MXPA06008153A - Bed mattress using permeable reinforcing member and foaming material, and method of manufacturing the same - Google Patents

Abstract

Disclosed herein is a bed mattress and a method of manufacturing the same, in which a permeable reinforcing member is provided at an upper portion and a lower portion of a spring assembly which is one of frame constituents of the bed mattress, and a foaming material is disposed on the permeable reinforcing member so as to be foamed, so that the spring assembly and the foaming material are integrally formed while the foaming material is expanded through fine holes and/or foam expansion holes of the permeable reinforcing member.

Description

BED MATTRESS THAT USES REINFORCEMENT MEMBER AND FOAM FORMAT MATERIAL, AND METHOD TO MANUFACTURE IT BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The present invention relates to a bed mattress that utilizes a permeable reinforcing member and a foaming material, and to a method for manufacturing it. More particularly, it relates to said bed mattress and to a method for manufacturing it, wherein a permeable reinforcing member is provided in an upper portion and in a lower portion of a spring assembly, which is one of the constituents of the frame. of the bed mattress, and a foam-forming material is disposed on the permeable reinforcing member, so as to foam it, so that the spring assembly and the foam-forming material are integrally formed, while the foam material expands to through small holes and / or holes for expansion of the foam, of the permeable reinforcing member.

BACKGROUND OF THE RELATED ART In general, a bed mattress is mounted in a frame or bed frame, and used as a means to provide a cushioning force and a compensating force. The bed mattress basically includes a spring assembly, an intermediate member, fixed in a laminated manner on the upper and lower surfaces of the spring assembly, an edge skimmer, tightly fixed to the lateral surface of the spring assembly, and a spring member. cover to protect the surfaces of the intermediate member and the edge former. There will be described hereinafter, a process for manufacturing a conventional bed mattress, briefly and with reference to Figure 14. With reference to Figure 14, first a spring assembly 10 is fabricated, which includes coil springs 1 2, arranged along row and column directions, over the entire area of the mattress for bed, in such a way that they are separated from one another at regular intervals, and a helical spiral 14, to securely couple the springs in spiral 12 together. An edge former 30, as a support means, is then tightly fixed to the side surface of the spring assembly 1 0. A multi-layer cushioning means, including a felt and a non-woven fabric, is then continuously laminated as a member. intermediate 32, on the upper and lower surfaces of the spring assembly 10. Finally the upper and lower surfaces and the circumferential edge surface of the intermediate member 32, as well as the outer surface of the edge former 30, are covered with a cover member 28, and then a seam portion of the cover member 28 is sealingly sealed with a sealing means.

Therefore, when a user lies down to sleep, a load exerted on the bed mattress is absorbed and cushioned by means of a damping force of the intermediate member and a compensating force of the spring, so that the user can feel convenience and comfort . However, this conventional structure of the mattress for bed has drawbacks, since its manufacturing process is complicated and requires several processes, which tends to increase the manufacturing cost and decrease their work capacity. That is, since the conventional bed mattress, manufactured by the process mentioned above, is manufactured by means of various processes, such as a process in which a multi-layered intermediate member, such as a felt and a non-woven fabric, is laminately fixed. woven, on the upper and lower surfaces of the spring assembly, etc. , the cost of manufacturing and the cost of labor are increased, and the manufacturing speed is lowered to thereby deteriorate the unit productivity. In particular, for the mattress for conventional bed, a problem occurs, since a noise is generated (for example, the noise due to contact between the springs, or a squealing sound due to the compression of the springs) by means of the load exerted on the mattress for bed during its use, or for aging, and use of the springs, in accordance with the long-term use of the mattress.

