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CN103763992A - Foam mattress with progressive support characteristics and method for manufacturing the same - Google Patents

Foam mattress with progressive support characteristics and method for manufacturing the same Download PDF

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Publication number
CN103763992A
CN103763992A CN201280039747.7A CN201280039747A CN103763992A CN 103763992 A CN103763992 A CN 103763992A CN 201280039747 A CN201280039747 A CN 201280039747A CN 103763992 A CN103763992 A CN 103763992A
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CN
China
Prior art keywords
layer
recess
foam
mattress
protuberance
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
CN201280039747.7A
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Chinese (zh)
Inventor
约翰·法纳姆
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Kingsdown Inc
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Kingsdown Inc
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Publication of CN103763992A publication Critical patent/CN103763992A/en
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C23/00—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases
    • A47C23/04—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases using springs in compression, e.g. coiled
    • 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 or 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
    • 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
    • A47C27/14—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
    • 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
    • A47C27/146—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
    • 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
    • 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
    • Y10T29/00—Metal working
    • Y10T29/48—Upholstered article making
    • Y10T29/481—Method

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

Abstract

A mattress includes top and bottom foam layers. A bottom surface of the top foam layer and a top surface of the bottom foam layer include protrusions and recessions. The protrusions of the top surface of the bottom foam layer protrude into the recessions of the bottom surface of the top foam layer, and the protrusions of the bottom surface of the top foam layer protrude into the recessions of the top surface of the bottom foam layer. The most protruded surfaces of the protrusions of the bottom surface of the top foam layer are separated from corresponding surfaces of the recessions of the top surface of the bottom foam layer by a channel, but there is no channel between most protruded surfaces of the protrusions of the top surface of the bottom foam layer and corresponding surfaces of the recessions of the bottom surface of the top foam layer.

Description

There is foam pad mattress and the manufacture method thereof of progressive support performance
Technical field
Illustrative embodiment relates to mattress, especially, has the ventilation of progressive support performance, improvement and the foam pad mattress of cooling characteristics and manufacture method thereof.
Background technology
Mattress comprises the support component of some types, for example as built-in spring core or the foam core made by polyurethane form.
Compare with built-in spring core mattress, some prefer foam core mattress.But, to compare with built-in spring core mattress, foam core mattress has several shortcomings.
For example, different from conventional foam core mattress, the resistance transmission that built-in spring core mattress can provide by built-in spring is supported to human body.This built-in spring can be configured so that human body keeps correct body position calibration, redistributes equably human body weight, to alleviate interfacial pressure on wide territory simultaneously.
In addition, some built-in spring core mattresses are configured to the human body that is supported to that provides progressive, this means along with more body weight put on built-in spring core, and built-in spring core provides the robustness increasing gradually.When keeping correct body position calibration, the built-in spring core of support of this progress can provide the comfort level of increase.But, use conventional foam core mattress to realize not yet reliably the support performance of this progress.
Foam core mattress also has the shortcoming that polyurethane foam is good heat insulator.Therefore, the mattress with polyurethane foam supporting-core or polyurethane foam batts can retain too many heat, thereby the people that make to sleep on mattress feel uncomfortable.Really, when sleeping on foam pad mattress or foam pad mattress batts, some complain that it becomes too warm.
In addition the method that, tradition is manufactured foam pad mattress is consuming time and wastes as clicking technique and profile cut technique.Therefore, need new manufacture method manufacture foam pad mattress, to reduce and/or the material of Waste reduction and reduce manufacturing time.
Above-mentioned sensation is very long, but it is an open question still in articles for use industry in bed.
Summary of the invention
Other shortcomings that illustrative embodiment overcomes above-mentioned shortcoming and do not describe above.In addition, illustrative embodiment does not need to overcome above-described shortcoming, and illustrative embodiment can not overcome above-described any problem.
