Support device for a piece of furniture

Abstract

Support device (100) for a piece of furniture, wherein the support device comprises: a first layer (110) comprising a first polymer foam with a first density in the range of 30 kg / m³ 3 up to 60 kg / m 3 , a second layer (120) arranged on top of the first layer (110), wherein the second layer (120) is a second polymer foam with a second density in the range of 60 kg / m³ 3 up to 90 kg / m 3 exhibits, wherein the second layer (120) comprises a unitary layer of the second polymer foam.

Description

TECHNICAL AREA

[0001] Various aspects of this disclosure relate to a support device for a piece of furniture, a method for manufacturing the support device, and a method for attaching the support device to the piece of furniture. BACKGROUND

[0002] The following background discussion is intended solely to facilitate understanding of the present disclosure. It is noted that this discussion does not constitute an acknowledgment or admission that the material referenced was published, known, or part of the common knowledge in any jurisdiction at the priority date of this disclosure.

[0003] Conventional support devices for mattresses or chairs use several pieces of foam, each with a similar thickness and shape, to ensure consistent firmness for support and user comfort.

[0004] The multiple foam pieces may lack structural integrity, adjustable firmness, and support, making them unable to provide the necessary ergonomic support for extended periods. Therefore, a user spending long times on such conventional supports may experience discomfort, stiffness, and chronic body aches and pains. Furthermore, the multiple foam pieces may shift relative to each other with prolonged use, compromising their supportive function for the user.

[0005] Furthermore, conventional support devices often tend to deform with long-term use, due to stress on the material over time and / or repeated tilting of the device. Additionally, the manufacture of conventional support devices, which incorporate multiple foam components, can be complex and expensive.

[0006] Therefore, there is a need for an improved support device and / or a method for manufacturing such a support device, which should solve at least one of the problems mentioned above. BRIEF EXPLANATION

[0007] The present disclosure was designed to provide an improved support device for a piece of furniture. For this purpose, the improved support device comprises a first polymer foam with a density of 30 kg / m³. 3 up to 60 kg / m 3and a second polymer foam layered on top of it, the second polymer foam having a density of 60 kg / m³ 3 up to 90 kg / m 3The different densities between the two polymer foams ensure structural integrity, even pressure distribution, and ergonomic support for one or more users, which can alleviate users' physical discomfort and thus improve their health. Furthermore, the improved support device is durable and resistant to deformation during prolonged use. For example, the improved support device retains its original shape and structure despite repeated reclining movements over time and is suitable for providing optimal ergonomic support for a wide range of users with varying body weights and shapes. Moreover, embodiments of the disclosure provide a simple, cost-effective, and rapid assembly manufacturing process for the improved support device.

[0008] The improved support device is particularly suitable for use as a seat and / or backrest in a chair, e.g., a gaming chair or vehicle seat, or in a mattress.

[0009] According to a first aspect of the disclosure, a support device for a piece of furniture is provided, wherein the support device comprises: a first layer comprising a first polymer foam with a first density in the range of 30 kg / m³ 3 up to 60 kg / m 3 comprising a second layer arranged on top of the first layer, the second layer comprising a second polymer foam with a second density in the range of 60 kg / m³ 3 up to 90 kg / m 3 exhibits, wherein the second layer comprises a unitary layer of the second polymer foam.

[0010] In various embodiments, the first polymer foam has a first matrix structure, wherein the first matrix structure comprises a plurality of first foam cells, and the second polymer foam has a second matrix structure, wherein the second matrix structure comprises a plurality of second foam cells, wherein the second foam cells differ from the first foam cells, and wherein each second foam cell from the plurality of second foam cells has a density greater than the density of each first foam cell from the plurality of first foam cells.

[0011] In various embodiments, the second matrix structure, which comprises the majority of second foam cells, has a uniform matrix structure along at least one of a lateral plane, a longitudinal plane and / or a diagonal plane of the second layer.

[0012] In various embodiments, the ratio of the first density to the second density is in a range of 50% to 95%, optionally in a range of 60% to 90%.

[0013] In various embodiments, the first polymer foam has a first IFD value (Indentation Force Deflection) with 40% deflection in a range of 20 to 80; and the second polymer foam has a second IFD value with 40% deflection in a range of 250 to 500.

[0014] In various embodiments, the first layer comprises: a circumferential section located at one end of the first layer, the circumferential section having a circumferential thickness; and a central section extending from the circumferential section in a direction perpendicular to a lateral axis of the first layer, the central section having a central thickness greater than the circumferential thickness of the circumferential section. In some embodiments, the circumferential thickness ranges from 0.5 cm to 10 cm, and the central thickness ranges from 15 cm to 25 cm.

[0015] In various embodiments, the second layer has a recess extending at least partially along a surface of the second layer, and the first layer has a projection extending at least partially from a surface of the first layer, wherein the recess of the second layer is configured to accommodate the projection of the first layer. In some embodiments, the recess has a first recess segment with a first recess depth and a second recess segment with a second recess depth greater than the first recess depth, and the projection has a first projection segment with a first projection height and a second projection segment with a second projection height greater than the first projection height, wherein the first recess segment and the second recess segment are configured to accommodate the first projection segment and the second projection segment, respectively.to take up the second leading segment.

