EP2938229A1 - Matelas à mobilité améliorée - Google Patents

Matelas à mobilité améliorée

Info

Publication number
EP2938229A1
EP2938229A1 EP12890961.1A EP12890961A EP2938229A1 EP 2938229 A1 EP2938229 A1 EP 2938229A1 EP 12890961 A EP12890961 A EP 12890961A EP 2938229 A1 EP2938229 A1 EP 2938229A1
Authority
EP
European Patent Office
Prior art keywords
mattress
bolster
bolster elements
viscoelastic foam
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP12890961.1A
Other languages
German (de)
English (en)
Other versions
EP2938229A4 (fr
Inventor
Chrisotpher ARENDOSKI
Tyler W. Kilgore
Mohamed F. Alzoubi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tempur Pedic Management LLC
Original Assignee
Tempur Pedic Management LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tempur Pedic Management LLC filed Critical Tempur Pedic Management LLC
Publication of EP2938229A1 publication Critical patent/EP2938229A1/fr
Publication of EP2938229A4 publication Critical patent/EP2938229A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/20—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in foamed material

Definitions

  • the present invention relates to mattresses, and more particularly to mattresses including one or more layers of foam.
  • Many mattresses are constructed entirely or partially out of foam material.
  • polyurethane foam is commonly used in many mattresses, pillows, and cushions, and can be used alone or in combination with other types of cushion materials.
  • viscoelastic material is used, providing the mattress with an increased ability to conform to a user and to distribute the weight or other load of the user.
  • the shape-conforming property of viscoelastic foam is desirable for use in mattresses, it can also impair the user's mobility while supported on the mattress.
  • the user may have difficulty exerting force on the mattress in order to change positions. Jn some cases, this impaired mobility is due at least in part to the design of the mattress and/or the choice of materia!(s) used in various locations of the mattress.
  • the invention provides, in one aspect, a mattress including a first layer of viscoelastic foam having an upper surface and a layer of non-viscoelastic foam supporting the first layer.
  • the mattress also includes a plurality of static bolster elements positioned beneath the upper surface and clustered together to define a plurality of troughs between adjacent bolster elements.
  • the first layer of viscoelastic foam is further compressible in regions of the mattress corresponding with the troughs than surrounding regions corresponding with the bolster elements.
  • Each of the bolster elements is capable of exerting a reaction force having a lateral component on an individual pushing against the bolster element with a line of action through one of the troughs.
  • the invention provides, in another aspect, a mattress including a first layer of viseoelastic foam having an upper surface and a layer of non- viseoelastic foam supporting the first layer.
  • the mattress also includes a plurality of static bolster elements positioned beneath the upper surface and clustered together to define a plurality of troughs between adjacent bolster elements.
  • the bolster elements and the troughs extend in a direction parallel to a length of the mattress, and the bolster elements include a hardness that is at least about 2.5 times a hardness of the first layer of viseoelastic foam.
  • FIG. 1 is a perspective view of a mattress according a first embodiment of the invention
  • FIG. 2 is a cross-sectional view of the mattress of Fig. 1, taken along line 2-2 of Fig. 1.
  • FIG. 3 is a perspective view of a mattress according a second embodiment of the invention.
  • Fig. 4 is a cross-sectional view of the mattress of Fig. 3, taken along line 4-4 of Fig. 3.
  • FIG. 5 is a perspective view of a mattress according a third embodiment of the invention.
  • Fig. 6 is a cross-sectional view of the mattress of Fig. 5, taken along line 6-6 of Fig. 5.
  • FIG. 7 is a perspective view of a mattress according a fourth embodiment of the invention.
  • Fig. 8 is a cross-sectional view of the mattress of Fig. 7, taken along line 8-8 of Fig. 7.
  • FIG. 9 is a perspective view of a mattress according a fifth embodiment of the invention.
  • Fig. 10 is a cross-sectional view of the mattress of Fig. 9, taken along line 10-
  • Fig. 11 is a perspective view of a mattress according a sixth embodiment of the invention.
  • Fig. 12 is a cross-sectional view of the mattress of Fig. 11 , taken along line 12-
  • FIG. 1 illustrates a mattress 110 according to an embodiment of the invention.
  • the mattress 1 10 includes a top surface 114, a bottom surface 118, and a thickness t (Fig. 2) between the top surface 114 and the bottom surface 1 18.
  • the mattress 1 10 is substantially rectangular in shape and includes a length dimension L and a width dimension i (Fig. 1 ). In other embodiments, the mattress 1 10 may include any of a number of different shapes.
  • the top surface 114 and the bottom surface 1 18 are substantiaUy planar.
  • either or both of the top and bottom surfaces 3 14, 1 18 may be non-planar, including without limitation surfaces having ribs, bumps, waves, and other protrusions of any shape and size, surfaces having grooves and other apertures, and the like.
  • the mattress 1 10 includes a plurality of foam layers that interact to provide the mattress 110 with a soft and comfortable feel, while providing adequate support for the user.
  • the mattress 1 10 includes a first or overlying viscoelastic foam layer 122 and a second or underlying non-viscoelastic foam layer 126, which may include latex, standard polyurethane foam, high-resilience polyurethane foam, or any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene).
  • the viscoelastic foam layer 122 provides the body-conforming and low-resilience qualities associated with viscoelastic foam, while the non-viscoelastic foam layer enhances and/or provides some degree of resilience or "bounce" to the mattress 110 typically associated with conventional spring-based mattresses.
  • the viscoelastic foam layer 122 includes a top surface 122a and a bottom surface 122b.
  • the top surface 122a coincides with the top surface 114 of the mattress 1 10.
