KR102657284B1 - Air mattress and menufacturing method thereof - Google Patents

Abstract

The present invention is provided with an air cell consisting of a plurality of air pockets that have a hollow inside and expands by air inflow or contracts by air outflow, and a frame shape with a predetermined height to maintain the air cell inside the frame. frame part; The invention relates to an air mattress having an upper cover that covers the upper surface of an air cell, a lower cover that supports the frame portion and the air cell on the upper surface, and a method of manufacturing the same.
The present invention is characterized in that the height of the frame is formed higher than the height of the air cell, thereby maintaining the upper cover inside the frame, thereby reducing the process steps and manufacturing time for fixing the upper cover to the frame.

Description

Air mattress and its manufacturing method {AIR MATTRESS AND MENUFACTURING METHOD THEREOF}

The present invention relates to an air mattress filled with air inside the mattress and a method of manufacturing the same. More specifically, it relates to an air mattress that simplifies the manufacturing process and reduces the possibility of damage during use.

In general, spring mattresses with coil springs inside are widely used as bedding mattresses. However, the shock applied to a part of a spring mattress is transmitted to the surrounding area, causing vibration, and the elasticity of the coil spring is set uniformly during manufacturing, so the user cannot arbitrarily adjust the strength of the cushion, and the elasticity of the coil spring deteriorates when used for a long period of time. There is a problem.

To compensate for these shortcomings of spring mattresses, an air mattress in which the interior of the mattress is filled with air is used, as disclosed in Patent Document 1.

Patent Document 1: Republic of Korea Patent No. 10-2130707 (2020.07.07.)

Generally, in an air mattress, air is injected to create an appropriate cushion through the air pressure formed inside. As shown in Figure 12a, this air mattress includes an air cell (1) in the form of a plurality of air pockets, a lower module assy (3) for accommodating and maintaining the air cell (1) and the lower module in an internal space, and It consists of an upper module foam (2) that covers and protects the lower module and air cell (1) from the top.

In the above-described air mattress, as shown in FIG. 12A in consideration of the level difference, the area of the upper module foam 2 is equal to the area of the upper surface of the lower module assemblies 3 located below the upper module foam 2. They are manufactured to be identical. And, as shown in FIGS. 12A and 12B, the upper module foam 2 is placed on the upper surface of the foam forming the side of the lower module assembly 3.

In order to manufacture such an air mattress, first, the lower module assembly (3) and air cell (1) having a predetermined shape are manufactured, and then the lower module and air cell (1) are installed in the internal accommodation space of the lower module assembly (3). Let it settle down. Then, after applying an adhesive such as hot melt to both the side walls of both longitudinal ends of the lower module assembly (3) and the upper surface of the side wall extending between them, the upper module foam (2) is attached to the lower module assembly (3). Cover and adhere to the upper surface.

In order to manufacture an air mattress using this method, adhesive must first be applied to all of the plurality of side walls, so it takes a long time to apply the adhesive. In addition, if the upper module form (2) is misaligned in the process of covering the upper surface of the lower module assembly (3), the upper module form (2) and lower module assembly (3) are glued together and the position cannot be corrected. This becomes impossible.

In addition, if repair is required due to a problem with the lower module mounted inside the lower module assembly (3), such as the control unit for controlling the pressure inside the air cell (1), the air pump, and the supply line, or the air cell ( If 1) is damaged and needs to be replaced, the upper module foam (2) attached to the lower module assembly (3) must be removed to access the part requiring repair or replacement. However, since the lower module assembly (3) or upper module foam (2) is generally made of PU foam or sponge foam material, in the process of removing the upper module foam (2) attached to the lower module assembly (3), Damage to the upper module foam (2) attached to the lower module assembly (3) is inevitable, and the removal process itself requires a lot of force and is not easy to work with.

Additionally, the present inventors discovered the problems shown in FIGS. 11A and 11B in addition to the problems described above in the conventional air mattress. As shown in Figure 11a, the upper module foam (2) is placed on the top of the air cell (1). The present inventors found that when a durability test of an air mattress was performed for a long period of time or was used in this state for a long period of time, a crack (b) occurred on the lower surface of the upper module foam (2), as shown in Figure 11b. . As a result of analyzing the cause, the present inventors found that when using an air mattress, frequent friction occurs between the lower surface of the upper module foam (2) of the air mattress and the upper surface of the air cell (1), and damage due to this friction occurs. It was found that cracks (b) occur due to accumulation.

The present invention was devised to solve the above problems, and its purpose is to provide an air mattress that simplifies the manufacturing process and reduces the possibility of damage during use.

An air mattress according to the present invention for solving the above problems includes an air cell formed with a hollow interior and a plurality of air pockets that expand by air inflow or contract by air outflow; A frame portion having a frame shape with a predetermined height and maintaining the air cell inside the frame; An upper cover covering the upper surface of the air cell; A lower cover supporting the frame portion and the air cell is provided on the upper surface, and the height of the frame portion is formed to be higher than the height of the air cell, so that the upper cover is maintained inside the frame.

