Mattress

Abstract

 A shock-absorbing body (1) comprising an internal body (2) made of open-cell polyurethane material covered by a protective element (3) which comprises an elastomeric film made of closed-cell polyurethane material.

Description

[0001] The present invention relates to a shock-absorbing body, and more specifically to a mattress, and to a method for its provision.

[0002] Shock-absorbing bodies are known, which have a "mattress" structure, are of various types and designed for different uses.

[0003] For the purposes of example, such mattresses are used for protection in environments like gyms, swimming pools, playgrounds, side protections for poles, trees etc..

[0004] In recent times it has been found extremely useful to use shock-absorbing bodies as pallets for animals and, specifically, for cattle.

[0005] Typically, shock-absorbing bodies for the above-mentioned uses are constituted by panel-like elements which are made of deformable material (such as a foam, for example polyurethane) and are generally covered by a protective element the function of which is to protect the foam that forms the actual shock-absorbing body from shocks, and possibly from the action of atmospheric agents.

[0006] In order to improve the technical characteristics of shock-absorbing bodies, solutions have been proposed in which it was attempted to make the inner surface of the protective element adhere closely to the outer surface of the panel-like element made of deformable material so as to ensure an effective transfer of the pressure from the protective element to the panel-like element while at the same time preventing the creation of wrinkles which in the long term can result in the rupture of the protective element.

[0007] A first attempt, developed specifically for making protective mattresses for use for example on ski runs or in gyms, consisted of covering the panel-like element with a layer of covering in PVC (Polyvinyl chloride) which is maintained adherent to the outer surface of the panel-like element thanks to the use of connection thongs between the abutting free flaps of the layer of covering.

[0008] In a development of the above-mentioned solution, the layer of covering in PVC is rolled around the surface of the panel-like element and the free flaps are hermetically welded so as to seal the layer of covering so as to produce an impermeable protective layer for the shock-absorbing body.

[0009] The solutions described above entail some drawbacks, however, such as problems of an environmental nature and problems of waste disposal resulting from the use of PVC, and problems relating to the laboriousness of the process of production and assembly which, in any case, does not always ensure a perfect adhesion between the layer of covering and the panel-like element.

[0010] In order to seek, among other things, to overcome such drawbacks a shock-absorbing body, used specifically as a pallet for cattle, has been proposed in which a protective shell of PE (polyethylene), made by way of rotational molding, is filled with a polyurethane foam and then sealed.

[0011] This solution too, although valid in conceptual terms, has some drawbacks.

[0012] In particular it has been found that, after use of the shock-absorbing body, the protective shell tends to detach, thus shortening its life.

[0013] Moreover, the production process is extremely expensive and inflexible since it necessitates a dedicated mold for each geometric shape to be produced.

[0014] The aim of the present invention is to provide a shock-absorbing body that is capable of eliminating, or at least drastically reducing, the above-mentioned drawbacks.

[0015] Within this aim, an object of the present invention is to provide a shock-absorbing body that is capable of offering good shock-absorbing properties and at the same time a high level of resistance to penetration.

[0016] Another object of the invention is to make available a shock-absorbing body in which the protective layer or shell is closely connected to the panel-like inner element so as to reduce the risk of separation after intense use.

[0017] Another object of the invention is to devise a method for providing a shock-absorbing body which makes it possible to produce, at competitive production costs, shock-absorbing bodies of extremely varied shapes and hardnesses so as to enable their use in widely varying fields of application.

[0018] This aim and these and other objects which will become more apparent hereinafter are achieved by a shock-absorbing body and by a method for its provision according to the independent claims herein.

[0019] Further characteristics and advantages of the invention will become more apparent from the description of some preferred but not exclusive embodiments of a shock-absorbing body and of a method for its provision according to the present invention, which are illustrated by way of nonlimiting example in the accompanying drawings wherein:

Figure 1 is a perspective view of an embodiment of the shock-absorbing body, according to the invention;

Figure 2 is a sectional view of the shock-absorbing body in Figure 1 taken along the line II-II.

[0020] In the embodiments that follow, individual characteristics shown in relation to specific examples may in reality be interchanged with other, different characteristics, existing in other embodiments.

