Cushioning layer for mattress assembly, and mattress assembly

Abstract

To provide a cushioning layer for a mattress assembly.SOLUTION: A cushioning layer (14) is placed on a spring core assembly (12) comprising at least one spring coil (34). The cushioning layer (14) comprises a frame made of a foam, and a thermoplastic elastomer (TPE) grid layer. The thermoplastic elastomer grid layer is surrounded by the frame. The invention further relates to a mattress assembly comprising a cushioning layer (14) and a spring core assembly (12).SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a cushioning layer for a mattress assembly including a spring core assembly.Further, the present invention relates to a mattress assembly. [Background technology]

[0002] In the state of the art, cushioning layers containing gel inserts are known that provide a desirable lying comfort for the user, however these gel inserts are usually heavy and have little to no breathability, thus retaining undesirable moisture.

[0003] Furthermore, mattress assemblies with several different layers are also known from the state of the art, which provide a desired comfort to the user of the mattress assembly.

[0004] Furthermore, foam mattress assemblies consisting of foam layers are known in the state of the art, at least one of which provides various lying zones (also called body zones), for example by means of cut-outs and / or recesses. For example, the widely known Emma One Foam Mattress is a mattress assembly consisting of foam layers.

[0005] Furthermore, so-called hybrid mattress assemblies are also known, which comprise a spring core layer and at least one foam layer placed on top of the spring core layer. Usually, the spring core layer comprises a number of spring pockets manufactured in the same way. These mattress assemblies may also have different lying zones, which are established, for example, by means of cutouts and / or recesses in the interior of the foam layer, and with the aid of additional foam layers placed on top of the spring core layer. Alternatively or additionally, several foam layers are provided, which provide different lying zones, for example, by means of cutouts and / or recesses. For example, the Emma Hybrid Mattress provides five different lying zones, while comprising three foam layers and one spring core layer.

[0006] In general, the size and / or shape of the individual notches and / or recesses can be varied to establish different zones, for example zones with different hardness or stiffness.

[0007] In fact, the concept of providing different lying / body zones is used because foam layers can be manufactured in a cost-effective manner, so it is not very costly to provide foam layers with different properties.

[0008] However, the provision of cutouts and / or recesses can result in cutting or wasting material, which is disadvantageous. To overcome this disadvantage, it is already known to provide corresponding foam layers from foam blocks, whereby cutting or wasting material can be reduced. This concept is described in German Publication No. 10 2017 117 556 A1. Summary of the Invention [Problem to be solved by the invention]

[0009] However, there is a need for an improved mattress assembly that reduces material waste, as well as an improved cushioning layer that reduces the weight of the cushioning layer and the overall mattress assembly while maintaining the user experience, i.e., lying comfort. [Means for solving the problem]

[0010] The present invention provides a cushioning layer for a mattress assembly. The cushioning layer is configured to be placed on a spring core assembly with at least one spring coil. The cushioning layer comprises a frame made of foam and a thermoplastic elastomer (TPE) grid layer, i.e. a layer made of thermoplastic elastomer (TPE) and having a grid structure. The thermoplastic elastomer grid layer is surrounded by the frame. In other words, the thermoplastic elastomer grid layer constitutes only a partial area of ​​the entire cushioning layer. The remaining area is provided with a frame made of foam.

[0011] Thus, the cushioning layer of the present invention ensures that the thermoplastic elastomer grid layer is substantially supported by its material and structure, as well as the frame surrounding the thermoplastic elastomer grid layer.By using a thermoplastic elastomer material instead of a gel material, and by using a discrete grid structure, the weight of the cushioning layer can be reduced compared to a solid layer made of gel material.

[0012] Additionally, the thermoplastic elastomer grid layer is essential to provide improved breathability and reduce the amount of moisture retained, thus improving the overall user experience by using a thermoplastic elastomer grid layer in the cushioning layer.

[0013] In particular, the different air permeabilities of the thermoplastic elastomer grid layer and the foam frame result in different cooling characteristics, and in fact the combination of the thermoplastic elastomer grid layer and the foam frame provides more cooling to the body compared to the extremities because the thermoplastic elastomer grid layer is in relation to the body.

[0014] Additionally, the thermoplastic elastomer grid layer ensures that the entire cushioning layer is foldable and rollable, so that the cushioning layer can be easily placed in a shipping configuration, e.g., rolled up, and the thermoplastic elastomer grid layer packed into a shipping bag.

[0015] In particular, it is possible to fold and (then) roll up the entire cushion layer. This can be achieved by the combination, particularly the individual properties, of the thermoplastic elastomer grid layer and the frame. As a result, the mattress is easier to transport and can be stored more efficiently.

[0016] The frame surrounds the thermoplastic elastomer grid layer while at the same time providing sufficient support. The frame is made entirely of foam (a solid material) while the thermoplastic elastomer grid layer contains voids filled with air. Thus, the frame does not contain any additionally introduced voids. In other words, a frame made of foam contains only the inherent air entrapment associated with the foam material.

[0017] In reality, the cushioning layer has two opposing main surfaces and four side surfaces, each of which is established by a respective surface of the frame and a respective surface of the thermoplastic elastomer grid layer, whereas the side surfaces are only constructed of the frame, i.e., the foam material of the frame.

[0018] Typically, the frame and the thermoplastic elastomer grid layer are connected to one another in a permanent manner, thereby ensuring that the entire cushioning layer is a single layer. For example, the permanent connection between the frame and the thermoplastic elastomer grid layer is established by welding and / or chemical bonding.

[0019] Thus, the cushioning layer of the present invention is distinguished from an assembly including a frame with a receptacle and an insert disposed within the receptacle, although the frame and insert are formed separately and are not permanently connected to one another, even if they are connected together in an assembled state.

[0020] Additionally, the frame and the thermoplastic elastomer grid layer each have a geometric center, and the geometric centers are coincident.