  • a pad, topper or one or more other foam or non-foam layers may be positioned upon the top surface 122a.
  • both the top surface 122a and the bottom surface 122b are substantially planar.
  • At least one of the top surface 122a and the bottom surface 122b may be non-planar, including without limitation surfaces having ribs, bumps, waves, and other protrusions of any shape and size, surfaces having grooves and other apertures that extend partially or fully through the viscoelastic foam layer 122, and the like.
  • the viscoelastic foam layer 122 has a hardness of at least about 20 N and no greater than about 80 N for desirable softness and body-conforming qualities. In other embodiments, the viscoelastic foam layer 122 may have a hardness of at least about 30 N and no greater than about 70 N. In still other embodiments, the viscoelastic foam layer 122 may have a hardness of at least about 40 N and no greater than about 60 N.
  • the hardness of any foam material referred to herein is measured by exerting pressure from a plate against a sample of the material to a compression of 40% of an original thickness of the material at approximately room temperature (e.g., 21 -23 Degrees Celsius), wherein the 40% compression is held for a set period of time, following the International Organization of Standardization (ISO) 2439 hardness measuring standard.
  • ISO International Organization of Standardization
  • the viscoelastic foam layer 122 also includes a density providing a relatively high degree of material durability.
  • the density of the viscoelastic foam layer 122 can also impact other characteristics of the foam, such as the manner in which the viscoelastic foam layer 122 responds to pressure, and the feel of the foam.
  • the viscoelastic foam layer 122 has a density of no less than about 30 kg m 3 and no greater than about 150 kg/m 3 .
  • the viscoelastic foam layer 122 may have a density of at least about 40 kg m 3 and no greater than about 135 kg m 3 .
  • the viscoelastic foam layer 122 may have a density of at least about 50 kg/m 3 and no greater than about 120 kg/m 3 .
  • the viscoelastic foam layer 122 may be reticulated.
  • Reticulated viscoelastic foam has characteristics that are well suited for use in the mattress 1 10, including an enhanced ability (i.e., when compared to non- reticulated viscoelastic foam) to permit the movement of air therethrough, thereby providing enhanced air and/or heat movement within, through, and away from the viscoelastic foam layer 122.
  • Reticulated foam is a cellular foam structure in which the cells of the foam are essentially skeletal, in other words, the cells of the reticulated foam are each defined by a plurality of apertured windows surrounded by ceil struts.
  • the ceil windows of reticulated foam can be entirely gone (leaving only the cell struts) or substantially gone.
  • the foam is considered "reticulated” if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts).
  • Such structures can be created by destruction or other removal of cell window material, or preventing the complete formation of cell windows during the manufacturing process of the foam.
  • the second or non-viscoelastic foam layer 126 includes a top surface 126a and a bottom surface 126b.
  • the top surface 126a is positioned adjacent the bottom surface 122b of the viscoelastic foam layer 122, such that the non-viscoelastic foam layer 126 supports the viscoelastic foam layer 122.
  • the viscoelastic foam layer 122 can rest upon the non-viscoelastic foam layer 126 without being secured thereto.
  • the layers 122, 126 may be secured to one another by adhesive or cohesive bonding material, and/or by being bonded together during formation of the layers 122, 126.
  • Tape a hook and loop fastener material, conventional fasteners, stitches extending at least partially through the layers 122, 126, or any of a number of different structures or processes may be utilized to secure the layers 122, 126 to each other.
  • thin adhesive strips may be positioned between the layers 122, 126. Such adhesives may extend across the entire width and length of the mattress 110, or in some embodiments may instead extend only across discrete portions of the width and/or length of the mattress 1 10. Such adhesi ve strips are flexible enough to form a softer structure than other, more conventional adhesive glues.
  • both the top surface 126a and the bottom surface 126b of the non-viscoelastic foam layer 126 are substantially planar.
  • at least one of the top surface 126a and the bottom surface 126b may be non-planar, including without limitation surfaces having ribs, bumps, waves, and other protrusions of any shape and size, surfaces having grooves, and other apertures that extend partially or fully through the non-viscoelastic foam layer 126, and the like.
  • the non-viscoelastic foam layer 126 includes latex foam having a hardness of at least about 30 and no greater than about 130 N for a desirable overall mattress firmness and "bounce" when used in conjunction with the viscoelastic foam layer .122 described above.
  • the non-viscoelastic foam layer 126 includes high-resilience polyurethane foam having a hardness of at least about 80 N and no greater than about 200 N.
  • the non-viscoelastic foam layer 126 has hardness of at least about 40 N and no greater than about 120 N for this purpose.
  • the non-viscoelastic foam layer 126 may have a hardness of at least about 50 N and no greater than about 1 10 N.
  • the non-viscoelastic foam layer 126 includes latex foam having a density of no less than about 40 kg/m 3 and no greater than about 100 kg m 3 .
  • the non-viscoelastic foam layer 126 includes high-resilience polyurethane foam having a density of no less than about 10 kg/m 3 and no greater than about 80 kg/m 3 .
  • the non-viscoelastic foam layer 126 may have a density of at least about 50 kg m 3 and no greater than about 100 kg/m 3 .
  • the non-viscoelastic foam layer 126 may have a density of at least about 60 kg m 3 and no greater than about .100 kg/m 3 .
  • the mattress 110 includes a plurality of bolster elements 130 positioned beneath the top surface 122a of the viscoelastic foam layer 122.
  • the bolster elements 130 extend along the entire length L of the mattress 1 10 and are positioned within the non-viscoelastic foam layer 126. More particularly, the bolster elements 130 are disposed between the top surface 126a and the bottom surface 126b such that the bolster elements 130 are substantially encased by the non- viscoelastic foam layer 126.