BRIEF DESCRIPTION OF THE INVENTION Consequently, the present invention has been made in view of the problems mentioned above, which occur in the prior art; and it is an object of the present invention to provide a bed mattress utilizing a permeable reinforcing member and a foaming material; and a method for manufacturing it, wherein the permeable reinforcing member is provided in an upper portion and / or in a lower portion of a spring assembly for the mattress for the bed, and a foam forming material is provided over the member permeable reinforcement, to be foamed, so that the permeable reinforcing member is soaked into the foam-forming material and, simultaneously, the spring assembly and the foaming material are formed integrally with each other, while expanding the forming material of the foam. foam through thin holes of the permeable reinforcing member. It is another object of the invention to provide a bed mattress utilizing a permeable reinforcing member and a foaming material, and a method of making it; wherein the permeable reinforcing member is formed penetratingly thereon, with a plurality of foam expansion holes disposed along row and column directions, in such a manner that they are spaced apart at regular intervals , so as to further increase the degree of foaming of the foaming material through the holes for expansion of the foam and penetrate a coupling portion between a spring of the spring assembly and a helical coil; and / or a sewing portion between the springs or a portion of space between the springs, within the foam-forming material, expanded through the holes for expansion of the foam; in order to further increase, in that way, the connecting force between the spring assembly, which includes the springs and the foam-forming material. Still another object of the present invention is to provide a mattress structure for a bed, wherein a foam forming material is provided in an upper portion and in a lower portion of the spring assembly, as well as the foam is advanced in a lateral surface of the spring assembly, so that a lateral foam forming material is formed integrally with the spring assembly, on the lateral surface of the spring assembly. Yet another objective of the present invention is to provide a mattress structure for a bed, in which a foam of a foam-forming material passes through the through holes of an intermediate layer, and then adheres to the respective springs or spiral helical of a spring assembly, so that it coagulates, in order to prevent a crack from being generated due to a fatigue load accumulated in the springs and in the helical turns, in order to prolong the useful life of the interior materials of the mattress and the mattress itself, as well as reducing the noise of the spring itself. Obtaining the above objectives of the present invention allows the elimination of various other processes, including an existing process in which a multi-layered intermediate member, such as a felt and a non-woven fabric, is laminated on the surfaces. top and bottom of the spring assembly, etc., so that the manufacturing cost and labor cost are substantially reduced and the unit productivity can be improved. In particular, an excellent bonding force is provided between the spring assembly and the foam material, through a foaming process of the foam material, using the permeable reinforcing member, the generation of a noise due to the contact between the springs, and you can extend the useful life of the mattress for bed. To obtain the above objective, according to one aspect of the present invention, a bed mattress is provided which includes a spring assembly consisting of a plurality of springs disposed along row and column directions for the entire area of the mattress for bed, and a helical spiral to securely attach the springs to each other; the bed mattress comprising: a permeable reinforcing member, provided on an upper surface and / or on a lower surface of the spring assembly; the permeable reinforcing member being formed of a single layer or multilayer structure; and a foam material, disposed on the outer surface of the permeable reinforcing member so that it is to be foamed; wherein the permeable reinforcing member is soaked in the foam material and, simultaneously, the spring assembly and the foam material are formed integrally with each other, by means of the foaming of the foam forming material passing through a plurality of thin holes formed in the permeable reinforcing member. A cushioning material, such as foam forming material, is a polyurethane foam that is intended to be foamed while it is curing. Thus, in the case where two liquids are mixed together, ie a polyether polyol and a polyfunctional isocyanate, they are cured while being subjected to an entanglement reaction; where the two liquids are linked together. In particular, an example of the foam material may include a foam-forming material, such as polyethylene, etc. , in addition to polyurethane. All foam forming materials, made of a soft material, especially a memory foam, can also be taken as an example of the foam-forming material. In a preferred embodiment, the permeable reinforcing member is further formed with a plurality of holes for expansion of the foam, arranged following row and column directions, in such a way that they are spaced apart at regular intervals, so that a part of the foam forming material penetrates through it into the spring assembly in an increased amount, through the holes for foam expansion, so that it is frothed in a convex manner, and a coupling portion between the spring of the spring assembly and a helical spiral and / or a seam portion between the springs, or a portion of space between the springs, is embedded in the convexly foamed part of the foam-forming material. In particular, the permeable reinforcing member is a fine mesh having thin holes, each of which has a size from 1 to about 30 mm x 1 to about 30 mm, and / or holes for foam expansion , each of which has from 3 to 80 mm. Also the permeable reinforcing member is a non-woven fabric having holes for expansion of the foam, each of which has a diameter of 3 to 80 mm. It is preferred that the diameter of the holes for expansion of the foam, of the permeable reinforcing member, be within a range of between 25 mm and 35 mm. In a preferred embodiment, holes are preferably formed for the expansion of the foam penetratingly into the permeable reinforcing member; in such a way that they are arranged in a position corresponding to the coupling portion between each spring of the spring assembly and the coil, and / or the seam portion between the springs or in the portion of space between the springs . Additionally, an edge skimmer is tightly fixed to the side surface of the spring assembly; but a side foam forming material is not foamed along the side surface of the spring assembly. To obtain the above objective, according to another aspect of the present invention, there is provided a method for manufacturing a bed mattress including a spring assembly, consisting of a plurality of springs and a helical coil for secure attachment the springs to each other; the method comprising the steps of: a first step in which a permeable, single-ply or multi-ply reinforcement member is fixedly disposed on the upper surface of the spring assembly; a second step in which the spring assembly is seated in a foaming space of a foam forming apparatus, filled with a foam-forming material; such that the outer surface of the permeable reinforcing member is in contact with the foaming space of the foam forming apparatus, and then the foaming material is foamed; a third step in which foaming of the foaming material is allowed through the thin holes of the permeable reinforcing member, to cause the permeable reinforcing member and the partial upper portion of the spring assembly to be embedded in the foam forming material; and a fourth step in which the third step is carried out in case there are holes for foam expansion, formed additionally in the permeable reinforcing member, in addition to the fine holes; and wherein part of the foam forming material is simultaneously allowed to penetrate through the interior of the spring assembly, in an increased amount, through the holes for expansion of the foam, of the permeable reinforcing member, so that foam is convexly shaped, so that a coupling portion between a spring of the spring assembly and the helical turn, and / or a seam portion between adjacent springs, or a space portion between the springs, is embedded in the part foamed convexly, foam forming material. Additionally, the foam forming material is formed integrally with the upper and lower portions of the spring assembly, through a fifth step of firmly arranging the single layer or multilayer permeable reinforcing member, on the bottom surface of the assembly. spring; and then perform the second, third and fourth steps, in the same way. An edge skimmer is tightly fixed to the side surface of the spring assembly, instead of the process of foaming the foaming material made on the side surface of the spring assembly, and then the foaming process is carried out in the portions top and bottom of the spring assembly. To achieve the above objective, according to another aspect of the present invention, there is also provided a bed mattress which includes a spring assembly having a plurality of springs arranged in column and row directions, throughout the area of the mattress for bed, and a permeable reinforcing member and an intermediate layer disposed on the upper / lower surfaces of the spring assembly, and a cushioning material (a foam material); where a permeable reinforcing member, of the mesh type, and an intermediate layer formed in the form of a single layer or multilayer sheet, and formed therein with a plurality of through holes, are interposed between the spring assembly and the material damper (a foam-forming material) so that the dampening material formed of a foam-forming material is foamed in order to cause the foam-forming material to foam through the through holes to expand convexly and adhere to the reinforcing member permeable and the spring assembly to be coagulated. To achieve the above objective, according to another aspect of the present invention, there is also provided a method for manufacturing a bed mattress that includes a spring assembly consisting of a plurality of springs, and a helical turn to engage with each other, in a safe way, the springs; the method comprises the steps of: loading a cushioning material, such as a foam-forming material, into a mold frame with the shape of the mattress; laminating an intermediate layer formed therein, with through holes disposed spaced apart from each other at regular intervals in the cushioning material; laminating the permeable reinforcing member, of the mesh type, on the intermediate layer; deposit the spring assembly on the permeable reinforcing member; allowing foaming of the cushioning material (the foaming material) to continue; and allowing the foamed cushion material to expand convexly through the through holes of the intermediate layer and the permeable reinforcing member, so that it adheres to the spring assembly, so that it coagulates; or the steps of: loading a cushioning material, such as a foam-forming material, into a mold frame with the shape of the mattress; integrally assembling together the spring assembly, a permeable reinforcing member and an intermediate layer, to form an assembly; and arranging the assembly on the cushioning material (the foam forming material); allowing foaming of the cushioning material (the foaming material) to continue; and allowing the foamed cushion material to be convexly expanded through through holes of the intermediate layer and of the permeable reinforcing member to adhere to the spring assembly, so as to coagulate.

