WO2012155132A1 - Constructions de mousse et de matelas de relâchement de tension - Google Patents

Constructions de mousse et de matelas de relâchement de tension Download PDF

Info

Publication number
WO2012155132A1
WO2012155132A1 PCT/US2012/037766 US2012037766W WO2012155132A1 WO 2012155132 A1 WO2012155132 A1 WO 2012155132A1 US 2012037766 W US2012037766 W US 2012037766W WO 2012155132 A1 WO2012155132 A1 WO 2012155132A1
Authority
WO
WIPO (PCT)
Prior art keywords
tension relief
pad
foam
tension
mattress system
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.)
Ceased
Application number
PCT/US2012/037766
Other languages
English (en)
Inventor
David MORET
Andy BEAMON
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sealy Technology LLC
Original Assignee
Sealy Technology LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sealy Technology LLC filed Critical Sealy Technology LLC
Priority to CN201280034648.XA priority Critical patent/CN103702591A/zh
Priority to JP2014510533A priority patent/JP2014512936A/ja
Priority to CA2835841A priority patent/CA2835841A1/fr
Priority to EP12782124.7A priority patent/EP2706888A4/fr
Publication of WO2012155132A1 publication Critical patent/WO2012155132A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04—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
    • A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06—Spring inlays or spring units therefor
    • A47C27/063—Spring inlays or spring units therefor wrapped or otherwise protected
    • A47C27/064—Pocketed springs

