Cushioning layer and mattress assembly for 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. Furthermore, the present invention relates to a mattress assembly. [Background technology]

[0002] In recent technology, cushioning layers containing gel inserts are known to provide users with desirable lying-down comfort. These gel inserts are typically heavy and have little breathability, thus retaining undesirable moisture.

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

[0004] Furthermore, foam mattress assemblies consisting of foam layers are known in the latest technology, in which at least one of the foam layers provides various lying zones (also called body zones) using, for example, notches 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 include a spring core layer and at least one foam layer placed on top of the spring core layer. Typically, the spring core layer comprises multiple spring pockets manufactured in the same manner. These mattress assemblies may also have various lying zones, established, for example, by notches and / or recesses within the foam layer, using additional foam layers placed on top of the spring core layer. Alternatively or additionally, multiple foam layers are provided, for example, using notches and / or recesses, to provide various lying zones. For example, the Emma Hybrid Mattress provides five different lying zones while including three foam layers and one spring core layer.

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

[0007] In fact, the concept of providing various lying / body zones is used. The reason is that foam layers can be manufactured in a cost-effective manner, and therefore it is not very expensive to provide foam layers with various properties.

[0008] However, creating notches and / or recesses can result in cutting or waste of material, which is undesirable. To overcome this drawback, it is already known that a corresponding foam layer can be provided from a foam block, thereby reducing material cutting or waste. This concept is described in German Journal No. 10 2017 117 556 A1. [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] However, there is a need for improved mattress assemblies that reduce material waste. Similarly, there is a need for improved cushioning layers that reduce the weight of the cushioning layer and the overall mattress assembly while maintaining 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 having 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) 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 portion of the entire cushioning layer. The remaining area is provided with a frame made of foam.

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

[0012] Furthermore, the thermoplastic elastomer grid layer is essential for providing improved breathability and reducing the amount of moisture retained. Therefore, using a thermoplastic elastomer grid layer in the cushioning layer improves the overall user experience.

[0013] In particular, due to the different breathabilities of the thermoplastic elastomer grid layer and the foam frame, different cooling characteristics can be obtained. In fact, the combination of the thermoplastic elastomer grid layer and the foam frame provides more cooling to the body than to the limbs. This is because the thermoplastic elastomer grid layer is associated with the body.

[0014] Furthermore, the thermoplastic elastomer grid layer ensures that the entire cushion layer is foldable and rollable. Therefore, the cushion layer can be easily put into the shipping state, for example, the rolled-up state, and the thermoplastic elastomer grid layer is packed into a shipping bag.

[0015] Specifically, it is possible to fold (and then) roll up the entire cushion layer. This can be achieved by the combination of the thermoplastic elastomer grid layer and the frame, especially depending on their individual characteristics. 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 providing sufficient support at the same time. The frame is made entirely of foam (solid material), while the thermoplastic elastomer grid layer contains voids filled with air. Thus, the frame does not contain additional introduced voids. In other words, the frame made of foam contains only the inherent air inclusions associated with the foam material.

[0017] In fact, the cushion layer has two opposing main surfaces and four side surfaces. Each of the main surfaces is established by the individual surfaces of the frame and the individual surfaces of the thermoplastic elastomer grid layer. In contrast, the side surfaces are constructed only of the frame, i.e., the foam material of the frame.

[0018] Generally, the frame and the thermoplastic elastomer grid layer are connected to each other in a permanent manner, thereby ensuring that the entire cushion 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 connection.

[0019] Therefore, the cushion layer according to the present invention is distinguished from an assembly including a frame with receptacles and an insert disposed within the receptacles. However, the frame and the insert are formed separately and, even if they are connected to each other in an assembled state, it is not permanent.

[0020] Furthermore, the frame and the thermoplastic elastomer grid layer each have a geometric center, and the geometric centers thereof coincide.

