ITMI20111109A1 - MATTRESS WITH VENTILATION HOLES OBTAINED BY EXTENDING CORRESPONDING INSERTS - Google Patents

Description

DESCRIPTION

The present invention relates in general to the sector of articles for personal use. More specifically, this invention refers to mattresses.

The mattress is an object of common use that is used to allow optimal relaxation of the body during a period of rest (or simply rest). For example, during the night's rest, the mattress performs a support function for the body, and in particular for the spine, allowing a relaxation of the muscles and joints (especially of the lower limbs) which during daytime activities perform to this support function.

In general, in order to allow a satisfactory quality of rest for a wide variety of users, a mattress should possess characteristics such as ergonomics (i.e., level of comfort), breathability (i.e., the ability to be crossed by humid air) and hygiene (degree of cleaning).

In particular, a mattress with ergonomics is able to adapt to the body, in order to guarantee a correct, comfortable and natural posture of the spine, substantially regardless of the type of body type (weight and / or height) of the user and a position assumed during rest, and at the same time is able to avoid that abnormal localized compressions lead to the formation of body regions with poor or inadequate blood supply.

On the other hand, a mattress with breathability is able to guarantee a recirculation of air that allows the humid air emitted from the body to be removed, so as not to cause the latter substantial thermal variations during rest. Typically, a breathable mattress also has good hygiene characteristics, since the recirculation of air tends to make it inhospitable for nesting of germs and other organisms (for example, mites) that can cause allergic disorders.

As is well known, the ergonomics of a mattress is mainly determined by the types of materials used to make it.

In this regard, among the mattresses on the market, those that have significant ergonomic properties are synthetic latex mattresses, which allow an enveloping and diversified support for individual body regions, and foam mattresses (for example, polyurethane foam, high elasticity foam, or viscoelastic foam - or â € œmemory foamâ €), which have high resistance and flexibility.

Although these mattresses are typically also endowed with good breathability and hygiene, in order to obtain an improvement of these characteristics, they are often subject to particular manufacturing procedures and / or equipped with specific auxiliary technical devices.

For example, in order to obtain better hygiene, synthetic latex mattresses and foam mattresses can be produced using special antibacterial treatments, or be combined with suitable fabrics and padding, so as to reduce respiratory disorders. Furthermore, to obtain even better breathability, these mattresses can be associated with a suitable support base (such as a wooden slatted base), or they can be equipped with suitably positioned ventilation holes.

In the latter case, the holes can be made on one or more surfaces of the mattress; for example, a mattress structure, called bialveolar, comprises upper holes made on an upper surface of the mattress, and lower holes, not communicating with the upper holes, made on a lower surface of the mattress opposite the upper surface. Furthermore, in more recent and advanced models of mattresses through holes are used, ie in which holes are made between the upper surface and the lower surface of the mattress. This allows to obtain high performance mattresses in terms of comfort and ventilation.

In any case, mattresses provided with holes, and in particular those provided with through holes, have manufacturing drawbacks which preclude their wider use.

In fact, the holes are obtained by digging and extracting portions (of suitable shape) of a core of the mattress; this means that, during a mattress production process, an excessive amount of processing waste is generated, substantially represented by the extracted (and no longer reusable) portions of the mattress core. Therefore, the production process, involving a high waste of material, is inefficient and expensive.

Furthermore, in order to reduce such processing waste, it is often preferred to make a relatively small number of holes, with a consequent decrease in the breathability and hygiene of the mattress, and in general in its quality.

In general terms, the solution according to one or more embodiments of the present invention is based on the idea of making a mattress in which the holes are obtained in a condition of extension of the mattress starting from notches made on the mattress in a condition of rest.

In particular, one or more aspects of the solution in accordance with specific embodiments of the invention are indicated in the independent claims, with advantageous characteristics of the same solution that are indicated in the dependent claims, the text of which is incorporated herein to the letter for reference (with any advantageous feature provided with reference to a specific aspect of the solution in accordance with an embodiment of the invention which applies mutatis mutandis to any other aspect thereof).

