WO2013112840A1 - Production de mousses synthétiques et de matelas en mousse - Google Patents

Production de mousses synthétiques et de matelas en mousse Download PDF

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Publication number
WO2013112840A1
WO2013112840A1 PCT/US2013/023151 US2013023151W WO2013112840A1 WO 2013112840 A1 WO2013112840 A1 WO 2013112840A1 US 2013023151 W US2013023151 W US 2013023151W WO 2013112840 A1 WO2013112840 A1 WO 2013112840A1
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WO
WIPO (PCT)
Prior art keywords
foam
layer
top layer
mattress
engineered
Prior art date
Application number
PCT/US2013/023151
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English (en)
Inventor
Steve TYREE
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
Priority to DK13741433.0T priority Critical patent/DK2806771T3/en
Priority to US14/374,613 priority patent/US20150067967A1/en
Priority to EP13741433.0A priority patent/EP2806771B1/fr
Priority to ES13741433.0T priority patent/ES2583207T3/es
Publication of WO2013112840A1 publication Critical patent/WO2013112840A1/fr

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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
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C21/00—Attachments for beds, e.g. sheet holders, bed-cover holders; Ventilating, cooling or heating means in connection with bedsteads or mattresses
    • A47C21/04—Devices for ventilating, cooling or heating
    • A47C21/042—Devices for ventilating, cooling or heating for ventilating or cooling
    • A47C21/046—Devices for ventilating, cooling or heating for ventilating or cooling without active means, e.g. with openings or heat conductors
    • 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
    • A47C27/056—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 with different layers of foamed material
    • 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
    • A47C27/08—Fluid mattresses or cushions
    • A47C27/085—Fluid mattresses or cushions of liquid type, e.g. filled with water or gel
    • 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
    • A47C27/08—Fluid mattresses or cushions
    • A47C27/088—Fluid mattresses or cushions incorporating elastic bodies, e.g. foam
    • 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
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
    • A47C27/144—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24496—Foamed or cellular component
    • Y10T428/24504—Component comprises a polymer [e.g., rubber, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249981—Plural void-containing components