According to an illustrative embodiment, a kind of mattress, comprising: a top foam layer, an and bottom foam layer, wherein the lower surface of this top foam layer comprises a series of protuberances and recess, wherein the top surface of this bottom foam layer comprises a series of protuberances and recess, wherein the protuberance of the top surface of this bottom foam layer stretches into the recess of the lower surface of this top foam layer, wherein the protuberance of the lower surface of this top foam layer stretches into the recess of the top surface of this bottom foam layer, wherein the major part of the protuberance of the lower surface of this top foam layer is protruded surface corresponding surface separation with the recess of the top surface of this bottom foam layer by passage, and wherein between the major part protrusion surface of protuberance of top surface of this bottom foam layer and the corresponding surface of the recess of the lower surface of this top foam layer, there is no passage.
According to another illustrative embodiment, a kind of method of manufacturing mattress is provided, the method comprises: one first foam member is cut to two halves, to form the first and second top layers, the lower surface of this first top layer comprises a series of protuberances and recess, and the top surface of this second top layer comprises a series of protuberances and the recess relative with recess with a series of protuberances of this first top layer; One second foam member is cut to two halves, to form the first and second bottom layer, the lower surface of this first bottom layer comprises a series of protuberances and recess, and the top surface of this second bottom layer comprises a series of protuberances and the recess relative with recess with a series of protuberances of this first bottom layer; And this first top layer is placed on the top of this second bottom layer, so that the protuberance of the top surface of this second bottom layer stretches into the recess of the lower surface of this first top layer, make the protuberance of the lower surface of this first top layer stretch into the recess of the top surface of this second bottom layer; Wherein carry out this first foam member is cut to two halves and this second foam member is cut to two halves, so that when the first top layer is positioned on the top of this second bottom layer, the major part of the protuberance of the lower surface of this first top layer is protruded surface corresponding surface separation with the recess of the top surface of this second bottom layer by passage, and there is no passage between the major part protrusion surface of protuberance of top surface of this second bottom layer and the corresponding surface of the recess of the lower surface of this first top layer.
Accompanying drawing explanation
Below with reference to appended graphic description illustrative embodiment, wherein similar Reference numeral represents similar components.
Fig. 1 is the cutaway view of the top layer of the foam pad mattress of the explanation progress consistent with an illustrative embodiment;
Fig. 2 is the cutaway view of the bottom layer of the foam pad mattress of the explanation progress consistent with an illustrative embodiment;
Fig. 3 A is the cutaway view of the foam core of the explanation progress that comprise top layer and bottom layer consistent with an illustrative embodiment;
Fig. 3 B is consistent with an illustrative embodiment before top layer and bottom layer combine for explanation, comprises the enlarged diagram of a part for the foam core of the progress of top layer and bottom layer;
Fig. 4 is the cutaway view that the typical case of the foam pad mattress 400 of the explanation progress consistent with an illustrative embodiment builds structure;
Fig. 5 is the cutaway view of the firm structure structure of the foam pad mattress 500 of the explanation progress consistent with an illustrative embodiment;
Fig. 6 for explanation in bottom layer 21 Fen Lis with 22 and be placed as and face up with its protuberance and recess after, the top view of the bottom layer 21 and 22 consistent with the illustrative embodiment of Fig. 2 demonstration; And
Fig. 7 is the flow chart of the method for the foam pad mattress of the explanation description manufacture progress consistent with an illustrative embodiment.
The specific embodiment
Fig. 1 is the cutaway view of the top layer 11 and 12 of the foam pad mattress of the explanation progress consistent with an illustrative embodiment.As shown in Figure 1, the first foam member 100 is cut to two halves, and to form the top layer (that is, the first top layer 11 and the second top layer 12) of two separation, it respectively can be in the foam pad mattress of two different progress.This cutting can include, but are not limited to blade, laser instrument, convolution machine etc. with any suitable cutter sweep and carry out.According to an illustrative embodiment, this foam can be polyurethane foam etc.
