Spring element unit for a padding element, especially a mattress

[0001] The invention relates to a mattress according to the preamble of claim 1. Furthermore, the invention relates to an assembly of spring elements with a large number of spring elements for such a mattress.

[0002] The above-mentioned mattress is disclosed in DE 20 2005 015 047 U1. This combined mattress consists of a large number of spring elements that adhere to each other with their peripheral surfaces and must be welded together with a peripheral tape. To fix the tape, the spring elements have a groove. Spring elements are made of latex.

[0003] Furthermore, spring core mattresses are known in which metal springs fixed in material pockets are used as spring elements. The core of metal springs thus formed is referred to as the core of bonell or pocket springs. Above the core of the metal springs there is an upholstery made of foam, which is usually made of block foam and has a certain elasticity. In addition, foam mattresses with wire springs embedded in the foam core are known.

[0004] From DE 299 18893 U1, a padded element for furniture and mattresses is known, in which a large number of spring elements are combined to form a flat composite structure. The spring elements are made of sheep's wool and are embedded in pockets, preferably made of cotton, the upper faces of the pocket springs forming a later load surface. In order to create a padded element with a large surface area, a large number of spring elements are placed next to each other and connected together in individual rows, preferably by sewing.

[0005] Furthermore, from DE 39 37214 A1 a padded element is known for supporting a lying human body. The mattress part of flexible material, such as foam material, for example, contains a large number of channels arranged next to each other, in which inserts of varying elasticity are inserted, thanks to which the mattress part on its lying surface is equipped with areas of locally varying elasticity. The inserts can be made of flexible material, corresponding to the material of the mattress.

[0006] For these known padded elements, especially those used for mattresses, it has proved disadvantageous that heat and moisture accumulate between the human body and the padded element. This problem occurs to a high degree in the case of mattresses, because there, due to covering the human body with a duvet, heat and moisture collect, especially in the area of ​​the lying mattress surface, which is in contact with the human body.

[0007] In addition, GB 902 272 A discloses an artificial foam cushion that consists of two foam plates connected to each other at the edges, and support elements placed between them in a vertical position . Artificial foam is a polyether foam material. Foam plates are glued together at the edges. Supporting elements can be made of cylindrical rings or straight or curved ribs. Supporting elements can be made of polyether foam, latex foam or polyester foam.

[0008] GB 476 659 A discloses a padded seat padding which has a large number of spring elements made of soft rubber.

[0009] JP 8-103 581 A discloses a foam body that is characterized by air permeability and flexibility. To this end, the foam body is made of polyolefin resin.

[0010] WO 95/09886 A1 discloses polyurethane foam and a method for producing such foam that should have comparable properties to latex.

[0011] The object of the invention is to propose a mattress and spring assembly that prevents the accumulation of heat and moisture between the body and the padded element.

[0012] This task is solved by a mattress according to claim 1 and a set of spring elements according to claim 17. Preferred embodiments and a set of spring elements are defined in claims 2 to 16 and 18 to 20.

[0013] The spring assembly according to the invention consists in recognizing the forming of the spring member fully from flexible soft polyurethane foam and providing it with at least one recess. The recess is used to remove heat and moisture, or to allow air to flow towards the support surface of a sitting or lying person. In other words, the recess creates an air channel. In principle, the spring element can also be provided with a number of recesses. Because the spring element is made of soft, breathable foam, heat and moisture are further improved through the airflow towards the support surface.

[0014] It is additionally added that the soft polyurethane foam can easily be given any shape by means of form foaming, and thus spring elements of various shapes can be produced, depending on the case of use, and the required material values, such as elasticity and permeability. In addition, soft polyurethane foam has proven to be advantageous in terms of the possibility of long-term, relatively durable loading.

In this case, the spring element is metal-free, i.e. it does not require the use of any metal inserts, for example in the form of steel springs. Consequently, the spring assembly according to the invention is particularly suitable for persons who are sensitive to the magnetic field produced by metal elements.

[0016] The individual spring elements can be manufactured with different material parameters, in particular the varying hardness indicated by pressing, and depending on the needs, they can be combined into a packet, as a set of spring elements. If necessary, the spring elements can be replaced.

