EP1400191B1 - Perforation device for a mattress layer - Google Patents
Perforation device for a mattress layer Download PDFInfo
- Publication number
- EP1400191B1 EP1400191B1 EP03076480A EP03076480A EP1400191B1 EP 1400191 B1 EP1400191 B1 EP 1400191B1 EP 03076480 A EP03076480 A EP 03076480A EP 03076480 A EP03076480 A EP 03076480A EP 1400191 B1 EP1400191 B1 EP 1400191B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- mattress
- layer
- perforations
- zones
- latex foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 229920001821 foam rubber Polymers 0.000 claims description 19
- 210000004243 sweat Anatomy 0.000 claims description 4
- 210000000689 upper leg Anatomy 0.000 claims description 3
- 238000010276 construction Methods 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 9
- 239000007787 solid Substances 0.000 abstract description 7
- 239000010410 layer Substances 0.000 description 49
- 238000004080 punching Methods 0.000 description 15
- 239000011159 matrix material Substances 0.000 description 10
- 239000000463 material Substances 0.000 description 6
- 238000009423 ventilation Methods 0.000 description 6
- 239000004411 aluminium Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 239000004816 latex Substances 0.000 description 4
- 229920000126 latex Polymers 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 229940084434 fungoid Drugs 0.000 description 3
- 239000007795 chemical reaction product Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 210000001124 body fluid Anatomy 0.000 description 1
- 230000037396 body weight Effects 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 235000000396 iron Nutrition 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000004073 vulcanization Methods 0.000 description 1
- 235000012773 waffles Nutrition 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/146—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/26—Means for mounting or adjusting the cutting member; Means for adjusting the stroke of the cutting member
- B26D7/2614—Means for mounting the cutting member
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/0084—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor specially adapted for perforating rubber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/02—Perforating by punching, e.g. with relatively-reciprocating punch and bed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/02—Perforating by punching, e.g. with relatively-reciprocating punch and bed
- B26F1/14—Punching tools; Punching dies
Definitions
- the present invention relates to an upper mattress made of latex foam.
- U.S. patent application No. 5,327,597 relates to a foam mattress pad having a bottom surface, a convoluted top surface and apertures extending through the pad randomly placed in relation to the convoluted pattern of the top surface.
- the convoluted top surface of the pad comprises a repeating pattern of peaks and troughs wherein at least two peaks are in proximity to each other without a valley therebetween adjacent the same number of proximate valleys without a peak therebetween.
- German Offenlegungsschrift 34 10 603 relates to a mattress, mattress pad or the like, which is divided into a plurality of zones of varying resilience or hardness so that the shoulder and hip areas can sink in deeper in order to keep the spine in its natural straight position and avoid stress on the spine.
- perforations in the mattress layer can enhance the comfort of the person lying on the mattress and improve the moisture discharge of the mattress, in which connection it can be mentioned in particular that people on average secrete up to 1 litre of sweat a night while sleeping. Said moisture is discharged into the surrounding atmosphere as a result of a good ventilation of the mattress, which in itself makes the mattress feel drier, which in turn enhances the sleeping comfort of the user of the mattress. If a moist mattress is insufficiently provided with moisture-discharging means, the mattress will be susceptible to fungoid growth. The provision of additional ventilation in the mattress gives the mattress a higher sense of comfort, and in addition ensures a longer life of the mattress. Furthermore it is known in that people make frequent movements while sleeping, and the shifts in the body weight on the mattress produce a so-called pumping movement, which in turn leads to a satisfactory ventilation and transmit of the moisture.
- the aforesaid perforations are usually provided according to a specific matrix pattern in the mattress layer, either over the entire surface area of the mattress layer or only in specific zones, after the latex layer has been formed.
- Latex foam of itself has a unique open cell structure, which means that millions of microscopically small interconnected air bubbles in the latex foam provide a good ventilating effect.
- moulding elements such as waffle irons are used, with latex foam being poured into a closed mould provided with aluminium pins to ensure a good heat conduction, and subsequently being vulcanised, washed and dried into an end product.
- the mattress the end product
- the mattress comprises vertical, continuous recesses that ensure a proper ventilation of the mattress.
- mattresses having a thickness of up to 20 cm can be produced, with the thickness mainly being limited by the speed at which the heat can be introduced into the core of the latex material.
- the second method for producing latex foam according to the well-known Dunlop process is the pouring of latex foam on an endless conveyor belt, followed by vulcanisation, washing and finally drying.
- the maximum height of the mattress built up of latex foam is approximately 5 cm, because heat cannot be introduced into the core of the latex material sufficiently quickly due to the absence of aluminium pins on the conveyor belt.
- the latex plate that is obtained does not have any vertical, continuous channels.
- the mattress plate is provided with perforations.