Definitions

  • Solid foams included closed cell and open cell (reticulated) structures, provide lightweight cellular engineering materials for weight bearing and distribution (pressure distribution) and energy absorption.
  • open-cell-structured foams have pores that are interconnected in a network.
  • the interstitial spaces of open-cell foams can be filled with gas, liquid or solid material.
  • the density of foam is determined in part by both the amount of structural material which forms the cells, such as polyurethane, polyethylene or latex, and the volume or size of the cells.
  • Closed-cell foams generally do not have interconnected pores, generally have relatively higher compressive strength due to the closed cell bubble structures, and are relatively more dense.
  • the closed-cell structure foams have higher dimensional stability, low moisture absorption coefficients, and higher strength compared to open-cell-structured foams.
  • the closed cells can be filled with gases to provide improved insulation, or with other materials to alter the physical properties of the foam. All types of foam have been widely used as core material in sandwich structure composite materials.
  • syntactic foam A special class of closed-cell foams is known as syntactic foam, which contains hollow particles embedded in a matrix material.
  • the spheres can be made from several materials, including glass, ceramic, and polymers.
  • the advantage of syntactic foams is that they have a very high strength-to-weight ratio, making them ideal materials for many applications, including deep-sea and space applications.
  • One particular syntactic foam uses shape memory polymer which enables the foam to take on the characteristics of shape memory resins and composite materials with hysteresis properties which enable it to be reshaped repeatedly when heated above a certain temperature and cooled.
  • Shape memory foams have been increasingly used in bedding products such as mattresses and pillows.
  • a significant performance issue and problem with visco-elastic and latex foam mattresses is the concentration of heat which accumulates during use as a result of the high density and low thermal conductivity of the foam material.
  • Gels are a dispersion of molecules of a liquid within a solid in which the solid is the continuous phase and the liquid is the discontinuous phase.
  • Gels consist of a solid three-dimensional network that spans the volume of a liquid medium and increases surface tension. The network structure may result from physical bonds (physical gels) or chemical bonds (chemical gels), as well as crystallites or other junctions that remain intact within the fluid.
  • Different mediums can be used as an extender including water (hydrogels), oil, and air (aerogel). Gels are mostly fluid in composition by weight and volume and exhibit densities similar to those of their constituent liquids.
  • Gels including polyurethane gels provide even pressure distribution and reduced pressure concentration by deformation in multiple dimensions in response to loads. Gels have measurable hardness and elastic properties, which can be engineered and selected for particular applications and uses. Test method ISO 3386-1 provides for calculation of a compression stress/strain value for gel and a resultant hardness value. A gel sample (5cm x 5cm x 2.5cm) is compressed to 70%, with hardness measure as the stress applied (kPa) at 40% compression. Polyurethane gels are known to be resistant to hardening over time, have limited expandability and are resistant to degradation. [009] In addition to gel as an additive to foam for enhanced mechanical (e.g.
  • phase change material has been combined with foam to enhance or improve thermal transfer and temperature regulation properties.
  • PCMs are materials with a high heat of fusion which melt and solidify at particular temperature or temperature range depending upon the type and purity of the material, and are capable of storing and releasing large amounts of energy in the phase transition. Heat is absorbed or released when the material changes from solid to liquid and vice versa.
  • Latent heat storage can be achieved through solid-solid, solid-liquid, solid-gas and liquid-gas phase change.
  • the only phase change used for PCMs is the solid-liquid change. Initially, the solid-liquid PCMs behave like sensible heat storage (SHS) materials; i.e. temperature increases as heat is absorbed.
  • SHS sensible heat storage
  • PCMs Unlike conventional SHS, however, when PCMs reach the temperature at which the phase change occurs, heat is absorbed at an almost constant temperature. Heat absorption continues without a significant rise in temperature until all the material is transformed to the liquid phase. When the ambient temperature around a liquid material falls, the PCM solidifies, releasing its stored latent heat.
  • a large number of PCMs are available in any required temperature range from -5 up to 190 °C. Within the human comfort range of 20° to 30°C, some PCMs are very effective, and can store 5 to 14 times more heat per unit volume than conventional storage materials such as water, masonry or rock.
  • PCMs have been applied to fabrics and to thin foam layers as a surface coating for temperature control, particularly for heat retention and storage properties, as disclosed for example in U.S. Patent Nos. 5,290,904 and 5,955, 188.
  • the PCM is provided in microsphere encapsulation and mixed with a polymer binder for adhesion to a substrate.
  • U.S. Patent No. 6,699,266 discloses use of PCMs with melting temperatures in a range of 18 to 32 degrees Centigrade, held in a liquid suspension in a support pad to absorb body heat with no appreciable increase in temperature of the pad.
  • Patent No. 5,366,801 discloses a coating of PCM capsules as a textile finish.
  • U.S. Patent No. 5,637,389 discloses foam with embedded PCM microcapsules.
