Ergonomic mattress

An ergonomic mattress is provided with a support layer; a foam layer disposed on a top of the support layer; a first comfort layer disposed on a top of the foam layer; and a second comfort layer disposed under the support layer. Alternatively, a latex layer is further disposed between the support layer and the foam layer.

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Description
BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to mattresses and more particularly to an ergonomic mattress.

2. Description of Related Art

People spent one third of time to stay on bed. Mattress is one of the appliances used at highest frequency and time during whole period of life. A mattress satisfying ergonomics will bring along permanent and healthy sleeping for people. The mattress brought along healthy sleeping for people involves in the following five factors: 1. keeping spine of human body naturally stretching; 2. keeping a maximum contract area of human body with the mattress to make the contracting part of human body with the mattress to bear the less resistance strength as possible; 3. The materials with which the mattress is made of are with low heat conduction rate, but a good heat preservation performance; 4. good permeability enabling skin of human body to satisfy demand for “breathing”; and 5. ensuring a good touch on the mattress when skin of human body contacts it. In the typical technology, mattress is made of sole material, and sole material is hard to satisfy all requirements for healthy sleeping from human body. This is because any one material has no way to enjoy equal supporting performance, proper deformation capability, excellent touch, heat preservation and permeability. In particular, equal supporting performance is a contradiction to proper deformation for mattress made of sole material. Good equal supporting performance means less deformation, but less deformation means fail for human body to keep a maximum contact area with the mattress causing an increased resistance strength of the mattress to the contact part of the human body, and some parts of the human body cannot get a good rest due to fail of effective support making people feel uncomfortable during or after sleeping. For different races, people are different in both of weight and body curves at various age groups. For example, comparing with Asian people at the same age group, Caucasian are heavier in weight and have larger unevenness in body curve, so they need better supporting and wrapping.

Most of the typical methods of manufacturing mattresses apply spring or plant fiber resilient material as core material of the mattress with an inlayer of sponge or other linings, and only a cloth cover made from different materials is used as a shield. The biggest drawback of manufacturing method of this kind of mattress rests on that no any relationship between resilience and thickness of different materials made of the mattress with spine of human body and physiological curve has been taken into consideration, meaning how to composite core materials to achieve minimum resistance loaded on part of human body contacting the mattress and to provide equal supporting for human body, and fail to take how to satisfy natural physiological curves of human body by adjusting resilience and thickness of different part of the mattress and thus to achieve healthy sleeping for human body into consideration either. Due to fail in taking the factors above, the mattress made by the typical method most probably fails in effectively relaxing muscle and organ of people during sleeping, and fails in satisfying the requirements for healthy sleeping.

Thus, the need for improvement still exists.

SUMMARY OF THE INVENTION

It is therefore one object of the invention to provide an ergonomic mattress. The mattress is made of materials enjoying proper deformation performance and good equal supporting capacity having overcome the limitation of sole material and satisfying requirements for human body at different age groups and healthy sleeping.

In one aspect of the invention an ergonomic mattress manufacturing method is provided. The mattress comprises support layer and foam layer. When manufacturing, it is to select resilience, thickness and density of the support layer based on weight of a sleeper. The support layer bears the weight of a sleeper. It is to select resilience, thickness and density of the foam layer, and the foam layer deforms to fit properly body curve of the sleeper.

In above ergonomic mattress manufacturing method:

range of the support layer for weight of a sleeper T≦15 kg is resilience of the support layer is 40-45%, thickness is 30-50 mm, and density is 120-135 kg/m3;

range of the support layer for weight of a sleeper 15 kg<T≦40 kg, resilience of the support layer is 38-43%, thickness is 50-70 mm, and density is 115-125 kg/m3;

range of the support layer for weight of a sleeper 40 kg<T≦70 kg, resilience of the support layer is 35-40%, thickness is 80-100 mm, and density is 110-120 kg/m3;

range of the support layer for weight of a sleeper 70 kg<T≦100 kg, resilience of the support layer is 40-45%, thickness is 110-130 mm, and density is 120-135 kg/m3; and

range of the support layer for weight of a sleeper 100 kg<T≦150 kg, resilience of the support layer is 40-45%, thickness is 140-160 mm, and density is 120-135 kg/m3;