Definitions

  • the present invention is in the field of reflexive support systems including support systems for humans such as bedding or seating.
  • a tension relief foam pad is a generally rectangular piece of foam having a top surface and a bottom surface opposite and parallel to the top surface with four side wall which are perpendicular to and extend between the top and bottom surface.
  • the length and width measurements of the pad are substantially equal to that of a mattress with which it is to be used.
  • either the top or bottom surface contains a plurality off cuts arranged in a checkerboard or other pattern, while the opposite surface is substantially planar. The cuts create a plurality of square or rectangular blocks on the surface of the pad and independent modules which have independent support characteristics, and which may be coupled with other support elements such as springs.
  • FIG. 1A is a perspective view of a preferred placement of a tension relief ft>am topper among other foam layers in a mattress system.
  • FIG. IB is a perspective view of an alternate placement of a tension relief foam pad among other foam layers in a mattress system.
  • FIG. 2 is a side view of one embodiment of tension relief foam pad and inn ⁇ rspring.
  • FIG. 3 is a side view of an alternate embodiment of tension relief foalm pad and innerspring.
  • FIG. 4 is a chart showing the surface deflection on a tension relief foam pad in variojis locations among other foam layers in a mattress system.
  • FIG. 5 is a chart showing the surface strain on a tension relief foamj pad in various locations among other foam layers in a mattress system.
  • FIG. 6A is a perspective view showing the stress distribution across
  • FIG. 6B is a perspective view showing the stress distribution across a tension relief foam p ⁇ d when the pad is used as a bottom layer of a mattress system.
  • FIG. 7 is a side view of an alternate embodiment of tension relief foim pad and innerspring]
  • FIG. 8 is a top view of a tension relief foam pad with non-uniform sized blocks.
  • FIG. 9 is a side view of one embodiment of tension relief foam pa with non-uniform sized blocks.
  • FIG. 10 is a side view of an alternate embodiment of tension re
  • FIG. 11 is a side view of an alternate embodiment of tension relief foam pad with nonuniform sized blocks.
  • tension relief foam pads, mattresses and support systems of the present disclosure and related inventions utilize surface modified foams to achieve independent and localized deformation, support and movement and reduced tension or shear forces in the horizontal plane, benefitting the conformance and motion separation character sites of the system.
  • T ie various forms of tension relief foam pieces and pads described herein (also referred to herein as "pad” or “foam pad” or “topper”) 10 are generally in the form off rectangular block planar shapes having a top surface and a bottom surface opposite and parallel to the top surface.
  • the length and width measurements of the pad 10 are substantially equal to that ol ' a mattress with which it is to be used.
  • the teim "tension relief foam” refers generally to each of the various described foam configurations and constructs, and more generally to foam body configurations which reduce or eliminate stress forces within the cellular structure of a body of foam.
  • the design concepts ajid configurations are equally applicable to any type of foam from which such shapes and configurations can be manufactured, including open cell and closed cell type foams.
  • either the top or bottom surface contains a plurality of continuous cuts 18 arranged in a checkerboard or other pattern, while the opposite surface is substantially planar and generally without cuts.
  • the cuts 18 create a plurality of square or rectangular blocks 16 on one surface of the pad 10.
  • a typical mattress system includes a foundation or box spring, support unit and optionally, a comfort unit.
  • the foundation can be of conventional internal design and construction, having a rectangular frame on which are mounted a plurality of spring elements or modules to provide flexible support for an overlying grid, which defines the foundation surface.
  • the spring modules in the foundation may be formed of wire or made of a composite material, or be entirely without individual spring modules and rather in the form of a flexible support surface.
  • Foundation units are typically supported by a bed frame which may further include side boards, a head board and foot board.
  • the support unit or innerspring of the mattresses of the disclosure are dimensioned to fit upon the foundation surface and be fully supported thereby.
  • the support unit or innerspring may be of conventional design, containing a plurality of interconnected spring coils.
  • the support unit may alternatively be a high performance foam core structure without any internal wire or spring elements.
  • the support surface has relatively few layers of material, which cover the innerspring, such as one or more layers of mat or foam or other sheet-like fabric or non-woven material.
  • the primary purpose of layers is to provide a smooth surface over the ends of the coils of tie innerspring.
  • a comfort unit is dimensioned to fit upon the support unit. It has a generally
  • the comfort unit contains additional layers of compressible, conformable internal layers of materials.
  • a comfort unit may contain one or more foam core layers and intermediate and outer layers made of matted material, synthetic or organic, such as cotton or wool fibers, polyester, or hybrid material mats. Extra material layers may also be used, such as woven cotton, wool or synthetic cloths or hybrids thereof, or sheet materials such as plastic films, solid or perf Drated, which may serve as moisture barriers, aeration promoters, liners or flame or heat retardants.
  • the feel of the comfort unit may be adjusted by using different insert materials such as polyurethane foams, visco-elastic foams, latex foams, fibers, gels or various combinations thereof.
  • the comfort unit materials are encapsulated by upholstery, which may include ticking, for example foam or padding backed woven or embroidered material, side wall material or ticking, tape edges, and a gusset which extends from the pillowtop to the top of the support unit.
  • the upholstery of the comfort unit may be a combination of materials.