[0021] One aspect of the invention provides that the thermoplastic elastomer grid layer has a higher hardness, in particular by 10% to 20%, compared to the hardness of the frame, and a minimum net density higher than the minimum net density of the frame, in particular 5 to 10 times, preferably 6 to 8 times higher. This ratio ensures optimized properties in terms of support, handling and cushioning, i.e. hardness and / or stiffness. Despite the fact that the thermoplastic elastomer grid layer has a higher hardness and a higher minimum net density than the frame, the thermoplastic elastomer grid layer offers the user a softer feel in terms of lying comfort compared to the frame. This is ensured by the structure of the thermoplastic elastomer grid layer, which is not a solid material but has a lattice structure, i.e. air-filled voids.

[0022] In particular, the thermoplastic elastomer grid layer has a strength of 230 kg / m 3 and / or a hardness of 2.8 kPa. These properties, together with the structure, i.e., voids, of the thermoplastic elastomer grid layer ensure that the desired lying comfort is achieved.

[0023] Furthermore, the thermoplastic elastomer grid layer constitutes 40% to 70%, preferably 50%, of the cushioning layer. This means that the average area where the user sleeps is covered by the thermoplastic elastomer grid layer, and the user experience is not compromised. As a result, the size of the thermoplastic elastomer grid layer depends on the overall size of the cushioning layer, which in turn depends on the size of the mattress. However, by not having the thermoplastic elastomer grid layer constitute the entire area of ​​the cushioning layer, the handling and lying comfort of the cushioning layer can be improved.

[0024] Another embodiment of the invention is a foam having a compressibility of 32 kg / m 3 It is specified that the foam is a hypersoft foam with a minimum net density of 0.01 kPa and / or a hardness of 2.5 kPa. These properties ensure that the desired lying comfort is obtained. In contrast to the thermoplastic elastomer grid layer, the foam is produced in a completely foamed, i.e. solid, manner. The minimum net density and hardness of the thermoplastic elastomer grid layer is therefore higher compared to the frame, due to the fact that the thermoplastic elastomer grid layer is structured differently to include voids.

[0025] The thermoplastic elastomer grid layer has a plurality of walls that intersect with each other, thereby defining voids, and the thermoplastic elastomer grid layer includes voids that are uniformly or differently sized. By including differently sized voids, the thermoplastic elastomer grid layer can provide different lying / body zones and improve the user experience, i.e., provide preferred support for each lying / body zone, e.g., hips, shoulders, and other body parts that have different requirements. In fact, differently sized voids can be used to provide various lying / body zones with different characteristics.

[0026] Generally, the voids are established by walls that intersect with each other, regardless of their size, thereby defining the voids. Furthermore, the voids allow the cushioning layer to be foldable, because even if the cushioning layer is made of a TPE material having the above-mentioned properties, there is room for the wall material to enter when the cushioning layer is folded.

[0027] Preferably, the thermoplastic elastomer grid layer includes support regions in which the voids have a smaller size compared to the voids located in other regions of the thermoplastic elastomer grid layer, ensuring optimal comfort and differential support for various body zones resulting in an improved user experience.

[0028] The cavities may have various shapes, in particular rectangular, hexagonal and / or honeycomb shapes. For example, a rectangular shape is related to a square. These forms generally offer different stability, which also depends on the size of the cavities, i.e. the distance of the opposing walls that limit the individual cavities. Moreover, they are relatively easy to manufacture, so they do not add significantly to the production costs.

[0029] The present invention further provides a mattress assembly comprising a cushioning layer and a spring core assembly, the spring core assembly comprising a bottom fabric, a top fabric, and at least one spring pocket having at least one spring coil disposed between the bottom fabric and the top fabric, the basis weight of the bottom fabric being different from the basis weight of the top fabric.

[0030] Thus, a spring core assembly that can be used as a spring core layer in a mattress assembly includes spring pockets with different fabrics above and below the individual spring coils, thereby ensuring that the spring core assembly, and in particular the individual spring coils, have improved support.

[0031] For example, the bottom and top fabrics are polypropylene (PP) fabrics, eg, textiles derived from the thermoplastic polymer polypropylene.

[0032] The spring core assembly has a number of spring pockets, for example, 448 spring pockets (90cm x 190cm), or 462 spring pockets (90cm x 200cm). Depending on the width of the spring core assembly, a different number of spring pockets may be provided.

[0033] Generally, a bottom fabric and a top fabric are placed on either side of each spring pocket.

[0034] For example, the spring core assembly has a height of 195 mm.

[0035] One embodiment provides that the basis weight of the bottom fabric is higher than that of the top fabric. Thus, due to the higher basis weight of the bottom fabric, the support of the spring coils is ensured. In fact, the spring core assembly, i.e., the spring core layer, may be associated with the bottom layer of the mattress assembly, and the higher basis weight of the bottom fabric ensures that the mattress assembly can be rested on the bed frame by the springs, i.e., by the bottom fabric, thereby providing sufficient support and sufficient durability.

[0036] For example, the ratio of the basis weight of the top fabric to the basis weight of the bottom fabric is between 0.375 and 0.8, preferably between 0.4 and 0.6, in particular 0.5, ensuring optimized properties in terms of (mechanical) support and mattress properties, such as firmness and / or rigidity.

[0037] In particular, the basis weight of the upper fabric is 60 g / m 2 ~80g / m 2 range, e.g. 65g / m 2 Alternatively or additionally, the basis weight of the bottom fabric is 100 g / m 2 ~160g / m 2 For example, 130 g / m2 These particular basis weights ensure that the spring coils are supported in a predetermined manner while at the same time providing sufficient support from the spring core assembly due to the high basis weight of the bottom fabric.

