|
(11) | EP 4 555 903 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
|||||||||||||||||||||||||||
| (54) | MULTILAYERED FLEXIBLE MATTRESS |
| (57) The present invention is enclosed in the area of mattresses. In particular, it is
directed to a flexible multilayered foam mattress with adjustable firmness and dynamic
bounce responsiveness. The purpose of the object of the present invention is to provide
a durable, comfortable, springless mattress that presents good performance in terms
of firmness and bounce responsiveness, while being flexible to be rolled or folded
to facilitate packaging and transportation operations.
|
FIELD OF THE INVENTION
[0001] The present invention is enclosed in the area of mattresses. In particular, it is directed to a flexible multilayered foam mattress with adjustable firmness and dynamic bounce responsiveness.
PRIOR ART
[0002] Mattresses are objects made to support and to provide comfort to a user during resting occasions, thus having a profound impact on the quality of life of a person. There are several types of mattresses to choose according to the user preferences, often classified depending on the type of materials used in the manufacturing process: spring mattresses, foam mattresses, or hybrid mattresses containing aspects of both spring and foam mattresses. Spring mattresses, the most traditional type of mattress, have several advantages: spring mattress provide solid support and firmness to the user, have good bounce responsiveness and its open structure allows good airflow for thermal regulation. Spring mattresses are also usually more affordable. However, spring mattresses present several disadvantages: high degree of motion transfer, in the sense that localized movements can be felt in other areas of the mattress; spring mattresses do not conform evenly to the body's contours, which may lead to discomfort; faster deterioration, as the inner springs wear over time and often unevenly, resulting in sagging and dips in the mattress; and spring mattresses are also noisier, as the springs often produce squeaking and cracking sounds with movement. Lastly, spring mattresses are difficult to roll or fold in order to facilitate transport and packaging operations.
[0003] Foam mattresses constitute an improved alternative to spring mattresses in several aspects, such as increased comfort and mattress conformity to the body's contours, increased long-term longevity, lower degree of motion transfer, good shape recovery in response to applied forces such as body weight. Foam mattresses can be folded or rolled without difficulty to facilitate packaging and transportation operations. However, foam mattresses also have some drawbacks, as they usually lack the firmness and bounce responsiveness necessary to support certain types of sleepers, and also present a sinking effect caused by the increased softness intended for user comfort. Although some foam mattresses may present high firmness with the increased foam density of the mattress body, the downside to this increase in density is that the mattresses lose the ability to be rolled or folded for transport and packaging.
[0004] Therefore, an ideal foam mattress would present a broad range of firmness to provide a high level of support to the user and higher bounce responsiveness with low motion transfer, it would be durable and resistant to extended and repeated use and would be flexible enough to be easily folded and/or rolled to facilitate packaging and transportation operations.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention a mattress characterized by comprising:
- At least one foam material layer, wherein one of said foam material layer is arranged as a mattress top layer;
- A base layer, arranged as a mattress bottom layer;
- At least one intermediate layer of at least one fiber material selected from the group of materials consisting of aramid fibers and carbon fibers.
[0007] The different layers that constitute the mattress of the present invention have distinct functions, wherein the base layer is arranged as the bottom layer of the mattress, to be in contact with support structures such as bed frames or platforms, providing the main structural support to the mattress.
[0008] The mattress comprises at least one foam material layer arranged as the mattress top layer to be in contact with the user and providing comfort to the user.
[0009] The mattress of the present invention comprises at least one intermediate layer composed of at least one fiber material selected from the group of materials consisting of aramid fibers and carbon fibers, wherein the aramid and/or carbon fibers provide the mattress with adjustable firmness, bounce responsiveness and durability, and also reduce the deformation of the mattress over repeated and extended use.
[0010] The mechanical properties such as firmness, bounce responsiveness and deformation reduction upon applied force depend on the aramid/carbon fiber ratio and density, whereas carbon fibers increase the bounce responsiveness of the intermediate layer, while aramid fibers such as Kevlar® reduce the deformation of the intermediate layer upon applied forces.
[0011] The incorporation of at least one intermediate layer composed of aramid and/or carbon fibers is an advantageous alternative to the use of springs or rigid boards in mattresses, as the fiber material is light and pliable, which allows the mattress to be folded and to be rolled for packaging in 30 cm3 containers, which translates to a cost reduction for packaging and transportation operations, as opposed to spring mattresses that are difficult to fold or roll. The mattress compression and flexibility depend on the materials used in each layer and also on the thickness of each individual layer.
[0012] The arrangement of the different layers is made according to the properties of each layer, wherein the intermediate layer is preferably arranged to be in contact with the base layer on one side (bottom side), and in contact with a foam material layer on the other side (top side).
[0013] The base layer of the mattress contains polyurethane foam, in which the firmness to support the additional layers as well as the user's body weight is proportional to the polyurethane foam density. By adjusting the polyurethane foam density of the mattress base layer, it is possible to fine-tune the mattress firmness required to support the body weight of the user and to provide an orthopedic effect for spinal alignment. The air permeability of the polyurethane foam base layer also improves air circulation against moisture and odors and also improves the thermal insulation of the mattress.