According to the present invention described above, it is possible to position the upper cover by the frame of the frame and maintain the upper cover in that position simply by placing the upper cover inside the receiving space of the frame. Accordingly, there is no need to join the frame portion to position and fix the upper cover, thereby shortening the number of manufacturing processes and manufacturing time compared to the prior art.

Preferably, a head block form capable of supporting the user's head is provided in the space between one longitudinal end of the air cell and one side wall of the frame section, and a head block form capable of supporting the user's head is provided in the space between the other longitudinal end of the air cell and the other side wall of the frame section. The space can be equipped with a foot block form that can support the user's legs. According to the above configuration, air cells are provided in locations where the user's load is concentrated and complex control is required, but the user is supported by foam in other areas, thereby maintaining the effect of an air mattress. Costs can be reduced. And, it becomes possible to stably maintain the air cell between the foot block form and the head block form.

Preferably, the lower surface of the upper cover can be bonded to the upper surface of either the head block form or the foot block form using an adhesive. According to the above structure, it is possible to fix the upper cover more firmly. In addition, since only one longitudinal end of the upper cover is fixed with adhesive, when repair or replacement of the module inside the frame is required, the inside of the frame can be easily accessed with the upper cover flipped. Therefore, maintenance becomes easy.

Preferably, a supply line is further provided connecting the air cell and a pump for supplying air to the air cell, and the foot block foam is made of two foams spaced apart from each other in the width direction of the air mattress, 2 The space between the foams may be provided with a control unit for controlling the supply and discharge of air from the supply line to the air pocket, thereby adjusting the pressure inside the air pocket. According to the above-described configuration, it is possible to secure a space where the control unit can be located inside the frame unit, thereby increasing the usability of the internal space of the frame unit. In addition, by placing the control unit, which combines electronic equipment and an air pump, at a location far from the user's head, the user's foreign body sensation or discomfort can be reduced when the air mattress is operated.

Preferably, a control cover foam may be further provided on the upper surface of the control unit to protect the control unit. In this case, the control unit can be effectively protected from impacts applied from the upper part of the control unit, and also, the cushioning feeling of the air mattress can be prevented from being deteriorated due to the relatively hard control unit.

Preferably, a cover layer made of non-woven fabric may be attached to at least the lower surface of the upper cover that contacts the air cell. According to the cover layer made of the non-woven material described above, the influence on the upper cover due to friction generated between the upper foam of the air cell and the air cell of the upper cover can be reduced. Therefore, even when the air mattress is used for a long time, cracks in the upper cover can be prevented.

Preferably, the upper cover is formed by stacking a plurality of foams, and the uppermost foam among the plurality of foams may be composed of a replaceable topper foam that is separate from the foam below it. According to the above configuration, the user can maintain a constant cushioning feeling and cleanliness by periodically replacing the replaceable topper foam where the cushioning feeling deteriorates or becomes contaminated.

Preferably, a sheet cover covering the front of the air mattress may be further provided. In this case, contamination inside the air mattress can be prevented through the seat cover.

In order to solve the above problems, the method of manufacturing an air mattress according to the present invention includes preparing an air cell consisting of a plurality of air pockets that expand by air inflow or contract by air outflow; Preparing a lower module assembly having an open upper receiving space in the form of a pocket therein; Seating the air cell inside the receiving space; And above the air cell, inserting an upper cover to cover the receiving space into the receiving space.

Preferably, the step of inserting the upper cover into the receiving space includes applying adhesive in a single shape to a portion of the upper surface of the lower module assembly surrounding the air cell; It may include bonding an upper cover for covering the receiving space to the lower module assembly using the applied adhesive.

According to the above configuration, there is no need to join the frame portion for positioning and fixing the upper cover, or the adhesive points for fixing the upper cover can be reduced compared to the prior art, thereby shortening the number of manufacturing processes and manufacturing time. It becomes possible.

According to the air mattress and its manufacturing method according to a preferred embodiment of the present invention, the height of the frame portion supporting the lower surface of the air cell is formed to be higher than the height of the air cell, and the upper cover is fixed by maintaining the upper cover inside the frame. It is possible to reduce the number of adhesion points required to do so. Therefore, compared to the prior art, the number of manufacturing processes and manufacturing time can be reduced.

In addition, according to the air mattress according to a preferred embodiment of the present invention, a cover layer made of non-woven fabric as a release material from the upper cover is provided on the lower surface of the upper cover in contact with the air cell, so that cracks occur in the upper cover even after long-term use. You can prevent it from happening. Therefore, there is an effect of increasing the lifespan of the product and reducing the occurrence of consumer claims related thereto.