  • the bolster elements 130 are not limited to being encased by the non-viscoelastic foam layer 126, and may extend through the mattress 1 10 at any point along the thickness t, between the top surface 126a of the viscoelastic foam layer 122 and the bottom surface 126b of the non-viscoelastic foam layer 126. in addition, the bolster elements 130 may be shorter than the length L of the mattress 1 10.
  • the bolster elements 130 have a generally hexagonal cross-sectional shape, and each of the plurality of bolster elements 130 is substantially identical. Adjacent bolster elements 130 are positioned contiguously such that adjacent bolster elements 130 are in contact with each other. In other embodiments, adjacent bolster elements 130 may be spaced apart or may overlap. Furthermore, bolster elements 130 having other cross-sectional shapes may be utilized in the mattress 1 10.
  • the bolster elements 130 are formed from a suitable high-resilience polymeric material, such as polystyrene foam.
  • the bolster elements 130 can include any expanded polymer (e.g.. expanded ethylene vinyl acetate, polypropylene, polyethylene, and the like).
  • the bolster elements 130 may be formed individually by any suitable process (e.g., by direct injection expanded foam molding). In other embodiments, the bolster elements 130 may be formed together as a single piece.
  • the bolster elements 130 may be formed separately from the non-viscoelastic foam laye 126 and subsequently positioned within the layer 126 (e.g., within cavities formed or otherwise created in the layer 126), or the bolster elements 130 may be formed simultaneously with the non-viscoelastic foam layer 126 using a co-injection molding process, in the illustrated embodiment of the mattress 110, the bolster elements 130 have a hardness of at least about 200 N. In some embodiments, the bolster elements 130 may have a hardness of at least about 2,5 times the hardness of the viscoelastic foam layer 122 and no greater than about 10 times the hardness of the viscoelastic foam layer 122.
  • the bolster elements can also have a hardness that is greater than that of the non-viscoelastic foam layer 126, such as a hardness of at least 1.1 times that of the non-viscoelastic foam layer 126, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 126, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 126.
  • a hardness that is greater than that of the non-viscoelastic foam layer 126 such as a hardness of at least 1.1 times that of the non-viscoelastic foam layer 126, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 126, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 126.
  • a plurality of troughs 134 is defined between adjacent boister elements 130.
  • Each of the troughs 134 is defined by feeing, oblique surfaces 138 of adjacent bolster elements 130, respectively.
  • the troughs 134 extend along the entire length L of the mattress 1 10 with the boister elements 130.
  • the viscoelastic foam layer 122 may be deformed or compressed further into regions 136 of the mattress 1 10 corresponding with the troughs 134 than regions 132 of the mattress 110 surrounding the troughs 134 as a result of the relatively high hardness of the bolster elements 130 compared to the layers 122, 326. Accordingly, the user is able to feel the locations of the bolster elements 130 by compressing the foam layers 122, 126 into the troughs 134.
  • the troughs 134 provide the user with locations or regions 136 on the mattress
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 110.
  • the user when the user desires to move or change position, the user exerts a force F on the mattress 110 having a line of action through one of the troughs 134.
  • a corresponding reaction force R is exerted on the user by the boister elements 130.
  • the reaction force R may have a line of action norma! to the surface 138 of the bolster element 130.
  • the reaction force R may be resolved into at least horizontal and vertical force vector components Rx, Ry.
  • the horizontal component Rx is hereafter referred to as a lateral component.
  • the lateral component Rx of the reaction force 7? exerted on the user by one or more of the bolster elements 130 allows the user to accelerate a mass (e.g., the user's body) in a lateral direction. This facilitates lateral movement of the user on the mattress 110, and enables the user to roll, turn, or move off the mattress 110 with reduced effort.
  • a mass e.g., the user's body
  • the shape-conforming properties of the viscoelastic foam might allow the user to "sink" into the foam and thereby inhibit their lateral movement, causing the user to struggle when rolling, turning, or moving off such a conventional mattress.
  • FIGs. 3 and 4 illustrate a mattress 210 according to another embodiment of the invention.
  • This embodiment employs much of the same structure and has many of the same properties as the embodiment of the mattress 110 described above in connection with Figs, 1 and 2. Accordingly, the following description focuses primarily upon the structure and features that are different tha the embodiment described above in connection with Figs. 1 and 2. Reference should be made to the description above in connection with Figs. 1 and 2 for additional informatio regarding the structure and features, and possible alternatives to the structure and features of the mattress illustrated in Figs. 3 and 4 and described below. Structure and features of the embodiment shown in Figs. 3 and 4 that correspond to structure and features of the embodiment of Figs. 1 and 2 are designated hereinafter in the 200 series of reference numbers,
  • the mattress 210 includes a top surface 214, a bottom surface 218, and a thickness / (Fig. 4) between the top surface 2.14 and the bottom surface 218.
  • the mattress 210 is substantiall rectangular in shape and includes a length dimension L and a width dimension W (Fig. 3).
  • the top surface 21 and the bottom surface 218 are substantially planar,
  • the mattress 210 includes a first or overlying viscoelastic foam layer 222 and a second or underlying non-viscoeiastic foam layer 226.
  • the viscoelastic foam layer 222 provides the body-conforming and low-resilience qualities associated with viscoelastic foam, while the non-viscoelastic foam layer enhances and/or provides some degree of resilience or "bounce" to the mattress 210 typically associated with conventional spring-based mattresses.
  • the mattress 210 includes a plurality of bolster elements 230 positioned beneath a top surface 222a of the viscoelastic foam layer 222.