[0021] One aspect of the present invention defines that the thermoplastic elastomer grid layer has a hardness that is particularly 10% to 20% higher compared to the hardness of the frame, and has a minimum net density that is higher than the minimum net density of the frame, particularly 5 to 10 times, preferably 6 to 8 times higher. This ratio ensures optimized characteristics with respect to support, handling, and cushioning properties, i.e., hardness and / or rigidity. Despite having a higher hardness than the frame and a higher minimum net density than the frame, the thermoplastic elastomer grid layer provides a softer feel to the user with respect to 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 a lattice structure, i.e., having voids filled with air.

[0022] Particularly, the thermoplastic elastomer grid layer has a minimum net density of 230 kg / m 3 and / or a hardness of 2.8 kPa. These characteristics ensure that, together with the voids, the desired lying comfort can be obtained with the structure of the thermoplastic elastomer grid layer.

[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, ensuring that the user experience is not compromised. Consequently, 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 constituting the entire area of ​​the cushioning layer, the handling and lying comfort of the cushioning layer can be improved.

[0024] Another aspect of the present invention is that the foam is 32 kg / m³ 3 It is specified that the foam is a hypersoft foam (ultra-soft foam) having a minimum net density 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 entirely foamed, i.e., manufactured in a solid manner. Therefore, due to the fact that the thermoplastic elastomer grid layer is structured differently to contain voids, the minimum net density and hardness of the thermoplastic elastomer grid layer are higher compared to the frame.

[0025] A thermoplastic elastomer grid layer has multiple intersecting walls that define voids, and the thermoplastic elastomer grid layer contains voids that are uniformly or unequally sized. By containing unequally sized voids, the thermoplastic elastomer grid layer can provide different lying / body zones, improving the user experience, i.e., providing preferred support for each lying / body zone, for example, the buttocks, shoulders, and other body parts with different requirements. In fact, by using unequally sized voids, various lying / body zones with different properties can be provided.

[0026] Generally, voids, regardless of their size, are defined by intersecting walls. Furthermore, these voids allow the cushion layer to be folded. This is because, even if the cushion layer is made of TPE material with the aforementioned properties, there is room for the wall material to fit inside when the cushion layer is folded.

[0027] Preferably, the thermoplastic elastomer grid layer includes support areas where the voids are smaller in size compared to voids in other areas of the thermoplastic elastomer grid layer. This ensures optimal comfort and different support for various body zones, resulting in an improved user experience.

[0028] The voids may have various shapes, particularly rectangular, hexagonal, and / or honeycomb shapes. For example, the rectangular shape is related to a square. These forms generally offer different stabilities, but this also depends on the size of the voids, i.e., the distance between the opposing walls that limit the individual voids. Furthermore, since they are relatively easy to manufacture, they do not add significantly to the manufacturing cost.

[0029] Furthermore, the present invention provides a mattress assembly. The mattress assembly comprises a cushion layer and a spring core assembly, the spring core assembly comprising a bottom fabric, an top fabric, and at least one spring pocket having at least one spring coil installed between the bottom fabric and the top fabric. The basis weight of the bottom fabric is different from the basis weight of the top fabric.

[0030] Therefore, a spring core assembly that can be used as a spring core layer within a mattress assembly features spring pockets with different fabrics above and below the individual spring coils. This ensures that the spring core assembly, and in particular the individual spring coils, have improved support.

[0031] For example, the bottom fabric and top fabric are polypropylene (PP) fabrics, such as textile products derived from the thermoplastic polymer polypropylene.

[0032] The spring core assembly has multiple 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, the bottom and top fabrics are placed on either side of each individual spring pocket.

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

[0035] One embodiment specifies that the basis weight of the bottom fabric is higher than that of the top fabric. Consequently, the higher basis weight of the bottom fabric ensures proper support for the spring coils. In fact, the spring core assembly, i.e., the spring core layer, may also relate to the bottom layer of the mattress assembly, and the higher basis weight of the bottom fabric ensures that the mattress assembly can rest on the bed frame by the springs, i.e., by the bottom fabric, thereby providing sufficient support and durability.