BRIEF DESCRIPTION OF THE DRAWINGS The foregoing objects, aspects and advantages, and others, of the present invention will become apparent from the following detailed description of the preferred embodiments of the invention, together with the accompanying drawings, in which: Figure 1 is a perspective view illustrating the structure of a bed mattress using a permeable reinforcing member and a foam-forming material according to the present invention; where a lower portion of the bed mattress structure represents a state after foam formation is completed, and an upper portion thereof represents a state prior to the completion of foaming. Figures 2a and 2b are cross-sectional views sequentially illustrating the process of manufacturing a bed mattress using a single permeable reinforcing member and a foam material according to the present invention; Figure 2a shows a state in which the foam-forming material is foamed expansively in a coupling portion between a spring of the spring assembly and a helical coil; and Figure 2b shows the state in which the foam-forming material is foamed expansively in a seam portion between the springs, or a portion of space between the springs. Figure 3 is a cross-sectional view illustrating the structure of a bed mattress using a multi-layer permeable reinforcing member (at least two layers) and a foam-forming material according to the present invention. is a sectional view illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming material according to the present invention, in which thin holes are formed, but the holes for expansion of the foam they are not formed in the permeable reinforcing member Figure 4a is a cross-sectional view illustrating the structure of a bed mattress using a permeable reinforcing member and a foam-forming material according to the present invention, where the Foaming is additionally carried out on a lateral surface in addition to the foaming carried out in the upper and lower portions of the spring assembly. Fig. 5 is a sectional view illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming material according to the present invention, where an edge skimmer is tightly attached to the side surface of the assembly. of spring; but separate lateral foaming is not effected along the lateral surface of the spring assembly in addition to foaming performed on the upper and lower portions of the spring assembly. Fig. 6 is a perspective view illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming material according to the present invention, which is identical to the structure of Fig. 1, but a the one that applies another spring assembly. Figures 7a and 7b are cross-sectional views, which sequentially illustrate the manufacturing process of a bed mattress, using a single permeable reinforcing member and a foam-forming material, in accordance with the present invention; where the structure of the mattress for bed is identical to that of figures 2a and 2b, but with another spring assembly applied; and wherein Figure 7a shows a state in which the foam forming material is foamed expansively in at least one coupling portion between a spring of the spring assembly and a helical coil; and Figure 7b shows a state where the foaming material foams expansively at a seam portion between the springs, or a portion of space between the springs. Figure 8 is a cross-sectional view illustrating the structure of a bed mattress using a multilayer permeable reinforcing member (at least two layers), and a foam-forming material according to the present invention, which it is identical to the structure of figure 3, but to which another spring assembly is applied. Figure 8a is a cross-sectional view illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming material according to the present invention; where the foaming is further carried out on a side surface in addition to the foaming performed on the upper and lower portions of the spring assembly, which is identical to the structure of figure 4a, but to which another spring assembly is applied. Fig. 9 is a sectional view illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming forming material according to the present invention, in which thin holes are formed; but the holes for expansion of the foam are not formed on the permeable reinforcing member, which is identical to the structure of Figure 4, but to which another spring assembly is applied. Fig. 10 is a cross-sectional view illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming material according to the present invention, where an edge skimmer is tightly attached to the side surface of the spring assembly, but no separate lateral foaming is performed along the lateral surface of the spring assembly, other than the foaming performed on the upper and lower portions of the spring assembly, which is identical to the structure of the figure 5, but to which another spring assembly is applied. Figures 1 1 a and 1 1 b are simulated views illustrating the structure of a bed mattress manufactured using an intermediate layer having a plurality of through holes formed therein, a permeable reinforcing member, of the mesh type, and a material damper, such as a foam-forming material according to another embodiment of the present invention. Figures 12a and 12b are perspective views illustrating the structure of the intermediate layer applied to the bed mattress of Figures 1 1 a and 1 1 b. Figures 13a and 13b are cross-sectional views sequentially illustrating the manufacturing process of the bed mattress of Figures 1 1 a and 1 1 b; and Figure 14 is a cross-sectional view illustrating the structure of a conventional bed mattress.