  • the bolster elements 230 extend along the entire length L of the mattress 210 and are positioned within the non-viscoelastic foam layer 226. More particularly, the bolster elements 230 are disposed between a top surface 226a and a bottom surface 226b of the non-viscoelastic foam layer 226 such that the bolster elements 230 are substantially encased by the non-viscoelastic foam layer 226.
  • the bolster elements 230 are not limited to being encased by the non-viscoelastic foam layer 226, and may extend through the mattress 210 at any point along the thickness /, between the top surface 226a of the viscoelastic foam layer 222 and the bottom surface 226b of the non-viscoelastic foam layer 226. In addition, the bolster elements 230 may be shorter than the length L of the mattress 210.
  • the bolster elements 230 have a generally circular cross-sectional shape, and each of the plurality of bolster elements 230 is substantially identical. Adjacent bolster elements 230 are positioned contiguously such that adjacent bolster elements 230 are in contact with each other. In other embodiments, adjacent bolster elements 230 may be spaced apart or may overlap. Furthermore, bolster elements 230 having other cross-sectional shapes may be utilized in the mattress 210.
  • the bolster elements 230 are formed from a suitable high-resilience polymeric material, such as polystyrene foam.
  • the bolster elements 230 can include any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polyethylene, and the like).
  • the bolster elements 230 may be formed individually by any suitable process (e.g., by direct injection expanded foam molding). In other embodiments, the bolster elements 230 may be formed together as a single piece.
  • the bolster elements 230 may be formed separately from the non- viscoelastic foam layer 226 and subsequently positioned within the layer 226 (e.g., within cavities formed or otherwise created in the layer 226), or the bolster elements 230 may be formed simultaneously with the non-viscoelastic foam layer 226 using a co-injection molding process.
  • the bolster elements 230 have a hardness of at least about 200 N.
  • the bolster elements 230 may have a hardness of at least about 2.5 times the hardness of the viscoelastic foam layer 222 and no greater than about 10 times the hardness of the viscoelastic foam layer 222.
  • the bolster elements can also have a hardness that is greater than that of the non-viscoelastic foam layer 226, such as a hardness of at least 1.1 times that of the non- viscoelastic foam layer 226, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 226, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 226.
  • a plurality of troughs 234 is defined between adjacent bolster elements 230.
  • Each of the troughs 234 is defined by facing, arcuate surfaces 238 of adjacent bolster elements 230, respectively.
  • the troughs 234 extend along the entire length L of the mattress 210 with the bolster elements 230.
  • the viscoelastic foam layer 222 may be deformed or compressed further into regions 236 of the mattress 210 corresponding with the troughs 234 than regions 232 of the mattress 210 surrounding the troughs 234 as a result of the relatively high hardness of th bolster elements 230 compared to the layers 222, 226. Accordingly, the user is able to feel the locations of the bolster elements 230 by compressing the foam layers 222, 226 into the troughs 234.
  • the troughs 234 provide the user with locations or regions 236 on the mattress
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 210.
  • the user when the user desires to move or change position, the user exerts a force F on the mattress 210 having a line of action through one of the troughs 234.
  • a corresponding reaction force R is exerted on the user by the bolster elements 230.
  • the reaction force R may have a line of action normal to the surface 238 of the bolster element 230.
  • the reaction force jfi may be resolved into at least lateral and vertical force vector components Rx, Ry.
  • the lateral component Rx of the reaction force R exerted on the user by one or more of the bolster elements 230 allows the user to accelerate a mass (e.g., the user's body) in a lateral direction. This facilitates lateral movement of the user on the mattress 210, and enables the user to roll, turn, or move off the mattress 210 with reduced effort.
  • a mass e.g., the user's body
  • the shape-conforming properties of the viscoelastic foam might allow the user to "sink" into the foam and thereby inhibit their lateral movemen causing the user to struggle when rolling, turning, or moving off such a conventional mattress.
  • FIGs. 5 and 6 illustrate a mattress 310 according to another embodiment the invention.
  • This embodiment employs much of the same structure and has many of the same properties as the embodiments of the mattresses 1 10 and 210 described above in connection with Figs. 1-4. Accordingly, the following description focuses primaril upon the structure and features that are different than the embodiments described above in connection with Figs. 1-4. Reference should be made to the description above in connection with Figs, 1-4 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress 310 illustrated in Figs. 5 and 6 and described below. Structure and features of the embodiment shown in Figs. 5 and 6 that correspond to structure and features of the embodiment of Figs. 1-4 are designated hereinafter in the 300 series of reference numbers.
  • the mattress 310 includes a top surface 314, a bottom surface 318, and a thickness / (Fig. 6) between the top surface 314 and the bottom surface 318.
  • the mattress 310 is substantially rectangular in shape and includes a length dimension L and a width dimension W (Fig. 1).
  • the top surface 314 and the bottom surface 318 are substantially planar.
  • the mattress 310 includes a first or overlying viscoelastic foam layer 322 and a second or underlying non-viscoelastic foam layer 326.
  • the viscoelastic foam layer 322 provides the body-conforming and low-resilience benefits associated with viscoelastic foam, while the non-viscoelastic foam layer 326 enhances and/or provides some degree of resilience or "bounce" to the mattress 310 typically associated with conventional spring-based mattresses.
  • the mattress 310 includes a plurality of bolster elements 330 positioned beneath a top surface 322a of the viscoelastic foam layer 322.
  • the bolster elements 330 extend along the entire length L of the mattress 310 and are positioned within the non-viscoelastic foam layer 326. More particularly, the bolster elements 330 are disposed between a top surface 326a and a bottom surface 326b of the non-viscoelastic foam layer 326 such that the bolster elements 330 are substantially encased by the non-viscoelastic foam laye 326.