- the devices for providing such perforations consist of a punch with punching pins arranged in a specific matrix pattern on a punching block and being positioned opposite a piercing die with holes being arranged in the same matrix pattern, in line with the aforesaid punching pins.
- the piercing die consists of as many blocks as there are holes, each block being provided with only one hole, which blocks are arranged in rows and columns in a common framework.
- the present invention provides an upper mattress according to claim 1, which exhibits very favourable characteristics as regards the comfort of the person lying on the mattress and the moisture discharge.
- the present invention refers further to a method and a device for providing a series of perforations in a mattress layer, in which an upper mattress is obtained whose closed cell structure is visible at the upper side and the lower side thereof.
- the method and the device are not covered by the claims.
- the piercing die is substantially composed of one or more solid die blocks, each provided with several holes.
- An advantage of such a device is the fact that a piercing die comprising several holes in one and the same solid die block is much more robust than in the known devices, as a result of which the holes in the piercing die can be spaced relatively closely, making it possible when using such a device according to the invention to realise mattress layers comprising perforations which can be spaced relatively closely at need.
- the method for providing a series of perforations in a mattress layer, using the present device comprises the following steps:
- steps ii)-iv) after completion of step iv), with steps iii)-iv) being carried out in specific zones of the mattress layer.
- step i) In order to obtain an optimum comfort of the person lying on the mattress and a satisfactory moisture discharge, it is preferable to provide a mattress layer in step i) in which specific zones at the upper side of the upper surface of the mattress layer are profiled.
- the improved upper mattress according to the present invention which upper mattress is made of latex foam, is characterized in that the vulcanised layer of latex foam is provided with perforations in at least one zone of the upper surface thereof and with a profile in at least one zone of said upper surface.
- the aforesaid perforations are formed in zones near those parts of a user's body that secrete the most sweat, mainly the neck, the back and the thighs.
- the advantage of this is that the body moisture can be discharge directly via the aforesaid perforations, which is achieved in part as a result of the changes in the user's position, which produced movements of air through the perforations, thus effecting a natural ventilation of the upper mattress.
- the perforations thus prevent moisture remaining accumulated within the mattress too long, which might lead to fungoid growth and further unpleasant effects.
- the profiles present in specific zones at the upper side of the upper layer of the mattress enhance the sleeping comfort of the user, because the mattress feels softer in said zones, depending on the shape and the dimensions of said profiles.
- zones comprising perforations alternating with zones comprising profiles will lead to an upper mattress which meets each and every requirement of an exacting user as regards sleeping comfort.
- Special embodiments of the present upper mattress are defined in the subclaims.
- the Figures 1-4 show a device, which mainly consists of a table 1 having upright side edges 2; a driving mechanism 3 in the form of rollers 4 and 5, respectively, which are arranged in spaced-apart relationship a certain distance above the top of the table 1, and which are mounted in supports 6-7 positioned opposite each other on either side of the table 1, with the roller 5 being driven by a motor 8; a punching device 9, which is positioned near a transverse recess 10 in the table 1 between the aforesaid rollers 4-5, and which extends across the width of the table 1; and a cutting device 11, which is disposed some distance away from the roller 5 at the location of a second transverse recess in the table 1.
- the punching device 9 mainly consists of a stand 12; a punch 14 suspended from said stand 12 by means of a hydraulic cylinder 13, which punch is provided with a series of punching pins 15 arranged in a specific matrix pattern, and a piercing die 16 positioned opposite said punch 14, which is attached to said stand by means of a framework 17, in such a manner that the upper surface of the piercing die 16 lies in the same plane as the upper surface of the top of the table 1.
- the piercing die 16 is in this case made of one solid die block 18, in a special embodiment five such solid die blocks may be used, each provided with several holes 19 in line with the aforesaid punching pins 15, more specifically in the same matrix pattern as the punching pins 15, comprising a relatively small number of rows 20 extending across the width of the table 1 and a relatively large number of columns 21 extending in the longitudinal direction of the table 1.
- the device is disposed at the end of the production line for manufacturing a continuous mattress layer 22 of latex foam or the like, in which, as is shown in Figures 1 and 2 , the mattress layer 22 is moved over the table 1 between the punch 14 and the piercing die 16 by the driving mechanism 3, more in particular by the driven roller 5.
- the motor 8 of the driven roller 5 is stopped temporarily each time a series of perforations 23 is to be provided in said continuous mattress layer 22, so that the mattress layer is held in a fixed position, after which, as is shown in Figure 4 , the cylinder 13 of the punching device 9 is driven to move the punching pins 15 downwards into the underlying holes 19 of the piercing die 16, so that the punching pins 15 are driven through the mattress layer 22 in a manner which is known.
