The subject of the invention is a mattress layer made of pocket spring components with a rim stiffened with a tape of textile material. The invention also relates to a mattress comprising such a layer.

Currently, in the construction of mattresses, a whole range of materials and components capable of achieving desired properties ensuring support and comfort for the user are used in the industry. These products and materials are either used in the form of a single element constituting the mattress structure (an example of such a product can be a latex mattress made of a single layer of latex), or a combination of various materials and components is used to produce the final product. An example of such product may be a mattress in which a layer of latex is arranged over a mattress layer composed of pocket spring components in the form of springs or blocks of foam wherein each one is placed in individual pockets which are joined together to form webs of pocket spring components. Said webs are joined together to form a mattress layer.

One of the significant technical problems in the design of mattress layers is to provide stiffening of the edges of such layers. In the state of the art, numerous solutions can be found based on the appropriate adjustment of the parameters of the spring components, e.g. by purposeful selection of the wire thickness or the number of turns of the spring or the hardness of the foam from which the blocks constituting the spring element of the pocket spring component are made. Closer packing of springs can also be used at the edges of the mattress layers, as in DE 40 31 654 A1 . In another solution, the springs forming the outer periphery are placed in the intermediate space formed between two springs of an adjacent web of pocket springs.

However, such solutions are quite complicated in terms of manufacturing such mattress layers. In addition, while flexibility is of course available in designing the different zones of stiffening the rim using known technical means, the implementation of such solutions in practice involves the need to make often costly changes to the already existing production lines. The aim of the present invention is, therefore, to provide a mattress layer with a stiffened rim, suitable for use in a mattress construction, which can be manufactured in a simple and inexpensive manner, and which at the same time provides the possibility of configuring different stiffening zones of the rim of the mattress layer.

The aim stated above is achieved by the solutions according to the invention, as defined by independent patent claims. Preferred embodiments of the invention are defined by dependent claims.

The subject of the invention is a mattress layer comprising a plurality of adjoining spring components, wherein each spring component is placed individually in a pocket of textile material, and each pocket being connected to an adjacent pocket to form a web of spring components, the adjacent webs of spring components being connected one to another, wherein the mattress layer according to the invention is characterized in that at least one strip of textile material is provided on at least one rim of said mattress layer and attached to at least two adjacent textile pockets.

In a preferred embodiment of the invention, in the mattress layer, the spring component is an elastic element made of foam material, and more preferably it is a block made of foam in the shape of a cuboid.

In another preferred embodiment, in the mattress layer according to invention said foam material is selected from latex foam, reticulated or flexible polyurethane foam (inter alia, standard or highly resilient or viscoelastic), preferably flame retardant foam, also preferably with the addition of biocomponents or with the addition of recycled, expanded polymer foam selected from expanded ethylene vinyl acetate, polypropylene, polystyrene or polyethylene. Preferably, the density of said foam material ranges from 15 kg/m ³ to 150 kg/m ³ , preferably it is 28 kg/m ³ . Also preferably, the hardness of the foam material ranges from 10 N to 400 N, preferably it is 150 N.

In a preferred embodiment, the spring component is a spring.

In a preferred embodiment, said strip is provided on two opposite rims of the mattress layer, wherein preferably each of said strips extends substantially along the entire length of the rim and is attached to the pockets of the mattress layer over the entire length of the rim. Also preferably, said strip is provided in the form of an individual strip on all rims of the mattress layer, in a preferred variant, each strip extends substantially along the entire extent of the rim on which said strip is provided, with the strips connected with one another at the corners of the mattress layer.

In another preferred variant of the solution according to the invention, the strip is provided in the shape of the letter C and attached to the pockets of three adjoining rims, preferably two C-shaped strips are provided with their extent covering substantially the entire extent of the rims of the mattress layer.

In another preferred embodiment of the invention, the strip is L-shaped and attached to the pockets of two adjacent rims. Preferably, two L-shaped strips are provided, extending substantially over the entire extent of the rim of the mattress layer.

In a preferred embodiment of the mattress layer according to the invention, the strip is attached to each of the pockets where the strip adjoins, and preferably also, the strip is provided on both sides of the mattress layer.

The invention also provides a mattress which comprises a mattress layer comprising a plurality of adjoining spring components, wherein each spring component is placed individually in a pocket of textile material and each pocket is connected to an adjacent pocket to form a web of spring components, the adjacent webs of spring components being connected one to another, the mattress according to the invention being characterized in that at least one textile strip is provided on at least one rim of said mattress layer and attached to at least two adjacent textile pockets.

