EP4489618A1 - Matelas thermoplastiques double face sous forme de matelas portable comprenant au moins une couche de matelas en fibres thermoplastiques, procédé de fabrication des couches de matelas dudit matelas et dispositif de mise en oeuvre dudit procédé - Google Patents

Matelas thermoplastiques double face sous forme de matelas portable comprenant au moins une couche de matelas en fibres thermoplastiques, procédé de fabrication des couches de matelas dudit matelas et dispositif de mise en oeuvre dudit procédé

Info

Publication number
EP4489618A1
EP4489618A1 EP23723641.9A EP23723641A EP4489618A1 EP 4489618 A1 EP4489618 A1 EP 4489618A1 EP 23723641 A EP23723641 A EP 23723641A EP 4489618 A1 EP4489618 A1 EP 4489618A1
Authority
EP
European Patent Office
Prior art keywords
mattress
nozzles
fibres
thermoplastic
infeed
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.)
Pending
Application number
EP23723641.9A
Other languages
German (de)
English (en)
Inventor
Marcin Kamil MICHALSKI
Tomasz WELENC
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Refoamed Sp Z OO
Original Assignee
Refoamed Sp Z OO
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from PL440611A external-priority patent/PL246666B1/pl
Application filed by Refoamed Sp Z OO filed Critical Refoamed Sp Z OO
Publication of EP4489618A1 publication Critical patent/EP4489618A1/fr
Pending legal-status Critical Current

Links

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
    • A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
    • A47C27/122—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with special fibres, such as acrylic thread, coconut, horsehair
    • 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
    • A47C31/007—Anti-mite, anti-allergen or anti-bacterial means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/345—Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
    • B29C48/83—Heating or cooling the cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/875—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling for achieving a non-uniform temperature distribution, e.g. using barrels having both cooling and heating zones
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/91—Heating, e.g. for cross linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G11/00—Finished upholstery not provided for in other classes
    • B68G11/02—Finished upholstery not provided for in other classes mainly composed of fibrous materials
    • B68G11/03—Finished upholstery not provided for in other classes mainly composed of fibrous materials with stitched or bonded fibre webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G7/00—Making upholstery
    • B68G7/02—Making upholstery from waddings, fleeces, mats, or the like
    • B68G7/04—Making upholstery from waddings, fleeces, mats, or the like by conveyor-line methods
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/83—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M16/00—Biochemical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. enzymatic
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/06—Processes in which the treating agent is dispersed in a gas, e.g. aerosols
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92561—Time, e.g. start, termination, duration or interruption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92704—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/355—Conveyors for extruded articles
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D01F1/103—Agents inhibiting growth of microorganisms
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/30—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising olefins as the major constituent

Definitions

  • a double-sided thermoplastic mattress in the form of a sleeping pad comprising at least one mattress layer made of thermoplastic fibres, a method of manufacturing of the mattress layers of the said mattress and a device to implement the said method
  • the subject-matter of the invention is a double-sided thermoplastic mattress in the form of a sleeping pad comprising at least one mattress layer made of thermoplastic fibres, a method of manufacturing of the mattress layers of the said mattress and a device to implement the said method.
  • mattresses made of chemical foam are known from the prior art.
  • utility model description PL68734 Y1 provides for a double-sided foam mattress in a cover, having the form of a rectangular sleeping pad with horizontal channels located longitudinally and transversely crossing each other.
  • spatial elements are inseparably attached to the longer sides of the said mattress pad to form rectangular planes of the mattress and its edges, which have the shape of a cuboid, and are made of a foam much more firm than the foam of which the mattress pad is made, and the channels are located on the both opposite surfaces of the mattress pad, the channels on one side of the mattress pad being deeper than the channels located on its other side.
  • Utility design PL63662 Y 1 describes a mattress consisting of a lower base part (A) made of a traditional resilient polyurethane foam, whose upper surface is formed by evenly distributed depressions and protuberances, with the tops of the protuberances touching the upper part (B), whereby the hollow recesses contain empty spaces; in addition, upper part (B) is made of a foam material, which is characterised by low elasticity with high cushioning capacity and slow return to its original shape after deformation.
  • Canadian patent application CA2958348 describes a mattress set consisting of a layer of polyurethane foam comprising a porous foam body containing a plurality of air pockets; and a gel and an antimicrobial agent mixed and soaked into the foam in such a way that the gel and the antimicrobial agent occupy the air pockets of the porous foam body.
  • the antimicrobial agent comprises a polymer in an amount of 90 to 99.9 weight percent, an oxidant in an amount of 0.004 to 1 weight percent and metallic silver in an amount of 0.002 to 1 weight percent, the weight percent being based on the total weight of the antimicrobial agent.
  • oxidant in an amount of 0.004 to 1 weight percent
  • metallic silver metallic silver in an amount of 0.002 to 1 weight percent
  • document CN111188125 discloses a nano-antimicrobial medical mattress and a method of manufacturing it.
