KR20230146350A - Double-layer cushion module for mattress and Customized foam mattress using the same - Google Patents

Abstract

The present invention relates to a cushion module for a mattress to support the lower part of the mattress and provide individual cushioning force according to the load of each part of the body. The main body part is made of polyurethane foam and has a two-stage structure divided into a lower part and an upper part. For a mattress including a top plate coupled to the upper part of the main body and supporting the upper part of the mattress, a lower cover configured to receive and cover the lower part of the main body, and an upper cover configured to cover at least a portion of the upper part of the main body. A two-stage cushion module is provided.

Description

Double-layer cushion module for mattress and Customized foam mattress using the same}

The present invention relates to a cushion module for a mattress, and more specifically, to a two-stage cushion module for a mattress and a customized foam mattress using the same.

As is well known, in the past, bed mattresses made by foreign bed companies that advertised 'unmoving comfort' have become very popular, and recently, bed mattresses with built-in pocket springs have become the mainstream of the bed market. The advantage of bed mattresses with these pocket springs (see Registered Utility Model Publication No. 20-0372690, No. 20-0278881, and No. 20-0489616) is that they are less likely to shake even when the person next to them moves and noise caused by the spring is less. In addition, the seating and cushioning are good and there is little external change even when used for a long period of time, so user satisfaction is high.

Generally, a pocket spring has a coil spring built into a pocket made of fabric such as non-woven fabric. In the case of bed mattresses including these pocket springs, in addition to the many advantages described above, a number of problems are raised. Looking at them in detail, they are as follows.

In the case of a bed mattress with built-in pocket springs, it is necessary to provide means for binding the upper and lower parts of the pocket springs, respectively, in order to fix a plurality of pocket springs arranged in a checkerboard shape on the plane (Public Utility Model Publication No. 20-2019 -See number 0000889). Therefore, there is a problem that the internal configuration of the mattress becomes extremely complicated.

In addition, the pocket spring has a hard steel spring built inside, so if the upper sheet is thin or the number of layers is small, a hard feeling may be transmitted to the user, causing discomfort. Therefore, in order to prevent the user from feeling uncomfortable when lying on the bed, thicker or more sheet layers must be stacked, which causes a problem of increased material costs.

Moreover, in the case of mattresses with built-in pocket springs, most of the pocket springs built into one product have the same spring hardness, which has the disadvantage of not providing appropriate load distribution according to the load or shape characteristics of each body part of the user. .

Accordingly, the present invention was developed to solve the above problems, and provides a two-stage cushion module for a mattress for appropriate load distribution according to the load or shape characteristics of each body part of the user and a customized foam mattress using the same. The purpose.

According to one form of the present invention for achieving the above object, it is a cushion module for a mattress to support the lower part of the mattress and provide individual cushioning force according to the load of each part of the body, and is composed of polyurethane foam and has a lower part and an upper part. A main body part of a two-stage structure divided into parts, a top part coupled to the upper part of the main body part to support the upper part of the mattress, a lower cover configured to accommodate and cover the lower part of the main body part, and at least a part of the upper part of the main body part. A two-stage cushion module for a mattress including a top cover configured to cover is provided.

According to the present invention, the upper plate, lower cover, and upper cover are characterized by being made of rubber material, silicone material, or synthetic resin material.

Preferably, the lower part and the upper part have different areas and thicknesses or different hardness and density, wherein the lower part has a relatively large diameter (or cross-sectional area) and thickness or relatively high hardness and density, The upper portion is characterized by having a relatively small diameter (or cross-sectional area) and thickness or relatively low hardness and density.

According to the present invention, the upper cover is configured to extend downward from the top of the upper part of the main body to cover the circumference of the upper part, the surface of the upper cover is made of wrinkles, and a threaded part for coupling the upper plate to the upper end. It is characterized by the formation of .

According to the present invention, the upper plate is characterized in that a fastening part that is screwed to the upper part of the upper cover is formed on the bottom surface, and an embossed protrusion for providing an acupressure effect is formed on the upper surface.

From the above-described features, the present invention can reduce the manufacturing cost of the mattress and maximize durability by configuring the density and hardness of each part of the foam mattress differently, and can also customize the load according to the load or shape characteristics of each body part of the user. By configuring it to allow for dispersion, it is possible to provide a more comfortable and comfortable sleep.

1 is an exploded perspective view of a two-stage cushion module for a mattress according to the present invention;
Figure 2 is a cross-sectional view showing the assembled state of the two-stage cushion module for the mattress of Figure 1;
Figure 3 is a cross-sectional view showing the operating state of the two-stage cushion module for the mattress of Figure 1;
Figure 4 is a process chart showing the construction state of the two-stage cushion module for the mattress of Figure 1 and the assembly process of the mattress using the same;
Figure 5 is a plan view showing a first embodiment of the foam mattress of the present invention according to the arrangement of the two-stage cushion module for the mattress of Figure 1 by type;
Figure 6 is a plan view showing a second embodiment of the foam mattress of the present invention according to the arrangement of the two-stage cushion module for the mattress of Figure 1 by type.