In a preferred embodiment of the invention, in the mattress layer, the spring component is an elastic element made of foam material, and more preferably it is a block made of foam in the shape of a cuboid.

In another preferred embodiment, in the mattress layer according to the invention, said foam material is selected from latex foam, reticulated or flexible polyurethane foam (inter alia, standard or highly resilient or viscoelastic), preferably flame retardant foam, also preferably with the addition of biocomponents or with the addition of recycled, expanded polymer foam selected from expanded ethylene vinyl acetate, polypropylene, polystyrene or polyethylene. Preferably, the density of said foam material is from 15 kg/m ³ to 150 kg/m ³ , preferably it is 28 kg/m ³ . Also preferably, the hardness of the foam material is from 10 N to 400 N, preferably it is 150 N.

In a preferred embodiment, the spring component is a spring.

In a preferred embodiment, said strip is provided on two opposite rims of the mattress layer, preferably each of the strips extending substantially along the entire length of the rim and being attached to the pockets of the mattress layer over the entire length of the rim.

Also preferably, said strip is provided in the form of an individual strip on all rims of the mattress layer, in a preferred variant, each strip extends substantially along the entire extent of the rim on which said strip is provided, with the strips connected with one another at the corners of the mattress layer.

In another preferred variant of the solution according to the invention, the strip is provided in the shape of the letter C and is attached to the pockets of three adjoining rims, preferably two C-shaped strips are provided with their extent covering substantially the entire extent of the rims of the mattress layer.

In another preferred embodiment of the invention, the strip is L-shaped and attached to the pockets of two adjacent rims. Preferably, two L-shaped strips are provided, extending substantially over the entire extent of the rims of the mattress layer.

In a preferred embodiment of the mattress layer according to the invention, the strip is attached to each of the pockets to which the strip adjoins, and preferably also, the strip is provided on both sides of the mattress layer.

In a preferred embodiment of the mattress layer according to the invention, the strip is provided on both sides of the mattress layer.

Within the meaning of the invention, the mattress layer is formed by a plurality of spring components arranged next to each other (e.g. springs or foam blocks), wherein each spring component is placed individually in a pocket of textile material, and each pocket is connected to an adjacent pocket to form a web of spring components, wherein adjacent webs of spring components are connected one to another. In this way, a mattress layer is formed, the height (thickness) of which is determined the height of the spring components, and the length and width of the mattress layer is determined by the length and number of interconnected webs of spring components. Within the meaning of the invention, the rim of the mattress layer is to be understood as the end part of the surface of the mattress layer. The quadrangular mattress layer thus has four rims, one on each side of the layer. On its sides the mattress layer has two rims formed by one, and preferably two or more end webs of spring components, and two rims formed by end pockets of the joined together adjacent webs of spring components.

The subject of the invention is presented in more detail in the following description and in the drawing, in which:

Fig. 1 is a perspective view of a mattress layer in a preferred embodiment.

Fig. 2 is a top view of the mattress layer according to Fig. 1 .

Fig. 3 is a bottom view of the mattress layer according to Fig. 1 .

Fig. 4 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 5 is a top view of the mattress layer according to Fig. 4.

Fig. 6 is a bottom view of the mattress layer according to Fig. 4.

Fig. 7 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 8 is a top view of the mattress layer according to Fig. 7.

Fig. 9 is a bottom view of the mattress layer of Fig. 7.

Fig. 10 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 1 1 is a top view of the mattress layer according to Fig. 10.

Fig. 12 is a bottom view of the mattress layer of Fig. 10.

Fig. 13 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 14 is a top view of the mattress layer according to Fig. 13.

Fig. 15 is a bottom view of the mattress layer of Fig. 13.

Fig. 16 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 17 is a top view of the mattress layer of Fig. 16.

Fig. 18 is a bottom view of the mattress layer of Fig. 16. Fig. 19 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 20 is a top view of the mattress layer of Fig. 19.

Fig. 21 is a bottom view of the mattress layer of Fig. 19.

Fig. 22 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 23 is a top view of the mattress layer of Fig. 22.

Fig. 24 is a bottom view of the mattress layer of Fig. 22.

Fig. 25 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 26 is a top view of the mattress layer of Fig. 25.

Fig. 27 is a bottom view of the mattress layer of Fig. 25.

Fig. 28 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 29 is a top view of the mattress layer of Fig. 28.

Fig. 30 is a bottom view of the mattress layer of Fig. 28.

Fig. 31 is a perspective view of a mattress layer in another preferred embodiment.