1 is an exploded perspective view showing an air cell support structure in an air mattress according to a preferred embodiment of the present invention.
Figure 2 is a perspective view showing the assembly process of an air mattress according to a preferred embodiment of the present invention.
Figure 4 is a perspective view showing an air cell applied to an air mattress according to a preferred embodiment of the present invention.
Figure 4 is a diagram schematically showing the valve connection structure of an air mattress according to a preferred embodiment of the present invention.
Figure 5a is a side cross-sectional view of an air mattress according to a preferred embodiment of the present invention.
Figure 5b is a partial enlarged view of Figure 5a.
Figure 6 is a perspective view of an air mattress according to a preferred embodiment of the present invention.
Figure 7 is a perspective view of the air mattress excluding the top cover from the perspective view shown in Figure 6.
Figure 8 is a photograph of the internal structure of an air mattress according to a preferred embodiment of the present invention.
Figure 9 is a partial enlarged view showing the seat cover portion of an air mattress according to a preferred embodiment of the present invention.
Figure 10 is a flow chart showing a method of manufacturing an air mattress according to a preferred embodiment of the present invention.
Figure 11a is a photograph of the internal structure of a conventional air mattress in its initial state of use.
Figure 11b is a photograph of a crack occurring in the upper module foam of a conventional air mattress after long-term use.
Figure 12a is a side cross-sectional view of a conventional air mattress.
Figure 12b is a partial enlarged view of Figure 12a.

The technical problems achieved by the present invention and its implementation will become clear by the preferred embodiments described below. Hereinafter, preferred embodiments of the present invention will be examined in detail with reference to the attached drawings. It should be understood that the differences between the embodiments of the present invention described below are not mutually exclusive. That is, without departing from the spirit and scope of the present invention, the specific shapes, structures and characteristics described may be implemented in other embodiments with respect to one embodiment, and the positions of individual components within each disclosed embodiment. Alternatively, it should be understood that the arrangement may be changed, and similar reference numbers in the drawings refer to the same or similar functions across various aspects, and the length, area, thickness, etc. may be exaggerated for convenience.

Figure 1 is an exploded perspective view showing the air cell support structure in an air mattress according to a preferred embodiment of the present invention, and Figure 2 is a perspective view showing the assembly process of an air mattress according to a preferred embodiment of the present invention.

As shown in the drawings, the air mattress according to a preferred embodiment of the present invention is provided with an air cell 100 consisting of a plurality of air pockets 110 and a frame shape, and has an air cell 100 inside. It is provided with a frame part 300 that holds, an upper cover 200 that covers the upper surface of the air cell 100, and a lower cover 400 that supports the frame part 300 and the air cell 100.

The lower cover 400 is a component that forms the bottom surface of the air mattress, and functions to support the frame portion 300 and the air cell 100, which will be described later, on its upper surface. The lower cover 400 may be made of square plate-shaped foam. The lower cover 400 may be made of a sponge made of natural material such as foamed rubber or a sponge made of synthetic resin such as foamed urethane.

A control unit lower foam 410 that supports the lower surface of the control unit 10 may be provided on the upper surface of the lower cover 400 at a position where the control unit 10, which will be described later, is seated. According to the above structure, the control unit 10 can be protected from impact from below the air mattress, and the lower cover 400 is prevented from being damaged due to friction between the control unit 10 and the lower cover 400. can do. In addition, a plurality of ventilation holes into which a plate and Velcro for fixing the control unit 10 are inserted may be formed near the lower foam 410 of the control unit. Through this, the control unit 10 can be more firmly maintained on the lower cover 400. Additionally, a control unit cover form 550 may be provided above the control unit 10 to cover the upper surface of the control unit 10. According to the above structure, the control unit 10 can be protected from impact from above the Ever Mattress, and damage to the sex cover 200 due to friction between the control unit 10 and the upper cover 200 is prevented. can do. In addition, the relatively hard control unit 10 can prevent the cushioning of the air mattress from deteriorating.

A frame portion 300 is mounted along the edge of the lower cover 400. In this embodiment, the frame portion 300 may be formed of four bar-shaped foams. However, it is not limited to this, and the frame portion 300 may be configured in various shapes depending on the formation of the lower cover 400. For example, if the planar shape of the lower cover 400 is pentagonal, the frame portion 300 can also be formed of five foams. In the embodiment shown in FIGS. 1 and 2, the frame unit 300 includes a foot guard form 310 that is seated on the edge of the lower cover 400 corresponding to the user's feet, and a lower cover corresponding to the user's head. It consists of a head guard form 330 seated on the edge of 400 and side guard forms 320 and 340 extending between the foot guard form 310 and the head guard form 330. The frame portion 300 forms a space for accommodating the air cells 100 therein and performs the function of maintaining the external shape of the air mattress. Like the lower cover 400, the frame portion 300 may be made of sponge of natural or synthetic material, and the frame portion 300 is bonded to the lower cover 400 using an adhesive such as hot melt. It can be.

Preferably, a head block form 540 and a foot block form 530 may be provided on the upper surface of the lower cover 400 and the inner space of the frame part 300.

Preferably, the head block foam 540 has a longitudinal foam shape extending long in the width direction of the air mattress. The head block form 540 is provided to be in contact with the inner wall of the head guard form 330 of the frame unit 300 and functions to support the user's head. Therefore, in order to provide a predetermined cushioning feeling, the head block foam 540 may be made of a sponge made of natural material or synthetic material.