[0021] Moreover, it should be noted that anything found to be already known during the patenting process is understood not to be claimed and to be the subject of a disclaimer.

[0022] The present invention relates to a shock-absorbing body, generally designated with the reference numeral 1, comprising an internal body 2 made of open-cell polyurethane material covered by a protective element 3 which comprises an elastomeric film made of closed-cell polyurethane material.

[0023] Delving deeper into the details, the open-cell polyurethane material comprises a two-component polyurethane constituted by a first component, which comprises polyether polyols, chain extenders, catalysts and stabilizers, and a second component, which comprises an isocyanate and, more specifically, 4,4'-diphenyl methane diisocyanate.

[0024] With particular reference to the first component that constitutes the open-cell polyurethane material, the polyether polyols can be constituted by polyols based on propylene and ethylene oxide with a molecular weight comprised between 250 and 6200, while tertiary aliphatic amines can be used as catalysts.

[0025] The closed-cell polyurethane material comprises, in turn, a two-component polyurethane constituted by a first component, which comprises polyether polyols, catalysts and stabilizers, and a second component, which comprises an isocyanate and, more specifically, 4,4'-diphenyl methane diisocyanate.

[0026] In the first component that constitutes the closed-cell polyurethane material, the polyether polyols can be constituted by polyols based on propylene and ethylene oxide with a molecular weight comprised between 250 and 6200, the catalysts can comprise tertiary aliphatic amines or organometallic catalysts, and the stabilizers can be constituted by molecular sieves and antifoam agents.

[0027] Depending on the type of application required, the elastomeric film made of closed-cell polyurethane material has a thickness comprised between 0.5 mm and 15 mm while the internal body 2 can be variously contoured.

[0028] The present invention also relates to a method for providing a shock-absorbing body 1 comprising a step of providing an internal body 2 made of open-cell polyurethane material and a step of covering this internal body 2 made of open-cell polyurethane material with a protective element 3 which comprises an elastomeric film made of closed-cell polyurethane material.

[0029] According to a preferred embodiment, the open-cell polyurethane material comprises a two-component polyurethane constituted by a first component, which comprises polyether polyols, chain extenders, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

[0030] Conveniently, the closed-cell polyurethane material comprises, in turn, a two-component polyurethane constituted by a first component, which comprises polyether polyols, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

[0031] It has been found to be particularly advantageous to choose the covering step from the group comprising:

• a step of covering by application of a film;
• a step of covering by application of a spray;
• a step of covering by pouring.

[0032] Alternatively, the method for providing the shock-absorbing body 1 can comprise:

• a step of deposition, at the forming surfaces of a mold which in the closed condition are intended to be arranged so as to face each other, of a layer of closed-cell polyurethane material in the liquid state, advantageously a closed-cell two-component polyurethane constituted by a first component, which comprises polyether polyols, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate;
• a step of closing the mold and,
  during the solidification process of the layer of closed-cell polyurethane material in the liquid state,
• a step of injecting, into the mold, an open-cell polyurethane material, advantageously constituted by a two-component polyurethane comprising a first component, which comprises polyether polyols, chain extenders, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

[0033] It has been found that, with injection of the open-cell polyurethane material during the step of hardening or solidification of the layer of closed-cell polyurethane material, thanks to the pressure exerted by the open-cell polyurethane material against the forming surfaces of the mold, a uniformity is obtained of the thickness of the closed-cell polyurethane material, as well as the covering of the hole through which the open-cell polyurethane material is fed into the mold.

[0034] It has been found that the method just described is particularly advantageous for the production of "standard" pieces whereas, if it is desired to maintain a high flexibility of production in order to provide shock-absorbing bodies of various shapes or sizes, using the first method described may be appropriate.

[0035] From an analysis of the experimental results, it has been found that the shock-absorbing body 1 according to the present invention has a protective element 3 that, although having a soft matrix and thus being capable of adapting to the shape of the outer surface of the internal body 2, is provided with a high level of resistance both to penetration and to shocks thus safeguarding the internal body 2 which, by its nature, is optimal for absorbing shocks but is much less resistant to penetration.

