Mattress

Abstract

A mattress is described, comprising an ergonomic layer made of foam material and a breathable layer made of three-dimensional polymeric material. The ergonomic layer and the breathable layer are mutually coupled. The breathable layer is individually wrapped in a casing made of a three-dimensional breathable fabric. The combination between the breathable layer and the respective casing, which is also manufactured with a three-dimensional breathable type of material, allows to obtain the maximum breathable characteristics for the mattress.

Claims

1. A mattress comprising: an ergonomic layer made of foam material; and a breathable layer made of three-dimensional polymeric material, wherein said ergonomic layer and said breathable layer are mutually coupled to one another, and wherein the breathable layer is individually wrapped in a casing made of a three-dimensional breathable fabric.

2. The mattress according to claim 1, wherein the foam material with which the ergonomic layer is manufactured is a memory foam material.

3. The mattress according to claim 2, wherein the memory foam material is a polyurethane foam.

4. The mattress according to claim 2, wherein the memory foam material is a latex foam.

5. The mattress according to claim 1, wherein the foam material with which the ergonomic layer is manufactured is a polyurethane having a density ranging between 15 and 30 kg/m.sup.3.

6. The mattress according to claim 1, wherein the three-dimensional polymeric material with which the breathable layer is manufactured is a three-dimensional polyester.

7. The mattress according to claim 1, wherein it also comprises a base layer made of polyurethane foam, coupled to the ergonomic layer and to the breathable layer.

8. The mattress according to claim 1, wherein the breathable layer is arranged on top of the ergonomic layer.

9. The mattress according to claim 1, wherein the breathable layer is provided with a shape maintaining element arranged along at least a peripheral portion of an upper edge of said breathable layer.

10. The mattress according to claim 7, wherein at least one between the base layer and the ergonomic layer is wrapped in a casing manufactured with a three-dimensional fabric.

11. The mattress according to claim 7, wherein the base layer and the ergonomic layer are wrapped together in a casing manufactured with a waterproof fabric.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Further characteristics and advantages of the present invention will become clear from the description of a preferred but not exclusive embodiment of the mattress, shown by way of a non-limitative example in the annexed drawings, wherein:

(2) FIG. 1 is a schematic sectional view of the mattress according to the present invention; and

(3) FIG. 2 is an enlarged view of a detail of FIG. 1, indicated with the letter A.

(4) With reference to the aforementioned figures, a mattress is shown, indicated as a whole with the reference numeral 1.

DETAILED DESCRIPTION OF THE INVENTION

(5) The mattress 1 comprises an ergonomic layer 2, made of foam material, and a breathable layer 3, made of a three-dimensional polymeric material. The ergonomic layer 2 and the breathable layer 3 are mutually coupled to one another. The ergonomic layer 2 and the breathable layer 3 can advantageously be separated from one another.

(6) Preferably, the foam material with which the ergonomic layer 2 is manufactured is a shape memory type of material. This material can be a polyurethane memory foam, better known as memory foam. Alternatively, it is possible that said memory foam is a worked and vulcanized latex foam.

(7) It is also possible that the foam material is not of the shape memory type. In this case, it is preferable that this material is obtained using a low density polyurethane foam, i.e. having a suitable density, ranging between 15 and 30 kg/m.sup.3, more preferably ranging between 20 and 25 kg/m.sup.3.

(8) According to the preferred embodiment, the three-dimensional polymeric material with which the breathable layer 3 is manufactured is made with polyester polymer. More precisely, said three-dimensional polymeric material comprises springs made with a three-dimensional polymeric material, i.e. with a polyester polymer.

(9) The coupling of the ergonomic layer 2 made of foam material and of the breathable layer 3 made of three-dimensional polymeric material has a synergic technical effect, which goes beyond the simple summing up of the advantages achieved by said layers when taken individually. Actually, as both the ergonomic layer 2 and the breathable layer 3 are used together, the foam material of the ergonomic layer 2 receives the weight and adapts to the body pressure, leaving the three-dimensional polymer of the breathable layer 3 sufficiently slightly compressed to maintain its breathability. This effect is also obtained even when the breathable layer 3 made of three-dimensional polymer material is arranged on top of the memory foam ergonomic layer 2.

(10) It is decisively more advantageous to have the breathable layer 3 arranged on top of the ergonomic layer 2 (FIG. 1), so that the body lying on said breathable layer 3, thus benefiting the microclimatic characteristics that develop in the contact area between the mattress 1 and the body.

(11) Typically, the memory foam material has a density ranging between 50 kg/m.sup.3 and 70 kg/m.sup.3, preferably substantially equal to 60 kg/m.sup.3, whereas the three-dimensional polymeric material has a density ranging between 20 kg/m.sup.3 and 40 kg/m.sup.3, preferably substantially equal to 30 kg/m.sup.3. Obviously other density values can be provided for these materials.

