EP3153071A1 - Mattress and processing system for producing the mattress - Google Patents

Abstract

A mattress (1) with a mattress core (4) forming the foam body (2), the top and / or bottom (6,8) is designed as a reclining surface for a person should in a particularly simple way, a high sleeping and lying comfort So allow a particularly favorable ergonomics for the user, at the same time particularly effective ventilation. For this purpose, according to the invention, the foam body (2) is provided with a number of ventilation channels (14) extending in the direction from the top to the bottom (6, 8).

Description

The invention relates to a mattress with a mattress core forming foam body whose top or bottom are each designed as a reclining surface for a person. It further relates to a processing plant for the introduction of ventilation channels in a foam body, which can be used in particular for producing such a mattress.

For mattresses with high sleeping and lying comfort on the one hand the ergonomics in the support of the various body zones of particular importance. On the other hand, it is important in the use of foam for the mattress core or mattress base to adjust the moisture balance and the climate within the foam properly to avoid moisture penetration or the like even with prolonged use of the mattress. Therefore, intended for use as a mattress or mattress core foam body are usually provided with ventilation channels through which a moisture and air exchange can take place from the interior of the foam body with its environment. However, such ventilation ducts conceptually represent a local weakening of the mattress body, which in turn could affect the ergonomics.

The invention has for its object to provide a mattress of the type mentioned above, for a particularly simple way a high sleeping and lying comfort, so a particularly favorable ergonomics for the user, is given at the same time particularly effective ventilation. Furthermore, a particularly suitable for the production of such a mattress processing plant should be specified.

With respect to the mattress, this object is achieved according to the invention by forming the mattress core foam body with a number of in the direction is provided from the top to the bottom, so lying mattress in a "vertical" direction, running ventilation channels.

The invention is based on the consideration that the ventilation ducts, which generally run in a "horizontal" direction, that is to say parallel to the upper or lower side of the mattress, fundamentally permit a reliable exchange of gas and moisture between the interior of the mattress body and its surroundings , However, especially during use of the mattress, these channels can be compressed or crushed, which on the one hand can lead to impairment of their function and on the other hand within the respective foam body to form transverse forces and transverse loads that can hinder ergonomic support of the user's various body zones. In order to counteract this, it is now provided to guide the ventilation channels within the foam body in a "vertical" direction, ie in the direction parallel to the surface normal of the upper or lower surfaces forming the lying surfaces of the mattress.

This orientation makes it possible, even with high functionality and reliability of the ventilation channels with respect to air and moisture exchange with the environment, to use the ventilation channels in the manner of additional use as a design means for targeted adjustment of the mechanical properties of the mattress such as elasticity and support function. In particular, an individualized design of hole arrangements, even with different diameters and hole spacings, which may also be aligned to human body parts, to obtain a balanced relaxing point elasticity, which may even be adapted depending on the human percentiles or to the needs and requirements of the individual user , In addition, in this embodiment, even when vertical load of the mattress body by the human lying down, the foam volume fully loaded and ready for use, as caused by the vertically aligned ventilation ducts no physical forces as negative transverse loads under the stress of the elastic foam webs.

In principle, the ventilation channels can be introduced into the foam body by suitable processing methods, for example by punching. Advantageously, however, the ventilation channels are designed as boreholes, d. H. they are introduced into the foam body by a suitably chosen drill. For a particularly careful and precise processing of the foam body is possible, so that in relation to the desired support function can be made particularly needs. In particular, it is possible by various, tailored to suit selected hole diameter spatial arrangements of the foam holes in various foam qualities with variable densities and compression hardness of polyurethane foam in standard, cold and viscoelastic qualities and in different dimensions of length, width and height, so that a variety of ergonomically and physiologically effective variants can be produced by a drilled out foam part. In particular, such an embodiment is for designing in the form of vertical round perforations of polyurethane foams with quality designations, such as besipielsweise "standard", "cold" or "viscoelastic" into consideration.