[0017] The spring assembly according to the invention can be used in a large number of applications. The spring assembly is suitable, inter alia, for mattresses, but also for seats, in particular passenger seats in motor vehicles or aircraft. In this connection, the spring assembly according to the invention is applied to both the seating surface as well as to the backrests. In addition, the spring assembly according to the invention is used for padded furniture.

[0018] The spring element extends completely through the recess in the axial direction. The spring element has a first face and a second face, wherein the recess is made continuously from the first face to the second face. To create a suitable air channel, the recess preferably extends substantially perpendicular to the first and second faces.

[0019] The spring element is made of shaped foam. To this end, during the production of the spring element, the reaction mixture is introduced into the foam mold and by means of foam the final shape is obtained. To achieve this, the foaming mold is shaped in such a way that, thanks to the foaming process, the spring element is provided with a recess. In this way, subsequent drilling or cutting of the spring element is unnecessary to create a recess. In this way, a simple springing element can be produced by means of a simple foaming method which achieves adequate point elasticity and favorable breathability. In addition, one-piece spring element assembly with a series of spring elements can also be produced.

[0020] Preferably, the recess is located approximately centrally. In this way, it is possible that during loading, the spring element is significantly symmetrically deformed, and thus the individual areas of the spring element are loaded evenly to a considerable extent. In addition, the recess can be arranged in such a way as to obtain a certain form of deformation.

[0021] With respect to the configuration of the recess, it has proved to be advantageous if, in cross-section and / or in longitudinal section, the recess has a rectilinear or curved shape.

EP 1 962 644 B1

Such a configuration also includes a rectilinear, relatively curved shape and a combined shape over certain sections. In this way, also thanks to the shape of the recess it is possible to control or influence the possibility of deformation of the spring element. Furthermore, the shape of the recess along its orientation in the spring element can be varied, for example conical.

[0022] Also with respect to the configuration of the spring element, i.e. mainly with respect to the outer side surface of the spring element, various shapes can be selected. For example, a barrel or tubular shape, i.e. a polygonal or round base, is particularly preferred. According to the invention, the body has an octagonal cross section. In addition, a cross-sectional shape that is variable in the vertical line of the spring assembly, such as, for example, a half-tapered shape, may be considered. Also, by the shape of the outer side surface of the spring element, its deformability can be influenced.

[0023] The spring element assembly is characterized by a large number of spring elements arranged next to each other, the spring elements being connected to each other by means of an inseparable direct connection, preferably glued. In this way, a set of spring elements can be combined with any number of spring elements. Such different sets of spring elements can then be joined together to form a support surface, the individual packages having different values ​​of elasticity in order to meet the requirements for different lying or sitting zones. Furthermore, it is preferred that the non-detachable direct connection is at least partially flexible. This avoids overly rigid connection of the spring elements.

[0024] According to the invention, the spring elements are arranged next to each other in such a way that a free space is left in the area between the outer surfaces of the adjacent spring elements. This free space is advantageously obtained due to the appropriate selection of a spring element, taking into account a combination of the type of composite structure. The shape of the octagonal profile is particularly suitable for the spring element. The free space created between the spring elements can also be used to remove heat and moisture from the seating or sitting surfaces.

[0025] The claimed mattress benefits from the advantages of the spring assembly according to the invention. In addition, it is possible to dispense with the relatively laborious joining of a number of spring elements in a system such as rows by means of tapes, or with the formation of pockets and their incorporation into the mattress core. In addition, the body can also be made of foam material, so that the entire padded element is metal-free. The body can easily be made of block foam and can be of any dimensions. In regards to the advantages

Preferably, the separately manufactured spring assembly is referenced to the above explanations.

[0026] According to the invention, the body has at least one recess in which the spring element assembly is fixed. Thus, a large number of spring elements arranged next to each other can be placed on the base of the recess as a set of spring elements, and for example they can be supported from the side by the peripheral wall of the body. Preferably, the spring assembly has approximately the same height as the recess. With respect to the base of the body, the recess can be made, for example, in an area in which a shoulder portion or pelvis of a person is supported. Only one cavity can be formed, located substantially throughout the entire area. It is particularly advantageous if, in the case of a couch, one recess is made in the shoulder area and a further recess in the pelvic area.