[0036] For example, the ratio of the basis weight of the upper fabric to the basis weight of the bottom fabric is 0.375 to 0.8, preferably 0.4 to 0.6, and particularly 0.5. This ratio ensures optimized properties with respect to (mechanical) support and mattress characteristics, such as hardness and / or stiffness.

[0037] In particular, the basis weight of the upper fabric is 60 g / m². 2 ~80g / m 2 A range, for example, 65 g / m 2 As an alternative or addition, the basis weight of the bottom fabric is 100g / m². 2 ~160g / m 2 This range includes, for example, 130 g / m².2 These specific basis weights ensure that the spring coil is supported in a predetermined manner, while the high basis weight of the bottom fabric provides sufficient support from the spring core assembly.

[0038] Another embodiment specifies that the spring core assembly comprises a first type of spring pocket and a second type of spring pocket. Both types of spring pockets have the same bottom fabric and the same top fabric. The basis weight of the bottom fabric differs from that of the top fabric. The first type of spring pocket has a first spring coil installed between the bottom fabric and the top fabric. The second type of spring pocket has a second spring coil installed between the bottom fabric and the top fabric. The first and second spring coils are different. For example, the first and second spring coils have different characteristics with respect to stiffness.

[0039] Different types of spring pockets, namely the first type of spring pocket and the second type of spring pocket, ensure that the spring core assembly provides different lying / body zones, resulting in different zones throughout the mattress assembly.

[0040] The first and second type spring pockets may be adjacent to each other and bonded together. This ensures that different types of spring pockets can connect to each other, even if they have different stiffness characteristics due to the various spring coils. Since the spring pockets are bonded to each other, their relative positions are fixed.

[0041] The first and second spring coils 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 rigidity. Thus, different lying / body zones can be obtained, including either the first type of spring pocket or the second type of spring pocket.

[0042] The ratio of the diameter of the first spring coil to the diameter of the second spring coil may be in the range of 0.72 to 0.95, and may even be 0.9. This ratio ensures that the user can recognize different lying / body zones while maintaining a good feel, as there is no significant difference in the hardness of the individual spring coils.

[0043] For example, the diameter of the first spring coil ranges from 1.6mm to 1.9mm, and is particularly 1.8mm. Alternatively or additionally, the diameter of the second spring coil ranges from 1.8mm to 2.2mm, and is particularly 2mm. These diameters ensure sufficient firmness and stability for each individual spring coil while providing the desired comfort in the lying / body zone.

[0044] A further embodiment specifies that a plurality of first-type spring pockets are connected in series, particularly by welding, thereby forming a row of first-type spring pockets. Alternatively or additionally, a plurality of second-type spring pockets are connected in series, particularly by welding, thereby forming a row of second-type spring pockets. Depending on the size, particularly the width, of the spring core assembly, individual rows may comprise a different number of spring pockets connected to one another by welding, thereby providing a row of first-type or second-type spring pockets. Thus, individual rows may be associated with the width of the spring coil assembly or mattress assembly. Consequently, 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 the first type of spring pockets are installed adjacent to each other, and the spring pockets of adjacent rows are bonded to each other. Alternatively or additionally, at least two rows of the second type of spring pockets are installed adjacent to each other, and the spring pockets of adjacent rows are bonded to each other. Individual zones of the same type of spring pockets can be established by providing two or more rows of the same type of pocket springs. However, a particular zone may be realized by only a single row, in particular a single row of the first type of spring pocket. Zones established by the second type of spring pockets may always include at least two rows of the second type of spring pockets.

[0046] In general, adjacent rows of spring pockets, regardless of their type, may be bonded to each other, thereby establishing a spring core assembly.

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

[0048] Generally, a 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 orthogonal to each other. Thus, the spring core assembly has a symmetrical design, thereby ensuring that the same spring core assembly can be used in two different directions, i.e., rotated 180 degrees around its center in a plane, without, for example, inverting the spring core assembly. In other words, since the opposing edges are interchangeable, the spring core assembly has neither an upper edge nor a lower edge. To put it another way, the bottom fabric is always oriented toward the floor, for example, toward the frame of a bed when in use.