  • the bolster elements 330 are not limited to being encased by the non-viscoelastic foam layer 326, and may extend through the mattress 310 at any point along the thickness /, between the top surface 326a of the viscoelastic foam layer 322 and the bottom surface 326b of the non- viscoelastic foam layer 326. In addition, the bolster elements 330 may be shorter than the length L of the mattress 310.
  • the bolster elements 330 have a generally hexagonal cross-sectional shape, and each of the plurality of bolster elements 330 is substantially identical. Additionally, the bolster elements 330 are arranged in a first row 340 and a second row 344 substantially identical to the first row 340. Horizontally adjacent bolster elements 330 in both the first row 340 and the second row 344 are positioned contiguously such that adjacent bolster elements 330 are in contact with each other. The first row 340 is also positioned contiguously with the second row 344 such that vertically adjacent bolster elements 330 are substantially aligned and in contact with each other. In other embodiments, adjacent bolster elements 330 may be spaced apart or may overlap.
  • bolster elements 330 having other cross-sectional shapes may be utilized, any number of rows of bolster elements 330 may be used, and vertically adjacent rows of bolster elements 330 may be positioned relative to one another in any suitable manner (e.g., spaced apart, nested, etc.).
  • the bolster elements 330 are formed from a suitable high-resilience polymeric material, such as polystyrene foam.
  • the bolster elements 330 can include any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polyethylene, and the like).
  • the bolster elements 330 may be formed individually by any suitable process (e.g., by direct injection expanded foam molding), in other embodiments, the bolster elements 330 may be formed together as a single piece.
  • the bolster elements 330 may be formed separately from the non- viscoelastic foam layer 326 and subsequently positioned within the layer 326 (e.g., within cavities formed or otherwise created in the layer 326), or the bolster elements 330 may be formed simultaneously with the non-viscoelastic foam layer 326 using a co-injection molding process.
  • the bolster elements 330 have a hardness of at least about 200 N. in some embodiments, the bolster elements 330 may have a hardness of at least about 2.5 times the hardness of the viscoeiastic foam layer 322 and no greater than about 10 times the hardness of the viscoeiastic foam layer 322.
  • the bolster elements can also have a hardness that is greater than that of the non-viscoelastic foam layer 326, such as a hardness of at least 1.1 times that of the non- viscoelastic foam layer 326, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 326, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 326.
  • a hardness that is greater than that of the non-viscoelastic foam layer 326 such as a hardness of at least 1.1 times that of the non- viscoelastic foam layer 326, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 326, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 326.
  • a plurality of troughs 334 is defined between adj acent bolster elements 330 in the first row 340.
  • Each of the troughs 334 is defined by facing, oblique surfaces 338 of adjacent bolster elements 330, respectively.
  • the troughs 334 extend along the entire length L of the mattress 310 with the bolster elements 330.
  • the viscoeiastic foam layer 322 may be deformed or compressed further into regions 336 of the mattress 310 corresponding with the troughs 334 than region 332 of the mattress 310 surrounding the troughs 334 as a result of the relatively high hardness of the bolster elements 330 compared to the layers 322, 326. Accordingly, the user is able to feel the locations of the bolster elements 330 by compressing the foam layers 322, 326 into the troughs 334.
  • the troughs 334 provide the user with locations or regions 336 on the mattress
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 310.
  • the user exerts a force F on the mattress 310 having a line of action through one of the troughs 334.
  • a corresponding reaction force R is exerted on the user by the bolster elements 330.
  • the reaction force R may have a line of action normal to the surface 338 of the bolster element 330,
  • the reaction force R may be resolved into at least lateral and vertical force vector components Rx, Ry.
  • the lateral component Rx of the reaction force R exerted on the user by one or more of the bolster elements 330 allows the user to accelerate a mass (e.g., the user's body) in a lateral direction. This facilitates lateral movement of the user on the mattress 310, and enables the user to roll, turn, or move off the mattress 330 with reduced effort.
  • a mass e.g., the user's body
  • the shape-conforming properties of the viscoelastic foam might allow the user to "sink" into the foam and thereby inhibit their lateral movement, causing the user to struggle when rolling, turning, or moving off such a conventional mattress.
  • FIGs. 7 and 8 illustrate a mattress 410 according to another embodiment of the invention.
  • This embodiment employs much of the same structure and has many of the same properties as the embodiments of the mattresses 1 10-3 10 described above in connection with Figs. 1 -6. Accordingly, the following description focuses primarily upon the structure and features that are different than the embodiments described above in connection with Figs. 1 - 6. Reference should be made to the description above in connection with Figs. 1 -6 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress 410 illustrated in Figs. 7 and 8 and described below. Structure and features of the embodiment shown in Figs, 7 and 8 that correspond to structure and features of the embodiment of Figs. 1 -6 are designated hereinafter in the 400 series of reference numbers.
  • the mattress 410 includes a top surface 414, a bottom surface 418, and a thickness / (Fig. 8) between the top surface 414 and the bottom surface 418.
  • the mattress 410 is substantially rectangular in shape and includes a length dimension L and a width dimension W (Fig. 7).
  • the top surface 414 and th bottom surface 418 are substantially planar.
  • the mattress 410 includes a first or overlying viscoelastic foam layer 422 and a second or underlying non-viscoelastic foam layer 426.
  • the viscoelastic foam layer 422 provides the body-conforming and low-resilience qualities associated with viscoelastic foam, while the non-viscoelastic foam layer enhances and/or provides some degree of resilience or "bounce" to the mattress 410 typically associated with conventional spring-based mattresses.
  • the mattress 410 includes a plurality of bolster elements 430 positioned beneath a top surface 422a of the viscoelastic foam layer 422.