DETAILED DESCRIPTION OF THE PREFERRED MODALITY Reference will now be made in detail to the preferred embodiment of the present invention, with reference to the accompanying drawings. Figures 1 to 5 and figures 6 to 10, attached, show the same foam-forming structure, but different spring assemblies. In the drawings, the spring assembly is merely an illustrative example for explaining the foam forming structure and the manufacturing process of the present invention. It is natural that various types of the spring assemblies should be applied to the bed mattress according to the present invention, so as to implement the foaming process. Figures 1 and 6 are perspective views illustrating the structure of a bed mattress using a permeable reinforcing member and a foaming material according to the present invention, wherein a lower portion of the mattress structure for "bed" represents a state after foaming is completed, and an upper portion of it represents the state prior to foaming being completed. Figures 2a, 2b, 7a and 7b are sectional views sequentially illustrating the manufacturing process of a bed mattress using a single permeable reinforcing member and a foaming material according to the present invention; and Figures 3 and 8 are cross-sectional views illustrating the structure of a bed mattress using a multilayer permeable reinforcing member (at least two layers) and a foam-forming material according to the present invention. The present invention is intended to provide a bed mattress having excellent durability even through a simple process of integrally forming the foam forming material with the spring assembly on the upper and lower surfaces of the spring assembly by means of a member permeable reinforcement. In particular, the present invention allows the foaming of a foam-forming material to advance toward the spring assembly, through thin holes and / or holes for expansion of the foam, formed in the permeable reinforcing member, to provide that way an excellent bonding force between the spring assembly and the foam forming material, and prevent the generation of noise due to contact between the springs of the spring assembly.

As mentioned previously, the spring assembly 10 for a bed mattress includes a plurality of springs 12 disposed along row and column directions substantially over the same area as that of the bed mattress; and a helical coil as a means for securely coupling the respective respective springs 1 2 to each other. More specifically, the upper and lower ends of the spring 12 are connected together with those of the adjacent spring 12 and a connection portion between the springs 12 is referred to as a seaming portion 18. A permeable, single-layer or reinforcement member 20 of several layers (at least two layers) is disposed on the upper and / or lower surfaces of the spring assembly 10, formed in the above structure, and then fixed to the spring assembly 10 by means of an anchor ring , in which an air gun shoots a circular piece in the shape of a curl towards an object to be fixed, to fix it. In addition to this anchoring ring, various other methods may be used, such as a method of connecting the reinforcing member permeable to the spring assembly, with an adhesive. The permeable reinforcing member 20 is a mesh-like structure, which is formed in a penetrating manner with a plurality of thin or thin holes 21 therein, arranged in row and column directions; and is embedded in a foam-forming material 24, together with the partial top term of the spring assembly, to serve as a frame, which will be described later.