Like the head block foam 540, the foot block foam 530 also has a longitudinal foam shape extending long in the width direction of the air mattress. The foot block form 530 is provided to come into contact with the inner wall of the foot guard form 310 of the frame unit 300 and functions to support the user's feet. Therefore, like the head guard foam 540, it may be made of a sponge of natural material or synthetic material to provide a cushioning feeling. More preferably, the foot block form 530 may be made of a plurality of members spaced apart from each other in the width direction of the air mattress. In addition, the control unit 10 can be positioned in the space between the foot block forms 530 that are spaced apart from each other. In this case, the usability of the internal space of the frame unit 300 can be increased by securing a space where the control unit 10 can be located. In addition, by placing the control unit 10, which combines electronic equipment and an air pump, at a position far from the user's head, the user's foreign body sensation or discomfort can be reduced when the air mattress is operated. In addition, when adopting the above structure, the control unit cover form 550 extends between the spaced apart foot block forms 530, and its upper surface is on the same plane as the upper surface of the foot block form 530. do.

An air cell bottom form 520 that supports the air cell 100 at its upper surface may be provided in the space between the head block form 540 and the foot block form 530. The air cell bottom foam 520 has the same area as the air cell 100 and may be composed of a plate-shaped foam of a predetermined thickness that can protect the air cell 100.

In addition, the air cell bottom foam 520 is provided with a concave portion 521 that extends long along its length and is recessed in the thickness direction of the air cell bottom foam 520. Therefore, the cable 15 for connecting the control unit 10 and an external input device or power source, or the supply line 12 for connecting the air cell 100 and the air pump 11, is located within the concave portion 521. It can be stored and extended along the concave portion 521 to the outside of the air mattress or to the control unit 10 and the air pump 11. To this end, the proximal end of the concave portion 521 may extend to the air pump 11 provided integrally with the control portion 10, and the tip of the concave portion 521 may extend to the head block form 540. It can be. In addition, as shown in FIG. 2, a cable holding hole 541 is formed in the head block form 540 and communicates with the gap between the concave portion 521 or the intermediate form 510 and the head guard form 330. It communicates with the cable holding hole 541, and a hole portion 331 for entering and storing the cable 15 is formed penetrating therethrough. Accordingly, the cable 15 extending from the control unit 10 may extend to the outside of the air mattress across the concave portion 521, the cable holding hole 541, and the hole portion 331.

And, by bonding the upper surface of the air cell lower foam 520 and the lower surface of the air cell 100 to each other using an adhesive such as hot melt, the air cell 100 is positioned and fixed to the upper surface of the air cell lower foam 520. . When the air cell 100 is fixed to the air cell lower form 520 in this way, as in the prior art, a male and female movement regulation member is passed through the air cell 100 and the air cell lower form 520. The process of machining a hole and inserting and fixing a movement regulating member become unnecessary. Therefore, the number of processes and manufacturing time can be reduced. Additionally, in the air mattress described above, the air cells 100 have a structure that is seated in the internal space of the frame portion 300. Therefore, since the position of the air cell 100 can be stably determined simply by seating the air cell 100 in the internal space of the frame portion 300, a deviation occurs in the position of applying the adhesive to the adhesive portion 522. Even so, it is possible to prevent the fixed position of the air cell 100 from being distorted.

More preferably, the air cell bottom foam 520 may be composed of a plurality of first air cell bottom foams 520a and second air cell bottom foams 520b arranged side by side in the width direction of the air mattress. In the case of an air mattress, the air cells 100 may be composed of two air cells separated in the width direction of the air mattress to facilitate separate control of pressure in the left and right areas in the width direction. In this case, each air cell can be adhered to the first air cell bottom form 520a and the second air cell bottom form 520b, respectively. According to the above structure, when one of the plurality of air cells is damaged, it is possible to separate and replace only the relevant air cell. In addition, when a break in the cable 15 or the supply line 12 occurs and repair is required, it is possible to separate only some of the air cells and access the relevant location, making maintenance easier.

And, in this case, the concave portion 521 may be provided in each form (520a, 520b). According to this structure, each supply line 12 extending from the air cell 100 bonded to each form 520a and 520b is received in the concave portion 521 formed in each form 520a and 520b. It can be connected to the control unit 10 along the corresponding concave portion 521. Alternatively, the supply line 12 can be accommodated in one recess, and the cable 15 extending from the control unit 10 can be accommodated in the other recess. Through this, the storage space for the supply line 12 and the cable 15 can be separated from each other, thereby making maintenance easier.

Preferably, a separate intermediate foam 510 may be provided between the air cell lower foam 520 and the lower cover 400. Through this, the cushioning feeling can be strengthened, and the air cell bottom foam 520, which maintains the cable 15 or the supply line 12 and the air cell 100, is not damaged due to friction with the lower cover 400. You can prevent it from happening. In addition, as shown in FIGS. 1 and 2, the intermediate foam 510 may be made of a plurality of foams extending in the longitudinal direction and arranged with a certain gap from each other in the width direction. In this case, a gap extending in the longitudinal direction of the air mattress is formed between the foams forming the intermediate foam 510. Therefore, in this case, instead of accommodating the cable 15 in the concave portion 521, it is also possible to accommodate it in the gap between the foams forming the intermediate foam 510.