[0016] In various embodiments, an adhesive layer is arranged between the first layer and the second layer, the adhesive layer being configured to attach the first layer to the second layer, and having a thickness in the range of 0.1 cm to 0.5 cm. In some embodiments, the adhesive layer comprises an adhesive that is arranged at least partially along the surface of the second layer and / or partially along the surface of the first layer.

[0017] In various embodiments, the first polymer foam comprises a memory foam polymer, and the second polymer foam comprises a cold foam polymer.

[0018] According to a second aspect of the disclosure, a chair is provided which includes the support device of the first aspect. In various embodiments, the support device may comprise the seat and / or the backrest of the chair. In some embodiments, the support device may comprise a part, e.g., the central section of the backrest of the chair.

[0019] According to a third aspect of the revelation, a mattress is provided which has the support device of the first aspect.

[0020] According to a fourth aspect of the disclosure, a method for manufacturing a support device for a piece of furniture is provided, wherein the method comprises: providing a first layer comprising a first polymer foam with a first density in the range of 30 kg / m³ 3 up to 60 kg / m 3comprising providing a second layer for arrangement on top of the first layer, wherein the second layer comprises a second polymer foam with a second density in the range of 60 kg / m³ 3 up to 90 kg / m 3 exhibits, wherein the second layer comprises a unitary layer of the second polymer foam.

[0021] In various embodiments, the first polymer foam has a first matrix structure comprising a plurality of first foam cells, and the second polymer foam has a second matrix structure comprising a plurality of second foam cells, wherein the second foam cells differ from the first foam cells, and wherein each second foam cell from the plurality of second foam cells has a density greater than the density of each first foam cell from the plurality of first foam cells.

[0022] In various embodiments, the provision of the first layer includes the provision of a projection extending at least partially from a surface of the first layer, and the provision of the second layer includes the provision of a recess extending at least partially along a surface of the second layer, wherein the recess of the second layer is configured to accommodate the projection of the first layer.

[0023] In various embodiments, the provision of the first layer further comprises: forming a circumferential section positioned at one end of the first layer on another surface of the first layer, wherein the circumferential section has a circumferential thickness, and a central section extending from the circumferential section in a direction perpendicular to a lateral axis of the first layer, wherein the central section has a central thickness greater than the circumferential thickness of the circumferential section.

[0024] In various embodiments, the method further comprises providing an adhesive layer for placement on at least one of the surfaces of the first layer and / or one surface of the second layer, for attaching the first layer to the second layer, wherein the adhesive layer has a thickness in the range of 0.1 cm to 0.5 cm.

[0025] In various embodiments, the second layer is produced according to a cold foam manufacturing process.

[0026] According to a fifth aspect of the disclosure, a method for attaching the support device of the first aspect to the piece of furniture is provided, wherein the piece of furniture has a main frame configured to receive the support device, the method comprising: positioning the second layer of the support device on the main frame of the piece of furniture, the second layer having at least one opening extending into an interior of the second layer, the at least one opening being configured to receive a fastener; attaching the second layer of the support device to the main frame of the piece of furniture by securing the fastener to the at least one opening of the second layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The revelation is more easily understood with reference to the detailed description in conjunction with the non-restrictive examples and the appended drawings. These show: - Fig. 1 a schematic representation of a perspective view of an exemplary support device 100 for a piece of furniture; - Fig. 2 a schematic representation of a side view of the in Fig. 1 exemplary support device 100 shown; - Fig. 3 a schematic representation of a front view of the in Fig. 1 and Fig. 2 exemplary support device 100 shown; - Fig. 4 a schematic representation of a perspective view of another exemplary support device 100 for a piece of furniture; - Fig. 5 a schematic representation of an exemplary embodiment of a backrest 200 of a chair, which has a support device; - Fig. 6 a flowchart showing a process 300 for manufacturing a support device for a piece of furniture; - Fig. 7 a flowchart showing a method 400 for attaching a support device to a piece of furniture; - Fig. 8. A schematic representation of method 400 for attaching the support device to an exemplary piece of furniture, comprising a chair seat; and - Fig. 9 a schematic representation (A) of the method 400 for attaching the support device to another exemplary piece of furniture having a chair backrest; and (B) of the assembled piece of furniture 430 having the support device. DETAILED DESCRIPTION

[0028] The following detailed description refers to the accompanying drawings, which illustrate specific details and embodiments in which the disclosure can be implemented. These embodiments are described in sufficient detail to enable a person skilled in the field to implement the disclosure. Other embodiments may be used, and structural and logical modifications may be made without departing from the scope of the disclosure. The various embodiments are not necessarily mutually exclusive, as some embodiments may be combined with one or more other embodiments to form new embodiments.

[0029] Features described in connection with one embodiment may be applicable to the same or similar features in other embodiments. Features described in connection with one embodiment may be applicable to other embodiments even if they are not explicitly described in those other embodiments. Furthermore, additions, combinations, and / or alternatives as described for a feature in connection with one embodiment may be applicable to the same or similar feature in the other embodiments.