In above ergonomic mattress manufacturing method:

range of the support layer for weight of a sleeper T≦15 kg, resilience of the support layer is 41-43%, thickness is 35-45 mm, and density is 125-130 kg/m3;

range of the support layer for weight of a sleeper 15 kg<T≦40 kg, resilience of the support layer is 40-42%, thickness is 55-65 mm, and density is 118-122 kg/m3;

range of the support layer for weight of a sleeper 40 kg<T≦70 kg, resilience of the support layer is 37-39%, thickness is 85-95 mm, and density is 112-118 kg/m3;

range of the support layer for weight of a sleeper 70 kg<T≦100 kg, resilience of the support layer is 41-43%, thickness is 115-125 mm, and density is 125-130 kg/m3; and

range of the support layer for weight of a sleeper 100 kg<T≦150 kg, resilience of the support layer is 40-42%, thickness is 145-155 mm, and density is 125-130 kg/m3;

In above ergonomic mattress manufacturing method:

range of the foam layer for 10 mm<unevenness of a sleeper's body curve L≦20 mm, resilience of the foam layer is 25-30%, thickness is 25-30 mm, and density is 70-80 kg/m3;

range of the foam layer for 10 mm<unevenness of a sleeper's body curve 20 mm<L≦35 mm, resilience of the foam layer is 22-25%, thickness is 40-50 mm, and density is 65-70 kg/m3;

range of the foam layer for 10 mm<unevenness of a sleeper's body curve 35 mm<L≦50 mm, resilience of the foam layer is 18-23%, thickness is 60-75 mm, and density is 60-65 kg/m3; and

range of the foam layer for 10 mm<unevenness of a sleeper's body curve 50 mm<L≦80 mm, resilience of the foam layer is 15-20%, thickness is 80-100 mm, and density is 55-60 kg/m3;

In above ergonomic mattress manufacturing method:

range of the foam layer is 10 mm<unevenness of a sleeper's body curve L≦20 mm, resilience of the foam layer is 26-28%, thickness is 26-28 mm, and density is 72-78 kg/m3;

range of the foam layer is 10 mm<unevenness of a sleeper's body curve 20 mm<L≦35 mm, resilience of the foam layer is 23-24%, thickness is 43-48 mm, and density is 66-68 kg/m3;

range of the foam layer is 10 mm<unevenness of a sleeper's body curve 35 mm<L≦50 mm, resilience of the foam layer is 19-21%, thickness is 65-70 mm, and density is 61-63 kg/m3; and

range of the foam layer is 10 mm<unevenness of a sleeper's body curve 50 mm<L≦80 mm, resilience of the foam layer is 17-19%, thickness is 85-95 mm, and density is 56-58 kg/m3.

In above ergonomic mattress manufacturing method, the support layer and foam layer are equipped with comfort layer. Resilience of comfort layer is 15-20%, thickness is 10-20 mm, and density is 50-60 kg/m3.

In above ergonomic mattress manufacturing method, resilience of the comfort layer is 16-18, thickness is 12-18 mm, and density is 50-60 kg/m3.

It is envisaged by the invention to design and manufacture a mattress satisfying sleepers based on body condition. The mattress of the invention is comprised of three layers: the support layer is required to have function of equal supporting, and proper deformation capacity under certain pressure as well, so as to achieve sufficient support to human body and makes human body comfortable; the foam layer needs larger deformation to absorb part of the pressure from human body and transmits pressure of human body to the support layer by the foam layer. By way of overlaying and combining the materials with different deformation capacities, the various materials will play various functions during sleeping: supporting, releasing (dispersing pressure), permeability, heat preservation, and good touch. After test by the inventor, the support layer, foam layer and comfort layer should have different deformation capacities, and among all them all, deformation capacity of support layer is smallest, the foam layer is bigger, and the comfort layer is the biggest. During sleeping, spine of all people shows a curve, and a good mattress will keep the spine in a state of natural stretching free of compression, squeezed and distortion. The support layer will provide good equal supporting performance, the foam layer provides proper deformation capacity, and integration of them two will keep a maximum contacting area of human body with the mattress; the comfort layer of the mattress made of shell fabric enjoying good permeability, heat preservation and touch will satisfy the requirements of human body for permeability, heat preservation and touch to the mattress.

