WO2013106066A1 - Structures de surmatelas à faible cisaillement - Google Patents

Structures de surmatelas à faible cisaillement Download PDF

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Publication number
WO2013106066A1
WO2013106066A1 PCT/US2012/037720 US2012037720W WO2013106066A1 WO 2013106066 A1 WO2013106066 A1 WO 2013106066A1 US 2012037720 W US2012037720 W US 2012037720W WO 2013106066 A1 WO2013106066 A1 WO 2013106066A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
foam
layers
internal
mattress topper
Prior art date
Application number
PCT/US2012/037720
Other languages
English (en)
Inventor
David MORET
Steven TYREE
Andy BEAMON
Original Assignee
Sealy Technology, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sealy Technology, Llc filed Critical Sealy Technology, Llc
Publication of WO2013106066A1 publication Critical patent/WO2013106066A1/fr

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
    • A47C27/122—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with special fibres, such as acrylic thread, coconut, horsehair
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/22—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with both fibrous and foamed material inlays

Definitions

  • the present disclosure and related inventions is in the general field of cushion devices and products, including bedding and mattresses and sleep sets.
  • a core which consists bf springs, foam or other reflexive devices or materials and in various combinations.
  • additional components or layers of materials referred to as comfort layers, which together with the core define the underlying support characteristics of the mattress.
  • the core, comfort layers and other internal components of the mattress are covered by upholstery which includes one or more vertically oriented side panels referred to as the border, and a top panel over the support or sleep surface.
  • the top panel typically includes upholstery fabric with some additional backing such as a thin layer of foam on the underside or flame resistant material, and a liner such as a non-woven sheet material.
  • top panel is commonly stitched throughout the entire surface area by a multi-needle sewing machine which forms a quilt-like pattern and appearance on the surface of the top panel upholstery by the compression of the fabric against the backing material. For this reason tfie top panel is often referred to as a "quilt panel” or "quilted topper".
  • additional foam layers or foam layjers of greater thickness are used in an effort to improve the cushion characteristics of the uppermost region of the mattress.
  • frictional shear forces between the layers of material of the quilt package can result in unevenness in the quilt upholstery surface, binding ins ide of the quilt package, and lateral transfer of forces through the quilt package.
  • the manufacturing oif the quilt package can be problematic when there is frictional binding between the internal layers
  • FIG. 1 is an elevation cross-sectional view of a mattress including a
  • FIG. 2 is a cross-sectional view of one embodiment of a low shear mattress topper of the present disclosure and related inventions, and
  • FIG. 3 is a cross-sectional view of an alternate embodiment of a low shear mattress topper the present disclosure and related inventions.
  • the present disclosure and related inventions is directed to cushioning and support device or assembly such as a mattress, having various combinations (if materials and layers of material which provide additional cushioning and support, including multiple layers foam ar d a low friction or low shear layer between the layers foam which allows ease of relative movement between the foam layers for an improved feel and support performance of the comfort layers of the mattress.
  • the low friction or low shear lay ⁇ between the layers of foam creates a relatively low coefficient of friction and reduced shear forces as compared to a foam-to-foam contact interface, and allows two or more layers of foam to easily slide or deform laterally relative to each other.
  • the upper layer of foam is thus ab e to compress and move independently, and laterally in particular, relative to the underlying or adjacent layer or layers of foam, so that two or more layers of foam such as are provided in a mattress do not behav as a monolithic block of foam and do not bind or resist movement or conformance due io frictional shear forces.
  • a representative mattress construction of the disclosure includes a core, generally indicated at 50.
  • the core 50 may be of any construction, such as an array of interconnected steel wire coiled springs (innerspring) as shown in FIG. 2, wire coil springs contained in fabri bc material (pocketed coils) also shown in FIG. 2, one or more pieces of foam (foam core) as shown in FIG.
  • the representative mattress constructions 10 are illustrated as "one-sided" type mattresses, with only one side of the core designed for use as a sleep surface, and the opposite underside 55 as a mounting surface on which the mattress is supported by a foundation, frame, floor or other support structure.
  • the low shear mattress topper constructions of the present disclosure however can be incorporated into the construction of a two sided mattress in which both sides of the core are configured for use as a sleep surface.
  • the underside 55 of the core 50 can be optionally configured with one or more layers of generally planar material, indicated at 60, to provide a planar surface for mounting of the mattress on a support structure.
