Honeycomb padding for mattresses or upholstered furniture in general and mattress obtained therewith

Abstract

The invention is a new filling for mattresses or upholstered furniture in general, comprising at least one perforated layer (100) made of foam material, having two opposite main faces (110, 120) and a predetermined thickness (H), and wherein said perforated layer (100) is provided with a plurality of through holes (200, 300) extending between said main faces (110, 120), and wherein the cross section of each of said holes (200, 300), drawn on a section plane parallel to said faces (110, 120), is constant along the entire thickness (H) of the perforated layer (100) and can be inscribed in a circle whose diameter is not less than 2 cm.

Description

[0001] HONEYCOMB PADDING FOR MATTRESSES OR UPHOLSTERED

[0002] FURNITURE IN GENERAL AND MATTRESS OBTAINED THEREWITH DESCRIPTION

[0003] The present patent relates to mattresses and paddings / fillings in general, and in particular it concerns a new padding / filling for mattresses or upholstered furniture in general and a mattress obtained therewith.

[0004] Mattresses are known which usually comprise a cover enclosing an internal supporting structure, which in turn can be made in various possible ways.

[0005] Structures comprising only the filling are known, that is, a soft or elastic material such as wool or foam materials.

[0006] Supporting structures are also traditionally known which comprise a plurality of springs constrained to one another, which can be encased in fabric pockets or not and which provide the mattress with the required elasticity.

[0007] Mattresses are also known which have structures where the above-mentioned elements are combined, and which thus comprise both a plurality of springs and one or more layers made of a soft material, for example a foam material.

[0008] One of the most appreciated characteristics of mattresses and upholstered furniture in general is their breathability. Particularly in mattresses, breathability is important for the purpose of preventing the accumulation of moisture inside the mattress itself and thus fighting the growth of mould, mites and microorganisms.

[0009] It is known that open-cell foam layers or layers with through holes with diameter in the order of 1 cm or less, which should allow for minimal ventilation, are used for this purpose. It has actually been found that the size of said holes is not sufficient to ensure the efficient flow of air, especially when the perforated layers are subjected to a load that inevitably causes their deformation. This deformation actually causes the holes to close, thus preventing the passage of air.

[0010] Furthermore, even in the absence of a load, the presence of said holes does not guarantee sufficient and adequate ventilation.

[0011] The need to differentiate the stiffness of the mattress, according to the different loads exerted on different areas, is also known. For this purpose, there are structures in which the stiffer areas are reinforced, for example with springs, or in which the different areas are obtained by gluing together foam materials with different stiffness. The mattress manufacturing process is therefore more complex, which increases material and production costs and thus the final cost of the product.

[0012] The subject of the present patent is a new filling for mattresses or upholstered furniture in general, the main purpose of which is to maximize air recirculation within the filling itself and, more generally, within the mattress or the entire furniture upholstery.

[0013] Another important object of the present invention is to achieve differentiated stiffness in the different areas of the filling.

[0014] An advantage of the present invention lies in the saving of material, as less material is needed to make the new filling.

[0015] Another advantage of the present invention lies in that a lighter product is obtained. Another advantage lies in that production time and costs are reduced.

[0016] These and other direct and complementary objects are achieved by the new filling for mattresses or upholstered furniture in general and by the mattress obtained therewith.

[0017] The new filling comprises at least one layer of foam material, having two opposite main faces and a predetermined thickness, and wherein said layer is provided with a plurality of through holes extending between said main faces, wherein the cross section of each of said holes, drawn on a section plane parallel to said faces, can be inscribed in a circle whose diameter is not less than 2 cm.

[0018] According to the invention, said holes are distributed and sized in such a way that the perforated surface is at least 10% of the total surface of each face, meaning that the empty volume is at least 10% of the total volume of the layer. More preferably, the empty volume is 10-60% of the total volume of the layer and even more preferably it is 45-60% of the total volume of the layer.

[0019] It has been observed that in this way the air flow is sufficient to achieve adequate ventilation.

[0020] In addition, the characteristics of the holes are also such that the stiffness of the layer is substantially modified, in particular under compression, which makes the layer softer.

