WO2023096486A1

WO2023096486A1 - Modular body support assembly

Info

Publication number: WO2023096486A1
Application number: PCT/NL2022/050678
Authority: WO
Inventors: Frans De La Haye
Original assignee: Ubed B.V.
Priority date: 2021-11-24
Filing date: 2022-11-24
Publication date: 2023-06-01
Also published as: NL2029887B1; NL2029887A; DE202022106593U1; BE1029913A1; BE1029913B1

Abstract

A first aspect of the invention concerns a modular body support assembly comprising at least a first mattress support unit comprising at least one spring coil assembly; and at least a first mattress top-layer comprising at least one random loop bonded structure of a synthetic material, wherein the mattress support unit(s) and the mattress top-layer(s) are configured to mutually engage; and wherein the mattress support unit(s) and the mattress top-layer(s) are each equipped with parts of a first mutually engaging reversible attachment means.

Description

Modular Body Support Assembly

This invention relates to a modular body support assembly comprising at least a first mattress support unit, itself comprising at least one spring coil assembly, and at least a first mattress top-layer, itself comprising at least one random loop bonded structure of a synthetic material. The mattress support unit(s) and the mattress top-layer(s) are configured to mutually engage; and wherein the mattress support unit(s) and the mattress top-layer(s) are each equipped with parts of a first mutually engaging reversible attachment means.

BACKGROUND

A typical mattress is made up of three parts: (i) an inner spring section, (ii) a padding layer and (iii) an upholstery layer. These sections are generally formed separately, and then irreversibly attached to one another by wrapping in a sturdy fabric and sewing or gluing together. This provides a unitary mattress that cannot easily be taken apart into its component parts. This is disadvantageous for several reasons, the first of which is that the mattress as a whole tends to be large and unwieldly, with installing or removing mattresses though narrow hallways and tight staircases often proving problematic.

Another disadvantage is that the component parts of a mattress cannot be easily removed so as to be aired or otherwise cleaned. Yet another disadvantage of the unitary mattress is that it is difficult to replace a component part, with the result that damage to a part of the mattress usually requires replacement of the whole mattress at significant cost. The different components of a mattress may have vastly different life cycles. For instance, the spring coils may last 20-25 years before needing replacement, while the padding may need to be replaced after 3-10 years. Thus, the current unitary mattress typically severely limits the lifespan of a mattress to the lifespan of the component with the shortest lifespan.

Another disadvantage of the presently available unitary mattresses is that they are difficult to recycle, as the various components comprise various materials that need to be separated to be recycled, such as metal of a spring section, rubber of a latex padding layer, plastics and fabrics of the upholstery layer. Disposal of current mattresses pose both an ecological and economic issue. To date, the vast majority of mattresses are disposed of by incineration or landfill.

WO 2011/072022 A1 discloses a “pillowtop mattress” which comprises a base mattress and a pillowtop removably attached to the base mattress portion by mutually engaging reversible attachments means constituted by hook-and-loop patches. The mattress topper comprises a foam core enveloped by a fire-retardant fabric and an outermost fabric cover. A disadvantage of such systems is that traditional foam resilient cores, such as foamed latex rubber, have poor breathability.

However, a disadvantage of such uniform toppers resides in the fact that for mattresses used by two users with difference individual specific support profile and related comfort preferences, such as might arise where users are of different weights, heights or prefer to sleep on their sides vs. backs, etc. Here, a unitary mattress or a mattress with a unitary topper will always necessitate some degree of compromise that may serve neither of the desired resilience profiles. It also obstructs switching places, in case of a 2-person mattress where the users have different comfort preferences.

A further disadvantage is that mattresses with two toppers usually form a nonunitary shape, resulting in undesired wrinkles and folds, which in time may lead to increased wear and tear, and eventually failure of the covering fabric. Further, side-by-side mattress toppers on a single base mattress typically exhibit a “gap” in user support between the mattress toppers that’s a user typically finds uncomfortable.

Accordingly, there remains a need to provide for a mattress with better sustainability and allowing for individual support choices, while retaining a unitary appearance and comfort functionality.

BRIEF SUMMARY OF THE DISCLOSURE

One aspect of the present disclosure includes a modular body support assembly comprising a mattress support unit and a first mattress top-layer, wherein the mattress support unit and mattress top-layer are configured to mutually engage and wherein the mattress support unit and mattress top-layer are each equipped with parts of a mutually engaging reversible attachment mean. The mattress support unit comprises a spring coil assembly. The mattress top-layer comprises a random loop bonded structure of a synthetic resin.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:

Figure 1 depicts a perspective view of a modular body support assembly according to the present invention.

Figure 2 depicts a partially exploded view of a modular body support assembly according to the present invention. The mattress support unit and mattress top-layer are depicted as mutually engaged by reversible attachment means, as well as the cover (separate top and bottom pieces). Figure 3 depicts a partially exploded view of a modular body support assembly according to the present invention, wherein the mattress support unit and mattress top-layer have been separated, along with the cover (separate top and bottom pieces).

Figure 4 depicts a fully exploded view of a modular body support assembly according to the present invention, depicting the components of the mattress support unit, mattress top- layer and cover.

Figures 5 and 6 depict a cut-away sections of a modular body support assembly according to the present invention, depicting all the components in a mutually engaged position, engaged by reversible attachment means.

Figure 7 depicts the replacement of a random loop bonded structure of a synthetic material in the mattress top-layer in a modular body support assembly according to the invention.

Figure 8 depicts the replacement of a spring coil core assembly in a mattress support unit of a modular body support assembly according to the invention.