As shown in Figure 1, this foam member 100 is divided into two halves, so that each of the first top layer 11 and the second top layer 12 circled round, and comprises a series of protuberances and recess.Particularly, this foam member 100 cuts with a series of protuberances 13 of this second top layer 12 and the mode that recess 15 forms simultaneously with a series of protuberances 16 and the recess 14 of this first top layer 11.
That is to say, for example, as shown in Figure 1, when the cut action of foam member 100 separates, this cutting forms a recess 14 simultaneously and in the second top layer 12, forms a corresponding protuberance 13 relatively in the first top layer 11.This cutting continues to carry out along the whole length of foam member 100, until the first top layer 11 is separation with the second top layer 12.The conventional art that uses convolution machine to cut apart foam is known in the field, and can be for division foam member 100.
Therefore, consistent with an illustrative embodiment, the top layer of two separation (, the first top layer 11 and the second top layer 12) be formed in single splitting operation, wherein the top layer of these two separation respectively can be in the foam pad mattress of two different progress, and this single splitting operation need to be about the machine time of 20-30 second.On the contrary, for the manufacture of traditional clicking technique and the profile cut technique of the foam core of mattress, conventionally need the machine time of 10-15 minute, to form comparable froth bed.
Further contrary with profile cut technique with traditional clicking technique of the foam core for the manufacture of mattress, consistent with an illustrative embodiment, almost without the foamed material of waste, cause foam member 100 to be cut to two halves.
According to an illustrative embodiment, top layer 11 and 12 can have multiple holes or passage 17, its top surface from top layer 11 and 12 extends to the lower surface of top layer 11 and 12, as be on January 22nd, 2011 submit to U.S. Patent application the 61/425th, in No. 303, describe, be entitled as " mattress with the cooling characteristics of improvement ", this patent application is all quoted as a reference at this.Air Flow is convenient in the short transverse of top layer 11 and 12 in hole 17.The size in hole 17 and/or structure can be conditioned to control and reduce the heat insulation characteristics of top layer 11 and 12, thereby provide the comfort level of increase for the people that have a rest thereon.
According to an illustrative embodiment, hole 17 can have the diameter as 1/4 inch.In one embodiment, the hole 17 in top layer 11 and 12 can be formed as trellis pattern, and the distance of 2 inches separated from one another.
Understandably, in top layer 11 and 12, form hole 17 and can reduce the support structure of top layer 11 and 12.Therefore, only need hole 17 as much as possible that the air-flow of requirement is provided, this hole 17 can be formed on top layer 11 and 12, to keep the support structure of foam.Although the diameter in the hole 17 in an illustrative embodiment is 1/4 inch, the hole that can use other sizes according to the required air-flow of top layer 11 and 12 and support performance.
Similar with the top layer 11 and 12 of Fig. 1, Fig. 2 is the cutaway view of the bottom layer 21 and 22 of the foam pad mattress of the explanation progress consistent with an illustrative embodiment.As shown in Figure 2, the second foam member 200 is divided into two halves, and to form the bottom layer (that is, the first bottom layer 21 and the second bottom layer 22) of two separation, the bottom layer of these two separation respectively can be in the foam pad mattress of two different progress.
As shown in Figure 2, use if convolution machine is by foam member 200 dimidiations, so that each of the first bottom layer 21 and the second bottom layer 22 circled round, and comprise a series of protuberances and recess.Particularly, foam member 200 is divided with a series of protuberances 23 of this second bottom layer 22 and the mode that recess 25 forms simultaneously by a series of protuberances 26 with this this first bottom layer 21 and recess 24.
That is to say, for example, as shown in Figure 2, when the cut action division of foam member 200, this cutting forms recess 24 simultaneously and in the second bottom layer 22, forms corresponding relative protuberance 23 in the first bottom layer 21.This cutting continues to carry out along the whole length of foam member 200, until the first bottom layer 21 is separation with the second bottom layer 22.