Hereinafter, the present invention will be described in more detail through the attached drawings and examples.

In the following examples, illustrations and descriptions are omitted except for essential parts in explaining the invention, and throughout the specification, identical and similar elements are assigned the same reference numerals and detailed descriptions thereof are omitted without repetition. do.

The present invention is to provide a foam mattress that can distribute the load in a customized manner according to the load or shape characteristics of each body part of the user. As a basic element for constructing such a customized foam mattress, the present invention includes a two-stage cushion module for the mattress. provided.

Figure 1 is an exploded perspective view of a two-stage cushion module for a mattress according to the present invention, and Figure 2 is an assembled cross-sectional view of the two-stage cushion module for a mattress of Figure 1. As shown, the two-stage cushion module for a mattress (1) is a part of the mattress. It is arranged at regular intervals under the upper layer (M ₂ ...) and is provided in a configuration to provide a two-stage cushioning function according to the weight of each part of the user's body.

This two-stage cushion module (1) for a mattress is made of a polyurethane foam material and has a lower part (11) with a relatively large diameter (or cross-sectional area) and an upper part (12) with a relatively small diameter (or cross-sectional area). A main body 10, a top plate 20 coupled to the upper part of the main body 10 to support the upper part of the mattress (M ₂ ...), and a lower part 11 of the main body 10 are accommodated. It is composed of a lower cover 30 configured to cover and an upper cover 40 configured to cover at least a portion of the upper portion 12 of the main body 10.

The upper plate 20, lower cover 30, and upper cover 40 are intended to maintain the function and shape of each part of the main body 10 made of polyurethane foam, and are made of rubber, silicone, or synthetic resin. It may be composed of the same material.

Among the configurations of the two-stage cushion module 1 of the present invention, the main body 10 may be configured so that the lower part 11 and the upper part 12 have different areas and thicknesses, and the lower part 11 and the upper part 12 may be configured to have different areas and thicknesses. The upper portion 12 may have different hardness and density so as to have different cushioning forces. For example, the hardness and density of the upper portion 12 may be configured to be low, while the hardness and density of the lower portion 11 may be configured to be high. In this case, when the user lies down on the foam mattress, the hardness and density of each part of the body may be adjusted. Only the upper portion 12 of the main body 10 may be compressed, or the upper portion 12 may be compressed first and then the lower portion 11 may be compressed sequentially.

The lower part 11 of the main body 10 is received in a full state inside the lower cover 30. For this purpose, the lower cover 30 has a space 31 therein for accommodating the lower part 11 of the main body 10, and the upper part 12 of the main body 10 is located in the center of the upper surface. An opening 32 is provided for passage.

The top cover 40 is configured to cover at least a portion of the upper portion 12 of the body portion 10, preferably extending downwardly from the top of the upper portion 12 and the perimeter of the upper portion 12. The surface of the upper cover 40 may be composed of wrinkles 41, and the upper portion may be composed of a threaded portion 42 for coupling the upper plate 20.

The upper plate 20 has a fastening portion 22 extending from the bottom for screwing with the upper end of the upper cover 40, and the entire upper surface of the upper plate 20 has embossed projections (acupressure projections 21) to provide an acupressure effect. ) can be formed in large numbers at regular intervals.

Figure 3 shows the operating state of the two-stage cushion module for the mattress of Figure 1. When the user's body weight (P) is applied to the mattress (M ₂ ...), the main body part of the two-stage cushion module moves downward. It is compressed, and at this time, the compression action occurs first in the upper part of the main body, and then compression occurs in the lower part.

In addition, depending on the weight of each part of the body, only the upper portion 12 of the main body 10 may be compressed, or the upper portion 12 may be compressed first and then the lower portion 11 may be compressed sequentially, e.g. For example, in the case of limbs or head parts that weigh less in each part of the user's body, compression may occur only in the upper part of the main body unit 10, and in general, the upper body or buttocks parts that weigh a lot are compressed by the body part 10. In addition to the upper portion 12 being compressed, the lower portion 11 may be further lowered and compressed. In this case, the compression action of the main body portion 10 may be performed in the order that the upper portion 12 is compressed first and then the lower portion 11 is compressed. When the lower part 11 of the main body 10 is compressed, a portion of the upper part 12 of the main body 10 enters the inside of the lower cover 30 through the opening 32 as shown in FIG. 3. You can enter.

