EP2449925B1 - Mattress and method for its production - Google Patents

Description

The invention relates to a mattress having a mattress pad formed in a longitudinal direction and a transverse direction, which comprises a core pad, an upper pad and a lower pad and in which the core pad on its facing the upper pad and padding large areas with over the transverse direction extending rounded ribs and the Upper cushion and the lower cushion is provided with facing the core cushion recesses whose width corresponds to the width of the ribs and whose depth is greater to form an air duct than the height of the projecting into the respective recess rib.

The mattress pad of a mattress, in particular lying mattress, determines the lying characteristics of the mattress and in particular the lying hardness. The mattress pad is usually surrounded on all sides with a mattress cover, which is preferably removable to be washed or replaced. In some cases, the mattress is supplemented by a cover layer which is inserted between the mattress cover formed by the mattress cover and the relevant side of the mattress pad. If the mattress to be supplied on both sides, a cover layer may be provided on both large areas of the mattress pad.

The lying characteristics, which are determined by the mattress pad, include in particular the lying hardness. Mattresses are therefore divided into several (for example, four) hardness classes, in order to give the interested party an orientation as to whether he prefers to lie on a firm or very firm or a soft or very soft mattresses and sleeps. In addition, it is known about the longitudinal direction of the mattress, ie the direction in which the person lying on the mattress is intended to be oriented from head to toe, to provide different hardness ranges, for example, to allow the deeper sinking of the shoulder of the lying on the mattress person with a firm support of the head, causing a kinking of the neck lying on the side Person is avoided. Similarly, the waist may be supported and the pelvic area allowed to sink in to provide the most direct possible alignment of the spine of the person lying on the side.

Numerous solutions have become known for constructing mattresses in their height direction, ie perpendicular to the lying surface, in two parts. In particular, for a reversing mattress, which is to be supplied from both sides, it may be useful to provide for a lying surface towards a harder material and the other lying surface a softer material so that the person using the mattress on demand from a harder lying surface on a softer lying surface and vice versa by turning the mattress can change. The dividing line between the two parts of the mattress pad can be a plane that is aligned parallel to the lying surfaces, but can also consist of a wavy extending surface. In such a mattress is in DE 299 17 541 U1 provided that the two lying surfaces are interconnected by elastic positive locking means consisting of widthwise extending webs, which dip into undercut grooves, thereby filling the groove completely.

US 3,222,697 discloses a two-part mattress, in which both parts are formed by a respective smooth outer side and a mutually facing profiled inside. The profiled inside has square or corrugated webs. The two parts of the mattress are stacked so that the Webs perpendicular to each other. The parts of the mattress can be cut from a base body with the aid of a hot wire formed in the profile shape. In such a three-part construction, the center piece pointing up and down profiling on. The preparation of a base body is then carried out with two heated wires which are formed parallel to each other. The composition of the mattress takes place after rotation of the center piece by 90 °, so that the profiles of the center piece on the one hand and of the upper part and lower part on the other hand perpendicular to each other.

By CH 477 847 is a three-part mattress known in which the middle layer may consist of a harder foam than the two outer layers. The two interfaces between the three layers are flat. In this parting plane, an intermediate layer is introduced, which is glued to at least one of the two adjacent layers. The intermediate layer consists of a tensile stress not or only slightly yielding network, z. B. jute. This liner is intended to provide greater stability to the mattress so that softer and less durable materials can be used for the foam layers of the mattresses.

DE 295 03 620 U1 discloses a mattress consisting of a unitary mattress body, which is provided on at least one side with mutually parallel webs, through which the comfort of lying is to be improved. The cutting out of several mattress body from an initial block of material takes place without loss of formation of the webs.