DETAILED DESCRIPTION

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

In a first embodiment, the modular body support assembly comprises:

- At least a first mattress support unit (11) comprising at least one spring coil assembly (12); and at least a first mattress top-layer (13) comprising at least one random loop bonded structure of a synthetic material (14), wherein the mattress support unit(s) (11) and the mattress top-layer(s) (13) are configured to mutually engage; and wherein the mattress support unit(s) (11) and the mattress top-layer(s) are each equipped with parts of a first mutually engaging reversible attachment means (15). The modular body support assembly may have two easily separable pieces, a mattress support unit and a mattress top-layer. The mattress support unit forms the base of the modular mattress and provides the base support for the mattress user. This is particularly advantageous as it allows an end user of the modular body support assembly to modify the comfort of the modular body support assembly by easily replacing the mattress top-layer with a different comfort profile (e.g. softer, firmer, etc). This is also particularly advantageous of extending the life-span of the mattress support unit as a whole, as the first element to become degraded beyond use can be easily replaced, rather than disposing of the modular body support assembly as a whole. A further advantage is that the ease of separating the modular body support assembly allows for easier recycling of the body support assembly as a whole by facilitating separation of the various recyclable materials into different recycling streams.

The mattress support unit comprises a spring coil assembly, which may be wrapped in a sturdy fabric. The size and shape of the spring coil assembly depends on the size of mattress being produced. The spring coil assembly may be composed of any suitable mattress coil. Suitable mattress coils include: (i) continuous coils, (ii) Bonnell coil, (iii) offset coils and (iv) Marshall coils. Continuous coils feature an innerspring configuration in which the rows of coils are formed from a single piece of wire. Bonnell coils are knotted, round-top, hourglass-shaped steel wire coil, which are typically laced together with cross wire helicoils to form an innerspring unit, also referred to as a Bonnell unit. Offset coils are an hourglass type coil on which portions of the top and bottom convolutions have been flattened. In assembling the innerspring unit, these flat segments of wire are hinged together with helical wires. The hinging effect of the unit is designed to conform to body shape. Left Facing Knot (LFK) coils are an offset coil with a cylindrical or columnar shape. Marshall coils, which are also known as pocket springs or wrapped or encased coils, are thin-gauge, barrel-shaped, knotless coils individually encased in fabric pockets. The fabric is usually a man-made, non-woven fibre. Some manufacturers precompress these coils, which makes the mattress firmer and allows for motion separation between the sides of the bed. As the springs are not wired together, they work more or less independently: the weight on one spring does not affect its neighbours. This allows them to react to pressure independently instead of all together, which minimizes movement and allows for a more buoyant feel. Preferably, the spring coil assembly/assemblies is/are composed of Bonnell coils or Marshall coils, most preferably the spring coil assembly/assemblies is/are composed of Marshall coils.

The mattress top-layer comprises a random loop bonded structure of a synthetic resin. Suitable random loop bonded structures of a thermoplastic resin are described in described in EP2848721 and EP3064627. A suitable, commercially-available random loop bonded structure of a thermoplastic resin is Breathair®, obtainable from Toyobo Co. Such materials have excellent air permeability properties which exceeds 200 cm³/s/cm². The random loop bonded structures are advantageous because their weight per volume is low. Preferably, the mattress top-layer comprises at least one sheet of random loop bonded structures of a thermoplastic resin. More preferably, the mattress top-layer comprises multiple sheets of random loop bonded structures in a laminar structure (i.e. laid one upon the other). These multiple layers are almost as permeable for air as the air permeability of the bulk of the material. A modular body support assembly comprising a mattress top-layer itself comprising a random loop bonded structure of a synthetic resin has a higher air permeability than comparable top-layers comprising foam structures, and are therefore advantageously aids in heat and humidity regulation when the mattress is in use due to allowing greater air-flow.

Random loop bonded structures are made in a continuous process wherein a continuous linear structure of a polymer in a near molten state are poured into a shallow layer of for example water. The polymer will form random loops and mutually contact and connect ate these contact points to form bonded points. At the bottom and at the surface a planar random bonded structure results and between these planar surfaces a three dimensional randomly bonded structure results. This production technique limits the thickness of the sheets of random loop bonded material. The distance between these planar surfaces may for example be between 1 cm and 10 cm. Depending on the desired thickness of the mattress top-layer, i.e., distance between top surface and bottom surface of the mattress top-layer, one or more layers of such random loop bonded structures may be used. In order to obtain optimal cushion properties, it may be preferred to combine different layers with different compression hardness of these materials.

The random loop bonded structures comprise between 550 and 1150 bonded points per gram of the three-dimensional random loop bonded structure, preferably between 600-1100, more preferably between 650-1050 and even more preferably between 700 - 1000 bonded points per gram. The number of bonded points per unit weight (unit: the number of bonded points/gram) is a value obtained by a measuring method described in EP 2848721. In this method a piece in the form of a rectangular parallelepiped is prepared by cutting a network structure into the shape of a rectangular parallelepiped measuring 5 cm in length x 5 cm in width so that the rectangular parallelepiped includes two surface layers of the sample but does not include the peripheral portion of the sample, dividing the number of bonded points per unit volume (unit: the number of bonded points/cm³) in the piece by the apparent density (unit: g/cm³) of the piece. The number of bonded points is measured by a method of detaching a welded part by pulling two linear structures; and measuring the number of detachments. A random loop bonded structure has an average apparent density within a range of preferably 0.005 g/cm³ to 0.200 g/cm³. The random loop bonded structure having an average apparent density within the above range is expected to show the function of a cushioning material. The average apparent density of less than 0.005 g/cm³ fails to provide sufficient resistance to compression, and thus the random loop bonded structure is unsuitable for a cushioning material. The average apparent density exceeding 0.200 g/cm³ gives to much resistance to compression and therefore is generally uncomfortable as a mattress material. This is not preferable. The apparent density in the present invention is more preferably 0.010 g/cm³ to 0.150 g/cm³, even more preferably within a range of 0.020 g/cm³ to 0.100 g/cm³.