  • the bolster elements 430 have a generally circular cross-sectional shape and are elongated in a thickness direction of the mattress 430.
  • the bolster elements 430 are cylindrical and extend along the thickness dimension of the mattress 410. Accordingly, the bolster elements 430 are comparatively shorter in length and more numerous than any of the bolster elements 130, 230, or 330 described above.
  • the bolster elements 430 are disposed between a to surface 426a and a bottom surface 426b of the non-viscoelastic foam layer 426 such that the bolster elements 430 are substantially encased by the non-viscoelastic foam layer 426.
  • the bolster elements 430 are not limited to being encased by the non-viscoelastic foam layer 426.
  • Adjacent bolster elements 430 are positioned contiguously, such that the bolster elements 430 form an array of rows extending along the width W of the mattress 410 and columns extending along the length L of the mattress 410 (Fig. 7).
  • Each row of bolster elements 430 is substantially identical (i.e., each row of bolster elements 430 has the same quantity and arrangement of bolster elements 430), and each column of bolster elements 430 is substantially identical (i.e., each column of bolster elements 430 has the same quantity and arrangement of bolster elements 430).
  • the individual bolster elements 430 are substantially identical. In other embodiments, adjacent bolster elements 430 may be spaced apart or may overlap, or bolster elements 430 having other cross-sectional shapes may be utilized.
  • any number of rows or columns of bolster elements 430 may be used, and bolster elements 430 may be positioned relative to one another in any suitable manner (e.g., spaced apart, nested, etc.).
  • the bolster elements 430 include flat surfaces 448 that are coplanar with each other, such that an aggregate of the flat surfaces 448 defines a single plane substantially parallel to the top surface 422a.
  • the contiguous arrangement of the bolster elements 430 defines a plurality of troughs 434 between adjacent rows and columns of bolster elements 430,
  • the bolster elements 430 are formed from a suitable high-resilience polymeric material, such as polystyrene foam, in some embodiments, the bolster elements 430 can include any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polyethylene, and the like).
  • the bolster elements 430 may be formed individually by any suitable process ⁇ e.g., by direct injection expanded foam molding), in other embodiments, the bolster elements 430 may be formed together as a single piece.
  • the bolster elements 430 may be formed separately from the non-viscoelastic foam layer 426 and subsequently positioned within the layer 426 (e.g., within cavities formed or otherwise created in the layer 426), or the bolster elements 430 may be formed simultaneously with the non-viscoelastic foam layer 426 using a co-injection molding process.
  • the bolster elements 430 have a hardness of at least about 200 N. in some embodiments, the bolster elements 430 may have a hardness of at least about 2.5 times the hardness of the viscoelastic foam layer 422 and no greater than about 10 times the hardness of the viscoelastic foam layer 422.
  • the boister elements 430 can also have a hardness that is greater than that of the non-viscoelastic foam layer 426, such as a hardness of at least 1.1 times that of the non- viscoelastic foam layer 426, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 426, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 426.
  • a hardness that is greater than that of the non-viscoelastic foam layer 426 such as a hardness of at least 1.1 times that of the non- viscoelastic foam layer 426, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 426, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 426.
  • the viscoelastic foam layer 422 may be deformed or compressed further into regions 436 of the mattress 410 corresponding with the troughs 434 than regions 432 of the mattress 410 surrounding the troughs 434 as a result of the relatively high hardness of the bolster elements 430 compared to the layers 422, 426. Accordingly, the user is able to feel the locations of the bolster elements 430 by compressing the foam layers 422, 426 into the troughs 434.
  • the troughs 434 provide the user with locations or regions 436 on the mattress
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 410.
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 410.
  • the user exerts a force F on the mattress 410 having a line of action through one of the troughs 434.
  • a corresponding reaction force R is exerted on the user by the bolster elements 430.
  • the reaction force R may be resolved into at least lateral and vertical force vector components Rx, Ry.
  • the lateral component Rx of the reaction force R exerted on the user by one or more of the bolster elements 430 allows the user to accelerate a mass (e.g., the user's body) in a lateral direction. This facilitates lateral movement of the user on the mattress 410, and enables the user to roll, turn, or move off the mattress 410 with reduced effort.
  • a mass e.g., the user's body
  • the shape-conforming properties of the viscoelastic foam might allow the user to "sink" into the foam and thereby inhibit their lateral movement, causing the user to struggle when rolling, turning, or moving off such a conventional mattress.
  • FIGs. 9 and 10 illustrate a mattress 510 according to another embodiment of the invention.
  • This embodiment employs much of the same structure and has many of the same properties as the embodiments of the mattresses 1 10-410 described above in connection with Figs. 3-8. Accordingly, the following description focuses primarily upon the structure and features that are different than the embodiments described above in connection with Figs, 1-8. Reference should be made to the description above in connection with Figs. 1-8 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress illustrated in Figs. 9 and 10 and described below. Structure and features of the embodiment shown in Figs. 9 and 10 that correspond to structure and features of the embodiment of Figs. 1-8 are designated hereinafter in the 500 series of reference numbers.
  • the mattress 510 includes a top surface 5 4, a bottom surface 518, and a thickness / (Fig. 10) between the top surface 514 and the bottom surface 518.
  • the mattress 510 is substantially rectangular in shape and includes a length dimension L and a width dimension W (Fig, 9).
  • the to surface 514 and the bottom surface 518 are substantially planar.
  • the mattress 510 includes a first or overlying viscoelastic foam layer 522 and a second or underlying non-viscoefastic foam layer 526.
  • the viscoelastic foam layer 522 provides the body-conforming and low-resilience qualities associated with viscoelastic foam, while the non-viscoelastic foam layer enhances and/or provides some degree of resilience or "bounce" to the mattress 510 typically associated with conventional spring-based mattresses.