[0027] According to a further preferred embodiment, a cover element is provided adjacent the spring element assembly and / or the body, the cover element being connected by means of a direct connection with the body and / or the spring element assembly, preferably glued. Especially in the case where a recess is made in the body, then the cover element forms a kind of cover and thus forms the upper end of the padded element. Preferably, the cover element is made of soft polyurethane foam. Alternatively, the cover element may be formed by means of an air-permeable layer, especially an air-permeable padding.

In order to ensure permanently inseparable positioning of the spring element assembly relative to the body, the spring element assembly is connected to the body by means of a direct non-detachable connection, preferably glued. Preferably, the connection is carried out on the bottom surface of the spring element assembly, i.e. in the area of ​​that surface which, through the body, lying or sitting on the padded element, transfers the load to the body. In the case where the spring element assembly is positioned in the body cavity, then, alternatively or additionally, the spring element assembly may be connected through its side surfaces, at least on certain sections, to the body edge surface limiting the recess.

[0029] Preferably, the body, as well as the spring element, is made of soft polyurethane foam. Preferably, the body is made of block foam so that a fully automated manufacturing process can be used that is carried out continuously. In addition, a large amount of starting materials need not be stored in stock to manufacture the spring assembly and bodies.

[0030] Preferably, the body and / or cover element is made of soft polyurethane foam. Thanks to this, the entire padded element can be made of basic material.

[0031] Furthermore, it has proved to be advantageous when the hardness determined by pressing in the spring element assembly differs from the hardness determined by pressing the body and / or the covering body. Preferably, the hardness determined by pressing in the spring assembly is in the range of from about 40 N to about 350 N, preferably in the range of from about 60 N to about 260 N.

[0032] In a further preferred embodiment, the body and / or cover element have indentations parallel to each other. These indentations can be made with or without material selection. In addition, indents can be made both in the longitudinal direction and in the transverse direction. The surface tension specific to the material of the body or cover element is reduced by means of indents.

[0033] In order to obtain areas of varying hardness, in certain zones, such as in the shoulder blade or pelvis zone, the indentations may have different distances from each other. Thanks to this, the adjacent indentations in the area of ​​the shoulder blades allow for greater softness, thanks to which the arms can collapse deeper and softer, while the areas in the cuts, farther apart, stiffen the spring and thus provide better support.

[0034] Furthermore, it is advantageous if the indentations have a cross-section that extends inwards, in particular a cross-section in the form of drops. In this way, ventilation is further improved.

[0035] Preferably, the body and / or cover element is made of block foam, whereby the body and / or cover element can be manufactured in a continuous process as a product sold in meters of any dimensions. Due to the usually simple geometrical dimensions, bodies and cover elements can be cut easily. In addition, the at least one cavity can be shaped in a simple, fully automated manner by cutting. [0036] The spring assembly is made of shaped foam so that a simple manufacturing method can also be implemented. In this case, after removal from the foaming tool, the spring element produced by means of foaming can be simply and preferably also completely automated, mounted on the body or embedded in the body cavity. In particular, the recess made in the spring element proved to be helpful. Finally, it is possible for the cover element to be provided with air-permeable covering. Such padding may be arranged alternatively or in addition to said soft polyurethane foam material.

[0037] The invention is explained in more detail below with reference to the drawings. The drawings schematically show:

Fig. 1a a perspective view of a first embodiment of a spring assembly according to the invention;

Fig. 1b a horizontal section through the spring element assembly according to Fig. 1a;

EP 1 962 644 B1

Fig. 1c a vertical section through the assembly of spring elements according to Fig. 1a;

Fig. 2 a further cross-sectional view of a further embodiment of a spring assembly according to the invention, alternatively to Fig. 1b;

Fig. 3 a further cross-sectional view of an assembly of the spring elements according to the invention, alternatively to Fig. 1c;

Fig. 4 a horizontal cross-section through a set of spring elements according to the invention, with a plurality of spring elements according to Fig. 1a;

Fig. 5a a vertical cross-section through a first embodiment of a padded element according to the invention with a large number of spring element assemblies according to Fig. 4;

Fig. 5b a top view of the body of the padded element of Fig. 5a, without the cover element;

Fig. 6a a vertical cross-section through a second embodiment of a padded element according to the invention with a large number of spring element assemblies according to Fig. 4;

Fig. 6b a top view of the body of the padded element according to Fig. 6a, without the cover element;

Fig. 7a a longitudinal section through a third embodiment of a padded element according to the invention with a large number of spring element assemblies according to Fig. 4;

Fig. 7b a top view of the body of the padded element of Fig. 7a, without the cover element.