Meanwhile, when the upper part 12 of the main body 10 is compressed, a contraction action occurs simultaneously in the upper cover 40 surrounding the upper part 12. At this time, the wrinkles of the upper cover 40 (41) is contracted together to the same height as the upper part 12 was compressed, and when the upper part 12 is restored to its original state, it is simultaneously stretched to its original length. In order to enable the smooth expansion and contraction of the wrinkles 41, it may be desirable for the upper cover 40 to make at least the wrinkles 41 a soft and flexible material.

Figure 4 is a process diagram showing the construction state of the two-stage cushion module for the mattress of Figure 1 and the assembly process of the mattress using the same. The two-stage cushion module (1) for the mattress of the present invention is the upper layer (M ₂ ...) of the mattress. It is installed uniformly at regular intervals in the horizontal and vertical directions over the entire area of the lower layer (M ₁ ) located below.

In this case, the two-stage cushion module 1 is molded so that the main body 10 is formed integrally with the lower layer M ₁ during the polyurethane foaming process, or is formed uniformly on the surface of the lower layer M ₁ in the horizontal and vertical directions. It can also be installed by forming grooves (not shown) at regular intervals and mounting each cushion module 1 in these grooves.

By placing the upper layers (M ₂ ...) of the mattress on the two-stage cushion modules (1) of the present invention installed in this way and finishing the exterior, a customized foam mattress with a built-in two-stage cushion module of the present invention can be completed. there is. For this purpose, the upper layer (M ₂ ...) of the mattress is preferably made of polyurethane foam.

Next, various embodiments of the foam mattress of the present invention according to the arrangement of each type of the above-described two-stage cushion module for the mattress are illustratively shown and explained.

Figure 5 is a plan view showing a first embodiment of the foam mattress of the present invention according to the arrangement of the two-stage cushion module for the mattress of Figure 1 by type. As described above, the two-stage cushion module (1) for the mattress shown in Figure 1 The foam mattress of the present invention can be configured by forming it integrally with a foam mattress made of polyurethane or by installing it in a plurality of grooves in the lower layer of the mattress (M ₁ ).

This foam mattress uses a two-stage cushion module (1) installed on the lower layer of the mattress (M ₁ ) to determine the hardness and density of the upper and lower parts (12) (11) of the main body (10; see Figure 1) at each position on the mattress. can be configured to vary, allowing customized load distribution according to the load or shape characteristics of each body part of the user.

Referring to Figure 5, the middle part (S ₁ ) of the foam mattress, where the weight of each part of the body is applied when a person lies down, is the density (Density) of the main body 10 constituting the two-stage cushion module 1 of Figure 1. It is possible to configure the main body 10 of the two-stage cushion module 1 to have high density and low hardness in the surrounding portion (S ₂ ). In addition, since a person may sit on the edge portion (S ₃ ) in some cases, the density and hardness of the main body portion (10) of the two-stage cushion module (1) are set to the same or higher than the center portion (S ₁ ). It may be desirable.

Illustratively, the main body 10 of the two-stage cushion module 1 has an upper part 12 in the middle part (S ₁ ) of the foam mattress with a density of 42 kg/㎥ (±1 to 2) and a hardness of 5 (± When using polyurethane foam of 1~2), the lower part 11 can use polyurethane foam with a density of 60 kg/㎥ (±1~2) and a hardness of 14 (±1~2).

In addition, the main body portion 10 of the two-stage cushion module 1 has an upper portion 12 of the peripheral portion S ₂ of the foam mattress with a density of 42 kg/㎥ (±1 to 2) and a hardness of 5 (±1 to 2). When using the polyurethane foam of 2), the lower part 11 can use polyurethane foam with a density of 50 kg/㎥ (±1 to 2) and a hardness of 13 (±1 to 2).

Here, the hardness values of the upper part 12 and the lower part 11 represent Rockwell hardness, and the standards for calculating the hardness values of the upper part 12 and the lower part 11 are as follows. .

First, place a flat test piece on the target of the testing machine, place a circular pressure plate on the top of the test piece, apply a load of 0.5 kg in advance, and define the thickness of the test piece at this time as the initial thickness. Next, as a preliminary pressurization, the circular pressure plate was compressed to 75% of the initial thickness at a speed of 50 mm/min, the load was immediately removed, and the load was measured after compressing it again to 25% of the initial thickness and stopping in that state for 20 seconds. It is decided.

In other words, the determined hardness value represents the load when 50 mm thick polyurethane foam is compressed to 25% of the initial thickness with a circular pressure plate with a diameter of 20 cm at a speed of 50 mm/min, and the unit is kg/314 cm2. Therefore, hardness 1 corresponds to 1kg/314cm2, hardness 5 corresponds to 5kg/314cm2, and hardness 14 corresponds to 14kg/314cm2.