The invention comprises the foam layer with proper deformation capacity with the support layer with good equal supporting performance, and thus has overcome the limitation of sole material and satisfied two factors of factor 1 and 2 relating to healthy sleeping. The remained three factors of factor 3, 4 and 5 relating to healthy sleeping use shell fabric featuring good touch, heat preservation, permeability and large deformation to composite and manufacture the comfort layer contacting human body and to satisfy requirements for comfort from skin of human body. The foam layer can ensure a maximum contact area of the comfort layer with human body to disperse pressure from human body to eh larger area as possible. The pressure of human body is transmitted to the foam layer by deformation of the comfort layer, deformation volume of the foam layer is less than that of the comfort layer. After deformation, the foam layer keeps the body curve in a basic and natural stretching state during sleeping and disperses body pressure to a larger area by transmission between the foam layers. Finally, due to the bottom layer (support layer) made of materials with the largest resistance strength, the body pressure from the middle layer (foam layer) will cause slight deformation of the bottom layer (support layer). Therefore, with the precondition of ensuring good supporting to body pressure, the mattress further increases a degree of comfort for human body during sleeping and ensures spine and curve of human body in a state of natural stretching.

By adjusting thickness and resilience of the support layer, foam layer and heat preservation comfort layer, the mattress of the invention shall satisfy various demands for mattress from group of people in various races and at age groups during various developmental stages: e.g. infant mattress, youngster mattress, adult mattress and middle-aged and senior people mattress. Such a structure ensures to keep spine curve of human body in a state of natural stretching during sleeping, and ensures a perfect fit of the mattress with body curve to achieve a healthy sleeping.

The inventors keep making research on healthy, natural and scientific sleep for long-term, serves as inventor, creator and pacemaker of plant fiber mattress in China, and is a professional company integrating with production, marketing and R&D. After years' production and R&D, the company has concluded relationship between weight of a sleeper, body curve with density and resilience of mattress support layer and foam layer. Aiming at various sleepers, the company is able to provide mattress suitable for them all. Wherein, unevenness of body curve is measured by way of: the human body lays on a platform free of distortion with face up in an ease form and tries to keep a natural contact with the platform. The height difference measured from peak point of buttocks to the lowest point of waist is the body curve unevenness. Due to different body curve of each sleeper, shape of the spine when lying on a bed shall vary form each other. For example, when the adults are at weight respectively of 50 kg and 100 kg, the person at weight of 100 kg should select the support layer at larger thickness and resilience for better supporting effect. Because the latter is larger in weight, thicker in fat, has a fat waist and buttocks, and thus has a larger unevenness of body curve. When lying with face up, the spine will be caused seriously distorted. Therefore, thickness of the foam layer to be selected should be larger than curve unevenness of the body to sleep, and it is to select resilience of the foam layer based on weight. Only by this way can have body better wrapped to keep the spine straight and stretched; and thus the whole body will be thoroughly relaxed.

Function of the support layer at different thickness and resilience lies in providing equal supporting and heat preservation for human body, and keeps the spine in a state of natural stretching. Function of the foam layer at different thickness and resilience lies in ensuring natural curve of body shape, reduces contacting part of human body with the mattress for less resistance strength making muscles, tissues and organs effectively relaxed. Function of the comfort layer at different thickness and resilience lies in further strengthening the function of the foam layer and plays the function of permeability, heat preservation and good touch. There is no inevitable relationship between thickness and resilience, but the resilience enjoys certain relationship with density. Those with larger density are with larger resilience, and vice-versa.

Based on experiences collected and concluded during long-term production and over one thousand cases of test, the inventor has accumulated abundant original data. After making scientific analysis, induction and reorganization, the inventor finally succeeded in obtaining the optimized parameter combination for different weight and different body curves. Because the comfort layer has only the auxiliary function of foam layer wrapping, it main function includes permeability, heat preservation and provides good touch for human body. Therefore, all tests are made with the comfort layer made of materials at resilience of 20%, thickness of 10 mm and density of 60 kg/m3.

Exemplary Test 1:

Regarding support layer: Resilience is 45%, thickness is 40 mm, and density is 120 kg/m3;

Regarding foam layer: Resilience is 25%, thickness is 30 mm, and density is 70 kg/m3;

Regarding weight of a sleeper being 14 kg and body curve unevenness being 16 mm: The spine keeps a natural stretching, body curve properly fits the mattress, and the mattress provides equal support;

Regarding weight of a sleeper being 33 kg and body curve unevenness being 26 mm: The spine keeps a natural stretching, three is a small gap between body curve and the mattress, and there is a strong sense of conflicting for the part of body contacting the mattress; and

Regarding weight of a sleeper being 51 kg and body curve unevenness being 40 mm: The spine distorts due to compression, muscle fails to relax and normal sleeping cannot be achieved.