[0049] One embodiment specifies 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 various materials, in particular various 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 cushion layer is bonded to the third additional layer. All (additional) layers have different properties, e.g., different minimum densities and / or different hardnesses. Furthermore, different types of adhesives may be used to bond the individual layers to each other. As described 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 cushion layer is connected to the third additional layer using a water-based adhesive.

[0052] However, various adhesives can be used, such as water-based adhesives and / or hot-melt adhesives.

[0053] Generally, the foam used for 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 referred to as comfort foam, is associated with the first additional layer that is placed directly on top of the spring core assembly. For example, the first additional layer has a minimum net density 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 a 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 has a minimum net density 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 a hardness of 2.5 kPa.

[0056] The third additional layer may be made of visco memory foam or hypersoft foam. For example, the third additional layer has a minimum net density 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 a hardness of 1.6 kPa.

[0057] The top layer is provided by a cushion layer consisting of a frame surrounded by foam, preferably hypersoft foam, and a thermoplastic elastomer grid layer.

[0058] Generally, spring core assemblies and mattress assemblies may have a length of 2m or 1.9m, and therefore 33 rows or 32 rows of spring pockets are used, respectively. Each row can be established by two different types of spring pockets, in particular rows of spring pockets.

[0059] In a particular embodiment, for example, with a width of 90 cm, the spring core assembly has 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. Therefore, a spring core assembly or mattress assembly with a width greater than 90 cm may have more than 14 spring pockets per row.

[0060] A first embodiment of the spring core assembly may have 11 zones.

[0061] In fact, the first zone, starting from the first edge, may include two rows of a particular type of spring pocket, for example, a second type of spring pocket. The second zone is adjacent to the first zone and includes six rows of a particular type of spring pocket, for example, a first type of spring pocket. The third zone is adjacent to the second zone and includes five rows of a particular type of spring pocket, for example, a second type of spring pocket. The fourth zone is adjacent to the third zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The fifth zone is adjacent to the fourth zone and includes two rows of a particular type of spring pocket, for example, a second type of spring pocket. The sixth zone is adjacent to the fifth zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The seventh zone is adjacent to the sixth zone and includes two rows of a particular type of spring pocket, for example, a second type of spring pocket. The eighth zone is adjacent to the seventh zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. Zone 9 is adjacent to Zone 8 and contains five rows of a specific type of spring pocket, for example, Type 2 spring pockets. Zone 10 is adjacent to Zone 9 and contains six rows of a specific type of spring pocket, for example, Type 1 spring pockets. Zone 11 is adjacent to Zone 10 and contains two rows of a specific type of spring pocket, for example, Type 2 spring pockets. Zone 11 ends at the second edge opposite the first edge.

[0062] The symmetry line of the spring core assembly extends along the sixth zone, for example, along a single row provided by the sixth zone. Another symmetry line extends perpendicularly to it and intersects all zones, for example, all rows. Both symmetry lines intersect each other at the center of the spring core assembly.

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

[0064] In fact, the first zone, starting from the first edge, may include two rows of a particular type of spring pocket, for example, a second type of spring pocket. The second zone is adjacent to the first zone and includes six rows of a particular type of spring pocket, for example, a first type of spring pocket. The third zone is adjacent to the second zone and includes six rows of a particular type of spring pocket, for example, a second type of spring pocket. The fourth zone is adjacent to the third zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The fifth zone is adjacent to the fourth zone and includes two rows of a particular type of spring pocket, for example, a second type of spring pocket. The sixth zone is adjacent to the fifth zone and includes only one row of a particular type of spring pocket, for example, a first type of spring pocket. The seventh zone is adjacent to the sixth zone and includes six rows of a particular type of spring pocket, for example, a second type of spring pocket. The eighth zone is adjacent to the seventh zone and includes six rows of a particular type of spring pocket, for example, a first type of spring pocket. Zone 9 is adjacent to Zone 8 and contains two rows of a specific type of spring pocket, for example, a second type of spring pocket. Zone 9 ends at the second edge, which is opposite the first edge.

