ES2603784T3 - Mattress made of polyurethane material with aeration incisions - Google Patents

Abstract

Layer (1) of a mold casting material, such as polyurethane, polyurethane foams, latexes and the like, for the formation of a mattress, said layer comprising a plurality of incisions (10) that pass through its entire thickness and arranged in succession one after the other along the direction of development of the incision and at intervals of each other from a distance (dx) such that at least one line (20, 30) of incisions is formed, preferably two or more incision lines parallel to each other and separated from each other by a step (dy) such that, in correspondence with the application of a traction (T) to the layer (1) substantially orthogonal to said incision line (20, 30) , the incisions open to form, each, a through opening, each incision having a predetermined length (L), characterized in that the length (L) of each incision is comprised within a range of between 8 cm and 20 cm, preferably between 10 cm and 20 cm and even better between 15 cm and 20 cm, for example, 18 cm, said distance (dx) being included between intervals between the incisions (10) within a range between 4 cm and 10 cm, preferably between 5 cm and 8 cm, for example, 6 cm.

Description

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DESCRIPTION

Mattress made of polyurethane material with aeration incisions

5 Technical field

The present invention relates to the technical field related to mattresses for rest, as well as cushions, seats and the like.

In particular, the invention relates to an innovative layer 1 suitable for forming a mattress, or a cushion or a seat in general, of a casting material such as polyurethane, polyurethane foams, latexes and the like and provided with particular aeration incisions .

Prior art

15 Mattresses made of materials that can be cast into molds, such as polyurethane or latex, have been known for a long time. An example is known from document DE202006011190U.

In general, the production process provides for the casting in a mold of a predetermined amount of fluid, for example, of the polyurethane type which, after the reaction, expands in the mold, filling its volume and, therefore, forming the body of the mattress itself .

The particularity of such materials is that they adapt perfectly well to the physiognomy of the body following the contour of the body when the body rests on them and then, at the end of use, they return to their original form. By

Therefore, they have high adaptability to the contours of shapes and are useful for maintaining correct postures, for example, in the case of painful pathologies such as cervical problems.

Such types of materials, above all, make the production process much simpler with respect to the classic spring mattress since the casting of such a fluid in the mold is sufficient, instead of mounting a plurality of springs in the inside of a layer of padding composed of wool and other materials.

Therefore, in one case a complex production line is necessary, while in the case of polyurethanes a simple forming mold is sufficient.

35 However, materials such as polyurethane and latex have the technical disadvantage of not allowing perfect perspiration, therefore they accumulate heat and turn out to be particularly suffocating, and such heat cannot be eliminated.

With this objective, solutions have been devised that provide for the manufacture of holes in the mattress, making through openings, for example, through machinery consisting of a plurality of punches or blades.

The punches penetrate the mattress, making a removal of material and, therefore, creating a plurality of circular aeration holes.

45 In order to save material in the production of holes and to also have more functional aeration holes, another known technique provides for the making of incisions through knives that penetrate the mattress.

The incisions are distributed in such a way that they form lines on the surface of the mattress, parallel to each other and each line provides for a plurality of incisions separated from each other by a predetermined amount. There is also a passage distance between a line and the subsequent one located in parallel and with the staggered lines alternately.

Once the incisions have been made, the mattress is usually tensioned with a traction (T) that is orthogonally directed to the incision development line so that the incisions open in

55 correspondence with a linear expansion of the mattress in the direction of such a traction (T). At this point, the mattress is locked in the traction realization through the application of an upper layer that adheres to the mattress, joining it to maintain a tensioned position of this type with the open incisions.

However, it has been found in general that non-suitable incisions, which are improperly placed or those of wrong sizes, can cause various problems, including lack of aeration or tearing of the mattress when it is tensioned.

In particular, very small size incisions do not allow a large volume of air to be maintained below, thus significantly reducing the aeration effect, while very long incisions and / or the 65 incisions that are erroneously arranged with with respect to the others, they can increase the volume of air maintained but there is a risk of excessively weakening the mattress, causing possible tears of the same

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When it tenses.