An upper cover 200 is provided on the top of the air cell 100 to form the upper surface of the air mattress and to protect the air cell 100.

In the example shown in FIGS. 1 and 2, the top cover 200 is made by stacking an air cell top foam 210 and a replaceable topper foam 230 held on the upper surface of the air cell top foam 210.

The air cell top foam 210 is composed of a flat foam shape and functions to protect the air cell 100 by covering the upper part of the air cell 100.

The bottom surface of the air cell top foam 210 can prevent damage to the air cell 100 or the air cell top foam 210 due to friction between the air cell 100 and the air cell top foam 210. To this end, a cover layer 220 made of a non-woven material of a different type is provided with the air cell top foam 210.

This cover layer 220 is made by applying an adhesive such as hot melt to the lower surface of the air cell upper foam 210 to bond the upper surface of the cover layer 220 and the lower surface of the air cell upper foam 210. It can be fixed to the lower surface of (210). Also, like a seat cover, the cover layer 220 may be provided in the form of a cover that surrounds the entire air cell top foam 210. In the present invention, as shown in FIG. 8, there is no limitation on the attachment type as long as there is a cover layer made of non-woven fabric between the air cell top foam 210 and the air cell 100.

According to the cover layer 220 made of the non-woven material described above, the impact on the upper cover 200 due to friction occurring between the air cell top foam 210 and the air cell 100 of the upper cover 200 can be reduced. You can. Therefore, according to the inventor's own durability test results, it was confirmed that cracks did not occur in the upper cover 200 even when the air mattress was used for a long time.

The replaceable topper form 230 is composed separately from the air cell top form 210 to facilitate replacement by the user, does not use adhesive, and is configured to be placed on the air cell top form 210. You can. Accordingly, the user can maintain a constant cushioning feeling and cleanliness by periodically replacing the replaceable topper foam 230 where the cushioning feeling has deteriorated or is contaminated.

As shown in FIG. 9 and the like, the air mattress may include a sheet cover that entirely covers the support structure of the air cell 100 also shown in FIG. 1. The seat cover may preferably be made of natural material or synthetic resin material. And, as shown in FIG. 9, the seat cover may include an upper seat cover 610 and a lower seat cover 620. The upper sheet cover 610 is manufactured in the form of a plate with a certain area so that it can cover the upper surface of the air mattress. The lower seat cover 620 is manufactured in a shape including a plate shape with a certain area and a band shape extending along the edge of the plate shape so as to cover the bottom and side surfaces of the air mattress. The upper seat cover 610 and the lower seat cover 620 are detachably connected to each other by a first zipper portion 630 extending along the edge. And, as shown in FIG. 9, a second zipper portion 640 extending in the vertical direction is provided on the strip-shaped portion constituting the side surface of the lower seat cover 620. The second zipper portion 640 is positioned to extend in a direction transverse to the hole portion 331 formed in the frame portion 300 when the seat cover 600 is mounted. Therefore, when the second zipper portion 640 is opened to a predetermined height, it becomes possible to pull out the cable 15 from the hole portion 331 to the outside through the open space. In addition, when the air mattress is not in use, the cable 15 is stored in the inner space of the hole 331 of the frame part 300 and the second zipper part 640 is closed all the way, so that the cable 15 is exposed to the outside. It is possible to prevent this from happening and stably maintain the cable 15 inside the frame portion 300. Therefore, it is possible to provide the user with a sense of aesthetics and aesthetic unity, and when moving the air mattress, the cable 15 is stored inside the frame part 300 and then moved with the second zipper part 640 closed, so that the cable 15 is moved in a closed state. (15) can prevent damage from hitting or rubbing against the floor surface.

Figure 3 is a perspective view showing an air cell applied to an air mattress according to a preferred embodiment of the present invention.

As shown in FIG. 3, the air cell 100 may include a plurality of air pockets 110 and a lower plate 120. Each of the air pockets 110 has a hollow interior formed therein and expands due to air inflow or contracts due to air outflow. The pressure of the air filled in the air pocket 110 receives and supports the user's load when the user lies down on the air mattress. When air is supplied to the air pocket 110, the air pocket 110 expands. When adjacent air pockets 110 expand and come into contact with each other, the formation of pressure to be formed by each air pocket 110 is inhibited. Therefore, the plurality of air pockets 110 are arranged at regular intervals between adjacent air pockets 110 so that each air pocket 110 does not contact each other. And adjacent air pockets 110 may be in air communication with each other through a connection passage connecting the air pockets 110. When the air pockets 110 connected to each other through the connection flow path are configured as a group and the air cells 100 are formed in a plurality of groups, the air flow rate supplied to each group is separately controlled, so that the air pockets in each group It is possible to independently control the air pressure of 110. Accordingly, in the air cell 100, it is also possible to control the air pressure in a specific area (for example, an area corresponding to the user's upper body) to be higher than the air pressure in other areas excluding this area. Therefore, the pressure of a plurality of areas on the air cell 100 can be independently controlled depending on the intended use.