By the mode of illustration, Fig. 6 for explanation in bottom layer 21 Fen Lis with 22 and its protuberance and recess are placed as and are faced up after, the top view of the bottom layer 21 and 22 consistent with the illustrative embodiment of Fig. 2 demonstration.
After forming top layer 11 and 12 and bottom layer 21 and 22, top layer 11 is positioned on the top of bottom layer 22, as shown in Figure 3A, and to form the foam core 300 of progress of foam pad mattress of the progress consistent with an illustrative embodiment.As shown in Figure 3A, the protuberance 23 of bottom layer 22 stretches into the recess 14 of top layer 11, as jigsaw puzzle part, is assembled together.Similarly, the protuberance 16 of top layer 11 stretches into the recess 25 of bottom layer 22.
Fig. 3 B is that explanation is consistent with an illustrative embodiment just before top layer 11 and bottom layer 22 combine, and comprises the enlarged diagram of a part for the foam core 300 of the progress of the foam pad mattress of the progress of top layer 11 and bottom layer 22.
Significantly, top layer 11 and bottom layer 22 are so configured to be convenient to after top layer 11 is positioned on the top of bottom layer 22, as shown in Figure 3A, void space remains between the protuberance 16 of top layer 11 and the recess 25 of bottom layer 22, thereby form passage 30, air can flow by this passage 30.Especially, the major part of the protuberance 16 of top layer 11 is protruded surface corresponding surface separation with the recess 25 of bottom layer 22 by passage 30.
For example, because put on the power of the top surface (, applying by the people that have a rest) of mattress on mattress, increase, this structure (in other advantages) provides the foam core 300 of the progress with firm gradually support performance.Void space in passage 30 between top layer 11 and bottom layer 22 provides progressive support profiles, and it can use the support profiles of the progressive spring coil simulation of tradition mattress.When power puts on the top surface of foam core 300, due to the support performance of the foam using in top layer 11, top layer 11 provides support to a certain degree.When top layer 11 compresses and when the protuberance 16 of top layer presses downwards by passage 30 and contacts with the recess 25 of bottom layer 22, because the support performance of the foam of bottom layer 22 is in conjunction with the support performance of the foam of top layer 11, provides largely and support.Effect is progressive support profiles, and the support wherein providing by foam core 300 increases along with applying more power from the top of foam core.
By selection, be used for top and bottom layer foam type and/or density and by the distance between 30Zhong top, selector channel layer 11 and bottom layer 22, can realize various support performances.
This structure also provides the cooling characteristics of enhancing to progressive foam core 300.
Or, between the major part protrusion surface of protuberance 23 of top surface of bottom layer 22 and the corresponding surface of the recess 14 of the lower surface of top foam layer 11, there is no this void space or passage.
Consistent with an illustrative embodiment, the surface of the protuberance 23 of the top surface of bottom layer 22 adheres to the correspondence surface of the recess 14 of the lower surface of top layer 11 by adhesive.But, between the major part protrusion surface of protuberance 16 of lower surface of top layer 11 and the corresponding surface of the recess 25 of the top surface of bottom layer 22, there is no adhesive.Use roller bearing, adhesive is only coated on the top surface of the protuberance 23 of bottom layer 22.Then, top layer 21 is positioned and is placed on the top of bottom layer 22.Then, the top surface of protuberance 23 adheres to the correspondence surface of recess 25.
The illustrative embodiment showing according to Fig. 3 A, the height at protuberance 16 places can be " 2.0-5.0 ", the height at recess 14 places can be " 0.75-3.5 ".In addition, the height at protuberance 23 places can be " 2.0-6.0 ", and the height at recess 25 places can be " 1.0-3.0 ".The total height of progressive foam core 300 can be " 2.75-9.5 ".As shown in Figure 3A, the height of passage 30 is at least 0.25, but is less than 1.5.Between protuberance 23 and recess 14, there is no space.But the present invention is not limited to above-mentioned size, and those of ordinary skill in the art will recognize, can make various modifications to the above-mentioned size consistent with the present invention.