[0065] The symmetry line of the spring core assembly extends along the fifth zone, for example, between the two rows provided by the fifth zone. Another symmetry line extends perpendicular to it and intersects all zones, for example, all rows. Both symmetry lines intersect each other at the center of the spring core assembly.

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

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

[0068] When combined with a mattress assembly, the additional layer, namely the foam layer, ensures pressure relief and comfort, and makes the mattress assembly more durable.

[0069] Generally, the additional layer, i.e., the foam layer, is manufactured without notches and / or recesses, for example, as a complete material layer.

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

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

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

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

[0074] In particular, since the entire mattress assembly is foldable and rollable, the mattress assembly has a shipping condition in which the cushion layer and spring core assembly are folded and rolled up at least once. As mentioned above, since the cushion layer is foldable and rollable, the cushion layer can be shipped in that condition. The spring core assembly is manufactured end-to-end and can be folded and rolled up, for example, even without surrounding foam. As a result, the entire mattress assembly, including the cushion layer and spring core assembly, is foldable and rollable. In other words, when the entire mattress assembly is folded and rolled up, the cushion layer rests on top of the spring core assembly. [Brief explanation of the drawing]

[0075] The aforementioned aspects of the claimed subject matter and the methods of the associated advantages will be more readily understood by referring to the following description in conjunction with the attached drawings.

[0076] [Figure 1] A schematic diagram of the entire mattress assembly according to the first embodiment of the present invention, using the spring core assembly according to the first embodiment of the present invention, is shown. [Figure 2] The diagram schematically shows the entire cushion layer that can be used in any of the embodiments described, and the cushion layer comprises a thermoplastic elastomer grid layer and a foam frame. [Figure 3] Examples of thermoplastic elastomer grid layers are shown; Figure 3A shows rectangular voids, and Figure 3B shows triangular voids. [Figure 4] A schematic diagram of the entire mattress assembly according to the second embodiment of the present invention, using the spring core assembly according to the second embodiment of the present invention, is shown. [Figure 5] A schematic diagram of the entire mattress assembly according to the third embodiment of the present invention, using the spring core assembly according to the third embodiment of the present invention, is shown. [Figure 6]A schematic diagram of the entire mattress assembly according to the fourth embodiment of the present invention, using the spring core assembly according to the fourth embodiment of the present invention, is shown. [Modes for carrying out the invention]

[0077] Figure 1 shows a mattress assembly 10 including a spring core assembly 12, and a top view thereof is also shown in Figure 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] Furthermore, the mattress assembly 10 includes a cushion layer 14 that corresponds to the upper layer of the mattress assembly 10.

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

[0080] Therefore, the mattress assembly 10 is related to the stack assembly, because various layers 12-18 are stacked on top of each other to form the mattress assembly stack.

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

[0082] The cushion layer 14 (shown in detail in Figure 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 cushion layer 14 such that the geometric centers of the frame 20 and the TPE grid layer 22 coincide. In practice, the central area of ​​the user lying on top of the mattress assembly 10 is supported by the TPE grid layer 22.

[0084] This ensures that the cushion layer 14 has different cooling characteristics.

[0085] In fact, the different breathability of the thermoplastic elastomer grid layer 22 and the foam frame 20 provides different cooling properties. Specifically, the thermoplastic elastomer grid layer 22 is associated with the body and provides more cooling compared to the foam frame associated with the user's limbs lying on the cushion layer 14.

[0086] Below, we detail examples of standard European and UK mattress sizes and weights. However, the exact values ​​may vary depending on the 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 an 80cm x 200cm mattress, the TPE grid layer 22 may have a width of 60cm and a length of 150cm, and the weight of the TPE grid layer 22 will be 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 is 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 is 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 is 8.0kg.