In a particularly advantageous embodiment of the mattress core forming foam body is made of several layers and formed by a number of foam layers, the ventilation channels are designed to run continuously and penetrate all superposed foam layers. By such a multi-layer design, in the manner of a "sandwich construction", it is possible by appropriate selection or specification of the parameters for the individual layers or layers, such as compression hardness, density, elasticity or the like, tailored to a needs and individualized combination with to provide the desired overall properties.

However, such a multi-layered design of the foam body in the manner of a sandwich construction also allows a very special and as an independently inventive designed execution of the mattress. In this embodiment it is provided that the holes forming the ventilation channels, which are arranged congruently one above the other in the individual foam layers are and thus each form a continuous ventilation channel, have a foam layer to foam layer increasing diameter. In this case, the "lowest", ie the underside adjacent, foam layer preferably has boreholes with the comparatively largest hole diameter and the "uppermost", ie the upper side adjacent foam layer, boreholes with the comparatively smallest hole diameter. Seen in the longitudinal direction of the ventilation ducts, these thus have an internal cross-section which gradually reduces in size from the bottom to the top side. By way of example and preferably, the hole diameter in the "lowest" foam layer is about 20 to 25 millimeters and in the "uppermost" foam layer about 10 to 15 millimeters.

By this configuration with different sized hole diameters in the individual foam layers, in which the foam parts with their channel holes congruent to each other with "down" comparatively large and "up" down smaller hole diameters are stacked, can arise when lying in the so-called Bernoulli effect and used for cooling purposes. This is favorable in terms of sleep physiology for the bed climate and arises when an air volume located or drawn in a larger hole has to accelerate through a smaller diameter by means of pressing pressure. In particular, by the everlasting Liegewechsel the sleeper and thus resulting compression pressure of the mattress foam through the different perforations an acceleration of the air flow and thus also a cooling and a faster air change.

With regard to the processing system for introducing ventilation ducts into a foam body, in particular for producing a mattress in the embodiment described above, the stated object is achieved with a tubular drill provided for producing the ventilation ducts, into the inner hollow space of which an ejection ram is guided. Under "pipe drill" is in this case in particular a drill to understand the drill head is designed in the manner of a pipe or pipe section as a hollow cylinder, the free end of this pipe section or hollow cylinder forms the cutting edge and for this purpose in particular designed suitable, for example, provided with cutting means sharpened or the like, can be executed.

In the inner cavity formed by this hollow cylinder, the ejection ram is guided. After the actual drilling pass, the cylindrically drilled foam waste piece can thus be pushed out of the foam body and fed to disposal by means of the pressure ram, which is mounted on the ram bar and forms the ejection ram. Particularly preferably, the ejection ram is hydraulically or pneumatically, preferably by air hose, driven.

In an advantageous embodiment, the processing plant comprises a plurality of tubular borers arranged on a common drill rig, so that a corresponding number of boreholes can be introduced into the respective foam body in a single operation and according to a predeterminable hole pattern.

The method of making a ventilated foam body, particularly intended for use as a mattress core or body, using said tubular drills is also considered to be inherently inventive.

The advantages achieved by the invention are in particular that by the method of preparation of the ventilation channels in the form of vertical round boreholes through the foam body through an improved ventilation of the foam body along with a possible cooling of the bed and a balancing body relief for the user, and thus a particularly good ergonomics, is achievable. The foam holes can thereby by a suction effect - with or without weight burden by frequent normal body turns of man - also a rain air and moisture exchange between the outer microclimate and the inner bed cavity - ie between the lying surface of a "perforated" mattress and the blanket - bring forth.

FIG. 1

eine Matratze,

FIG. 2

ausschnittsweise eine alternative Matratze mit Oberflächenkontur,

FIG. 3

ausschnittsweise die Matratze gem. FIG. 1 im Schnitt,

FIG. 4

eine Bearbeitungsstation,

FIG. 5

einen Rohrbohrer zur Verwendung in der Bearbeitungsstation gem. FIG. 4, und

FIG. 6

die Bearbeitungsstation gem. FIG. 4 ausschnittsweise in Draufsicht.