The illustrative embodiment showing according to Fig. 3 A, passage 30 is formed on the top surface of bottom layer 22.The width that passage 30 is crossed bottom layer 22 at least in part extends, and this width extends perpendicular to head to the pin length direction of bottom layer 22.According to an illustrative embodiment, the whole width that passage 30 can be crossed bottom layer 22 extends.
Passage 30 is convenient to air-flow and is crossed the width of bottom layer 22.The size of passage 30 and/or structure can be conditioned to control and reduce the heat insulation characteristics of bottom layer 22, thereby provide the comfort level of increase for the people that have a rest thereon.
According to an illustrative embodiment, passage 30 can be waveform.Or passage 30 can be longitudinally, diagonal ground or extend in other directions of crossing bottom layer 22.As another alternative embodiment, passage 30 can have the shape except waveform, as long as passage 30 allows air to flow at the top of bottom layer 22.
The one side or the multi-lateral that is attached at mattress is 3-D fabric (not shown).This 3-D fabric 16 is to place along the both sides of the edge of foam core 300, and wherein the end of passage 30 is positioned at the both sides of the edge of this foam core 300.Understandably, this 3-D fabric can be 3-D grid or separation net type fabric to those of ordinary skill in the art.This 3-D fabric has an open knitting structure, and it provides environment under low pressure, and this environment under low pressure allows air easily by fabric, to flow, and needs little power to draw air by fabric.This 3-D fabric is attached at the sidepiece of foam core 300.
According to an illustrative embodiment, cold air moves by convection current, crosses the top surface of top layer 11.When people lie on the mattress that comprises top layer 11 and bottom layer 22, by human body, make to rise air is warmed via the hole 17 in top layer 11 and the cold air that sucks by passage 30.Although heat keeps by polyurethane foam conventionally, the air-flow of crossing the increase at the top of mattress provides cooling effect for the people that lie on mattress.The human heat of this rising produces convection current, and it sucks cold air by the multiple holes 17 in passage 30 and 3D fabric.This cold air flows at the top of top layer 11, is operated to reduce body temp, allows people to lie in comfily on the top of mattress not overheated in the situation that.
In addition, according to an illustrative embodiment, passage 30 can extend to be connected with the air vent (not shown) being placed on top or bottom end surface or the side surface of bottom layer 22, to replace 3D fabric or except 3D fabric.This air vent can go deep into the outside of mattress.Can use according to the air-flow of requirement the air vent of any amount, to provide to bottom layer 22.This air vent is little metal or plastics fluting ventilation component, and it allows air easily to flow through mattress cover and flow to passage 30.Or, can use the air vent of other types, as long as air slight drag ground passes through air vent.
When people lie on the top of the mattress that comprises bottom layer 22, from the heat of human body, surrounding air is warmed so that its rising.By the convection current from rising warm air, cold air sucks by hole 17, and by air vent admission passage 30.From this air of hole and air vent suction, along the waveform passage that reduces human body temperature, advance, cause the sleeping surface that human body is more comfortable.
Fig. 4 is the cutaway view that the typical case of the foam pad mattress 400 of the explanation progress consistent with an illustrative embodiment builds structure.
As shown in Figure 4, comfortable (or batts) layer 40 can be provided on the layer 11A of top.Basic unit 45 also can be provided under bottom layer 22A.In addition, track 46 can be provided in progressive foam pad mattress 400 around.
According to the illustrative embodiment showing as Fig. 4, this comfort liner 40 can be smooth or coil, and can be made by for example foam.This comfort liner 40 can have 2.0 height, but is not limited to these sizes.
As shown in Figure 4, basic unit 45 can have 1.0 height, but this basic unit 45 is not limited to these sizes.
According to the illustrative embodiment showing as Fig. 4, top layer 11A has protuberance 16A and recess 14A.Bottom layer 22A has protuberance 23A and recess 25A.The height of protuberance 16A can be 3.5, and the height of recess 14A can be 1.75.The height of protuberance 23A can be 4.75, and the height of recess 25A can be 2.375.The total height of top layer 11A and bottom layer 22A can be 6.5.The total height of progressive foam pad mattress 400 can be 9.5.But the present invention is not limited to the specific dimensions of the illustrative embodiment of Fig. 4 demonstration.