[0038] Another aspect provides that the spring core assembly includes a first type spring pocket and a second type spring pocket. Both types of spring pockets have the same bottom fabric and the same top fabric. The basis weight of the bottom fabric is different from the basis weight of the top fabric. The first type spring pocket has a first spring coil disposed between the bottom fabric and the top fabric. The second type spring pocket has a second spring coil disposed between the bottom fabric and the top fabric. The first spring coil and the second spring coil are different. For example, the first spring coil and the second spring coil have different characteristics with respect to stiffness.

[0039] The different types of spring pockets, ie, first type spring pockets and second type spring pockets, ensure that different lying / body zones are provided by the spring core assembly resulting in different zones throughout the mattress assembly.

[0040] The first type spring pocket and the second type spring pocket may be adjacent and glued together, ensuring that the different types of spring pockets can be connected together even though they have different characteristics in terms of stiffness due to the various spring coils. Because the spring pockets are glued together, their relative positions are fixed.

[0041] The first spring coil and the second spring coil may have different diameters. In particular, the diameter of the first spring coil is smaller than the diameter of the second spring coil. The different diameters of the spring coils provide different hardness or stiffness. Thus, different lying / body zones are obtained, which include either the first type of spring pocket or the second type of spring pocket.

[0042] The ratio between the diameter of the first spring coil and the diameter of the second spring coil may be in the range 0.72 to 0.95, in particular 0.9, as this ratio ensures that the user can perceive the different lying / body zones but has a good feel and there is no big difference between the individual hardness of the spring coils.

[0043] For example, the diameter of the first spring coil is in the range of 1.6 mm to 1.9 mm, in particular 1.8 mm. Alternatively or additionally, the diameter of the second spring coil is in the range of 1.8 mm to 2.2 mm, in particular 2 mm. These diameters ensure sufficient stiffness and stability of the individual spring coils while at the same time providing the desired comfort of the lying / body zone.

[0044] A further aspect provides that a plurality of spring pockets of a first type are connected in series, in particular by welding, thereby forming a row of spring pockets of the first type. Alternatively or additionally, a plurality of spring pockets of a second type are connected in series, in particular by welding, thereby forming a row of spring pockets of the second type. Depending on the size, in particular the width, of the spring core assembly, the individual rows may comprise a different number of spring pockets connected to each other by welding, thereby providing a row of spring pockets of the first type or a row of spring pockets of the second type. Thus, the individual rows may be associated with the width of the spring coil assembly or mattress assembly. Thus, the same type of spring pockets are used along the width dimension of the spring coil assembly or mattress assembly.

[0045] Furthermore, at least two rows of spring pockets of the first type are placed adjacent to each other, the spring pockets of adjacent rows being glued to each other. Alternatively or additionally, at least two rows of spring pockets of the second type are placed adjacent to each other, the spring pockets of adjacent rows being glued to each other. Individual zones of spring pockets of the same type can be established by providing two or more rows of pocket springs of the same type. However, a particular zone may also be realized by only a single row, in particular a single row of spring pockets of the first type. A zone established by spring pockets of the second type may always include at least two rows of spring pockets of the second type.

[0046] In general, adjacent rows of spring pockets, regardless of their particular type, may be glued together to establish a spring core assembly.

[0047] Pocket springs in adjacent rows may be glued to each other, while pocket springs in the same row may be welded to each other.

[0048] In general, the spring core assembly may be symmetrical with respect to two lines of symmetry that intersect each other at the center of the spring core assembly. In particular, the lines of symmetry are perpendicular to each other. Thus, the spring core assembly has a symmetrical design, which ensures that the same spring core assembly can be used in two different orientations, i.e., rotated 180 degrees around its center in a plane, without, for example, flipping the spring core assembly. In other words, the spring core assembly has no upper or lower edge, since the opposing edges are interchangeable. In other words, the bottom fabric is always oriented toward the floor, e.g., the frame of a bed, when in use.

[0049] One embodiment provides that the mattress assembly is a stack assembly comprising a spring core assembly, a cushion layer, and at least two additional layers, the at least two additional layers being positioned between the spring core assembly and the cushion layer and being made of different materials, in particular different foams. Thus, the mattress assembly has at least four different layers, in particular five different layers, stacked on top of each other, thereby providing a mattress assembly stack. The different layers, i.e. the spring core assembly, the first additional layer, the second additional layer and the third additional layer, each have different properties, e.g. different minimum net densities and / or different hardnesses. Furthermore, the different (additional) layers may be made of different materials, e.g. different foams.

[0050] Generally, hardness can be measured according to ISO 3386.

[0051] In a particular embodiment, the spring core assembly is the bottom layer of the mattress assembly and the first additional layer is placed on top of the spring core assembly. The second additional layer is bonded to the first additional layer. The third additional layer is bonded to the second additional layer. The cushioning layer is bonded to the third additional layer. All the (additional) layers have different properties, for example different minimum densities and / or different hardnesses. Furthermore, different types of adhesives may be used to bond the individual layers to each other. As mentioned above, a water-based adhesive may be used to connect the first additional layer to the second additional layer. The second additional layer is connected to the third additional layer using a water-based adhesive. Furthermore, the cushioning layer is connected to the third additional layer using a water-based adhesive.

[0052] However, a variety of adhesives may be used, such as water-based adhesives and / or hot melt adhesives.

[0053] Generally, the foam used in the additional layer may be related to polyurethane (PU), which is also referred to as comfort foam, visco memory foam, and / or hypersoft foam.

[0054] The polyurethane (PU) foam, also called comfort foam, is associated with a first additional layer that is placed directly on top of the spring core assembly. For example, the first additional layer may have a strength of 30 kg / m 3 and / or a hardness of 3 kPa. Alternatively, the first additional layer has a minimum net density of 31 kg / m 3 and / or hardness of 2.8 kPa.