An embodiment of the invention will be explained in more detail with reference to a drawing. Show:

FIG. 1

a mattress,

FIG. 2

in sections an alternative mattress with surface contour,

FIG. 3

Partially the mattress gem. FIG. 1 on average,

FIG. 4

a processing station,

FIG. 5

a pipe drill for use in the processing station gem. FIG. 4 , and

FIG. 6

the processing station acc. FIG. 4 partially in plan view.

Identical parts are provided with the same reference numerals in all figures.

The mattress 1 acc. FIG. 1 is designed as a foam mattress and comprises a foam body 2, which forms the mattress core 4. The foam body 2 has a top 6 and a bottom 8, wherein the terms "top" and "bottom" in terms of the use of the mattress 1, ie in the horizontal state to understand. In the exemplary embodiment, especially with regard to the subsequently explained embodiment of the mattress 1, only the upper side 6 is provided as a lying surface for a person; in alternative variants, however, both the upper side 6 and the lower side 8 could be designed as a lying surface.

The foam body 4 is multi-layered and formed by a number of foam layers 10, 12. In the embodiment, two foam layers 10, 12 are provided; Of course, but also three or more layers may be provided. The foam layers 10, 12 are in terms of their characteristic parameters, in particular compression hardness and Volume weight, configured and selected so that the mattress body formed by their combination is particularly well adapted to desired specifications with respect to the overall properties.

The mattress 1 is designed in a special way both for a high sleeping and lying comfort and for a particularly effective ventilation of the interior of the foam body 2. For this purpose, the foam body 2 is provided with a number of integrated ventilation channels 14. These are - in contrast to conventional arrangements - in the foam body 2 in - relative to the mattress 1 in the state of use, so lying on the bottom 8 - arranged in the vertical direction, d. H. in the direction from top 6 to bottom 8. The ventilation channels 14, which were introduced in the exemplary embodiment by vertical drilling in the foam body 2 and thus formed by holes 16, thereby forming in plan view a hole arrangement or a hole pattern that individualized and to special needs or requirements, for example, with regard to local elasticity or point elasticity, can be adjusted. Such a configuration of the hole arrangement, even with different diameters and hole spacing, may in particular also be aligned with human body parts, for example in order to obtain a balanced relaxing point elasticity, and / or adapted according to the human percentiles or adapted to the needs and specifications of the individual user , In particular, in this embodiment, even when vertical loading of the foam body 2 by the human lying down, the foam volume fully loaded and ready for use, since no vertical forces caused by the vertically oriented ventilation channels 14 as negative transverse loads under the stress of the elastic foam webs.

An alternative variant for the mattress 1 is fragmentary in Fig. 2 shown, wherein the top 6 has a milled into the foam surface zoned recumbent well 18, in the lower part of cut as an ergonomic and physiological combination of effects with the vertical ventilation channels 14 additional holes can be drilled.

With regard to the functionality of the ventilation channels 14, the foam layers 10, 12 of the mattress 1 gem. Fig. 1 positioned in the sense congruent to each other that the respective holes 16 of the lower foam layer 10 on the one hand and the upper foam layer 12 on the other hand directly superimposed and thus form continuous ventilation ducts 14.

In addition, the ventilation channels 14 forming boreholes 16 are performed in a very special degree for effective ventilation and cooling of the foam body 2. For this purpose, the drill holes 16 are designed specifically for the use of the Bernoulli effect. For this purpose, the boreholes 16 have a diameter which increases from the first, lower foam layer 10 to the second, upper foam layer 12. In the exemplary embodiment, in this case, the lower, the bottom 8 adjacent foam layer 10 holes 16 with a hole diameter of about 20 to 25 millimeters and the upper, the top 6 adjacent foam layer 12 holes 16 with a relatively smaller hole diameter of about 10 to 15 millimeters. As in particular from the partially enlarged sectional view in Fig. 3 becomes clear, the ventilation channels 14 thus seen in their longitudinal direction on a from the bottom 8 to the top 6 toward gradually decreasing inside cross-section. In the embodiment, only two foam layers 10, 12 are shown; Of course, however, further foam layers with correspondingly adapted hole geometry and dimensioning can also be provided.