[0030] Although terms like "first," "second," etc., can be used to describe different elements, these elements need not be limited to the terms mentioned above. The terms above are used only to distinguish one element from another and do not define corresponding elements, such as an order and / or significance of the elements. Without altering the scope of the description, a first element may be referred to as a second element, and likewise, a second element may be referred to as a first element.

[0031] In the context of various embodiments, the articles "a", "an", and "the", "a", "a", as used in relation to a feature or element, refer to one or more of the features or elements. As used here, the term "and / or" refers to all combinations of one or more of the elements listed.

[0032] In the context of various embodiments, the specified values ​​or limits of the ranges listed below with respect to the terms "density," "value," "thickness," "height," and "depth" may refer to an average of these terms. For example, the specified values ​​or limits of the ranges for the terms "first density," "second density," "third density," "first IFD value," "second IFD value," "first projection height," "second projection height," "first recess depth," "second recess depth," "circumference thickness," "center thickness," "first thickness," and "second thickness" may refer to the average value or average limit of the range.

[0033] Throughout this description, the term "piece of furniture," as used here, can refer to objects suitable for supporting a user and / or providing comfort to the user. The term "piece of furniture" can refer to, but is not limited to, household furnishings such as a chair, bed, sofa, recliner, or ottoman. In various embodiments, the chair can include a gaming chair, an office chair, or a dining chair. The piece of furniture can also refer to parts of a vehicle's interior, such as a vehicle seat, e.g., a driver's or passenger's seat, or a child seat.

[0034] Throughout this description, the term "support device," as used herein, can refer to any object designed to bear at least the weight of a user and to provide comfort by allowing the user to rest upon it, for example, by sitting, leaning, kneeling, or lying down. Non-restrictive examples of a support device include a cushion, a pillow, a headrest, or a mattress. In various embodiments, the support device may be part of the piece of furniture. For example, the support device may be a seat and / or a backrest, or part thereof, of a chair. In some embodiments, the support device may be a mattress. In some embodiments, the support device may be detachably attached to the piece of furniture.

[0035] Throughout this description, the term "polymer foam," as used here, can refer to a solid cellular matrix structure containing foam cells, each of which can have an open-cell or closed-cell structure. The foam cells can be made of a polymer, such as polyurethane. The structural arrangement of the foam cells within the cellular structure can impart mechanical properties to the polymer foam, such as density, strength, and viscoelasticity.

[0036] Fig. Figure 1 shows a schematic representation of a perspective view of an exemplary support device 100 for a piece of furniture. Fig. 2 and Fig. Figure 3 shows a schematic representation of a side view or a front view of the in Fig. 1. Exemplary support device 100 shown. Fig. Figure 4 shows a schematic representation of a perspective view of another exemplary support device 100 for a piece of furniture.

[0037] Referring to Fig. 1, Fig. 2 to Fig. 3. The support device 100 can have a seat of a chair. Additionally or alternatively, the support device 100 can be provided as a backrest of a chair or part thereof, such as a middle section of the chair, as shown in Fig. Figure 2 shows that in various embodiments the chair can be a gaming chair, an office chair, or a car seat.

[0038] Referring to Fig. 1, Fig. 2, Fig. 3 to Fig. 4 The support device 100 can have a first layer 110 comprising a first polymer foam with a first density in the range of 30 kg / m³ 3 up to 60 kg / m 3has various embodiments, when the support device 100 has a seat surface, as in Fig. 1, Fig. 2 to Fig. As shown in section 3, the first density can optionally be in a range of 50 kg / m³. 3 up to 60 kg / m 3 and optionally at 57.5 kg / m 3 lie. In various other embodiments, when the support device 100 is the central part of a backrest, as in Fig. As shown in section 4, the first density can optionally be in a range of 35 kg / m³. 3 up to 45 kg / m 3 , optionally at 40 kg / m 3 lay.

[0039] The first layer 110, which comprises the first polymer foam, can exhibit a first IFD (Indentation Force Deflection) value in a range of 20 to 80 at 40% deflection. In some embodiments, when the support device 100 is provided as a seat surface (see Fig. 1, Fig. 2 to Fig. 3), the first IFD value at 40% deflection can be in a range of 30 to 40, optionally 35.5. In some other embodiments, when the support device 100 is provided as a central part of the backrest (see Fig. 4), the first IFD value at 40% deflection can be in a range of 45 to 55, optionally at 50.

[0040] In various embodiments, the first layer 110, which comprises the first polymer foam, has a first matrix structure, wherein the first matrix structure comprises a plurality of first foam cells. The first foam cells can have an open-cell structure. The first matrix structure can comprise loosely packed first foam cells, each of which has an inner pocket, i.e., an open cell, with air-filled spaces. As such, the first matrix structure can allow air to flow through it, providing a breathable material. The first matrix structure also enables the first layer 110 to be viscoelastic, i.e., the first layer 110 can be deformation-resistant and retain its original structure and shape when an applied load, e.g., the weight of a user, is removed. In some embodiments, the first layer 110 can comprise a memory foam polymer.

