WO2019092741A1 - Matelas - Google Patents

Matelas Download PDF

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Publication number
WO2019092741A1
WO2019092741A1 PCT/IN2018/050719 IN2018050719W WO2019092741A1 WO 2019092741 A1 WO2019092741 A1 WO 2019092741A1 IN 2018050719 W IN2018050719 W IN 2018050719W WO 2019092741 A1 WO2019092741 A1 WO 2019092741A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam
approximately
resiliency
horizontal layer
mattress
Prior art date
Application number
PCT/IN2018/050719
Other languages
English (en)
Inventor
Mayank Pahwa
Original Assignee
Bono Sleep Private Limited
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 Bono Sleep Private Limited filed Critical Bono Sleep Private Limited
Publication of WO2019092741A1 publication Critical patent/WO2019092741A1/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
    • A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience

Definitions

  • the present invention relates to a mattress, specifically relates to a mattress with a unique layered structure.
  • Coir and Cotton mattresses generally are very firm and not so durable. They do not conform to human body and provide poor support resulting in excessive pressure on critical bony joints such as hip and shoulder joints, which results in frequent tossing and turning during the night. The entire weight of the sleeper is exerted on few areas of the mattress rather than being distributed along the entire length. These results in sagging of the mattress along areas under excessive pressure (also referred to as “bottoming out”). These mattresses bottom out in short duration of use and exhibit a "hard feel" (i.e. no rebound or resiliency) upon sleeping on it. Sleeping on a bottomed out mattress further worsens functioning of critical bony joints, negatively impacts quality of sleep and impairs overall health and wellness.
  • PU foam mattresses have gained significant market share of organized mattress industry in India.
  • a horizontal layer of polyurethane foam with lower Indentation Load Deflection (ILD) is positioned above a base layer of polyurethane foam of higher ILD.
  • ILD Indentation Load Deflection
  • Such conventional PU foam mattresses have inferior mechanical properties and are also not so durable.
  • conventional PU foam mattresses also bottom out and results in similar aforementioned issues. When compared with latex mattressesthey have poor support and lower resiliency or rebound ("bounce"). When compared with memory foam mattresses they provide no pressure relief, poor weight distribution and no motion transfer isolation.
  • Low resiliency viscoelastic (“memory”) foam is specialized polyurethane foam characterized by its slow recovery on deformation, which aids in pressure relief.
  • Memory foam was invented as a result of NASA's research on energy absorbing foam to prevent damage to astronauts during space missions in the mid 1960s. It was introduced to the US mattress industry in the early 1990s as pressure relieving foam with motion transfer isolation properties (i.e. if one sleeper moves it does not disturb another adjacent sleeper).
  • U.S. patent number 6,541,094 granted to Dan Landvik and Michael Allaway a laminated viscoelastic foam mattress construction is described for pressure-relief.
  • Latex has very high resiliency (i.e. "bounce"), breathability (i.e. air flow) and provides good support.
  • breathability i.e. air flow
  • the present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available techniques and processes. Accordingly, the present invention has been developed to provide benefits of high resiliency foams (latex, latexlike foam or High Resiliency polyurethane foam) and low resiliency (viscoelastic) foam, without foregoing drawbacks.
  • the current invention comprises of a horizontal layer of viscoelastic foam is positioned on top to provide comfort, allow motion transfer isolation as it contours around the body and better weight distribution.
  • the second horizontal layer of high resiliency foam is sandwiched and positioned below the first horizontal layer to prevent sleeper from sinking deeper, improve airflow and provide support to the sleeper's body.
  • the third horizontal layer of viscoelastic foam is positioned below the second horizontal layer and provides deep pressure relief to critical bony joints such as hip and shoulder joints.
  • the main objective of the present invention to provide a novel foam mattress construction that provides benefits of high resiliency foams (latex, latex-like foam or High Resiliency polyurethane foam) and low resiliency (viscoelastic) foam.
  • FIG. l is a cross-sectional view of a in accordance with some embodiments.
  • FIG. 2A is a cross section view of a mattress in accordance with some embodiments.
  • FIG. 2B is a perspective view of a mattress in accordance with some embodiments.
  • Density- Density of foam is its mass per unit volume. Density may be measured in pounds per cubic foot (pcf) or kg per cubic meters (kg/m or D). Dentisty of the foam determines the grade of the foam. Higher density implies better grade, and therefore better durability.
  • IFD Indentation Force Deflection tests measure firmness of flexible foams. IFD is defined as the amount of force, in pounds, required to indent a fifty square inch round indentor foot into a predefined foam specimen a certain percentage of the specimen's total thickness. IFD is usually measured at 25% and 65% deflection (i.e. compression) of the specimen's height and is measured in pounds. IFD at 25% means the amount of load (in pounds) required to indent or compress 4-inch thick sample of foam until it reaches 3 -inches of thickness.
