WO2014111867A1

WO2014111867A1 - Modular support system

Info

Publication number: WO2014111867A1
Application number: PCT/IB2014/058304
Authority: WO
Inventors: Vincent VERHAERT; Steven LEURIDAN; Dorien VAN DEUN; Claus CLAEYS
Original assignee: Katholieke Universiteit Leuven
Priority date: 2013-01-15
Filing date: 2014-01-15
Publication date: 2014-07-24

Abstract

A modular support system for supporting a body part, whereby the modular support system comprises the assembly of a base unit, whereby the base unit contains at least one opening, and at least one insert with a length (Li), whereby the insert can be placed in the opening, and whereby the insert furthermore comprises a plurality of attachment means.

Description

MODULAR SUPPORT SYSTEM

Field of the invention

The present invention generally relates to modular support systems and a method of assembling a modular support system with components applied therein. Furthermore, the present invention relates to a method of replacing at least one insert of a modular support system. More specifically, the invention relates to a modular mattress, a seat, a box spring or a back-support surface, with the aim that a user or person lies more comfortably and/or is supported and/or gets more restful sleep and/or that physical complaints related to posture and/or the presence of pressure points or overload and/or excessive sweating and/or complaints regarding comfort, more specifically thermal comfort, such as for example having too hot or too cold, can be reduced and/or avoided.

Background of the invention

A bed system or sleep system, whereby a sleep system is a combination of a mattress and bed base, is one of the most important components of the sleep environment, with which the human body continuously interacts during sleep. An improperly designed bed system can lead to physical discomforts that can ultimately contribute to and/or result in back pain and sleeplessness or insomnia.

Bed systems can be classified by the materials and/or technologies that are used. Common mattresses are innerspring mattresses, polyurethane foam mattresses, latex foam mattresses, memory foam mattresses, mattresses with fluid elements, etc. Examples of bed bases are a.o. box springs, slat bases, spiral bases, etc.

Bed systems can also be classified according to the degree of personalization that can be achieved. Customizing a bed system comes down to adjusting the properties of the bed to meet specific user needs which may vary with different physical and thermal preferences of each individual.

So far, most bed systems have the same mechanical and thermal properties over the entire sleeping surface. Such (homogenous) systems are not provided for differing dimensions and weight distribution on the longitudinal direction of the human body and are therefore not able to guarantee an economically correct support of the body.

More advanced bed systems contain zones with different characteristics (e.g. a different firmness). These so-called comfort zones may be contained in the mattress core and/or the comfort layer and/or the bed base. In known bed systems, these comfort zones may for example be found at the position of the head, the shoulders, the lumbar region, the hips, the thighs, the legs, or the feet. These bed systems, which are not modular or adjustable, are traditionally made by having the persons for whom they are being made, lie down to test a number of bed systems with adjustable comfort zones, and creating a personalized mattress on the basis of their preferences by providing some comfort zones more hard and other comfort zones more soft. This has as a disadvantage that that the mattress cannot be adjusted to the person's needs as these vary over time. Thus, it may happen that during the lifetime of the mattress, the person's weight evolves, causing the comfort zones not to be correctly situated anymore with respect to the body.

The most advanced systems contain zones which can be set or adjusted separately to the individual preferences or needs of the user. A person with broad shoulders and narrow hips should after all be supported in a different way than someone with wide hips and narrow shoulders. Adjustable bed systems facilitate this advanced form of personalization so that different people can be supported correctly with the same bed system. Most adjustable bed systems consist of an adjustable bed base and a non-adjustable mattress. There are only a few mattresses, such as those described in BE1019722, that are modular and/or adjustable, whereby they are made from a base part provided with a recess and selectively chosen inserts that fit in the recess.

An important disadvantage of existing modular mattresses is that the replacement of a module or insert is very cumbersome and the bed system and the mattress have to be dismantled down to the inserts to allow replacement of an insert.

There is still a need for handy and easy to use modular support systems.

Summary of the invention

It is an aim of the invention to provide a support system that allows easy adjustment of sleep and/or sitting comfort. It is also an aim of the invention to provide a method to easily replace modules or inserts of a modular support system. It is an advantage of embodiments of the present invention that a modular support system is provided that allows modular body support.

A support system according to the invention is preferably modular, which means that a support system can be composed of a selectable number of modules or components.

