Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B21/10—Open-work fabrics
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
  • A47C31/006—Use of three-dimensional fabrics
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
  • A47C31/10—Loose or removable furniture covers
  • A47C31/105—Loose or removable furniture covers for mattresses
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47D—FURNITURE SPECIALLY ADAPTED FOR CHILDREN
  • A47D15/00—Accessories for children's furniture, e.g. safety belts or baby-bottle holders
  • A47D15/001—Mattresses
  • A47D15/003—Mattresses foldable, e.g. baby mats
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
  • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/10—Physical properties porous
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2403/00—Details of fabric structure established in the fabric forming process
  • D10B2403/01—Surface features
  • D10B2403/011—Dissimilar front and back faces
  • D10B2403/0112—One smooth surface, e.g. laminated or coated
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2403/00—Details of fabric structure established in the fabric forming process
  • D10B2403/02—Cross-sectional features
  • D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
  • D10B2403/0213—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics with apertures, e.g. with one or more mesh fabric plies
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2503/00—Domestic or personal
  • D10B2503/06—Bed linen
  • D10B2503/062—Fitted bedsheets

Definitions

• the invention relates to a method for producing a breathable mat, in particular a breathable lying mat for a child's bed.
• the invention relates to a method for producing a breathable mat, and a breathable mat obtained by a method according to the invention.
• the present invention aims to find a solution for at least some of the above-mentioned problems.
• the invention relates to a method for producing a breathable mat according to claim 1. More in particular, the invention relates to a method for producing a breathable mat, preferably a lying mat for a child's bed, comprising:
• the invention relates to a mat according to claim 13. More in particular, the invention relates to a breathable mat for use as a lying mat, characterised in that said mat is fabricated by means of a method according to the present invention.
• the invention relates to a method for producing a breathable mat, in particular a breathable lying mat for a child's bed. Moreover, the invention relates to a breathable mat for use as a lying mat.
• A means for example one or more than one segment.
• the citation of numeric intervals by means of end points includes all integers, fractions and/or real numbers between the end points, including these end points.
• the invention in a first aspect, relates to a method for producing a breathable mat, preferably a lying mat for a child's bed.
• the method comprising fabricating a compact three-dimensional knitting product by means of a knitting machine, in which said knitting product is kept under tension during fabrication; stretching said compact three-dimensional knitting product; and thermally fixing the stretched knitting product.
• three-dimensional knitting product in the description of the invention refers to the distinction with a conventional - bi-dimensional - knitting product.
• Conventional knitting products comprise one layer of textile consisting of - in a simplified embodiment - a number of rows with a number of stitches.
• different textile layers must be sewn to each other, or hems must be provided for.
• Three-dimensional knitting products however comprise a plurality of textile layers without having to sew them to each other and without one or several hems having to be provided for.
• thermally fixing refers to a process in which fibres, yarns, fabrics, textile and/or a knitting product are treated with heat for stabilising it.
• a compact three-dimensional knitting product is made by means of a knitting machine.
• the knitting product is continuously stretched as a result of which more robust and larger stitches can be fabricated than when no tension would be maintained.
• the robustness of stitches prevents that stitches come loose in an undesired way during the further production process or use of the knitting product or the produced lying mat, while larger stitches induce a larger mesh in the textile and consequently increase the breathability of the knitting product and the finally produced lying mat. It is indeed important that the textile can be stretched later during the production in order to increase the mesh in the textile and thus induce a breathable structure in the textile.
• the stretching of the three-dimensional knitting product during the fabrication of a three-dimensional knitting product also induces the advantage that the knitting product is stretched continuously as a result of which stitches, rows of stitches and layers thereof can be applied much more easily, straighter and more equal.
• a three-dimensional knitting product is fabricated in a pattern of a honeycomb structure.
• a three-dimensional honeycomb structure pattern offers sufficient support and offers a support that is equally spread over the complete surface of the respective knitting product.
• the meshes in the honeycomb structure pattern provide for a breathability of the textile.
• the honeycomb structure pattern especially comprises hexagonal shapes.
• a tension is applied to the compact three-dimensional knitting product, increasing the width of the respective knitting product with 10% to 50%, compared to when no tension would be applied to the respective knitting product.
• the compact three-dimensional knitting product has a width of 180 to 220 cm during the fabrication and under tension.
• the compact three-dimensional knitting product has a width of 120 to 150 cm when no tension is applied to the knitting product.
• the number of needles per inch of a knitting machine is a measure for the fineness of the stitches that can be knitted by means of the respective knitting machine. The more needles per inch a knitting machine comprises, the finer the stitches can be knit.
• fine stitches have to be knitted, as in this way, a large number of stitches can be knitted at a relatively small surface and/or volume.