[0041] With reference to Fig. 1, Fig. 2, Fig. 3 to Fig. 4 The support device 100 further comprises a second layer 120 arranged on the first layer 110, wherein the second layer 120 is a second polymer foam with a second density in the range of 60 kg / m³ 3 up to 90 kg / m 3 , optionally in a range of 60 kg / m 3 up to 70 kg / m 3 and optionally at 66 kg / m 3 exhibits. The second density can be the same, regardless of whether the second layer is 120 as a seating surface (see Fig. 1, Fig. 2 to Fig. 3) or as the center section of the backrest (see Fig. 4) is provided.

[0042] In various embodiments, the second layer 120, which comprises the second polymer foam, can have a second IFD value at 40% deflection in a range of 250 to 500, optionally in a range of 250 to 350, and optionally at 280. The second IFD value can be the same regardless of whether the second layer 120 serves as a seat surface (see Fig. 1, Fig. 2 to Fig. 3) or as the center section of the backrest (see Fig. 4) is provided.

[0043] The second layer 120, which contains the second polymer foam, has a second matrix structure comprising a plurality of second foam cells. These second foam cells may differ from the first foam cells and have a closed-cell structure. The second matrix structure may contain densely packed second foam cells, each with a closed and compact structure. Accordingly, each of the second foam cells in the second layer 120 may have a density greater than that of each of the first foam cells in the first layer 110, and the second matrix structure may provide a second polymer foam that is more compact and denser than the first polymer foam, exhibiting high elastic recovery and durability. In other words, the second layer 120 does not deform when an applied load, e.g.,The weight of a user is applied and removed, and it retains its original shape and structure even with long-term use. In some embodiments, the second layer 120 can be a cold foam polymer.

[0044] In various embodiments, the second layer 120 comprises a unitary layer of the second polymer foam, e.g., a cold foam polymer, and has a uniform matrix structure along at least one of a lateral plane, a longitudinal plane, and / or a diagonal plane of the second layer 120. In other words, the second layer 120 can comprise only a single, e.g., a single, discrete layer of the second polymer foam and cannot, as in conventional support devices, comprise multiple layers of stacked foam parts that lack structural integrity and ergonomic support and deform with long-term use. In this respect, the use of a unitary, e.g.,The single layer of the second polymer foam ensures a uniform consistency throughout the entire second layer 120 to achieve uniform pressure distribution and thereby guarantee structural integrity and ergonomic support for one or more users, especially since the second layer 120 does not have multiple pieces of foam that can slip or move relative to each other and impair the supportive function of the conventional support device.

[0045] In various embodiments, the ratio of the first density of the first polymer foam of the first layer 110 to the second density of the second polymer foam of the second layer 120 can be in a range of 50% to 95%, depending on which part of the piece of furniture the support device 100 is suitable for. In some embodiments, when the support device 100 serves as a seat (see Fig. 1, Fig. 2 to Fig. 3) is provided, the ratio of the first density to the second density can optionally be in a range of 85% to 90%. In some other embodiments, when the support device 100 is used as the center piece of the backrest (see Fig. 4) If provided for, the ratio of the first density to the second density may optionally be in a range of 55% to 60%.

[0046] In various embodiments, the first layer 110, e.g., memory foam polymer, can have different density and IFD value ranges depending on the use of the support device 100 on the chair, while the second layer 120, e.g., cold foam polymer, can have a constant density and a constant IFD value regardless of the use of the support device 100 on the chair. For example, the first layer 110 can have a higher density and a lower IFD value if it is intended as a seat surface (see Fig. 1, Fig. 2 to Fig. 3), and can have a lower density but a higher IFD value when used as a center section of a backrest (see Fig. 4) However, the second layer 120 can have a constant density and a constant IFD value range when it is provided as a seat surface or as the center section of the backrest. The second layer 110 can therefore provide a rigid base that does not deform under an applied load, while the first layer 110 can provide a viscoelastic layer for user comfort. Accordingly, the support device 100, when provided as a seat surface (see Fig. 1, Fig. 2 to Fig. 3) provides optimal ergonomic support, which is necessary for comfort over long hours, and is provided as the center section of the backrest (see Fig. 4) resistant to deformation despite repeated reclining movements of the backrest.

[0047] Referring to Fig. 2. The first layer 110, e.g., memory foam polymer, can further comprise a projection 116 that extends at least partially from a surface of the first layer 110. The projection 116 can extend from the surface configured to be located on the second layer 120. The projection 116 can have a first projection segment 118 located at one end of the projection 116 and a second projection segment 119 located at another, e.g., opposite, end of the projection 116. In various embodiments, the first projection segment 118 can extend to and terminate in the second projection segment 119. It is also conceivable that the projection 116 extends completely along a surface of the first layer 110.

[0048] In various embodiments, the first projection segment 118 can have a first projection height h1, and a second projection segment 119 can have a second projection height h2 that is greater than the first projection height h1. In some embodiments, the first projection height h1 can be from 5 mm to 3 cm, optionally from 1 cm to 3 cm, and the second projection height h2 can be from 4 cm to 6 cm.

[0049] The second layer 120, e.g., cold foam polymer, can have a recess 122 that extends at least partially along a surface of the second layer 120. The recess 122 can be located on the surface configured to be layered onto the first layer 110 and can be configured to accommodate the projection 116 of the first layer 110. The recess 122 can have a first recess segment 124 located at one end of the recess 122 and a second recess segment 126 located at another end, e.g., the opposite end, of the recess 122. For example, the first recess segment 124 can extend into and terminate in the second recess segment 126, as shown in Fig. 2 shown. It is conceivable that the recess 122 extends completely along a surface of the second layer 120.