  • the top surface of the tension relief pad 10 is generally planar while the bottom surface contains a plurality of cuts 18 arranged in a checkerboard or other pattern.
  • the cuts or voids 18 between discrete islands Of foam c an be uniform in size and spacing or not, generally linear or not, and dimensioned uniform ly or not.
  • the foam structures 16 can be formed by molding, cutting, water-jet forming or by any other suitable process.
  • the tension relief foam 10 pad is generally placed directly above the innerspring 15 and below any other foam layers 12 of the mattress or comfort unit, as shown in FIGS. 1A, 2 and 3.
  • a thin fabric or fiber layer or insulation layer may be located between the tension relief foam pad 10 and the innerspring 15.
  • the individual blocks 16 on the bottom surface of the pad 10 may be aligned with or correspond in location to the positions of the upper terminal convolutions of the coils 14 of the mattress innerspring 15, as shown in FIGS. 2 and 3.
  • each block may correspond and work in combination with two or more springs or coils 14 of the innerspring 15 to provide improved independent movement of the foam 10 and coils 14 accentuating the feel of the coils 14.
  • Each of the individual blocks 16, in combination with the innerspring 15, is separately compressible in response to the weight placed directly thereon. Placing the tension relief pad 10 directly on op of the innerspring 15, below other foam layers 12, is shown to provide more local compl iance, a lower surface strain and a lower complex stress state, as shown in the charts of FIGJS. 4 and 5 and on the stress state mapping shown in FIG. 6B.
  • the springs may be individually pocketed or Marshall- type coils or the coils may be without a pocket or encasement.
  • Each cf the individual foam blocks 16 may be associated with one or more corresponding spring 14 of a spring unit 15, as shown in FIGS.
  • each coil 14 in direct or indirect physical contact with an opposing face of a foam block 16 pijovides a hybrid sprinjg combination by which a force applied to the area of a particular foam block 16 is transferred in whole or in part to the corresponding spring 14, and the matched
  • the size of eaclj block 16 in the patteijn may be uniform, such as, for example, the pad 10 shown in FIG. 7 wherein each uniformly sized foam block 16 corresponds to a single coil unit 14 of the inneijspring 15. Also, FIG shows a pad 10 with uniformly sized foam blocks 16 correspond to every two coil units 14 (j>f the innerspring 15.
  • the size of the foam blocks 16 in the pattern may be non uniform, such as, for example, the pad 10 shown in FIG. 2, wherein blocks 16 having a first size, which corresponds to three coil units 14 of the innerspring 15, are interspersed between blocks 16 having a second size which corresponds to two coil units 4 of the innerspring 1
  • the individual blocks 16 may be zoned such that the blocks 16 varjf in number or size.
  • the blocks 16 located along the short edges of the pad 10 may have a larger width while the remainder of the blocks 16 located therebetween may havej a uniform width, which is less than the width of the blocks 16 along the short edges of the pad 10.
  • Any pattern of uniform or non-uniform sized blocks 16, which correspond to any nujmber of coils 14 may bje used to create different zones in the tension relief foam pad 10 an mattress system of the present invention.
  • the bottom surface of the tension relief foam pad 10 is generally planar while the top surface contains a plurality of cuts 18 arranged in a checkerboard or other uniform or non-uniform pattern.
  • the tension relief foam pad 10 is typically placed between additional foam layers 12 of the mattress construction.
  • the tension relief pad 10 may be laminated.
  • the cuts 18 may be of any width or opening (or no opening, such as in the form of a slit) or any si2e width from 1mm to 10mm or greater.
  • the cuts 18 may have generally planar and parallel walls or tapered or other shape, and may be formed in straight and orthogonal lines is shown or in other arrangements which have the similar result of relieving tension in the foaijn piece.
  • the tension relief foam pad 10 dimensions, block cut and geometr atiect the surtace deformation, surface strain, stress state upon the layer and deformation modes of the pad 10. For example, if the height of the blocks 16 is too great, it may cause weak points between each block 16, which may be subject to tearing when a force is applied thereto. If the width of the cuts 18 or the gap between each block 16 is too wide, it may cause local depressions on the top surface of the mattress. If the gap 18 is too narrow, there may be too much contact between adjacent blocks 16 preventing independent movement.
  • the thickness of the foam pad 10 or the overall solid height of the foam pad 1- must be greater than or equal to 1 inch; the block 16 width must be greater than or equal to the block 16 height or greater than or equal to 2.5 inches; the gap width must be 15% of the smallest block 16 width or less than 0.75 inches.
  • a tension relief foam pad 10 may be approximately 3 inches thick with cuts 18 between each block 16 being approximately 2 inches deep or extending approximately 2/3 of the way into the foam pad 10.
  • the individual blocks 16 may have a uniform size, such as 3.75 inches wide by 3.75 inches long with the width of the cut or gap 18 between blocks 16 being approximately 0.25 inch wide.
  • the individual blocks 16 may vary in size such that the blocks 16 located at the short edges are larger than the blocks 16 located therebetween, wherein the blocks 16 located at the short edges of the pad 10 are approximately 7.35 inches wide and the blocks 16 located therebetween are approximately 5.2 inches wide.
  • This example tension relief foam pad 10 enables a zoned mattress construction wherein blocks 16 of different sizes can be formed and located in particular zones or regions where different support characteristics are desired, such as the shoulder or lumbar areas of the mattress where blocks 16 of a relatively larger size may have a relatively greater density and relatively less freedom of individual movement or deformation to provide firmer support which still has the enhanced conformance of the structurally modified foam and a corresponding spring or core unit support.
  • Tension relief foam pads 10 having various thickness measurements are shown in FIGS. 9, 10 and 11.