It is an advantage of at least some embodiments of the invention to provide a method that enables easy exchange or replacement of inserts in a modular system by making use of a cover capable of resisting large tensile forces and that has a low friction coefficient with respect to surrounding materials.

It is an advantage of embodiments of the modular support system that problems with the lateral insertion of an insert into an opening in a base unit can be overcome by providing a method according to embodiments of the present invention that facilitates the exchange or replacement of inserts. It is an advantage of at least some embodiments that a cover is provided that can be applied tightly around the insert and that facilitates exchange without tearing or damaging the cover or the insert due to the large tensile forces that often occur. Preferably the cover is tightly applied around the insert with the aid of a zipper.

An additional advantage of modular support systems, for example mattresses, as compared to bed bases with an adjustable bed base is that as the mattress ages, only the inserts that are worn out have to be replaced, not the entire mattress. Also with regard to the transport, a modular mattress offers advantages because a mattress made of a single piece is very hard to move.

The "tightness" of the cover is preferably defined analogously to fits and tolerances when fitting an axle in an opening (loose fit, transitional fit, and/or tight fit). Preferably the insert can be placed tightly in the opening and there is little tolerance for movement in the opening. It goes without saying that loose fits or transitional fits are possible.

It is an advantage of embodiments of the method that an insert can be replaced in a single movement, without requiring two steps of first having to pull one insert out of the opening before being able to insert a new insert.

Materials that are used for the inserts comprise for example flexible and elastic materials, such as polyurethane foams, latex foams, pocket springs, etc., which can make the insertion of inserts cumbersome due to the fact that the base unit is also made of flexible and elastic materials, which leads to high friction/adhesion between the insert and the base unit.

The high friction coefficient is also increased due to the fact that the opening of the base unit, because of the elastic materials of which it is comprised, also becomes slack as a result of the materials placed on the base unit, such as e.g. a cover layer for comfort. If someone wants to remove the insert, tensile forces, which may be large in order to overcome the existing friction, may even cause tearing of the insert. Moreover, it is very hard to place a new insert into the base unit, as illustrated in FIG. 3, because when pushing, the friction forces to be overcome are greater than the forces necessary to deform the elastic insert, so that the insert deforms before it slips into the opening. This is why some embodiments of the invention provide a cover for at least one insert which reduces the friction coefficient and which is preferably provided with inelastic means to resist the large tensile forces. Moreover, the method of replacing inserts offers a solution for slack openings, since the insert is replaced in a single, simple movement while pulling. The inelastic means are preferably placed in such a way that a minimum of friction is created and whereby the insert can resist the tensile force necessary for pulling the insert out of the base unit.

In embodiments of the invention, the base unit can be used as a cover for at least one insert. In other embodiments, the length of the insert Li preferably has the same size as the width of the assembly or base unit bs,b, or has the same size as the width of the assembly or base unit bs,b minus the length or space necessary to enable to access the attachment elements.

It is an advantage of embodiments of the invention that inserts can be inserted and taken out without having to take apart the modular support system.

The invention comprises, according to a first aspect, modular support systems for supporting a body part, whereby the modular support system contains an assembly of a base unit, whereby the base unit contains at least one opening, and whereby at least one insert has a length (Li) wherein the insert can be placed into the opening, and wherein the insert further comprises a plurality of attachment means.

The at least one opening is preferably located laterally across the width of the base unit.

In preferred embodiments, the attachment means are placed on the lengthwise ends and/or on the sides of the insert.

In preferred embodiments, the insert is a loose, insertable and/or removable insert. The insert is preferably laterally insertable and/or removable.

In preferred embodiments, the base unit and/or at least one insert is provided with a separate cover. Preferably the cover is provided tightly around the base unit and/or the insert.

In preferred embodiments, the cover comprises a stretchable and/or elastic fabric so that the load of the insert during normal use is not or only minimally influenced by the cover itself. Preferably the cover may comprise knitted and/or woven fabrics consisting of unstretchable and/or stretchable fibers or a combination of these.

In preferred embodiments, the modular support system comprises the characteristic that the firmness of the insert is different from the firmness of the nearby zones of the base unit and/or another nearby insert. The mechanical properties , e.g. firmness, of an insert according to embodiments of the invention, are preferably determined on the basis of two standards: IS02439 (foam components) and/or EN1957 (functional properties of mattresses and bed systems). Moreover, according to alternative embodiments of the invention, a difference in firmness can be obtained by combining various materials or by providing various embodiments of the same product, e.g. the density of the foam or the wire thickness of pocket springs, in nearby zones.