The synthetic resin of which the random loop bonded structures are composed of is not particularly limited as long as the linear structures can be curled and brought into mutual contact and the contacted parts can be welded. In terms of satisfying both cushioning properties and quietness, the synthetic resin is preferably a soft polyolefin, a polystyrene thermoplastic elastomer, a polyester thermoplastic elastomer, a polyurethane thermoplastic elastomer or a polyamide thermoplastic elastomer, more preferably a soft polyolefin or a polyester thermoplastic elastomer. Furthermore, for the purpose of satisfying both cushioning properties and quietness while improving heat resistance and durability, a polyester thermoplastic elastomer is particularly preferable.

In an embodiment, the synthetic resin of which the random loop bonded structures are composed of is a soft polyolefin selected from low density polyethylene (LDPE), random copolymers of ethylene and an a-olefin with a carbon number of 3 or greater, and block copolymers of ethylene and an a-olefin with a carbon number of 3 or greater. Preferably, the a- olefin with a carbon number of 3 or greater comprises propylene, isoprene, butene-1 , pentene- 1 , hexene-1 , 4-methyl-1 -pentene, heptene-1 , octene-1 , nonene-1 , decene-1 , undecene-1 , dodecene-1 , tridecene-1 , tetradecene- 1 , pentadecane- 1 , hexadecene-1 , heptadecene- 1 , octadecene-1 , nonadecene-1 , eicosene-1 or combinations thereof. More preferably the a-olefin with a carbon number of 3 or greater is selected from propylene, isoprene or combinations thereof.

In another embodiment, the synthetic resin of which the random loop bonded structures are composed of is a polyester thermoplastic elastomer. More preferably wherein the synthetic resin of which the random loop bonded structures are composed of is a polyester thermoplastic elastomer selected from: (i) a polyester-ether block copolymer whose hard segment(s) is a (are) thermoplastic polyester(s) and whose soft segment(s) is a (are) polyalkylene diol(s); (ii) a polyester-ester block copolymer whose soft segment is an aliphatic polyester; or (iii) a combination thereof. More preferably, the polyester-ether block copolymers are triblock copolymers formed of:

(i) at least one dicarboxylic acid selected from: (a) aromatic dicarboxylic acids; (b) alicyclic dicarboxylic acids; and (c) ester-forming derivatives of these dicarboxylic acids [of (i)(a) or (i)(b)];

(ii) at least one diol component selected from: (a) aliphatic diols; (b) alicyclic diols; and (c) and ester-forming derivatives of these diols [of (ii)(a) or (ii)(b)]; and

(iii) and at least one polyalkylene diol, selected from: (a) polyethylene glycol; (b) polypropylene glycol; (c) polytetramethylene glycol and (d) ethylene oxide-propylene oxide copolymers, which have an average molecular weight of about 300 to 5000.

Specific examples of (i)(a) aromatic dicarboxylic acids are terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid and diphenyl-4,4'- dicarboxylic acid. Specific examples of (i)(b) alicyclic dicarboxylic acids include 1 ,4 cyclohexane dicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid and dimer acid, and ester-forming derivatives of these dicarboxylic acids.

Specific examples of polyester-ether block copolymers that are triblock copolymers include triblock copolymers formed from the above-mentioned dicarboxylic acid and diol and at least one of polyester diols such as polylactone having an average molecular weight of about 300 to 5000.

Particularly preferred polyester-ester block copolymers are:

1 . a triblock copolymer formed from (i) terephthalic acid and/or isophthalic acid as a dicarboxylic acid; (ii) 1 ,4-butanediol as a diol component; and (iii) polytetramethylene glycol as a polyalkylene diol; and

2. a triblock copolymer formed (i) terephthalic acid or/and naphthalene-2,6-dicarboxylic acid as the dicarboxylic acid; (ii) 1 ,4-butanediol as the diol component; and (iii) polylactone as a polyester diol.

Preferably, the polystyrene thermoplastic elastomer comprise random copolymers of (a) styrene and butadiene, (b) block copolymers of styrene and butadiene; (c) random copolymers of styrene and isoprene; (d) block copolymers of styrene and isoprene; and/or (e) hydrogenated products of these [of (a) through (d)].

In another embodiment, the synthetic resin of which the random loop bonded structures are composed of is a polyurethane thermoplastic elastomer. Such a polyurethane thermoplastic elastomer may comprise a polyurethane elastomer obtained from use of a pre-polymer, which has isocyanate groups at both terminal ends and is obtained by allowing (i) a polyether and/or polyester having a number average molecular weight of 1000 to 6000 and having hydroxyl groups at terminal end(s) to react with (ii) a polyisocyanate, comprised mainly of organic diisocyanate repeating units, in the presence or absence of usual solvent (dimethylformamide, dimethylacetamide, etc), and then extending the chain of the pre-polymer by reaction with (iii) a polyamine whose main component is a diamine. Preferably, the polyurethane thermoplastic elastomer is obtained from use of a pre-polymer as above, in which:

(i) polyester and/or polyether are selected from polybutylene adipate co-polyesters and polyalkylene diols (by way of non-limiting example: polyethylene glycol, polypropylene glycol, polytetramethylene glycol and ethylene oxide-propylene oxide copolymers) which have an average molecular weight of about 1000 to 6000, preferably 1300 to 5000 are allowed to react with

(ii) a polyisocyanate, preferably selected from an isocyanate including diphenylmethane-

4,4'-diisocyanate as a main component, to which a minute amount of a conventionally known triisocyanate etc. has been added, and then extending the chain of the pre-polymer by reaction with

(iii) a polyamine including as a main component a diamine (by way of non-limiting example ethylenediamine or 1,2-propylenediamine), to which a minute amount of a triamine and/or tetraamine has been added according to need.