Exemplary Test 2:

Regarding support layer: Resilience is 40%, thickness is 60 mm, and density is 115 kg/m3;

Regarding foam layer: Resilience is 30%, thickness is 40 mm, and density is 65 kg/m3;

Regarding weight of a sleeper being 9 kg and body curve unevenness being 15 mm: The Spine curve slightly changes, body curve properly fits the mattress;

Regarding weight of a sleeper being 38 kg and body curve unevenness being 32 mm: The spine keeps a natural stretching, body curve properly fits the mattress, and the mattress provides equal support;

Regarding weight of a sleeper being 64 kg and body curve unevenness being 45 mm: The spine keeps a natural stretching, there is a small gap between body curve and the mattress, and there is a strong sense of conflicting for the part of body contacting the mattress; and

Regarding weight of a sleeper being 80 kg and body curve unevenness being 57 mm: The spine distorts due to compression, muscle fails to relax and normal sleeping cannot be achieved.

Exemplary Test 3:

Regarding support layer: Resilience is 41%, thickness is 90 mm, and density is 120 kg/m3;

Regarding foam layer: Resilience is 21%, thickness is 55 mm, and density is 65 kg/m3;

Regarding weight of a sleeper being 11 kg and body curve unevenness being 13 mm: The spine curve slightly changes, body curve properly fits the mattress;

Regarding weight of a sleeper being 42 kg and body curve unevenness being 25 mm: The spine curve slightly changes, body curve properly fits the mattress, and the mattress provides equal support;

Regarding weight of a sleeper being 58 kg and body curve unevenness being 48 mm: The spine keeps a natural stretching, body curve properly fits the mattress, and the mattress provides equal support; and

Regarding weight of a sleeper being 91 kg and body curve unevenness being 60 mm: The spine slightly distorts due to compression, there is a strong sense of conflicting for the part of body contacting the mattress.

Exemplary Test 4:

Regarding support layer: Resilience is 42%, thickness is 120 mm, and density is 130 kg/m3;

Regarding foam layer: Resilience is 20%, thickness is 80 mm, and density is 60 kg/m3;

Regarding weight of a sleeper being 32 kg and body curve unevenness being 18 mm: The Spine curve seriously changes, body curve closely fits the mattress, but there is no equal support;

Regarding weight of a sleeper being 65 kg and body curve unevenness being 45 mm: The spine curve slightly changes, body curve properly fits the mattress, and the mattress provides equal support; and

Regarding weight of a sleeper being 93 kg and body curve unevenness being 62 mm: The spine keeps a natural stretching, body curve properly fits the mattress, and the mattress provides equal support.

Exemplary Test 5:

Regarding support layer: Resilience is 45%, thickness is 150 mm, and density is 131 kg/m3;

Regarding foam layer: Resilience is 18%, thickness is 90 mm, and density is 60 kg/m3;

Regarding weight of a sleeper being 10 kg and body curve unevenness being 16 mm: The Spine curve seriously changes, body curve closely fits the mattress, but there is no equal support;

Regarding weight of a sleeper being 41 kg and body curve unevenness being 28 mm: The spine curve slightly changes, body curve properly fits the mattress, and the mattress provides equal support;

Regarding weight of a sleeper being 90 kg and body curve unevenness being 59 mm: The spine keeps a natural stretching, body curve closely fits the mattress, but there is no equal support; and

Regarding weight of a sleeper being 130 kg and body curve unevenness being 67 mm: The spine keeps a natural stretching, body curve properly fits the mattress, and the mattress provides equal support.

Exemplary Test 6:

Regarding support layer: Resilience is 45%, thickness is 120 mm, and density is 130 kg/m3;

Regarding foam layer: Resilience is 30%, thickness is 60 mm, and density is 65 kg/m3;

Regarding weight of a sleeper being 14 kg and body curve unevenness being 17 mm: The spine curve seriously changes, body curve closely fits the mattress;

Regarding weight of a sleeper being 31 kg and body curve unevenness being 22 mm: The spine curve slightly changes, body curve properly fits the mattress, and the mattress provides equal support;

Regarding weight of a sleeper being 50 kg and body curve unevenness being 41 mm: The spine keeps a natural stretching, body curve closely fits the mattress, but mattress provides equal support; and

Regarding weight of a sleeper being 90 kg and body curve unevenness being 55 mm: The spine keeps a natural stretching, there is small gap between body curve and the mattress, and there is a sense of conflicting for part of body contacting the mattress.