In preferred embodiments, a modular support system comprises the feature that the thermal insulation and/or air and/or moisture permeability of the insert differs from the thermal insulation and/or air and/or moisture permeability of nearby zones of the base unit and/or another nearby insert.

Preferably the modular support system is provided with means to reduce the friction between base unit and insert. In preferred embodiments, the means to reduce the friction between a base unit and an insert is a cover.

In preferred embodiments, at least one insert furthermore comprises inelastic means. The inelastic means are preferably placed on a part of the surface of a contact surface between two adjacent inserts and/or on a part of the surface of a contact surface between the insert and the base unit and/or on a part of the surface on one and/or both lengthwise ends of the insert. By lengthwise ends, is meant the ends that define the beginning or the end in the lengthwise direction of the insert. Preferably the part of the surface may comprise at least 100% of the contact surface and/or the surface at the lengthwise ends. Preferably the part of the surface may comprise at least 90% of the contact surface and/or the surface at the lengthwise ends. Preferably the part of the surface may comprise at least 80% of the contact surface and/or the surface at the lengthwise ends. Preferably the part of the surface may comprise at least 70% of the contact surface and/or the surface at the lengthwise ends. Preferably the part of the surface may comprise at least 60% of the contact surface and/or the surface at the lengthwise ends.

In alternative embodiments of the invention, inelastic means may be placed on a part of the elastic or stretchable surfaces.

Preferably the inelastic means are inelastic or rigid fabrics or materials, consisting of synthetic or natural fibers, or whereby the inelastic means comprise a bonded web, e.g. PP nonwoven.

Preferably the attachment means are placed on the inelastic means. In embodiments of the invention, the placement of attachment means may be provided by way of a suitable attachment mechanism, such as by stitching and/or gluing and/or attaching with Velcro and/or by means of snap fasteners and/or by zipping.

In preferred embodiments, the inelastic means may be adapted and placed so as to resist large tensile forces which are required to overcome friction during the insertion and/or removal of the insert into and/or out of the opening.

Preferably the inelastic means are adapted so as to prevent damage to the insert by the large tensile forces. Preferably at least one insert can resist a tensile force of at least 60 N. Preferably at least one insert can resist a tensile force of at least 50 N. Preferably at least one insert can resist a tensile force of at least 40 N. Preferably at least one insert can resist a tensile force of at least 30 N.

The tensile forces that are measured for an insert with cover, according to embodiments of the invention, may run up to 60 N. The tensile forces without covers may run up a lot higher, due to greater friction/adhesion, but an exact value is not measurable considering that the foams, without a cover, can tear at a tensile force between 25 N and 30 N. Theoretically on the basis of the calculated friction coefficients of comparable materials, the tensile force may even run up to a multiple of 60 N.

Preferably at least one insert may comprise a rectangular, trapezoidal, circular, ellipsoidal, quadrilateral, or any other polygonal cross section.

In preferred embodiments, at least one insert is provided with one or more notches over its width, which have the effect that the insert can be easily folded around these notches.

In preferred embodiments, the at least one opening is capable of receiving multiple inserts.

In preferred embodiments, a dimension and/or the firmness of at least one insert can be selected and/or adapted corresponding to the physical dimensions and/or weight distribution of a user.

In preferred embodiments, the thermal insulation and/or air and/or moisture permeability of at least one insert can be selected and/or adapted with the aim of meeting specific preferences of the user.

In preferred embodiments, the thermal insulation and/or air and/or moisture permeability of at least one insert can be selected and/or adapted with the aim of meeting specific thermal preferences of the user. In preferred embodiments, when depending on the mattress or back-support surface, an insert can be selected and/or adapted to offer optimal support to the spine of a user, whereby the user is brought into a predetermined position.

In preferred embodiments, at least one insert comprises additional monitoring means. Preferably the monitoring means may comprise accelerometers, temperature sensors, optical fibers/cables, moisture sensors, pressure sensors, displacement sensors, and/or sensors adapted to measure biological parameters of the user.

Preferably the monitoring means are placed on a flexible sensor mat.

Preferably power supply for the monitoring means may be provided by a power cord that is hooked up to an external power source or by making use of an integrated battery.