  • the present invention is of foam mattress constructions made and engineered foams which contain additives for improved mechanical and thermal properties.
  • engineered foam for use as a layer in a foam mattress construction having multiple layers including a top layer of foam and at least one additional layer of foam, and a coating of phase change material applied to a top surface of the top layer of foam.
  • Surface application of phase change material to a top surface of a top layer of foam of a foam mattress provides more efficient transfer of heat away from a body on the mattress and reduced heat accumulation at the body-mattress interface.
  • the surface applied phase change material is micro- encapsulated phase change material in combination with a binder, and applied to a substantial area of a top surface of a top layer of foam of a mattress.
  • the surface application of phase change material can be used on any of the foam types used in mattress construction and aftermarket foam pads, and with foam additives such as gel or other material in the foam structure.
  • the engineered foams can also be used in innerspring and pocketed spring mattresses, and as separate foam cushions or layers outside of mattress upholstery.
  • the upper or uppermost layers of a one-sided mattress are typically made of various types of visco-elastic or "memory" foam.
  • at least one of the upper layers and preferably a top foam layer includes a temperature control additive.
  • at least one of the upper layers has a gel material in the foam, i.e. integrated into the cellular structure of the foam.
  • the temperature control additive is preferably in the form of a phase change material, for example as packaged or contained in micro-capsules or microspheres and applied to or otherwise integrated with the foam material, but is preferably located substantially at a surface of the foam and not within the foam structure.
  • intermediate layer in addition to the coated top layer, there is at least on intermediate layer and preferably two intermediate layers and even more preferably two or more intermediate layers which underlie the top layer.
  • the intermediate layers may be of the same type of foam or a different type of foam as top layer, and with or without any gel additive.
  • the intermediate layer or layers may be of the same or greater thickness than top layer, and when there are two or more intermediate layers the respective thicknesses may be the same of different.
  • FIG. 1 is a perspective view of an embodiment of a foam mattress of the present disclosure
  • FIG. 2 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure
  • FIG. 3 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure
  • FIG. 4 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure
  • FIG. 5 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure.
  • FIG. 6 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure.
  • FIG. 7 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure.
  • FIG. 8 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure.
  • FIG. 9 is a partial cross-sectional view of an alternate embodiment of a foam mattress of the present disclosure.
  • FIG. 10 is a perspective view of an alternate embodiment of a foam mattress construction of the present disclosure.
  • FIG. 11 is a perspective view of an alternate embodiment of an innerspring mattress construction of the present disclosure.
  • FIG. 12 is an exploded view of an alternate embodiment of a foam mattress construction of the present disclosure.
  • Novel engineered foams and foam mattress constructions are disclosed which include engineered foams as layers in foam mattresses.
  • engineered foam refers to and means the various different types and configurations of described foams and attendant properties, and the various described additives and treatments and related methods of manufacturing and processing.
  • Each of the various alternate embodiments of the foam mattresses are constructed of multiple layers of foam of differing types, configurations, dimensions, properties and additives or modifiers.
  • the upper or uppermost layers of a one-sided mattress are typically made of various types of visco-elastic or "memory" foam with densities in an approximate range of 2.0-8.0 lbs/cu.ft, and an initial force deflection (IFD, 25% indentation) in an approximate range of 10 to 20 lbs.
  • IFD initial force deflection
  • upper layer As used herein, the terms “upper layer”, “upper layers”, “comfort layers” and , “top layer” and “topper” all refer to and mean the one or more layers of a foam mattress construction which are located in an upper or uppermost region of the mattress, proximate to or forming the support surface of the mattress, and supported by one or more intermediate layers and a one or more base layers or core layers, which generally has an aggregate thickness dimension greater than a thickness dimension of the upper layers.
  • At least one of the upper layers and preferably a top foam layer includes a temperature control additive.
  • at least one of the upper layers has a gel material in the foam, i.e. integrated into the cellular structure of the foam.
  • the temperature control additive is preferably in the form of a phase change material, for example as packaged or contained in micro-capsules or microspheres and applied to or otherwise integrated with the foam material, but is preferably located substantially at a surface of the foam and not within the foam structure.
  • the phase change material may be of the paraffmic hydrocarbon type as listed in Table I, and preferably contained or encapsulated within microspheres (also referred to as "micro-capsules"), which may range in diameter from 1 to 100 microns.
  • microspheres also referred to as "micro-capsules”
