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Patent Searching and Data


Title:
FOAM SPRING WITH UNIFORMELY DIMPLED INNER AND OUTER SURFACE
Document Type and Number:
WIPO Patent Application WO/2013/110961
Kind Code:
A1
Abstract:
A foam spring for use in pillows, mattresses, bed bases, toppers or the like, the foam spring having a tubular body made of foam with uniformely dimpled inner and outer surface in order the dimples of the one match the protrusions of the adjacent foam spring.

Inventors:
BAIRAKTARIS, Georgios (51 Xarilaou Trikoupi Str, Rodopolis Attikis, GR-145 74, GR)
Application Number:
GR2013/000008
Publication Date:
August 01, 2013
Filing Date:
January 28, 2013
Export Citation:
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Assignee:
BAIRAKTARIS, Georgios (51 Xarilaou Trikoupi Str, Rodopolis Attikis, GR-145 74, GR)
International Classes:
A47C27/06; A47C27/14; A47G9/10
Foreign References:
US20050172468A1
US20060290039A1
DE202005015047U1
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Claims:
CLAIMS

1. The current invention refers to a foam spring for use in pillows, mattresses, bed bases, toppers or the like, the foam spring having a tubular body made of foam with uniformely dimpled inner and outer surface in order the dimples of the one match the protrusions of the adjacent foam spring.

2. The mattress consisted by foam springs according to claim 1 , are placed vertically with their tubular bodies parallel to each other in vertical and horizontal lines in right angle to form a mattress.

3. The pillow consisted by foam springs according to claim 1 , are placed vertically with their tubular bodies parallel to each other in vertical and horizontal lines in right angle to form a pillow.

4. An important point of this invention is that the foam springs according to claim 1 , interconnect to each other due to their dimpled outer surface, resulting in the reduction of the "dead" area without support in between the springs and also preventing of the collapsing of the springs due to the extensive use.

5. The foam spring according to claim 1 , under compression, has an increased resistance due to the protrusions of the inner and outer surface coming in contact, by eliminating the dimples between them, therefore increasing the density of the compressed foam spring. Thus, the foam spring works in a similar way as the coils of a conventional metal spring when it is tightly coiled.

6. The method of manufacturing the foam spring according to claim 1 , uses an already existed foam shaping machine and is made by passing through the machine a foam sheet, which slices it in half, ending with two sheets of usable foam with uniformly dimpled surfaces with mirror image pattern which marry to each other. The two sheets produced are then glued together back to back with the dimpled surfaces on the outside and result in a single foam sheet with both sides with uniform dimpled pattern. The produced sheet is cut to rectangular pieces in the desired dimensions and each foam piece is bent back on itself and glued to form a hollow tubular body which consists the foam spring.

7. The current invention can also be manufactured in different dimensions than the dimensions described above.

8. The current invention can be used for the manufacture of mattresses, toppers, pillows, bed bases and any other case where absorption of pressure is needed.

Description:
FOAM SPRING WITH UNIFORMELY DIMPLED INNER AND OUTER SURFACE

The invention concerns a foam spring, for use in pillows, mattresses, bed bases or the like, made by polyurethane foam or similar to foam products such as latex, with tubular body and uniformely dimpled inner and outer surface. Fig. 1 ,2,3

Today, mattress industry is using metal spring technology such as bonnel, pocket and microsprings and/or foam materials such as HR foam (high resilience), memory foam, latex , etc. The former have good recovery but they create pressure points and they store energy due to compression that they seek to release, which means overtime they lose their ability to recover. In addition, they are required to be overiayed with multiple layers of foam or similar materials in order the metal not to come in direct contact with the body, resulting in price increase and use of unnesessary resources.

The latter have better recovery last longer compared with metal springs, and minimal pressure points, but they have limited air circulation due to their high density by nature, resulting in accumulation of humidity which leads to discomfort and perspiration. Finally, metals springs cannot fully support the body due to the "dead" areas created between them while placed in a mattress, which may cause uneven support and mattress deterioration.

The current invention eliminates the drawbacks of the conventional spring and foam mattresses mentioned above.

The current invention consists of a barrel shaped foam spring with outer diameter of 13 cm and inner diameter of 3 cm. These foam units are placed tight in horizontal and vertical lines. An important point of this invention is that the foam springs interconnect to each other due to their dimpled outer surface resulting in the reduction of the "dead" area in between the foam springs (Fig.4). This interconnection between neighbour foam springs also results in mutual support, therefore preventing the collapsing of the foam springs due to the extensive use.

Another important point of this invention is that under compression, the resistance is increased due to the protrusions of the inner and outer surface coming in contact, by eliminating the dimples between them, therefore increasing the density of the compressed foam (Fig. 5). This works in a similar way as the coils of a conventional metal spring when it is tightly coiled.

In addition, due to the special construction of the foam springs, almost two thirds of the volume of foam is needed to produce a mattress when compared with ordinary foam mattresses. Furthermore, the manufacturing procedure of the foam spring eliminates wastage of foam.

The construction of the current invention is based in an already existing foam shaping machine. By passing through the machine a foam sheet of 4cm, which slices it in half, we end up with 2 sheets of 3.5cm usable foam with dimpled surfaces with mirror image pattern which marry to each other. During this process no foam waste is created, hence this is a more ecological mattress manufacturing process.

Then the two sheets produced are glued together back to back with the dimpled surfaces on the outside before being cut to the desired dimensions, and each piece is bent back on itself and glued to form a hollow tubular body which becomes the foam spring.

The current invention can also be manufactured in different dimensions than the dimensions described above.

This invention can be used for the manufacture of mattresses, toppers, pillows, bed bases and any other case where absorption of pressure is needed.