Description of the invention

5 Therefore, the objective of the present invention is to provide a new type of layer of a material such as polyurethane, latex or the like, suitable for the formation of a mattress and to solve said technical inconveniences.

In particular, the objective of the present invention is to provide an innovative type of layer 1 which is provided with incisions arranged in the correct positions and of such sizes that optimize the aeration effect without incurring risks of tearing the mattress itself.

These and other objectives are achieved with the present layer 1 according to claim 1.

Layer 1 comprises a plurality of incisions (10) that pass through its entire thickness and arranged in succession one after another along the direction of development of the incision. They are placed at intervals of each other from a distance (dx) and form at least one line (20, 30) of incisions, preferably two or more lines of incisions parallel to each other and separated from each other by a step (dy).

Thus, in correspondence with the application of a traction (T) to the layer (1) substantially orthogonal to said line (20, 30) of incisions, the incisions open to form, each, a through opening, each having incision a predetermined length (L).

Surprisingly, it has been found that the geometries of the incisions indicated below, and their distribution, optimize the effects of aeration and durability of the layer.

In particular, the length (L) of each incision may be within a range of between 8 cm and 20 cm, preferably between 10 cm and 20 cm and even better between 15 cm and 20 cm, for example 18 cm.

The distance (dx) between an incision and the posterior, on the line, may instead be within a range of 4 cm to 10 cm, preferably between 5 cm and 8 cm, for example 6 cm.

Such sizes allow obtaining an optimal compromise between the aeration effect of the layer and the durability over time of the layer itself.

Additional advantages can be deduced from the dependent claims.

Brief description of the drawings

Additional features and advantages of the present invention will become clearer with the following description of some embodiments, made to illustrate but not limit, with reference to the attached drawings, in which:

- Figure 1 shows in an axonometric view a layer 1 suitable, for example, to form a mattress or a seating area of a seat, a cushion, a backrest and the like, provided with a plurality of incisions;

Figure 2 shows in a view from above the same figure 1 and highlights the displacement (Dx) between an incision line and the posterior line;

Figure 3 shows a part of layer 1 on which a traction T is applied in an orthogonal direction to that of the development of the incisions such that the incisions open;

-Figure 4 shows some geometric characteristics of the incisions obtained, made to optimize the durability and aeration of layer 1;

Figure 5 shows an embodiment of a mattress according to the invention,

Figure 6 shows in an axonometric view the solution of the mattress of Figure 5 in which a tear is made in layer 6 to highlight the underlying open incisions obtained in the intermediate layer 1.

Description of some preferred embodiments

According to the invention, Figure 1 shows a layer 1 of a mold casting material, such as polyurethane, polyurethane foams, latexes and the like.

65 The polyurethane material can be of any type, for example, "viscoelastic foam" or in some way any other type of viscoelastic polyurethane of different densities and supports.

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The polyurethane material is well known per se in the state of the art and is not the subject of the present application, therefore it will not be described in more detail herein.

5 Layer 1 can be geometrically of any shape and size, including thickness, length and width.

Layer 1 forms an upper surface 2 and a lower surface 3 separated from each other through the thickness of the layer itself.

10 Always as shown in Figure 1, layer 1, of a predetermined length and width, provides for a plurality of incisions distributed on its surface and passing through its entire thickness.

As described in the state of the art, such incisions, when made, are made with a type of fine blade so that the incision remains in effect closed on itself. The incisions can be opened as soon as traction is applied in an orthogonal or substantially orthogonal direction to the direction of formation of the incision itself since the two edges move away from each other.

With this aim, Figure 2 shows precisely, in a view from above, a layer of material of this type which is provided with said plurality of incisions 10. The same solution of Figure 2 shows a tension T applied to

20 the two opposite sides of the layer in an orthogonal direction to that of the incision. As a consequence, the layer 1 extends and the size of its sides 4 increases through an opening of the incisions thus forming through air ducts throughout the entire thickness of the layer itself.