[0093] Depending on the size of the cushion layer 14, the thermoplastic elastomer grid layer 22 constitutes 40% to 70% of the cushion layer 14. Therefore, the foam frame 20 has a size corresponding to 30% to 60% of the cushion layer 14, which also depends on the individual size of the cushion layer 14.

[0094] In particular, as shown in Figures 3a and 3b, the TPE grid layer 22 has a plurality of walls 24 that intersect each other, thus defining gaps 26 between them. The gaps 26 are empty of material and are filled with, for example, air. Thus, the TPE grid layer 22 has a grid structure due to the walls 24 and gaps 26, with the open side of the gaps 26 facing upward. Accordingly, the TPE grid layer 22 has a continuous base 27 through which the TPE grid layer 22 is installed on top of individual additional layers, for example, a third additional layer 18. The plurality of walls 24 may extend vertically upward from the continuous base 27.

[0095] The void 26 can have any shape. For example, the void 26 can be rectangular, hexagonal, and / or honeycomb-shaped. These shapes provide sufficient and different support while offering desirable comfort to the user. Furthermore, these different shapes can be implemented in a cost-effective manner.

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

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

[0098] The gaps 26 of different sizes can establish different support areas, thus providing a rigid or rather softer support.

[0099] The TPE grid layer 22, i.e., the TPE material, has a density of at least 230 kg / m². 3 It has a density and / or a hardness of 2.8 kPa.

[0100] In contrast, the hypersoft foam constitutes the frame 20 of the cushion layer 14, which surrounds the TPE grid layer 22, with a density of 32 kg / m². 3 It has a minimum net density and / or a hardness of 2.5 kPa. However, while the frame 20 is solid, the TPE grid layer 22 contains additionally introduced voids 26.

[0101] Therefore, the thermoplastic elastomer (TPE) grid layer 22 has a higher hardness than the frame 20, and is particularly 10% to 20% harder.

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

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

[0104] In particular, the various layers 14-18 are interconnected using adhesive. Different adhesives may be used depending on the type of layers being interconnected. Preferably, water-based glue / adhesive is used. However, heat-activated adhesives, heat-setting, sewing, etc., can also be used.

[0105] For example, the cushion layer 14 is bonded to the third additional layer 18 using a water-based adhesive. The third additional layer 18 is similarly bonded to the second additional layer 17 using a water-based adhesive. Furthermore, the second additional layer 17 is also bonded to the first additional layer 16 using a water-based adhesive.

[0106] These layers 14-18, which are bonded together, are placed on top of the spring core assembly 12.

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

[0108] As mentioned above, the additional layers 16-18 are made of foam, particularly different foams. 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 density of 30 kg / m². 3 It has a minimum net density and a hardness of 3 kPa.

[0110] The second additional layer 17 has a load capacity of 50 kg / m³. 3 It may also be made from visco memory foam having a minimum net density and a hardness of 1.8 kPa.

[0111] For example, the third additional layer 18 has a density of 32 kg / m³. 3 It is made from hypersoft foam with a minimum net density and a hardness of 1.5 kPa.

[0112] The spring core assembly 12 comprises a plurality of spring pockets 28 schematically shown in Figure 1. Each spring pocket 28 includes a bottom fabric 30 and an upper fabric 32, and the spring pocket 28 is bonded to the first additional layer 18 via the upper fabric 32.

[0113] Each spring pocket 28 has a spring coil 34 positioned between the bottom fabric 30 and the top fabric 32. The spring coil 34 is made of metal wire.

[0114] Each fabric, i.e., the bottom fabric 30 and the top fabric 32, has a different grammage. For example, the grammage of the bottom fabric 30 is higher than that 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 upper 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 / m². 3 ~80g / m 3 The range, especially 65g / m 3 On the other hand, the basis weight of the bottom fabric 30 is 100 g / m². 3 ~160g / m 3 The range, especially 138g / m² 3 That is the case.