  • IFD at 25% value of 10 means 10 lbs of load is required to indent or compress 4-inch foam by 1 inch or in other words, until it reaches a thickness of 3- inches.Higher IFD implies more firmness. Lower IFD indicates softer foam.
  • IFD is interchangeable with Indentation Load Deflection (ILD).
  • SF of foam is the ratio of 65% IFD over 25% IFD and is a unitless measurement. Higher SF implies better support of foam. Foams with lower SF values bottoms out easily.
  • Resiliency or Rebound Resiliency or rebound of foam is its ability to spring back to original shape or position.
  • Recovery of foam is a measure of how quickly a foam returns to original shape after being displaced and is measured in seconds. It is usually used for measuring recovery time of viscoelastic foams.
  • Airflow of foam is a measure of its air permeability. It is measured in standard cubic feet per minute (scfm). Higher airflow values make foam more breathable which aides in heat dissipation.
  • T g Glass Transition Temperature
  • the glass transition temperature of foam is defined as the temperature range where the foam changes over from a firm state to a soft and flexible state. This is mostly applicable to viscoelastic foam where its mechanical properties are attributed to its glass transition temperature. At temperature above T gi memory foam feels softer and loses its viscoelastic properties. At temperatures below T g , it feels firmer and becomes too viscoelastic (no or extremely slow recovery).
  • Viscoelastic foams are temperature sensitive polyurethane foams with a low resilience and slow recovery from deformation. Viscoelastic foam, herein, refers to any foam where:
  • Resiliency is less than 25%
  • Recovery time is greater than 1 second.
  • Latex foam is a foam, that is produced from liquid latex by process of vulcanization. It may be natural (plant based), synthetic (chemical based) or blended. Synthetic latex most commonly is made from Styrene Butadiene Rubber (SBR) but may also be made from other chemicals. Blended latex may be any blend of natural latex, synthetic latex, polyurethane or polyethylene materials. Latex foam, herein, refers to foam where:
  • i. Resiliency may be greater than 40%
  • Support Factor may be greater than 2;
  • Airflow may be greater than 0.94 L/s.
  • Latex-like foam herein, is referred to any non-latex foam that simulatesaforementioned mechanical properties (resiliency, support factor, and airflow) of latex foam. They are most often polyurethane based but can be made from other chemicals.
  • HR foam is afoam that has higher resiliency than conventional foam.
  • HR foam herein, refers to a foam where:
  • i. Resiliency may be greater than 40%
  • Support core herein, is defined as any foam or combination of foam, springs, pocket coils and any natural or artificial fibers, placed to provide basal support and may be made of one or more layers.
  • ASTM American Society of Testing and Materials
  • ASTM D3574-1 1 Test Bi An 8 inch diameter steel plate (called as indentor foot) is used to indent or compress into a foam sample to a stated percentage of the test sample's initial height. The amount of load (in pounds) needed to compress the foam sample to 25% and 65% of its total thickness is measured. The measurements at 25% and 65% are referred to as IFD at 25% and IFD at 65% respectively. IFD at 25% is usually used as industry standard to indicate hardness of a foam. IFD at 65% is used to calculate Support Factor (SF) or compression modulus of a foam, where:
  • ASTM D3574-1 1 Test H A steel ball of 16 mm diameter, weighing 16.3 gm, is dropped through a vertical clear plastic tube onto a foam sample and the height of rebound is expressed as the percentage of the original ball drop height.
  • Test M The indentor foot (as described in Test Bi) is used to indent or compress a foam specimen with 4.5N of force and time taken to recover from compression is recorded in seconds.
  • Air is passed through 1 inch thick foam sample of 2 inch length and 2 inch breadth at 125 Pa of pressure and the volume of air that escapes on the other end is measured. Airflow values are expressed in Litre per second (L/s) or standard cubic feet per minute (scfm).
  • DMT A Dynamic Mechanical Thermal Analysis
  • testing methods are done in controlled settings and are intended to provide global standardization. However, performance of foams with similar values may vary in different geographic weather and housing conditions of variable temperature, humidity, atmospheric pressure, wind, or precipitation.
  • the invention described, herein, may be of any length and width. It relates to all Indian or global sizes, standard or non standard.
  • the total thickness of the mattress may range from 1 to 22 inches.
  • low and high resiliency foams are utilized in a novel way to provide their unique benefits while also minimizing their drawbacks.
  • a horizontal layer of viscoelastic foam is positioned on top to provide comfort, allow motion transfer isolation as it contours around the body and better weight distribution.
  • the second horizontal layer of high resiliency foam is positioned below the first horizontal layer to prevent sleeper from sinking deeperby providing bounce and therefore minimizing "being stuck" and "quicksand” feeling of low resiliency viscoelastic foam, improve airflow andprovide support to the sleeper's body.
  • Better airflow of high resiliency foam aids in heat dissipation and therefore prevents excessive heat retention in the top low resiliency viscoelastic foam layer.
  • the third horizontal layer of low resiliency viscoelastic foam is positioned below the second horizontal layer to provide deep pressure relief to critical bony joints such as hip and shoulder joints.