[0055] The second additional layer may be made of comfort foam or visco-memory foam. For example, the second additional layer may be made of 50 kg / m 3 and / or a hardness of 1.8 kPa. Alternatively, the second additional layer has a minimum net density of 34 kg / m 3 and / or hardness of 2.5 kPa.

[0056] The third additional layer may be made of Viscomemory foam or Hypersoft foam. For example, the third additional layer may be made of 32 kg / m 3 and / or a hardness of 1.5 kPa. Alternatively, the third additional layer has a minimum net density of 40 kg / m 3 and / or hardness of 1.6 kPa.

[0057] The upper layer is provided by a cushioning layer consisting of a thermoplastic elastomer grid layer surrounded by a frame made of foam, preferably Hypersoft foam.

[0058] Typically, the spring core assembly and mattress assembly may have a length of 2m or 1.9m, so that 33 or 32 rows of spring pockets are used respectively. Every row can be established by two different types of spring pockets, specifically the rows of spring pockets.

[0059] In certain embodiments, for example with a width of 90 cm, the spring core assembly includes 14 spring pockets per row welded together. However, the number of spring pockets per row depends on the width of the spring core assembly or mattress assembly. Thus, a spring core assembly or mattress assembly with a width greater than 90 cm may include more than 14 spring pockets per row.

[0060] The first embodiment of the spring core assembly may include eleven zones.

[0061] Indeed, the first zone starting from the first edge may contain two rows of spring pockets of a particular type, for example the second type. The second zone is adjacent to the first zone and contains six rows of spring pockets of a particular type, for example the first type. The third zone is adjacent to the second zone and contains five rows of spring pockets of a particular type, for example the second type. The fourth zone is adjacent to the third zone and contains only a single row of spring pockets of a particular type, for example the first type. The fifth zone is adjacent to the fourth zone and contains two rows of spring pockets of a particular type, for example the second type. The sixth zone is adjacent to the fifth zone and contains only a single row of spring pockets of a particular type, for example the first type. The seventh zone is adjacent to the sixth zone and contains two rows of spring pockets of a particular type, for example the second type. The eighth zone is adjacent to the seventh zone and contains only a single row of spring pockets of a particular type, for example the first type. A ninth zone is adjacent to the eighth zone and includes five rows of a particular type of spring pockets, e.g., the second type of spring pockets. A tenth zone is adjacent to the ninth zone and includes six rows of a particular type of spring pockets, e.g., the first type of spring pockets. An eleventh zone is adjacent to the tenth zone and includes two rows of a particular type of spring pockets, e.g., the second type of spring pockets. The eleventh zone terminates at a second edge opposite the first edge.

[0062] A line of symmetry of the spring core assembly extends along the sixth zone, e.g., along a single row provided by the sixth zone. Another line of symmetry extends perpendicular thereto and intersects all zones, e.g., all rows. Both lines of symmetry intersect each other at the center / centre of the spring core assembly.

[0063] A second embodiment of the spring core assembly may include nine zones.

[0064] Indeed, the first zone starting from the first edge may include two rows of spring pockets of a particular type, for example, the second type. The second zone is adjacent to the first zone and includes six rows of spring pockets of a particular type, for example, the first type. The third zone is adjacent to the second zone and includes six rows of spring pockets of a particular type, for example, the second type. The fourth zone is adjacent to the third zone and includes only a single row of spring pockets of a particular type, for example, the first type. The fifth zone is adjacent to the fourth zone and includes two rows of spring pockets of a particular type, for example, the second type. The sixth zone is adjacent to the fifth zone and includes only a single row of spring pockets of a particular type, for example, the first type. The seventh zone is adjacent to the sixth zone and includes six rows of spring pockets of a particular type, for example, the second type. The eighth zone is adjacent to the seventh zone and includes six rows of spring pockets of a particular type, for example, the first type. A ninth zone is adjacent to the eighth zone and includes two rows of a particular type of spring pocket, e.g., a second type of spring pocket. The ninth zone terminates at a second edge opposite the first edge.

[0065] A line of symmetry of the spring core assembly extends along the fifth zone, e.g., between the two rows provided by the fifth zone. Another line of symmetry extends perpendicularly thereto and intersects all the zones, e.g., all the rows. Both lines of symmetry intersect each other at the center / centre of the spring core assembly.

[0066] When a user lies on the mattress assembly, different zones are used to provide different support to the user.

[0067] Generally, the distribution of different spring coils, especially spring coils with different diameters, ensures a zonal setting of the spring core assembly or mattress assembly. Zonal setting means providing support and relief to different areas of the body. In fact, the different zones of the body are the head, shoulders, lower back, pelvis, thighs, calves, and feet. The spring core assembly provides appropriate support and comfort to people of different body types, regardless of their sleeping position.

[0068] In combination with the mattress assembly, the additional layer, ie, the foam layer, ensures pressure relief and comfort and makes the mattress assembly more durable.

[0069] Typically, the additional layer, i.e. the foam layer, is fabricated without cutouts and / or recesses, e.g. as a full material layer.

[0070] The additional layers may have the same height, for example 15mm.

[0071] The spring core assembly may have a height of approximately 200 mm, in particular 195 mm.

[0072] The cushioning layer may have an additional layer height, for example 15mm.

[0073] The entire mattress assembly may have a height of 260mm.