  • comfort layers On the sleep surface side or sides of the core 50 are provided bne or more comfort layers, generally indicated at 70, which are most commonly layers of foam, with a first comfort layer 71 placed directly over the support surface area of the core 50, and additional comfort layers such as layer 72 placed in contact with the surface area of layer 71, etcetera. Layers of materials other than foam may also be similarly incorporated into the comfort layers 70 of the mattress construction.
  • the mattress core 50 and comfort layers 70 are covered by upholktery, indicated at 80, which extends around the vertical sides of the mattress in the form of a border generally indicated at 81, and also a sheet material covering over the under underside 55.
  • Upholstery 80 also extends over the topper 100, which may or may not be the same type or style material of the upholstery of the border 81.
  • the topper upholstery 102 is attached to the border upholstery 81 along a seam, generally indicated at 90, the construction pf which may further include a tape edge 92 which encapsulates the adjoining edges of the upholstery material, This is referred to as the "tape edge” or “tape edge seam” and is the primary or sole attachment of the topper 100 to the remainder of the mattress.
  • the topper 100 includes, in addition to the topper upholstery 10&, one or more layers of topper material or mattress topper layers or mattress topper internal layers which may include foam, fibers, cotton, wool, feathers or any other synthetic or natural materials in a generally co-planar arrangement as shown.
  • a first layer of topper material 104 is preferably a fiber based material which can be adhered to substantially the entirety of the underside of topper upholstery 102 or otherwise arranged to provide support and loft to the topper upholster) 102, and which also preferably includes, is made of or treated with a flame resistant or fir retardant material as known in the art.
  • Topper layer 104 thus serves as a flame resistam barrier which will withstand the standardized flame burn test for mattresses over the entire: surface area of the topper 100.
  • the fire resistant material for topper layer 104 may include flame and heat resistant materials such as fiber mats, woven or noriwoven fabrics, knittec! fabrics, films, laminates, and flexible composites or combinations thereof. Fibers of topper layer 104 can be formed into a batt or fabric web and stitchbonded using the appropriate yarn to form a fire resistant layer.
  • Flame and heat-resistant fibers known in the art include boron, basalt, carbon, glass, ceramic, graphite, aramid polymers, polytetrafluoroethylene (PTFE), polyimide, phenolformaldehyde, polybis-imidazole, polyvinylidene chloride, polysulfide, melamine, silicon carbide, and blends thereof.
  • PTFE polytetrafluoroethylene
  • polyimide polyimide
  • phenolformaldehyde polybis-imidazole
  • polyvinylidene chloride polysulfide
  • melamine silicon carbide
  • Topper material 106 is in this embodiment a layer of foam material or the like which also extends over substantially the entirety of the topper 100 and comfort layers 70, and which is adjacent to or immediately adjacent to topper layer 104.
  • Another topper layer 1 10 hi also preferably made of foam, and can be of the same or different thickness than topper laye r 106.
  • Topper layer 110 as illustrated serves as a base layer of the topper 100 for primary contact with the top surface of the comfort layers 70.
  • a low shear layer 108 which is preferably in the form of a polymeric fiber layer in the form of planar mat, either spunbound or meltbound wherein the fibers are interconnected but provide loft and spacing between opposing sides of the layer, and a high degree of motion by flexure of the fibers under shear or compression.
  • topper layer 108 are preferably in direct contact with the facing surfaces of topper layers 106 and 110 and, due to the dissimilarity of materials there is a relatively high coefficient of friction at those layer interfaces, greater than the internal shear force of topper layer 108, so that topper layer l Oi allows a greater degree of lateral displacement between topper layers 106 and 1 10 than i foam-to-foam interface.
  • Topper layer 108 is also referred to herein as "low shear layer” and "low shear low shear insert layer”.
  • any suitable material which has an internal shear force measurement, internal friction or resistance to lateral deformation which is less than the adjacent layers of the topper 100 can serve as the low shear layej in accordance with tljie principles of the present invention.
  • Stitches 1 12 may extend through the various layers of the mattress topper 100, fbr example in a quilt-like pattern in order to maintain general alignment of the layers.
  • the relatively high degree of freedom of movement of topper layer 108 combined with the ability of the stitches 112 to deform with lateral forces enables the low shear motion, function and feel of the mattress topper 108.
  • the low shear insert layer between any two layers of foam can be any material which has a lower internal coefficient of friction than foam. This is also referred to herein as “lew shear” and “low shear resistance”.
  • Shear force as defined and used herein is an amount af force applied parallel to opposing planar surface of a layer of material of a mattress, such as a topper layer, sufficient to displace one surface of the layer or portion thereof relative to the other surface.
  • Shear resistance as used herein refers to the tendency of a material layer of a mattress topper to resist lateral displacement of one or both major planar sides of the layer.
  • shear force of one of the layers of the mattress top of the: present disclosure is less than the shear force of another layer of the piattress topper such as) a foam layer, or less than the shear force between contacting layers o the mattress topper, it is referred to herein as "low shear” or “reduced shear” or lower shear resistance”.