  • Polymeric microspheres containing paraffmic wax or n-octadecane or n- eicosane are commercially available and are suitable for combination with foam, either as an additive in any area or region of a particular piece or layer of foam, or as a surface coating, for example when contained in a water based acrylic-latex coating which can be applied to a foam surface by spraying or roll coating to any desired thickness or density, such as for example in the range of 50- 100 g m 2 .
  • the paraffmic wax can be selected or blended to have a desired melt temperature or range.
  • the polymer for the microspheres is selected for compatibility with the foam material.
  • a preferred PCM has a phase transition temperature range is 28-32 degrees C, such as are commercially available from Outlast Technologies, Inc.
  • a foam mattress 10 as shown in FIG. 1 has an uppermost or top layer or top layer 100 (also referred to herein as "PCM coated layer” and “top layer of foam”) which is made of a visco-elastic foam with a density in an approximate range of 4.0 to 8.0 lbs./cu.ft. and an IFD (25% indentation) in an approximate range of 10 to 20 lbs.
  • top layer 100 also referred to herein as "PCM coated layer” and “top layer of foam”
  • top layer 100 also referred to herein as "PCM coated layer” and "top layer of foam”
  • top layer 100 which is made of a visco-elastic foam with a density in an approximate range of 4.0 to 8.0 lbs./cu.ft. and an IFD (25% indentation) in an approximate range of 10 to 20 lbs.
  • at least one side of the top layer 100 has a convoluted surface, i.e. non-planar which is oriented downward to face the underlying layers of the mattress
  • an area 101 is a prescribed area in which a PCM is applied by sprayed, rolled or other mode of application as a relatively thin layer or coating, referred to generally herein as "PCM coating".
  • the area 101 is illustrated as somewhat less than the total surface area of the top layer 100, but can alternatively be equal to the total surface area of top layer 100.
  • the PCM is in the described microcapsule encapsulation form, and in combination with an adhesive or binding agent (or "binder") which adheres the PCM microcapsules to the surface of top layer 100.
  • the PCM microspheres are mixed with an acrylic binder that makes up 55% of the solids, for example in a mixed liquid formulation which is sprayed onto the foam surface.
  • the foam with the applied PCM can then be passed under heaters to evaporate the liquid carrier from the surface.
  • a preferred thickness of the applied PCM layer is on the order of approximately 50-100 mils or greater, and may be varied in accordance with the concentration of PCM microcapsules, the type of PCM in the microcapsules, and the amount of heat absorption desired. It is preferred that the PCM coating layer reside primarily and substantially at the surface of top layer 100, although some penetration of the PCM into the top layer 100 is acceptable. This configuration maximizes the thermal transfer and heat sink efficiency of the PCM with a body in contact with top layer 100. In a further alternate embodiment, the top layer 100 is substantially impregnated with PCM, either by application to one or both surfaces of the layer 100, or integrated into the foam structure in the manufacturing process.
  • top layer 100 has a relatively small thickness dimension, for example 2 inches or less, whereby the PCM in the top layer 100 is present in sufficient quantity and held in close proximity to a body in contact with the top layer 100 for efficient thermal transfer.
  • a further advantage of the topical layer, coating or surface application of PCM to the top layer 100 of a foam mattress is that the PCM is present in an effective amount or concentration without altering the support characteristics or feel of the foam.
  • the top layer 100 retains all of its compression, resilience and support properties which are effectively unaltered by the relatively thin layer or PCM. Furthermore there is no degradation of the foam structure, and no surface tension is created which alters the firmness or feel of the top layer 100.
  • the area 101 of the PCM coating or layer is sufficient to be in thermal contact with one or more bodies on the mattress 10 and to effectively absorb heat from the body or bodies, i.e. to undergo the phase transition without an appreciable increase in the temperature at the surface of top layer 100.
  • the size, shape and thickness of area 101 of the foam top layer 100 can be varied for any desired thermal performance on any size or type of foam mattress, or with any type of mattress (foam or innerspring or other non-foam core or components).
  • Multiple areas or zones of surface applied PCM may be formed on top layer 100. Applying PCM as a coating to an area or areas witrjin the boundaries of top layer 100 results in concentration of PCM enhances the thermal transfer efficiency.
  • Application by template or controlled spray provides precise control and tolerances and is adaptable to any size mattress.
  • the PCM does not penetrate into the foam structure no more than 1 to 2 mm.
  • a particular advantage of the surface application or coating of PCM on the top layer of a foam mattress construction is the absorption of heat from one or more bodies on the mattress and reduction in the increase of the surface temperature of the mattress. With the PCM in the closest possible proximity to the body heat source, the transfer of heat into the foam of the mattress is retarded. The foam of the mattress thus receives and stores a lesser amount of heat. As the mattress cools, the stored heat is released from the PCM more efficiently than heat from a non-PCM coated foam mattress.
  • the PCM surface coating 101 can be applied to any layer of a foam mattress of any configuration.
  • PCM may be applied to an underside of such layer and provide the described thermal functions.
  • both sides of one or more foam layers of a mattress may be coated with PCM in the same or different patterns.