[0074] In particular, the entire mattress assembly is foldable and rollable, so that the mattress assembly has a shipping state in which the cushion layer and the spring core assembly are folded at least once and rolled up. As mentioned above, the cushion layer is foldable and rollable, so that the cushion layer can be in a shipping state. Even if the spring core assembly is manufactured end-to-end, e.g., without surrounding foam, it is possible to fold and roll the spring core assembly. As a result, the entire mattress assembly including the cushion layer and the spring core assembly is foldable and rollable. In other words, when the entire mattress assembly is folded and rolled up, the cushion layer is placed on top of the spring core assembly. [Brief description of the drawings]

[0075] The foregoing aspects and attendant advantages of the claimed subject matter will become more readily understood by reference to the following description when taken in conjunction with the accompanying drawings, in which:

[0076] [Figure 1] 1 shows a schematic overall view of a mattress assembly according to a first embodiment of the invention, which uses a spring core assembly according to a first embodiment of the invention; [Diagram 2] 1 shows a schematic overall view of a cushioning layer that may be used in any of the contemplated embodiments, the cushioning layer comprising a thermoplastic elastomer grid layer and a foam frame. [Diagram 3] 3A shows an example of a thermoplastic elastomer grid layer, with FIG. 3A showing rectangular voids and FIG. 3B showing triangular voids. [Figure 4] 2 shows a schematic overall view of a mattress assembly according to a second embodiment of the invention, which uses a spring core assembly according to a second embodiment of the invention; [Diagram 5] 2 shows a schematic overall view of a mattress assembly according to a third embodiment of the invention, which uses a spring core assembly according to a third embodiment of the invention; [Figure 6]13 shows a schematic overall view of a mattress assembly according to a fourth embodiment of the invention, which uses a spring core assembly according to a fourth embodiment of the invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0077] 1, a mattress assembly 10 is shown including a spring core assembly 12, a top view of which is also shown in Fig. 1. As shown in the overview of the mattress assembly 10, the spring core assembly 12 corresponds to the bottom layer of the mattress assembly 10.

[0078] Additionally, the mattress assembly 10 includes a cushioning layer 14 that corresponds to the upper layer of the mattress assembly 10 .

[0079] Between the cushioning layer 14 and the spring core assembly 12 , the mattress assembly 10 further includes a first additional layer 16 , a second additional layer 17 and a third additional layer 18 .

[0080] Thus, mattress assembly 10 refers to a stack assembly because the various layers 12-18 are stacked on top of each other to establish the mattress assembly stack.

[0081] In contrast to the spring core assembly 12, the additional layers 16-18 are made of foam.

[0082] The cushioning layer 14 (shown in more detail in FIG. 2) comprises a frame 20 made of foam and a thermoplastic elastomer (TPE) grid layer 22. The exact size of the TPE grid layer 22 depends on the overall size of the mattress assembly, which means that the foam frame 20 is selected based on the size of the TPE grid layer 22.

[0083] The TPE grid layer 22 is positioned in the center of the cushioning layer 14 such that the geometric centers of the frame 20 and the TPE grid layer 22 coincide. In effect, the central region of a user lying on top of the mattress assembly 10 is supported by the TPE grid layer 22.

[0084] This ensures that the cushion layers 14 have different cooling characteristics.

[0085] In effect, the different air permeabilities of the thermoplastic elastomer grid layer 22 and the foam frame 20 provide different cooling characteristics. In effect, the thermoplastic elastomer grid layer 22 provides more cooling compared to the foam frame associated with the body and the user's extremities overlying the cushioning layer 14.

[0086] Below we detail examples of standard European and UK mattress sizes and weights, however the exact values ​​may vary depending on which country the mattress is intended for.

[0087] For a 90cm x 200cm mattress, the TPE grid layer 22 has a width of 60cm and a length of 150cm, and the weight of the TPE grid layer 22 is 3.2kg.

[0088] For a 80cm x 200cm mattress, the TPE grid layer 22 may have a width of 60cm and a length of 150cm, giving a weight of 3.2kg.

[0089] For a 140cm x 200cm mattress, the TPE grid layer 22 has a width of 110cm and a length of 150cm, and the weight of the TPE grid layer 22 is 5.9kg.

[0090] For a 140cm x 190cm mattress, the TPE grid layer 22 has a width of 110cm and a length of 140cm, and the weight of the TPE grid layer 22 would be 5.5kg.

[0091] For a 160cm x 200cm mattress, the TPE grid layer 22 has a width of 130cm and a length of 150cm, and the weight of the TPE grid layer 22 would be 7.0kg.

[0092] For a 180cm x 200cm mattress, the TPE grid layer 22 has a width of 150cm and a length of 150cm, and the weight of the TPE grid layer 22 will be 8.0kg.

[0093] Depending on the size of the cushioning layer 14, the thermoplastic elastomer grid layer 22 may comprise 40%-70% of the cushioning layer 14. Thus, the foam frame 20 has a size that corresponds to 30%-60% of the cushioning layer 14, depending on the particular size of the cushioning layer 14.

[0094] As shown in particular in Figures 3a and 3b, the TPE grid layer 22 has a number of walls 24 that cross each other and thus define gaps 26 between them. The gaps 26 are devoid of material and are filled, for example, with air. The TPE grid layer 22 thus has a lattice structure due to the walls 24 and the gaps 26, with the open side of the gaps 26 facing upwards. The TPE grid layer 22 thus has a continuous base 27, via which the TPE grid layer 22 rests on top of the individual additional layers, for example the third additional layer 18. The walls 24 may extend vertically upwards from the continuous base 27.

[0095] The voids 26 can have any shape. For example, the voids 26 are rectangular, hexagonal and / or honeycomb shaped. These shapes provide sufficient and different support while providing the desired comfort for the user. Moreover, these different shapes can be achieved in a cost-effective manner.

[0096] In the embodiment shown in Figure 3b, the voids 26 have a honeycomb shape. In contrast, the voids 26 in the embodiment shown in Figure 2 relate to a square. Thus, they have a rectangular shape.

[0097] In general, the voids 26 may be uniformly sized, as shown in Figures 2 and 3b, or may be differently sized, as shown in the embodiment shown in Figure 3a.

[0098] Voids 26 of different sizes can establish different support areas, thus providing harder or rather softer support.