The random loop bonded structures preferably only consist of recyclable plastic material, such as polyester which can be easily recycled into a circular production process. Preferably, the synthetic resin of which the random loop bonded structures are composed of is recyclable. More preferably, the recyclable synthetic resin of which the random loop bonded structures are composed of is selected from a soft polyolefin, a polystyrene thermoplastic elastomer, a polyester thermoplastic elastomer, a polyurethane thermoplastic elastomer or a polyamide thermoplastic elastomer, more preferably a soft polyolefin or a polyester thermoplastic elastomer.

In the context of the embodiments of the disclosure in which: (i) the synthetic resin of which the random loop bonded structures are composed of is recyclable; and (ii) the mattress top-layer comprises an opening means (17) for reversibly removing the random loop bonded structure of a synthetic resin from the mattress top-layer, this advantageously allows for easy separation of the recyclable material for recycling. In particular, it allows for easy isolation of the recyclable synthetic resin from non-cyclable material typically encountered in matrasses, such as adhesives, metal tacking, non-recyclable elements such as adhered fabrics or metallic elements. The ease of isolating the recyclable material is often limiting in whether or not an article enters the recycling stream, with greater ease of isolation allowing for larger entry into the recycling stream.

Within the context of the general disclosure, the combination of (i) the random loop bonded structures being composed of a recyclable synthetic resin; and (ii) the recyclable synthetic resin being selected from a soft polyolefin, a polystyrene thermoplastic elastomer, a polyester thermoplastic elastomer, a polyurethane thermoplastic elastomer or a polyamide thermoplastic elastomer is advantageous in satisfying both cushioning properties and quietness and being recyclable.

In the context of the present disclosure, the random loop bonded structure of a synthetic resin (14) and the attachment means (15) are preferably both essentially composed of the same material. This facilitates recycling of the modular body support assembly, as both the synthetic resin (14) and the attachment means (15) may enter the same recycling stream, reducing the need to separate these elements during recycling. Mattress top-layers may be provided in a range of compression hardness’s. This provides the advantage that the end-user of the mattress may select their ideal comfort level of the modular body support assembly by selecting a mattress top-layer of the appropriate hardness. This offers the further advantage that the end user can change the hardness of the modular support body by replacing a first mattress top-layer with a first hardness with a second mattress top-layer with a different second hardness. The modular body support preferably comprises an outer cover. An advantage of such an outer cover is that it may confer a preferable tactile feel to the mattress top-layer. Where present, the outer cover is preferably configured to envelop both the mattress top- layers) and the mattress support unit(s). Where present, the outer cover comprises a mutually engaging reversible attachment means configured to allow access to the mattress top-layer(s). This advantageously allows access to the mattress top layers without necessitating removal of the outer cover layer whilst also protecting the mattress top-layer(s) and the mattress support unit(s) against wear and soiling. Preferably, the mutually engaging reversible attachment means are selected from one or more zippers; one or more hook and loop fasteners; and/or a combination of one or more zippers and one or more hook and loop fasteners. Preferably, the outer cover is made of a soft fabric, such as such as linen or cotton ticking.

Where present, the outer cover preferably comprises a mutually engaging reversible attachment means configured to allow access to the mattress top-layer(s) and also (ii) the mattress support unit(s). This advantageously allows access to the mattress support unit(s). The mattress top-layer preferably comprises a cover. The top-layer cover may be arranged around the one or more random loop bonded structures so as to envelop the one or more random loop bonded structures. An advantage of such a top-layer cover is that it confers a preferable tactile feel to the mattress top-layer, even in the absence of an outer cover.

The top-layer cover is preferably configured so as to reversibly envelop the one or more random loop bonded structures. This allows the one or more random loop bonded structures to be removed from the mattress top-layer. This confers multiple advantages. One advantage is that this allows the outer cover to be washed and dried separately from the one or more random loop bonded structures (i.e. , in a conventional house-hold washing machine), which is faster and easier than washing the entire mattress top-layer. A second advantage is that it allows the outer cover or the one or more random loop bonded structures to be replaced when they are worn out or irredeemably soiled. A third advantage is that it allows the two materials to be easily separated and be placed in separate waste streams, allowing easier recycling of materials.

The top-layer cover preferably comprises a closable opening with a reversible sealing means. Suitable reversible sealing means include one or more zippers, one or more hook and loop fasteners or a combination of one or more zippers and one or more hook and loop fasteners. Preferably, the outer cover is made of a soft fabric, such as linen or cotton ticking.

The mattress top-layer preferably comprises a spacer fabric between a cover and the one or more random loop bonded structures. The spacer fabric is preferably 6-20 mm thick, more preferably 8-18 mm thick, yet more preferably 10-16 mm thick and most preferably 12-14 mm thick. The spacer fabric is permeable to air, with an air permeability higher than 50 cm³/s/cm², preferably higher than 100 cm³/s/cm² and most preferably higher than 200 cm³/s/cm² as measured by the Standard Test Method for Air Permeability of Textile Fabrics, ATSM D737- 96. Suitable materials include non-woven fabrics and knitted materials, such as the warp knitted spacer fabric as described in WO 2015/140259 and US 2018187348 A1. Such warp knitted spacer fabrics have a first warp-knit layer and a second planar warp-knit layer joined by spacer yarns. The spacer fabric is compressible under pressure and allows pressure applied to the mattress top-layer to be redistributed more evenly. The spacer fabric advantageously aids in heat and humidity regulation when the mattress is in use due to allowing air flow.