[0014] In a preferred embodiment of the present invention, the intermediate layer may contain a combination of aramid and carbon fibers in the form of a woven fabric, wherein the ratio of both materials is adjustable according to the desired mechanical properties of the mattress, such as firmness and bounce responsiveness, as well as mattress durability.
[0015] The foam material layer may contain viscoelastic foam, often known as "memory foam", due to its shape recovery properties in response to applied forces and the relaxation effect in response to body heat, softening with heat and hardening in cold conditions.
[0016] In a preferred embodiment of the present invention, an additional foam material layer is arranged on top of the viscoelastic foam layer, wherein the additional foam material layer comprises latex foam. The additional latex foam layer provides a higher bounce responsiveness to the mattress.
[0017] The mattress can be assembled in several configurations and is not limited to any of its described embodiments.
DESCRIPTION OF THE FIGURES
[0018] Figure 1 illustrates an exploded view of a preferential embodiment of the mattress (100), having each layer individually separated from each other and in order of assembly: a base layer (1) on the bottom, an intermediate layer (2) on top of the base layer (1), a first layer of foam material (3) on top of the intermediate layer (2), and a second layer of foam material (4) as top layer of the mattress. The base layer (1) has an increased thickness, compared to the other layers constituting the mattress, to fully support the mattress user's body weight. The intermediate layer (2) comprises a woven fabric containing at least one fiber material selected from aramids, such as Kevlar®, and/or carbon fibers, to provide the desired mechanical properties, such as mattress firmness, shape recovery and bounce responsiveness, depending on the amount and fiber ratio of aramid and/or carbon fibers used to weave the fabric. The first layer of foam material (3) is stacked on top of the intermediate layer (2), whereas this first layer of foam has an intermediate thickness to provide support and to conform to the body contours of the mattress user in an ergonomic way, also contributing to overall comfort to the user. The second layer of foam material (4) is arranged as the mattress top layer, which will be in direct contact with the mattress user, whereas the type of foam used is preferably softer and less dense, to provide comfort and softness to the touch, and is thinner in terms of thickness than the first layer of a foam material (3) to avoid sinking and sagging sensations to the mattress user.
[0019] Figure 2 illustrates a perspective view of the assembled mattress (100), in which the corner section of the mattress has the first and second layers of foam material (3)(4) cut-out from the mattress to show the woven fabric that constitutes the intermediate layer (2), comprising a woven fabric containing at least one fiber material selected from aramids and/or carbon fibers, whereas said intermediate layer (2) is stacked on top of the base layer (1) of the mattress.
[0020] Figure 3 illustrates a perspective view of the assembled mattress (100), depicting the stratified structure of the mattress, whereas the different layers are stacked in the following order: base layer (1), intermediate layer (2), first layer of foam material (3) and second layer of foam material (4).
DETAILED DESCRIPTION
[0021] The more general and advantageous configurations of the present invention are described in the Summary of the invention. Such configurations are detailed below in accordance with other advantageous and/or preferred embodiments of implementation of the present invention.
[0022] In a preferred aspect of the present invention, the mattress (100) comprises a base layer (1), arranged as bottom layer of the mattress (100), consisting of polyurethane foam; an intermediate layer (2), arranged on top of the base layer (1), consisting of a woven Kevlar® and carbon fiber fabric; a first layer of foam material (3), arranged on top of the intermediate layer (2), consisting of viscoelastic foam; and a second layer of foam material (4), arranged as top layer of the mattress (100), containing latex and polyurethane foam.
[0023] In another aspect of the present invention, the intermediate layer (2) may contain a combination of aramid or carbon fibers with polyester, such as Mylar®, to improve the durability and resistance to mechanical stresses of the intermediate layer (2).
[0024] In an advantageous aspect of the present invention, the density of the fiber materials elected from the group of materials consisting of aramid fibers and carbon fibers, comprised in the intermediate layer (2), is variable along the plane of the at least one intermediate layer. The variation of aramid/carbon fiber density allow the mattress to present localized areas of increased or decreased firmness and bounce responsiveness, depending on the fiber density in each localized area. This feature is especially useful for the manufacture of mattresses that have, for example, two halves with distinct levels of firmness, so that two persons having different firmness requirements may share the same mattress without compromising the sleep quality and comfort. In this particular embodiment, the density of the fiber material, aramid and or carbon fiber, is variable along the transverse axis of the intermediate layer (2), thus resulting in a mattress with one extra firm side wherein the fiber density within the intermediate layer is increased, and a softer side wherein the fiber density is decreased.
[0025] In another embodiment of the present invention, the intermediate layer (2) is arranged between the first (3) and second layer of foam material (4), whereas the intermediate layer (2) is closer to the top so that it provides proximal bounce responsiveness to the user, as the body weight is applied to the intermediate layer (2) with less shock absorbance from the foam layers, as only the top second foam layer (4) is positioned between the user and the intermediate layer (2). Therefore, the intensity of the force exerted by the body of the user on the intermediate layer (2) is increased, resulting in a proportionally increased bounce-back response of the intermediate layer (2) on the user.