[0099] The TPE grid layer 22, i.e. the TPE material, has a resistance of at least 230 kg / m 3 and / or a hardness of 2.8 kPa.

[0100] In contrast, the Hypersoft foam constitutes the frame 20 of the cushioning layer 14, which surrounds the TPE grid layer 22 and has a compressibility of 32 kg / m 3 and / or a hardness of 2.5 kPa. However, whereas the frame 20 is solid, the TPE grid layer 22 includes additionally introduced voids 26.

[0101] Thus, the thermoplastic elastomer (TPE) grid layer 22 has a higher hardness than the frame 20, in particular a hardness that is 10% to 20% higher.

[0102] Furthermore, the thermoplastic elastomer (TPE) grid layer 22 has a minimum net density higher than the minimum net density of the frame 20, in particular 5 to 10 times higher, preferably 6 to 8 times higher.

[0103] In particular, the frame 20 is defined only by side walls, which means that the frame 20 does not have a continuous bottom.

[0104] In particular, the various layers 14-18 are interconnected to one another using adhesives. Depending on the type of layers being interconnected, different adhesives may be used. Preferably, a water-based glue / adhesive is used. However, it is also possible to use thermal adhesives, heat fixing, sewing, etc.

[0105] For example, the cushioning layer 14 is adhered to the third additional layer 18 using a water-based adhesive. The third additional layer 18 is adhered to the second additional layer 17, also using a water-based adhesive. The second additional layer 17 is in turn adhered to the first additional layer 16, also using a water-based adhesive.

[0106] These layers 14 - 18 , bonded together, are then placed over the spring core assembly 12 .

[0107] In the illustrated embodiment, the cushioning layer 14 and the additional layers 16-18 have the same height, ie 15mm, while the spring core assembly 12 has a height of 195mm or 200mm, resulting in an overall height of 255mm or 260mm.

[0108] As mentioned above, the additional layers 16-18 are made of foam, in particular different foams, and therefore the individual properties of the additional layers 16-18 may differ.

[0109] The first additional layer 16 may be made of comfort foam, for example PU foam, which has a strength of 30 kg / m 3 and a hardness of 3 kPa.

[0110] The second additional layer 17 is 50 kg / m 3 The mattress may be made of visco-memory foam having a minimum net density of 0.01 g and a hardness of 0.05 g.

[0111] For example, the third additional layer 18 has a strength of 32 kg / m 3 It is made of hyper soft foam having a minimum net density of 1.0 and a hardness of 1.5 kPa.

[0112] The spring core assembly 12 includes a plurality of spring pockets 28, shown generally in Figure 1. Each spring pocket 28 includes a bottom fabric 30 and a top fabric 32 through which the spring pockets 28 are adhered to the first additional layer 18.

[0113] Each spring pocket 28 has a spring coil 34 disposed between a bottom fabric 30 and a top fabric 32. The spring coils 34 are made from metal wire.

[0114] The individual fabrics, i.e., the bottom fabric 30 and the top fabric 32, have different grammage. For example, the grammage of the bottom fabric 30 is higher than the grammage of the top fabric 32. Several spring pockets 28 may each have their own bottom fabric 30 and / or top fabric 32. Alternatively, several spring pockets 28 may share a common bottom fabric 30 and / or a common top fabric 32.

[0115] For example, the ratio of the basis weight of the top fabric 32 to the basis weight of the bottom fabric 30 is in the range of 0.4 to 0.6, particularly 0.5.

[0116] Specifically, the basis weight of the upper fabric 32 is 60 g / m 3 ~80g / m 3 range, especially 65g / m 3 while the basis weight of the bottom fabric 30 is 100 g / m 3 ~160g / m 3 range, especially 138g / m 3 It is.

[0117] In fact, the bottom fabric 30 provides the support surface for the entire mattress assembly 10, as shown in FIG.

[0118] Thus, the different basis weights of the fabrics 30,32 ensure proper support for the spring coils 34 located within the spring pockets 28 and therefore for the user of the mattress assembly 10 as a whole.

[0119] For example, the bottom fabric 30 and the top fabric 34 are made of polypropylene (PP) fabric, eg, a textile derived from the thermoplastic polymer polypropylene.

[0120] A top view of the spring core assembly 12 is also shown in FIG. 1 and referenced below.

[0121] The top view shows that the spring core assembly 12 is defined by two different types of spring pockets 28 , namely a first type spring pocket 36 and a second type spring pocket 38 .

[0122] The different types of spring pockets 36,38 are distinguished from one another by the individual spring coils 34, and in particular the diameter of the individual spring coils 34.

[0123] In practice, the first type of spring pocket 36 has a first spring coil 42 with a diameter in the range 1.6 mm to 1.9 mm, in particular 1.8 mm, while the second spring coil 42 has a diameter in the range 1.8 mm to 2.2 mm, in particular 2 mm.

[0124] For example, the ratio of the diameter of the first spring coil 40 to the diameter of the second spring coil 42 is in the range of 0.72 to 0.95, and in particular 0.9.

[0125] In the illustrated embodiment, the spring core assembly 12 includes a number of different zones A-I, a total of nine different zones. The zones are established by the areas defined by the different types of spring pockets 28.

[0126] Each zone AI comprises only one type of spring pocket 28, ie either the first type spring pocket 36 or the second type spring pocket 38.

[0127] Each of the nine different zones includes at least one row of spring pockets 28 of a particular type.

[0128] Generally, a row of spring pockets 28 of a particular type means that the individual spring pockets 28 are made of the same type and are interconnected to one another by welding. The row of spring pockets 28 has a length that corresponds to the width W of the spring core assembly 12 or mattress assembly 10.

[0129] Regardless of the particular type of spring pocket 28, in the illustrated embodiment, one row includes fourteen spring pockets 28.