[0021] It has also been observed that by varying the size of the holes, that is, the percentage of empty volume compared to the total volume, and their distribution, that is, the distance between them, it is possible to vary the stiffness.

[0022] In particular, the solid parts between two adjacent holes, that is, with no hole between them, actually form a rib, the thickness and shape of which determine its rigidity. Said at least one perforated layer of the new filling can thus include areas distributed in any way and featuring differentiated stiffness, depending on the size of the holes, their distance from one another and the percentage of empty volume compared to the total volume.

[0023] According to the invention, said layer comprises holes made in the entire surface of said opposite faces.

[0024] According to the invention, it is possible but not necessary for the layer to have a perimeter area without holes, which will thus be more rigid, forming a kind of structural ring.

[0025] According to the invention, furthermore, said holes have a constant cross section over the entire thickness of the layer.

[0026] The new filling can comprise one or more additional layers facing said perforated layer, wherein said additional layers can also be completely or partially perforated, as described above. In essence, the mattress obtained with said one or more layers, at least one of which is perforated, will be characterized by high air permeability at least in the direction orthogonal to the main faces of the layers, and furthermore it can have differentiated stiffness, even if only one layer made of a single material is used.

[0027] No complicated operations for the assembly of different materials are therefore necessary and, furthermore, the presence of the empty spaces makes it possible to considerably reduce the quantity of material used, which consequently also reduces the overall weight of the finished product.

[0028] The characteristics of the new filling and of the mattress with the new filling are better clarified in the following description, making reference to the drawings, which are attached by way of non-limiting example.

[0029] Figure 1 shows a plan view of a first example of embodiment of a perforated layer (100) forming the new filling.

[0030] Figure la shows a sectional view of a part of the perforated layer (100) of Figure 1 according to section plane A- A as indicated in Figure 1.

[0031] Figure 2 shows a plan view of a second example of embodiment of a layer (100’).

[0032] The new filling comprises at least one perforated layer (100) having two main opposite faces (110, 120) and a predetermined thickness (H).

[0033] Said perforated layer (100) is provided with a plurality of through holes (200, 300) extending between said opposite faces (110, 120).

[0034] Said holes (200, 300) can all be the same in shape and size, or they may be different from one another, thus giving the different areas of the mattress different ventilation and stiffness characteristics. Furthermore, said holes (200, 300) can also be homogeneously distributed on the entirety or on part of the surface of the perforated layer (100), or they can be distributed in a diversified manner, thus giving the different areas of the mattress different ventilation and stiffness characteristics.

[0035] In the example shown in Figure 1, said holes (200, 300) are all hexagonal, but the same inventive concept can be applied to holes of any shape, polygonal or non- polygonal, of fancy shapes, etc., even of several shapes different from one another. According to the invention, the cross section of each hole (200, 300), drawn on a section plane parallel to said faces (110, 120), can be inscribed in a circle whose diameter is not less than 2 cm or the dimensions of the hole are such that it can be inscribed in a circle whose diameter is not less than 3 cm. In the example of Figure 1, the layer comprises first smaller holes (200), hexagonal in shape and suited to be inscribed in a circle with a diameter of 5 cm, and second larger holes (300), hexagonal in shape and suited to be inscribed in a circle with a diameter of 8 cm. The dimensions of the holes can vary but the same inventive concept can be maintained. In the example shown in Figure 1, said holes (200, 300) are essentially distributed over the entire surface of the perforated layer (100), except for the perimeter area (130), which has no holes in the faces (110, 120). The presence of said nonperforated perimeter area is not necessary.

[0036] In the example of Figure 1, said holes (200, 300) are distributed according to 5 differentiated strips along the longitudinal direction (X) of the perforated layer (100), as described below.

[0037] - First strip (A): comprises a plurality of said first smaller holes (200) distributed rather densely so that the solid part forms a sort of thick grid with hexagonal meshes, wherein the thickness (SI) of the ribs (210) defined between two adjacent holes (200) is rather small; said first strip (A) is characterized by a given stiffness R1 and a given value VI of empty volume percentage per volume unit.