From information above, we can know that the mattress of the invention is no more classified simply for sleeper as adult, youngster and infant, but the mattress with various kinds of support layer and foam layer parameters. When purchasing the mattress, the buyer makes no more blind selection based on age and individual experiences. It is to provide a reasonable parameter range for support layer and foam layer of the mattress based on measured weight of each sleeper and body curve unevenness. And then to have the sleeper personally feel it and to select the mattress personally feeling comfortable and beloved by sleeper within the given parameter range. Comparing with the existing technology, the mattress of the invention made after compositing materials with different resiliencies based on the two parameters of body physiological curve and weight satisfies individualized demand, and can provide effective support to human body during sleeping and ensure sufficient sleeping for human body from muscle to organ. Suck kind of design can scientifically provide uncommon mattress to all individuals to satisfy individualized demand for all of them.

The above and other objects, features and advantages of the invention will become apparent from the following detailed description taken with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal sectional view of an ergonomic mattress according to a first preferred embodiment the invention; and

FIG. 2 is a longitudinal sectional view of an ergonomic mattress according to a second preferred embodiment the invention.

 DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an ergonomic mattress in accordance with a first preferred embodiment of the invention comprises the following components as discussed in detail below.

An ergonomic mattress comprises from bottom to top a first comfort layer 4, a support layer 1, a foam layer 2, and a second comfort layer 4. When manufacturing, it is to select resilience, thickness and density of the support layer 1 based on weight of a sleeper. The support layer 1 bears the weight of a sleeper. It is to select resilience, thickness and density of the foam layer 2 based on body curve unevenness of the sleeper, and the foam layer 2 deforms to fit properly body curve of the sleeper.

After tests, the range of support layer 1 can achieve the effect of the invention.

Weight of a sleeper T≦15 kg, resilience of the support layer 1 is 40-45%, thickness is 30-50 mm, and density is 120-135 kg/m3;

Weight of a sleeper 15 kg<T≦40 kg, resilience of the support layer 1 is 38-43%, thickness is 50-70 mm, and density is 115-125 kg/m3;

Weight of a sleeper 40 kg<T≦70 kg, resilience of the support layer 1 is 35-40%, thickness is 80-100 mm, and density is 110-120 kg/m3;

Weight of a sleeper 70 kg<T≦100 kg, resilience of the support layer 1 is 40-45%, thickness is 110-130 mm, and density is 120-135 kg/m3;

Weight of a sleeper 100 kg<T≦150 kg, resilience of the support layer 1 is 40-45%, thickness is 140-160 mm, and density is 120-135 kg/m3.

Range of foam layer 2 is as below:

10 mm<unevenness of a sleeper's body curve L≦20 mm, resilience of the foam layer 2 is 25-30%, thickness is 25-30 mm, and density is 70-80 kg/m3;

20 mm<L≦35 mm, resilience of the foam layer 2 is 22-25%, thickness is 40-50 mm, and density is 65-70 kg/m3;

35 mm<L≦50 mm, resilience of the foam layer 2 is 18-23%, thickness is 60-75 mm, and density is 60-65 kg/m3; and

50 mm<L≦80 mm, resilience of the foam layer 2 is 15-20%, thickness is 80-100 mm, and density is 55-60 kg/m3.

The support layer 1 and the foam layer 2 are equipped with first and second comfort layers 4. Resilience of each of the first and second comfort layers 4 is 15-20%, thickness is 10-20 mm, and density is 50-60 kg/m3.

Referring to FIG. 2, an ergonomic mattress in accordance with a second preferred embodiment of the invention is shown. The characteristics of the second preferred embodiment are substantially the same as that of the first preferred embodiment except the following: For preventing displacement of the mattress during using, a latex layer 3 is provided between the support layer 1 and the foam layer 2.

Alternatively, in an ergonomic mattress manufacturing method the mattress comprises from bottom to top a first comfort layer 4, a support layer 1, a latex layer 3, a foam layer 2, and a second comfort layer 4. When manufacturing, it is to select resilience, thickness and density of the support layer 1 based on weight of a sleeper. The support layer 1 bears the weight of a sleeper. It is to select resilience, thickness and density of the foam layer 2 based on body curve unevenness of the sleeper, and the foam layer 2 deforms to fit properly body curve of the sleeper.