In one preferable embodiment, the mattress top-layer comprises one or more random loop bonded structures enveloped by the spacer fabric, with the spacer fabric itself enveloped by the outer cover. In this preferable embodiment, both the outer cover and the spacer fabric comprises a closable opening with a reversible sealing means. Suitable reversible sealing means include one or more zippers, one or more hook and loop fasteners or a combination of one or more zippers and one or more hook and loop fasteners. This allows the outer cover, spacer fabric and random loop bonded structure to be washed and dried separately from the one another, each of which may be washed and cleaned in the manner most efficient and or convenient for that material. For example the outer cover may be washed in a conventional house-hold combination washing/drying machine, the spacer fabric may be washed with soapwater, rinsed and air-dried and the random loop bonded structure flushed with compressed air. This confers the advantage that the mattress top-layer may be cleaned in part. Another advantage is that cleaning the separable parts is faster and easier than washing an entire mattress top-layer. A third advantage is that it allows the outer cover, the spacer fabric or the one or more random loop bonded structures to be replaced when they are worn out or irredeemably soiled. This allows the mattress top-layer as a whole to have a longer lifespan than that of the shortest-lived component. A fourth advantage is that it allows the outer cover, the spacer fabric and the random loop bonded structure to be easily separated from one another at the end of life of the mattress top-layer and be placed in separate waste streams. This allows easier disposal of the mattress top-layer and also allows for easier recycling of materials. A fifth advantage is that it allows the random loop structure to be replaced without physically removing the top-layer from the modular body support, which is less physically demanding and is advantageously quicker to perform.

In this preferred embodiment, the random loop bonded structures, the spacer fabric, the outer cover and the reversible sealing means all wholly consist of recyclable materials. This allows for the entire mattress top-layer to be recycled at minimal cost, as each material is easily separated into the correct recycling stream.

In a particularly favoured embodiment, the modular support body comprises a mattress support unit with a recess configured to receive the first mattress top-layer. The recess is configured so that when the first mattress top-layer is inserted into the recess, the upper surface of the mattress support unit and the upper surface of the first mattress top-layer are approximately co-incident. Preferably, the walls that form the recess are composed of a soft, thick layer of non-woven polyester fibres, often referred to as wadding.

Preferably, wherein the mattress support unit(s) and the mattress top-layer(s) are each equipped with parts of a first mutually engaging reversible attachment means, wherein the attachment means is composed essentially of polyethylene terephthalate. This advantageously allows for easier recyclability of the mattress support unit as a whole, as attachment means being composed essentially of recyclable polyethylene terephthalate obviates the need to separate out non-recyclable attachment means.

In a particularly favoured embodiment, the modular body support assembly comprises: - At least a first mattress support unit (11) comprising at least one spring coil assembly (12);

- at least a first mattress top-layer (13) comprising at least one random loop bonded structure of a synthetic material (14); and

- an outer cover (19) configured to envelop both the mattress top-layer(s) (13) and the mattress support unit(s) (11) and comprising a mutually engaging reversible attachment means (20) configured to allow access to the mattress top-layer(s), wherein the mattress support unit(s) (11) and the mattress top-layer(s) (13) are configured to mutually engage; and wherein the mattress support unit(s) (11) and the mattress top-layer(s) are each equipped with parts of a first mutually engaging reversible attachment means (15); and wherein the mutually engaging reversible attachment means (15, 20) are configured to allow access to the spring coil assemblies.

In this preferable embodiment, both the outer cover and the spacer fabric comprises a closable opening with a reversible sealing means.

This embodiment allows access to the spring coil assemblies without necessitating removal of either the outer cover layer or the mattress top-layer, whilst also protecting the mattress top-layer(s) and the mattress support unit(s) against wear and soiling. This is particularly advantageous, as it allows the spring coil assembly to be replaced with an alternative spring coil assembly, allowing for: altering the comfort level of the body support assembly by replacing a spring coil assembly with a first comfort level with a second spring coil assembly with a second comfort level (altering the degree of firmness or support); alternating the spring coil orientation (colloquially known as “flipping the mattress”, widely considered as a measure to extend the life-span of a spring coil assembly); replacement of worn-out spring assemblies, even further extending the life-span of the modular body support assembly; and allowing for cleaning of the spring coil assembly.

Preferably, the mutually engaging reversible attachment means are selected from one or more zippers; one or more hook and loop fasteners; and/or a combination of one or more zippers and one or more hook and loop fasteners.

In a preferred embodiment, the modular body support assembly comprises: a mattress support unit; and at least a first mattress top-layer; and at least a second mattress top-layer; wherein the mattress support unit and the mattress top-layers are configured to mutually engage; wherein the mattress support unit and the first mattress top-layer are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit and the second mattress top-layer are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit comprises a spring coil assembly; and wherein the first mattress top-layer and the second mattress top-layer both comprise a random loop bonded structure of a synthetic resin, and wherein each mattress top- layer has a different or identical density, firmness, -compression resilience, heat transfer coefficient and/or air transmissivity.

In another preferred embodiment, the invention concerns a modular body support assembly comprising: at least a first mattress support unit; and at least a first mattress top-layer; and at least two spring coil assemblies; and at least two random loop structures of a synthetic material, wherein the mattress support unit(s) and the mattress top-layer(s) are configured to mutually engage; wherein the mattress support unit(s) and the mattress top-layer(s) are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit(s) comprises at least two spring coil assemblies; and wherein the mattress top- layers) comprise at least two random loop bonded structures of a synthetic resin.

One advantage of such an embodiment is that a modular body support assembly may be provided to meet the comfort requirements of a plurality of modular body support users. In the case where two different modular body support assembly users have different comfort preferences the first spring coil assembly and a corresponding first random loop bonded material may be selected according to the comfort preference of a first user and the second spring coil assembly and corresponding second random loop bonded material may be selected according to the comfort preference of the second user. By way of a non-limiting example, if a first user prefers a firm mattress and the second used prefers a soft mattress, the first spring coil assembly and first random loop bonded material may be comparatively firm and the second coil assembly and second random loop bonded material may be comparatively soft. This allows both mattress users to rest at close to their optimal comfort level, rather than compromising on a level of discomfort with one mattress or by sleeping in separate beds.