- the punch 14 is moved upwards again, after which the mattress layer 22 is moved a suitable distance ahead over the table 1 by means of the driving mechanism 3 and the punch is moved downwards again in order for a next strip to be punched.
- the continuous mattress layer 22 is provided with perforations 23 strip after strip in a semi-continuous process.
- Pieces 24 of the perforated mattress layer 22 are cut to the desired length by means of the aforesaid cutting device 11, which pieces 24 can subsequently be used in the production process for composing mattresses.
- piercing die 16 is made of one solid die block 18 is that this makes it possible to space the holes 19 of the piercing die 16 relatively closely, as a result of which perforations 23 arranged in a relatively dense matrix pattern can be realised with one single punching movement, which may be advantageous in particular cases in connection with the comfort of a person lying on a mattress provided with such a piece of perforated mattress layer 24.
- the pieces of mattress layer 24 are shown to be provided with perforations 23 over the entire surface thereof in the Figures, it is quite possible to provide such pieces of mattress layer 24 with perforations only in specific zones in alternative embodiments, with zones provided with perforations and zones not provided with perforations being arranged in alternating relationship, in which case the punch 14 and the piercing die 16 do not necessarily have to extend across the entire width of the mattress layer 22 to be perforated. Preferably, however, the piercing die 16 will extend across the entire width of the zone of the mattress layer 22 that is to be perforated.
- Figure 5 shows a variant of a piercing die 16, in which the piercing die 16 is composed of several solid die blocks 18, each provided with holes 19 arranged in a matrix comprising several rows and columns of holes, which are arranged side-by-side in a continuous row in a common framework 17.
- a piercing di e 16 may also be composed of die blocks 18 comprising several aligned holes 19, which may form part of a respective row or column of the matrix pattern of the piercing guide 16.
- FIGS. 6 and 7 schematically show an improved upper mattress according to the invention in the simplest form thereof.
- the layer 1 is a rectangular layer of latex foam having a specific thickness.
- the upper surface 2 of the layer 1 is provided with profiles 4 in particular zones 3, for example in the form of corrugations extending in the crosswise direction of the layer 1, over the entire width thereof, with perforations 6 being provided in the intermediate zones 5, which perforations form a connection between the upper surface 2 and the lower surface 7 of the layer 1, with the zones 3 and the zones 5 thus alternating in the longitudinal direction of the mattress.
- Figures 8 and 9 show an embodiment of a mattress, in this case consisting of two layers arranged one on top of the other, viz. an improved upper mattress or layer 1 of latex foam as described above, and a full lower layer 8.
- Figure 9 clearly shows that the zones 2 provided with perforations 6 are located near those parts of a user's body 9 where the user secretes the most sweat, viz. the neck 10, the back 11 and the thighs 12. At these locations the bodily fluid is indeed directly discharged in downward direction through the perforations 6, so that the latex foam layer 1 that is in contact with the user's body 9 will remain dry at all times, and consequently will not be affected by fungoid growth or the like.
- the varying thickness of the layer 1 in the profiles zones 3 makes the mattress feel softer or harder in said zones 3, as desired, depending on the shape and the dimensions of the corrugations.
- Figures 10 and 11 show a variant of an embodiment of a mattress in which, in this case, the improved upper mattress or layer 1 of latex foam is arranged on top of an elastic lower layer 13 composed of spring elements 14 arranged in side-by-side relationship, for example in the form of metal coil springs, elastic elements of plastic material or the like, in which case a protective layer 15, for example in the form of a mattress cover made of a layer of a textile such as felt, jute or the like, is preferably arranged between the layer 1 of latex foam and the lower layer 13.
- a protective layer 15 for example in the form of a mattress cover made of a layer of a textile such as felt, jute or the like, is preferably arranged between the layer 1 of latex foam and the lower layer 13.
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- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
- Bedding Items (AREA)
- Treatment Of Fiber Materials (AREA)
- Measurement Of The Respiration, Hearing Ability, Form, And Blood Characteristics Of Living Organisms (AREA)
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- Chemical Or Physical Treatment Of Fibers (AREA)
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Abstract
Description
- The present invention relates to an upper mattress made of latex foam.