  • the disclosed method of producing antimicrobial mattresses includes the following steps: degumming a sheet of coconut fibre and processing it to obtain coconut fibre; immersing the coconut fibre in a methylthiodiazomethane solution, mixing, followed by immersion in solvents and then loading the coconut fibre with methylthiodiazomethane in a heat treatment of the coconut fibre, followed by washing and drying to obtain a modified coconut fibre.
  • the modified coconut fibre is then exposed to the nanosilver dispersion in the conditions with an increased temperature.
  • the fibres are then centrifuged and washed to obtain nanosilver-modified coconut palm fibre composites.
  • the silver- modified coconut fibre composites and kapok fibre were then blended to produce the blended fibres.
  • a board was then produced of the resulting blended fibres together with a polyurethane solution by means of a cold pre-moulding involving a dedicated board followed by a hot moulding process.
  • the stage of heating the extruded fibres in the outer vertical heaters zone further stabilises their structure, protects the fibres from premature cooling as they leave the nozzle and flow into the water, increases the extent to which the threads are twisted and, in the silver-ion-coating variants, ensures increased binding of the silver ions to the surface of the thermoplastic fibres;
  • the mattress according to the invention allows absorbing heat from the user’s body. The resulting temperature is then transferred through the structure of the mattress;
  • the mattress according to the invention absorbs less than 38% water.
  • the mattress layers of the mattress according to the invention are characterised by a high water throughput of 99 to 99.8%; • High air throughput, i.e. the amount of air diverted from one side of the mattress that has passed to the other side of the mattress, reaching up to 90%; It is worth noting that some of the air bounces back, or propagates in a direction transverse to the direction from which it is blown into the mattress;
  • the mattress according to the invention is easy to clean, since the total drying time of its mattress layer does not exceed 18 hours, and within 1 hour, the mattress is dry in 85%; whereby, the drying time was determined after water been shaken/squeezed off the mattress layer for 10 seconds subsequently to the mattress layer fully absorbing water;
  • each fibre of the mattress layer of the mattress according to the invention is modified with silver ions, which adds antibacterial properties to the mattress; furthermore, because each fibre of the mattress material is coated with silver ions, the entire body, rather than only the surface of the mattress, has antibacterial properties.
  • the invention covers a double-sided mattress made of thermoplastic material in the form of a sleeping pad comprising at least one mattress layer made of thermoplastic fibres, characterised in that it has a resilience of 40 to 70 per cent, a water permeability of at least 90 per cent and each layer has a density of 30 to 190 kg/m 3 .
  • Both the mattresses and the mattress layers according to the invention manufactured using the method according to the invention are widely applicable for industrial manufacturing. In particular, they can be intended for the manufacture of mattresses for humans or animal beds.
  • Another envisaged potential use of the mattress according to the invention is a pillow, headrest, seat or overlay for an existing mattress.
  • the mattress comprises a single mattress layer. In another one, the mattress comprises two mattress layers, whereby said layers may be identical or different. In another embodiment, the mattress according to the invention comprises three mattress layers, wherein said mattress layers may be identical or different.
  • the resilience of the mattress according to the invention is 40%, whereby in another one, the resilience is 44%. In yet another embodiment, the resilience is at least 50%, advantageously 52% and advantageously 54%. In another embodiment, the resilience of the mattress is at least 60%. In another embodiment, the resilience of the mattress according to the invention is 70%.
  • the water throughput of the mattress according to the invention is 93%. In other embodiments, the water throughput of the mattress according to the invention is 95%. In other embodiments, the water throughput of the mattress according to the invention is 98%. In an advantageous embodiment, the water throughput through the mattress is 99.5%. In another embodiment, the water throughput through the mattress is 99.99%.
  • the mattress according to the invention absorbs less than 38% water.
  • each fibre of the mattress layer is coated with silver ions.
  • the mattress according to the invention comprises silver in an amount ranging from 0.00005% to 0.0001% by the weight of the filling of the entire mattress.
  • the mattress layer is made of fibres of uniform diameter. In some embodiments, the diameter of the fibres of the mattress layer is 0.6 mm. In other embodiments, the diameter of the fibres of the mattress layer is 0.7 mm or 0.8 mm or 0.9 mm or 1.00 mm or 1.1 mm or 1.5 mm, respectively.
  • the mattress layer of the mattress according to the invention is made of fibres of different diameters.
  • the fibres of which the mattress layer is made come in two different diameters.
  • the first diameter is 0.7 mm and the other one is larger than 0.7 mm and may be, for example, 1.00 mm.
  • the first diameter is 0.6 mm and the other one is greater than 0.7 mm and may be, for example, 0.7 mm.
  • the first diameter is 0.6 mm and the other one is greater than 0.7 mm and may be, for example, 1.5 mm.
  • the time for complete drying of the mattress layer of the mattress according to the invention after prior shaking of the mattress for 10 seconds is up to 24 h. In some embodiments, after 1 h the mattress is 80% dry. In the advantageous embodiment, the mattress dries 80-93% after 1 hour. In the advantageous embodiment, the mattress dries 99% after 1 hour. In the advantageous embodiment, the mattress dries 83-96% after 2 hours. In the advantageous embodiment, the mattress dries 100% after 2 hours. In the advantageous embodiment, the mattress dries 89-99% after 6 hours. In the advantageous embodiment, the mattress dries 100% after 6 hours. In the advantageous embodiment, the mattress dries 96-100% after 18 hours. Whereby, the drying time was determined after water had been shaken/ squeezed off the mattress layer for 10 seconds subsequently to the mattress layer fully absorbing water.