Landscapes

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

Abstract

La présente invention concerne des composants à base de mousse technique pour des matelas qui réduisent des forces de tension dans la mousse et dans le plan horizontal ou des pièces planes de bloc, et améliorent la conformité et les caractéristiques de séparation de mouvement des systèmes de support à base de mousse. Le matelas de mousse de relâchement de tension est une pièce généralement rectangulaire présentant une surface supérieure et une surface inférieure ; les mesures de longueur et de largeur des pièces de mousse construites sont sensiblement égales à celles d'un matelas avec lequel elle va être utilisée. Selon l'agencement du matelas mousse de relâchement de tension dans la construction du matelas, la surface supérieure ou la surface inférieure contient une pluralité de découpes, fentes ou ouvertures disposées dans des motifs en damier ou analogues avec une surface plane opposée non découpée.
PCT/US2012/037766 2011-05-12 2012-05-14 Constructions de mousse et de matelas de relâchement de tension Ceased WO2012155132A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
CN201280034648.XA CN103702591A (zh) 2011-05-12 2012-05-14 张力缓解泡沫及床垫构造
JP2014510533A JP2014512936A (ja) 2011-05-12 2012-05-14 張力軽減フォームおよびマットレス構造
CA2835841A CA2835841A1 (fr) 2011-05-12 2012-05-14 Constructions de mousse et de matelas de relachement de tension
EP12782124.7A EP2706888A4 (fr) 2011-05-12 2012-05-14 Constructions de mousse et de matelas de relâchement de tension

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161485364P 2011-05-12 2011-05-12
US61/485,364 2011-05-12

Publications (1)

Publication Number Publication Date
WO2012155132A1 true WO2012155132A1 (fr) 2012-11-15

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PCT/US2012/037766 Ceased WO2012155132A1 (fr) 2011-05-12 2012-05-14 Constructions de mousse et de matelas de relâchement de tension

Country Status (6)

Country Link
US (1) US20120284927A1 (fr)
EP (1) EP2706888A4 (fr)
JP (1) JP2014512936A (fr)
CN (1) CN103702591A (fr)
CA (1) CA2835841A1 (fr)
WO (1) WO2012155132A1 (fr)