More specifically, an aspect of the solution in accordance with an embodiment of the present invention proposes a mattress. The mattress comprises at least one elastic core (for example, in synthetic latex or foam) having a first main surface and a second main surface opposite each other. In a rest condition the elastic core has at least one extension at rest along an extension direction parallel to the main surfaces (for example, a width at rest); the elastic core has a plurality of notches (for example, through notches with a straight segment) extending at least in part between the first main surface and the second main surface with at least one component transversal to the direction of extension (for example, arranged in alignments longitudinal staggered between them). The mattress further comprises extension means (for example, one or more rigid and / or semi-rigid sheets) applied to the elastic core (for example, by gluing on one of its main surfaces, or on both) to maintain the ™ elastic core in an extended condition. In the extended condition the elastic core has an extended extension along the direction of greatest extension of the extension at rest (for example, approximately double), with each notch widened to define corresponding holes (for example, rhomboid-shaped through holes) extending at least in part between the first main surface and the second main surface.

Another aspect of the solution according to an embodiment of the present invention proposes a corresponding method for producing a mattress.

The solution in accordance with one or more embodiments of the invention, as well as further characteristics and relative advantages, will be better understood with reference to the following detailed description, given purely by way of non-limiting indication, to be read in conjunction with the attached figures ( in which corresponding elements are indicated with the same or similar references and their explanation is not repeated for the sake of brevity). In this regard, it is expressly understood that the figures are not necessarily to scale (with some details that may be exaggerated and / or simplified) and that, unless otherwise indicated, they are simply used to conceptually illustrate structures and procedures. described. In particular:

FIG.1A-1C show the main steps of a mattress manufacturing process according to an embodiment of the present invention;

FIG.2 shows a mattress according to another embodiment of the present invention, e

FIG.3A-3C show the main steps of a mattress manufacturing process according to a further embodiment of the present invention.

With particular reference to FIG.1A-1C, they show the main steps of a production process of a mattress 100 (visible as a whole in FIG.1C, at the end of the production process) in accordance with an embodiment of the present invention.

Referring first to FIG.1A, the mattress comprises a core 105 made of elastic material (preferably, although not necessarily, synthetic latex or foam - for example, polyurethane foam, high elasticity foam, or viscoelastic foam). In this way, the soul 105 can be extended or stretched along a certain direction of extension.

In particular, the core 105 is shown in FIG.1A in a rest condition along the direction of extension x (transversal); in this condition, the soul 105 has an extension at rest D1 along the x direction.

As can be seen in this figure, the core 105 has a main surface 110u (for example, an upper surface of the core 105 parallel to the x direction) and a further main surface 110d (for example, a lower surface of the core 105 opposite the 110u surface).

The core 105 further comprises two lateral regions 115a and 115b which extend along a longitudinal direction y transverse to the x direction, and which delimit a useful (central) region 120 of the core 105. This region 120, which has extension a rest L (along the x direction) less than the extension D1, defines, as will be clarified below, the region of the core 105 within which, following an extension operation, holes will actually be obtained, while the region 115a, 115b represents the region that will act as a gripping end to facilitate the extension operation.

In the soul 105 in the rest condition a plurality of carvings are made; in the example described, such notches are through notches 125 extending between the surface 110u and the surface 110d in the region 120.

In the exemplary but not limiting embodiment described, these notches 125 are all arranged along the y direction, and they all have the same shape (for example, with a straight segment) and length (for example, 10-15 cm).

The arrangement of the notches 125 is such as to define a regular texture, which in general comprises a plurality of identical pairs (ten, in the representation of FIG.1A) of alignments of offset adjacent notches. More specifically, each pair includes an alignment of equidistant notches (for example, at 5-10 cm along the y direction), and a further alignment of notches similar to the previous one but offset with respect to it. As can be seen in the figure, a first and a last notch of one of the two alignments of each pair terminate before an upper edge (delimited by a lateral surface 110l orthogonal to the surface 110u, 110d) and a lower edge (delimited by a further lateral surface 110l2 orthogonal to surface 110l1), respectively, of core 105, while the first and last notches of the other alignment of the pair define through edge notches 125b, open on the upper and lower edges, respectively. In this way, for each edge (upper and lower) of the core 105 a sequence of notches 125b is obtained along the x direction (that is, a respective notch 125b per pair of notches alignments), which allows, as will be clarified in short, to obtain high extensions of the region 120 of the soul 105.