  • the mattress 510 includes a plurality of bolster elements 530 positioned beneath a top surface 522a of the viscoelastic foam layer 522.
  • the bolster elements 530 extend along the entire length L of the mattress 510 and are positioned within the non -viscoelastic foam layer 526. More particularly, the bolster elements 530 are disposed between a top surface 526a and a bottom surface 526b of the non-viscoelastic foam layer 526 such that the bolster elements 530 are substantially encased by the non-viscoelastic foam layer 526.
  • the bolster elements 530 are not limited to being encased by the non-viscoelastic foam layer 526, and may extend through the mattress 510 at any point along the thickness /, between the top surface 526a of the viscoelastic foam layer 522 and the bottom surface 526b of the non-viscoelastic foam layer 526. In addition, the bolster elements 530 may be shorter than the length L of the mattress 510.
  • the bolster elements 530 have a generally quadrangular or diamond-like cross-sectional shape, and each of the plurality of bolster elements 530 is substantially identical. Adjacent bolster elements 530 are connected by connecting portions or thin webs 552 to form a single bolster 556. Accordingly, the bolster elements 530 and the webs 552 are collectively referred to as the bolster 556.
  • the bolster 556 is formed from a suitable high-resilience polymeric material, such as polystyrene foam.
  • the bolster 556 may include any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polyethylene, and the like).
  • the bolster 556 may be formed separately from the non-viscoelastic foam layer 526 and subsequently positioned within the layer 526 (e.g., within a cavity formed or otherwise created in the layer 526), or the bolster 556 may be formed simultaneously with the non-viscoelastic foam layer 526 using a co-injection molding process.
  • the bolster 556 has a hardness of at least about 200 N.
  • the bolster 556 may have a hardness of at least about 2.5 times the hardness of the viscoelastic foam layer 522 and no greater than about 10 times the hardness of the viscoelastic foam layer 522.
  • the bolster elements 530 can also have a hardness that is greater than that of the non-viscoelastic foam layer 526, such as a hardness of at least 1.1 times that of the non- viscoelastic foam layer 526, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 526, or (in still other embodiments) a hardness that is at least twice that of the non-viscoelastic foam layer 526.
  • a plurality of troughs 534 is defined between adjacent bolster elements 530 of the holster 556.
  • Each of the troughs 534 is defined by facing, oblique surfaces 538 of adjacent bolster elements 530, respectively.
  • the troughs 534 extend along the entire length L of the mattress 510 with the bolster 556.
  • the viscoelastic foam layer 522 may be deformed or compressed further into regions 536 of the mattress 510 corresponding with the troughs 534 than regions 532 of the mattress 510 surrounding the troughs 534 as a result of the relatively high hardness of the bolster 556 compared to the layers 522, 526. Accordingly, the user is able to feel the locations of the bolster elements 530 by compressing the foam layers 522, 526 into the troughs 534.
  • the troughs 534 provide the user with locations or regions 536 on the mattress
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 510.
  • the user exerts a force F on the mattress 510 having a line of action through one of the troughs 534.
  • a corresponding reaction force R is exerted on the user by the bolster elements 530.
  • the reaction force R may have a line of action normal to the surface 538 of the bolster element 530.
  • the reaction force R may be resolved into at least lateral and vertical force vector components Rx, Ry.
  • the lateral component Rx of the reaction force R exerted on the user by one or more of the bolster elements 530 allows the user to accelerate a mass (e.g., the user's body) in a lateral direction. This facilitates lateral movement of the user on the mattress 510, and enables the user to roll, turn, or move off the mattress 510 with reduced effort.
  • a mass e.g., the user's body
  • the shape-conforming properties of the viscoelastic foam might allow the user to "sink" into the foam and thereby inhibit their lateral movement, causing the user to struggle when rolling, turning, or moving off such a conventional mattress.
  • FIGs. 1 1 and 12 illustrate a mattress 610 according to another embodiment of the invention.
  • This embodiment employs much of the same structure and has many of the same properties as the embodiments of the mattresses 110-510 described above in connection with Figs. 1-10. Accordingly, the following description focuses primarily upon the structure and features that are different than the embodiments described above in connection with Figs. 1 -10, Reference should be made to the description above in connection with Figs. 1 -10 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress illustrated in Figs. 1 1 and 12 and described below. Structure and features of the embodiment shown in Figs. 1 1 and 12 that correspond to structure and features of the embodiments of Figs. 1-1.0 are designated hereinafter in the 600 series of reference numbers.
  • the mattress 610 includes a top surface 614. a bottom surface 618, and a thickness t (Fig. 12) between the top surface 634 and the bottom surface 618.
  • the mattress 610 is substantially rectangular in shape and includes a length dimension L and a width dimension W (Fig. 11).
  • the top surface 614 and the bottom surface 618 are substantially planar.
  • the mattress 610 includes a first or overlying viscoelastic foam layer 622 and a second or underlying non-viscoelastic foam layer 626,
  • the viscoelastic foam layer 622 provides the body-conforming and low-resilience qualities associated with viscoelastic foam, while the non-viscoelastic foam layer enhances and/or provides some degree of resilience or "bounce" to the mattress 610 typically associated with conventional spring-based mattresses.
  • the bolster elements 630 include a plurality of bolster elements 630 positioned beneath a top surface 622a of the viscoelastic foam layer 622.
  • the bolster elements 630 extend along the entire length L of the mattress 610 and are positioned within the non-viscoelastic foam layer 626. More particularly, the bolster elements 630 are disposed between a top surface 626a and a bottom surface 626b of the non-viscoelastic foam layer 626 such that the bolster elements 630 are substantially encased by the non-viscoelastic foam layer 626.