  • These 3 layers forming a sandwich apparatus may be positioned above support core. This construction provides pressure relief, bounce, motion transfer isolation and support, while also alleviating feeling of "getting stuck”, “sleeping hot” and “excessive pressure and bounce”.
  • A. First Embodiment In afirst embodiment as depicted in FIG. 1, mattress 100 having total thickness 195 of 1 to 22 inches, preferably 3 to 13 inches. A horizontal layer of viscoelastic foam 120 is positioned on top to provide comfort, allow motion transfer isolation as it contours around the body and better weight distribution. This layer has thickness 160 of 0.25 to 5 inches, preferably 0.5 to 2 inches, more preferably 0.5 to 1.5 inches and most preferably 0.5 to 1.0 inch.
  • the mechanical properties are listed: i. Density of 32 to 130 kg/m 3 , preferably 40 to 90 kg/m3, more
  • 3 3 preferably 48 to 80 kg/m and most preferably 60 to 70 kg/m .
  • IFD IFD at 25% of 3 to 24, preferably 6-18, more preferably 8-16 and most preferably 10-14.
  • Support Factor of 1.1 to 3.2, preferably 1.6 to 2.7, more preferably 1.8 to 2.5 and most preferably at 1.9 to 2.3.
  • Resiliency of less than 25%, preferably less than 10%, more preferably less than 5% and most preferably less than 2%.
  • T g Glass Transition Temperature T g (DMTA) is between 0°C and 40 °C, preferably between 10 °C to 30 °C, more preferably between 12 °C to 24 °C and most preferably 15 °C to 21 °C.
  • a second horizontal layer of high resiliency foam 130 is sandwiched and positioned below the first horizontal layer to prevent sleeper from sinking deeper, improve airflow and provide support to the sleeper's body.
  • This may be Latex, Latex-like foam or High Resiliency (HR) polyurethane foam layer with thickness 170 of 0.25 to 5 inches, preferably 0.5 to 2 inches and more preferably 0.5 to 1.5 inches.
  • HR High Resiliency
  • Density of 30 to 150 kg/m 3 preferably 35 to 100 kg/m 3 , more preferably 48 to 80 kg/m 3 and most preferably 55 to 70 kg/m 3 .
  • Support Factor (ASTM D3574-11 Test of greater than 2, preferably greater than 2.5, more preferably greater than 3 and most preferably greater than 3.5.
  • v. Airflow (ASTM D3574-11 Test G) of greater than 0.94L/s, preferably greater than 1.4 L/s and more preferably greater than 1.65 L/s.
  • a third horizontal layer of viscoelastic foam 140 provides deep pressure relief to critical bony joints such as hip and shoulder joints.
  • This layer has thickness 180 of 0.25 to 5 inches, preferably 0.5 to 3 inches, more preferably 0.5 to 2 inches and most preferably 1 to 2 inches.
  • the mechanical properties are listed:
  • IFD IFD at 25% of 3 to 24, preferably 6 to 21, more preferably 8 to 18 and most preferably 10-16.
  • Support Factor of 1.1 to 3.2, preferably 1.6 to 2.7, more preferably 1.8 to 2.5 and most preferably at 1.9 to 2.3.
  • Resiliency of less than 25%, preferably less than 10%, more preferably less than 5% and most preferably less than 2%.
  • T g Glass Transition Temperature T g (DMTA) is between 0°C and 40 °C, preferably between 10 °C to 30 °C, more preferably between 12 °C to 24 °C and most preferably 15 °C to 21 °C.
  • Support core provides basal support to the mattress.
  • lt may be made of one or more layers of latex, latex-like foam, viscoelastic foam, inner springs, pocket coils, natural, artificial fibers or any combination thereof. It may have total thickness 190 of 0.5 to 15 inches thick, preferably 2 to 12 inches.
  • the mattress may also comprise a cover 110.
  • mattress 200 may have a total thickness 290 similar to first embodiment and have a top layer of viscoelastic foam 210 quilted with mattress ticking (i.e. cover) fabric.
  • This quilted layer may have thickness 250 of0.25 inch to 3 inches, preferably 0.5 to 2 inches, more preferably 0.5 to 1.5 inches and most preferably 0.5 to 1 inch.
  • Viscoelastic foam used, herein, may be following mechanical properties:
  • Density of 16 to 90 kg/m preferably 25 to 80 kg/m , more preferably 32 to 72 kg/m 3 and most preferably 48 to 64 kg/m 3 .
  • IFD IFD at 25% of 3 to 18, preferably 5-16, more preferably 6-14 and most preferably 8-12.
  • Support Factor of 1.1 to 3.2, preferably 1.6 to 2.7, more preferably 1.8 to 2.5 and most preferably at 1.9 to 2.3.
  • Resiliency of less than 25%, preferably less than 10%, more preferably less than 5% and most preferably less than 2%.
  • T g Glass Transition Temperature T g (DMTA) is between 0°C and 40 °C, preferably between 10 °C to 30 °C, more preferably between 12 °C to 24 °C and most preferably 15 °C to 21 °C.
  • the second horizontal layer 220 is similar in properties and thickness 260to second horizontal layer of first embodiment.
  • the third horizontal layer 230 is similar in properties and thickness270 to second horizontal layer of first embodiment.
  • These three layers 210, 220 and 230 form a sandwich apparatus, which may be positioned above support core240.
  • the support core 240 is similar in properties and thickness 280 to support core of first embodiment.
  • a does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element.
  • the term “sandwich” or “sandwiched” are intended to be only illustrative and not to be used in restrictive sense unless explicitly stated otherwise herein.
  • the terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein.
  • the terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art.
  • the term “positioned” as used herein is defined as attached, although not necessarily directly and not necessarily mechanically. A structure or apparatus that is "constructed” in a certain way is constructed in at least that way, but may also be constructed in ways that are not listed. This is done merely for the sake of convenience and to provide a general sense of the scope of the invention.