A further advantage is that of motion isolation. Motion isolation means that when one partner rolls over or tosses and turns, movement on the other side of the bed is barely noticeable. This typically affords a much more pleasant sleeping experience with fewer disturbances. Preferably, each random loop structures of a synthetic material is configured to approximately the same width and length as a corresponding spring coil assembly and the modular body support assembly configured so that when the components are reversibly engaged, each random loop structure resides substantially over said corresponding coil assembly (i.e. roughly the same width and length random loop structure rests on top of a corresponding coil assembly).

In another aspect, the invention concerns a kit of parts comprising one mattress support unit and a plurality of mattress top-layers, wherein the mattress support unit and each individual mattress top-layer are configured to mutually engage; wherein the mattress support unit and each mattress top-layer are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit comprises a spring coil assembly; and wherein the mattress top-layer comprises a random loop bonded structure of a synthetic resin; and wherein the plurality of mattress top-layers exhibit each individually a different hardness increase upon compression.

Such a kit of parts is ideally suited to the high-end hotel sector, where the renter of a room may selected their preferred comfort level and the hotel arrange for the appropriate mattress top-layers that individually exhibit the desired firmness (hardness increase upon compression) to be reversibly engaged with the mattress support unit.

Throughout the description and claims of this specification, the words “comprise”, “composed” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps, unless the wording is “solely composed of” is used, in which case this wording “solely composed of” excludes other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

DESCRIPTION OF THE EMBODIMENTS

Figure 1 depicts a perspective view of a modular body support assembly (10) according to the present invention. This embodiment is enveloped in a two-part outer fabric cover (19) comprising a lower part (19A) and an upper part (19B). The depicted lower fabric cover (19A) comprises a first part of a first mutually engaging reversible attachment means (20A), by way of a no-limiting example a first row of protruding teeth of a second zipper (120A). The depicted upper mattress support unit cover (19B) comprises a second part of the second mutually engaging reversible attachment means (20B), by way of a no-limiting example a second row of protruding teeth and slider (120B) [not depicted] of the second zipper (120B). The first and second part of a second mutually engaging reversible attachment means (20A, 20B) are configured to mutually engage in a reversible manner, by way of a no-limiting example a first row of protruding teeth of a first zipper (120A) may reversibly engage a second row of protruding teeth (120B) and be engaged and disengaged through use of the slider (120B’). The two-part part outer fabric cover (19) is depicted in the reversable, mutually engaged position enveloping the mattress support unit (11) and a mattress top-layer (13) [not visible]. By way of a non-limiting example, the lower part of the outer fabric cover (19A) may be a spacer fabric with a thickness of 4-6 mm. By way of a non-limiting example, the upper part of the cover (19B) may be spacer fabric of 10-15 mm thickness.

Figure 2 depicts a partially exploded view of a modular body support assembly (10) according to the present invention. The mattress support unit (11) and mattress top-layer (13) are depicted as mutually engaged by reversible attachment means, as well as the cover (separate top and bottom pieces). The depicted mattress support unit (11) of Figure 2 comprises a first part of a first mutually engaging reversible attachment means (15A), by way of a no-limiting example a first row of protruding teeth of a first zipper. The depicted mattress top- layer (13) of Figure 2 comprises a second part of the first mutually engaging reversible attachment means (15B), by way of a no-limiting example a second row of protruding teeth and slider of a first zipper (115B) [slider not depicted]. The first and second parts of a first mutually engaging reversible attachment means (15A, 15B) are configured to be able to mutually engage in a reversible manner, which is depicted here. By way of a non-limiting example, the first and second parts of a first mutually engaging reversible attachment means (15A, 15B) depicted in Figure 2 are a first and second row of protruding teeth and a slider of a first zipper (115A, 115B). By way of a no-limiting example a first row of protruding teeth of the first zipper (115A) are reversibly engaging a second row of protruding teeth (115B) and may be disengaged through use of the slider (115B’). Alternative first and second parts of a first mutually engaging reversible attachment means (15A, 15B) may be readily envisaged, such as hook-and-loop fastening means (215) (e.g., VELCRO® patches or DUAL-LOCK tape from 3M).

Figure 3 depicts a partially exploded view of a modular body support assembly (10) according to the present invention, wherein the mattress support unit and mattress top-layer have been separated, along with the cover (separate top and bottom pieces). The first and second parts of a first mutually engaging reversible attachment means (15A, 15B) of the depicted assembly are configured to be able to mutually engage in a reversible manner, although here they are depicted unengaged here. By way of a non-limiting example, the first and second parts of a first mutually engaging reversible attachment means (15A, 15B) depicted in Figure 3 are a first and second row of protruding teeth and a slider of a second zipper (115A, 115B). By way of a no-limiting example a first row of protruding teeth of the second zipper may reversibly engage the second row of protruding teeth through use of the slider (115A, 115B). Alternative first and second parts of a first mutually engaging reversible attachment means (15A, 15B) may be readily envisaged, such as hook-and-loop fastening means (215A, 215B) (e.g., VELCRO® patches or DUAL-LOCK tape from 3M).

Figure 4 depicts an exploded view of a modular body support assembly (10) according to the invention. The modular body support assembly (10) depicted comprises a mattress support unit (11) and a mattress top-layer (13).

The depicted mattress support unit (11) comprises two spring coil assemblies (12A and 12B). Each of the depicted spring coil assemblies (12A, 12B) are surrounded on four sides by a layer of non-woven polyester fibres (22). The spring coil assemblies are of conventional construction and comprise a plurality of metal coils (23) disposed within respective pockets of a fabric encasement (24). By way of a non-limiting example, the spring coil assembly depicted here is a Marshall coil assembly. However, the skilled person would readily appreciate that an alternative spring coil assembly could also be used, such as a Bonnell coil assembly.