The permeable reinforcing member 20 can be incorporated in the form of a single layer or double layer structure, in view of the thickness of the foam forming material 24. Of course it should be appreciated that the permeable reinforcing member 20 can be formed by more than two layers, if necessary. In particular, the permeable reinforcing member 20 can additionally be formed of a penetrating pan with a plurality of foam expansion holes 22, circular in shape, arranged in row and column directions, in such a way that they are separated from each other. at regular intervals. For example, a predetermined area of the permeable reinforcing member 20, formed with thin holes 21, following row and column directions, is cut to a circular shape at a time, and is penetratingly formed with holes 22 for the expansion of foam. Accordingly, when a foam-forming material 24 is disposed on the outer surface of the permeable reinforcing member 20 to advance the foaming of the foaming material, the permeable reinforcing member is embedded in the foam-forming, foaming material 24. so that it acts as a frame and, simultaneously, the upper and lower ends of the springs 10 and of the helical turn 14 to securely couple the springs together, are also embedded within the foam forming material 24. Concurrently , the foaming of the foam forming material 24 advances towards the spring assembly 10 through the holes 22 for expansion of the foam, formed in the permeable reinforcing member 20, such that it additionally expands convexly. Meanwhile, as shown in FIGS. 4 and 9, even if the permeable reinforcing member 20 formed only with the thin holes 21, but not formed with the holes 22 for expansion of the foam, is used, it is foaming of the foam forming material 24 on the upper and lower portions of the spring assembly is possible. In this case, since the foaming of the foam-forming material advances through the thin holes 21 only, the height of the foam-forming material 24 passing through the thin holes 21 is maintained uniformly; but the thickness of the foam-forming material 24 that is foamed is not sufficient, relatively. At this time, the permeable reinforcing member 20 preferably employs any fine mesh or non-woven fabric. In the case where the permeable reinforcing member 20 is a fine mesh, each thin hole preferably has a size from 1 to about 30 mm x 1 to about 30 mm. The reason for this is that if the thin hole has a size of less than 1 mm x 1 mm, the foam-forming material 24 does not normally penetrate through the thin hole during its foaming; whereas if the fixed hole has a size of more than 30 mm x 30 mm, the foam forming material 24 penetrates excessively through the fine hole. Additionally, each hole 22 for expansion of the foam, of the permeable reinforcing member 20, preferably has a diameter of 3 mm to 80 mm. The reason for this is that if the hole 22 for expansion of the foam has a diameter of less than 3 mm, the area of the foam-forming material 24 that passes through the hole 22 for expansion of the foam is small, but the height of the foaming material 24 being foamed increases; whereas if the hole 22 for expansion of the foam has a diameter of more than 80 mm, the area of the foam-forming material 24 which passes through the hole 22 for foam expansion is large, but the height of the forming material of foam 24 decreases; and at that time the foam-forming material spreads laterally. Particularly more preferably, the diameter of the hole 22 for expansion of the foam, of the permeable reinforcement material, is within a range between 25 and 35 millimeters. Of course, the hole 22 for expansion of the foam becomes larger than the thin hole 21. For example, if the thin hole 21 has a size of 1 mm x 1 mm, the diameter of the hole 22 for expansion of the foam is selectively applied within a range between 2 mm and 80 mm, in view of the thickness of the application of the foam forming material 24. On the other hand, if the thin hole 21 has a size of 10 mm x 10 mm, the diameter of the hole 22 for expansion of the foam is selected to be applied within a scale comprised between 1 1 mm and 80 mm, in view of the application thickness of the foam forming material 24. Furthermore, if the thin hole 21 has a size of 30 mm x 30 mm, the diameter of the hole 22 for expansion of the foam is selectively applied inside. of a scale comprised between 31 mm and 80 mm, in view of the application thickness of the foam forming material 24. This is merely an illustrative example, and the hole is fixed 22 for the expansion of the foam to be larger than the thin hole 21, in such a way that the size of the thin hole 21 and the hole 22 for expansion of the foam are applied in view of the thickness of the application of the foam-forming material 24. In particular, the hole 22 for expansion of the foam is preferably formed perpendicularly on the permeable reinforcing member 20 in such a way that it is disposed in a position corresponding to the coupling portion between each spring 12 of the spring assembly 10 and the helical coil 14. It is more preferable that the hole 22 for expansion of the foam is further pervasively formed in the permeable reinforcing member 20 in such a way as to be arranged in a position corresponding to the sewing portion 18, between the springs 12 of the spring assembly 10, or the portion of space between the springs 12. The reason for this is that the foam n of the foamer material 24 advances towards the coupling portion between each spring 12 and the helical coil 14; and the sewing portion 1 8 between the springs 12 adjacent to each other, and the space portion between the adjacent springs 1 2 through the holes 22 for expansion of the foam of the permeable reinforcing member 20, in such a manner, which expands further in a convex manner, thereby increasing the bonding force between the spring assembly 10 and the foam-forming material 24, in the coupling portion between each spring 12 and the helical coil 14, and the portion of stitching 18 between the springs 12, adjacent to each other, and the portion of space remaining between the adjacent springs 12. Consequently, as shown in Figure 2a, expandable foaming is carried out on the helical coil 14 of the spring assembly 10. As shown in Figure 2b, expandable foaming can also be carried out on the seaming portion 18 between the adjacent springs, and the portion of space remaining between the adjacent springs. In addition to the helical spiral 14 of the spring assembly 1 0. A method for manufacturing a mattress for a bed, using a foaming material according to the present invention, in detail, and with reference to Figures 2a, 2b, 7a and 7b. Firstly, the bed mattress includes a spring assembly 10 consisting of a plurality of springs 12, arranged in row and column directions, over its entire area, in such a way that they are spaced apart at regular intervals, and a helical spiral 14 for securely coupling the springs 12. Thereafter, a permeable reinforcing member 20 of single or multi-layer (at least two layers) is disposed on the upper surface of the spring assembly, and it is fixed, using the anchor ring, where a pneumatic gun shoots a circular piece in the shape of a curl, towards an object that is going to be fixed, to fix it. Of course, in addition to the above anchoring ring, various methods can be used which include a method for fixing the permeable reinforcing member 20 on the upper surface of the spring assembly 10, using an adhesive. Next, as the foaming of the foam-forming material 24 advances on the outer surface of the permeable reinforcing member 20, the foaming material 24 is foamed into the spring assembly 10 through the thin holes 21. , so that the permeable reinforcing member is embedded in the foamed material 24 which is foaming to serve as a frame and, simultaneously, the upper end of the spring 12 is embedded in the foaming material 24, to thereby do so that the foam-forming material 24 and the spring 12 of the spring assembly are formed integrally with each other. Additionally, in the case where the permeable reinforcing member 20 is additionally formed with holes 22 for expansion of the foam, in addition to the thin holes, a part of the foam forming material penetrates through the interior of the spring assembly, in an increased amount, through the holes 22 for expansion of the foam, of the permeable reinforcing member 20, so that it is frothed in an expandable manner in a convex way. Accordingly, a coupling portion between the springs 12 of the "spring assembly 10 and the helical turn 14, which securely engages the springs 12, and a seam portion located between the springs 12 or a portion of space located between the springs 12, are imbibed in the foamed foamed material convexly inwardly of the spring assembly 10 so as to further increase the bonding force between the spring assembly 10 and the foam-forming material 24, the coupling portion between each spring 12 and the helical coil 14 and the seaming portion 18 between the springs 12, and the space portion between the adjacent springs 12. Similarly, a permeable reinforcing member 20 is fixedly disposed of, a single layer or multi-layer (at least two layers), on the lower surface of the spring assembly 10, and then the foam forming material 24 is subjected to a process of foaming which is equal to the previous foaming process, so that the foaming material 24 is formed integrally with the lower portion of the spring assembly 10. Thus, as shown in the last figures of Figures 2a, 2b, 7a and 7b, a bed mattress product is manufactured in which the foaming material 24 is formed integrally with the upper and lower portions of the spring assembly 1 0. As an alternative embodiment the foaming material 24 can be foamed in any of the upper surface and the lower surface of the spring assembly 10, according to the circumstances.