[0050] In various embodiments, the first recess segment 126 can have a first recess depth d1, and the second recess segment 126 can have a second recess depth d2 that is greater than the first recess depth d1. In some embodiments, the first recess depth d1 can range from 5 mm to 3 cm, and the second recess depth d2 can range from 4 cm to 6 cm, to correspond to the first projection height h1 and the second projection height h2 of the projection 116, respectively. Thus, the first recess segment 124 and the second recess segment 126 can be configured to accommodate the first projection segment 118 and the second projection segment 119, respectively.

[0051] The projection 116 of the first layer 110 and the corresponding recess 122 of the second layer 120, which is configured to receive the projection 116, can simplify the assembly and manufacturing process of the support device 100 by ensuring that the first layer 110, which has a lower IFD value (i.e., is softer), fits easily onto and is mounted on the second layer 120, which has a higher IFD value (i.e., is harder). Furthermore, if the support device 100 is intended as the center section of a backrest (see Fig. 4) The engagement between the projection 116 and the recess 122 enables the support device 100 to retain its original shape and structure despite repeated reclining movements of the backrest. While Fig. 1, Fig. 2, Fig. 3 to Fig. 4 showing the engagement between the recess 122 and the projection 116 of the support device 100, it is conceivable that the support device 100 has alternative fitting features to facilitate the layering of the first layer 110 onto the second layer 120 and thereby simplify the assembly and manufacturing process.

[0052] In various embodiments, the support device 100 further comprises an adhesive layer 130, which is arranged and configured between the first layer 110 and the second layer 120 to attach the first layer 110 to the second layer 120. In various embodiments, the adhesive layer 130 can comprise an adhesive that is arranged at least partially or completely along a surface of the second layer 120 and / or partially or completely along a surface of the first layer 110. In some embodiments, the adhesive can be arranged partially or completely on both surfaces of the first layer 110 and the second layer 120. For example, the adhesive can be arranged on the projection 116, e.g., the first 118 and / or the second 119 projection segment of the first layer 110, and / or the recess 122, e.g., the first 124 and the second 126 recess segment of the second layer 120.Non-restrictive examples of the adhesive include an adhesive and / or one or more hook-and-loop fasteners. The adhesive may include any means suitable for joining the first layer 110 and the second layer 120 to each other.

[0053] In various embodiments, the adhesive layer 130 can have a thickness of 0.1 cm to 0.5 cm, optionally from 0.1 cm to 0.3 cm. In some embodiments, the thickness of the adhesive layer 130 can be uniform so as not to impair the user's experience with the support device 100.

[0054] As in Fig. 1, Fig. 2 to Fig. Figure 3, in which the support device 100 can be provided as a seat, furthermore the support device 100 can have raised edges 140, 150 arranged on opposite sides of the support device 100. In various embodiments, the first layer 110 can have first raised edges 142, 152 arranged on second raised edges 144, 154 of the second layer 120.

[0055] In various embodiments, the first layer 110 can further comprise a circumferential section 112, which is arranged at one end of the first layer 110, and a central section 114, which extends from the circumferential section 112 in a direction perpendicular to the lateral axis of the first layer 110. For example, the central section 114 can extend upwards and away from the circumferential section 112. In various embodiments, the circumferential section 112 can have a circumferential thickness t1, and the central section 114 can have a central thickness t2 that is greater than the circumferential thickness t1 (see Fig. 2) In some embodiments, the circumferential thickness t1 ranges from 0.5 cm to 10 cm, optionally from 5 cm to 10 cm; and the central thickness t2 ranges from 15 cm to 25 cm, optionally from 18 cm to 22 cm. The varying thickness and inclination between the circumferential section 112 and the central section 114 of the support device 100 provides a pebble-shaped seating surface that offers optimal ergonomic support to promote the natural movement of the spine by providing a larger contact area and more even pressure distribution. Furthermore, the raised edges 140, 150 can provide more space to accommodate multiple user postures. It is also conceivable that the thickness of the first layer 110 and / or the second layer 120 and various parts thereof could be varied to enhance the ergonomic properties of the support device 100 when it is used as a seat.

[0056] In various embodiments, the second layer 120 can have a first section 121, which is arranged at one end and has a first thickness, and a second section 123, which is arranged at an opposite end of the second layer 120 and has a second thickness (see Fig. 1) In some embodiments, the first section 121 may have a first thickness in a range of 1 cm to 2.5 cm; and the second section 123 may have a second thickness in a range of 0.5 cm to 5 cm.

[0057] In various other embodiments and with reference to Fig. 4, in which the support device 100 can be provided as the central part of a backrest, the second layer 120 has the first section 121, which is arranged at one end and has a first thickness, and a second section 123, which is arranged at an opposite end of the second layer 120 and has a second thickness. In some other embodiments, the first section 121 can have a first thickness of 0.5 cm to 2 cm; and the second section 123 can have a second thickness of 1 cm to 2.5 cm.