-
U.S. patent application No. 5,327,597 relates to a foam mattress pad having a bottom surface, a convoluted top surface and apertures extending through the pad randomly placed in relation to the convoluted pattern of the top surface. The convoluted top surface of the pad comprises a repeating pattern of peaks and troughs wherein at least two peaks are in proximity to each other without a valley therebetween adjacent the same number of proximate valleys without a peak therebetween. -
German Offenlegungsschrift 34 10 603 relates to a mattress, mattress pad or the like, which is divided into a plurality of zones of varying resilience or hardness so that the shoulder and hip areas can sink in deeper in order to keep the spine in its natural straight position and avoid stress on the spine. This is achieved in that the zones of varying resilience are formed by materials of varying degrees of hardness and/or grooves are introduced into said zones of the foamed material body, said grooves passing through the foamed material body from the bottom towards the top. - It is a known fact that perforations in the mattress layer can enhance the comfort of the person lying on the mattress and improve the moisture discharge of the mattress, in which connection it can be mentioned in particular that people on average secrete up to 1 litre of sweat a night while sleeping. Said moisture is discharged into the surrounding atmosphere as a result of a good ventilation of the mattress, which in itself makes the mattress feel drier, which in turn enhances the sleeping comfort of the user of the mattress. If a moist mattress is insufficiently provided with moisture-discharging means, the mattress will be susceptible to fungoid growth. The provision of additional ventilation in the mattress gives the mattress a higher sense of comfort, and in addition ensures a longer life of the mattress. Furthermore it is known in that people make frequent movements while sleeping, and the shifts in the body weight on the mattress produce a so-called pumping movement, which in turn leads to a satisfactory ventilation and canalisation of the moisture.
- The aforesaid perforations are usually provided according to a specific matrix pattern in the mattress layer, either over the entire surface area of the mattress layer or only in specific zones, after the latex layer has been formed.
- Latex foam of itself has a unique open cell structure, which means that millions of microscopically small interconnected air bubbles in the latex foam provide a good ventilating effect. There are two methods of obtaining latex foam in accordance with the well-known Dunlop process. According to a first method, moulding elements such as waffle irons are used, with latex foam being poured into a closed mould provided with aluminium pins to ensure a good heat conduction, and subsequently being vulcanised, washed and dried into an end product. As a result of the presence of the aluminium pins in the closed mould, the mattress (the end product) comprises vertical, continuous recesses that ensure a proper ventilation of the mattress. According to this method, mattresses having a thickness of up to 20 cm can be produced, with the thickness mainly being limited by the speed at which the heat can be introduced into the core of the latex material. The second method for producing latex foam according to the well-known Dunlop process is the pouring of latex foam on an endless conveyor belt, followed by vulcanisation, washing and finally drying. The maximum height of the mattress built up of latex foam is approximately 5 cm, because heat cannot be introduced into the core of the latex material sufficiently quickly due to the absence of aluminium pins on the conveyor belt. Thus, owing to the absence of the aluminium pins on the conveyor belt, the latex plate that is obtained does not have any vertical, continuous channels. In order to obtain a good ventilation in such a mattress layer yet, the mattress plate is provided with perforations.
- The devices for providing such perforations that are known from the prior art consist of a punch with punching pins arranged in a specific matrix pattern on a punching block and being positioned opposite a piercing die with holes being arranged in the same matrix pattern, in line with the aforesaid punching pins.
- With these known devices, the piercing die consists of as many blocks as there are holes, each block being provided with only one hole, which blocks are arranged in rows and columns in a common framework.
- One drawback of these known devices is the fact that a relatively large spacing must be maintained between the holes in the piercing die so as to prevent the walls of the individual mattress blocks surrounding the holes becoming too thin, which would increase the risk of the blocks tearing open or breaking during the perforating of the mattress layer, with all the consequent inconveniences and drawbacks.
- Another drawback of the fact that the spacing between the holes must not be smaller than a predetermined value with the known devices is that this requirement also imposes limitations as regards the spacing between the perforations in the mattress layer, as a result of which the possibilities of increasing the comfort of the person lying on the mattress and the moisture discharge of the mattress layer by reducing the spacing between the perforations are relatively limited.
- The present invention provides an upper mattress according to
claim 1, which exhibits very favourable characteristics as regards the comfort of the person lying on the mattress and the moisture discharge. - The present invention refers further to a method and a device for providing a series of perforations in a mattress layer, in which an upper mattress is obtained whose closed cell structure is visible at the upper side and the lower side thereof. The method and the device are not covered by the claims.
- The piercing die is substantially composed of one or more solid die blocks, each provided with several holes.
- An advantage of such a device is the fact that a piercing die comprising several holes in one and the same solid die block is much more robust than in the known devices, as a result of which the holes in the piercing die can be spaced relatively closely, making it possible when using such a device according to the invention to realise mattress layers comprising perforations which can be spaced relatively closely at need.
- Special embodiments of the present invention will become apparent from the description of the Figures herein; said embodiments are furthermore defined in the subclaims.
- The method for providing a series of perforations in a mattress layer, using the present device comprises the following steps:
- i) providing a mattress layer of latex foam,
- ii) passing the mattress layer obtained in step i) between the punch and the piercing die,
- iii) moving punching pins in downward direction into the underlying holes of the piercing die, and
- iv) moving the punch upwards again.