[0117] In fact, the bottom fabric 30 provides a support surface for the entire mattress assembly 10, as shown in Figure 1.

[0118] Therefore, these different basis weights of the fabrics 30 and 32 ensure proper support for the spring coils 34 installed in the spring pockets 28, and ensure proper support for the user of the entire mattress assembly 10.

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

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

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

[0122] Different types of spring pockets 36, 38 are distinguished from one another by the diameter of the individual spring coils 34, particularly the diameter of the individual spring coils 34.

[0123] In fact, the first type of spring pocket 36 has a first spring coil 42 with a diameter in the range of 1.6 mm to 1.9 mm, especially 1.8 mm, while the second spring coil 42 has a diameter of 1.8 mm to 2.2 mm, especially 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, particularly 0.9.

[0125] In the illustrated embodiment, the spring core assembly 12 comprises several different zones A to I, i.e., a total of nine different zones. The zones are established by regions defined by different types of spring pockets 28.

[0126] Each zone A to I is provided with only one type of spring pocket 28, namely either a first type spring pocket 36 or a second type spring pocket 38.

[0127] Each of the nine distinct zones comprises at least one row of a specific type of spring pocket 28.

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

[0129] In the illustrated embodiment, regardless of the specific type of spring pocket 28, one row comprises 14 spring pockets 28.

[0130] In fact, Zone 1A contains two rows of Type 2 spring pockets 38. The adjacent Zone 2B contains six rows of Type 1 spring pockets 36. Zone 3C contains six rows of Type 1 spring pockets 38. Zone 4D contains a single row of Type 1 spring pockets 36. Zone 5E contains two rows of Type 2 spring pockets 38. Zone 6F contains a single row of Type 1 spring pockets 36. Zone 7G contains six rows of Type 2 spring pockets 38. Zone 8H contains six rows of Type 1 spring pockets. Finally, Zone 9I contains two rows of Type 2 spring pockets 38.

[0131] In the illustrated embodiment, the spring core assembly 12 has a length L of 190 cm. Thus, the spring core assembly 12 comprises 40 rows, and these 40 rows are interconnected by adhesive.

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

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

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

[0135] Furthermore, each spring pocket 28 is bonded along a second dimension, for example, length L, which is perpendicular to the first dimension, for example, width W.

[0136] Furthermore, the spring core assembly 12 is symmetric with respect to two lines of symmetry S1 and 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, specifically between both rows of the fifth zone E, i.e., between the 16th and 17th rows of the spring pocket 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 inside the fifth zone E, that is, between the seventh and eighth columns of the spring pocket 28 along the width W.

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

[0140] This additional row creates 11 zones A through K, resulting in a distribution of different zones.

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

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

[0143] Zone 1A contains two rows of Type 2 spring pockets 38. Adjacent Zone 2B contains six rows of Type 1 spring pockets 36. Adjacent Zone 3C contains five rows. Adjacent Zone 4D contains a single row of Type 1 spring pockets 36. Adjacent Zone 5E contains two rows of Type 2 spring pockets 38. Adjacent Zone 6F contains a single row of Type 1 spring pockets 36.

[0144] The sixth zone F also includes a second symmetry axis S2 that intersects the first symmetry access at the center M, passing through a single row.

[0145] The adjacent 7th zone G contains two rows of type 2 spring pockets 38. The adjacent 8th zone H contains only one row of type 1 spring pockets 36. The adjacent 9th zone I contains five rows of type 2 spring pockets 38. The adjacent 10th zone J contains six rows of type 1 spring pockets 36. Finally, the adjacent 11th zone K contains two rows of type 2 spring pockets 38.

[0146] The cushion layer 14 and additional layers 16-18 are the same as those in the first embodiment shown in Figure 1, and refer to that.

[0147] Figure 5 shows a third embodiment, which includes a mattress assembly 10 and a spring core assembly 12 having a length of 190 cm. Its size is the same as that of the first embodiment shown in Figure 1.