A mattress with a mattress pad of the type mentioned is known as mattress AR S 18 in the prospectus "Annette Rummel" (February 2009) of Rummel mattresses GmbH & Co. KG, Neustadt / Aisch. The mattress pad has over the height of a three-part construction, are formed in the upper cushion and lower pads identical and the mattress pad is constructed mirror-symmetrically in a section in the longitudinal direction, so that no head and foot are defined. Upper cushions and lower cushions are each supported on a core pad, which is formed by a 4cm thick plate. On the surface facing the core cushion surfaces of the upper cushion and the lower pad these have approximately U-shaped recesses. The core pad is zoned with ribs that can engage in the recesses. Ribs are only in a middle Area of the core cushion, wherein the height of the rib decreases starting from the center and is reduced approximately in the region of the rib cage to zero, so that there are no more ribs in this area. Only at the extreme ends of the core pad has two ribs, which engage in recesses. Of the 34 recesses each of the upper cushion and the lower cushion, 18 remain empty, ie no ribs protrude into it. The core cushion is also reinforced in the middle area by a special insert. The core cushion thus essentially has the function of providing different lying zones over the longitudinal direction of the mattress. The formation of the recumbent zones is supplemented in the transverse direction by recesses of the upper cushion and the lower cushion which are open to the side of the couch, numerous incisions being present in the softest possible area (eg shoulder area), while a halved number of incisions is provided for the pelvic area. Between these areas are areas without cuts. The cuts are intended to contribute to the formation of support and relief zones through the core cushion. However, a system used for this, which corresponds to the supporting effect of the core cushion, is not recognizable. Furthermore, it is not apparent how the parts of the mattress pad are held together. Usually for this bonds are. As a relative movement in the longitudinal direction is excluded by the engaging in the recesses ribs for the known mattress, it seems conceivable to hold the mattress pad only by the mattress cover. However, this considerably complicates the handling.

The present invention is based on the problem of being able to produce mattresses in a rational manner with different degrees of hardness, mattresses with a uniform lying surface, but also with a distributed over the longitudinal direction in different hardness zones lying surface to be produced.

To solve this problem, a mattress of the type mentioned is characterized in that the core pad in the longitudinal direction one behind the other in each case equally spaced ribs have the same height and a greater hardness than the upper cushion and the lower pad, so that different mattress padding different mattresses are adjustable by different core pads and that the upper cushion and the lower cushion between the recesses ribs of the same height form, in between the ribs engage the recesses existing in the core pad, wherein the ribs are each formed with a slight oversize relative to the associated recess and engage so deep in the recesses that upper cushion, core pad and pad without fasteners form a solid for handling the mattress cohesion.

The mattress according to the invention thus has a three-part construction, which corresponds to the structure of the known mattress. By the measures according to the invention, however, it is ensured that a firm cohesion between upper cushion, core cushion and lower cushion is given and that the hardness of the mattress is determined decisively by the core pad used. As a result, upper cushions and lower cushions can be used unchanged for all hardness classes, while the respective hardness class is set exclusively by the core cushions.

It should be noted that the use of the terms "upper cushion" and "lower cushion" is not intended to be committed to a top of the mattress and a bottom of the mattress, since the invention is of course also applicable to a reversing mattress on both sides of a Has lying surface. After turning the mattress would then be the "lower cushion" above and the "upper cushion" below.

The mattress according to the invention may be formed with a uniform lying surface but is preferably a formation of upper cushion and lower cushion with several hardness zones over the longitudinal direction of the mattress, wherein the hardness zones are not formed mirror-symmetrical in the vertical section, so for the bed surface, a head and a foot are defined. hereby allows an anatomically more adapted support of lying on the mattress body, especially in its lateral position, achieve.

The mattress according to the invention can thus be assembled in the manner of a modular system. It can be kept upholstery and padding, for example, have a uniform bed surface on the one hand and a multi-zone bed surface on the other hand. These upholstery and pads can be combined with different core pads to realize mattresses of different Lieharden.

The core pad is formed in a preferred embodiment of a uniform material with which the desired degree of hardness is adjustable. Accordingly, mattresses in three degrees of hardness can be offered with, for example, three different core pads and only one type of upper cushion and lower cushion.

If, in addition or alternatively, upper and lower cushions with several hardness zones are kept available over the longitudinal direction, multi-zone mattresses can be created in three degrees of hardness without having to change the upper cushions and lower cushions for this purpose.

The formation of the multiple lying zones through the upper cushion and the lower cushion can be realized in a conventional manner by different incisions on the side of the upper cushion or cushions.