  • One exemplary embodiment is non-woven synthetic fibers such as polyester or polypropylehe which are loosely arranged in a mat form without any binding agent, so that the fibers of tne mat are free for relative movement including lateral displacement.
  • he disclosure include woven sheet material, preferably of synthetic fibers which have relatively low sliding coefficient of friction with itself and with other material such as foa n.
  • woven or n woven materials include silk, polyester, polypropylene, acrylic, acetate, acrylonitrile or Rayon.
  • the tension relief quilt or low shear mattress topper 100 includes a first layer of foam 110, the first layer of foam having a generally planar top surface and a generally planar bottom surface parallel tb and opposite the generally planar top surface, and four generally planar side walls that are perpendicular to and extend between the generally planar top and bottom surfaces.
  • the first layer of foam is positioned closest to the mattress core 50, such as an innerspring or foam core.
  • the generally planar top surface of the first foam layer is in direct contact with a bottom surface of a first fiber layer (also referred to herein as an "low shear insert layer").
  • the top surface of the first fiber layer, which is opposite the bottom surface is in direct contact with a bottom surface of a second foam layer.
  • the second foam layer has a generally planar top surface and a generally planar bottom surface parallel to and opposite the generally planar top surface, and four generally planar side walls which are perpendicular to and extend between the generally planar top and bottom surfaces.
  • the first fiber layer 108 which is placed between the first and second foam layers, can be made of non-fire retardant, non-woven, non-densified, high-loft fiber.
  • non-woven is used in the textile industry to denote fabrics which are neither woven nor knitted.
  • Non-woven fibers are engineered fibers that are typically manufactured by putting small fibers together in the form of a sheet or web, and then bonding them together by chemical, mechanical, heat or solvent treatment.
  • non-densified refers to fibers which have not bonded to each other through the melting and re-solidification of bonding fibers.
  • “High- loft” is a term given to a fiber structure that contains more air than fiber.
  • high-loft fibers retain more warmth.
  • Foam-on-foam contact creates a significant amount of friction between two foam surfaces.
  • the first fiber layer operates to create a low coefficient of friction between the first and second foam layers. Therefore, the fiber layej- must be made of material which has a slick or slippery surface.
  • Such materials include, but ire not limited to: polyester, polypropylene, nylon silk, acrylic, acetate and rayon.
  • the first fiber layer which is sandwiched between the first and second foam layers, is made of .5 oz. 100% polyester fiber
  • the first foam layer which is positioned closest to the mattress core or innerspring, or below the first fiber layer, can be made of any suitable foam material.
  • the thickness, density and indentation force deflection (IFD) may vary according to the desired jnattress qualities
  • the first foam layer is made of Hypersoft Quilt Polyurethane Foam having a thickness of approximately 1 -inch, a density of approximately 1.15 lb/ft 3 and an IFD of 14.5 lbs.
  • Hypersoft is a super soft supple foam having an improved tear strength and permeability.
  • a second foam layer 106 which is positioned closest to the mattresjs surface, or above the first fiber layer, can be made of any suitable foam material.
  • the thickness, density and IFD may vary according to the desired mattress qualities.
  • the second foam layer is identical to the first foam layer or a 1-inch layer of Hypersoft Quilt Polyurethane Foam having a density of approximately 1.15 lb/ft 3 and an IFD of 14.5 lbs.
  • the second foam layer may be a 1-inch polyurethane layer having a density of approximately .75 lb/ft 3 .
  • the second foam layer may be a 1-inch polyurethane layer having a density of approximately 1.15 lb/ft 3 .
  • the was density layer positioned closest to the mattress surface results in a softer initial feel to a user sitting or lying thereon.
  • a second fiber layer 104 may be positioned above the second foam layer and below the mattress tick.
  • the second fiber layer is made of .8 oz.
  • Light Fire Retardant (FR) or Rayon. Fire retardant material in a non-woven or low shear insert layer may increase the internal coefficient of friction of a such a layer, but the described action of the adjacent foam layers may still be achieved.
  • Other additives which enhance the low-friction/low-shear properties could be used with non-woven layers or inserts made of other materials as disclosed.
  • any combination of materials may be used for the low shear insert layers, such a first low shear insert layer of a first type of material adjacent to a surface of a first layer of foam, and a second low shear insert layer of a second type of material which has a relatively low coefficient of friction with the first type of material positioned adjacent to an opposing surface of a second layer of foam.
  • Other embodiments include multiple (i.e., more than two) layers of foam, with an low shear insert layer between each layer of foam, or with low shear insert layers of varying coefficients of static or sliding friction between the foam layers.
  • Fire retardant material can be incorporated into any of the described layers of the mattress topper.