[0058] Fig. Figure 5 shows a schematic representation of an exemplary embodiment of a chair backrest 200, which includes a support device. The support device can refer to the support device 100 as described in Figure 5. Fig. 1, Fig. 2, Fig. 3 to Fig. 4 is described, without repeating descriptions.

[0059] The backrest 200 can further comprise an outline layer 210 arranged adjacent to the sides of the support device 100. The outline layer 210 can comprise a headrest 212 arranged adjacent to one side of the support device 100, as well as inclined side wings 214, 216 positioned on opposite sides of the support device 100.

[0060] In various embodiments, the outline layer 210 can incorporate a third polymer foam with a third density in the range of 60 kg / m³. 3 up to 90 kg / m 3 , optionally in a range of 60 kg / m 3 up to 70 kg / m 3 and optionally at 66 kg / m 3The third polymer foam, however, can have an IFD value at 40% deflection in a range of 250 to 500, optionally in a range of 400 to 500, and optionally at 423. In one embodiment, the third polymer foam can be a cold-cure foam polymer. In other words, the outline layer 210 can be similar to the second layer 120 in that the third polymer foam has a third density, which can be the same as the second density of the second layer 120, but can have a higher IFD value, i.e., a higher hardness, compared to the second layer 120. Thus, the outline layer 120 can provide additional support to the support device 100 during repeated reclining movements of the backrest 200, and the support device 100 can retain its original shape and structure.

[0061] While the support device 100 has been described with reference to the first layer 110 and the second layer 120, it is also conceivable that the support device 100 further comprises one or more additional layers arranged on top of the first layer 110 and / or the second layer 120 and / or between the first layer 100 and the second layer 120. Furthermore, it is conceivable that the first polymer foam, the second polymer foam, and / or the third polymer foam have perforations to optimize pressure distribution.

[0062] According to another aspect of the revelation, a chair is provided which supports the device 100, as with reference to Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 explained, features. In various embodiments, the support device 100 can serve as a seat (see Fig. 1, Fig. 2 to Fig. 3) and / or as part, e.g. as the center piece of a backrest (see Fig. 4 and Fig. 5).

[0063] According to another aspect of the disclosure, a mattress is also provided which has the support device 100, as referred to in Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 explained. In various embodiments, the support device 100 can be arranged at the base of the mattress, and the mattress can furthermore have one or more additional layers arranged on top of the first layer 110. It is conceivable that the one or more additional layers comprise a viscoelastic material, e.g., a memory foam polymer.

[0064] Fig. Figure 6 shows a flowchart that explains a method 300 for manufacturing a support device for a piece of furniture according to another aspect of the disclosure. The support device may refer to the support device 100, which is described in relation to Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 was explained, and a further explanation is omitted here.

[0065] Method 300 involves: providing a first layer consisting of a first polymer foam with a first density in the range of 30 kg / m³ 3 up to 60 kg / m 3 exhibits (step 302); providing a second layer to be arranged on top of the first layer, wherein the second layer is a second polymer foam with a second density in the range of 60 kg / m³ 3 up to 90 kg / m 3The second layer comprises a unitary layer of the second polymer foam (step 306). Method 300 further comprises providing an adhesive layer for placement on at least one surface of the first layer and / or one surface of the second layer to attach the first layer to the second layer (step 304).

[0066] In various embodiments, in step 302, when the seat surface has the first layer, the first density can optionally be in a range of 50 kg / m². 3 up to 60 kg / m 3 and optionally at 57.5 kg / m 3 In various other embodiments, where the first layer is contained in the central part of the backrest, the first density can optionally be in a range of 35 kg / m³. 3 up to 45 kg / m 3 and optionally at 40 kg / m 3 lay.

[0067] In various embodiments, the first polymer foam in step 302 can have a first IFD value at 40% deflection in a range of 20 to 80. If the first layer is intended as a seat surface, the first IFD value at 40% deflection can be in a range of 30 to 40, optionally 35.5. If the first layer is intended as the center section of a backrest, the first IFD value at 40% deflection can be in a range of 45 to 55, optionally 50.

[0068] In various embodiments, the first polymer foam can be a memory foam polymer. The first layer comprising the first polymer foam can be produced according to a memory foam manufacturing process, which may include a step of molding the first polymer foam at a temperature in the range of 20 °C to 35 °C, optionally from 25 °C to 30 °C.

[0069] In various embodiments, the provision of the first layer in step 302 may further include the provision of a projection that extends at least partially from a surface of the first layer. In some embodiments, the projection may have a first projection segment with a first projection height and a second projection segment with a second projection height that is greater than the first projection height.

[0070] In various embodiments, the provision of the first layer in step 302 may further comprise: forming a circumferential section on another surface of the first layer, which is positioned at one end of the first layer, wherein the circumferential section has a circumferential thickness, and a central section extending from the circumferential section in a direction perpendicular to a lateral axis of the first layer, wherein the central section has a central thickness that is greater than the circumferential thickness of the circumferential section.

[0071] In various embodiments of method 300, the first polymer foam has a first matrix structure comprising a plurality of first foam cells, and the second polymer foam has a second matrix structure comprising a plurality of second foam cells, wherein the second foam cells are different from the first foam cells. Each second foam cell from the plurality of second foam cells can have a density greater than the density of each first foam cell from the plurality of first foam cells.