[0038] Figs. 1a to 1c show a spring element 10 of which the spring element assembly 20 is constructed, shown in Fig. 4. The spring element assembly 20 is used in the padded element 30, for example in the form of a mattress as shown in figures 5a to 7b.

[0039] The spring element consists exclusively of flexible soft polyurethane foam with open cells and is produced by molding foaming. The cylindrical spring element 10 has a side surface 16, an upper surface 14 and a lower surface 15. The upper surface 14 and the lower surface 15 are arranged substantially parallel to the sitting or lying surface. As it is shown especially in fig. 1b, the spring element 10 has an octagonal contour that does not change over the entire height of the spring element 10, whereby the side surface 16 is divided into vertical connection surfaces 17 and diagonal side surfaces 18.

[0040] In the center of the spring element 10 is placed in a recess 12, arranged in the axial direction, which is created by the appropriate shape of the foaming tool. Recess 12 has a circular cross-section (horizontal cross-section), with a shape that does not change vertically (vertical cross-section), and serves as an air channel for removing heat and moisture.

[0041] Alternatively, the spring element 10 and / or recess 12 may have a shape, as indicated for example in figures 2 and 3, wherein individual side surfaces and recess forms may also be joined together. As shown in Fig. 2, the spring element, in horizontal section, may have rectilinear or curved shape over certain sections, such as circular, elliptical or hexagonal shape. In addition, as indicated in Fig. 3, the spring element 10 can, when viewed in the direction of the vertical section, be provided with a cross section that varies vertically, for example with a curved shape, especially with a narrowing shape in the center, or with a rectilinear shape in certain sections, for example a conical shape, or also forms in which the width or diameter of the top surface 14 and bottom surface 15 have different sizes.

[0042] Fig. 4 shows a preferred embodiment of the spring element assembly 20, which has a total of four spring elements 10 corresponding to figures 1a to 1c. In the area of ​​their opposite attachment surfaces 17, the spring elements 10 arranged side by side are connected to each other by means of a direct non-detachable connection, by means of an adhesive connection. At least partially, the adhesive layer can be shaped elastically to prevent the connection being formed too rigidly. Thanks to the octagonal shape of the spring elements 10 and the connection through the connecting surfaces 19, between the oblique side surfaces 18, in addition to the individual central recesses 12, a free space 28 is left, which also allows heat and moisture to be dissipated.

[0043] As an alternative to the spring element assembly 20 with four spring elements 10, other combinations with any number of spring elements 10 are also possible. In this way, prefabricated spring element packages or rows of spring elements can be formed.

[0044] On the basis of the spring element assembly 20 as explained above in Fig. 4, a number of embodiments of the padded element 30 formed with a plurality of spring element assemblies 20 will be explained below. In this case, figures 5a to 7b differ essentially in the number of spring element assemblies 20 provided and in the corresponding configuration or number of recesses 44.

[0045] Thus, in all figures 5a to 7b there is respectively shown a padded element 30 in the form of a mattress, with a body 40 forming a mattress core, with a covering element 50 and a large number of spring element assemblies located between the element 8

EP 1 962 644 B1 to the cover 50 and the body 40. All the components of the spring element 30, i.e. the individual spring elements 10 for forming the spring element assembly 20, the body 40 and the cover element 50 are made entirely of soft open-cell polyurethane foam . The hardness determined by pressing in the spring elements 10 is about 40 N to about 350 N, preferably about 60 N to about 260 N. The body 40 has an upper surface 4, a lower surface 42 and a circumferential side surface 43.