On the other hand, with reference to Figure 7b, the foaming material is also foamed expansively in the seaming portion between the springs or in the space portion between the springs 12, in addition to the coupling portion between the springs 12 and the helical spiral 14, in order to further increase, in this way, the binding force between the spring assembly 10 and the foam-forming material 24. Now, in addition to the foaming process carried out in the upper and lower portions of the assembly of spring, the foaming process on a side surface of the spring assembly will be described in the following. Figures 4a and 8a are cross-sectional views illustrating the structure of a bed mattress using a permeable reinforcing member and a foam-forming material according to the present invention, in which further foaming is carried out a side surface of the spring assembly, in addition to the foaming performed on the upper and lower portions of the spring assembly. To describe the foaming process on the lateral surface of the spring assembly, a non-woven fabric 26 is first attached along the side surface of the spring assembly 10, and then fixed to the spring assembly by means of anchor rings. , before the foaming process advances in the upper and lower portions of the spring assembly 1 0. Then the foaming process proceeds in the upper and lower portions of the spring assembly 10, as described above, and is carried out the side foaming process. That is, the spring assembly 1 0 fixed with the nonwoven fabric on the side surface is placed inside a mold (not shown) of the foam forming apparatus, and foam forming material 24 is injected along the surface side of spring assembly 1 0. Then, when the spring assembly 10 is removed from the mold, after the foaming of the foaming material 24 is complete, a side foaming process is completed, in which the foaming material 24 is additionally formed integrally with the side surface of the spring assembly 10. Additionally, as shown in Figs. 5 and 10, an edge skimmer 30 is tightly fixed to the side surface of the spring assembly, without separate side foaming. for the spring assembly 1 0, and then foaming can be effected in the upper and lower portions of the spring assembly 1 0. In the following, another embodiment of the present invention will be described. Figures 1 1 a and 1 1 b are simulated views illustrating the structure of a bed mattress manufactured using a permeable reinforcing member, of the mesh type, an intermediate layer having a plurality of through holes formed therein, and a material foam former, such as a cushioning material according to the present invention, wherein Figure 1 1 a shows a state in which the helical turns are coupled with the springs, and Figure 1 1 b shows a state in that the helical turns are not coupled with the springs. Figures 12a and 12b are pective views illustrating the structure of the intermediate layer applied to the bed mattress of Figures 1 1 a and 1 1 b; wherein Figure 12a shows a single layer structure of the intermediate layer, and Figure 12b shows a multilayer structure of the intermediate layer; and Figures 13a and 13b are cross-sectional views, which illustrate sequentially the manufacturing process of the bed mattress of Figures 11a and 11b. As shown in Figures 1 1 a and 1 1 b, the bed mattress structure of the present invention employs a foam-forming material as a cushioning material 36, and is configured such that a mass 40 is convexly foamed , formed by foaming the foaming material, is securely coupled with the spring assembly 10, through the through holes of the intermediate layer. As shown in Figures 1 1 a and 1 1 b, the bed mattress includes a spring assembly 10 having springs 12 disposed in row and column directions, throughout the area of the bed mattress; where the springs 12 are fixed securely or are not fixed together, by means of a helical turn 14, a permeable reinforcing member 20 of the mesh type, disposed on the upper and lower surfaces of the permeable reinforcing member, which is formed in a single-ply or multi-ply sheet form, and a cushioning material such as a foam-forming material on the upper and lower surfaces of the intermediate ply. The cushioning material 36, which is a polyurethane foam, is intended to be foamed while it is being cured. Thus, in the case where two liquids are mixed together, ie, a polyether polyol and a polyfunctional isocyanate, they are cured while they are being subjected to an entanglement reaction, in which the two liquids are bonded together. In particular, an example of the foam forming material may include a foam-forming material, such as polyethylene, etc., in addition to the polyurethane. Also all foam forming materials made of a soft material, especially a memory foam, can be taken as an example of the foam forming material. The intermediate layer 36 is formed into the form of a single layer or multilayer sheet, which is made of various interior materials, such as felts, non-woven fabrics, palms or the like, and has a uniform thickness. The intermediate layer 356 is formed with a plurality of through holes 38 disposed spaced apart at regular intervals, following row and column directions. The through holes 34 serve as passages for the expansion of the foam-forming material, through which a foam of a foam-forming material passes, and then adhered to respective springs 12 or helical turns 14 of the spring assembly 10, so that it coagulates. At that time the through holes 38 are formed in the entire area of the bed mattress. The reason for this is that the uniform distribution of the foamed mass 40 is induced, to thereby establish a stronger bond between the spring assembly 10 and the cushioning material 36 (the foaming material). In particular, the foamed mass 40 of the cushioning material 36 (the foaming material) penetrates through the through holes 38 of the intermediate layer 34, and then adheres to the respective springs 12 or the helical turns 14 of the assembly spring 1 0, so that it is coagulated, so as to prevent the generation of a crack, due to the load of accumulated fatigue in the springs and the helical turns, in order to prolong in this way the useful life of the interior materials of the mattress and the mattress itself, as well as reduce the noise of the mattress itself. As shown in Figures 12a and 12b, the through holes 38, formed in the intermediate layer 34, are arranged in such a way that they are formed following row and column directions on the intermediate layer 34, in such a way that they are separated from each other continuously in an equidistant manner. In this case, the through holes 38 are formed into a shape that allows easy escape from the foamed mass 40. The through holes 38 can have any shape and arrangement that increases the bond strength between the spring assembly 10 and the material 36 cushioning (the foam forming material). On the other hand, the permeable reinforcing member 20 is formed to the shape of a strip of the mesh type, with uniform intervals, so that the foamed mass 40 adheres to the mesh type strip, to increase the flexibility or the immobilization of the mattress structure, thereby improving the operation of joining the spring assembly 10 and the cushioning material 36 (the foam-forming material) as well as obtaining uniform distribution and damping of the load of a sleeping person . The permeable reinforcing member 20 is designed such that it is laminated between the intermediate layer 34 and the spring assembly 10., during the manufacturing process of the mattress for bed. The bed mattress, as constructed in the above, is configured in such a way that the foam forming material used as cushioning material 36 is foamably expandable through the through holes 38 formed within the intermediate layer 34 and , simultaneously, coagulates to cause the spring assembly 10 and the cushioning material 36 (the foam forming material) to be tightly bonded together. The process of assembling the bed mattress according to the present invention will now be described, with reference to Figure 1 3a, which shows a diagram of the assembly process. First, a foam-forming material, such as a cushioning material 36, is loaded into the lower mold frame in the form of a mattress, and the intermediate layer 34, formed with the through holes 38, which are spaced apart from each other, is sequentially laminated. regular intervals, and the permeable reinforcing member 20, on the cushioning material (the foam-forming material). At that time, since the foam-forming material is foamed slowly, the laminated structure (ie, the intermediate layer, the mesh-type permeable reinforcing member and the spring assembly) is preferably quickly laminated before it is foamed The foaming material is continued to foam the foaming material, still while a predetermined period of time (about 15 minutes) elapses, in a state in which the spring assembly 10 is laminated onto the permeable reinforcing member 20. The foamed mass 40 is convexly expanded through the through holes 38 of the intermediate layer 34, so as to adhere to the spring assembly 10. In this case, the spring assembly 10, the permeable reinforcing member 20 and the intermediate layer 34 are laminated separately on the cushioning material 36 (the foam-forming material) in Figure 13a.Alternatively, they are assembled strongly in an integral manner. gral the permeable reinforcing member 20 and the intermediate layer 34, with the lower end of the spring assembly 10, to form an assembly, and the assembly is laminated on the cushioning material 36 (the foam-forming material in Figure 1 3b . At the same time it is preferable to cover an upper mold frame on the lower mold frame, and to fix the upper mold frame so that the foamed mass 40 penetrates through the through holes 38 of the intermediate layer 34, in a state wherein the laminated structure is fixed securely when foaming the foamed mass 40.