The lower plate 120 is coupled at the lower side of the plurality of air pockets 110 to shield the hollow portion of the air pocket 110. As shown in FIG. 4, the lower plate 120 may have a plate shape with a predetermined area. As shown in FIG. 5, a nozzle 130 may be formed on the lower plate 120 for supplying and discharging air to the air pocket 110. Preferably, on the lower plate 120, a plurality of air pockets 110 are arranged in each of the horizontal and vertical directions to form a plurality of rows and columns to form one air cell 100.

Figure 4 is a diagram schematically showing the valve connection structure of an air mattress according to a preferred embodiment of the present invention.

Referring to Figure 4, the air mattress is a structure for supplying air into the air cell 100, and includes a control unit 10, an air pump 11, a nozzle 130, and supply lines 12-1 to 12-4. ), pressure sensor 13, and valve 14.

The control unit 13 is located on the lower cover 400 and is connected to the valve 14, the pressure sensor 13, and the air pump 11, and is connected to the pressure of the air pocket 110 measured by the pressure sensor 13. Accordingly, the on/off of the valve 14 and the operation of the air pump 11 can be controlled. Through this, the control unit 13 can adjust the pressure inside the air pocket 110. For example, in the example shown in FIG. 5, the control unit 13 may adjust the pressure of a plurality of air pockets 110 located in each of the first to fourth zones.

The nozzle 130 may be an injection port that supplies and discharges air into the air pocket 110. The nozzle 130 may be installed on the lower plate 130 to supply or discharge air to the air pocket 110. In addition, one or more nozzles 14 may be formed in each zone of the first to fourth zones. As the nozzle 14 is formed for each zone, the pressure inside the air pocket 110 can be controlled for each zone of the air cell 100.

The supply line 12 connects the valve 14 and the nozzle 130 and forms a line through which air can pass. One end of the supply line 12 is connected to the nozzle 130, and the other end is connected to the valve 14. A plurality of supply lines 15 may be provided, and each supply line 12 may be connected to the nozzle 130 and valve 14 for each zone of the air cell 100. For example, the first supply line 12-1 connects the nozzle 130 provided in the first zone and the corresponding first valve 14-1. Air is supplied into the air pocket 110 and air is discharged from the air pocket 110 through the supply line 12.

The valve 14 can control the amount of air supplied from the air pump 11 to the air pocket 110 and the amount of air discharged from the air pocket 110. Preferably, the valve 14 may be a solenoid valve that operates by receiving control duty from the control unit 10. The valve 14 may be provided as many as the number of zones in the air cell 100 and connected to each supply line (12-1 to 12-4) connected to each zone. By independently opening or closing the plurality of valves 14, the amount of air supplied to each zone of the air cell 100 can be independently controlled.

The pressure sensor 13 can measure the pressure inside the air pocket 110. Like the valve 14, the pressure sensor 13 may be provided as many as the number of zones in the air cell 100 and connected to each supply line 12-1 to 12-4 connected to each zone. The pressure of the current air pocket 110 in each zone is detected through the measurement result of the pressure sensor 13, and the control unit 10 controls the valve 14 according to the detected result, so that the pressure in each zone is set to the target pressure. Control to satisfy the value.

The air pump 11 supplies air to the air cell 100 through supply lines 12-1 to 12-4. Preferably, the air pump 11 may be mounted inside the same assembly as the control unit 10 and be integrated with it. The air pump 11 may use a known pump device. The air pump 11 is connected to the control unit 10 and is turned on/off by a control signal from the control unit 10.

Hereinafter, in the air mattress according to a preferred embodiment of the present invention, the structure for fixing the upper cover 200 to the frame portion 300 will be described in more detail with reference to FIGS. 5A to 7.

Figure 5a is a side cross-sectional view of an air mattress according to a preferred embodiment of the present invention, Figure 5b is a partial enlarged view of Figure 5a, Figure 6 is a perspective view of an air mattress according to a preferred embodiment of the present invention, and Figure 7 is, The perspective view shown in Figure 6 is a perspective view of the air mattress excluding the top cover.

As shown in FIGS. 5A and 7, the area of the upper cover 200 when the upper cover 200 is viewed from above is the area of the frame portion 300 when the frame portion 300 is viewed from above. The upper cover 200 is formed to be substantially equal to the area formed by the inner edges of the foot guard form 310, the head guard form 330, and the side guard form 320.

And, as shown in FIG. 5A, the frame portion 300 is formed so that the height direction position of the upper surface of the frame portion 300 is higher than the height direction position of the air cell 100 when the air mattress is viewed from the side. do.

