Mattress made of latex foam integrating a structure of springs sacked or held in other supporting material

Abstract

It is proposed a new construction system for mattress made of latex including sacked springs, that allows an assembly without glueings or fastenings of mechanical type and allows to supply different bearing surfaces for the human body with different support densities, suitable for the different zones of human body in the rest position and related manufacturing method.

1 . Mattress made of latex foam including a structure of springs or other bearing material, that is obtained by a construction system of mattress including sacked springs, that allows an assembly without glueings or fastenings of mechanical type or seams, and allows to create different bearing surfaces for the human body with different support densities suitable for the different zones of human body in the rest position, characterised in that a structure of many sacked springs is included in a block of latex foam, and that allows to differentiate the surfaces in areas having different densities or support capacities and forms for including in the more suitable manner the different human body zones in the rest position as back, legs, shoulder zone, for getting a complete rest, require a differentiated support and with different absorption depths and transpiration of the human body laid on the mattress.  
     
     
         2 . Process for the fabrication of the mattress of  claim 1 , characterised in that the spring structure is inserted in a closed mold or mold with hinged cover having dimensions slightly higher than the ones of the spring structure so that an empty jacket remains between the mold and the structure in conjuction with each mattress face, and that over the spring structure there are foreseen one or more strata of any material having the aim to insulate better the springs from the latex foam or to increase the comfort of the mattress or simply to increase its thickness, and afterwards the mold is closed hermetically by a cover and in that the mold is supplied with nozzles suitably located so that it is possible to inject the latex foam through them and in the following it occurs the injection of the latex foam that causes the filling of one, some and/or all interspaces over, under and on the sides of the spring structure, also partially, but not in the inside of springs, being the springs sacked and made impermeable (completely or partially) to the latex foam material covering them, and in that after the injection it is made the normal process for forming a latex foam block, whatever is the process applied.  
     
     
         3 . A mattress according to  claim 1  and manufactured by the process of  claim 2 , having the following general characteristics: 
 INTERNAL PART 
 Springs sacked singularly, or in groups, or on the whole.  
 Springs of any form, type and material and in any number.  
 The spring structure can be homogeneous or not homogeneous as regards the spring forms, the density per square meter, and each spring characteristic.  
 Strata of any material can be put over the springs and/or on the various faces with a different aim owing to its position and the used material (to insulate, to increase the comfort, or to increase the thickness, etc.).  
 
 EXTERNAL PART 
 The surface can be smooth or machined for dividing the structure in zones; alveolar or filled: differentiated or equal on both sides. 
 The flanks can be filled or supplied with holes or machined.  
 One or more faces/flanks can be provided also without latex foam.  
 
 
 FOAM COMPOSITION 
 The composition and/or density of used latex foam can be changed in relation to characteristics of the finished product that it is wished to obtain, then it can be changed density, injection temperature, mixture composition, additive adding, etc.,  
 
 
     
     
         4 . Mattress and fabrication method according to preceding claims, characterised in that the mold can be of “opened” type instead of “closed” type as above described in claim  2 ; in this case the latex foam shall be not injected into the mold, but it will be simply poured into the mold, that is kept opened until its also partial filling and it is closed only in the following phases, so that the spring structure is inserted into the latex foam mass after the filling, also partial of the mold (but before its closing) or during the filling operation.  
     
     
         5 . Mattress and fabrication method according to preceding claims, characterised in that the spring structure is made “impermeable” (completely or partially) to the latex foam using a sacked spring structure, but being also used all of types of springs, provided that the springs are wound or closed in a suitable material, the winding concerning the whole complete structure or spring blocks or rows, or each single spring, including also the mixed “naked” and covered spring solutions.  
     
     
         6 . Mattress and fabrication method according to preceding claims, characterised in that the springs are made impermeable against the latex foam (completely or partially), by various materials such as fabric, unweaved fabric, gauze, polyether, polyurethane, polyethylene, paper or any other material, including jute, hemp, raffia and cotton suitable for the insulation and/or impermeabilization aims (completely or partially) of the latex foam, including plastic materials and films, thin sheets, bands.  
     
     
         7 . Mattress and fabrication method according to preceding claims, characterised in that instead of integrating a spring structure into the latex foam it is inserted a block or many blocks of any other material, such as a block or some blocks of polyurethane foam eventually and suitably shaped or a block/s of coco fibres, or a block/s of polyesther fibres for obtaining mattresses “in strata” (sandwich) and/or divided in zones, including also mixed solutions.  
     
     
         8 . Mattress and fabrication method according to preceding claims, characterised in that, in the case of use of closed mold, the foam is injected, from the cover, or in alternative also (or solely) from the walls and/or also (or solely) from the mold bottom.  
     
     
         9 . Mattress and fabrication method according to preceding claims, characterised in that the mold includes a bulkhead (preferably made of aluminium alloy) detachable/extractable, that allows to get a mattress of the type for two persons or, contemporaneously, two mattresses for a sole person. 
 In the name of Applicant    DR. FABIO FORMENTI    The Mandatary