The reason for this is that if the foamed mass 40 of the foam-forming material is not applied with a strength of the laminated structure, a case occurs in which the volume increases completely, merely, but the foamed mass 40 does not escape from the through holes 38. At the same time, in the case where the permeable reinforcing member 20 is included in the bed mattress, the joining operation of the spring assembly 10 and the foam forming material is improved, thereby elevating the maximum the joining force between the spring assembly 10 and the foam-forming material, as well as increasing a damping function through the uniform distribution and absorption of the load of a sleeping person. In such a way, since the present invention allows the spring assembly 10, the permeable reinforcing member 20 and the intermediate layer 34 to be integrally fixedly joined with the cushioning material 36, as a foam-forming material, by means of the foamed mass, without a separate fixing apparatus, the bonding strength between the spring assembly 1 0 and the cushioning material 36 is relatively increased, compared to a conventional manufacturing process, to thereby prolong the useful life of the mattress for bed. Further, since foamed mass 40 is coagulated in springs 12 or helical turns 14, the noise generated due to contact between coil springs 12 itself is reduced, as well as the risk of cracking of coil turns to increase. that way the useful life of the inner springs.

Additionally, in the conventional manufacturing process of the bed mattress, the intermediate layer member, such as a felt, a non-woven fabric and a palm, is attached independently to the upper and lower portions of the spring assembly, which leads to an increase in the number of work processes and a load. However, in the manufacturing process of the bed mattress according to the present invention, the foam forming material penetrates through the through holes of the intermediate layer and is strongly assembled with the spring assembly and, thus, simplifies the manufacturing process. As will be apparent from the foregoing, in accordance with the present invention, in connection with a bed mattress using a permeable reinforcing member and a foaming material and a method for manufacturing it, the permeable reinforcing member having thin holes and a plurality of holes for expansion of the foam is provided in an upper portion and / or in a lower portion of the spring assembly for the bed mattress, and a foaming material is disposed in the permeable reinforcing member, so as to of foaming, so that the permeable reinforcing member is embedded in the foam-forming material and, simultaneously, the degree of foaming of the foaming material is simultaneously increased through the holes for expansion of the foam and the portion coupling between the spring of the spring assembly and the helical spiral, and / or the sewing portion between the springs or the portion of space in The springs are embedded in the foam-forming material, expanded through the holes for expansion of the foam, to thereby provide an excellent bonding force between the spring assembly, which includes the springs, and the material foam former Furthermore, the present invention allows the elimination of various processes, including a process in which the intermediate multilayer member, such as a felt and a non-woven fabric, is laminated on the upper and lower surfaces of the spring assembly. , and a process of joining the intermediate member, etc., so that the manufacturing cost and the labor cost can be substantially reduced, and the unit productivity can be improved. In particular, since the present invention has a structure in which the springs and a helical spiral portion for securely coupling the springs to each other, is surrounded by a foam-forming material, the foam-forming material absorbs a noise caused by friction between the helical spirals and the adjacent springs, due to a load exerted on the mattress in its use, so that it suppresses the generation of noise. Additionally, in the present invention, the foamed mass, convexly expanded through the through holes of the intermediate layer, is fixedly attached to the permeable reinforcing member.; to the spring assembly and the helical spiral, in order to thereby increase, relatively, the joining force between the spring assembly 10 and the foam-forming material, compared to a conventional manufacturing process, to prolong the useful life of the mattress for bed. In addition, since the foamed mass is coagulated in the springs or in the helical turns, the noise of the coil springs themselves is reduced, as well as the risk of cracking of the coil springs is reduced, thereby prolonging the useful life of the inner springs. Furthermore, in the conventional manufacturing process of the bed mattresses, the intermediate layer member, such as a felt, a non-woven fabric and a mat, is attached independently to the upper and lower portions of the spring assembly, which leads to an increase in the number of work processes and a load. However, in the manufacturing process of the bed mattress according to the present invention, the foam forming material penetrates through the through holes of the intermediate layer and is tightly assembled with the spring assembly, thereby simplifying the manufacturing process. While the present invention has been described with reference to the particular illustrative embodiments, it should not be restricted to the modalities but only by the claims that follow. Those having experience in the art will appreciate that modalities can be changed or modified without departing from the scope or spirit of the present invention.