[0148] In fact, the spring core assembly 12 also has 40 rows of spring pockets 28. The distribution of the different types of spring pockets 28, namely the first type of spring pockets 36 and the second type of spring pockets 38, is similar to that shown in Figure 1. Therefore, refer 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 manufactured differently.

[0150] Generally, the additional layers 16 and 18 each have a height of 15 mm, similar to 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 in the additional layers 16 and 18.

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

[0153] Therefore, the same spring core assembly 12 is used, but it is used in combination with different additional layer structures, thereby providing mattress assemblies 10 with different characteristics.

[0154] Figure 6 shows a fourth embodiment, 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 the spring core assembly 12 have a length of 2 m, similar to the second embodiment, but the mattress assembly 10 includes the same additional layers 16-18 used in the third embodiment.

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

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

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

[0158] In particular, since the entire mattress assembly 10 is foldable and retractable, the entire mattress assembly 10, including the spring core assembly 12 and the cushion layer 14, can be returned to its shipping state. Therefore, the shipping state of the mattress assembly 10 is obtained, for example, by folding it at least once along an axis perpendicular to the long side of the mattress assembly 10, and then retracting the mattress assembly 10; that is, the mattress assembly 10 is folded at least once. Thus, the entire mattress assembly 10, i.e., the spring core assembly 12 and the cushion layer 14, is folded at least once and retracted to its shipping state.

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

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

[0161] This achieves a compact size for the entire mattress assembly 10, allowing it to be placed inside a shipping bag.

Claims

1. A cushioning layer (14) for a mattress assembly (10), The cushion layer (14) is configured to be placed on top of a spring core assembly (12) which has at least one spring coil (34), The cushion layer (14) comprises a frame (20) made of foam and a thermoplastic elastomer (TPE) grid layer (22). The thermoplastic elastomer grid layer (22) is directly surrounded by the frame (20), The frame (20) and the thermoplastic elastomer grid layer (22) each have a geometric center, and their geometric centers coincide. The cushion layer (14) has two opposing main surfaces and four sides, each of which is established by the individual surfaces of the frame (20) and the individual surfaces of the thermoplastic elastomer grid layer (22), while the sides are constructed solely from the foam material of the frame (20). The frame (20) and the thermoplastic elastomer grid layer (22) are permanently connected to each other, thereby ensuring that the entire cushion layer (14) is a single layer. The thermoplastic elastomer (TPE) grid layer (22) has a continuous base (27) and a plurality of intersecting walls (24) thereby defining voids (26). Multiple walls (24) extend vertically upward from the continuous base (27), The thermoplastic elastomer (TPE) grid layer (22) contains voids that are sized uniformly or differently. The thermoplastic elastomer grid layer (22) has a minimum net density of 230 kg / m³. The cushion layer (14) is foldable and / or rollable, so that the cushion layer (14) has a shipping state in which the cushion layer (14) is folded and / or rolled up at least once.

2. The cushion layer (14) according to claim 1, wherein the thermoplastic elastomer (TPE) grid layer (22) has a higher hardness than the frame (20) and a lower minimum net density than the frame (20).

3. The thermoplastic elastomer grid layer (22) has a hardness of 2.8 kPa, and the cushion layer (14) is as described in claim 1 or 2.

4. The cushion layer (14) according to claim 1, wherein the thermoplastic elastomer grid layer (22) constitutes 40% to 70% of the cushion layer (14).

5. The foam is 32 kg / m³ ３ The cushion layer (14) according to claim 1, which is a hypersoft foam having a minimum net density and / or a hardness of 2.5 kPa.

6. The thermoplastic elastomer (TPE) grid layer (22) contains voids of different sizes, The cushion layer (14) according to claim 1, wherein in the support region, the voids (26) are smaller in size than the voids (26) located in other regions of the thermoplastic elastomer (TPE) grid layer (22).

7. The cushion layer (14) according to claim 1, wherein the voids (26) have various shapes, in particular rectangular, hexagonal and / or honeycomb shapes.

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