Going deeper into the detail of the invention, Figure 2 shows that the incisions are arranged along rows 25 parallel to each other.

For clarity purposes, Figure 2 shows two rows 20 and 30 of incisions parallel to each other and taken as a reference.

30 Generally, as shown in Figure 2, the incision lines are offset from each other by a predetermined amount (Dx).

In particular, as shown in Figure 2, the line 20 is offset with respect to the line 30 so that an incision of the line 20 is not exactly superimposed with the incision of the line 30 but instead turns out to be only partially overlapping each other or not overlapping (depending on the sizes of the incisions and the distances between an incision and the posterior).

This type of displacement generally, but not necessarily, remains constant between one line and another alternately.

40 In this way, it is a question of obtaining a displacement so that a line, for example, line 30, is composed of incisions completely contained within surface 2 such that they leave a margin of complete material between the two incisions that they are closer to the 4 sides of the surface. The overlying and underlying line are instead displaced by an amount such as Dx such that the

45 last incisions cut sides 4 (or at least one incision cuts a side 4).

In this way, the combined effect of favoring the opening of the incisions and, therefore, the extension of the layer 1 in the direction of traction is obtained, without running the risk of excessive weakening of the layer 1 itself.

50 If, in fact, all the incisions were distributed in such a way that none of them cut an edge 4 of the layer 1, the effect of expansion of the layer 1 in the direction of traction T, after the application of a traction T of This type would be minimal with a consequent lack of opening of the incisions.

If, instead, all the lines were so that the two incisions of the ends were located at the edge, then there would be a risk of excessive expansion of the layer 1 with the risk of tearing it.

A solution such as that described represents an optimal compromise.

Having said that, it has been surprisingly found that the following additional geometries, described below, have a significant advantage in terms of aeration optimization without causing excessive weakening of the layer itself.

With particular reference to Figure 4, in order to obtain said technical effects the length (L) of the groove may be within a range of between 8 cm and 20 cm, preferably between 10 cm and 20 cm and even better than 65 between 15 cm and 20 cm.

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In particular, the incision within said range between 10 cm and 20 cm, in particular between 15 cm and 20 cm, allows optimizing the volume of air trapped in the grooves, after traction, without creating excessive weakening. Furthermore, after the alternating Dx offset in the direction of the lines (20, 30), there is at least one end groove that is located on side 4 and that alternates with a groove that is not located on side 4.

5 In this way, an optimization of the expansion of layer 1 is obtained, without the risk of tearing and with an optimized aeration effect.

For these reasons, a particularly optimal value provides for an exact length (L) of 18 cm preferably using, but not necessarily, a blade of a thickness of approximately 8 mm.

10 The offset distance Dx of the lines is generally set as half of the selected incision length L.

The distance (dx) in a line of incisions, between an incision and the posterior, can be within a range of between 4 cm and 10 cm, preferably between 5 cm and 8 cm.

A particularly optimal measure for the present objectives is, for example, 6 cm.

In particular, the optimum distance (dx) of 6 cm, with incisions of a length of approximately is cm and a displacement Dx equal to half of the length L (therefore, 9 cm) allows to optimize the results.

Distances (dx) of less than 4 cm would weaken layer 1 too much since they would result in too many incisions and too close to each other, especially if they are combined with grooves of approximately 18 cm in length.

25 The distance (dy) between a line of incisions and the posterior (that is, the passage) can be variable. In general, the step can be selected based on the material used and the extent to be obtained, always to the extent that the product does not weaken.

30 A step (dy) that can be used as a good compromise is within a range of between 3 cm and 5 cm, preferably between 4 cm and 5 cm and even better than 4 cm or 4.5 cm.

Following the structural description of the invention, the layer of Figure 1 can be assembled in different ways to form a mattress or a cushion or somehow a surface on which to extend the body or body parts 35.