[0026] An alternative embodiment of the present invention consists in a mattress (100) comprising a base layer (1); a first intermediate layer (2.1) consisting of a Kevlar® woven fabric, arranged on top of the base layer (1); a first layer of foam material (3), arranged on top of the first intermediate layer (2.1); a second intermediate layer (2.2) consisting in a carbon fiber woven fabric, arranged on top of first layer of foam material (3); and a second layer of foam material (4) arranged on top of the second intermediate layer (2.2). The first intermediate layer (2.1) consisting of a Kevlar® woven fabric, provides firmness and decreases the mattress deformation, while the second intermediate layer (2.2) consisting in a carbon fiber woven fabric provides firmness and bounce responsiveness to the mattress. The second intermediate layer (2.2) consisting in a carbon fiber woven fabric comprises a maximum thickness of 2 mm, so that the mattress remains flexible and pliable to be folded or rolled for packaging and transportation operations.
[0027] It is also an object of the present invention a process for making the mattress (100) comprising the following steps:
- coating the base layer (1), the at least one layer of foam material (3)(4) and the at least one intermediate layer (2) with an adhesive substance, such as glue;
- stacking the base layer (1), the at least one layer of foam material (3)(4) and the at least one intermediate layer (2), wherein the base layer (1) is arranged as bottom layer and that at least one layer of foam material (3)(4) is arranged as top layer, thereby obtaining a stratified body;
- applying pressure to the stratified body, thereby obtaining the mattress (100).
[0028] The action of the adhesive substance in addition to the applied pressure on the stratified body leads to the permanent union of the individual layers, thus forming the mattress. In alternative to the use of adhesive substances, the individual layers can be heat pressed together to form the mattress, as the aramid and/or carbon fibers of the intermediate layer can be fused to both polyurethane and viscoelastic foam by heating and pressing together the stack of layers.
[0029] The mattress (100) resulting from the described process is a parallelepipedal object comprising several layers stacked on top of each other, wherein the base layer (1) forms the bottom side of said parallelepipedal object, and at least a layer of foam material (3)(4) forms the top side of said parallelepipedal object. The lateral sides of the mattress are formed by the stacked layers of the mattress, in which the height of the lateral sides of the mattress is equal to the sum of the thickness of each layer comprised in the mattress.
[0030] A fabric cover may be provided to cover the lateral sides of the mattress, so that the inner layers comprised in the mattress are covered and the surface of the lateral sides is homogeneous. The fabric cover can be fixed to the lateral sides of the mattress by ticking, knitting or using adhesive substances, such as glue.
1. A mattress characterized by comprising:
- At least one foam material layer, wherein one of said foam material layer is arranged as a mattress top layer;
- A base layer, arranged as a mattress bottom layer;
- At least one intermediate layer of at least one fiber material selected from the group of materials consisting of aramid fibers and carbon fibers.
2. A mattress according to claim 1 wherein the at least one intermediate layer is arranged
such that one side of the at least one intermediate layer contacts one side of the
base layer.
3. A mattress according to any of the previous claims wherein the at least one intermediate
layer is arranged such that one side of the at least one intermediate layer contacts
one side of the foam material layer.
4. A mattress according to any of the previous claims wherein the base layer comprises
polyurethane foam.
5. A mattress according to the previous claim wherein the base layer consists of a polyurethane
foam layer.
6. A mattress according to any of the previous claims wherein the foam material is selected
from the group of materials consisting of viscoelastic foam and latex.
7. A mattress according to any of the previous claims, wherein the at least one intermediate
layer comprises a woven fabric containing the at least one fiber material selected
from the group of materials consisting of aramid fibers and carbon fibers.
8. A mattress according to any of the previous claim, wherein the density of the at least
one fiber material selected from the group of materials consisting of aramid fibers
and carbon fibers, is variable along the plane of the at least one intermediate layer.
9. A mattress according to any of the previous claim, wherein the density of the at least
one fiber material selected from the group of materials consisting of aramid fibers
and carbon fibers, is variable along the transverse axis of the at least one intermediate
layer.
10. A mattress according to claim 7, wherein the woven fabric contains polyester.
11. A mattress according to claim 7, wherein the woven fabric consists of a carbon fiber
fabric, in which the carbon fiber fabric has a maximum thickness of 2 mm.
12. A process for making the mattress of any of the preceding claims, characterized by it comprises the following steps:
- coating the base layer, the at least one layer of foam material and the at least one intermediate layer with an adhesive substance;
- stacking the base layer, the at least one layer of foam material and the at least one intermediate layer, wherein the base layer is arranged as bottom layer and that at least one layer of foam material is arranged as top layer, thereby obtaining a stratified body;
- applying pressure to the stratified body, thereby obtaining the mattress.
13. A process according to the previous claim wherein it further comprises, upon applying
pressure to the stratified body, providing a fabric cover to at least a lateral side
of the mattress.
14. A process according to any of the claims 12-13 wherein the fabric cover is fixed to
the mattress by ticking, knitting or by the use of one or more adhesive substances.
15. A process according to any of the claims 12-14 wherein the adhesive substance used
to coat comprises a glue.