In preferred embodiments, at least one insert can be replaced after use so that data from the monitoring means can be established. Preferably the data can be processed with the aim of monitoring and/or adjusting the user and/or with the aim of monitoring and/or adapting the environmental parameters and/or to monitor and/or adjust the quality of the base unit. Preferably the data is processed in real time. In preferred embodiments, the data is transmitted to a data storage unit.

In preferred embodiments, the assembly further comprises an underframe.

In preferred embodiments, at least one insert further comprises means for manually moving and/or accessing the insert. Preferably the means for manually moving and/or accessing the insert can be open or closed, placed horizontally or vertically, be straight or curved. Preferably the means for manually moving the insert can be attached to the inelastic means.

In preferred embodiments, the attachment means may be snap fasteners, hook-and- loop fasteners, and/or zippers.

In preferred embodiments, the base unit and/or the insert comprises latex foam, polyurethane foam, memory foam, pocket springs, air elements or water elements.

In preferred embodiments, the base unit consists of a single piece. In alternative embodiments the base unit may consist of several modules. Thus the base unit, without inserts, may be composed of several modules. Preferably the modules may comprise a plurality of attachment means. Preferably the plurality of modules may comprise various materials.

In preferred embodiments, the assembly further comprises a cover layer. In preferred embodiments, the assembly preferably consist of a single piece. This assembly that consists of a single piece may be composed of various materials, for example such as in an embodiment where the assembly comprises a cover layer, base unit, and/or underframe, but where these elements preferably cannot be disassembled, with the result that if one wants to replace an insert, one cannot remove the cover layer, but that preferably one inserts or pulls out the insert laterally.

In alternative embodiments, the assembly may consist of several modules. Thus, the assembly, without inserts, may be composed of several modules. Preferably the modules may comprise a plurality of attachment means, the attachment means may preferably be placed on the side and/or at the lengthwise ends of the insert. The side of the insert is defined as those sides of the insert that define the insert in the length direction of the insert. The lengthwise ends correspond to the beginning or the end of the length direction of the insert. The sides of the insert that determine the lengthwise ends are typically positioned substantially perpendicular to the length direction of the insert. Preferably the plurality of modules may contain various materials. In alternative embodiments, the attachment means on the sides of the inserts and/or modules are used to connect the modules together or to disconnect the modules.

In preferred embodiments, the assembly may be a mattress, a bed base, a seat, a box spring, or a back-support surface.

The invention comprises, according to a second aspect, a base unit intended to be used in a modular support system according to embodiments of the invention.

The invention comprises, according to a third aspect, an insert intended to be used in a modular support system according to embodiments of the invention.

The invention comprises, according to a fourth aspect, an assembly intended to be used in a modular support system according to embodiments of the invention. Such an assembly comprises a base unit and at least one insert according to embodiments of the present invention.

The invention comprises, according to a fifth aspect, methods for assembling a modular support system according to embodiments of the invention, whereby the method comprises the following steps:

- calculating the shape of a user;

- determining the dimensions of at least one body part according to the estimated shape of the user; - calculating the sturdiness and/or dimensions of at least one insert according to the shape and/or the dimensions of the user.

In preferred embodiments, the method further comprises creating an individualized virtual model of the user and an underlying biomechanical model.

In preferred embodiments, the method comprises measuring at least one parameter by making use of the monitoring means.

The invention comprises, according to a sixth aspect, methods of replacing at least one insert of a modular support system, whereby the method comprises the following steps:

- attachment of a replacement insert to at least one insert placed in the opening, by making use of the attachment means at the lengthwise ends of the inserts;

- pulling the insert placed in the opening over a length Li.

The invention comprises, according to a seventh aspect, methods of replacing at least one insert of a modular support system, the modular support system comprising an assembly of on the one hand a base unit with at least one opening and on the other hand at least one insert with a length (Li), whereby the insert can be placed in the opening, for example an insert of a modular system according to embodiments of the invention, whereby the method comprises:

- attachment of a replacement insert to at least one insert placed in the opening, by making use of the attachment means on the lengthwise ends of the inserts;

- pulling the insert placed in the opening over a length Li.

Preferably several inserts can be replaced simultaneously.

Preferably the method further comprises replacing an insert in order to receive data from the monitoring means.

Preferably the method further comprises sending data wirelessly from the monitoring means to a data storage unit. Preferably the processing occurs in real-time.