The fibre frame (22) comprises a first pair of opposed polyester fibre side walls (25) and a first pair of opposed fibre end walls (26). Suitable material for the fibre side and end walls is a thick layer of bonded, non-woven, polyester fibres. By way of a non-limiting example, the fibre side walls (26) may be 2000 mm long, 150 mm high and 25 mm thick and the end walls may be 1000 mm wide, 150 mm high and 25 mm thick. Although not depicted in Figure 4, attached to the bottom surface of the frame (22) is a fabric (30) such that the fibre frame and fabric form a receiving space for the Marshall coil assembly. Suitable fabric for the bottom surface of includes felt fabrics.

The depicted mattress support unit (11) comprises a two-part mattress support unit cover (27), wherein the two-part mattress support unit cover (27) includes an upper mattress support unit cover (28) and a lower mattress support unit cover (29). The depicted upper mattress support unit cover (28) comprises a first part of a third mutually engaging reversible attachment means (21 A), by way of a no-limiting example a first row of protruding teeth of a third zipper (121A). The depicted lower mattress support unit cover (29) comprises a second part of the third mutually engaging reversible attachment means (21 B), by way of a no-limiting example a second row of protruding teeth and slider (121 B) [slider not depicted] of the third zipper (120). The first and second part of a third mutually engaging reversible attachment means (21 A, 21 B) are configured to mutually engage in a reversible manner, by way of a nolimiting example a first row of protruding teeth of a third zipper (121A) may reversibly engage a second row of protruding teeth (121 B) and be engaged and disengaged through use of the slider (121 B’). In this way, the two-part mattress support unit cover (28) may enclose the spring coil assemblies (12A, 12B).

The depicted mattress top-layer (13) comprises two random loop bonded structures of a synthetic material (14A, 14B) and spacer fabric (16). By way of a non-limiting example, each of the random loop bonded structures of a synthetic material (14A, 14B) may be 2030 mm long, 15 mm high and 760 mm wide. By way of a non-limiting example, the spacer fabric (16) may be 5 mm thick.

The depicted mattress support unit (11) of Figure 4 comprises a first part of a first mutually engaging reversible attachment means (15A), by way of a no-limiting example a first row of protruding teeth of a second zipper. The depicted mattress top-layer (13) of Figure 4 comprises a second part of the first mutually engaging reversible attachment means (15B), by way of a no-limiting example a second row of protruding teeth and slider of a second zipper (zipper not depicted). The first and second parts of a first mutually engaging reversible attachment means (15A, 15B) are configured to be able to mutually engage in a reversible manner. By way of a non-limiting example, the first and second parts of a first mutually engaging reversible attachment means (15A, 15B) depicted in Figure 4are a first and second row of protruding teeth and a slider of a second zipper. By way of a no-limiting example a first row of protruding teeth of the second zipper may reversibly engage a second row of protruding teeth and be engaged and disengaged through use of the slider. Alternative first and second parts of a first mutually engaging reversible attachment means (15A, 15B) may be readily envisaged, such as hook-and-loop fastening means (e.g. VELCO® patches).

The modular body support assembly (10) depicted in Figure 4 additionally comprises a cover (19) comprising a lower part of the cover (19A) and an upper part of the cover (19B), depicted as disengaged.

Figures 5 and 6 depict a cut away drawing of a modular body support assembly (10) according to the invention. The cut is primarily along the width of the modular body support assembly (10) and depicts all the components of the modular body support assembly (10) in a mutually engaging position. Figure 6 depicts that attached to the bottom surface of the fibre frame (22) is a fabric (30) such that the fibre frame and fabric form a receiving space for the Marshall coil assembly.

Figure 7 depicts a perspective view of the replacement of a random loop bonded structure of a synthetic material (14) in the mattress top-layer (13) of a modular body support assembly (10) according to the invention. By way of non-limiting example, the modular body support assembly (10) is depicted with a first and second mutually engaging reversible attachment means (15, 20, respectively), which may be partially disengaged so as to allow the replacement of a random loop bonded structure of a synthetic material (14). By way of a further non-limiting example, the modular body support assembly (10) is depicted with a first and second zipper (115, 120, respectively), which may be partially unzipped so as to allow the replacement of a random loop bonded structure of a synthetic material (14). This is advantageous in minimizing the physical strength required to replace the random loop structure of a synthetic material (14), and thus extend the lifespan of the mattress as a whole, which would be particularly difficult for an elderly person or physically less able person to achieve.

Figure 8 depicts a perspective view of the replacement of a spring coil assembly (12) in a mattress support unit (11) of a modular body support assembly (10) according to the invention. By way of non-limiting example, the modular body support assembly (10) is depicted with a first, second and third mutually engaging reversible attachment means (15, 20 and 21 , respectively), which may be partially disengaged so as to allow the replacement of a random loop bonded structure of a synthetic material (14). By way of a further non-limiting example, the modular body support assembly (10) is depicted with a first, second and third zipper (115, 120 and 121 , respectively), which may be partially unzipped so as to allow the replacement of a random loop bonded structure of a synthetic material (14). This is advantageous in minimizing the physical strength required to replace the random loop structure of a synthetic material (14), and thus extend the lifespan of the mattress as a whole, which would be particularly difficult for an elderly person or physically less able person to achieve. This is advantageous in minimizing the time and effort required to replace the random loop structure of a synthetic material (14), which would be particularly difficult for an elderly person or physically less able person to achieve.

LIST OF REFERENCES

Similar reference numbers used in the description to indicate similar elements (but only differ in the hundreds) are implicitly included [e.g. 101 and 201],

10 modular body support.

11 mattress support unit.

12 spring coil assembly.

13 mattress top-layer.