Wherein, preferred range of the support layer 1 is as below:

Weight of a sleeper T≦15 kg, resilience of the support layer 1 is 41-43%, thickness is 35-45 mm, and density is 125-130 kg/m3;

Weight of a sleeper 15 kg<T≦40 kg, resilience of the support layer 1 is 40-42%, thickness is 55-65 mm, and density is 118-122 kg/m3;

Weight of a sleeper 40 kg<T≦70 kg, resilience of the support layer 1 is 37-39%, thickness is 85-95 mm, and density is 112-118 kg/m3;

Weight of a sleeper 70 kg<T≦100 kg, resilience of the support layer 1 is 41-43%, thickness is 115-125 mm, and density is 125-130 kg/m3; and

Weight of a sleeper 100 kg<T≦150 kg, resilience of the support layer 1 is 40-42%, thickness is 145-155 mm, and density is 125-130 kg/m3.

Preferred range of the foam layer 2 is as below:

10 mm<unevenness of a sleeper's body curve L≦20 mm, resilience of the foam layer 2 is 26-28%, thickness is 26-28 mm, and density is 72-78 kg/m3;

20 mm<L≦35 mm, resilience of the foam layer 2 is 23-24%, thickness is 43-48 mm, and density is 66-68 kg/m3;

35 mm<L≦50 mm, resilience of the foam layer 2 is 19-21%, thickness is 65-70 mm, and density is 61-63 kg/m3; and

50 mm<L≦80 mm, resilience of the foam layer 2 is 17-19%, thickness is 85-95 mm, and density is 56-58 kg/m3.

The support layer 1 and the foam layer 2 are equipped with first and second comfort layers 4. Resilience of each of the first and second comfort layers 4 is 16-18%, thickness is 12-18 mm, and density is 52-58 kg/m3.

Still alternatively, in an ergonomic mattress manufacturing method the mattress comprises from bottom to top a first comfort layer 4, a support layer 1, a latex layer 3, a foam layer 2, and a second comfort layer 4. When manufacturing, it is to select resilience, thickness and density of the support layer 1 based on weight of a sleeper. The support layer 1 bears the weight of a sleeper. It is to select resilience, thickness and density of the foam layer 2 based on body curve unevenness of the sleeper, and the foam layer 2 deforms to fit properly body curve of the sleeper.

After tests, the range of the support layer 1 can achieve the effect of the invention.

Weight of a sleeper T≦15 kg, resilience of the support layer 1 is 42%, thickness is 40 mm, and density is 128 kg/m3;

Weight of a sleeper 15 kg<T≦40 kg, resilience of the support layer 1 is 41%, thickness is 60 mm, and density is 120 kg/m3;

Weight of a sleeper 40 kg<T≦70 kg, resilience of the support layer 1 is 37%, thickness is 90 mm, and density is 115 kg/m3;

Weight of a sleeper 70 kg<T≦100 kg, resilience of the support layer 1 is 42%, thickness is 120 mm, and density is 125 kg/m3; and

Weight of a sleeper 100 kg<T≦150 kg, resilience of the support layer 1 is 42%, thickness is 150 mm, and density is 130 kg/m3.

Range of the foam layer 2 is as below:

10 mm<unevenness of a sleeper's body curve L≦20 mm, resilience of the foam layer 2 is 27%, thickness is 27 mm, and density is 75 kg/m3;

20 mm<L≦35 mm, resilience of the foam layer 2 is 23%, thickness is 45 mm, and density is 67 kg/m3;

35 mm<L≦50 mm, resilience of the foam layer 2 is 20%, thickness is 67 mm, and density is 62 kg/m3; and

50 mm<L≦80 mm, resilience of the foam layer 2 is 17%, thickness is 90 mm, and density is 57 kg/m3.

The support layer 1 and the foam layer 2 are equipped with first and second comfort layers 4. Resilience of each of the first and second comfort layers 4 is 17%, thickness is 15 mm, and density is 55 kg/m3.

Still alternatively, in an ergonomic mattress manufacturing method the mattress comprises from bottom to top a first comfort layer 4, a support layer 1, a latex layer 3, a foam layer 2, and a second comfort layer 4. When manufacturing, it is to select resilience, thickness and density of the support layer 1 based on weight of a sleeper. The support layer 1 bears the weight of a sleeper. It is to select resilience, thickness and density of the foam layer 2 based on body curve unevenness of the sleeper, and the foam layer 2 deforms to fit properly body curve of the sleeper. After tests, the range of support layer 1 can achieve the effect of the invention.