  • differing types of PCM materials may be surface applied to the same or opposing sides of one or more foam layers. Blends of different PCM materials may be surface applied, either in a single application or as applied layers.
  • PCM surface coating can be applied to any type of foam which is suitable for use in a foam mattress, or to any foam layers of any type of mattress such as innerspring or pocketed coil spring mattresses.
  • One or more layers of the foam mattress constructions of the present disclosure may be comprised of foam material, such as visco-elastic foam including for example natural or synthetic latex, polyurethane or polyethylene foams, and gel such as polyurethane gels, preferably in particular form.
  • foam material such as visco-elastic foam including for example natural or synthetic latex, polyurethane or polyethylene foams, and gel such as polyurethane gels, preferably in particular form.
  • the gel containing foam layer of layers of a foam mattress construction is comprised of any of the disclosed foam materials with discrete particles of gel interspersed and generally evenly distributed throughout the foam structure or cellular network.
  • the gel particles may range in size from less than 1mm to greater than 5mm in diameter. Substantially even distribution of gel particles throughout the foam structure produces a hybrid material in which the physical properties of the foam and gel, including hardness, density, energy absorption and thermal conductance are combined.
  • a visco-elastic foam with particular density and hardness properties will correspondingly deform at a particular rate under a load.
  • a dispersed gel additive the density of which is generally greater than that of foam, e.g. in a range of 600 to 1 100 kg/m 3
  • the rate and degree of deformation as well as the recovery rate (memory) when unloaded.
  • the thermal properties of gel are also employed when present as an additive in particulate or other form in the foam, and in combination with PCM applied to a surface of the foam.
  • gel has greater thermal conductivity than foam, and the thermal conductivity can be altered by use of certain fillers.
  • the thermal conductivity of the PCM coating applied to the top layer 100 can be selected, matched or balanced with reference to the thermal conductivity of the foam and/or the thermal conductivity of the gel in top layer 100 for the desired thermal management properties.
  • the thermal conductivity of the PCM corresponds to the thermal conductivity of the foam of the foam layer to which the PCM is applied, and/or to the gel in the foam layer to which the PCM is applied.
  • foam mattress constructions 10 shown in FIGS. 2-9 additional foam layers are provided in combination with the top layer 100 with the PCM coating layer 101. Any of the various layers may be planar on one or both sides, or convoluted or otherwise contoured on one or both sides.
  • the layers of the foam mattresses are referenced in groups as core layers Cl-Cn, intermediate layers Il-In, top layer 100. Gel is depicted in particulate form at G in FIGS. 2-9.
  • intermediate layer I in addition to the PCM coated top layer 100, there is at least on intermediate layer I and preferably two intermediate layers and even more preferably two or more intermediate layers which underlie the top layer 100.
  • the intermediate layers may be of the same type of foam or a different type of foam as top layer 100, and with or without any gel additive.
  • the intermediate layer or layers I may be of the same or greater thickness than top layer 100, and when there are two or more intermediate layers the respective thicknesses may be the same of different, as illustrated.
  • a preferred core construction of layers C1-C3 includes relatively thick layers CI and C3, each having a planar side and a non-planar side such as convoluted, with the non- planar sides in an opposing arrangement, and a medial core layer C2 which is planar and of substantially less thickness.
  • the relative thicknesses of layers CI and C3 may be the same of different as illustrated.
  • Representative total thickness dimensions for layers CI and C3 range from approximately 2 to 6 inches with a density of approximately between 2 to 2.25 lb/ft 3 , preferably 2.05 lb/ft 3 .
  • Representative thickness dimension for the medial core layer C2 is in the approximate range of 0.5 to 2 inches.
  • the core layers CI and C3 can also be configured with full thickness dual planar edge regions, indicated at 105 (shown in FIG. 1), which provide increased foam density and rigidity along the longitudinal edges of the mattress.
  • a planar insert 1051 can be provided at the edges, such as the longitudinal edges of layer C3 to provide greater hardness or rigidity in that region, and a flush planar wall construction of layers C3 and II, alternatively, optionally, or additionally along the longitudinal edge of layer CI, as shown in FIGS. 1 and 11.
  • FIG. 11 illustrates an alternate embodiment of a mattress of the disclosure wherein layers 100 and II are combined with an innerspring 200.
  • the innerspring 200 or spring core may be any type of innerspring which has a plurality of springs, such as coil springs or the like, which are arranged in a matrix and interconnected either by wire or other material such as fabric, such as pocketed or encased coils.
  • FIGS. 1, 10 and 11 Covering or upholstery for the different types of mattresses are illustrated in FIGS. 1, 10 and 11, indicated at U, enclosing the described foam constructions and other internal components such as innerspring or pocketed coils.
  • a PCM coated top layer 110 can be used external to the upholstery U of a mattress, which supplied for example as an accessory or an aftermarket product for use with a mattress. This provides the improved thermal properties and additional support of top layer 110 in combination with any mattress.