• a method of the present invention comprises the fabrication of a compact three-dimensional knitting product by means of a knitting machine comprising 12 needles per inch.
• Another parameter of a knitting machine is the mill plate distance.
• the yarn and the knitting pattern - it can be advantageous to adjust the mill plate distance, and thus the thickness of the fabricated knitting product.
• a method of the invention comprises the fabrication of a compact three-dimensional knitting product by means of a knitting machine having a mill plate distance of 3 to 15 mm, preferably 5 to 12 mm and more preferably of 8 mm.
• a method of the invention comprises the fabrication of a compact three-dimensional knitting product by means of a knitting machine comprising at least two rolls of yarns.
• the respective rolls of yarns comprise a different yarn.
• the three-dimensional knitting product is fabricated at a speed of 12 to 18 meter per hour.
• the fabricated compact three-dimensional knitting product is stretched.
• a fabricated three-dimensional knitting product undergoes undesired deformations, when no tension is maintained.
• the stretching of the fabricated knitting product such as in a method of the invention, allows to prevent and remove such deformations, and allows to bring and maintain the desired knitting product in a more desired shape.
• the compact three-dimensional knitting product is stretched only slightly during the fabrication step. As a result, a relatively compact knitting product is fabricated having still a lot of potential for being stretched out.
• the compact three-dimensional knitting product is stretched substantially after the fabrication process for the meshes in the textile structure of the knitting product being enlarged. Larger meshes increase the breathability of the knitting product.
• the stretching of the knitting product is made by inducing and maintaining similar tractive forces at both the longitudinal and the width sides of the compact three-dimensional knitting product.
• a stretched knitting product is obtained which is stretched out at all sides in similar extents, and thus, having a uniform textile structure and pattern over the complete stretched knitting product.
• the thickness of the compact knitting product is also stretched in an analogous way. Said uniform textile structure would not be obtained when already large tension and/or tractive forces were already maintained during the fabrication of the compact three-dimensional knitting product.
• the separation of the fabrication step of a compact three-dimensional knitting product and the stretching step of the respective knitting product allows for a controlled stretching-out of the knitting product.
• the knitting product is stretched when a mesh in the textile is obtained from 0,5 to 10 mm, and preferably 2 to 4 mm.
• the respective mesh allows the stretched knitting product to be both sufficiently breathable and supportive, and at the same time to feel comfortable for a user of a finally produced breathable mat. Larger meshes would feel less even - or even corrugated - and thus unpleasant for a user.
• the stretched knitting product has a thickness of 3 to 15 mm, more preferably 5 to 12 mm, and most preferably 8 mm.
• a lying mat with limited thickness has the advantage that it takes less volume and is easy to transport and to store. Moreover, a small thickness of a mat ensures that it is easy to wash. Nevertheless, it is important that a final produced lying mat is sufficiently thick for offering sufficient support to a user.
• a stretched knitting product will be thermally fixed for stabilising the structure, shape and dimensions thereof. More in particular, the thermal fixing of a stretched knitting product allows to maintain the shape and dimensions of the knitting product that have been obtained by stretching the compact three-dimensional knitting product. In this way, it is prevented that the stretched knitting product shrinks and again takes the dimensions of the compact three-dimensional knitting product when the knitting product is no longer subjected to stretching forces.
• thermal fixation of a knitting product often induces a higher volume, and a larger folding, wrinkling and/or temperature resistance of the resulting knitting product.
• the stretched knitting product is possibly fixed thermally when tensile forces are maintained at the respective compact three-dimensional knitting product. In this way, it is prevented that the shape, dimensions and/or structure of the thermally fixed knitting product deviate from the shape, dimensions and/or structure of the stretched knitting product.
• the stretched knitting product in the absence of tensile forces.
• the stretched knitting product must be subjected to tensile forces inducing permanent shape and structural changes of the knitting product.
• the stretched knitting product is fixed thermally at a temperature of 150-200°C, and more in particular, the knitting product is fixed thermally for 3 to 5 minutes.
• thermal fixation at 150-200°C induces a high degree of stabilisation of the textile of the stretched knitting product as a result of which the stretched knitting product maintains its shapes, volume and dimensions for a long time and during intensive use. Also, thermal fixation at such elevated temperatures allows that the stretched knitting product must be fixed thermally only during a short time, and that in this way, a fast production of a mat is possible. Thermal fixation at a higher temperature or for a longer time results in a decrease of resistance of the knitting product, while thermal fixation at a lower temperature or for a shorter time results in insufficient fixation, and thus stability, of the knitting product.
• the thermally fixed knitting product is at the lower side provided with one or a plurality of additional layers.
• an absorbent layer is provided at the thermally fixed knitting product.
• Such a layer ensures that the bodily fluid is absorbed, such as in non-limiting examples sweat, urine and saliva, of a user.
• the fixed knitting product (whether or not provided with an absorbent layer) will at the bottom be provided with an impermeable layer that is attached to the knitting product by means of a lamination process, or - if absent - at the absorbent layer.