- In a special embodiment, it is preferred to repeat steps ii)-iv) after completion of step iv), with steps iii)-iv) being carried out in specific zones of the mattress layer.
- In order to obtain an optimum comfort of the person lying on the mattress and a satisfactory moisture discharge, it is preferable to provide a mattress layer in step i) in which specific zones at the upper side of the upper surface of the mattress layer are profiled.
- The improved upper mattress according to the present invention, which upper mattress is made of latex foam, is characterized in that the vulcanised layer of latex foam is provided with perforations in at least one zone of the upper surface thereof and with a profile in at least one zone of said upper surface.
- Preferably, the aforesaid perforations are formed in zones near those parts of a user's body that secrete the most sweat, mainly the neck, the back and the thighs.
- The advantage of this is that the body moisture can be discharge directly via the aforesaid perforations, which is achieved in part as a result of the changes in the user's position, which produced movements of air through the perforations, thus effecting a natural ventilation of the upper mattress.
- The perforations thus prevent moisture remaining accumulated within the mattress too long, which might lead to fungoid growth and further unpleasant effects.
- The profiles present in specific zones at the upper side of the upper layer of the mattress enhance the sleeping comfort of the user, because the mattress feels softer in said zones, depending on the shape and the dimensions of said profiles.
- A suitable selection of the zones comprising perforations alternating with zones comprising profiles will lead to an upper mattress which meets each and every requirement of an exacting user as regards sleeping comfort. Special embodiments of the present upper mattress are defined in the subclaims.
- In order to provide a better understanding of the invention, a preferred, non-limitative embodiment of a device according to the invention for perforating a mattress layer will be described hereinafter with reference to the accompanying drawings, in which:
-
Figure 1 is a schematic side elevation of the device; -
Figure 2 is a top plan view ofFigure 1 ; -
Figure 3 is a larger-scale sectional view along the line III-III inFigure 1 ; -
Figure 4 shows the device ofFigure 1 , in another position thereof; -
Figure 5 shows a variant ofFigure 3 ; -
Figure 6 is a schematic, perspective view of an improved upper mattress according to the invention in this simplest form thereof; -
Figure 7 is a sectional view along the line II-II inFigure 6 ; -
Figure 8 is a sectional view of a mattress used in combination with an improved upper mattress according to the invention; -
Figure 9 is a sectional view similar to the view ofFigure 8 , in this case during use of the mattress, however; -
Figure 10 shows an embodiment of a mattress according toFigure 8 ; and -
Figure 11 is a larger-scale view of the part indicated at F6 inFigure 10 . - The
Figures 1-4 show a device, which mainly consists of a table 1 havingupright side edges 2; adriving mechanism 3 in the form ofrollers roller 5 being driven by amotor 8; apunching device 9, which is positioned near atransverse recess 10 in the table 1 between the aforesaid rollers 4-5, and which extends across the width of the table 1; and acutting device 11, which is disposed some distance away from theroller 5 at the location of a second transverse recess in the table 1. - The
punching device 9 mainly consists of astand 12; apunch 14 suspended from saidstand 12 by means of ahydraulic cylinder 13, which punch is provided with a series ofpunching pins 15 arranged in a specific matrix pattern, and apiercing die 16 positioned opposite saidpunch 14, which is attached to said stand by means of aframework 17, in such a manner that the upper surface of thepiercing die 16 lies in the same plane as the upper surface of the top of the table 1. - The
piercing die 16 is in this case made of onesolid die block 18, in a special embodiment five such solid die blocks may be used, each provided withseveral holes 19 in line with theaforesaid punching pins 15, more specifically in the same matrix pattern as thepunching pins 15, comprising a relatively small number ofrows 20 extending across the width of the table 1 and a relatively large number ofcolumns 21 extending in the longitudinal direction of the table 1. - The operation and the use of the device, which are very simple, are as follows.