Following an extension operation, the core 105 is extended, along the x direction, from its rest condition to an extended condition (shown in FIG.1B); this operation can be carried out, for example, by using a suitable apparatus (not shown) which, by gripping the region 115a, 115b, exerts a force (along the x direction) sufficient to cause the desired extension of the core 105.

In this way, in the extended condition the soul 105 assumes an extended extension D2 greater than the extension D1; in particular, in the extended condition, the region 120 undergoes an extension of the chosen entity (preferably between 5% and 400%, even more preferably between 50% and 200%, for example 100%, as shown in figure and indicated therein by the notation 2L), while the side portion 115a, 115b remains substantially unchanged (as it is used only as a gripping end to facilitate extension).

The widening of each notch 125,125b deriving from the extension of the core 105 (from its rest condition) defines corresponding through holes 130,130b. In the exemplary embodiment illustrated, the holes 130 have a substantially rhomboidal shape (while the holes 130b have a truncated rhomboid shape - by virtue of the opening on the edges of the notches from which they are obtained); however, it should be noted that the shape of the holes 130,130b, depending on parameters such as the extent of the extension and the length of the notches, is not to be understood in a limiting manner for the present invention. For example, each hole 130 will have an extension, along the y direction, equal to the length of the respective notch, and an extension along the x direction depending on the extent of the extension of the core 105 (for example , 5-10 cm).

As shown in FIG.1C, a plate (or extension layer o) 135 of rigid or semi-rigid material (possibly comprising the same material of which The soul 105 is formed), to obtain the mattress 100; in this way, the plate 135 keeps the core 105 stably in the extended condition (which, being elastic, would otherwise tend to return to the rest condition, shrinking at least in part along the x direction).

The described solution is advantageous in that the described mattress 100 has a remarkable breathability and hygiene. In fact, the holes 130,130b allow to expel air and body humidity, thus preserving the mattress 100 from the proliferation of germs and bacteria. This is achieved through a simple and effective production process, which allows holes 130,130b to be made without resorting to excavation and extraction operations. In this way, material waste is substantially avoided, thus obtaining reduced production costs.

This also means that these holes 130,130b can be made in large numbers without particular limitations, with a consequent improvement in the quality of the mattress. In fact, in addition to increasing the breathability and hygiene of the mattress, a high number of holes (together with the properties of the synthetic latex and / or the foam of which the soul is formed 105) implies a more refined ergonomics (for example, a greater ability to cushion, absorb or adapt to often underestimated parts of the body, such as shoulders and arms, avoiding soreness, tingling and numbness).

The specific additional features described above allow for further benefits.

In particular, the shape of the notches 125,125b, and of the corresponding holes 130,130b, allows to obtain (if necessary) the maximum extension; in fact, the rectilinear segment shape, making the orientation of the notches 125,125b and their alignment easier and more effective, lends itself to implementing wefts that allow to reduce an intrinsic rigidity of the core material 105 (such as the particularly advantageous weft described above, in which the notches, offset from each other, extend along the longitudinal direction).

In addition, the portion 115a, 115b, used as a gripping end, facilitates the extension of the core 105.

Furthermore, the use of a single sheet, not completely covering the holes 130,130b, allows to obtain the best possible ventilation for the mattress 100, and therefore excellent performance in terms of breathability.

Turning now to FIG.2, it shows a mattress 200 (visible, on the right, in the assembly at the end of the production process, and on the left with parts partially removed) in accordance with another embodiment of the present invention. The mattress 200 is substantially equivalent to the previous one (and is obtained by means of the same steps described above), but with respect to the latter it includes an additional sheet 140 (not necessarily of the same material as the sheet 135) fixed on the surface 110u.

This solution is particularly advantageous as it provides greater sealing stability of the core 105 in the extended condition, and prevents dirt or other external agents from getting inside the holes 130,130b. Furthermore, the solution described is more harmonious and tidy, and therefore more attractive to customers who are particularly attentive to aesthetic aspects.

With reference to FIG.3A-3C, they show the main steps of a production process of a mattress 300 (visible as a whole in FIG.3C at the end of the production process) in accordance with a further embodiment of the present invention.