Fig. 5 is the cutaway view of the firm structure structure of the foam pad mattress 500 of the explanation progress consistent with an illustrative embodiment.Compare with the illustrative embodiment that Fig. 4 shows, the illustrative embodiment that Fig. 5 shows provides firmer support performance.
As shown in Figure 5, comfortable (or batts) layer 40 can be provided on the layer 11B of top.Basic unit 45 also can be provided under bottom layer 22B.In addition, track 46 can be provided in progressive foam pad mattress 500 around.The illustrative embodiment showing with Fig. 4 is contrary, and the illustrative embodiment that Fig. 5 shows comprises high supporting layer 59 extraly.This high supporting layer 59 can have 2.0 height, but is not limited to these sizes.
The illustrative embodiment showing according to Fig. 5, comfort liner 40 can be smooth or coil, and can be made by for example foam.This comfort liner 40 can have 2.0 height, but is not limited to these sizes.
As shown in Figure 5, basic unit 45 can have 1.0 height, but this basic unit 45 is not limited to these sizes.
The illustrative embodiment showing according to Fig. 5, top layer 11B has protuberance 16B and recess 14B.This bottom layer 22B has protuberance 23B and recess 25B.The height of protuberance 16B can be 2.5, and the height of recess 14B can be 1.0.The height of protuberance 23B can be 3.5, and the height of recess 25B can be 1.5.The total height of top layer 11B and bottom layer 22B can be 4.5.The total height of progressive foam pad mattress 500 can be 9.5.But the present invention is not limited to the specific dimensions of the illustrative embodiment of Fig. 5 demonstration.
Fig. 7 is the explanation flow chart described for the manufacture of the method for progressive foam pad mattress consistent with an illustrative embodiment.As shown in Figure 7, operation S100 comprises: by the first foam member 100 dimidiations, to form the first top layer 11 with a series of protuberances 16 and recess 14 and the second top layer 12 with a series of protuberances 13 and recess 15.
Operation S200 comprises: the second foam member 200 dimidiations are had to the first bottom layer 21 of a series of protuberances 26 and recess 24 and have the second bottom layer 22 of a series of protuberances 23 and recess 25 to form.
Finally, operation S300 comprises: the first top layer 11 is placed on the top of the second bottom layer 22, so that the major part of protuberance 16 is protruded surface corresponding surface separation with recess 25 by passage 30, and protrude between surface and the corresponding surface of recess 14 and there is no passage in the major part of protuberance 23.
Above stated specification embodiment and advantage are only illustrative, and are not interpreted as limiting the present invention.Understandably, the present invention can easily be applied to the device of other types to those of ordinary skill in the art.In addition, the description of this illustrative embodiment is intended to illustrative, do not limit the scope of the claims, and those of ordinary skill in the art obviously can make many replacements, modification and conversion.
Claims (according to the modification of the 19th article of treaty)
1. a mattress, comprising:
One top foam layer; And
One bottom foam layer,
It is characterized in that, the lower surface of this top foam layer comprises a series of protuberances and recess,
Wherein, the top surface of this bottom foam layer comprises a series of protuberances and recess,
Wherein, the protuberance of the top surface of this bottom foam layer stretches into the recess of the lower surface of this top foam layer,
Wherein, the protuberance of the lower surface of this top foam layer stretches into the recess of the top surface of this bottom foam layer,
Wherein, the major part of the protuberance of the lower surface of this top foam layer is protruded surface corresponding surface separation with the recess of the top surface of this bottom foam layer by passage,
Wherein, between the major part protrusion surface of protuberance of top surface of this bottom foam layer and the corresponding surface of the recess of the lower surface of this top foam layer, there is no passage, and
Wherein, this mattress is configured to along with the power of the top surface that puts on mattress increases and firm gradually support performance is provided.