[0072] In various embodiments, step 306 may involve providing the second layer, which comprises a unitary layer of the second polymer foam. This second layer may consist of a single, discrete layer of the second polymer foam, wherein the second polymer foam has a second matrix structure comprising a plurality of second foam cells. In some embodiments, the second foam cells may have a closed-cell structure. In other words, the second layer may not have multiple stacked foam parts and may consist of only one layer of the second polymer foam. Accordingly, the second matrix structure may also have a uniform matrix structure along at least one of the lateral, longitudinal, and / or diagonal planes of the second layer.In this way, the second layer, which has a unitary structure, is able to provide the necessary structural integrity and ergonomic support for one or more users, since the second layer does not have multiple stacked foam pieces that can slip and move relative to each other to impair the supportive function of the second layer.

[0073] In various embodiments, the provision of the second layer in step 306 can further include the provision of a second polymer foam with a second density in the range of 60 kg / m³. 3 up to 90 kg / m 3 , optionally in a range of 60 kg / m 3 up to 70 kg / m 3 and optionally at 66 kg / m 3 exhibit. The second density can be the same regardless of whether the second layer is contained in the seat or in the middle part of the backrest.

[0074] In various embodiments, the provision of the second layer in step 306 can further include the provision of the second polymer foam with a second IFD value at 40% deflection in a range of 250 to 500, optionally in a range of 250 to 350, and optionally at 280. The second IFD value can be the same regardless of whether the second layer is contained in the seat surface or in the center section of the backrest.

[0075] In various embodiments, the second polymer foam can be a cold-cured foam polymer. The second layer, comprising the second polymer foam, can be produced according to a cold polymerization process that may include a step of forming the second polymer foam at a temperature in the range of 20 °C to 35 °C, optionally from 25 °C to 30 °C.

[0076] In various embodiments, the provision of the second layer in step 306 may further include the provision of a recess that extends at least partially along a surface of the second layer. The recess of the second layer may be configured to accommodate the projection of the first layer.

[0077] In various embodiments, the provision of the adhesive layer in step 304 can involve providing the adhesive layer on the surface of the projection of the first layer and / or the surface of the recess of the second layer. In some embodiments, the adhesive layer can have a thickness of 0.1 cm to 0.5 cm, optionally from 0.1 cm to 0.3 cm.

[0078] Fig. Figure 7 shows a flowchart that explains a method 400 for attaching a support device to a piece of furniture according to another aspect of the disclosure. Fig. Figure 8 shows a schematic representation of the method 400 for attaching the support device to an exemplary piece of furniture that has a seat of a chair. Fig. Figure 9 shows a schematic representation (A) of the method 400 for attaching the support device to another exemplary piece of furniture, which has a chair backrest, and (B) of the assembled piece of furniture 430, which has the support device. The support device may refer to the support device 100, which is described with reference to Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 is explained.

[0079] Referring to Fig. 7, Fig. 8 to Fig. 9. The piece of furniture can have a main frame 410 configured to receive the support device 100. As in Fig. As shown in Figure 8, the main frame 410 can, for example, be dimensioned to accommodate the support device 100, which has a seat; and in Fig. 9(A) The main frame 420 can be dimensioned to accommodate a backrest 200, which has the support device 100 as the central part of the backrest 200. In various embodiments, the main frame 410 can have at least one main frame opening 412 configured to accommodate a fastening means.

[0080] Method 400 comprises: positioning the second layer of the support device on the main frame of the furniture, wherein the second layer has at least one opening extending into an interior of the second layer, wherein the at least one opening is configured to receive a fastener (step 402); and attaching the second layer of the support device to the main frame of the furniture by attaching the fastener to the at least one opening of the second layer (step 404).

[0081] In various embodiments, the second layer 120 of the support device can have at least one opening 160 extending into an interior of the second layer 120. Accordingly, in step 402 of the method 400, positioning the second layer 120 on the main frame 410 can include positioning, e.g., aligning the at least one opening 160 of the second layer 120 to correspond with the at least one main frame opening 412 of the main frame 410 (see Fig. 8).

[0082] In some embodiments, such as in Fig. As shown in Figure 9(A), the support device 100, which includes a central part of a backrest, can first be mounted on the outline layer 210 of the backrest. The outline layer 210 can have at least one outline opening 222 extending through the interior of the outline layer 210 and configured to receive a fastener. In this embodiment, step 402 of the method 400 can include: (i.) positioning, for example, aligning the at least one opening 160 of the second layer 120 with the at least one outline opening 222 of the outline layer 210; and (ii.) positioning, for example, aligning the at least one opening 160 of the second layer 120 with the at least one outline opening 222 of the outline layer 210 with the at least one main frame opening 412 of the main frame 410.It is conceivable that the fastening means is inserted through the main frame opening 412 and the outline opening 222 to attach the backrest 200 to the main frame 410 of the piece of furniture.

