically adjust the pressure in the core. For example, it may supply additional air when leakage or pressure variation occurs due to temperature differences, or activate a valve that vents air when positive pressure is detected. The system is designed to exhaust when the pressure exceeds the maximum value of 0.4 bar.Some embodiments of the body support device may incorporate additional sensors for monitoring temperature, humidity and occupancy, thus enabling adaptive comfort control. The system may regulate airflow, enable thermal management functions, or identify multiple users, and adjust settings accordingly. If the bed is not used, it may be placed in a power save mode. These improvements maintain the core principle of a two-ply zoned inflatable support system and provide accurate pressure control and individual comfort.The present invention will now be described in more detail by way of non-limiting examples.DESCRIPTION OF THE FIGURESFigure 1 shows a body support device (1) having a core (2) comprising at least two layers (4), each layer comprising inflatable air cells (3). These layers are arranged in a vertically stacked configuration, thereby ensuring uniform pressure distribution and structural stability. The air cells (3) within each layer are organized into modules (5) which in turn are grouped into print zones (6). This zone configuration allows for independent pressure adjustment that optimizes comfort and support depending on the user's needs.Each module (5) has a plurality of air cells (3) in fluid communication with each other through ducts (7), thereby allowing controlled airflow within the module. The modules are supplied with air via hoses (8) connected to an air pump (9) responsible for inflating the cells and exhausting air from the cells. The air pump (9) is controlled by a control unit which processes real-time data from embedded sensors and dynamically adjusts the zone pressure.FIG. 2 shows a detailed view of a module ( 5) within the core ( 2) of the body support device ( 1). The module (5) consists of several inflatable air cells (3) which are connected to one another and arranged in a structured layout.The module (5) includes non-inflatable portions (10) which separate adjacent air cells from each other and at the same time serve as anchoring points for the fastening of the layers to each other. Within these non-inflatable portions, perforations (15) and apertures (15') are strategic. The cross-shaped perforations (15) allow the correct alignment and connection of the first and second layers of the device, thereby ensuring structural integrity and preventing misalignment during inflation and air exhaust cycles. The circular openings (15') serve as relief elements which contribute to the distribution of the mechanical forces and prevent tearing of the material during prolonged use.FIG. 3 shows a schematic plan view of the body support device ( 1). The air cells (3) are divided into five different pressure zones (6', 6", 6"', 6 IV, 6V) each corresponding to a different anatomical region to provide targeted support and adaptive pressure regulation.Zone 6' is located in the head area and consists of a module designed to support the head and neck gently and stably, thereby preventing excessive sinking or stiffness. Zone 6" covers the shoulder region and comprises two modules. Zone 6''' is located centrally under the lower back and consists of a module optimized for lumbar support and orientation, thus ensuring correct posture. Zone 6 IV is located under the hips and thigh and consists of two modules. Zone 6 V, which is located in the foot area, has three modules.A foam cushioning layer (13) surrounds the inflatable core. The air pump (9) is housed within the system and connected to the core by air distribution hoses (8) which independently transport air to each print zone.FIG. 4 shows sectional views of the body support device (1), wherein FIG. 4A shows a longitudinal section and FIG. 4B shows a cross section.The body support device (1) comprises the air core (2) and a padding comprising a foam padding (13) surrounding the core, as well as a bag spring layer (14). The foam layer ( 13) encapsulates the entire support structure. The pocket spring layer (14) provides structural support and resiliency, thereby providing proper weight distribution and conformability to body movements. The air pump (9) is located inside the structure. A dedicated channel is provided for cables. The air distribution system is also visible, with air hoses (8) that direct the air flow from the air pump (9) to different pressure zones. These hoses are passed through a special channel for hose lines, whereby the system remains ordered and blockages are avoided. In Fig. 4A, the cable system (16) is seen which connects the control unit to a power source.The present invention is in no way limited to the embodiments described in the examples and / or illustrated in the figures. On the contrary, the methods according to the present invention can be realized in many different ways without departing from the scope of the invention.List of reference characters1 Support device 2 core 3 inflatable air cell 4 layer 5 module 6 pressure zone 7 channel 8 hose 9 air pump 10 non-inflatable section 11 air cell inlet 12 connector 13 foam padding 14 pocket spring layer 15 perforation 15' opening 16 cable

Claims

A body support device (1) for supporting a person while resting or sleeping, such as a mattress, a topsheet or a box spring, the device comprising a core (2) having at least two layers (4), each layer comprising a plurality of inflatable air cells (3), each air cell being in fluid communication with at least one adjacent air cell (3) and being adapted to be connected to and inflated by one or more air pumps (9); wherein the core is divided into a plurality of pressure zones (6); and wherein the layers of the inflatable air core are secured together in a vertically stacked configuration.The body support device according to Embodiment 1, wherein the core includes non-inflatable portions (10), at least a part of the non-inflatable portions is disposed between the air cells, and the at least two layers are fixed to each other at the level of the non-inflatable portions (10).The body support device according to any one of embodiments 1 or 2, wherein the non-inflatable portions (10) comprise perforations (15) and / or openings (15').Body support device according to any of the preceding embodiments, wherein the layers (4) are fixed to each other by welding or by means of an adhesive.The body support device according to any of the preceding embodiments, wherein the air cells (3) within a layer (4) are organized into modules (5) and wherein air cells (3) within a module (5) are in fluid communication with each other through channels (7).Body support device according to the preceding embodiments, wherein at least one pressure zone (6) is formed by one module (5) per layer.A body support device according to any preceding embodiment, wherein at least one pressure zone (6) is formed by a plurality of modules (5) per layer, the modules within a zone being in fluid communication with each other by hoses (8) or channels (7).Body support device according to the preceding embodiments, wherein the hoses (8) are welded to the modules (5).A body support device according to any preceding embodiment, wherein each layer (4) comprises between 2 and 12 modules (5).A body support device according to any preceding embodiment, wherein each layer (4) has between 2 and 12 pressure zones (6).The body support device according to any of the preceding embodiments, wherein the support element further comprises padding on the core (2), below the core and / or embedding the core.The body support device according to the preceding embodiments, wherein the padding is made of a foam material such as a memory foam, a latex foam or a gel-added foam.The body support device according to any of the preceding embodiments, wherein the padding comprises a pocket spring layer (14).A body support device according to any preceding embodiment, wherein each pressure zone (6) is in fluid communication with at least one air pump (9).The body support device according to any one of the preceding embodiments, further comprising a controller configured to regulate the air pressure in the pressure zones (6).The body support device of any preceding embodiment, further comprising sensors configured to sense changes in pressure within the inflatable air core.The body support device according to any one of the preceding embodiments, wherein the support member is a mattress, a core of a box spring, a mattress toper, or a cushion.A bed comprising a body support device according to any of the preceding embodiments.

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