2. mattress as claimed in claim 1, is characterized in that, the major part of the protuberance of the top surface of this bottom foam layer is protruded the surperficial correspondence surface that adheres to the recess of the lower surface of this top foam layer by adhesive, and
Wherein, between the major part protrusion surface of protuberance of lower surface of this top foam layer and the corresponding surface of the recess of the top surface of this bottom foam layer, there is no adhesive.
3. mattress as claimed in claim 1, is characterized in that, further comprises: the first vent passages forming in the top surface of this bottom foam layer,
Wherein, this first vent passages extends on the width of mattress between the opposite side end surfaces of bottom foam layer, and this width extends to pin length direction perpendicular to the head of mattress.
4. mattress as claimed in claim 1, is characterized in that, further comprises: at the second vent passages extending from top surface to the short transverse of the mattress of the lower surface of top foam layer of top foam layer.
5. mattress as claimed in claim 1, is characterized in that, the height of the passage in the direction of the top surface perpendicular to bottom foam layer is at least 0.25 inch.
6. mattress as claimed in claim 5, is characterized in that, the height of the passage in the direction of the top surface perpendicular to bottom foam layer is for being less than 1.5 inches.
7. a method of manufacturing mattress, is characterized in that, the method comprises:
One first foam member is cut to two halves, to form the first and second top layers, the lower surface of this first top layer comprises a series of protuberances and recess, and the top surface of this second top layer comprises a series of protuberances and the recess relative with recess with a series of protuberances of this first top layer;
One second foam member is cut to two halves, to form the first and second bottom layer, the lower surface of this first bottom layer comprises a series of protuberances and recess, and the top surface of this second bottom layer comprises a series of protuberances and the recess relative with recess with a series of protuberances of this first bottom layer; And
This first top layer is placed on the top of this second bottom layer, so that the protuberance of the top surface of this second bottom layer stretches into the recess of the lower surface of this first top layer, make the protuberance of the lower surface of this first top layer stretch into the recess of the top surface of this second bottom layer;
Wherein, execution is cut to this first foam member two halves and this second foam member is cut to two halves, so that when the first top layer is positioned on the top of this second bottom layer, the major part of the protuberance of the lower surface of this first top layer is protruded surface corresponding surface separation with the recess of the top surface of this second bottom layer by passage, and there is no passage between the major part protrusion surface of protuberance of top surface of this second bottom layer and the corresponding surface of the recess of the lower surface of this first top layer.
8. method as claimed in claim 7, it is characterized in that, further comprise: this second top layer is placed on the top of this first bottom layer, so that the protuberance of the lower surface of this first bottom layer stretches into the recess of the top surface of this second top layer, and the protuberance that makes the top surface of this second top layer stretches into the recess of the lower surface of this first bottom layer
Wherein, execution is cut to this first foam member two halves and this second foam member is cut to two halves, so that when the second top layer is positioned on the top of this first bottom layer, the major part of the protuberance of the top surface of this second top layer is protruded surface corresponding surface separation with the recess of the lower surface of this first bottom layer by passage, and there is no passage between the major part protrusion surface of protuberance of lower surface of this first bottom layer and the corresponding surface of the recess of the top surface of this second top layer.

Claims (9)

1. a mattress, comprising:
One top foam layer; And
One bottom foam layer,
It is characterized in that, the lower surface of this top foam layer comprises a series of protuberances and recess,
Wherein, the top surface of this bottom foam layer comprises a series of protuberances and recess,
Wherein, the protuberance of the top surface of this bottom foam layer stretches into the recess of the lower surface of this top foam layer,
Wherein, the protuberance of the lower surface of this top foam layer stretches into the recess of the top surface of this bottom foam layer,
Wherein, the major part of the protuberance of the lower surface of this top foam layer is protruded surface corresponding surface separation with the recess of the top surface of this bottom foam layer by passage,
And wherein, between the major part protrusion surface of protuberance of top surface of this bottom foam layer and the corresponding surface of the recess of the lower surface of this top foam layer, there is no passage.