Fig. 32 is a top view of the mattress layer of Fig. 31 .

Fig. 33 is a bottom view of the mattress layer of Fig. 31 .

All references in the figures showing various embodiments of the invention refer to the like elements of the mattress layer.

Fig. 1 shows an embodiment of a mattress layer 1 which comprises a plurality of adjoining spring components 2. Each spring component is placed individually in a pocket 3 of textile material. As shown in the drawing, each pocket is connected to an adjacent pocket to form a web 4 of spring components 2, adjacent webs of spring components being interconnected (not shown). A strip (5.5') made of textile material is provided on each of the rim of the mattress layer 1 . Each of the four aforementioned strips acts as a reinforcement of the rims of the mattress layer. The webs 4 shown in Fig. 1 are connected to each other by gluing at the point where the pockets of adjacent webs touch each other, and the connection of the webs can be carried out in a known manner by gluing, sewing, ultrasonic or thermal welding, stapling or stitching.

In the embodiment shown in Fig. 1 (as well as in the other embodiments described hereinafter), the webs are shown extending along the long side of the mattress layer. It is obvious to the person skilled in the art that it is possible to construct a mattress layer in which the webs run along the short side of the mattress layer, and such a solution is also an object of the invention.

The pockets 3 formed in the webs are configured in such a way that after placing the spring component 2 (which in the embodiments shown in Fig. 1 -27 is a spring in the pocket, and in the example in Fig. 31 -33 a foam block), there remains on all sides a certain amount of free space between the spring component 2 and the pocket 3.

As shown in Fig. 1 , the pocket 3 defines a closed space in which a spring component 2 in the form of a spring is contained. The pocket can be made of any type of textile material, preferably non-elastic, in the form of a woven or non-woven fabric, which can be combined to form a closed pocket. A preferred method of joining the edges of said textile material, e.g. to produce a pocket, is by welding the material together by applying heat and pressure, resulting in the desired shape of the pocket. Such welding methods are known in the art and include thermal or ultrasonic welding. The pocket can be produced in an analogous manner to the method of manufacturing the pocket for springs. Methods for making pockets for springs are well known to those skilled in the art of upholstered furniture. Suitable materials that may be used to form the pocket include thermoplastic fibers known in the art, such as polymer-based, polyester, or polypropylene nonwovens. When forming the pocket, its size is designed to allow a certain amount of free space that allows the spring component to move within the pocket during compression when pressure is applied to the pocket spring component.

As shown in Fig. 1 , on the four rims on one side of the mattress layer, there are provided strips (5, 5') of textile material, which act as reinforcement of the rims of the layer. Two strips 5 are attached to the two outermost pockets of all the webs 4 at both ends of the mattress layer, which means that the strips 5 are attached to all pockets of the rim where the reinforcement in the form of strips 5 is provided. Two strips 5' are attached to the pockets in the webs 4 over which webs 5 do not extend (i.e. which are not covered by the strips 5) and at its both ends the strip 5' is attached to the respective ends of the strips 5. As it is better seen in Fig. 2 and Fig. 3, the lengths of the strips 5' and 5, respectively a 'and a correspond to the lengths of the rims of the mattress layer to which the strips (5,5') have been attached, and the described connection of the strips 5 and 5' at the corners of the mattress layer 1 provides additional reinforcement to the corners of the mattress layer.

The joining of the strips (5,5') with the pockets 3 in the webs 4 can be carried out in a manner known in the art, e.g. by means of glue, in a mechanical manner using fasteners such as e.g. a staple, a pin. The joining can also take place by thermal or ultrasonic welding.

The tape can be made of any textile material that provides a reinforcing effect (for example: felt, rigid polyester needled non-woven fabric, flat polypropylene non-woven fabric, woven or knitted element). The preferred thickness of the strip depends on the type of textile material used and the terget degree of stiffening of the rims and may be in the range of 1 mm to 30 mm. Similarly, the width of the strips (5.5'), b and b', respectively, are adapted to the respective dimensions of the individual pockets and webs to which the strips are attached. Thus, in the embodiments shown in Figs. 2 and 3 of the drawing, the strips (5,5') have dimensions (a, a) corresponding to the dimensions of the respective rims of the mattress layer. In this case, the strips cover the entire length of the rims. On the other hand, the dimensions (b, b) of the strips (5.5') correspond to the dimensions of the pockets filled with an spring component (two pockets in the embodiments presented here).