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

L'invention concerne des structures de surmatelas à faible cisaillement ayant de multiples couches internes de surmatelas comportant au moins une couche intermédiaire constituée d'un matériau à faible cisaillement et disposée entre la mousse ou d'autres couches afin de réduire les forces de cisaillement de friction et de permettre un degré supérieur de déplacement latéral entre les couches de surmatelas. La combinaison de couches de mousse et de fibres crée une sensation différente perceptible sur la surface du matelas par rapport à des structures de courtepointe de l'état de la technique, et permet aux couches de mousse de se déplacer plus librement les unes contre les autres en empêchant les deux couches de mousse de se lier au niveau de l'interface en raison des forces de cisaillement de friction élevées de la mousse contre la mousse.
PCT/US2012/037720 2011-05-11 2012-05-14 Structures de surmatelas à faible cisaillement WO2013106066A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US61/485,342 2011-05-11
US201161485342P 2011-05-12 2011-05-12

Publications (1)

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WO2013106066A1 true WO2013106066A1 (fr) 2013-07-18

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USD691400S1 (en) 2012-02-10 2013-10-15 Nomaco Inc. Stackable base for mattress assembly
USD693148S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693146S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693149S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693144S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693147S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693145S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD694041S1 (en) 2012-09-28 2013-11-26 Noel Group Llc Mattress bed cushion
USD694552S1 (en) 2012-04-27 2013-12-03 Noel Group Llc Mattress bed cushion
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USD697337S1 (en) 2012-07-03 2014-01-14 Nomaco, Inc. Stackable base for mattress assembly
USD701713S1 (en) 2012-11-09 2014-04-01 Noel Group, Llc Mattress bed cushion
USD704962S1 (en) 2013-09-09 2014-05-20 Noel Group Llc Mattress bed cushion
USD707467S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD707468S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD709301S1 (en) 2012-11-09 2014-07-22 Noel Group Llc Mattress bed cushion
US10045633B2 (en) 2013-04-26 2018-08-14 Noel Group Llc Cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow, and related methods
US11026517B2 (en) 2016-12-29 2021-06-08 Sealy Technology, Llc Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same

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USD691401S1 (en) 2009-03-06 2013-10-15 Noel Group, Llc Mattress bed cushion
USD693148S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693144S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693145S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD694553S1 (en) 2010-03-03 2013-12-03 Noel Group Llc Mattress bed cushion
USD691400S1 (en) 2012-02-10 2013-10-15 Nomaco Inc. Stackable base for mattress assembly
USD693146S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693149S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693147S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD694552S1 (en) 2012-04-27 2013-12-03 Noel Group Llc Mattress bed cushion
USD697337S1 (en) 2012-07-03 2014-01-14 Nomaco, Inc. Stackable base for mattress assembly
USD694041S1 (en) 2012-09-28 2013-11-26 Noel Group Llc Mattress bed cushion
USD701713S1 (en) 2012-11-09 2014-04-01 Noel Group, Llc Mattress bed cushion
USD707467S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD707468S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD709301S1 (en) 2012-11-09 2014-07-22 Noel Group Llc Mattress bed cushion
US10045633B2 (en) 2013-04-26 2018-08-14 Noel Group Llc Cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow, and related methods
USD704962S1 (en) 2013-09-09 2014-05-20 Noel Group Llc Mattress bed cushion
US11026517B2 (en) 2016-12-29 2021-06-08 Sealy Technology, Llc Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same

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