  • the velocity of air after it has passed through the mattress is at least 5 km/h with the input velocity of 18.72 km/h. In the advantageous embodiments, the velocity of the air after it has passed through the mattress is 5.14 km/h or 7.23km/h or 14.25 km/h.
  • the mattress layers according to the invention were used to manufacture a double-sided mattress.
  • the mattress layers can be placed in a cover.
  • the double -sided mattress made of thermoplastic materials comes in the form of a rectangular sleeping pad, which can be intended both for human or animal use, in particular for pets (such as, for example, dogs or cats).
  • the mattress according to the invention comprising mattress layers manufactured using the method according to the invention consists of at least one mattress layer.
  • the mattress may consist of a single mattress layer.
  • the mattress according to the invention consists of two mattress layers.
  • the mattress according to the invention consists of three mattress layers.
  • the mattress according to the invention consists of six mattress layers. Whereby, it is also possible to manufacture mattress consisting of more mattress layers.
  • a single mattress may comprise the same or different mattress layers.
  • the said different mattress layers may differ from each other in e.g. dimensions (i.e. length, width, density), resilience or density.
  • the individual mattress layers can be stacked on top of each other, side by side or in a combination of these ways.
  • the mattress layer produced using the method according to the invention is used to produce a double-sided mattress according to the invention with a modular structure, where a mattress layer produced by the method according to the invention, which performs the function of a panel, is referred to as a "module".
  • a module a mattress layer produced by the method according to the invention, which performs the function of a panel.
  • Several panels arranged in one plane make it possible to select different modules as desired.
  • the multiple panels may also be arranged in multiple layers, each of which may contain two or more panels.
  • the mattress is made of six modules (panels), each of which is a mattress layer made using the method according to the invention. Whereby, the said six modules are arranged in two layers (three modules in each layer).
  • the mattress is made of six modules (panels), each of which is a mattress layer made using the method according to the invention. Whereby, said six modules are arranged in two layers (three modules in each layer) and the middle module (panel) of the upper layer has an increased density with respect to the other two panels of the upper layer. This is for the sake of a lesser sinking of the lumbar section and an increased comfort for some people.
  • the mattress is made of six modules (panels), each of which is a mattress layer made using the method according to the invention.
  • said six modules are arranged in two layers (three modules in each layer) and the middle module (panel) of the upper layer has an increased density with respect to the other two panels of the upper layer.
  • the middle panel of the bottom layer has a reduced density relative to the other two panels of the bottom layer.
  • the modular mattress contains two layers, with three panels in each layer.
  • a mattress comprising mattress layers made using the method according to the invention exhibits a resilience of 40 to 70%. Furthermore, each layer of the said mattress has a density ranging from 30 to 190 kg/m3, whereby each fibre of the mattress layer is coated with silver ions.
  • the air permeability of the mattress according to the invention will be 100%.
  • the mattress according to the invention has an air throughput between 70% and 98%.
  • the mattress according to the invention is characterised by an air throughput of 80-94%.
  • a double-sided mattress measuring 120x200 cm with a resilience of 55% contains a single mattress layer made according to the invention with a thickness of 11 cm and a density of 80 kg/m3. Its air throughput, on the other hand, is 92%.
  • a double-sided mattress measuring 180x200 cm with resilience of 60% contains two mattress layers made according to the invention with the thickness of 25 cm and density of 120 kg/m3.
  • a double-sided mattress measuring 120x60 cm with a resilience of 50% contains a single mattress layer made according to the invention with the thickness of 11 cm.
  • the mattress according to the invention is a double-sided mattress measuring 1.40 x 0.66 m with a resilience of 48% containing two mattress layers each fibre of which is coated with silver ions. Whereby, each layer has a thickness of 6 cm and a density of 100 kg/m3. Its air throughput, on the other hand, is 90%.
  • the mattress according to the invention is a double-sided mattress measuring 120x200 cm with a resilience of 60%, containing a single mattress layer with a thickness of 11 cm and a density of 120 kg/m3. Whereby, each fibre of the mattress layer is coated with silver ions. Its air throughput, on the other hand, is 88%.
  • the mattress according to the invention is a double-sided mattress measuring 180x200cm with a resilience of 60%.
  • the mattress contains three mattress layers with a total thickness of 25 and a density of 120 kg/m3 (two layers each 10 cm thick and one having a thickness of 5 cm).
  • the mattress consists of three layers stacked on top of each other and has an air throughput of 82%.
  • the inventors carried out a number of tests to check the durability of the mattress according to the invention.
  • the ageing tests carried out showed that the deformation rate of the mattress according to the invention containing mattress layers made using the method according to the invention does not exceed 10% after 10 years.
  • the invention comprises a method of manufacturing mattress layers forming a mattress according to the invention.
  • the method of manufacturing a mattress layer of thermoplastic fibres according to the invention is a continuous process.