[0036] Since both of the materials used for the internal body 2 and for the protective element 3 are types of polyurethane, and, more specifically, two-component polyurethanes, in which in both first components there are polyols polyurethanes, and both second components are constituted by 4,4'-diphenyl methane diisocyanate, a sort of chemical (as well as mechanical) bond is created between the outer surface of the internal body 2 and the inner surface of the protective element 3 and determines an extremely strong adhesion between the two materials which prevents any peeling and the danger of wrinkles which in the long term could generate ruptures.

[0037] In essence, whereas on the macroscopic level the shock-absorbing body 1 can be considered as being constituted by two materials, on the chemical level it can be regarded as being constituted by a single material with different physical characteristics inside and on the surface.

[0038] Shock-absorbing bodies 1 which are structured according to the invention are suitable for numerous applications, which range over many and highly varied areas.

[0039] In fact it has been found that the shock-absorbing body 1 can be used in a zootechnical environment as a pallet for animals, such as cattle, horses, livestock in general or even pets, as well as in a play environment, as a wall protection.

[0040] In addition to the above-mentioned applications, there is also considerable interest in the product from water parks both as a protection for use at the edges of tanks, and as "in water" and "out of water" flooring in swimming pools for small children in order to prevent trauma after falling or in rehabilitation programs.

[0041] Also in water parks, the product can be used to cover man-made structures where steel structures currently present a considerable hazard.

[0042] The main use of this product is static, for example as a guard applied to trees, dangerous structures or structures that are too close to barriers or walls, for example in theme parks, playing fields, parish centers, schools, racing tracks (cycling, motorcycle, motocross, skiing, bobsleigh etc). A natural application of the product is as fenders in doors, and on moorings for watercraft.

[0043] It is also suitable for hospitals, especially geriatric hospitals, and to rehabilitation gyms, and this is a very important aspect since the materials used, by acting on the composition of the components, can have a variable density depending on the specifications of use.

[0044] In practice, thanks to the versatility of the material, the same product, by variation of its softness, can be used both in a kindergarten and as a pallet for cattle.

[0045] A very important application can make use of "heavy soft" modules to deploy shock-absorbing bodies 1 as a path for baby carriages, whereas the space where a patient has to undergo rehabilitation will be protected using shock-absorbing bodies 1 of a material that is very soft but made with the same production method.

[0046] The material is totally non-toxic, washable, and on request it can be "colored" both for indication of its hardness and for distinguishing the sports company by means of the company colors, or the municipality that chose to use the product.

[0047] From the tests performed, it has been found that the technical and use characteristics are not affected negatively by high or extremely harsh temperatures.

[0048] This last aspect is extremely advantageous for use as a protection on ski runs since, currently, the protections used are constituted by non-impermeable mattresses which fill up with water when the temperatures cause the snow to melt, and during the night and the early hours of the morning they freeze, reducing the effectiveness of the protection.

[0049] A very advantageous "static" application is as a fender for motorcyclists.

[0050] Guardrails which are normally supported by poles, more or less spaced, become an extremely dangerous obstacle if the unfortunate motorcyclist falls, slides and crashes against these poles.

[0051] The shock-absorbing body 1 offers a guard at fall height, which gives continuity to the guard-rail, and the softness greatly deadens the impact by distributing it over the length of the structure, thus preventing impacts with the support pole.

[0052] In practice it has been found that in all the embodiments the invention has achieved the set aim and objects.

[0053] In essence, the shock-absorbing body 1 is a monolithic object which is constituted by the internal body 2 (soft core) and the protective element 3 (covering).

[0054] Differently from products which similarly have a soft internal body and a robust protective element (covering), the shock-absorbing body according to the invention is not used, primarily, as a mattress or pallet for people, but as a fender and protection from violent traumas.

[0055] In fact, even if it is used as a mattress for animals, it performs the function of primary protection: cattle, when lying down, hits its limbs rather violently against the ground and, consequently, the shock-absorbing body 1 drastically reduces the impact thus preventing trauma for the animal.

[0056] It is needless to say that this, if used with other forms, can cover all areas of protection.