Alternatively or additionally, it is of course possible to effect the multi-zone formation of upper cushion and lower cushion by the upper cushion and the lower cushion from different sections, such as different densities of a foam, are assembled to form the desired multiple zones.

It is also possible to realize the multi-zone training also composed of several materials core pad. In this case, preferably a uniform upper cushion and lower cushions are used.

In a further embodiment, it is possible to use a core pad composed of different materials and to form the upper pad and lower pad in a corresponding manner with corresponding multiple zones, so that the zones of upper pad and lower pad on the one hand and core pads on the other coincide in the longitudinal direction. The formation of the different zones of upper cushion and lower cushion can be done by a corresponding variation of the incisions or by a composition of upper cushion and lower cushion of different pieces of material, which preferably differ only by their density.

In all cases, only different core cushions are required for mattresses of different hardness, while upper cushions and lower cushions are used in an unchanged manner for different degrees of hardness.

The ribs of the core pad, which are directed to the upper cushion on the one hand and the lower pad on the other hand, may be in pairs at the same height with respect to the longitudinal direction. However, a configuration in which the ribs directed toward the upper cushion are offset from each other by half the distance between the ribs with respect to the ribs facing the lower bolster allows a more rational manufacture of the core bolsters from a large core cushion block. Since a rib facing the upper upholstery is arranged with a recess facing the lower padding in the longitudinal direction at the same height, this results in a shape of the core padding which allows a substantially constant material thickness.

For the cohesion of upper cushion, core cushion and lower cushion according to the invention, it is advantageous if the ribs are limited in longitudinal section over part of their length by at least approximately parallel wall sections, which merge only at the top of the rib in a rounded end shape. The substantially parallel sections of Rib and associated recess ensure due to their static friction for a firm cohesion between the upper cushion and core padding on the one hand and core pad and padding on the other. As a result, the mattress can be handled uniformly without any adhesive bond or other connecting means, without the risk that the parts of the mattress unintentionally separate from one another. The uniform handling is maintained even when the mattress pad is removed from the mattress cover.

Figur 1

einen Längsschnitt durch eine erfindungsgemäße Matratze;

Figur 2

eine Draufsicht auf die Matratze gemäß Figur 1;

Figur 3

eine vergrößerte Detaildarstellung einer ersten Ausführungsform der Erfindung;

Figur 4

eine vergrößerte Detaildarstellung einer zweiten Ausführungsform der Erfindung;

Figur 5

eine vergrößerte Detaildarstellung einer dritten Ausführungsform der Erfindung;

Figur 6

eine vergrößerte Detaildarstellung einer vierten Ausführungsform der Erfindung.

The invention will be explained in more detail below with reference to exemplary embodiments illustrated in the drawing. Show it:

FIG. 1

a longitudinal section through a mattress according to the invention;

FIG. 2

a plan view of the mattress according to FIG. 1 ;

FIG. 3

an enlarged detail of a first embodiment of the invention;

FIG. 4

an enlarged detail of a second embodiment of the invention;

FIG. 5

an enlarged detail of a third embodiment of the invention;

FIG. 6

an enlarged detail of a fourth embodiment of the invention.

FIG. 1 shows a longitudinal section through a mattress according to the invention comprises a mattress pad 1, which is formed from an upper cushion 2, a core pad 3 and a lower pad 4. In this case, the core pad 3 to the upper cushion 2 and lower pad 4 facing ribs 5, which protrude into corresponding recesses 6 of the upper pad 2 and the lower pad 4, so that upper pad 2, core pad 3, pad 4 are interlocked.

FIG. 2 illustrates that the mattress pad 1 - and thus the mattress - has a longitudinal direction L and a transverse direction B and that the ribs extend straight in the transverse direction B in this embodiment.

FIG. 3 The core pad 3 consists of a uniform material whose hardness is greater than that of the unitary material of the upper pad 2 and the lower pad 4. The ribs 5 of the core pad 3 are separated by recesses 7 of the core pad 3 from each other separated, which preferably have a same width and a same (inverse) shape as the ribs 5. Over the length of the mattress pad 1, the core pad preferably has between 10 and 14 equally spaced ribs 5.