In preferred embodiments, the method further comprises processing the received data from the monitoring means for the purpose of determining the quality of the spine or buttock support and/or the quality of sleep during a particular period of time and/or the concentration of dust mites present in the modular support system or the wear on one or more functional components, for example due to sagging or moisture retention.

A modular support system according to embodiments of the invention can be used for example in the back support of an office chair, in the seat of a sofa or chair, in a bed system, or to optimally support a body part. It is an advantage of the invention that embodiments of the modular support system allow at least one insert to be replaced and/or introduced without having to disassemble the entire assembly apart.

Preferred embodiments of the invention are presented in the attached dependent patent claims.

Specific and preferred aspects of the invention are included in the attached independent and dependent claims. Features of the dependent claims can be combined with the features of the independent claims and with features of other dependent claims as appropriate and not merely as explicitly set out in the claims.

These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.

Brief description of the drawings

The drawings are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and relative dimensions sometimes do not correspond with the actual practical implementation of the invention.

Fig. 1 schematically illustrates a support system known in the state of the art.

Figs. 2a-2f schematically illustrate an insert according to embodiments of the invention.

Fig. 3 schematically illustrates which problems may arise when someone would like to place an insert into the opening of a base unit.

Figs. 4a-4c schematically illustrate an assembly according to an embodiment of the present invention.

Fig. 5 schematically illustrates a method for replacing at least one insert according to embodiments of the invention.

Fig. 6 schematically illustrates a method for assembling a modular support system according to embodiments of the invention.

Figs. 7a to 7c illustrate possible notches or cut-outs that may be provided in the inserts according to embodiments of the invention.

Any reference signs in the claims shall not be construed as limiting the scope of protection.

In the different drawings, the same reference signs refer to the same or analogous elements. Detailed description of exemplary embodiments of the invention

The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims.

It is to be noticed that the term "comprising", used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

Similarly it should be appreciated that in the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.

Fig. 1 schematically illustrates a support system that comprises an assembly, for example a bed system as known in the state of the art. The known bed systems usually have homogeneous material properties along the longitudinal axis. More advanced systems also exist, as described in Belgian patent BE1019722, wherein the mattress can consist of several comfort zones/inserts, which are placed along the length axis. These so-called multi-zone bed systems can provide different support for various parts of the body. But not all multi-zone bed systems are modular. In Belgian patent BE1019722, a modular mattress is referred to (i.e., the comfort zones contain exchangeable pieces), but multi-zone systems also exist whose properties cannot be changed afterwards.

The shoulder area, for example, requires soft support, the waist area requires sturdier support, and the hip preferably has a medium-hard material for support. Since the human body varies in dimensions and in weight distribution, optimal support of the body can be achieved only if the mechanical properties of the bed can be adjusted individually to the body dimensions and weight distribution of the user.

Fig. 2a schematically illustrates an insert 400 with a rectangular cross section according to an embodiment of the invention. The insert 400, with length (Li), width (bi) and thickness (di) preferably comprises attachment means (6) at the ends of the insert. The attachment means may preferably be snap fasteners, hook-and-loop fasteners and/or zippers. Separate pieces of fabric for example could also be taken, which may be knotted together, but preferably the attachment means can be simply/quickly detached or attached together.

The insert preferably comprises a cover which can be fit tightly around the insert with the aid of for example a zipper 9. The insert may further comprise means for manually moving and/or accessing the insert 8. The means for manually moving and/or accessing the insert may for example be open or closed, be placed horizontally or vertically, be straight or curved.

The insert preferably also comprises inelastic means 300, 301, 302, 303 as illustrated in Fig. 2b. The inelastic means are preferably placed on a part of the surface of a contact surface between two adjacent inserts and/or on a part of the surface of a contact surface, for example the side contact surface between the insert and the base unit and/or on a part of the surface at one or both of the lengthwise ends of the insert. In Fig. 2b, these inelastic means may, according to embodiments of the invention, be placed around the insert, over the entire surface, such as the surface formed by the planes (di, Li) 300, 301 and (di, bi) 302, 303. These inelastic means are preferably rigid, having for example an adapted Young's modulus. Preferably the inelastic means comprise materials and/or fabrics that are not stretchable. A relevant example may be: woven polyester, optionally stitched for extra sturdiness. Another relevant example may be a bonded web, such as for example a nonwoven polypropylene. However, these may also be other inelastic fabrics or materials, consisting of synthetic or natural fibers.