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US8356373B2 (en) 2009-03-06 2013-01-22 Noel Group Llc Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s)
USD688069S1 (en) 2012-09-28 2013-08-20 Noel Group Llc Mattress bed cushion
USD688492S1 (en) 2010-03-03 2013-08-27 Noel Group Llc Mattress bed cushion
USD690536S1 (en) 2012-07-26 2013-10-01 Nomaco Inc. Motion isolation insulator pad
USD691401S1 (en) 2009-03-06 2013-10-15 Noel Group, Llc Mattress bed cushion
USD691400S1 (en) 2012-02-10 2013-10-15 Nomaco Inc. Stackable base for mattress assembly
USD692694S1 (en) 2012-09-28 2013-11-05 Noel Group Llc Mattress bed cushion
USD692692S1 (en) 2011-04-29 2013-11-05 Noel Group Llc Mattress bed cushion
USD692693S1 (en) 2012-04-27 2013-11-05 Noel Group Llc Mattress bed cushion
USD693148S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693149S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693145S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693146S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693144S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693147S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD694041S1 (en) 2012-09-28 2013-11-26 Noel Group Llc Mattress bed cushion
USD694552S1 (en) 2012-04-27 2013-12-03 Noel Group Llc Mattress bed cushion
USD694553S1 (en) 2010-03-03 2013-12-03 Noel Group Llc Mattress bed cushion
USD697337S1 (en) 2012-07-03 2014-01-14 Nomaco, Inc. Stackable base for mattress assembly
USD701713S1 (en) 2012-11-09 2014-04-01 Noel Group, Llc Mattress bed cushion
USD704962S1 (en) 2013-09-09 2014-05-20 Noel Group Llc Mattress bed cushion
USD707467S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD707468S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD709301S1 (en) 2012-11-09 2014-07-22 Noel Group Llc Mattress bed cushion
USD738644S1 (en) 2013-09-20 2015-09-15 Future Foam, Inc. Pillow
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US8356373B2 (en) 2009-03-06 2013-01-22 Noel Group Llc Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s)
USD691401S1 (en) 2009-03-06 2013-10-15 Noel Group, Llc Mattress bed cushion
USD692690S1 (en) 2009-03-06 2013-11-05 Noel Group Llc Mattress bed cushion
USD692691S1 (en) 2009-03-06 2013-11-05 Noel Group Llc Mattress bed cushion
USD693148S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD694553S1 (en) 2010-03-03 2013-12-03 Noel Group Llc Mattress bed cushion
USD688492S1 (en) 2010-03-03 2013-08-27 Noel Group Llc Mattress bed cushion
USD693144S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD693145S1 (en) 2010-03-03 2013-11-12 Noel Group Llc Mattress bed cushion
USD692692S1 (en) 2011-04-29 2013-11-05 Noel Group Llc Mattress bed cushion
USD691400S1 (en) 2012-02-10 2013-10-15 Nomaco Inc. Stackable base for mattress assembly
USD693147S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD694552S1 (en) 2012-04-27 2013-12-03 Noel Group Llc Mattress bed cushion
USD692693S1 (en) 2012-04-27 2013-11-05 Noel Group Llc Mattress bed cushion
USD693146S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD693149S1 (en) 2012-04-27 2013-11-12 Noel Group Llc Mattress bed cushion
USD697337S1 (en) 2012-07-03 2014-01-14 Nomaco, Inc. Stackable base for mattress assembly
USD690536S1 (en) 2012-07-26 2013-10-01 Nomaco Inc. Motion isolation insulator pad
USD692694S1 (en) 2012-09-28 2013-11-05 Noel Group Llc Mattress bed cushion
USD688069S1 (en) 2012-09-28 2013-08-20 Noel Group Llc Mattress bed cushion
USD694041S1 (en) 2012-09-28 2013-11-26 Noel Group Llc Mattress bed cushion
USD701713S1 (en) 2012-11-09 2014-04-01 Noel Group, Llc Mattress bed cushion
USD707467S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD707468S1 (en) 2012-11-09 2014-06-24 Noel Group Llc Mattress bed cushion
USD709301S1 (en) 2012-11-09 2014-07-22 Noel Group Llc Mattress bed cushion
US10045633B2 (en) 2013-04-26 2018-08-14 Noel Group Llc Cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow, and related methods
USD704962S1 (en) 2013-09-09 2014-05-20 Noel Group Llc Mattress bed cushion
USD751322S1 (en) 2013-09-20 2016-03-15 Future Foam, Inc. Pillow
USD738644S1 (en) 2013-09-20 2015-09-15 Future Foam, Inc. Pillow
WO2016195700A1 (fr) * 2015-06-05 2016-12-08 Sealy Technology, Llc Ressorts non linéaires et matelas les comprenant
US10905246B2 (en) 2015-06-05 2021-02-02 Sealy Technology, Llc Non-linear springs and mattresses including the same
US10986935B2 (en) 2015-06-05 2021-04-27 Sealy Technology, Llc Non-linear springs and mattresses including the same

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EP2706888A1 (fr) 2014-03-19
EP2706888A4 (fr) 2014-10-01
US20120284927A1 (en) 2012-11-15
CN103702591A (zh) 2014-04-02
JP2014512936A (ja) 2014-05-29
CA2835841A1 (fr) 2012-11-15

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