Depending on the size of the pockets with the spring component, the dimensions of the strips can be adjusted accordingly, so as to ensure the desired stiffening of the rims. Thus, the strips may cover the entire extent of the rims (as in Figs 1 -3, for example), or substantially the entire extent of the rim (i.e. the length of the strips may be less than the length of the rim). Reinforcement of the rim can also be provided by providing the strip only in the portion of the rim where such reinforcement is desired, the strip then being attached to two or more adjacent pockets to which the strip adjoins. In the embodiment shown, the strips 5 and 5' are attached to all pockets to which the strip adjoins, and the reinforcement effect is provided along the whole of rims of the mattress layer. Figures 4-6 show an embodiment in which the strips, according to the arrangement provided in Fig 1 , are also placed on the underside of the mattress layer. In this embodiment, reinforcement is therefore provided at each rim of the mattress layer and at the corners of the mattress layer on both sides thereof.

Figures 7-9 show an embodiment of the invention in which four strips are provided, i.e. two strips 5 and two strips 5', wherein in this embodiment the dimension a of the strip 5 corresponds to the extent of the rim to which the strip 5 is attached while the strip 5' covers only the central part of the rim, i.e. the part which is not covered by the extension of the strips 5. In this embodiment, the strips 5 and 5' are attached to all pockets to which the strips adjoin, the strips 5 and 5' do not overlapping each other as in the earlier embodiments and are therefore not attached to each other at the corners of the material layer. In this embodiment, reinforcement of the rims is provided without additional stiffening of the corners by overlapping and connecting the strips 5 and 5'.

Figures 10-12 show an embodiment where the strips, according to the arrangement provided in Figure 6, are also placed on the underside of the mattress layer.

Figures 13-15 show an embodiment where on both sides of the mattress layer two strips 5 are provided on opposite rims of the layer, while Figures 16-18 show an analogous arrangement with two strips 5 placed only on one side of the mattress layer. In these embodiments, the strips 5 cover the entire rim of the layer. In these embodiments, the strips 5 are attached to the pockets transversely to the extension of the webs 4, stabilizing and reinforcing the rim of the mattress layer in that direction.

Figures 19-21 show an embodiment of a mattress layer in which strips 5' are provided on opposite rims of the mattress layer, while Figures 22-24 show an analogous arrangement where strips 5' are provided on rims on both sides of the material layer. In these embodiments, the strips 5' are attached to the pockets along the extension of the webs 4, stabilizing and reinforcing the rim of the mattress layer in that direction.

Figures 25-27 show an embodiment of a mattress layer in which the strips 6 are L-shaped. As shown in the drawing, this arrangement of the strips provides stiffening of the rims along their entire length, the arrangement also stabilizing the corners of the mattress layer. This arrangement can also be provided on both sides of the mattress layer (not shown). Figures 28-30 illustrate an embodiment of a mattress layer in which the strips 7 are C-shaped. As shown in the drawing, this arrangement of the strips provides stiffening of the rims along their entire length, the arrangement also stabilizing the corners of the mattress layer. This arrangement can be provided on both sides of the mattress layer (not shown).

Figures 31 -33 show the arrangement according to Fig. 1 , wherein in the shown embodiment, the spring component is in the form of a block of foam in the shape of a cuboid.

The solution according to the invention provides a simple, cheap and effective way to stiffen the rims of the mattress layer. A particular advantage is the ability to provide in a simple way different variants of stiffening the rim of the layer, depending on the requirements dictated by its intended use. By appropriate selection of the connection point and the number of strips reinforcing the rims, it is possible to control the stiffness parameters of the entire layer. Embodiments in which the strips at the corners of the mattress layer are connected to each other are particularly advantageous. This solution, in addition to the desired reinforcement of the rims of the layer, provides additional reinforcement of the corners and stabilization of the shape of the entire layer. Advantageous reinforcement of the corners is also provided by embodiments in which the reinforcement is provided in the form of substantially C-shaped or L-shaped strips.

Solution according to the invention is an effective, simpler and cheaper alternative to strengthening the rims of the mattress layer achieved by means of stiffer springs as used in the industry. At the same time, the solution according to invention significantly improves and stabilizes the shape of the corners, which become more filled and regular. Depending on the configuration of the strips used, the solution according to the invention makes it possible to provide different zones of comfort/firmness in the middle and outer parts of the mattress layer. Regardless of the above advantages, the production of the mattress layer proposed by the invention can be carried out at reduced production costs compared to the production of the known layer with a rim reinforced by the appropriate selection of the parameters of the rim springs.

The use of the mattress layer according to the invention in mattresses allows flexible configuration of the structure of the mattress layers or its core.