[0130] Indeed, the first zone A includes two rows of the second type of spring pockets 38. The adjacent second zone B includes six rows of the first type of spring pockets 36. The third zone C includes six rows of the first type of spring pockets 38. The fourth zone D includes a single row of the first type of spring pockets 36. The fifth zone E includes two rows of the second type of spring pockets 38. The sixth zone F includes a single row of the first type of spring pockets 36. The seventh zone G includes six rows of the second type of spring pockets 38. The eighth zone H includes six rows of the first type of spring pockets. Finally, the ninth zone I includes two rows of the second type of spring pockets 38.

[0131] In the illustrated embodiment, the spring core assembly 12 has a length L of 190 cm. The spring core assembly 12 therefore comprises 40 rows, which are interconnected with each other by adhesive bonding.

[0132] As indicated above, the individual spring pockets 28 of a row, and in particular their individual spring coils 34, are interconnected to one another by welding, thereby establishing the row.

[0133] In contrast, the spring pockets 28 in adjacent rows are connected to one another by adhesive.

[0134] Generally, the spring pockets 28, and in particular the spring coils 34 thereof, are each welded along a first dimension, e.g., width W.

[0135] Additionally, the spring pockets 28 are each bonded along a second dimension, eg, length L, which is perpendicular to the first dimension, eg, width W.

[0136] Furthermore, the spring core assembly 12 is symmetrical about two lines of symmetry S1, S2 that intersect each other at the center or midpoint M of the spring core assembly 12.

[0137] In fact, the second axis of symmetry S2 passes through the fifth zone E, and in particular between both rows of the fifth zone E, i.e. between the sixteenth and seventeenth rows of the spring pockets 28 of the entire spring core assembly 12 along its length L.

[0138] The second axis of symmetry S2 intersects the first axis of symmetry S1 within the fifth zone E, ie, between the seventh and eighth rows of spring pockets 28 along the width W.

[0139] 4 shows a similar embodiment, which differs from the first embodiment in that the length L of the spring core assembly 12 and mattress assembly 10 is increased to 2m. Thus, the spring core assembly 12 has one additional row, i.e. 33 in total.

[0140] This additional row provides 11 zones A to K, resulting in different zone distributions.

[0141] Again, the various zones A-K are established by rows of spring pockets 28, with each row including 14 spring pockets 28 in the illustrated embodiment.

[0142] Furthermore, the various zones can be established by two different types of spring pockets 28 , either a first type spring pocket 36 or a second type spring pocket 38 .

[0143] A first zone A includes two rows of the second type spring pockets 38. An adjacent second zone B includes six rows of the first type spring pockets 36. An adjacent third zone C includes five rows. An adjacent fourth zone D includes a single row of the first type spring pockets 36. An adjacent fifth zone E includes two rows of the second type spring pockets 38. An adjacent sixth zone F includes a single row of the first type spring pockets 36.

[0144] The sixth zone F also includes a second axis of symmetry S2 which passes through a single row and intersects the first symmetrical access at the center M.

[0145] The seventh adjacent zone G contains two rows of the second type spring pockets 38. The eighth adjacent zone H contains only one row of the first type spring pockets 36. The ninth adjacent zone I contains five rows of the second type spring pockets 38. The tenth adjacent zone J contains six rows of the first type spring pockets 36. Finally, the eleventh adjacent zone K contains two rows of the second type spring pockets 38.

[0146] The cushion layer 14 and the additional layers 16 to 18 are similar to those in the first embodiment shown in FIG. 1, and reference is made thereto.

[0147] 5 shows a third embodiment, showing a mattress assembly 10 and a spring core assembly 12 having a length of 190 cm, the size of which is similar to that of the first embodiment shown in FIG.

[0148] In fact, the spring core assembly 12 also comprises 40 rows of spring pockets 28. In fact, the distribution of the different types of spring pockets 28, i.e. the first type spring pockets 36 and the second type spring pockets 38, is similar to that shown in Fig. 1. Therefore, reference is made to the above description.

[0149] However, the mattress assembly 10 differs from that shown in the first embodiment because the additional layers 16-18 are constructed differently.

[0150] Typically, each of the additional layers 16, 18 has a height of 15 mm, similar to that of the first embodiment. Furthermore, these additional layers 16-18 are also bonded to each other using the same adhesive.

[0151] However, the properties of the additional layers 16-18 differ from those of the first embodiment, for example due to the different materials used for the additional layers 16,18.

[0152] In fact, the first additional layer 16 has a strength of 40 kg / m 3 The second additional layer 17 is made of visco-memory foam having a minimum net density of 42 kg / m and a hardness of 1.6 kPa. 3 The cushion is constructed of comfort foam having a minimum net density of 0.01 and a hardness of 2.5 kPa.

[0153] Thus, the same spring core assembly 12 may be used, but it may be used in combination with different additional layer structures to provide a mattress assembly 10 with different properties.

[0154] In Figure 6, a fourth embodiment is shown, which is a combination of the second embodiment shown in Figure 4 and the third embodiment shown in Figure 5. The mattress assembly 10 and spring core assembly 12 have a length of 2m as in the second embodiment, but the mattress assembly 10 includes the same additional layers 16-18 used in the third embodiment.

[0155] Thus, the spring core assembly 12 of the fourth embodiment includes 33 rows as already described in relation to the second embodiment shown in Figure 4, but the additional layers 16-18 are as described in relation to the third embodiment shown in Figure 5.

[0156] Accordingly, reference is made to the above description with respect to the second and third embodiments.

[0157] Typically, the cushioning layer 14 is foldable and rollable so that the cushioning layer can be in a shipping state, for example by folding the cushioning layer 14 at least once along an axis perpendicular to the long side of the cushioning layer 14 and then rolling up the cushioning layer 14, i.e. the cushioning layer 14 is folded at least once. In this way, a compact size of the cushioning layer 14 is achieved, and the cushioning layer 14 can be placed in a shipping bag.