14 (A,B) random loop structure of a synthetic material.

15 first mutually engaging reversible attachment means, by way of non-limiting example a zipper.

15A first part of a second mutually engaging reversible attachment means, by way of a nolimiting example a first row of protruding teeth of a second zipper.

15B second part of the second mutually engaging reversible attachment means, by way of a nolimiting example a second row of protruding teeth and slider of a second zipper.

16 spacer fabric.

17 opening means.

19 outer fabric cover.

19A lower part of outer fabric cover.

19B upper part of outer fabric cover.

20 second mutually engaging reversible attachment means, by way of non-limiting example a zipper.

20A first part of a second mutually engaging reversible attachment means, by way of a nolimiting example a first row of protruding teeth of a first zipper.

20B second part of the second mutually engaging reversible attachment means, by way of a nolimiting example a second row of protruding teeth and slider of the first zipper.

21 third mutually engaging reversible attachment means, by way of non-limiting example a zipper. 21A first part of a third mutually engaging reversible attachment means, by way of a no-limiting example a first row of protruding teeth of a third zipper.

21 B second part of the third mutually engaging reversible attachment means, by way of a nolimiting example a second row of protruding teeth and slider of a third zipper. 22 fibre frame.

23 metal coils.

24 pockets of fabric encasement.

25 first pair of opposed fibre side walls.

26 first pair of opposed end walls. 27 mattress support unit cover.

28 an upper mattress support unit cover.

29 a lower mattress support unit cover.

30 fabric.

Claims

1. A modular body support assembly (10) comprising:

- At least a first mattress support unit (11) comprising at least one spring coil assembly (12); and

- at least a first mattress top-layer (13) comprising at least one random loop bonded structure of a synthetic material (14), wherein the mattress support unit(s) (11) and the mattress top-layer(s) (13) are configured to mutually engage; and wherein the mattress support unit(s) (11) and the mattress top- layers) are each equipped with parts of a first mutually engaging reversible attachment means (15).

2. The modular body support assembly (10) according to claim 1, wherein the attachment means (15) are selected from one or more zippers; one or more hook and loop fasteners; and/or a combination of one or more zippers and one or more hook and loop fasteners.

3. The modular body support assembly (10) according to claim 1 or 2, wherein the attachment means (15) and top-layer (13) are solely composed of recyclable material, preferably derived from the same class of synthetic polymers.

4. The modular body support assembly (10) according to claim 3, wherein the attachment means (15) is composed essentially of polyethylene terephthalate.

5. The modular body support assembly (10) according to any one of claims 1 to 4, wherein the random loop bonded structure of a synthetic resin (14) is selected from a polyolefin, a polystyrene thermoplastic elastomer, a polyester thermoplastic elastomer, a polyurethane thermoplastic elastomer or a polyamide thermoplastic elastomer, more preferably a soft polyolefin or a polyester thermoplastic elastomer.

6. The modular body support assembly (10) according to any one of claims 1 to 5, wherein the random loop bonded structure of a synthetic resin (14) and the attachment means (15) are both essentially composed of the same material.

7. The modular body support assembly (10) according to any one of claims 1 to 6, wherein the mattress top-layer (13) comprises spacer fabric (16) and a random loop bonded structure of a synthetic resin (14).

8. The modular body support assembly according to claim 7, wherein the mattress top- layer comprises an opening means (17) for reversibly removing the random loop bonded structure of a synthetic resin from the mattress top-layer.

9. The modular body support assembly according to claim 7 or claim 8, wherein the mattress top-layer (13) comprises an top-layer cover (18), spacer fabric (16), a random loop bonded structure of a synthetic resin (14) and an opening means (17) for reversibly removing the random loop bonded structure of a synthetic resin from the mattress top-layer (13), wherein the opening means (17) is selected from one or more zippers; one or more hook and loop fasteners; or a combination of one or more zippers and one or more hook and loop fasteners.

10. The modular body support assembly (10) according to any one of claims 1 to 9, further comprising an outer fabric cover (19) shaped and configured to cover the sides of the mattress support unit and extending above the mattress support unit and comprising a part(s) of a mutually engaging reversible attachment means (15B) to engage the complementary part of the mutually engaging reversible attachment means (15A) attached to one or more of the mattress support unit(s) (11), and/or the mattress top-layer(s) thereby forming a unitary body.

11. A modular body support assembly comprising: a mattress support unit; and at least a first mattress top-layer; and at least a second mattress top-layer; wherein the mattress support unit and the mattress top-layers are configured to mutually engage; wherein the mattress support unit and the first mattress top-layer are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit and the second mattress top-layer are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit comprises a spring coil assembly; and wherein the first mattress top-layer and the second mattress top-layer both comprise a random loop bonded structure of a synthetic resin, and wherein each mattress top- layer has a different or identical density, firmness, -compression resilience, heat transfer coefficient and/or air transmissivity.

12. A modular body support assembly comprising: at least a first mattress support unit; and at least a first mattress top-layer; and at least two spring coil assemblies; and at least two random loop structures of a synthetic material, wherein the mattress support unit(s) and the mattress top-layer(s) are configured to mutually engage; wherein the mattress support unit(s) and the mattress top-layer(s) are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit(s) comprises at least two spring coil assemblies; and wherein the mattress top-layer(s) comprise at least two random loop bonded structures of a synthetic resin.

13. A kit of parts comprising one mattress support unit and a plurality of mattress top-layers, wherein the mattress support unit and each individual mattress top-layer are configured to mutually engage; wherein the mattress support unit and each mattress top-layer are each equipped with parts of a mutually engaging reversible attachment means; wherein the mattress support unit comprises a spring coil assembly; and wherein the mattress top-layer comprises a random loop bonded structure of a synthetic resin; and wherein the plurality of mattress top- layers exhibit each individually a different hardness increase upon compression.