Insert for mattress

Abstract

A support layer for a mattress and a corresponding manufacturing process are provided, comprising a first surface and a second surface, the second surface being disposed opposite the first surface. The first surface comprises a plurality of protrusions extending laterally to a length of the support layer, the protrusions defining a plurality of cavities extending laterally to the length of the support layer. The shape of the protrusions matches the shape of the cavities when the support layer is in a substantially planar state. The protrusions and cavities each have a base portion and a head portion, the head portion defining an undercut. Further, a mattress comprising at least one support layer is provided.

1 . A support layer for a mattress, comprising:
 a first surface and a second surface, the second surface being disposed opposite the first surface; wherein   the first surface comprises a plurality of protrusions extending laterally to a length of the support layer, the protrusions defining a plurality of cavities extending laterally to the length of the support layer, wherein   the shape of the protrusions matches the shape of the cavities when the support layer is in a substantially planar state, and   wherein the protrusions and cavities each have a base portion and a head portion, the head portion defining an undercut.   
     
     
         2 . The support layer according to  claim 1 , wherein the base portion has a first width and the head portion has a second width, the first width being less than the second width. 
     
     
         3 . The support layer according to  claim 1 , wherein the protrusions and cavities are symmetrical with respect to a vertical plane extending through the corresponding base portion, the vertical plane extending laterally to the length of the support layer and being substantially perpendicular thereto. 
     
     
         4 . The support layer according to  claim 1 , wherein the head portion is substantially flat. 
     
     
         5 . The support layer according to  claim 1 , wherein the protrusions and cavities have either a T-shape or an L-shape. 
     
     
         6 . The support layer according to  claim 1 , wherein the shape of the protrusions is configured to provide, upon deformation of the support layer along its length, a first stiffness when adjacent protrusions to not contact each other and a second stiffness when adjacent protrusions do contact each other. 
     
     
         7 . The support layer according to  claim 6 , wherein the first stiffness is less than the second stiffness. 
     
     
         8 . The support layer according to  claim 1 , wherein the support layer is made from a flexible material. 
     
     
         9 . The support layer according to  claim 1 , wherein the support layer is made from a material selected from the group consisting of polyurethane and latex. 
     
     
         10 . The support layer according to  claim 1 , wherein the plurality of protrusions and cavities are comprised in the first and second surfaces. 
     
     
         11 . The support layer according to  claim 10 , wherein the protrusions and cavities in the first surface have a size different from the protrusions and cavities in the second surface. 
     
     
         12 . The support layer according to  claim 9 , wherein the support layer is symmetrical with respect to a mid plane extending through the support layer, the mid plane being substantially parallel to the support layer. 
     
     
         13 . The support layer according to  claim 1 , wherein the second surface is substantially flat. 
     
     
         14 . A support layer for a mattress, comprising:
 an upper surface and a lower surface, the lower surface being disposed opposite the upper surface; wherein   the upper and lower surfaces comprise a plurality of protrusions extending laterally with respect to a length of the support layer, the protrusions defining a plurality of cavities extending laterally with respect to the length of the support layer, wherein   the protrusions and cavities each have a respective base portion and a respective head portion, the respective head portions being flat and defining an undercut, the protrusions having a T-shape, and wherein the support layer is made from a flexible material.   
     
     
         15 . The support layer according to  claim 14 , wherein the shape of the protrusions matches the shape of the cavities when the support layer is in a substantially planar state. 
     
     
         16 . A mattress comprising at least one support layer having a first surface and a second surface, the second surface being disposed opposite the first surface; wherein
 the first surface comprises a plurality of protrusions extending laterally to a length of the support layer, the protrusions defining a plurality of cavities extending laterally to the length of the support layer, wherein the shape of the protrusions matches the shape of the cavities when the support layer is in a substantially planar state, and   wherein the protrusions and cavities each have a base portion and a head portion, the head portion defining an undercut.   
     
     
         17 . The mattress according to  claim 16 , further comprising a lateral insert, the lateral insert comprising protrusions and cavities matching those of the support layer, the lateral insert extending along substantially a width of the support layer and being configured to increase a stiffness of the support layer in an area interested by the lateral insert. 
     
     
         18 . The mattress according to  claim 16 , further comprising a longitudinal insert, the longitudinal insert comprising protrusions and cavities matching those of the support layer, the longitudinal insert extending along substantially the length of the support layer and being configured to increase a stiffness of the support layer in an area interested by the longitudinal insert. 
     
     
         19 . A mattress comprising at least one support layer an upper surface and a lower surface, the lower surface being disposed opposite the upper surface; wherein the upper and lower surfaces comprise a plurality of protrusions extending laterally with respect to a length of the support layer, the protrusions defining a plurality of cavities extending laterally with respect to the length of the support layer, wherein the protrusions and cavities each have a respective base portion and a respective head portion, the respective head portions being flat and defining an undercut, the protrusions having a T-shape, the support layer being made from a flexible material, wherein
 the support layer is positioned between a superjacent layer and a subjacent layer, the superjacent layer having a substantially flat bottom surface and the subjacent layer having a substantially flat top surface, and wherein   the support layer is non-planar along its length, the support layer being curved along its length and straight along its width.   
     
     
         20 . The mattress according to  claim 19 , wherein the bottom surface of the superjacent layer and/or the top surface of the subjacent layer are in contact with the support layer and further comprising an upper padding layer and/or a lower padding layer, the upper and lower padding layers comprising cotton, wool, linen, silk, camel-hair, or combinations thereof, and
 wherein the mattress further comprises an external cover being a textile cover enclosing the entire mattress and layers comprised therein.