  • the feedstock constituting the material for producing the mattress layer may be Affinity 1280G, LLDPE, Braskem PP C123-01N, DOWTM LDPE 150ELDPE, another thermoplastic raw material or various combinations of known thermoplastic raw materials.
  • the granulate in the heating zones of the extruder auger is heated at a temperature between 145 °C and 280 °C for a minimum of 2 minutes so as to melt the granulate.
  • the temperature is 145 °C at this stage.
  • the temperature is 180 °C at this stage.
  • the temperature is 200 °C at this stage.
  • the temperature is 250 °C at this stage.
  • the temperature is 280 °C at this stage.
  • the next stage is the extrusion of fibres through a plurality of directed downwards dispersing nozzles of the extruder.
  • the diameter of each of the plurality of the dispersing nozzles used at this stage is 0.6 mm. In other embodiments, the diameter of the dispersing nozzles is 0.7 mm or 0.8 mm or 0.9 mm or 1.00 mm or 1.1 mm or 1.5 mm.
  • the outer vertical heaters are heated up to a temperature of 150°C-285°C.
  • the outer vertical heaters are heated up to a temperature of 230-250 °C.
  • the outer vertical heaters are heated up to 230 °C.
  • the method according to the invention provides that after passing through the outer vertical heaters, the thermoplastic fibres are transferred to a cooling tank containing a coolant kept at 2 - 8 °C, and the fibres are loosened and formed for 45 sec. to 5min. on the moulding rollers of the cooling tank, yielding thus a conjugate of a predetermined thickness.
  • the coolant in the cooling tank is kept at 5 - 8 °C.
  • the temperature is 4 °C.
  • the said coolant is water.
  • the conjugate moulded to the desired thickness is then transferred to the feed rollers that hold the conjugate under the surface of the coolant, and then to the infeed-receiving belt connecting the cooling tank with the post-heating furnace.
  • the method according to the invention provides that the moulded conjugate passes through the postheating furnace for 45 sec to 5 minutes, where it is subjected to a temperature of 120 to 350 °C.
  • the additional formation of the conjugate in the post-heating furnace in accordance with the method according to the invention provides improved bonding between the individual filaments of the conjugate to ensure a higher durability of the manufactured mattress material upon long-term use and provides improved fibre bonding, which reduces the level of deformation of the mattresses and improves their resilience.
  • a temperature of 200, 240 or 288 °C is applied.
  • the conjugate after passing through the post-heating furnace, is treated with hot air at 150 °C. In another advantageous embodiment, the conjugate is treated with hot air at 200 °C. In another advantageous embodiment, the conjugate is treated with hot air at 200 °C. In another advantageous embodiment, the conjugate is treated with hot air at 290 °C. In another advantageous embodiment, the conjugate is treated with hot air at 350 °C.
  • the conjugate After passing through the post-heating furnace, the conjugate is trimmed to a predetermined width by the edge knives of the infeed-receiving unit. Subsequently, the infeed-measuring unit with a distance sensor measures the pre-set length of the mattress layer, after which the conjugate is cut to the designated length by a cross-cutting device located downstream the infeed-receiving unit and equipped with a crosscutting knife actuator pressing the cut material. After being cut to the pre-set length, the resulting mattress layer is transferred to a receiving belt to receive the ready mattress layers.
  • the invention comprises a device for producing a mattress layer from thermoplastic fibres, which comprises an extruder unit, a cooling tank, a post-heating furnace and an infeed-receiving unit.
  • the infeed-receiving unit is followed by a receiving-infeed unit equipped with an infeed-measuring unit, behind which a cross-cutting device ending in a receiving belt to receive the ready material layers is located.
  • the extruder unit comprises a raw material feed unit connected to a tripartite auger where the second leg is connected to a gearbox connected to a three-phase motor and the third leg of the tripartite auger is elongated and equipped with multiple heating zones and cooling fans.
  • the last heating zone of the auger is connected to the extruder by a connector (e.g. an elbow).
  • each of the heating zones is equipped with a cooling fan.
  • the auger contains seven heating zones, each of which is equipped with a cooling fan.
  • the extruder includes inside built-in heaters and ends in a plurality of manufacturing nozzles (e.g., may include 1000 nozzles) aligned vertically downwards.
  • the extruder is equipped with nozzles, each with a diameter of 0.6 mm.
  • the extruder is equipped with nozzles, each with a diameter of 1.00 mm.
  • nozzles with other diameters can also be used.
  • the extruder comprises nozzles with different diameters.
  • the extruder comprises nozzles with two diameters.
  • the extruder comprises nozzles of two diameter sizes (diameter 1 and diameter 2) where diameter 1 is 0.7 mm and diameter 2 is greater than 0.7 mm and is 1.00 mm.
  • opposing outer vertical heaters are installed on the housing of the cooling tank to infuse silver ions into the extruded fibres and to cure the fibres coated with silver ions.
  • the spacing of said outer vertical heaters is wider than the spacing of the extruder manufacturing nozzles.
  • the cooling tank is provided with moulding rollers whose task is to form the extruded fibres.