- In the illustrated embodiment, the device is disposed at the end of the production line for manufacturing a
continuous mattress layer 22 of latex foam or the like, in which, as is shown inFigures 1 and2 , themattress layer 22 is moved over the table 1 between thepunch 14 and thepiercing die 16 by thedriving mechanism 3, more in particular by the drivenroller 5. - The
motor 8 of the drivenroller 5 is stopped temporarily each time a series ofperforations 23 is to be provided in saidcontinuous mattress layer 22, so that the mattress layer is held in a fixed position, after which, as is shown inFigure 4 , thecylinder 13 of thepunching device 9 is driven to move thepunching pins 15 downwards into theunderlying holes 19 of thepiercing die 16, so that thepunching pins 15 are driven through themattress layer 22 in a manner which is known. - As a result of the arrangement of the
punching pins 15 and theholes 19 in a matrix, single rows ofperforations 23 extending across the width of themattress layer 22 are formed in a relatively narrow strip of themattress layer 22 in question with each stroke. - After such a strip has been punched, the
punch 14 is moved upwards again, after which themattress layer 22 is moved a suitable distance ahead over the table 1 by means of thedriving mechanism 3 and the punch is moved downwards again in order for a next strip to be punched. - In this way the
continuous mattress layer 22 is provided withperforations 23 strip after strip in a semi-continuous process. -
Pieces 24 of theperforated mattress layer 22 are cut to the desired length by means of theaforesaid cutting device 11, whichpieces 24 can subsequently be used in the production process for composing mattresses. - An important advantage of the fact that the piercing die 16 is made of one
solid die block 18 is that this makes it possible to space theholes 19 of the piercing die 16 relatively closely, as a result of which perforations 23 arranged in a relatively dense matrix pattern can be realised with one single punching movement, which may be advantageous in particular cases in connection with the comfort of a person lying on a mattress provided with such a piece ofperforated mattress layer 24. - Although the pieces of
mattress layer 24 are shown to be provided withperforations 23 over the entire surface thereof in the Figures, it is quite possible to provide such pieces ofmattress layer 24 with perforations only in specific zones in alternative embodiments, with zones provided with perforations and zones not provided with perforations being arranged in alternating relationship, in which case thepunch 14 and the piercing die 16 do not necessarily have to extend across the entire width of themattress layer 22 to be perforated. Preferably, however, the piercing die 16 will extend across the entire width of the zone of themattress layer 22 that is to be perforated. - Furthermore it is quite possible for the rows and columns of the matrix patterns of the punching pins 15 and the
holes 19 not to extend perpendicularly to each other but at a particular angle with respect to each other. -
Figure 5 shows a variant of a piercingdie 16, in which the piercing die 16 is composed of several solid die blocks 18, each provided withholes 19 arranged in a matrix comprising several rows and columns of holes, which are arranged side-by-side in a continuous row in acommon framework 17. - It will be understood that a piercing di e 16 according to the invention may also be composed of die blocks 18 comprising several aligned
holes 19, which may form part of a respective row or column of the matrix pattern of the piercingguide 16. -
Figures 6 and 7 schematically show an improved upper mattress according to the invention in the simplest form thereof. - In this embodiment, the
layer 1 is a rectangular layer of latex foam having a specific thickness. Theupper surface 2 of thelayer 1 is provided withprofiles 4 inparticular zones 3, for example in the form of corrugations extending in the crosswise direction of thelayer 1, over the entire width thereof, withperforations 6 being provided in theintermediate zones 5, which perforations form a connection between theupper surface 2 and thelower surface 7 of thelayer 1, with thezones 3 and thezones 5 thus alternating in the longitudinal direction of the mattress. -
Figures 8 and9 show an embodiment of a mattress, in this case consisting of two layers arranged one on top of the other, viz. an improved upper mattress orlayer 1 of latex foam as described above, and a fulllower layer 8. -
Figure 9 clearly shows that thezones 2 provided withperforations 6 are located near those parts of a user'sbody 9 where the user secretes the most sweat, viz. theneck 10, the back 11 and thethighs 12. At these locations the bodily fluid is indeed directly discharged in downward direction through theperforations 6, so that thelatex foam layer 1 that is in contact with the user'sbody 9 will remain dry at all times, and consequently will not be affected by fungoid growth or the like. - The varying thickness of the
layer 1 in theprofiles zones 3 makes the mattress feel softer or harder in saidzones 3, as desired, depending on the shape and the dimensions of the corrugations. -
Figures 10 and 11 show a variant of an embodiment of a mattress in which, in this case, the improved upper mattress orlayer 1 of latex foam is arranged on top of an elasticlower layer 13 composed ofspring elements 14 arranged in side-by-side relationship, for example in the form of metal coil springs, elastic elements of plastic material or the like, in which case aprotective layer 15, for example in the form of a mattress cover made of a layer of a textile such as felt, jute or the like, is preferably arranged between thelayer 1 of latex foam and thelower layer 13. - The present invention is by no means limited to the embodiments described and shown herein by way of example; an improved upper mattress according to the invention can be realised in various forms and dimensions without departing from the scope of the invention which is defined by the appended claims.
Claims (6)
- An upper mattress made of latex foam, the vulcanised layer (1) of latex foam is provided with perforations (6), in at least one zone (5) of the upper surface (2), a profile (4) in at least one zone (3) of said upper surface (2),
characterized in that a profile (4) is present in at least one zone (3) of said upper surface (2), wherein said zones (3-5) extend across the width of the mattress and in that the zones (5) provided with perforations (6) and the zones (3) provided with a profile (4) alternate in the longitudinal direction. - An upper mattress according to claim 1, characterized in that the zones (5) provided with perforations (6) are located near those parts of a user's body (9) that secrete the most sweat, in particular the neck (10), the back (11) and the thighs (12).