  • the bolster elements 630 are not limited to being encased by the non-viscoelastic foam layer 626, and may extend through the mattress 610 at any point along the thickness t, between the top surface 626a of the viscoelastic foam layer 622 and the bottom surface 626b of the non-viscoelastic foam layer 626. In addition, the bolster elements 630 may be shorter than the length L of the mattress 610.
  • the bolster elements 630 have a generally hexagonal shape, and each of the plurality of bolster elements 630 is substantially identical. Adjacent bolster elements 630 are connected by connecting portions or thin webs 652 to form a single bolster 656. Accordingly, the bolster elements 630 and the webs 652 are collectively referred to as the bolster 656.
  • the bolster 656 is formed from a suitable high-resilience polymeric material, such as polystyrene foam, In some embodiments, the bolster 656 ma include any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polyethylene, and the like).
  • the bolster 656 may be formed separately from the non-viscoelastic foam layer 626 and subsequently positioned within the layer 626 (e.g., within a cavity formed or otherwise created in the layer 626), or the bolster 656 may be formed simultaneously with the non-viscoelastic foam layer 626 using a co-injection molding process.
  • the bolster 656 has a hardness of at least about 200 N. in some embodiments, the bolster 656 may have a hardness of at least about 2.5 times the hardness of the viscoeiastic foam layer 622 and no greater than about 10 times the hardness of the viscoeiastic foam layer 622.
  • the bolster elements 630 can also have a hardness that is greater than that of the non-viscoelastic foam layer 626, such as a hardness of at least 1.1 times that of the non-viscoelastic foam layer 626, or (in other embodiments) a hardness of at least 1.5 times that of the non-viscoelastic foam layer 626, or (in still other embodiments) a hardness that is at least twice that of the non- viscoelastic foam layer 626.
  • a plurality of troughs 634 is defined between adjacent bolster elements 630 of the bolster 656.
  • Each of the troughs 634 is defined by facing, oblique surfaces 638 of adjacent bolster elements 630, respectively.
  • the troughs 634 extend along the entire length L of the mattress 610 with the bolster 656.
  • the viscoeiastic foam layer 622 may be deformed or compressed further into regions 636 of the mattress 610 corresponding with the troughs 634 than regions 632 of the m attress 610 surrounding the troughs 634 as a result of the relatively h igh hardness of the bolster 656 compared to the layers 622, 626. Accordingly, the user is able to feel the locations of the bolster elements 630 by compressing the foam layers 622, 626 into the troughs 634.
  • the troughs 634 provide the user with locations or regions 636 on the mattress
  • the user may increase their mobility (i.e., leverage to initiate movement) on the mattress 610.
  • the user exerts a force F on the mattress 610 having a line of action through one of the troughs 634.
  • a corresponding reaction force R is exerted on the user by the bolster elements 630.
  • the reaction force R may have a line of action normal to the surface 638 of the bolster element 630,
  • the reaction force R may be resolved into at least lateral and vertical force vector components Rx, Ry.
  • the lateral component Rx of the reaction force R exerted on the user by one or more of the bolster elements 630 allows the user to accelerate a mass (e.g., the user's body) in a lateral direction. This facilitates lateral movement of the user on the mattress 610, and enables the user to roll, turn, or move off the mattress 610 with reduced effort.
  • a mass e.g., the user's body
  • the shape-conforming properties of the viscoeiastic foam might allow the user to "sink" into the foam and thereby inhibit their lateral movement, causing the user to struggle when rolling, turning, or moving such a conventional mattress.
  • the use of such bolster elements 130, 230, 330, 430, 530, 630 can limit or attenuate th impaired mobility that is normally experienced with many conventional viscoeiastic foam mattresses.
  • the shape, size, quantity, position, orientation, and construction of the bolster elements 130, 230, 330, 430, 530, 630 can therefore be selected to essentially "tune" the mattress to have any desired feel (i.e., the feel by the user of the body conforming and pressure-distributing properties of viscoeiastic foam), while still maintaining the benefits of enhanced mobility as described above.
  • 510, and 610 described above and illustrated in Figs. 1-12 are applicable to any other type of body support having any size and shape.
  • any of the features described above are equally applicable to mattress toppers, overlays, futons, sleeper sofas, or any other element used to support or cushion any part or all of a human or animal body.
  • the term "mattress” is intended to refer to any and all of such elements (in addition to mattresses).

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

L'invention concerne un matelas comprenant une première couche de mousse viscoélastique dotée d'une surface supérieure et une couche de mousse non viscoélastique supportant la première couche. Le matelas comprend également une pluralité d'éléments de boudin statiques positionnés en-dessous de la surface supérieure et regroupés afin de définir une pluralité de creux entre les éléments de boudin adjacents. La première couche de mousse viscoélastique est également compressible dans des régions du matelas correspondant aux creux entourant des régions correspondant aux éléments de boudin. Chacun des éléments de boudin peut exercer une force de réaction dotée d'un composant latéral sur un individu qui appuie sur l'élément de boudin avec une ligne d'action traversant l'un des creux.
EP12890961.1A 2012-12-28 2012-12-28 Matelas à mobilité améliorée Withdrawn EP2938229A4 (fr)

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EP (1) EP2938229A4 (fr)
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WO2014105045A1 (fr) 2014-07-03
CN104883932A (zh) 2015-09-02
CA2896709A1 (fr) 2014-07-03
EP2938229A4 (fr) 2016-11-23
US20150305515A1 (en) 2015-10-29
JP2016501672A (ja) 2016-01-21

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