  • feed rollers whose function is to keep the moulded conjugate below the surface of the coolant and to feed it to an infeed-receiving belt connecting the said cooling tank with a post-heating furnace, which is equipped with built-in heaters to cure the conjugate and fans to mix the air inside the furnace.
  • the aforementioned post-heating furnace is equipped with cooling fans.
  • a infeed-receiving belt runs through the entire working space of the post-heating furnace, transporting the moulded conjugate from the cooling tank to the infeed-receiving unit located downstream the post-heating furnace.
  • the terminal hot air nozzles are located at the outlet of the furnace.
  • the infeed-receiving unit located downstream of the post-heating furnace is equipped with pressure rollers and edge knives which cut the cured conjugate to the desired width.
  • the pressure rollers owing to the pressure rollers the material is cut evenly by the edge knives. If it were not for the pressure rollers in the manufacturing process, the edge knives might translocate the material.
  • the infeed-receiving unit is followed by a receivinginfeed unit equipped with an infeed-measuring unit, behind which a cross-cutting device ending in a receiving belt to receive the ready material layers is located.
  • the receiving-infeed unit is equipped with an infeed-measuring unit and a distance sensor, whose task is to measure the mattress layer at an appropriate spacing to be cut to the designated length by the cross-cutting device located downstream the receiving-infeed unit and equipped with a cross-cutting knife, actuators to press the material being cut and a receiving belt to receive the ready mattress layers.
  • fig. 1 presents a diagram of the heating zones, the infeed unit and the extruder motor of the device according to the invention
  • fig. 2 presents a diagram of a section of the device according to the invention with particular reference to the location of the nozzles dispersing silver ions and the outer heaters placed vertically towards the outlet of the manufacturing nozzles of the extruder
  • fig. 3 presents, on a diagram, the juxtaposition of the extruder with the cooling tank of the device according to the invention
  • fig. 4 shows a diagram of the post-heating furnace of the device according to the invention
  • fig. 5 presents, on a diagram, the infeed-receiving unit with edge knives
  • FIG. 6 depicts a receiving-infeed unit with an infeed-measuring unit; fig. 7 shows a cross-cutting device; fig. 8 shows a mattress according to the invention in an embodiment containing a single mattress layer made by the method according to the invention; fig. 9 depicts a mattress according to the invention in an embodiment containing two mattress layers manufactured using the method according to the invention; fig. 10 shows a mattress according to the invention in a two-layer embodiment, where each layer consists of three panels constituting mattress layers manufactured using the method according to the invention in a variant with an alternate arrangement of panels of different resilience in a single layer; fig.
  • FIG. 11 shows a mattress according to the invention in a two-layer embodiment, where each layer consists of three panels constituting mattress layers manufactured using the method according to the invention in a variant in which the panels of the upper layer exhibit higher resilience than those of the lower layer;
  • fig. 12 shows the results of a test using a thermal imaging camera, where A shows the view before the test, B shows the view after 60 seconds and C shows the view after 120 seconds;
  • fig. 13a shows the results of a test using a thermal imaging camera for a mattress layer according to the Oxymesh 1 invention;
  • fig. 13b shows the results of a test using a thermal imaging camera for the visco foam;
  • fig. 13c shows the test results using a thermal imaging camera for the latex foam;
  • fig. 13d shows the results of a test using a thermal imaging camera for the polyurethane foam;
  • 14 shows a conceptual drawing of the fibre arrangement in the mattress layer of a mattress according to the invention, type Oxymesh 4.
  • 1 denotes the three-phase motor of the extruder unit
  • 2 denotes the gearbox of the extruder unit
  • 3 denotes the raw material infeed unit
  • 4 denotes the auger of the extruder unit
  • 5 denotes the heating zones of the extruder auger
  • 6 denotes the coupling
  • 7 denotes the extruder
  • 8 denotes manufacturing nozzles
  • 9 denotes silver ions
  • 10 denotes dispersing nozzles
  • 11 denotes outer vertical heaters
  • 12 denotes cooling tank
  • 13 denotes moulding rollers
  • 14 denotes feed rollers
  • 15 denotes infeed-receiving belt
  • 16 denotes furnace built-in heaters
  • 17 denotes post-heating furnace cooling fans
  • 18 denotes post-heating furnace mixing fans
  • 19 denotes infeed-receiving unit
  • 20 denotes pressure rollers
  • 21 denotes edge knives
  • 22 denotes an infeedmea
  • the device according to the invention is designed to produce a mattress layer from thermoplastic fibres and comprises an extruder unit, cooling tank 12, a post-heating furnace and infeed-receiving unit 19.
  • the extruder unit comprises raw material infeed unit 3, which is connected to the first leg of tripartite auger 4.
  • the second leg of tripartite auger 4 is connected to gearbox 2 connected to three-phase motor 1.
  • the third leg of the tripartite auger 4 comprises heating zones 5 equipped with cooling fans.
  • auger 4 contains seven heating zones 5, each of which is equipped with a cooling fan.
  • the last heating zone 5 of auger 4 is connected by connector 6 in the form of an elbow to extruder 7 (fig. 2) with inside built-in heaters, which ends in a number of manufacturing nozzles 8 positioned vertically downwards.