Accordingly, when the upper cover 200 is seated above the air cell 100, the upper cover 200 is seated within the inner space of the frame portion 300, and the edge of the upper cover 200 is aligned with the frame portion 300. ) is configured to contact the inner surface of the foot block form 310, head guard form 330, and side guard form 320.

In addition, preferably, when the upper cover 200 is seated on the upper surface of the air cell 100, a step is not generated between the upper cover 200 and the upper surface and the upper surface of the frame portion 300, as shown in Figures 5A and 5A. As shown in FIG. 5B, when the air mattress is viewed from the side, the height direction position of the upper surface of the frame portion 300 is set to match the height direction position of the upper surface of the upper cover 200.

According to the above structure, the position of the upper cover 200 can be determined in the correct position by the frame portion 300 simply by seating the upper cover 200 in the inner space of the frame portion 300, and the frame portion 300 can be positioned in the correct position. By 300, the upper cover 200 can be stably maintained in the corresponding position. Accordingly, there is no need for separate fixing to maintain the separate upper cover 200 on the frame portion 300. Therefore, compared to the conventional example shown in FIGS. 12A and 12B, the number of processes or manufacturing time for manufacturing an air mattress can be reduced.

In addition, even if a problem occurs in the control unit 10, air pump 11, or supply line 12 located inside the frame unit 300, or if the air cell 100 is damaged and replacement is required, After removing the seat cover 600, it is possible to access the damaged or replacement part by simply grasping one end of the upper cover 200 and separating it from the frame part 300. Therefore, the maintenance work of the air mattress can be simplified and the time for maintenance can be reduced.

In addition, according to a preferred embodiment of the present invention, even when forming an adhesive portion (a) to more firmly maintain the upper cover 200 on the frame portion 300, as shown in FIG. 7, it is different from the conventional example. By comparison, it is possible to reduce the number of adhesion positions.

In the example shown in FIG. 7, a single-shaped adhesive portion (a) extending along the width direction of the air mattress is shown on the upper surface of the head guard form 540 mounted inside the frame portion 300. As described above, the upper cover 200 is maintained in its position by the frame formed by the frame portion 300, and an adhesive portion (a) is formed at one location above the head guard form 540 and the upper cover 200 It is possible to more firmly maintain the upper cover 200 on the frame portion 300 simply by adhering the lower surface of one longitudinal end of the cover 200 and the upper surface of the head guard form 540 to each other.

Additionally, in this case, other parts of the upper cover 200 except for the part glued to the upper surface of the head guard form 540 are not fixed to the frame portion 300 or other modules held on the frame portion 300. It is configured to be freely detachable.

If a problem occurs in the control unit 10, air pump 11, and supply line 12 mounted inside the frame unit 300, or if the air cell 100 needs to be replaced, it is not adhered by the adhesive portion (a). It is possible to access the inside of the frame portion 300 simply by grasping and lifting the other end of the upper cover 200 by hand. Therefore, even when the upper cover 200 is fixed using the adhesive portion (a), maintenance can be easily performed.

In addition, even in this case, since the adhesive portion (a) is only at one location, processing steps and manufacturing time can be reduced compared to the conventional example in which the adhesive portion needs to be formed at multiple locations.

Figure 9 is a flow chart showing a method of manufacturing an air mattress according to a preferred embodiment of the present invention. Hereinafter, a method for manufacturing an air mattress according to a preferred embodiment of the present invention will be described in detail with reference to FIG. 9.

First, as shown in FIG. 9, an air cell 100 is prepared (S10). Preferably, the air cell 100 may be manufactured through a vacuum forming process. For example, the air cell 100 can be manufactured by heating and stretching the film provided from the film providing device, vacuum forming the film into a desired shape using a vacuum forming device, and cutting the formed film through post-processing. there is.

Next, prepare the lower module assembly (S20). Here, the lower module assembly is a general term for modules mounted inside the frame portion 300, lower cover 400, and frame portion 300 excluding the upper cover 200 and the air cell 100.

When manufacturing the lower module assembly, first apply an adhesive such as hot melt to the upper edge of the floor form (400), and then attach the foot guard form (310), head guard form (330), and side guard form (320, 340). Adhere. Next, the foot block form 340, the head block form 540, and the control unit bottom form 410 are each attached to positions on the lower cover 400 illustrated in FIG. 2 using adhesive. Then, the control unit 10 is placed on the bottom foam 410 of the control unit, and the control unit cover foam 550 is covered on the top of the control unit 10. Then, the middle foam 510 and the air cell bottom foam 520 are sequentially stacked between the foot block form 340 and the head block form 540.

When the lower module assembly is prepared, the air cell 100 is seated inside the receiving space of the lower module assembly (S30). In the example shown in Figure 2, the accommodation space of the lower module assembly is formed by the inner surfaces of the side guard forms 320 and 340 on both sides and the inner surfaces of the foot block form 340 and the head block form 540. It is space. Before seating the air cell 100, an adhesive such as hot melt is first applied to the upper surface of the air cell lower foam 520 at a plurality of locations. Then, after connecting the nozzle 130 formed in the air cell 100 and the valve 14 provided in the control unit 10 by the supply line 12, the air cell 100 is connected to the frame unit 300 from above. It is lowered inside, and the upper surface of the air cell lower foam 520 and the lower surface of the air cell 100 are adhered.