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

Abstract

L'invention concerne une nouvelle structure de matelas en mousse dans laquelle une mousse à haute résilience (c'est-à-dire « élastique », « à récupération rapide ») est prise en sandwich entre des mousses viscoélastiques à faible résilience (c'est-à-dire des mousses « à récupération ou mémoire de forme lente »). La couche supérieure de mousse viscoélastique assure le confort, isole contre la transmission des mouvements et épouse la forme du corps du dormeur. La couche prise en sandwich est une mousse à haute résilience, qui procure de l'élasticité et empêche le dormeur de s'enfoncer trop profondément (c'est-à-dire d'éprouver la sensation de « rester coincé » ou « de sables mouvants » associée à la mousse à mémoire de forme). Elle est suivie d'une autre couche de mousse viscoélastique, qui soulage efficacement la pression. La couche supérieure de mousse viscoélastique peut être matelassée avec un revêtement de matelas. Ce dispositif en sandwich est positionné au-dessus d'une âme de support. Cette structure améliorée assure confort et soulagement de la pression, et empêche la sensation « d'être coincé ».
PCT/IN2018/050719 2017-11-08 2018-11-07 Matelas WO2019092741A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201711039718 2017-11-08
IN201711039718 2017-11-08

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WO2019092741A1 true WO2019092741A1 (fr) 2019-05-16

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4137012A1 (fr) 2021-08-19 2023-02-22 I-Sleep Matelas de lit adaptable a la morphologie de chaque utilisateur
US20230293369A1 (en) * 2022-01-26 2023-09-21 Boontham Nithi-Uthai Anti-bedsore mattress with improved load-bearing component

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150296995A1 (en) * 2014-04-21 2015-10-22 Philip Krim Mattress
US20170258242A1 (en) * 2015-03-17 2017-09-14 Richard Codos Spring Unit for a Mattress

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150296995A1 (en) * 2014-04-21 2015-10-22 Philip Krim Mattress
US20170258242A1 (en) * 2015-03-17 2017-09-14 Richard Codos Spring Unit for a Mattress

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4137012A1 (fr) 2021-08-19 2023-02-22 I-Sleep Matelas de lit adaptable a la morphologie de chaque utilisateur
FR3126180A1 (fr) * 2021-08-19 2023-02-24 I-Sleep Matelas de lit adaptable a la morphologie de chaque utilisateur
US20230293369A1 (en) * 2022-01-26 2023-09-21 Boontham Nithi-Uthai Anti-bedsore mattress with improved load-bearing component

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