The recesses 6 of the upper cushion 2 and lower cushion 4 are formed inversely to the shape of the ribs 5. Preferably, the recesses 6 are completely filled by the ribs 5. In this case, the width of the ribs 5 (ie, their extension in the longitudinal direction L) is slightly greater than the width of the recess 6, so that the ribs 5 sit under a directed in the longitudinal direction L bias in the recesses 6. The excess of the ribs 5 with respect to the recesses 6 is preferably between 0.1 and 1.5 mm. It does not naturally extend over the entire height of the ribs 5, but is sufficient even if the excess is present only over a portion of the rib 5 with respect to the recess 6.

Between the recesses 6, the upper cushion 2 and the lower cushion 4 has a rib 8 which projects into the recess 7 of the core cushion 3, but has a small height than the recess 7, so that between the bottom of the recess 7 and the rib 8 a Air duct 9 is located, which ensures a transverse ventilation of the mattress body 1.

FIG. 3 indicates that the air channels 9 are formed only between ribs 8 of the upper cushion 2 and / or the lower pad 4 and the associated recess 7 of the core pad 3, but not between rib 5 of the core pad 3 and recess 6 of upper pad 2 or lower pad 4, there the ribs 5 completely fill the associated recess 6.

On their upper side facing away from the core pad 3, which is thus directed to the mattress surface, upper cushions 2 and lower cushions 4 in the transverse direction B extending incisions 10 ensure in a known manner that upper cushion 2 and lower cushion 4 are slightly softer on the surface in the solid body, whose material hardness is designed for a certain support function.

In the case of the mattress pad 1 according to the invention, the core pad 3 has a significantly higher material hardness than the upper pad 2 and the lower pad 4. The lying hardness of the mattress as a whole is therefore determined by the hardness of the core pad 3.

This in FIG. 4 illustrated second embodiment of the invention differs from the first embodiment according to FIG. 3 merely in that in the upper side of the upper cushion 2 and lower cushion 4 different incisions 10, 10 ', 10 "are introduced, with which different areas over the longitudinal direction L of the mattress pad 1 can be realized greater depth and greater depth than the U-shaped incisions 10 cause a deeper sinking of the body in the mattress with the same weight.In contrast, the incisions 10 '', which have a small incision depth than the incisions 10, a greater support hardness.

The width of the incisions 10, 10 ', 10 "on the upper side of the mattress should be the same in order not to impart an irritating feeling to the person lying on the lying surface, so that the greater width of the incisions 10' will only be realized at a greater incision depth ,

The core pad 3 is identical to the core pad 3 according to the first embodiment as well as the recesses 6 and ribs 8 of the upper pad 2 and lower pad. 4

This in FIG. 5 illustrated third embodiment corresponds in principle to the second embodiment of FIG. 4 , wherein the different zones of the upper cushion 2 and the lower cushion 4 are now formed by different material sections 2.1, 2.2 and 2.3 of the upper cushion 2 and 4.1, 4.2 and 4.3 of the lower cushion 4. The material sections 2.1, 2.2 and 2.3 are expediently glued together. The same applies to material sections 4.1, 4.2 and 4.3.

In this embodiment, the incisions 10 may be formed so that they do not cause different zones. Of course, however, different incisions 10, 10 ', 10 "may also be provided in the different material sections 2.1, 2.2 and 2.3 in order to support the zone formation.

At the in FIG. 6 illustrated fourth embodiment, upper cushion 2 and lower pad 4 are shown as uniform as in the first embodiment. In this case, a core pad 3 'is used, which is composed of several material sections 3.1, 3.2., 3.3, as shown in FIG. 6 is indicated schematically. The material sections 3.1, 3.2 and 3.3 may be conveniently glued together. They serve to form different Lieharden over the longitudinal direction L of the mattress pad. 1

It should be noted that the illustration in FIG. 6 is only schematic. Periodically, the material sections 3.1, 3.2 and 3.3 will extend over much more ribs than in FIG. 6 is shown. The training of the length of the different lying zones depends - as the expert knows - on how many different lying areas are realized. A common number is five or seven different hardness zones. The resulting lengths of hardness zones are readily apparent to those skilled in the art.