After seating the air cell 100, adhesive is applied to the upper surface of the head guard form 540 mounted inside the frame portion 300 to form an adhesive portion (a) extending along the width direction of the air mattress. A ruler-shaped adhesive portion (a) is formed (S40).

After forming the adhesive portion (a), the upper cover 200 is inserted into the receiving space of the frame portion 300, and the lower surface of the upper cover 200 and the upper surface of the head guard form 540 are connected using the adhesive portion (a). Join them together (S50). At this time, other areas of the upper cover 200 other than the area fixed by the adhesive portion (a) are not adhered and remain separated from other components. Preferably, in this state, the manufacturing of the air mattress is completed by covering the front of the air mattress with a sheet cover.

In addition, the position of the upper cover 200 can be maintained by the frame portion 300, so step S40 of forming the adhesive portion (a) is omitted, and the upper cover 200 is placed in the inner space of the frame portion 300. An air mattress may be manufactured by covering the seat cover 600 with the inserted state.

Although representative embodiments of the present invention have been described in detail above, those skilled in the art will understand that various modifications can be made to the above-described embodiments without departing from the scope of the present invention. . Therefore, the scope of the present invention should not be limited to the described embodiments, but should be determined not only by the claims described later but also by equivalents to the claims.

1: Air Cell 2: Upper Module Foam
3: Lower module assembly 10: Control section
11: air pump 12: supply line
13: pressure sensor 14: valve
100: air cell 110: air pocket
120: lower plate 200: upper cover
210: Air cell top foam 220: Cover layer
230: Replaceable topper form 300: Frame part
310: Foot guard form 320,340: Side guard form
330: Head guard form 400: Lower cover
410: Control unit bottom form 510: Middle form
520: Air cell bottom form 521: Concave portion
530: Foot block form 540: Head block form
541: Cable holding hole 550: Control unit covering form
600: Seat cover

Claims (10)

An air cell composed of a plurality of air pockets that are hollow inside and expand by air inflow or contract by air outflow;
a frame portion having a frame shape with a predetermined height and maintaining the air cell inside the frame;
an upper cover covering the upper surface of the air cell;
A lower cover is provided on the upper surface to support the frame portion and the air cell,
The height of the frame portion is formed to be higher than the height of the air cell, so that the upper cover is maintained inside the frame,
A head block form capable of supporting the user's head is provided in the space between one longitudinal end of the air cell and one side wall of the frame portion,
A foot block form capable of supporting the user's legs is provided in the space between the other longitudinal end of the air cell and the other side wall of the frame portion,
Further comprising a supply line connecting the air cell and a pump for supplying air to the air cell,
The foot block foam is made of two foams spaced apart from each other in the width direction of the air mattress,
In the space between the two foams, a control unit is provided to control air supply and air discharge from the supply line to the air pocket, thereby adjusting the pressure inside the air pocket,
An air mattress, characterized in that the lower surface of the upper cover is joined to the upper surface of the head block form with an adhesive. delete delete delete In claim 1,
An air mattress further comprising a control cover foam on the upper surface of the control unit to protect the control unit. In claim 1,
An air mattress, wherein a cover layer made of non-woven fabric is attached to at least the lower surface of the upper cover that is in contact with the air cell. In claim 1,
The upper cover is formed by stacking a plurality of foams,
An air mattress, wherein the uppermost layer of the plurality of foams is composed of a replaceable topper foam that is separate from the lower foam. In claim 1,
An air mattress further comprising a sheet cover covering the front of the air mattress. Preparing an air cell consisting of a plurality of air pockets that expand by air inflow or contract by air outflow;
Preparing a lower module assembly having an open upper receiving space in the form of a pocket therein;
Seating the air cell inside the receiving space; and
Above the air cell, inserting an upper cover to cover the receiving space into the receiving space,
The lower module assembly is,
a frame portion having a frame shape with a predetermined height and maintaining the air cell inside the frame;
A lower cover is provided on the upper surface to support the frame portion and the air cell,
A head block form capable of supporting the user's head is provided in the space between one longitudinal end of the air cell and one side wall of the frame portion,
A foot block form capable of supporting the user's legs is provided in the space between the other longitudinal end of the air cell and the other side wall of the frame portion,
Further comprising a supply line connecting the air cell and a pump for supplying air to the air cell,
The foot block foam is made of two foams spaced apart from each other in the width direction of the air mattress,
In the space between the two forms, a control unit is provided to control air supply and air discharge from the supply line to the air pocket, and to adjust the pressure inside the air pocket,
In the step of adhering the upper cover and the lower module assembly,
A method of manufacturing an air mattress, characterized in that the lower surface of the upper cover is bonded to the upper surface of the head block form of the lower module assembly with an adhesive applied to the upper surface. delete