[0046] All of the depressions 44 shown in figures 5a to 7b are preferably made by cutting out a suitable volume of material from the block foam body forming the body 40. The depressions 44 are limited by a substantially horizontal base 45 and a peripheral edge surface 46 arranged respectively basically vertical. In all the embodiments of figures 5a to 7b, the spring element assembly 20 is supported by the body 40 in such a way that the spring element assembly 20 is located in the recess 44. In other words, the bottom surface 24 of the spring element assembly 20 adjoins the base 45. W To ensure stable and permanent adhesion of the spring element assembly 20 to the recess 44, the bottom surface 24 is connected to the base 45 by means of an adhesive layer. This adhesive layer can be placed over the entire surface, in the form of bands or only in points. A gap may be left between the side surface 26 of the spring member assembly 20 and the edge surface 46 of the body 40 at least over certain sections. The rim 47 has a sufficient thickness to provide lateral adhesion of the spring member assembly 20.

[0047] As an alternative to this glued connection, the side surface 26 of the spring element assembly 20 contacts the entire periphery with the edge surface 46. This contact is preferably obtained by means of over-fit, i.e. the dimensions of the recess 44 are at least slightly smaller than the external dimensions of the element assembly 20 spring.

[0048] After mounting the spring element assembly 20 in the recess 44 and fixing it preferably by means of an adhesive layer, the covering element 50 is applied to the upper surface 41 of the body 40, coinciding with it, and is connected to the body 40 by a direct permanent attachment by means of a layer adhesive, placed at least in some places. In addition, the bottom surface of the body 50 is glued to the top surface 22 of the spring assembly 20. Covering element 50 has the appropriate thickness and / or material properties, whereby it is sufficiently air permeable to provide heat and moisture removal towards the spring element assembly. In the embodiments of Figures 5a to 7b, the cover element 50 has a thickness of about 40 mm. Alternatively, cover element 50 may be formed with an air-permeable cover.

[0049] The embodiments according to figures 5a to 7b differ mainly in the number of recesses 44 and their size. Thus, in accordance with Figs. 5b and 7b, only one cavity 44 is provided, while in Fig. 6b two cavities 44 are made. According to Fig. 5b, the cavity is located in the first region A of the body 40, i.e. in the shoulder zone . According to Fig. 6b, in a second area C, approximately in the pelvis / hip area, a second recess 44 is additionally provided. Between the first area A and the third area C there is a second area B. According to Fig. 7b, the recess 44 is positioned almost completely on the base of the body 40, the wall 47 providing sufficient support for the spring element assembly 20.

[0050] Furthermore, as shown in Figs. 5a to 7b, the body 40 and the cover element 50 have parallel indentations 60. In this case, the indentations 60 are arranged in the area of ​​the top surface 52 of the cover element 50 and in the area of ​​the bottom surface 42 of the body 40 , in the form of material selection. These indentations 60 reduce surface tension and thus contribute to improving the point elasticity of the padded element 30.

[0051] As can be seen in figures 5a to 7b, in areas A, B, C, the indentations 60 are located at different distances. Thus, the distance between the indents 60 in both the body 40 and the covering element 50 in the region of the recess 44, i.e. according to Fig. 5b in the first area A and in Fig. 6b in the third area C, is correspondingly smaller than in the middle area B according to Figs. 5b and 6b. In other words, the indentation distance 60 in the area of ​​the spring element assemblies 20 is smaller. In addition, elasticity can be set in these areas by means of indentation 60. For example, the elasticity can be increased due to the smaller indenting distances 60. In the variant of Fig. 7b, the indentations 60 are further arranged in the area of ​​the only recess 44 with a large surface, in a number of partial areas, at different distances. In this way, the point elasticity can be adjusted in detail, guaranteed by the set of 20 spring elements with a large surface area.

[0052] Finally, the indentations 60 shown in Fig. 7b and 5b differ from the indentations 60 shown in Fig. 6b in the form of a cross-section extending inwardly in the form of drops.

List of markings [0053] spring element recess upper surface lower surface lateral surface connection surface lateral surface

EP 1 962 644 B1 spring element assembly 1 upper surface lower surface side surface free space padded element body upper surface lower surface side surface recess base surface edge wall covering element surface upper surface indentation

And the first area

B second area

C third area