In a first solution, the layer 1 is interposed between an upper layer 60 and a lower layer 60 whose objective is to keep the intermediate layer 1 in traction position, with the incisions open.

In particular, once the mattress is tensioned in such a way that the grooves are kept open, the layer 60 is fixed (for example, by adhesion), for example, to the surface 2. The layer 60 has to be a surface corresponding to that of the tensioned layer 1 and with such rigidity as to prevent the layer 1 from having an elastic return to the resting position. In this way, conformation with expanded incisions is maintained.

The layer 60 material can be the same polyurethane. By modifying the thicknesses and sizes of the layer 60, it can be obtained in such a way that it forces a permanent tension state, with the grooves open, to the layer 1 when it is adhered thereon.

The layer 60 itself may in turn be provided with a plurality of holes for aeration. Subsequently, in the same way the same layer 60 is applied, also to the opposite side 3.

Thus, according to the sectional view of Figure 6, a mattress that is perfectly breathable is obtained, since the "core" 1 is provided with such open incisions.

In the same way, a variant of the invention that is particularly important can provide for the application of layer 1 directly on a traditional spring mattress.

In this way, an extremely advantageous solution is obtained that combines the characteristics of a mattress

60 traditional springs with a foam mattress. In particular, the durability of a spring mattress is obtained in combination with the comfort effect of a foam mattress. Exactly for the case described above, the layer 1 is extended and fixed on the underlying spring mattress so that the incisions open according to the direction of traction.

65 The same can be said for other products such as cushions and seats in general.

Claims (9)

image 1 1. Layer (1) of a mold casting material, such as polyurethane, polyurethane foams, latexes and the like, for the formation of a mattress, said layer comprising a plurality of incisions (10) that pass through all their thickness and arranged in succession one after another along the direction of development of the incision and at intervals of each other from a distance (dx) such that at least one line (20, 30) of incisions is formed, preferably two or more incision lines parallel to each other and separated from each other by a step (dy) such that, in correspondence with the application of a traction (T) to the layer (1) substantially orthogonal to said line (20, 30 ) of incisions, the incisions are 10 open to form, each, a through opening, each incision having a predetermined length (L), characterized in that the length (L) of each incision is within a range of between 8 cm and 20 cm, preferably between 10 cm and 20 cm and even better between 15 cm and 20 cm, for example, 18 cm, said distance (dx) being included between intervals between the incisions (10) within a range between 4 cm and 10 cm, preferably between 5 cm and 8 cm, for example, 6 cm. fifteen 2. Layer (1) according to claim 1, wherein in the case of two or more incision lines, the passage (dy) is within a range of between 3 cm and 5 cm, preferably 4 cm. 3. Layer (1) according to claim 2, wherein the displacement (Dx) between the lines (10, 20) is equal to 20 half of the length (L) of the grooves. 4. Layer (1) according to one or more of the preceding claims, wherein said layer (1) is of a polyurethane material. A mattress or cushion comprising a layer (1) according to one or more of the preceding claims 1 to 4. 6. Mattress or cushion according to claim 5, wherein at least one layer (60) is provided, fixed to the layer (1), such that it forces the layer (1) to hold itself in one embodiment in which the slots are open. 30 7. A mattress or cushion according to claim 6, wherein an additional layer (60) is provided fixed to the opposite face of the layer (1), such that the layer (1) is comprised between the two layers (60) ). 8. Mattress or cushion according to claims 6 or 7, wherein the layer (60) is made of a polyurethane material. 35

9.

Mattress or cushion according to one or more of the preceding claims 6 to 8, wherein the layer (60) is provided with a plurality of holes for aeration.

10.

Mattress or cushion according to one or more of the preceding claims 5 to 9, wherein the layer (1) is fixed to a

The surface of a spring mattress, preferably to the surface on which the user rests, in an embodiment in which the grooves turn out to be open. 6