Weight of a sleeper T≦15 kg, resilience of the support layer 1 is 43%, thickness is 62 mm, and density is 121 kg/m3;

Weight of a sleeper 15 kg<T≦40 kg, resilience of the support layer 1 is 41%, thickness is 62 mm, and density is 121 kg/m3;

Weight of a sleeper 40 kg<T≦70 kg, resilience of the support layer 1 is 38%, thickness is 88 mm, and density is 117 kg/m3;

Weight of a sleeper 70 kg<T≦100 kg, resilience of the support layer 1 is 41%, thickness is 122 mm, and density is 128 kg/m3; and

Weight of a sleeper 100 kg<T≦150 kg, resilience of the support layer 1 is 42%, thickness is 153 mm, and density is 127 kg/m3.

Range of the foam layer 2 is as below:

10 mm<unevenness of a sleeper's body curve L≦20 mm, resilience of the foam layer 2 is 28%, thickness is 28 mm, and density is 73 kg/m3;

20 mm<L≦35 mm, resilience of the foam layer 2 is 24%, thickness is 46 mm, and density is 68 kg/m3;

35 mm<L≦50 mm, resilience of the foam layer 2 is 21%, thickness is 66 mm, and density is 61 kg/m3; and

50 mm<L≦80 mm, resilience of the foam layer 2 is 18%, thickness is 92 mm, and density is 56 kg/m3.

The support layer 1 and the foam layer 2 are equipped with first and second comfort layers 4. Resilience of each of the first and second comfort layers 4 is 17%, thickness is 16 mm, and density is 53 kg/m3.

While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims.

Claims

1. An ergonomic mattress comprising:

a support layer;
a foam layer disposed on a top of the support layer;
a first comfort layer disposed on a top of the foam layer; and
a second comfort layer disposed under the support layer.

2. The ergonomic mattress of claim 1, wherein a range of the support layer for: weight of a sleeper≦15 kg, resilience is 40-45%, thickness is 30-50 mm, and density is 120-135 kg/m3; 15 kg<weight of a sleeper≦40 kg, resilience is 38-43%, thickness is 50-70 mm, and density is 115-125 kg/m3; 40 kg<weight of a sleeper≦70 kg, resilience is 35-40%, thickness is 80-100 mm, and density is 110-120 kg/m3; 70 kg<weight of a sleeper≦100 kg, resilience is 40-45%, thickness is 110-130 mm, and density is 120-135 kg/m3; and 100 kg<weight of a sleeper≦150 kg, resilience is 40-45%, thickness is 140-160 mm, and density is 120-135 kg/m3.

3. The ergonomic mattress of claim 1, wherein a range of the support layer for: weight of a sleeper≦15 kg, resilience is 41-43%, thickness is 35-45 mm, and density is 125-130 kg/m3; 15 kg<weight of a sleeper≦40 kg, resilience is 40-42%, thickness is 55-65 mm, and density is 118-122 kg/m3; 40 kg<weight of a sleeper≦70 kg, resilience is 37-39%, thickness is 85-95 mm, and density is 112-118 kg/m3; 70 kg<weight of a sleeper≦100 kg, resilience is 41-43%, thickness is 115-125 mm, and density is 125-130 kg/m3; and 100 kg<weight of a sleeper≦150 kg, resilience is 40-42%, thickness is 145-155 mm, and density is 125-130 kg/m3.

4. The ergonomic mattress of claim 1, wherein a range of the foam layer for: 10 mm<unevenness of a sleeper's body curve≦20 mm, resilience is 25-30%, thickness is 25-30 mm, and density is 70-80 kg/m3; 20 mm<unevenness of a sleeper's body curve≦35 mm, resilience is 22-25%, thickness is 40-50 mm, and density is 65-70 kg/m3; 35 mm<unevenness of a sleeper's body curve≦50 mm, resilience is 18-23%, thickness is 60-75 mm, and density is 60-65 kg/m3; and 50 mm<unevenness of a sleeper's body curve≦80 mm, resilience is 15-20%, thickness is 80-100 mm, and density is 55-60 kg/m3.

5. The ergonomic mattress of claim 1, wherein a range of the foam layer for: 10 mm<unevenness of a sleeper's body curve≦20 mm, resilience is 26-28%, thickness is 26-28 mm, and density is 72-78 kg/m3; 20 mm<unevenness of a sleeper's body curve≦35 mm, resilience is 23-24%, thickness is 43-48 mm, and density is 66-68 kg/m3; 35 mm<unevenness of a sleeper's body curve≦50 mm, resilience is 19-21%, thickness is 65-70 mm, and density is 61-63 kg/m3; and 50 mm<unevenness of a sleeper's body curve≦80 mm, resilience is 17-19%, thickness is 85-95 mm, and density is 56-58 kg/m3.