Moreover, inserts according to preferred embodiments of the present invention, comprise an adapted cover so that the inelastic means can be optimally placed, so that a tensile strength which does not lead to rupture can be obtained. Assuming for example standard polyester yarns as material for the cover, which can have a Young's modulus of between 2 and 2.7 GPa, this leads to resistance to a tensile strength of 55 MPa. In reality, the material will of course be woven and stitched through, which will increase the actual tensile strength significantly further.

Preferably the top and/or bottom contact surfaces between the insert and the base unit, for example the surfaces 200, 201 in Fig. 2b, comprise materials having a low friction coefficient with respect to the base unit. The materials that are used for the top contact surfaces are preferably flexible, elastic, and stretchable. By making use of these materials with a low friction coefficient, the force necessary to pull the insert out is as optimal as possible, so that tearing/damaging of the cover and/or the insert is prevented and so that one does not have to apply too high forces.

The choice of elastic and nonelastic materials is preferably dependent on the cross section used for an insert. The required tensile force is preferably kept to a minimum, by using materials that have a low friction coefficient with respect to the materials that are located around these materials. For example between the insert and the base unit or between two inserts.

The inelastic elements of the insert according to embodiments of the invention allow flexible inserts, which may comprise soft latex foams or visco-elastic materials, to be easily introduced or taken out of the base unit without making use of other means. In case these inelastic means are not used, it is very difficult to introduce such a flexible insert into the base unit.

In preferred embodiments, the inelastic means are placed on a part of the surface of a contact surface between two adjacent inserts and/or on a part of the surface of a contact surface between the insert and the base unit and/or on a part of the surface of one and/or both lengthwise ends of the insert. Preferably the part of the surface may comprise at least 100% of the contact surface and/or the surface of the lengthwise ends. Preferably the part of the surface may comprise at least 90% of the contact surface and/or the surface of the lengthwise ends. Preferably the part of the surface may comprise at least 80% of the contact surface and/or the surface of the lengthwise ends. Preferably the part of the surface may comprise at least 70% of the contact surface and/or the surface of the lengthwise ends. Preferably the part of the surface may comprise at least 60% of the contact surface and/or the surface of the lengthwise ends.

It is an advantage of embodiments of the invention that the inelastic means, for example the inelastic edge, is able to resist large tensile forces required to overcome friction during introduction or removal of the insert. Further, by distributing these tensile forces over the entire insert, the inelastic edge can prevent damage to the insert (e.g. tearing).

The invention offers multiple advantages. First of all, the inserts can be placed and taken out laterally without opening the modular support system or assembly (see for example Fig. 5). The elastic edge of the insert also prevents tearing of the insert during insertion, and the elastic top and bottom surfaces of the insert insures correct deformation of the modules during normal use. It is important that the covers do not disturb the distribution of forces in the mattress. In case insufficient elasticity were provided in the top contact surfaces, the force is distributed over a larger surface area due to the cover, causing the material to respond more stiffly. Figures 2c-2f show inserts according to embodiments of the invention, where the cross section is varied.

In preferred embodiments, the inelastic means are placed in a plane perpendicular to the surface of the mattress, i.e., parallel to the load on the inserts when someone, for example a user, lies on it. In inserts having a triangle or hexagon as a cross section, oriented as illustrated in Figures 2e or 2f, the inelastic means are preferably affixed on one or both side surfaces and/or on one or both of the lengthwise ends of the insert. However, it is possible, according to alternative embodiments of the invention, that inelastic means are affixed to a part or several parts of the top contact surfaces, which are elastic or stretchable.

Fig. 3 schematically illustrates what the problem is if one would not use a cover, according to the configurations of the invention, to place inserts 405: pushing results in deformation of the insert, pulling is not recommended because the hand has to be stuck all the way through the mattress and because the insert stretches out and eventually tears.

In embodiments of the invention, the inserts may also comprise one or more notches (not shown in the figures) over the width, which have the effect of the insert can be easily folded around these notches. These notches have the advantage that stiffer inserts (e.g. in the waist area), according to embodiments of the invention, of a particular length can also be used if only a small space is available around the assembly. Besides notches, specific patterns may be provided in the inserts (for example by sawing or cutting them out) in order to locally adjust the firmness, for example lowering it. These patterns may be provided both on the surface of the insert as inside the insert.