Even if the core pad 3 'composed of several pieces of material 3.1, 3.2 and 3.3, the overall shape of the core pad 3' remains the same as in the core pad 3 formed from a uniform material.

Although in the illustrated embodiments, the ribs 5 of the core cushion facing the upper cushion 2 and the lower cushion 4 are always at the same height with respect to the longitudinal direction L, it is not excluded by the present invention and can even be realized with advantage in that the ribs 5 facing the Upper cushions 2 show relative to the ribs 5, which point to the lower pad 4, offset by half a distance between the ribs 5, so that the rib 5 facing the upper pad 2 is at the same height as a recess 7 directed towards the lower pad 4. In this way, a shape of the core pad, which corresponds to a wavy line with a substantially constant material thickness results.

Claims (11)

1. Mattress having an upholstered structure (1) which is formed with a longitudinal direction (L) and a transverse direction (B), contains a core element (3, 3'), an upper element (2) and a lower element (4) and in which the core element (3, 3'), on its large surfaces which are oriented towards the upper element (2) and lower element (4), is provided with rounded ribs (5) extending over the transverse direction (B), and the upper element (2) and the lower element (4) are provided with recesses (6) which are oriented towards the core element (3, 3') and of which the width corresponds to the width of the ribs (5), characterized in that the core element (3, 3') has ribs (5) of the same height spaced apart equally one behind the other in each case in the longitudinal direction (L) and also has a greater degree of hardness than the upper element (2) and the lower element (4), and therefore different degrees of lying hardness for the mattress can be set by using different core elements (3, 3'), and in that the upper element (2) and the lower element (4), between the recesses (6), form ribs (8) of the same height, which engage in recesses (7) which exist between the ribs (5) of the core element (3, 3'), wherein the ribs (5) are each slightly oversized in relation to the associated recess (6) and engage in the recesses (6) to such an extent that the upper element (2), core element (3) and lower element (4), without any fastening means being required, form a stable assembly for the handling of the mattress.
2. Mattress according to Claim 1, characterized in that the core element (3) is formed from a single material of a constant material hardness.
3. Mattress according to Claim 2, characterized in that the upper element (2) and/or the lower element (4) form/forms a lying surface with different degrees of supporting hardness for the mattress, as seen in the longitudinal direction (L).
4. Mattress according to Claim 3, characterized in that the different degrees of supporting hardness are formed by different widths and/or depths of incisions (10, 10', 10") in the surfaces of the upper element (2) and/or of the lower element (4).
5. Mattress according to Claim 3, characterized in that the upper element (2) and/or the lower element (4), as seen in the longitudinal direction (L), are/is made up of transversely extending portions (2.1, 2.2, 2.3; 4.1, 4.2, 4.3) of different degrees of material hardness.
6. Mattress according to Claim 1, characterized in that the core element (3'), as seen in the longitudinal direction (L), is made up of portions (3.1, 3.2, 3.3) of different degrees of material hardness which extend in the transverse direction (B).
7. Mattress according to Claim 6, characterized in that the upper element (2) and/or the lower element (4) are/is formed from a single material of a constant material hardness.
8. Mattress according to Claim 6, characterized in that the upper element (2) and/or the lower element (4) are made up of portions of different degrees of material hardness which extend in the transverse direction (B), wherein the portions coincide, at least in part, with the portions (3.1, 3.2, 3.3) of the core element.
9. Mattress according to one of Claims 1 to 8, characterized in that the ribs (5) of the core element (3, 3') which are oriented towards the upper element (2) and those which are oriented towards the lower element (4) are each arranged at the same pitch in respect of the longitudinal direction (L).
10. Mattress according to one of Claims 1 to 8, characterized in that the ribs (5) of the core element (3, 3') which are oriented towards the upper element (2) and those which are oriented towards the lower element (4) are offset in relation to one another in the longitudinal direction by half a spacing between the ribs (5).
11. Method of producing mattresses of different hardness classes with the mattress construction according to one of Claims 1 to 10, characterized in that use is made of identical upper and lower elements (2, 4), and in that use is made of a core element (3, 3') selected from a number of core elements (3, 3') of different degrees of material hardness.

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