2. mattress as claimed in claim 1, is characterized in that, the major part of the protuberance of the top surface of this bottom foam layer is protruded the surperficial correspondence surface that adheres to the recess of the lower surface of this top foam layer by adhesive, and
Wherein, between the major part protrusion surface of protuberance of lower surface of this top foam layer and the corresponding surface of the recess of the top surface of this bottom foam layer, there is no adhesive.
3. mattress as claimed in claim 1, is characterized in that, further comprises: the first vent passages forming in the top surface of this bottom foam layer,
Wherein, this first vent passages extends on the width of mattress between the opposite side end surfaces of bottom foam layer, and this width extends to pin length direction perpendicular to the head of mattress.
4. mattress as claimed in claim 1, is characterized in that, further comprises: at the second vent passages extending from top surface to the short transverse of the mattress of the lower surface of top foam layer of top foam layer.
5. mattress as claimed in claim 1, is characterized in that, the height of the passage in the direction of the top surface perpendicular to bottom foam layer is at least 0.25 inch.
6. mattress as claimed in claim 5, is characterized in that, the height of the passage in the direction of the top surface perpendicular to bottom foam layer is for being less than 1.5 inches.
7. mattress as claimed in claim 1, is characterized in that, this mattress is configured to along with the power of the top surface that puts on mattress increases and firm gradually support performance is provided.
8. a method of manufacturing mattress, is characterized in that, the method comprises:
One first foam member is cut to two halves, to form the first and second top layers, the lower surface of this first top layer comprises a series of protuberances and recess, and the top surface of this second top layer comprises a series of protuberances and the recess relative with recess with a series of protuberances of this first top layer;
One second foam member is cut to two halves, to form the first and second bottom layer, the lower surface of this first bottom layer comprises a series of protuberances and recess, and the top surface of this second bottom layer comprises a series of protuberances and the recess relative with recess with a series of protuberances of this first bottom layer; And
This first top layer is placed on the top of this second bottom layer, so that the protuberance of the top surface of this second bottom layer stretches into the recess of the lower surface of this first top layer, make the protuberance of the lower surface of this first top layer stretch into the recess of the top surface of this second bottom layer;
Wherein, execution is cut to this first foam member two halves and this second foam member is cut to two halves, so that when the first top layer is positioned on the top of this second bottom layer, the major part of the protuberance of the lower surface of this first top layer is protruded surface corresponding surface separation with the recess of the top surface of this second bottom layer by passage, and there is no passage between the major part protrusion surface of protuberance of top surface of this second bottom layer and the corresponding surface of the recess of the lower surface of this first top layer.
9. method as claimed in claim 8, it is characterized in that, further comprise: this second top layer is placed on the top of this first bottom layer, so that the protuberance of the lower surface of this first bottom layer stretches into the recess of the top surface of this second top layer, and the protuberance that makes the top surface of this second top layer stretches into the recess of the lower surface of this first bottom layer
Wherein, execution is cut to this first foam member two halves and this second foam member is cut to two halves, so that when the second top layer is positioned on the top of this first bottom layer, the major part of the protuberance of the top surface of this second top layer is protruded surface corresponding surface separation with the recess of the lower surface of this first bottom layer by passage, and there is no passage between the major part protrusion surface of protuberance of lower surface of this first bottom layer and the corresponding surface of the recess of the top surface of this second top layer.
CN201280039747.7A 2011-07-19 2012-07-18 Foam mattress with progressive support characteristics and method for manufacturing the same Pending CN103763992A (en)

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CA2842198A1 (en) 2013-01-24
US20140208521A1 (en) 2014-07-31
AU2012284077B2 (en) 2015-07-23
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RU2014100987A (en) 2015-08-27
MX2014000729A (en) 2014-04-30

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