As before, in FIG.3A a soul 305 is shown in the resting condition. The core 305 is substantially similar to the previous ones, but differs from them by the presence of notches with non-uniform concentration and / or size on the region 120.

In particular, the region 120 comprises a head area 345h and a foot area 345f (at an upper and lower end, respectively, along the y direction) in which the notches 125,125b are present (arranged describing the same weft previously described), and a central area 345c in which there are various notches (for example, still through notches, indicated with the reference 325).

As can be seen in the figure, the notches 325 have a shorter length than the notches 125 (for example, 40-70%), and define a different regular texture in the area 345c. More specifically, the texture defined by the notches 325 is similar to that defined by the notches 125,125b in the 345h and 345f zones, but compared to the latter it is denser (that is, the corresponding alignments of notches 325 are less spaced , for example, by 40-70%).

As before, the core 305 is extended in the extended condition (see FIG.3B), so that the notches 125,125b define the holes 130,130b and the notches 325 define corresponding through holes 330, for example still rhomboidal, of dimensions smaller and at a closer distance than the holes 130. The production process ends at the step shown in FIG.3C, in which sheet 135 and sheet 140 are applied to the extended core 305 (even if, as above, the sheet 140 can also be omitted), forming the mattress 300.

The described solution has the same advantages described above, but in addition it allows to obtain in a simple way a mattress with differentiated zones. In particular, the 345h and 345f zones can define comfortable zones for shoulders and legs, while the 345c zone can define a load-bearing zone for the lumbar region of the body, so as to provide the user with a particularly restful rest experience.

Naturally, in order to satisfy contingent and specific needs, a person skilled in the art can make numerous logical and / or physical modifications and variations to the solution described above. More specifically, although this solution has been described with a certain level of detail with reference to one or more embodiments thereof, it is clear that various omissions, substitutions and changes in form and detail as well as other embodiments are possible. . In particular, various embodiments of the invention can be put into practice even without the specific details (such as the numerical examples) set out in the previous description to provide a more complete understanding of them; on the contrary, well-known features may have been omitted or simplified in order not to obscure the description with unnecessary details. Furthermore, it is expressly understood that specific elements and / or method steps described in relation to each embodiment of the exposed solution can be incorporated into any other embodiment as a normal design choice.

Similar considerations apply if the mattress has a different structure or includes equivalent components. In any case, any of its components can be separated into several elements, or two or more components can be combined into a single element; moreover, each component can be replicated to support the execution of the corresponding operations in parallel. It is also noted that (unless otherwise indicated) any interaction between different components generally does not need to be continuous, and can be either direct or indirect through one or more intermediaries. For example, the mattress can be equipped with more than one elastic core, or with a multilayer elastic core (with these components that are extended separately and therefore joined together), and additional components can be provided (such as a bag coating). In this regard, it is expressly understood that the materials described are intended only as a non-limiting example; in fact, further materials can be used, such as natural latex (possibly in combination with synthetic latex and / or polyurethane).

For example, the shape and number of the notches, as well as the shape and number of the respective holes, can be any, depending on the particular characteristics of ergonomics, breathability and hygiene that you intend to give to the mattress. For example, it is possible to obtain circular holes (for example, oval), or in the form of slits (for example, obtainable starting from â € œpointsâ € notches).

The notches, and therefore the corresponding holes, do not necessarily have to pass through. In addition, they can also be made in the lateral region of the soul. In addition, lateral holes (through and / or non-through) can be provided in the lateral surfaces of the core, so as to obtain transverse holes (with respect to those described above) which allow to further increase the ergonomics of the core.

The direction of extension can be any; for example, the direction of extension and the longitudinal direction can be reversed with respect to the notation used in the description. Alternatively, the extension direction can also be oblique with respect to the longitudinal direction. For example, in the case of lateral holes, they can be obtained in a similar way to those described by carrying out an operation of extension in height of the core. Furthermore, there is nothing to prevent the core from extending along two (or more) directions of extension (for example, both longitudinally and transversely).

Similarly, the orientation of the notches illustrated here, and consequently the orientation of the respective holes, is not to be understood in a limiting manner; in this regard, similar results can be obtained by means of notches obtained only along the direction of extension, or both along the direction of extension and along the longitudinal direction. Alternatively, it is also possible to foresee notches obtained in an oblique direction, oriented at an appropriate angle with respect to the direction of extension or the longitudinal direction.