Claims (3)

1. CLAIMS 1 .- A mattress for bed that includes a spring assembly consisting of a plurality of springs arranged along row and column directions, throughout the area of the mattress for bed, and a helical spiral to couple with each other , safely, the springs; the mattress for bed comprising: a permeable reinforcing member provided on an upper surface and / or on a lower surface of the spring assembly; the permeable reinforcing member being formed of a single layer or multilayer structure; and a foam forming material disposed on the outer surface of the permeable foamed reinforcing member; wherein the permeable reinforcing member is embedded in the foam-forming material and, simultaneously, the spring assembly and the foam-forming material are formed integrally with each other by means of the foaming of the foam forming material passing through a plurality of thin holes formed in the permeable reinforcing member. 2. The bed mattress according to claim 1, further characterized in that the permeable reinforcing member is further formed with a plurality of holes for expansion of the foam, arranged along row and column directions, of such that they are spaced apart at regular intervals, so that a part of the foam forming material penetrates through the interior of the spring assembly in an increased amount, through the holes for expansion of the foam, of in a manner which is convexly foamed, and a coupling portion between a spring of the spring assembly and a helical coil and / or a seam portion between the coils, or a portion of space between the coils, is embedded in the part of the forming material of foam foamed convexly. 3.- The mattress for bed in accordance with the claim 1 or 2, further characterized in that the permeable reinforcing member is a fine mesh having thin holes, each of which has a size of 1 to 30 mm x 1 to 30 mm; and / or holes for expansion of the foam, each of which has a diameter of 3 mm to 80 mm. 4. A mattress for bed according to claim 3, further characterized in that the permeable reinforcing member is a non-woven fabric having holes for expansion of the foam, each of which has a diameter of 3 to 80 mm . 5. The mattress for bed according to claim 2, further characterized in that the hole for expansion of the foam is formed penetratingly in the permeable reinforcing member, in such a way that it is arranged in a position that corresponds to the coupling portion between each spring of the spring assembly and the helical turn and / or the seam portion between the springs, or the portion of space between the springs. 6. The mattress according to claim 1, further characterized in that an edge skimmer is tightly fixed to the lateral surface of the spring assembly, but a lateral foam forming material is not foamed, along the lateral surface of the spring. spring assembly. 7. A method for manufacturing a mattress for a bed, including a spring assembly consisting of a plurality of springs and a helical turn to securely couple the springs together; characterized in said method because it comprises the steps of: a first step of fixedly disposing a permeable, single layer or multi-layer reinforcing member on the upper surface of the spring assembly; a second step of seating the spring assembly in a foaming space of a foam forming apparatus, filled with a foam-forming material, so that the outer surface of the permeable reinforcing member is in intimate contact with the space of foaming of the apparatus for foaming, and then foaming the foaming material; a third step of allowing the foam forming material to foam through the thin holes of the permeable reinforcing member, to cause the permeable reinforcing member and the partial portion of the spring assembly to be embedded in the foam forming material; and a fourth step of effecting the third step in case holes are additionally formed for expansion of the foam in the permeable reinforcing member, in addition to the thin holes; and simultaneously allowing a portion of the foam material to penetrate through the interior of the spring assembly in an increased amount through the holes for expansion of the foam of the permeable reinforcing member, so that it is convexly foamed so that a coupling portion between a spring of the spring assembly and the helical turn and / or a seam portion between adjacent springs, or a space portion between the springs, is embedded in the convexly foamed part of the foam-forming material. 8. The method according to claim 7, further characterized in that the foam-forming material is formed integrally with the upper and lower portions of the spring assembly by means of a fifth step of fixedly disposing the permeable reinforcing member, of a single layer or multi-layer, on the lower surface of the spring assembly; and then carry out the second, third and fourth steps, in the same way. 9. The method according to claim 7 or 8, further characterized in that an edge skimmer is tightly fixed to the lateral surface of the spring assembly; and then the foaming process is carried out in the upper and lower portions of the spring assembly. 1 0.- A bed mattress including a spring assembly having a plurality of springs disposed in row and column directions over the entire area of the bed mattress, and a fixing means for securing a cushioning material disposed thereon. upper / lower surfaces of the spring assembly; characterized in that: a permeable reinforcing member, of the mesh type and an intermediate layer, formed in the form of a single layer or multilayer sheet and formed with a plurality of through holes between the spring assembly are interposed. and the cushioning material (the foam forming material) so that the cushioning material formed of a foam forming material is foamed to cause the foam forming material to foam through the through holes to expand convexly and adhere to the Permeable reinforcing member and spring assembly to coagulate. 1 .- The mattress for bed according to claim 1 0, further characterized in that the intermediate layer is one selected from a felt, a non-woven fabric and a mat.
2. 2. A method for manufacturing a mattress for a bed that includes a spring assembly consisting of a plurality of springs and a helical turn to securely couple the springs together; characterized in said method because it comprises the steps of: loading a cushioning material such as a foam-forming material into a mold frame having the shape of the mattress; laminating an intermediate layer formed with through holes disposed spaced apart at regular intervals in the cushioning material (the foam-forming material); arranging the spring assembly on the intermediate layer; allowing the foaming of the cushion forming material (the foaming material) to advance; and allowing the foamed cushion material to expand convexly through the through holes of the intermediate layer to adhere to the spring assembly, so as to coagulate.
3. 3. The method according to claim 12, further characterized in that the step of laminating the intermediate layer in the cushioning material (the foam-forming material) further comprises the step of laminating a permeable reinforcing member over the intermediate layer. . 14. A method for manufacturing a mattress for bed that includes a spring assembly that contains a plurality of springs and a helical spiral to securely engage the springs with each other.; characterized in said method because it comprises the steps of: loading a cushioning material such as a foam-forming material, into a mold frame having the shape of the mattress; integrally assembling together the spring assembly, a permeable reinforcing member and an intermediate layer to form an assembly; and arranging the assembly on the cushioning material (the foam forming material); allow the foaming of the cushioning material (the foaming material) to advance; and allowing the foamed cushion material to expand convexly through the through holes of the intermediate layer, to adhere to the spring assembly, so that it coagulates.