Figures 4a-4c schematically illustrate an assembly 10 according to embodiments of the invention. The assembly comprises a base unit 1 that comprises one opening 50 in which three inserts 401, 402, 403 are placed, preferably with a particular firmness or particular thermal properties, whereby the firmness of the inserts can be chosen on the basis of the body shape of an individual according to a measured biomechanical model. In other embodiments, partitions walls made of another material, for example the same material as the base unit 1, may also be placed between the inserts, or the base unit 1 may comprise two openings, whereby the openings are separated (not shown). Fig. 4b illustrates an assembly 10 which, besides a base unit 1 and an underframe 2 further comprises a cover layer 350. Fig. 4c illustrates an assembly 10 according to embodiments of the invention, where the assembly may furthermore comprise a parallel zipper or Velcro mechanism 600 which hides the inserts more esthetically, but which also offers easy access to the inserts that can be replaced.

According to embodiments of the invention, the inserts may also comprise monitoring means, one may for example use the sensor mat developed by Custom8 NV for this purpose, which besides sensors also offers the necessary flexibility. It goes without saying that other technologies can be used as monitoring means, for example pressure mats, such as Tekscan or Xsensor, and technologies to measure movement, breathing, or heartbeat (such as the one from Emfit), etc.

It is an advantage of a method to replace an insert according to embodiments of the invention, for example as shown in Fig. 4a, that when someone wants to replace at least one insert which is present in the opening of a base unit, one attaches this insert to a second insert, as shown in Fig. 5, by making use of the attachment means 6, and when one pulls the insert to be replaced 402out of the base unit over a length Li, the insert 400 will automatically follow along so that after this single action, the insert 402 is replaced by the insert 400. This method moreover insures that the opening in which the insert is placed is continuously supported, and this in itself also reduces the friction resistance between the insert and the surrounding material, helping to enable a smooth exchange of the inserts. It goes without saying that this method of replacing an insert can also be used in modular support systems other than the support systems described in this text. The attachment of the first insert to a second insert can happen in various ways, such as for example by means of snap fasteners, by means of Velcro or other hook-and-loop systems, by means of a zipper, etc.

In the embodiments described above, the inserts 401, 402, 403 can be used as replacement insert 400 and vice versa.

Fig. 6 schematically illustrates a method of assembling a modular support system according to embodiments of the invention, whereby the method comprises the following steps:

calculating a user's shape, for example by making use of a measuring device 610 that can measure a body shape, which can occur both standing up or lying down, depending on the embodiment, so that a virtual 3-D model 620can be created and preferably also an underlying biomechanical model. For example the Ikelo measuring device developed by Custom8 NV can be used for this, or other measuring devices that can determine body dimensions can be used, for example TC2's 3-D body scanners, or measuring body dimensions on the basis of webcam measurement, such as by making use of UPcload's technology. In "Ergonomic analysis of integrated bed measurements: towards smart sleep systems," by V. Verhaert, defended as doctoral dissertation in December 2011 at the Catholic University of Leuven, it is explained how for example a biomechanical model and/or a 3-D model can be drawn up.

On the basis of the 3-D virtual model, the mechanical properties (e.g. the firmness) can be determined 630 of at least one insert according to the shape/weight distribution and/or the dimensions of the user. In other embodiments, one may, besides mechanical properties, also on the basis of thermal properties and user preferences, select or adapt the thermal insulation and air and/or moisture permeability of at least one insert.

Moreover, the underlying biomechanical model can preferably be used to determine which configuration of inserts and which firmness of inserts can best be used for the user. This personalized configuration further offers optimal spine support in his/her habitual sleep position (preferred position). One may for example optimize an insert for the shoulder zone 632, an insert for the waist zone 634, and an insert for the hip zone 636.