In Fig. 4 is shown a suitable for preparing a mattress 1 and in particular for introducing the ventilation channels 14 in the foam body 2 and provided processing plant 20. For introducing the provided for forming the ventilation channels 14 boreholes 16, the machining system 20 is executed in the manner of a vertical drill and comprises a plurality of arranged on a common drill rig 22 drills 24 so that a corresponding number of boreholes 16 in a single operation and a corresponding predeterminable hole pattern introduced into the foam body 2 can be. For fixing and anchoring of the foam body 2 during the introduction of the holes 16 are laterally adjustable guide rails 26 and below the drill rig 22 hydraulically controlled Arretierladen 28 so that the segmentive, staggered boring from the flexible foam body 2 in dimensions of at least 10 to 30 inches high this is anchored against slipping on the support belt and something is compressed before drilling. After a drilling operation, the next segment drilling can take place via the treadmill and at an adjustable distance.

To carry out the drilling operation, the drills 24 are designed as a pipe drill 30, as he, for example, in Fig. 5 is shown. The tubular drill 30 comprises a drill head 32, which is designed as a hollow cylinder in the manner of a pipe or pipe section. In this case, the free end 34 of this pipe section or hollow cylinder forms the cutting edge and is designed for this purpose suitable, for example, provided with cutting means, sharpened or the like. In the inner cavity 36 of the drill head 32 forming tube piece an ejector ram 38 is guided over the after drilling process in the well 16 remaining residual piece of foam can be pushed out of the foam body 2. In the exemplary embodiment, the ejection ram 38 is pneumatically controlled via an air hose 40. In particular, after the drilling operation, the cylindrically drilled foam waste piece is forced downwardly through the hollow linkage by way of the plunger or ejection ram 38 via the air hose 40 with a pressure surge of about 6 bar down into a waste housing.

In Fig. 6 the drill frame 22 is shown in plan view. This is equipped with mechanical functional parts, which are circulating toothed belt 42 by means of electric motors 44, the interchangeable underlying tubular drill 30 are driven. In the figure, a double-drill set is shown with a possible sequence of 20 cylinder drills, the hole profile specifically targeted to body lying areas, for example, only in every fourth drill unit with a cylinder drill can be selected.

During operation of the processing unit 20, after the introduction of the foam body 2 to be processed in an example dimension of 90 to 220 cm width and a length of up to 220 centimeters, the drill frame is aligned and the corresponding hole pattern is drilled. Subsequently, the respective overlying ejection ram 38, controlled via the air hose 42, pneumatically disposed of the drilled piece of foam in the underlying waste housing.

LIST OF REFERENCE NUMBERS

1

mattress

2

foam body

4

mattress core

6

top

8th

bottom

10, 12

foam layers

14

ventilation duct

16

well

18

Sleeping Nest

20

processing plant

22

drilling rig

24

drill

26

guide rails

28

Arretierladen

30

pipe drill

32

wellhead

34

Free end

36

internal cavity

38

ejector ram

40

air hose

42

toothed belt

44

electric motor

Claims (6)

Mattress (1) with a mattress core (4) forming the foam body (2), the top and / or bottom (6,8) is designed as a reclining surface for a person, and with a number of in the direction from the top to the bottom (6,8) extending ventilation ducts (14) is provided. Mattress according to claim 1, whose ventilation channels (14) are formed by boreholes (16). Mattress according to claim 1 or 2, in which the mattress core (4) forming foam body (2) is multi-layered and formed by a number of foam layers (10, 12), wherein the ventilation channels (14) are designed to be continuous and all superimposed foam layers ( 10, 12) penetrate. A mattress according to claim 3, wherein the boreholes (16) forming the ventilation channels (14) have a diameter which increases from foam layer (10) to foam layer (12). Processing installation (20) for introducing ventilation ducts (14) into a foam body (2), in particular for producing a mattress (1) according to one of claims 1 to 4, with a tubular drill (30) provided for the production of ventilation ducts (14) the inner cavity (36) is guided an ejection ram (38). Machining plant (20) according to claim 5, comprising a plurality of tubular borers (30) arranged on a common drilling stand (22).

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