6. The ergonomic mattress of claim 1, wherein each of the first and second comfort layers have resilience of 15-20%, thickness of 10-20 mm, and density of 50-60 kg/m3.

7. The ergonomic mattress of claim 1, wherein each of the first and second comfort layers have resilience of 16-18%, thickness of 12-18 mm, and density of 50-60 kg/m3.

8. An ergonomic mattress comprising:

a latex layer;
a support layer disposed under the latex layer;
a foam layer disposed on a top of the latex layer;
a first comfort layer disposed on a top of the foam layer; and
a second comfort layer disposed under the support layer.

9. The ergonomic mattress of claim 8, wherein a range of the support layer for: weight of a sleeper 15 kg, resilience is 40-45%, thickness is 30-50 mm, and density is 120-135 kg/m3; 15 kg<weight of a sleeper≦40 kg, resilience is 38-43%, thickness is 50-70 mm, and density is 115-125 kg/m3; 40 kg<weight of a sleeper≦70 kg, resilience is 35-40%, thickness is 80-100 mm, and density is 110-120 kg/m3; 70 kg<weight of a sleeper≦100 kg, resilience is 40-45%, thickness is 110-130 mm, and density is 120-135 kg/m3; and 100 kg<weight of a sleeper≦150 kg, resilience is 40-45%, thickness is 140-160 mm, and density is 120-135 kg/m3.

10. The ergonomic mattress of claim 8, wherein a range of the support layer for: weight of a sleeper≦15 kg, resilience is 41-43%, thickness is 35-45 mm, and density is 125-130 kg/m3; 15 kg<weight of a sleeper≦40 kg, resilience is 40-42%, thickness is 55-65 mm, and density is 118-122 kg/m3; 40 kg<weight of a sleeper≦70 kg, resilience is 37-39%, thickness is 85-95 mm, and density is 112-118 kg/m3; 70 kg<weight of a sleeper≦100 kg, resilience is 41-43%, thickness is 115-125 mm, and density is 125-130 kg/m3; and 100 kg<weight of a sleeper≦150 kg, resilience is 40-42%, thickness is 145-155 mm, and density is 125-130 kg/m3.

11. The ergonomic mattress of claim 8, wherein a range of the foam layer for: 10 mm<unevenness of a sleeper's body curve≦20 mm, resilience is 25-30%, thickness is 25-30 mm, and density is 70-80 kg/m3; 20 mm<unevenness of a sleeper's body curve≦35 mm, resilience is 22-25%, thickness is 40-50 mm, and density is 65-70 kg/m3; 35 mm<unevenness of a sleeper's body curve≦50 mm, resilience is 18-23%, thickness is 60-75 mm, and density is 60-65 kg/m3; and 50 mm<unevenness of a sleeper's body curve≦80 mm, resilience is 15-20%, thickness is 80-100 mm, and density is 55-60 kg/m3.

12. The ergonomic mattress of claim 8, wherein a range of the foam layer for: 10 mm<unevenness of a sleeper's body curve≦20 mm, resilience is 26-28%, thickness is 26-28 mm, and density is 72-78 kg/m3; 20 mm<unevenness of a sleeper's body curve≦35 mm, resilience is 23-24%, thickness is 43-48 mm, and density is 66-68 kg/m3; 35 mm<unevenness of a sleeper's body curve≦50 mm, resilience is 19-21%, thickness is 65-70 mm, and density is 61-63 kg/m3; and 50 mm<unevenness of a sleeper's body curve≦80 mm, resilience is 17-19%, thickness is 85-95 mm, and density is 56-58 kg/m3.

13. The ergonomic mattress of claim 8, wherein each of the first and second comfort layers have resilience of 15-20%, thickness of 10-20 mm, and density of 50-60 kg/m3.

14. The ergonomic mattress of claim 8, wherein each of the first and second comfort layers have resilience of 16-18%, thickness of 12-18 mm, and density of 50-60 kg/m3.

Patent History
Publication number: 20140115791
Type: Application
Filed: Sep 18, 2013
Publication Date: May 1, 2014
Applicant: Guizhou Daziran Technology Co., Ltd (Guiyang City)
Inventors: Zongyong Chen (Guiyang City), Yuqian Li (Guiyang City), Jian Lin (Guiyang City), Tangqing Zhang (Guiyang City), Xiaobing Shi (Guiyang City), Zhenglie Dai (Guiyang City)
Application Number: 14/029,837
Classifications
Current U.S. Class: With Unusual Foam Material Or Configuration (5/740)
International Classification: A47C 27/15 (20060101);