Further, while some embodiments described herein comprise some but not other features comprised in other embodiments, combinations of the features of the different embodiments are meant to lie within the scope of the invention and they constitute various embodiments, as would be understood by a person skilled in the art. For example, in the following claims, any of the described embodiments can be used in any combination. REFERENCES

[10] assembly

[1] base unit

[2] underframe

[5] inelastic means

[6] attachment means

[8] means to allow manual movement of the insert [9] closing means (e.g. zipper)

[50] opening

[200] surface 1

[201] surface 2

[300] surface with preferably inelastic means

[301] surface with preferably inelastic means

[302] surface with preferably inelastic means [350] cover layer

[600] means for protection

[401, 402, 403] insert

[400] replacement insert

[405] insert without cover

[610] measuring device

[620] virtual model

[630] determining mechanical properties

[632] shoulder zone

[634] waist zone

[636] hip zone

Claims

1. A method of replacing at least one insert of a modular support system, the modular support system comprising an assembly of on the one hand a base unit with at least one opening and on the other hand at least one insert with a length (Li), whereby the insert can be placed in the opening, whereby the method comprises the following steps:

- attachment of a replacement insert to at least one insert placed in the opening, by making use of attachment means on the lengthwise ends of the inserts, and

- pulling the insert placed in the opening over a length (Li).

2. Method according to claim 1, wherein several inserts are replaced simultaneously.

3. Method according to any of the claims 1 to 2, further comprising replacing the/an insert in order to receive data from monitoring means accommodated in the at least one insert.

4. Method according to any of the claims 1 to 3, further comprising wirelessly transmitting data from monitoring means to a data storage unit.

5. Method according to any of the claims 3 to 4, further comprising processing the data in real time.

6. Method according to any of the claims 3 to 5, further comprising processing the data received from the monitoring means for the purpose of determining the quality of the spine or buttock support and/or the quality of sleep during a particular time period and/or the concentration of dust mites present in the modular support system or the wear on one or more functional components, for example due to sagging or moisture retention.

7. A modular support system for supporting a body part, whereby the modular support system comprises an assembly of a base unit, whereby the base unit contains at least one opening, and comprises at least one insert with a length (Li), whereby the insert can be placed in the opening, and whereby the insert further comprises a plurality of attachment means.

8. Modular support system according to claim 7, whereby the opening lies laterally across the width of the base unit.

9. Modular support system according to any of the claims 7 to 8, whereby the attachment means are placed at the lengthwise ends and/or on the sides of the insert.

10. Modular support system according to any of the claims 7 to 9, whereby the insert is a separate and/or laterally, insertable and/or removable insert.

11. Modular support system according to any of the claims 7 to 10, characterized in that the base unit and/or at least one insert is provided with a separate cover.

12. Modular support system according to claim 11, whereby the cover comprises a stretchable and/or elastic fabric, such that the load of the insert during normal use is not or minimally influenced by the cover itself, and/or whereby the cover may comprise knitted and/or woven fabrics consisting of unstretchable and/or stretchable fibers or a combination thereof.

13. Modular support system according to any of the claims 7 to 12, characterized in that the firmness and/or the thermal insulation and/or air and/or moisture permeability of the insert differs from the firmness and/or thermal insulation and/or air and/or moisture permeability of nearby zones of the base unit and/or another nearby insert.

14. Modular support system according to any of the claims 7 to 13, characterized in that it is provided with means for reducing the friction between the base unit and the insert.

15. Modular support system according to any of the claims 7 to 14, characterized in that at least one insert furthermore contains inelastic means.

16. Modular support system according to claim 15, whereby the attachment means are placed on the inelastic means.

17. Modular support system according to any of the claims 7 to 16, whereby the attachment means are placed by stitching and/or gluing and/or by providing Velcro and/or by means of snap fasteners and/or by zipping.

18. Modular support system according to any of the claims 7 to 17, whereby at least one insert further comprises monitoring means.

19. Modular support system according to any of the claims 7 to 18, whereby the attachment means can be snap fasteners, hook-and-loop fasteners, and/or zippers.

20. Modular support system according to any of the claims 7 to 19, whereby the assembly is a mattress, a bed base, a seat, a box spring or a back-support surface.

21. Base unit intended to be used in a modular support system according to any of the claims 7 to 20.

22. Insert intended to be used in a modular support system according to any of the claims 7 to 20.

23. Assembly intended to be used in a modular support system according to any of the claims 7 to 20.

24. A method of assembling a modular support system according to any of the claims 7 to 20, the method comprising the following steps:

- calculating a shape of a user; - determining the dimensions of at least one body part according to the estimated shape of the user;

- calculating the sturdiness and/or dimensions of at least one insert according to the shape and/or the dimensions of the user.

25. A method according to claim 24, further comprising the creation of an individualized virtual model of the user and an underlying biomechanical model.