  • extruder 8 is equipped with one thousand manufacturing nozzles 8, each of which has a diameter of 0.6 mm.
  • nozzles with a different diameter can be used (e.g. 0.7 mm or 0.8 mm or 0.9 mm or 1.00 mm or 1.1 mm or 1.2 mm or 1.5 mm).
  • cooling tank 12 filled with coolant (fig. 3).
  • the temperature of the coolant should be kept between 5 and 8 °C.
  • the coolant is water at a temperature of 5 °C.
  • two opposing lateral dispersing nozzles 10, which disperse silver ions 9 as a mist, are mounted on the housing of cooling tank 12. Whereby, the spacing of said dispersing nozzles 10 is wider than the spacing of manufacturing nozzles 8 of extruder 7. This arrangement makes it possible for the sprayed mist of silver ions 9 to cover, on both sides, the fibres extruded by the manufacturing nozzles 8.
  • opposing outer vertical heaters 11 are mounted on the housing of the cooling tank 12, which infuse the silver ions 9 into the surface of the extruded fibres and cure the fibres coated with silver ions.
  • the spacing of the said outer vertical heaters 11 is wider than the spacing of the manufacturing nozzles 8 of the extruder 7.
  • the cooling tank 12 is provided with moulding rollers 13 whose function is to form the extruded fibres.
  • feed rollers 14 whose function is to keep the moulded conjugate below the surface of the coolant and to feed it to infeed-receiving belt 15 connecting the said cooling tank 12 with the post-heating furnace, which is presented as a diagram in fig. 4.
  • the post-heating furnace is equipped with built-in heaters 16 to cure the conjugate and fans 18 to mix the air inside the furnace.
  • the said post -heating furnace is equipped with cooling fans 17.
  • infeedreceiving belt 15 transporting the moulded conjugate from cooling tank 12 to infeed-receiving unit 19, located downstream the post-heating furnace.
  • terminal hot air nozzles 28 are located at the outlet of the post-heating furnace.
  • feed-receiving unit 19 located downstream the post-heating furnace is equipped with pressure rollers 20 and edge knives 21, which cut the cured conjugate to the desired width.
  • pressure rollers 20 ensure that the material is cut evenly by the edge knives. If it were not for pressure rollers 20 in the production process, edge knives 21 might translocate the material.
  • a receiving-infeed unit equipped with an infeed-measuring unit 22 and a distance sensor 23, which serves to measure the correct length of the mattress layer to be cut to the designated length by the cross-cutting device (fig. 7) located downstream the receiving-infeed unit and equipped with a transverse cutter 25, actuators to press the cut material 26 and a receiving belt 27 to receive the ready mattress layers.
  • the diameter of one half of dispersing nozzles 10 is 0.6 mm while the diameter of the remaining dispersing nozzles 10 is greater than 0.6 mm and amounts to 0.7 mm.
  • the diameter of 30% of dispersing nozzles 10 is 0.7 mm while the diameter of the remaining dispersing nozzles 10 is greater than 0.7 mm and is 1.00 mm.
  • the device as in embodiment 1 can be used to produce a mattress layer of thermoplastic fibres.
  • the method for producing a thermoplastic fibre mattress layer according to the invention is a continuous process, the first step of which is the supply of the thermoplastic granulate to raw material infeed unit 3 of the extruder.
  • the thermoplastic material is LLDPE.
  • other thermoplastic materials e.g. (LLDPE, polyolefin plastomer, e.g. Affinity 1280G, Braskem PP C123- 01N, DOWTM LDPE 15OELDPE,) or combinations of thermoplastic materials can also be used as feedstock.
  • the granulate From the infeed unit, the granulate enters heating zones 5 of extruder auger 4, where the granulate is heated at 280°C for 2 minutes so that it is melted. After passing through heating zones 5, the melted material enters, through connector 6, extruder 7 equipped with built-in heaters and manufacturing nozzles 8 directed vertically downwards. The next stage is the extrusion of the fibres through multiple downward facing manufacturing nozzles 8 of extruder 7.
  • thermoplastic fibres are then moved downwards to outer vertical heaters 11 situated below, which operate at 250 °C.
  • the purpose of the treatment of the thermoplastic fibres is to harden them and to infuse silver into the fibre structure. Furthermore, it does not allow the fibres to lose temperature on their way from the nozzle to the water. Consequently, the more extreme difference in temperature between the cold water and the conjugate makes individual fibres more curled.
  • a single mattress layer (fig. 8) with a thickness of 11 cm and a density of 80 kg/m 3 was used.
  • the resilience of the resulting mattress is 55%.
  • each fibre of the mattress layer is coated with silver ions and the silver content of the mattress is 0.0001 % by weight of the filling of the entire mattress.
  • the mattress according to the invention has an air throughput of 92%.
  • a single mattress layer with a thickness of 11 cm and a density of 120 kg/m 3 was used to manufacture a double-sided mattress measuring 120x200 cm.
  • the resilience of the resulting mattress is 60%.
  • each fibre of the mattress layer is coated with silver ions.
  • the mattress has an air throughput of 88%.