In this way, the upper part 12 and the lower part 11 of the main body 10 of the two-stage cushion module 1 use polyurethane foams that have very large differences in density and hardness values, respectively. In this case, The upper part 12 uses polyurethane foam, which is much softer than the lower part 11, while the lower part 11 uses polyurethane foam, which is much harder than the upper part 12.

In this configuration, when the user lies down on the mattress and puts weight on the upper layer (M ₂ ...) of the mattress, the upper part (12), which is a soft part, is compressed first, and the lower part (12), which is a hard part, is compressed first. It uses the principle of a two-stage cushion according to the laws of physics in which the compression of 11) is performed later, and through this, the cushioning force of the upper layer (M ₂ ...) of the foam mattress itself and the cushioning force of the cushion modules (1) located at the bottom are used. However, the cushioning action enables appropriate load distribution according to the weight or shape characteristics of each body part of the user, allowing the user to sleep more comfortably and comfortably.

Figure 6 is a plan view showing a second embodiment of the foam mattress of the present invention according to the arrangement of the two-stage cushion module for the mattress of Figure 1 by type, and the central portion (S _1-1 ) of the foam mattress is a two-stage cushion module (1) ) of the main body 10 has the highest density and hardness, and the surrounding cross (+) part (S _1-2 ) has the main body of the two-stage cushion module 1 ( 10), the density and hardness are set to a medium level, and the outer edge portion (S _1-3 ) can be configured to have the lowest density and hardness of the main body 10 of the two-stage cushion module (1). Of course, as in Figure 5, since a person may sit on the edge portion (S ₃ ) in some cases, the density and hardness of the main body portion (10) of the two-stage cushion module (1) are measured in the central portion (S _1-1 ) of the foam mattress. ) or it may be desirable to consist of the same or more than the tens (+) character part (S _1-2 ).

Illustratively, the main body 10 of the two-stage cushion module 1 in the central portion (S _1-1 ) of the foam mattress has a density of 50 kg/㎥ (±1 to 2) and a hardness of 13 (±1 to 2). It is constructed using polyurethane foam, and the main body 10 of the two-stage cushion module 1 in the surrounding ten (+) part (S _1-2 ) has a density of 30 kg/㎥ (±1~2). ), and is constructed using polyurethane foam with a hardness of 15 (±1~2), and the main body (10) of the two-stage cushion module (1) at the outer edge (S _1-3 ) has a density of 20 kg/㎥ ( ±1~2) and can be constructed using polyurethane foam with a hardness of 15 (±1~2). In this case, since people may sometimes sit on the edge portion (S ₃ ) of the foam mattress, the main body (10) of the two-stage cushion module (1) has a density of 40 kg/㎥ (±1 to 2) and a hardness of 20 (± It may be desirable to construct it using the polyurethane foam of 1-2).

Although various embodiments of the present invention have been described above, the contents described so far are merely illustrative of some of the preferred embodiments of the present invention, except as may appear in the claims attached below. It is not limited by the above. Accordingly, those skilled in the art will understand that many changes, modifications and substitutions of the present invention can be made without departing from the technical spirit and gist of the invention within the scope set forth in the claims below. It will have to be done.

1: Two-stage cushion module for mattress
10: main body
11: lower part
12: upper part
20: top part
21: embossing protrusion
22: fastening part
30: lower cover
31: space part
32: opening
40: top cover
41: wrinkle part
42: threaded part

Claims (5)

A cushion module for a mattress that supports the lower part of the mattress and provides individual cushioning force according to the load of each part of the body,
A two-stage main body made of polyurethane foam and divided into a lower part and an upper part,
A top plate portion coupled to the top of the main body portion to support the upper layer of the mattress,
a lower cover configured to receive and cover the lower portion of the main body portion,
and a two-stage cushion module for a mattress including an upper cover configured to cover at least a portion of the upper portion of the main body portion. According to clause 1,
A two-stage cushion module for a mattress, characterized in that the upper part, lower cover, and upper cover are made of rubber material, silicone material, or synthetic resin material. According to clause 1,
The lower part and the upper part have different areas and thicknesses or different hardness and density, wherein the lower part has a relatively large diameter (or cross-sectional area) and thickness or relatively high hardness and density, and the upper part has a relatively large diameter (or cross-sectional area) and thickness or a relatively high hardness and density. A two-stage cushion module for a mattress, characterized by having a small diameter (or cross-sectional area) and thickness, or relatively low hardness and density. According to clause 1,
The upper cover is configured to extend downward from the top of the upper part of the main body to cover the circumference of the upper part, the surface of the upper cover is made of wrinkles, and a threaded part for coupling the upper plate is formed at the upper end. Two-stage cushion module for mattresses. According to clause 1,
A two-stage cushion module for a mattress, characterized in that the upper plate portion has a fastening portion screwed to the upper portion of the upper cover formed on the bottom surface, and an embossed protrusion for providing an acupressure effect is formed on the upper surface.

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