[0158] In particular, the entire mattress assembly 10 is also foldable and rollable, so that the entire mattress assembly 10, including the spring core assembly 12 and the cushioning layer 14, can be in the shipping state. The shipping state of the mattress assembly 10 can thus be obtained, for example, by folding at least once along an axis perpendicular to the long side of the mattress assembly 10 and then rolling up the mattress assembly 10, i.e., the mattress assembly 10 is folded at least once. Thus, the entire mattress assembly 10, i.e., the spring core assembly 12 and the cushioning layer 14, is folded at least once and rolled up into the shipping state.

[0159] Because the mattress assembly 10 includes a spring core assembly 12 and a cushioning layer 14, both the spring core assembly 12 and the cushioning layer 14 are folded, for example, along an axis perpendicular to the long side, and then the mattress assembly 10 is folded at least once and rolled up, i.e., the spring core assembly 12 and the cushioning layer 14 are folded and rolled up simultaneously.

[0160] Specifically, that is, when the cushioning layer 14 is placed on top of the spring core assembly 12, the entire mattress assembly 10 is folded and rolled up.

[0161] A compact size for the entire mattress assembly 10 is thus achieved, allowing the entire mattress assembly 10 to be placed within a shipping bag.

Claims

1. A cushioning layer (14) for a mattress assembly (10), comprising: The cushioning layer (14) is configured to be placed over a spring core assembly (12) having at least one spring coil (34); The cushioning layer (14) comprises a frame (20) made of foam and a thermoplastic elastomer (TPE) grid layer (22); A thermoplastic elastomer grid layer (22) is surrounded by a frame (20) of the cushioning layer (14).

2. 2. The cushioning layer (14) according to claim 1, wherein the thermoplastic elastomer (TPE) grid layer (22) has a hardness which is higher compared to the hardness of the frame (20), in particular by 10% to 20% higher, and a minimum net density which is higher than the minimum net density of the frame (20), in particular 5 to 10 times, preferably 6 to 8 times higher.

3. Thermoplastic elastomer grid layer (22) has a strength of 230 kg / m ３ 3. The cushioning layer (14) of claim 1 or 2, having a minimum net density of 0.01 g / cm and / or a hardness of 0.01 g / cm.

4. The cushioning layer (14) of any one of claims 1 to 3, wherein the thermoplastic elastomer grid layer (22) constitutes between 40% and 70% of the cushioning layer (14).

5. The foam has a strength of 32 kg / m ３ The cushioning layer (14) according to any one of claims 1 to 4, which is a hypersoft foam having a minimum net density of 0.01 and / or a hardness of 2.5 kPa.

6. The thermoplastic elastomer (TPE) grid layer (22) has a plurality of intersecting walls (24) thereby defining voids (26); The cushioning layer (14) of any of claims 1 to 5, wherein the thermoplastic elastomer (TPE) grid layer (22) comprises uniformly or differently sized voids (26).

7. A thermoplastic elastomer (TPE) grid layer (22) containing differently sized voids; 7. The cushioning layer (14) of claim 6, wherein in the support region, the voids (26) have a smaller size compared to the voids (26) located in other regions of the thermoplastic elastomer (TPE) grid layer (22).

8. 8. The cushioning layer (14) according to claim 6 or 7, wherein the cavities (26) have various shapes, in particular rectangular, hexagonal and / or honeycomb shapes.

9. The cushioning layer (14) according to any one of claims 1 to 8, wherein the cushioning layer (14) is foldable and rollable, so that the cushioning layer (14) has a shipping state in which it is folded at least once and rolled up.

10. A cushioning layer (14) according to any one of claims 1 to 9; A mattress assembly (10) comprising: a spring core assembly (12); The spring core assembly (12) comprises a bottom fabric (30), a top fabric (32), and at least one spring pocket (28) having at least one spring coil (34) disposed between the bottom fabric (30) and the top fabric (32); A mattress assembly (10) in which the basis weight of the bottom fabric (30) is different from the basis weight of the top fabric (32).

11. The mattress assembly (10) is a stack assembly including a cushion layer (14), a spring core assembly (12) and at least two additional layers (16, 17, 18), A mattress assembly (10) as described in claim 10, wherein the at least two additional layers (16, 17, 18) are made of different materials, in particular different foams, and in particular the at least two additional layers (16, 17, 18) are positioned between the spring core assembly (12) and the cushion layer (14).

12. The spring core assembly (12) is the bottom layer of the mattress assembly (10); The cushioning layer (14) is the upper layer, 12. A mattress assembly (10) according to claim 11, wherein at least two additional layers (16, 17, 18) are bonded to one another, in particular the cushioning layer (14) is bonded to its adjacent additional layer (18).

13. A mattress assembly (10) according to any of claims 11 to 12, wherein all layers have different properties, in particular a minimum density and / or a different hardness, and / or all layers have the same height, in particular 15 mm.

14. The spring core assembly (12) includes a first type spring pocket (36) and a second type spring pocket (38); Both types of spring pockets (36, 38) have the same bottom fabric (30) and the same top fabric (32); The basis weight of the lower fabric (30) is different from the basis weight of the upper fabric (32); The first type of spring pocket (36) has a first spring coil (40) disposed between the bottom fabric (30) and the top fabric (32); A second type of spring pocket (38) has a second spring coil (42) disposed between the bottom fabric (30) and the top fabric (32); A mattress assembly (10) according to any of claims 10 to 13, wherein the first spring coil (40) and the second spring coil (42) are different.

15. The mattress assembly (10) of any one of claims 10 to 14, wherein the mattress assembly (10) is foldable and rollable, so that the mattress assembly (10) has a shipping state in which the cushioning layer (14) and the spring core assembly (12) are folded at least once and rolled up.

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