EP2898797A1

EP2898797A1 - Mattress with improved heat and moisture dissipation

Info

Publication number: EP2898797A1
Application number: EP14152446.2A
Authority: EP
Inventors: Oscar Valdemoros Tobia; Javier Fernandez Lopez; Miguel Viguera Saenz
Original assignee: Tobia Esquete Fernando; Tobia Esquete Maria del Carmen; Tobia Esquete Rufino
Current assignee: Tobia Esquete Fernando; Tobia Esquete Maria del Carmen; Tobia Esquete Rufino
Priority date: 2014-01-24
Filing date: 2014-01-24
Publication date: 2015-07-29

Abstract

The present invention relates to a mattress comprising a core layer (10) and a topper. The core layer (10) has a honeycomb structure comprising a plurality of hexagonal-shaped openings (20); whereas the topper is made up of a foam or a plurality of foams having a high porosity. The hexagonal-shaped openings (20) are non-through openings that extend from the top of the core layer (10).

Description

Field of the Invention

The present invention generally relates to the field of mattresses, and more specifically to a mattress intended for improving heat and moisture dissipation.

Background of the Invention

It has been well established in the industry that good heat and moisture dissipation capabilities are required in a mattress in order to improve sleep and allow the user to get enough rest during the night. Several mattresses currently known and available on the market provide different solutions to meet this demand.
EP1962644B1 discloses a spring element unit for a mattress, the spring element unit being made integrally of a flexible polyurethane foam by mold foaming. The spring elements of the spring element unit have an octagonally shaped cross-section and a shell comprising predetermined jointing faces and side faces, wherein the spring elements are placed side-by-side such that the jointing faces of neighboring spring elements abut and a clearance is formed in an area between the side faces of neighboring spring elements. The spring elements comprise at least one recess as an air channel for dissipating moisture and a top end and a bottom end, wherein the recess extends end-to-end from the top end to the bottom end. The purpose of the recess in the spring element is to dissipate heat and moisture, respectively, to enable air to flow towards the bottom support surface.
Another solution to provide heat dissipation from a mattress is the use of a cooling pad to be placed on top of the mattress, such as ChiliPad™, for example. The cooling pad has a network of microtubes through which water circulates. The temperature of the water can be increased or reduced by an external system in order to adapt the temperature of the cooling pad to the preference of the user. This system provides a good cooling/warming solution for mattresses. However, it does not improve heat or moisture dissipation. Moreover, this solution is expensive to manufacture.
Therefore, there is still a need in the art for a mattress structure alternative to those known in the prior art, with optimal heat and moisture dissipation capabilities.

Brief Description of the Invention

The present invention discloses a mattress comprising at least a core layer and a topper. The core layer has a honeycomb structure comprising a plurality of hexagonal-shaped vertical openings; whereas the topper is made up of a foam or a plurality of foams having a high porosity.
Unlike previously known mattress structures, the hexagonal-shaped openings in the mattress according to the present invention are non-through openings that extend from the top of the core layer. Due to the non-through openings in the core layer, the mattress according to the present invention does not dissipate heat and moisture through the bottom thereof as is the case of mattresses of the prior art. Instead, a chimney effect occurs causing heat and moisture dissipation through the top of the mattress.
In practice, when a user lays on the mattress, the mattress is compressed under his weight, and so the air (carrying heat and moisture from the user) is also compressed down into the non-through openings. Since the air cannot exit the mattress through the bottom thereof, it is forced upwards by the chimney effect, dissipating through the porous topper and exiting the mattress through the top. This also causes a ventilation effect as a result of an increase in turbulent air circulation around the user, thus increasing heat dissipation.

Brief Description of the Drawings

The present invention will be better understood in reference to the following drawings illustrating a preferred embodiment of the invention in a non-limiting manner.

Figure 1 shows a top view of a core layer for a mattress according to the preferred embodiment of the invention.
Figure 2 shows a partial cross-section view of the core layer shown in Figure 1.