[0057] It should be noted that products which similarly have a soft internal body and a robust protective element involve an essentially indoor use.

[0058] The shock-absorbing body 1, however, is especially designed for outdoor use because its "bark" (i.e. the protective element 3) is impermeable so as to keep water from penetrating.

[0059] There is no reason why the production method should not also comprise rotational molding, thus producing the protective element 3 first, again in polyurethane, with the same characteristics as the sprayed polyurethane, in this way obtaining a bark of closed-cell material, where the open-cell polyurethane is injected later.

[0060] Such step of injecting can be executed before opening the mold or at another time, using a type of mold known as a "foaming" mold for this specific purpose.

[0061] The shock-absorbing body 1 can likewise also be produced by way of blow molding, thus again obtaining the covering in polyurethane with the same characteristics as the sprayed polyurethane by means of an adapted mold, and then later injecting the open-cell polyurethane, using a type of mold known as a "foaming" mold for this specific purpose.

[0062] Moreover, all the details may be substituted by other, technically equivalent elements.

[0063] The disclosures in Italian Patent Application No. VR2011A000188 from which this application claims priority are incorporated herein by reference.

[0064] Where the technical features mentioned in any claim are followed by reference numerals and/or signs, those reference numerals and/or signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference numerals and/or signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference numerals and/or signs.

Claims

1. A shock-absorbing body (1), characterized in that it comprises an internal body (2) made of open-cell polyurethane material covered by a protective element (3) which comprises an elastomeric film made of closed-cell polyurethane material.

2. The shock-absorbing body (1) according to claim 1, characterized in that said open-cell polyurethane material comprises a two-component polyurethane constituted by a first component, which comprises polyether polyols, chain extenders, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

3. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said closed-cell polyurethane material comprises a two-component polyurethane constituted by a first component, which comprises polyether polyols, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

4. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said polyether polyols have a molecular weight comprised between 250 and 6200.

5. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said elastomeric film made of closed-cell polyurethane material has a thickness comprised between 0.5 mm and 15 mm.

6. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said first component of said open-cell polyurethane material comprises polyether polyols constituted by polyols based on propylene and ethylene oxide.

7. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said first component of said open-cell polyurethane material comprises catalysts constituted by tertiary aliphatic amines.

8. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said first component that constitutes the closed-cell polyurethane material comprises polyether polyols constituted by polyols based on propylene and ethylene oxide.

9. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said first component of said closed-cell polyurethane material comprises catalysts selected from the group that comprises tertiary aliphatic amines or organometallic catalysts.

10. The shock-absorbing body (1) according to one or more of the preceding claims, characterized in that said first component of said closed-cell polyurethane material comprises m stabilizers constituted by molecular sieves and antifoam agents.

11. A method for providing a shock-absorbing body (1) comprising a step of providing an internal body (2) made of open-cell polyurethane material and a step of covering said internal body made of open-cell polyurethane material with a protective element (3) which comprises an elastomeric film made of closed-cell polyurethane material.

12. The method for providing a shock-absorbing body according to claim 11, characterized in that said covering step is selected from the group that comprises:

- a step of covering by application of a film;

- a step of covering by application of a spray;

- a step of covering by pouring.

13. The method for providing a shock-absorbing body (1), comprising:

- a step of deposition, at the forming surfaces of a mold which in the closed condition are intended to be arranged so as to face each other, of a layer of closed-cell polyurethane material in the liquid state;

- a step of closing said mold and,
during the solidification process of said layer of closed-cell polyurethane material in the liquid state,

- a step of injecting, into said mold, an open-cell polyurethane material.

14. The method for providing a shock-absorbing body (1) according to one or more of claims 11 to 13, characterized in that said open-cell polyurethane material comprises a two-component polyurethane constituted by a first component, which comprises polyether polyols, chain extenders, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

15. The method for providing a shock-absorbing body according to one or more of claims 11 to 14, characterized in that said closed-cell polyurethane material comprises a two-component polyurethane constituted by a first component, which comprises polyether polyols, catalysts and stabilizers, and a second component, which comprises 4,4'-diphenyl methane diisocyanate.

Drawing