- An upper mattress according to any one of the preceding claims 1 - 2, characterized in that said profile (4) is in the form of a pattern of corrugations.
- An upper mattress according to claim 3, characterized in that the corrugations of said pattern of corrugations extend in the crosswise direction of the mattress.
- An upper mattress according to any one of the claims 1 - 4, characterized in that the upper mattress has a closed cell structure along the upper surface (2) and the lower surface (7) thereof.
- Use of an upper mattress according to any one of the claims 1 - 5 on a spring construction.
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ES04075204T ES2283934T3 (en) | 2003-01-29 | 2004-01-28 | DEVICE AND PERFORATION METHOD FOR A MATTRESS COAT. |
DK04075204T DK1444925T3 (en) | 2003-01-29 | 2004-01-28 | Perforating device and method for machining a mattress layer |
EP04075204A EP1444925B1 (en) | 2003-01-29 | 2004-01-28 | Perforation device and method for a mattress layer |
AT04075204T ATE356565T1 (en) | 2003-01-29 | 2004-01-28 | PERFORATING DEVICE AND METHOD FOR LAYING A MATTRESS |
SI200430287T SI1444925T1 (en) | 2003-01-29 | 2004-01-28 | Perforation device and method for a mattress layer |
PT04075204T PT1444925E (en) | 2003-01-29 | 2004-01-28 | Perforation device and method for a mattress layer |
DE602004005255T DE602004005255T2 (en) | 2003-01-29 | 2004-01-28 | Perforating device and method for the layer of a mattress |
CY20071100744T CY1106641T1 (en) | 2003-01-29 | 2007-06-05 | APPARATUS AND METHOD OF DRILLING FOR A LAYER OF MAT |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BE200200543 | 2002-09-17 | ||
BE2002/0543A BE1015113A3 (en) | 2002-09-17 | 2002-09-17 | Perforation forming device for mattress, has piercing die with several blocks each provided with several holes |
BE2003/0065A BE1015335A3 (en) | 2003-01-29 | 2003-01-29 | Perforation forming device for mattress, has piercing die with several blocks each provided with several holes |
BE200300065 | 2003-01-29 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP1400191A2 EP1400191A2 (en) | 2004-03-24 |
EP1400191A3 EP1400191A3 (en) | 2004-05-06 |
EP1400191B1 true EP1400191B1 (en) | 2008-07-16 |
Family
ID=37905625
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP03076480A Expired - Lifetime EP1400191B1 (en) | 2002-09-17 | 2003-05-15 | Perforation device for a mattress layer |
EP04075204A Expired - Lifetime EP1444925B1 (en) | 2003-01-29 | 2004-01-28 | Perforation device and method for a mattress layer |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP04075204A Expired - Lifetime EP1444925B1 (en) | 2003-01-29 | 2004-01-28 | Perforation device and method for a mattress layer |
Country Status (9)
Country | Link |
---|---|
EP (2) | EP1400191B1 (en) |
AT (2) | ATE401176T1 (en) |
BE (2) | BE1015113A3 (en) |
CY (1) | CY1106641T1 (en) |
DE (2) | DE60322157D1 (en) |
DK (1) | DK1444925T3 (en) |
ES (1) | ES2283934T3 (en) |
PT (1) | PT1444925E (en) |
SI (1) | SI1444925T1 (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
PL1904570T3 (en) | 2005-07-01 | 2019-01-31 | Latexco Nv | Latex based composite foams |
GB2428001A (en) * | 2005-07-05 | 2007-01-17 | British Vita | A cushioning member |
ITMI20070885A1 (en) | 2007-05-04 | 2008-11-05 | Sapsa Bedding S R L | MATTRESS WITH QUILTED PANEL AND RELATED PROCESSING PROCEDURES |
CN106239615B (en) * | 2016-08-31 | 2018-04-13 | 浙江和也健康科技有限公司 | A kind of flexibility cushion block punch device |
CN110253673A (en) * | 2019-07-25 | 2019-09-20 | 安吉八塔机器人有限公司 | A kind of sponge perforating press |
CN114311128B (en) * | 2021-12-22 | 2023-08-08 | 湖南晚安床垫有限公司 | Mattress punching equipment |