• This impermeable layer preferably comprises polyurethane.
• This impermeable layer ensures that the mat remains moisture-proof.
• the lamination process takes place at a temperature between 140°C and 160°C.
• the provision of an impermeable layer at the bottom of the thermally fixed knitting product has the advantage that the base - preferably a mattress - is protected against bodily fluids such as sweat, urine and blood, and bacteria coming from a user.
• the mat which is produced according to the present method also functions as a protection of the base or mattress and said mat ensures the hygiene of the base or mattress. In this way, a breathable mat is produced ensuring cleanliness, safely and comfort.
• the produced final product will be composed of three layers.
• a first layer comprises the breathable layer (the thermally fixed knitting product) that is provided at the bottom with an impermeable layer. Between the breathable layer and the impermeable layer, a humidity-absorbing layer is provided.
• the invention in a second aspect, relates to a breathable mat for use as a lying mat, characterised in that the respective mat is obtained by means of a method according to the present invention.
• a breathable mat obtained by means of a method of the present invention ensures comfort, support and safety for a user, preferably a baby or child.
• a mat according to the present invention is highly breathable.
• a mattress according to the present invention allows that when a baby or a child rolls onto his or her belly, and more in particular when he or she is laying on his or her face, he/she can still breathe and does not suffocate.
• a high breathability of a mattress according to the present invention also ensures that parts of the body of a user, preferably a baby or child, that are in contact with the mat, are sufficiently ventilated and to not overheat.
• a mat according to the present invention offers sufficient support for a user, preferably a baby or a child, to lie in a comfortable, safe and healthy position.
• the breathable mat comprises an extended honeycomb structure pattern.
• a honeycomb structure pattern allows both sufficient and pleasant support and sufficient breathability.
• a breathable mat is made of a breathable textile.
• a breathable textile ensures that a mattress according to the invention is even more breathable.
• a breathable textile ensures a better ventilation of parts of the body that are in contact with the mat, and the breathable material also ensures more cooling and less risks for overheating of respective parts of the body.
• a breathable mat according to the present invention comprises a humidity-absorbing layer at the bottom side of the mat, whether or not provided with an impermeable layer.
• a humidity-absorbing layer ensures that the bodily fluid is absorbed, such as sweat, blood, saliva and urine, of a user as a result of which the thermally fixed knitting product of the mat is protected.
• An impermeable layer ensures a protection of the base - preferably a mattress - against human fluids such as blood, sweat and urine, and bacteria.
• An impermeable layer avoids that undesired human fluids and/or bacteria penetrate into the base - or the underlying mattress - and avoids in this way damage or pollution of the base.
• a breathable mat comprises flannel at at least one of its outer surfaces.
• Flannel is capable of absorbing lots of (bodily) fluid and can be washed at high temperatures. Therefore, flannel is used often as a fabric for blankets, sheets and cloths.
• flannel is used often as a fabric for blankets, sheets and cloths.
• a breathable mat comprises means for allowing attachment of the mat to a base, preferably a mattress. More preferably, a mat comprises means for allowing reversible attachment of the mat to a base, more preferably a mattress.
• Attachment of a breathable mat to a mattress avoids movement of the mat with respect to the mattress. This is essential with respect to the comfort of a user, but it also plays an important role as to the safety of a user. Thanks to attachment of a mat to a mattress, it is avoided that the mat moves or shifts in such way with respect to the mattress that a user of the mattress - or mat - rolls or falls and gets hurt.
• the provision of a reversible attachment of the mat to a mattress allows to loosen the respective mat of one mattress and to attach it to another mattress. This has the advantage that only the mat - and not the complete mattress - has to be transported, and that, when buying a new or another mattress, the same mat can be attached and used. Furthermore, the reversibility of the attachment allows to wash only the mat, without having to wash the complete mattress.
• the breathable mat can be washed at a temperature up to 60°C. Consequently, a mat according to the present invention can be washed by a machine. This allows a respective mat to be washed regularly as a result of which the cleanliness and hygiene of the mat is maintained.
• a breathable mat which is part of a mattress has a length and/or width that is equal to or is larger than the length and/or width of the respective mattress.
• a breathable mat according to the present invention is not limited to attachment or provision to a mattress, but that a mat according to the present invention can be attached or provided at any base, device or apparatus supporting one or a plurality of babies.
• a breathable mat according to the present invention is selected from the group consisting of 31 x 71 cm, 34 x 75 cm; 40 x 80 cm; 40 x 90 cm; 40 x 60 cm; 60 x 120 cm, 70 x 140 cm, 70 x 150 cm, 70 x 160 cm, 75 x 95 cm, 97 x 97 cm, and 90 x 200 cm.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Health & Medical Sciences (AREA)
• General Health & Medical Sciences (AREA)
• Pediatric Medicine (AREA)
• Invalid Beds And Related Equipment (AREA)
• Knitting Of Fabric (AREA)
• Carpets (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (1)

Publications (4)

Family

ID=57906373

Family Applications (1)

Country Status (3)

Cited By (1)

Family Cites Families (4)

• 2016
  • 2016-12-30 BE BE2016/5994A patent/BE1024424B1/nl active IP Right Grant
• 2017
  • 2017-12-22 EP EP17210204.8A patent/EP3342911B1/fr active Active
  • 2017-12-22 ES ES17210204T patent/ES2962652T3/es active Active

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