Detailed Description of the Invention

As used herein, the term "foam" when used to define the material making up the topper must be understood as comprising any foam or combination of a plurality of polymeric foams known in the art for manufacturing toppers for mattresses.
As mentioned above, the mattress according to the preferred embodiment of the present invention comprises a core layer and a topper.
As seen in Figure 1, the core layer (10) for a mattress according to the preferred embodiment of the present invention has a honeycomb structure comprising a plurality of hexagonal-shaped vertical openings (20). These openings are non-through openings (20) and they extend from the top of the core layer, as best seen in Figure 2.
According to the preferred embodiment of the invention, the non-through openings (20) of the core layer (10) extend about 2/3 of the height of the core layer (10) (Figure 2).
The core layer (10) is preferably 15 to 20 cm high, more preferably 18 to 20 cm high, and has a 40% ILD (Indentation Load Deflection) hardness of 10 to 50 N, more preferably 18 to 38 N. The 40% ILD hardness of the core layer is determined as set forth in ISO 2439.
According to another preferred embodiment of the invention, not shown in the drawings, the core layer of the mattress has two horizontally defined sections, each section of the core layer having a different hardness. Different hardness can be achieved by modifying the material composition used to manufacture each of the sections. Different comfort sections can thus be provided in the mattress, defining a first section adapted for a user with higher body weight and a second section adapted for a user with lower body weight, for example.
Different sections having a different hardness can also be provided in mattresses of any size suitable for supporting different parts of the user's body, for example head and legs.
The material used to make up the core layer has a very low porosity, therefore preventing air from diffusing through the core layer downwards and forcing air to exit through the top of the core layer by means of chimney effect as described above. This material is preferably synthetic latex or natural latex, more preferably natural latex.
According to alternative embodiments, the core layer can comprise a polymer selected from polyurethane, polyisoprene, polystyrene, poly(vinyl acetate), and the like, or combinations thereof. Any polymer commonly used in the art to manufacture such core layers can be used in the core layer of the present invention, taking into consideration that reducing the porosity (breathability) of the core layer is an important aspect of the invention to help create the aforementioned chimney effect.
The porosity of a material is measured by the volume of air that goes through a surface unit in a given time. If the material has a high porosity, the chimney effect will not occur or it will occur at a lesser degree. Advantageous values of porosity are in the range of 0-100L/min and more preferably are in the range of 79-94L/min.
As defined above, the topper is made up of a foam (or a plurality of foams) having a high porosity, preferably having a plurality of through holes. The through-holes in the topper are vertical through holes that extend from the top, intended for supporting the user, to the bottom in contact with the core layer. More preferably, the topper comprises a combination of vertical through holes and horizontal holes connecting the vertical through holes.
The air forced upwards by means of the chimney effect as described above will enter the network of vertical through-holes and horizontal holes present in the topper, and will exit the topper through the top side, enveloping the user. The air exiting the topper through the vertical through holes will increase turbulence around the user, and this turbulent air circulation will cause a ventilation effect that will further improve heat dissipation from the user.
According to the preferred embodiment of the present invention, the mattress further comprises a bottom support layer (not shown in the drawings). The purpose of the bottom support layer is mainly to adjust the thickness of the final mattress, and as such it is not specifically restricted. Any standard support material known in the mattress manufacturing industry (such as foam, latex, springs, etc., and combinations thereof) can be used as the bottom support layer of the present invention.

Example 1

A preferred mattress according to the present invention has the following characteristics:

A core layer with a honeycomb structure having hexagonal-shaped non-through openings as described above. The core layer has a height of 18 cm and the non-through openings that extend from the top of the core layer have a height of 10 cm. Each side of the hexagon is of 6 cm and the distance between the hexagons is of 5 cm. The porosity of the core layer is 93.5L/min, its density is 70 kg/m³ and the 40% ILD hardness is 21 N.

The topper is 7.5 cm high, and has a density of 88 kg/m³ and a 40% ILD hardness of 8 N.

Example 2

In another preferred mattress according to the present invention, the core layer has the porosity of 79.3L/min, density is 90 kg/m³ and the 40% ILD hardness is 21 N. The rest of the characteristics are as in example 1.
Both the core layer and the topper are made up of natural latex prepared by a vulcanization process consisting of adding sulfur to a mixture of monomers and providing heat in order to generate bonds that make the polymeric structure rigid. Generally, heat is provided by adding steam to the mixture and maintaining the temperature in a closed mold while the vulcanization reaction is carried out. However other processes can be used, as the one using ultrasound source of energy.
The present invention has been described in reference to preferred embodiments thereof. However, the invention is not limited to the specific embodiments which have been described but also encompasses any variation that can be applied by a person of skill in the art within the scope of the attached claims.

Claims

A mattress comprising a core layer and a topper,
- the core layer has a honeycomb structure comprising a plurality of hexagonal-shaped vertical openings;

- the topper is made up of a foam having a high porosity;
wherein the hexagonal-shaped openings are non-through openings that extend from the top of the core layer.
The mattress according to claim 1, wherein the core layer is made up of a material having a low porosity.
The mattress according to claim 2, wherein the porosity of the core layer is in the range of 0-100L/min.
The mattress according to claim 3, wherein the porosity of the core layer is in the range of 79-94L/min.
The mattress according to claim 1, wherein the non-through openings of the core layer extend 2/3 of the height of the core layer.
The mattress according to claim 1, wherein the core layer is 15 to 20 cm high and has a 40% ILD hardness of 10 to 50 N.
The mattress according to claim 6, wherein the core layer has a 40% ILD hardness of 18 to 38 N.
The mattress according to claim 6, wherein the core layer is 18 cm high and has a 40% ILD hardness of 21 N, the non-through openings of the core layer being 10 cm high from the top of the core layer.
The mattress according to claim 1, wherein the core layer has at least two horizontally defined sections, each section of the core layer having a different hardness.
The mattress according to claim 1, wherein the core layer comprises latex.
The mattress according to claim 10, wherein the latex is natural latex.
The mattress according to claim 1, wherein the core layer comprises a polymer selected from polyurethane, polyisoprene, polystyrene, poly(vinyl acetate) or combinations thereof.
The mattress according to claim 1, wherein the topper has a plurality of through holes.
The mattress according to claim 1, further comprising a bottom support layer which comprises a material selected from foam, latex, springs and combinations thereof.