[0083] In various embodiments, step 404 of the method 400 may further include the attachment of the second layer of the support device to the main frame 410 of the piece of furniture and the insertion of the fastening means through the main frame opening 412 and the opening 160 of the second layer (see Fig. 8) In some embodiments, step 404 may further include the insertion of the fastener through the main frame opening 412, the outline opening 222 and the opening 160 of the second layer (see Fig. 9(A)).

[0084] In various embodiments, the fastening means can comprise any suitable means for attaching the support device 100, e.g., the second layer 120, to the main frame 410 of the furniture. In some embodiments, the fastening means can comprise a rivet, a nail, or a screw.

[0085] Embodiments of the disclosure thus provide an improved support device 100 with different densities between two polymer foams to ensure structural integrity, uniform pressure distribution, and the necessary ergonomic support for one or more users. This can alleviate users' body pain and improve their health. The improved support device 100 is also durable and does not deform with prolonged use. For example, the improved support device 100 retains its original shape and structure despite repeated reclining movements of the device (as part of a backrest) over time. The improved support device 100 is also suitable for a wide variety of users with different body weights and body shapes.The disclosure also provides a method for manufacturing the improved support device 100, which is simple, inexpensive and quick to assemble.

[0086] Although the disclosure is shown and described in particular with reference to specific embodiments, the person skilled in the art will recognize that various modifications to the form and details thereof can be made without departing from the spirit and scope of the disclosure as defined by the appended claims. The scope of the disclosure is therefore specified by the appended claims, and all modifications that fall within the scope and equivalence of the claims are thus intended to be included.

Claims

[1] Support device (100) for a piece of furniture, wherein the support device comprises: a first layer (110) comprising a first polymer foam with a first density in the range of 30 kg / m³ 3 up to 60 kg / m 3 , a second layer (120) arranged on top of the first layer (110), wherein the second layer (120) is a second polymer foam with a second density in the range of 60 kg / m³ 3 up to 90 kg / m 3 exhibits, wherein the second layer (120) comprises a unitary layer of the second polymer foam. [2] Support device (100) according to claim 1, wherein the first polymer foam has a first matrix structure, wherein the first matrix structure has a plurality of first foam cells, wherein the second polymer foam has a second matrix structure, wherein the second matrix structure has a plurality of second foam cells, wherein the second foam cells differ from the first foam cells, and wherein each second foam cell from the plurality of second foam cells has a density greater than the density of each first foam cell from the plurality of first foam cells. [3] Support device (100) according to claim 2, wherein the second matrix structure comprising the plurality of second foam cells has a uniform matrix structure along at least one of a lateral plane, a longitudinal plane and / or a diagonal plane of the second layer. [4] The support device (100) according to any one of claims 1 to 3, wherein the ratio of the first density to the second density is in a range of 50% to 95%, optionally in a range of 60% to 90%. [5] Support device (100) according to any one of claims 1 to 4, wherein the first polymer foam has a first IFD (Indentation Force Deflection) value with 40% deflection in a range of 20 to 80 and wherein the second polymer foam has a second IFD value with 40% deflection in a range of 250 to 500. [6] Support device (100) according to any one of claims 1 to 5, wherein the first layer (110) comprises: a circumferential section (112) arranged at one end of the first layer (110), wherein the circumferential section (112) has a circumferential thickness (t1); and a central section (114) extending from the circumferential section (112) in a direction perpendicular to a lateral axis of the first layer (110), wherein the central section (114) has a mean thickness (t2) that is greater than the circumferential thickness (t1) of the circumferential section (112). [7] Support device (100) according to claim 6, wherein the circumferential thickness (t1) is in a range of 0.5 cm to 10 cm, and wherein the mean thickness (t2) is in a range of 15 cm to 25 cm. [8] Support device (100) according to any one of claims 1 to 7, wherein the second layer (120) has a recess (122) extending at least partially along a surface of the second layer (120), and the first layer (110) has a projection (116) extending at least partially from a surface of the first layer (110), and wherein the recess (122) of the second layer (120) is configured to accommodate the projection (116) of the first layer (110). [9] Support device (100) according to claim 8, wherein the recess (122) has a first recess segment (124) with a first recess depth (d1) and a second recess segment (126) with a second recess depth (d2) which is greater than the first recess depth (d1), wherein the lead (116) has a first lead segment (118) with a first lead height (h1) and a second lead segment (119) with a second lead height (h2) which is greater than the first lead height (h1), wherein the first recess segment (124) and the second recess segment (126) are configured to accommodate the first protrusion segment (118) and the second protrusion segment (119), respectively. [10] Support device (100) according to claim 8 or 9, further comprising an adhesive layer (130) arranged between the first layer (110) and the second layer (120), wherein the adhesive layer (130) is configured to attach the first layer (110) to the second layer (120), wherein the adhesive layer (130) has a thickness of 0.1 cm to 0.5 cm. [11] Support device (100) according to claim 10, wherein the adhesive layer (130) comprises: an adhesive that is arranged at least partially along the surface of the second layer and / or partially along the surface of the first layer. [12] Support device (100) according to any one of claims 1 to 11, wherein the first polymer foam comprises a memory foam polymer and wherein the second polymer foam comprises a cold foam polymer. [13] Chair comprising the support device (100) according to any one of claims 1 to 12. [14] Mattress comprising the support device (100) according to any one of claims 1 to 12.

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