[0038] Second strip (B): comprises a plurality of said second larger holes (300), so that the solid part forms a sort of grid with larger hexagonal meshes, wherein the thickness (S2) of the ribs (310) defined between two adjacent holes (300) exceeds said thickness (SI) of the ribs (210) of the first holes (200); said second strip (B) is characterized by a given stiffness R2, greater than Rl, and by a given value V2, smaller than V 1. Said second strip (B) is thus more rigid than said first band (A).

[0039] Third strip (C): similar to said first strip (A).

[0040] - Fourth strip (D): similar to said second strip (B).

[0041] - Fifth strip (E): similar to said first and third strips (A, C).

[0042] The above distribution is just an example, as the layer can instead comprise a single area with homogeneously distributed holes or an indefinite number of areas with holes distributed in any way.

[0043] In essence, said single perforated layer (100) can have diversified stiffness characteristics lengthwise and / or widthwise, simply obtained by selectively and optionally varying the size and / or the distribution of the holes (200, 300) and thus the percentage value V and the thickness S of the ribs (210, 310) between the holes (200, 300).

[0044] For example, Figure 2 shows a layer (100') in which the second holes (300') are smaller than the second holes (300) of the perforated layer (100) of Figure 1. The value V3 of the full-empty percentage is therefore greater than V2, while the thickness S3 of the ribs (310') between adjacent holes (300') is smaller than the thickness S2. In this way, using the same type of material, strips (B', D') are obtained which are stiffer than the corresponding strips (B, D) of the perforated layer (100) shown in Figure 1.

[0045] These are the schematic outlines that are sufficient for the expert in the art to carry out the invention, consequently, on practical application variants may be obtained that do not affect the substance of the innovative concept introduced herewith.

[0046] Therefore, with reference to the above description and the attached drawings, the following claims are made.

Claims

CLAIMS1. Filling for mattresses or upholstered furniture in general, characterized in that it comprises at least one perforated layer (100) made of foam material, having two opposite main faces (110, 120) and a predetermined thickness (H), and wherein said perforated layer (100) is provided with a plurality of through holes (200, 300) extending between said main faces (110, 120), and wherein the cross section of each of said holes (200, 300), drawn on a section plane parallel to said faces (110, 120), is constant along the entire thickness (H) of the perforated layer (100) and can be inscribed in a circle whose diameter is not less than 2 cm.

2. Filling according to claim 1, characterized in that said holes (200, 300) are distributed and sized in such a way that the value V of the empty volume percentage of the perforated layer (100) is at least 10% with respect to the total volume of the perforated layer (100) and more preferably is included between 10 and 60% and even more preferably between 45 and 60%.

3. Filling according to claim 1, characterized in that said holes (200, 300) of said at least one perforated layer (100) are all equal to one another other in shape and size.

4. Filling according to claim 1, characterized in that said holes (200, 300) of said at least one perforated layer (100) are in two or more different shapes and / or sizes.

5. Filling according to claim 1, characterized in that said holes (200, 300) of said at least one perforated layer (100) are homogeneously distributed on the entirety or part of said perforated layer (100).

6. Filling according to claim 1, characterized in that said holes (200, 300) of said at least one perforated layer (100) are distributed in a non-homogeneous manner on the entirety or part of said perforated layer (100).

7. Filling according to the preceding claims, characterized in that areas or strips(A, B, C, D, E) of said at least one perforated layer (100), with holes (200, 300) having different shape and / or size and / or distribution, have different values V of empty volume percentage per volume unit and have different thicknesses S of the ribs (210, 310) defined between adjacent holes (200, 300), and consequently have different air permeability in the direction orthogonal to said faces (110, 120) as well as different stiffness.

8. Filling according to the preceding claims, characterized in that said perforated layer (100) has a perimeter strip (130) without holes.

9. Filling according to the preceding claims, characterized in that it comprises one or more further layers facing said at least one perforated layer (100), and wherein one or more of said further layers are provided with holes or not.

10. Mattress comprising a filling according to one or more of the preceding claims.

Images