  • the mattress layers were used to produce a double-sided mattress measuring 180x200 cm, with the resilience of 60%.
  • the mattress consists of six mattress panels (i.e. six mattress layers made by the method according to the invention) arranged in two layers with a total thickness of 25 cm and a density of 120 kg/m 3 .
  • the middle panel of the upper layer has an increased density relative to the other panels of the upper layer. This is for the sake of a lesser sinking of the lumbar section and an increased comfort for some people.
  • each fibre of each panel i.e. the mattress layers made by the method according to the invention
  • the mattress has an air throughput of 85%.
  • the mattress layers were used to produce a double-sided mattress measuring 180x200 cm with its resilience of 60%
  • the mattress contains three mattress layers with a total thickness of 25 cm and a density of 120 kg/m 3 (two layers each 10 cm thick and one having a thickness of 5 cm).
  • the mattress consists of three layers stacked on top of each other. Whereby, each fibre of the mattress layer is coated with silver ions.
  • the silver content of the mattress represents 0.00005 % by weight of the filling of the entire mattress.
  • the mattress according to the invention has an air permeability of 82%.
  • the mattress layer produced by the method according to the invention was used to produce a double-sided mattress measuring 120x60cm with a resilience of 50%.
  • the mattress was created from a single mattress layer with a thickness of 11cm. Whereby, each fibre of the mattress layer is coated with silver ions.
  • the silver content of the mattress represents 0.0001 % by weight of the filling of the entire mattress.
  • the mattress layer produced by the method according to the invention was used to produce a double-sided mattress with a modular structure.
  • the mattress according to the invention is a two-layer mattress made of a total of six panels arranged in two mattress layers made by the method according to the invention in a variant in which the panels of the upper layer show higher resilience than the panels of the lower layer.
  • the dimensions of the mattress are 120x60cm.
  • the use of the panel variant of the mattress according to the invention may facilitate transport of the mattress and in a modular way choose which density of the mattress is best for which part of the body. This provides the customer with the possibility to select the modules as desired.
  • Example 20 In this non-limiting exemplary embodiment, the physical properties of a mattress according to the invention containing a single mattress layer manufactured by the method according to the invention were tested, samples of which are denoted as:
  • Oxymesh 1 was made using the method according to embodiment 4, except that the fibres in the zone of the outer heaters 11 are heated at 250°C, the temperature in the cooling tank was 4°C, the conjugate spent 2 minutes and 15 seconds in the heating furnace at 273°C.
  • the mattress had a size of 50x50x10 cm and a material density of 70 kg/m 3 .
  • Oxymesh 2 was made using the method according to embodiment 4, except that the fibres in the zone of the outer heaters 11 were heated at 255°C, the temperature in the cooling tank was 4°C, the conjugate spent 1 minute and 22 seconds in the heating furnace at 24O°C.
  • the mattress had a size of 50x50x10 cm and a material density of 35 kg/m 3 .
  • Oxymesh 3 was made by the method according to embodiment 4, except that the fibres were heated in the zone of the outer heaters 11 at 250C °C, the temperature in the cooling tank was 4C °C, the conjugate spent 2 minutes and 44 seconds in the heating furnace at 270°C.
  • the mattress was characterised by a size of 50x50x10 cm and a material density of 120 kg/m 3 .
  • Oxymesh 4 was made similarly to embodiment 4, except that the fibres in the zone of the outer heaters 11 were heated at 250°C, the temperature in the cooling tank was 4°C, the conjugate spent 2 minutes and 15 seconds in the heating furnace at 273°C.
  • a 5 cm thick mattress layer has fibres with a diameter of 0.7 mm and the remaining 5 cm has fibres with a diameter of 1.0mm. Because the fibres connect with each other when in contact with water, then between 4 and 6 cm of the cross-sectional thickness of the mattress, some of the fibres are thicker and some are thinner (as shown in fig. 13).
  • Oxymesh 5 was made as in embodiment 4, except that the fibres were heated in the zone of the outer heaters 11 at 250°C, the temperature in the cooling tank was 4°C, the conjugate spent 2 minutes and 15 seconds in the heating furnace at 250°C, where at the outlet of the heating furnace terminal hot air nozzles 28 blew air at 250°C into the mattress layer.
  • the mattress was characterised by a size of 50x50x10 cm and a material density of 70 kg/m 3 .
  • the mattresses according to the invention were compared with mattresses of analogous dimensions (i.e. 50x50x10 cm) made of typical known materials available on the market, such as visco foam, Latex or polyurethane foam.
  • the resilience analysis was carried out using the elasticity (rebound) test, which involved dropping a steel ball on the tested piece.
  • the load ball had a weight of 3kg.
  • the rebound height was then measured to express as a percentage of height drop.
  • the ball was dropped from a height of 1.1m.
  • a camera was set up nearby to record the fall and rebound of the ball.
  • the camera's perpendicular distance from the meter was 96 cm.
  • the distance from the ground to the camera was 64 cm and 11 cm for the camera in the second alignment 'from below'. All mattress samples tested were 10 cm thick. The experiment was repeated several times.