(12) It should be noted that the three-dimensional polymeric material could have a pre-formed surface so as to be adapted, from an anatomical point of view, to a predetermined pathology.

(13) According to the preferred embodiment, the mattress 1 also comprises a base layer 4 made of polyurethane foam, that is coupled to the ergonomic layer 2 and to the breathable layer 3. Said base layer 4 allows the mattress 1 to maintain its correct shape for long periods of time in comparison to known types of mattresses.

(14) As can be seen in FIG. 1, the base layer 4 is directly coupled to the ergonomic layer 2, which in turn is coupled to the breathable layer 3. Preferably, the base layer 4 and the ergonomic layer 2 are directly coupled by means of glue.

(15) Each of these layers comprises a respective sheet of material.

(16) In order to further maintain the correct shape of the mattress 1, it is preferable that the breathable layer 3 is provided with a shape maintaining element 5 arranged along at least a peripheral portion of an upper corner 3A of said breathable layer 3 (FIG. 2). Even more preferably, the shape maintaining element 5 is arranged along the entire upper corner 3A of the breathable layer 3, i.e. along its entire circumference.

(17) In order to maintain the shape of the mattress 1 in an optimal manner, a first shape maintaining element 5 should be provided, arranged along the entire periphery of the upper corner 3A of the breathable layer 3, and a second shape maintaining element (not shown in the figures), arranged along the entire periphery of the lower corner of the breathable layer 3.

(18) In the illustrated embodiment, the shape maintaining element 5 comprises a corner with resin coated wadding. Said shape maintaining element 5 is made integral with the three-dimensional polymer, preferably through heat-sealing, after the three-dimensional polymer layer is made.

(19) Preferably, at least one between the base layer 4 and the ergonomic layer 2 is wrapped in a casing 7 manufactured with a three-dimensional fabric 7.

(20) According to the invention, as shown in particular in FIG. 1, the breathable layer 3 is individually wrapped in a casing 6 manufactured with a three-dimensional breathable fabric. The combination between the breathable layer 3 and the respective casing 6, which is also manufactured with a three-dimensional breathable fabric, allows the maximum breathable characteristics to be obtained for the mattress 1.

(21) The breathable fabric of the casing 6 is preferably formed with 100% flame retardant (FR) polyester.

(22) The base layer 4 and the ergonomic layer 2 are preferably wrapped together in a casing 7 manufactured with a waterproof fabric. The greatest advantage is attained with a casing 7 made of waterproof fabric which is also a three-dimensional fabric. In the preferred embodiment, the waterproof casing 7 is manufactured with an orthogonal fabric.

(23) Each of the casings 6 and 7 is provided with respective closing means 6A and 7A, for example, a zip arranged on a lateral surface of the casing 6 or 7, when wrapped around the breathable layer 3 or the base layer 4 and the ergonomic layer 2, and arranged parallel to the upper or lower surface of the respective layer.

(24) Advantageously, the mattress 1 also comprises coupling means 8 for mutually coupling the breathable casing 6 (that wraps the breathable layer 3) and the waterproof casing 7 (that wraps the base layer 4 and the ergonomic layer 2). Preferably, said coupling means 8 include a zip, a first half 8A of which is arranged along a lower edge of the breathable casing 6, the second half being arranged on an upper edge of the waterproof casing 7, placed at the aforementioned lower edge of the breathable casing 6. The embodiment illustrated in the figures provides for the zip to be arranged along a single side of the casings 6, 7 (i.e. the zip is not arranged at a corner of the casings) in order to be straight. It is however preferable that the zip 8 is provided on the entire periphery of the corners involved, i.e. the lower corner of the breathable casing 6 and the upper corner of the waterproof casing 7.

(25) The mattress 1 has a standard size for a mattress, for example, 8020013 cm for a single size mattress, or 16020013 cm for a double size mattress. The ergonomic layer 2, the breathable layer 3 and the base layer 4 have an overall thickness ranging between 13 cm and 20 cm.

(26) The process for manufacturing the mattress 1 according to the present invention is as follows.

(27) Firstly, a sheet made of memory foam material, a sheet made of three-dimensional polymeric material and, if envisaged, a sheet made of polyurethane foam are manufactured. The sheet made of polyurethane foam is then preferably glued onto the memory foam material sheet.

(28) The sheet made of polyurethane foam and the sheet made of memory foam material are then both wrapped together in the casing 7 made of waterproof and three-dimensional fabric, whereas the sheet made of three-dimensional polymeric material is wrapped in the casing 6 made of three-dimensional breathable fabric.

(29) Each of the aforementioned casings 6 and 7 are then closed by means of respective closing means 6A and 7A, i.e. the zips. The casings 6 and 7 are then coupled by means of coupling means 8, i.e. the zip, the halves of which are arranged respectively at a lower edge of the casing 6 made of three-dimensional breathable fabric and at an upper edge of the casing 7 made of three-dimensional waterproof fabric.