Family Cites Families (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE456441C (en) * | 1926-07-25 | 1930-06-19 | Emil Kahle Fa | Perforating device |
DE655320C (en) * | 1935-04-11 | 1938-01-14 | Jaroslaw S Erste Glimmerwaren | Punching device for sproede, under pressure crumbling or disintegrating materials, such as mica or the like. |
GB522558A (en) * | 1938-12-17 | 1940-06-20 | James Arthur Barclay | Improvements in or relating to cutting-out presses |
US3217547A (en) * | 1963-10-07 | 1965-11-16 | Gustafson Mfg Company | Sampling device for pressurized conveyors |
US3407691A (en) * | 1966-06-01 | 1968-10-29 | Huck William F | Rotary perforating device |
US3477317A (en) * | 1967-04-12 | 1969-11-11 | Ibm | Method for producing an improved die for use with a multi-element punch |
SE423304B (en) * | 1979-01-10 | 1982-05-03 | Becker Wilhelm Ab | BEDDUNLAY, INCLUDING A RELATIVE THICKNESS |
US4273015A (en) * | 1979-06-04 | 1981-06-16 | Johnson Donald R | Dome head punch |
DE3410603A1 (en) * | 1984-03-22 | 1985-09-26 | Alexander E. 8000 München Gehring | Mattress or the like |
DK152202C (en) * | 1985-06-25 | 1988-07-11 | Jacobsen Sengesystem A S Bay | MACHINE FOR MANUFACTURING LONG AND CROSSING CHANNELS IN A FOAM FORM |
DE9202731U1 (en) * | 1991-12-04 | 1992-07-09 | Lueck, Werner, 4290 Bocholt | mattress |
US5327597A (en) * | 1992-07-02 | 1994-07-12 | Michael Rothbard | Convoluted mattress pad having multiple proximate peaks |
JP2592473Y2 (en) * | 1992-10-09 | 1999-03-24 | 富士重工業株式会社 | Press die for piercing |
ID17684A (en) * | 1996-02-08 | 1998-01-22 | Bpb Plc | SHOULDER BOARD |
DE29702699U1 (en) * | 1997-02-17 | 1997-04-10 | Trumpf Gmbh & Co, 71254 Ditzingen | Die on a punching machine |
US6041459A (en) * | 1997-10-03 | 2000-03-28 | The Spring Air Company | Convoluted foam cushion |
JP3722258B2 (en) * | 1998-09-25 | 2005-11-30 | 日本碍子株式会社 | Punching device for punching, punch for punching, and method for manufacturing punch for punching |
DE10046457B4 (en) * | 2000-09-18 | 2005-09-22 | Omasi-Anstalt | Mattress or cushions with interiorly arranged comfort areas |
-
2002
- 2002-09-17 BE BE2002/0543A patent/BE1015113A3/en not_active IP Right Cessation
-
2003
- 2003-01-29 BE BE2003/0065A patent/BE1015335A3/en not_active IP Right Cessation
- 2003-05-15 DE DE60322157T patent/DE60322157D1/en not_active Expired - Fee Related
- 2003-05-15 AT AT03076480T patent/ATE401176T1/en not_active IP Right Cessation
- 2003-05-15 EP EP03076480A patent/EP1400191B1/en not_active Expired - Lifetime
-
2004
- 2004-01-28 SI SI200430287T patent/SI1444925T1/en unknown
- 2004-01-28 AT AT04075204T patent/ATE356565T1/en not_active IP Right Cessation
- 2004-01-28 PT PT04075204T patent/PT1444925E/en unknown
- 2004-01-28 DK DK04075204T patent/DK1444925T3/en active
- 2004-01-28 ES ES04075204T patent/ES2283934T3/en not_active Expired - Lifetime
- 2004-01-28 DE DE602004005255T patent/DE602004005255T2/en not_active Expired - Fee Related
- 2004-01-28 EP EP04075204A patent/EP1444925B1/en not_active Expired - Lifetime
-
2007
- 2007-06-05 CY CY20071100744T patent/CY1106641T1/en unknown
Also Published As
Publication number | Publication date |
---|---|
EP1444925B1 (en) | 2007-03-14 |
ATE356565T1 (en) | 2007-04-15 |
SI1444925T1 (en) | 2007-08-31 |
BE1015113A3 (en) | 2004-10-05 |
ES2283934T3 (en) | 2007-11-01 |
PT1444925E (en) | 2007-06-08 |
DK1444925T3 (en) | 2007-07-09 |
DE60322157D1 (en) | 2008-08-28 |
EP1400191A3 (en) | 2004-05-06 |
EP1400191A2 (en) | 2004-03-24 |
DE602004005255T2 (en) | 2007-12-20 |
DE602004005255D1 (en) | 2007-04-26 |
BE1015335A3 (en) | 2005-02-01 |
EP1444925A1 (en) | 2004-08-11 |
CY1106641T1 (en) | 2012-01-25 |
ATE401176T1 (en) | 2008-08-15 |
EP1444925A9 (en) | 2005-03-02 |
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