  • the mattresses were 'forcibly' submerged under water in such a way as to absorb water into their structure.
  • the time of being submerged in water was 10 minutes.
  • the mattresses were then raised in the air for 60 seconds, to let the water out.
  • the mattresses were then weighed and the results are shown in Table 4 below:
  • the drying performance of the mattress was measured in a room with a humidity level of 40%.
  • the room temperature was 24.1 °C.
  • the floor temperature was 26.3 °C.
  • the pace of drying of the mattresses according to the invention is another fundamental advantage over existing solutions, as it allows for a fundamental reduction in the cleaning cycle of the mattresses and shortens their reuse time after cleaning.
  • the determination of the heat transfer coefficient consisted of blowing warm air from below at a distance of 25 cm on a piece of mattress structure.
  • the temperature of the mattress and the temperature distribution for the different mattress materials were examined before the test, after 60 seconds and after 120 seconds using an HTI HT-18 thermal imaging camera.
  • the room temperature was 11 °C+/-1.0°C.
  • test showed the air throughput of the mattress according to the invention and the exchange of warm air for cold air. While such results were not obtained with mattresses known from the state of the art.
  • the water throughput test was conducted for different mattress materials. A piece of the test mattress material was placed over a container of water in such a way that the water could only seep through the material, while it was impossible to pour water that 'bounced' off the mattress back into the container. Slowly, 1,000 grams of water were poured and 10 minutes were allowed to examine the results. The test was repeated 10 times. The results are shown in Table 7 below:
  • thermometer with a probe was used for the test, where the probe (thermometer) was inserted into the centre of the sample to a depth of 6 cm inside the mattress sample and halfway through the thickness of the sample, i.e. 5 cm.
  • the room temperature during the tests was 21.0+/- 1.0°C.
  • thermometer measured the temperature inside the structure
  • a thermal imaging camera was used to observe the temperature changes that were taking place outside.
  • the mattress loses temperature throughout the volume, not just from the inside.
  • the results obtained are shown in fig. 13a - 13d.
  • the thermal imaging camera it was noted that the Oxymesh 1 structure exhaled temperature differently to the foams tested according to Table 9. The temperature decreased throughout the volume of the mattress, and most rapidly from the bottom. For visco, latex and polyurethane foams, the exhalation of the temperature occurred in the direction from the corners to the centre of the tested mattress layer.
  • the heat loss rate of the mattress according to the invention was determined to be at least 30% within 10 minutes, advantageously 50 per cent.

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Abstract

L'objet de l'invention est de fournir un matelas thermoplastique double face sous forme de matelas portable comprenant au moins une couche de matelas en fibres thermoplastiques, caractérisé par une résilience comprise entre 40 et 70 %, une perméabilité à l'eau d'au moins 90 % et une densité de chaque couche comprise entre 30 et 190 kg/m3. Un autre objet de l'invention est de fournir un procédé de fabrication en continu, et un dispositif de production d'une couche de matelas en fibres thermoplastiques pour un tel matelas.
EP23723641.9A 2022-03-11 2023-03-12 Matelas thermoplastiques double face sous forme de matelas portable comprenant au moins une couche de matelas en fibres thermoplastiques, procédé de fabrication des couches de matelas dudit matelas et dispositif de mise en oeuvre dudit procédé Pending EP4489618A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
PL440611A PL246666B1 (pl) 2022-03-11 2022-03-11 Urządzenie do wytwarzania warstwy materacowej, sposób wytwarzania warstwy materacowej oraz materac zawierający wspomnianą warstwę
PL444043A PL444043A1 (pl) 2022-03-11 2023-03-11 Materac dwustronny z tworzyw termoplastycznych w postaci podkładu do spania składający się z co najmniej jednej warstwy materacowej z włókien termoplastycznych, sposób wytwarzania warstw materacowych wspomnianego materaca oraz urządzenie do realizacji tego sposobu
PCT/IB2023/052370 WO2023170663A1 (fr) 2022-03-11 2023-03-12 Matelas thermoplastiques double face sous forme de matelas portable comprenant au moins une couche de matelas en fibres thermoplastiques, procédé de fabrication des couches de matelas dudit matelas et dispositif de mise en œuvre dudit procédé

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EP4489618A1 true EP4489618A1 (fr) 2025-01-15

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EP23723641.9A Pending EP4489618A1 (fr) 2022-03-11 2023-03-12 Matelas thermoplastiques double face sous forme de matelas portable comprenant au moins une couche de matelas en fibres thermoplastiques, procédé de fabrication des couches de matelas dudit matelas et dispositif de mise en oeuvre dudit procédé

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KR102639110B1 (ko) * 2023-09-25 2024-02-21 주식회사 오리고코리아 누들 형태의 침구류 충전재

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CN105377083B (zh) * 2014-02-23 2017-08-29 喜恩吉股份有限公司 垫子芯材料及垫子
CN108606544A (zh) * 2018-05-29 2018-10-02 上海沐恒实业有限公司 立体网状结构
CN210471636U (zh) * 2019-08-13 2020-05-08 福建丹海新材料科技有限公司 一种竹原纤维银离子多功能床垫

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