The notches can define different wefts than the simpler ones illustrated, which have been described only to present the principles of the present invention. For example, it is possible to obtain a plurality of alignments of notches all offset from each other (possibly combining these offsets with different orientations of the notches).

The edge notches, if not necessary, may also not be present. This can happen, for example, if you want to make the structure more rigid.

The notches, and the corresponding holes, can define any number of zones of the mattress, which can be distinguished from each other by number, size, arrangement of the holes, and any combination thereof.

The slab, or extension layer, can in turn comprise composite structures, in order to give the mattress the desired characteristics. In any case, the possibility of providing other means of extension (for example, tie rods) is not excluded.

Furthermore, the mattress manufacturing process described above is merely illustrative and in no way limiting. For example, the same result can be achieved with equivalent processes (using similar steps, removing some non-essential steps, or adding additional optional steps); moreover, the steps can be performed in different order, in parallel or overlapping (at least in part). For example, it is possible to foresee that one or more slabs can be added later by a customer (or by the same manufacturer, at the request of the customer) to modify the configuration of the mattress and meet new resting needs.

Claims (10)

CLAIMS 1. A mattress (100,200,300) comprising: at least one elastic core (105,305) having a first main surface (110u) and a second main surface (110d) opposite each other, in a rest condition the elastic core having an extension at rest (D1) along at least one direction of extension (x) parallel to the main surfaces, in which the elastic core has a plurality of notches (125,125b, 325) extending at least in part between the first main surface and the second main surface with at least one component transverse to the direction of extension, e extension means (135,140) applied to the elastic core to keep the elastic core in an extended condition, in the extended condition the elastic core having an extended extension (D2) along the direction of greater extension of the extension a rest, with each notch enlarged to define corresponding holes (130, 130b, 330) extending at least in part between the first main surface and the second main surface. The mattress (100,200,300) according to claim 1, in which the notches (125,125b, 325) have a rectilinear segment shape, and in which the holes (130,130b, 330) have a rhomboidal shape. The mattress (100,200,300) according to claim 1 or 2, in which the direction of extension (x) is perpendicular to a longitudinal direction of the elastic core. The mattress (100,200,300) according to any one of claims 1 to 3, wherein the notches (125,125b, 325) are distributed in a plurality of alignments of notches extending perpendicular to the direction of extension (x). The mattress (100,200,300) according to claim 4, wherein each notch alignment is offset from each adjacent notch alignment. The mattress (100,200,300) according to any one of claims 1 to 5, wherein the notches (125,125b, 325) comprise a plurality of edge notches (125b) open on edges of the elastic core extending along the direction of extension (x). The mattress (100,200,300) according to any one of claims 1 to 6, wherein the notches (125,125b, 325) and the holes (130,130b, 330) have a non-uniform concentration and / or size on the main surfaces ( 110d, 110u). The mattress (100,200,300) according to claim 7, wherein the notches (125,125b, 325) and the holes (130,130b, 330) have a greater concentration and / or a smaller size in a central area (345c) of the surfaces main with respect to a foot area (345f) and a head area (345h) of the main surfaces. The mattress (100,200,300) according to any one of claims 1 to 8, wherein the extending means (135,140) comprises at least one extending layer (135,140) covering a corresponding one of the main surfaces (110u, 110d). 10. A method of producing a mattress (100,200,300), the method comprising the steps of: provide at least one elastic core (105,305) having a first main surface (110u) and a second main surface (110d) opposite each other, in a rest condition the elastic core having at least one extension at rest (D1) along a direction of extension (x) parallel to the principal surfaces, making a plurality of notches (125,125b, 325) extending at least in part between the first main surface and the second main surface with at least one component transverse to the direction of extension, extend the elastic core along the direction of extension, and apply extension means (135,140) to the elastic core to keep the elastic core in an extended condition, in the extended condition the elastic core having an extended extension (D2) along the direction of greater extension of the extension a rest, with each notch enlarged to define corresponding holes (130, 130b, 330) extending at least in part between the first main surface and the second main surface.