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  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

La présente invention concerne la production de matelas en mousse et des mousses synthétiques contenant des additifs qui confèrent des propriétés thermiques et mécaniques améliorées. Selon un mode de réalisation, l'invention concerne une mousse synthétique destinée à être utilisée en tant que couche dans une production de matelas en mousse comportant de multiples couches, dont une couche de mousse supérieure et au moins une couche de mousse additionnelle et un revêtement de matériau à changement de phase appliquée à une surface supérieure de la couche de mousse supérieure. L'application superficielle du matériau à changement de phase à une surface supérieure d'une couche de mousse supérieure d'un matelas en mousse permet un meilleur transfert de la chaleur du corps sur le matelas et une accumulation réduite de la chaleur sur la surface de contact du corps et du matelas.
PCT/US2013/023151 2012-01-25 2013-01-25 Production de mousses synthétiques et de matelas en mousse WO2013112840A1 (fr)

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DK13741433.0T DK2806771T3 (en) 2012-01-25 2013-01-25 Treated foams for foam mattress constructions
US14/374,613 US20150067967A1 (en) 2012-01-25 2013-01-25 Engineered foams and foam mattress constructions
EP13741433.0A EP2806771B1 (fr) 2012-01-25 2013-01-25 Production de mousses synthétiques pour matelas en mousse
ES13741433.0T ES2583207T3 (es) 2012-01-25 2013-01-25 Espumas diseñadas para las estructuras de colchones de espuma

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US201261590505P 2012-01-25 2012-01-25
US61/590,505 2012-01-25

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ES (1) ES2583207T3 (fr)
WO (1) WO2013112840A1 (fr)

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EP2806771A4 (fr) 2015-03-25
EP2806771A1 (fr) 2014-12-03
ES2583207T3 (es) 2016-09-19
DK2806771T3 (en) 2016-07-04
US20150067967A1 (en) 2015-03-12
EP2806771B1 (fr) 2016-03-30

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