ES2962652T3 - Procedure to produce a breathable mat - Google Patents

Abstract

The present invention relates to a method of producing a breathable mat, preferably a child's bed mat. The respective method comprises the manufacture of a compact fabric product, the stretching of said compact fabric product and the thermal fixation of the stretched fabric product. Furthermore, the invention relates to a breathable mat. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Procedure to produce a breathable mat

TECHNICAL DOMAIN

The invention relates to a method for producing a breathable mattress, in particular a breathable mattress for a children's bed.

STATE OF THE TECHNIQUE

The invention relates to a process for producing a breathable mattress and to a breathable mattress obtained by a process according to the invention.

Sometimes it happens that the breathing of babies or small children is strongly obstructed because they roll on their stomach and do not yet have the reflex to roll over again.

However, getting enough sleep is part of a healthy lifestyle and guarantees, especially for babies and young children, good physical and mental development. In addition, sleeping contributes to the release and relaxation of the body and mind. The number of hours of sleep per day that are necessary to get enough rest depends on each person. Additionally, the average number of hours of sleep needed to get enough sleep decreases as you age. For example, a 30-year-old adult needs an average of 7 to 9 hours of sleep per day, while a newborn baby 0 to 3 months old needs an average of 14 to 17 hours of sleep per day.

People, and especially babies, therefore, spend a substantial part of the day sleeping. Therefore, it is important to adopt a healthy, safe and comfortable position while sleeping.

Therefore, it is important that the parts of the body that are in contact with a mattress while sleeping are sufficiently ventilated to avoid overheating and damage or discomfort to the respective body parts. This is certainly also important with regard to bedridden people.

It is also known that sufficient, and possibly adaptive, support of body parts such as the neck and back is essential for a good night's rest. The current state of the art already describes personalized mattresses that are modified based on the specific anatomy of each person.

Three-dimensional fabrics or fabrics for use as a mattress have been described in EP1426473 and WO1996001602. A flexible breathable fabric having a liquid-permeable and breathable top surface layer was described in WO2001011127. Document WO2011107579 relates to a mattress for use in nursing homes and hospitals.

Although the current state of the art already describes one or more sleeping mats that can solve part of these problems, there is still a need for alternatives and/or optimization to solve these problems.

There is also a need for an efficient and effective procedure for producing a mattress that can offer a solution for one or more of the problems mentioned above.

The present invention aims to find a solution for at least some of the problems mentioned above.

SUMMARY OF THE INVENTION

The invention relates to a process for producing a breathable mattress according to claim 1.

DETAILED DESCRIPTION

The invention relates to a method for producing a breathable mat, in particular a breathable sleeping mat for a children's bed.

Unless otherwise specified, all terms used in the description of the invention, including technical and scientific terms, shall have the meaning generally understood by one skilled in the technical field of the invention. For a better understanding of the description of the invention, the following terms are specifically explained.

"A", "an" and "the" refer in the document to both the singular and plural forms, unless clearly understood differently in the context. "A segment" means, for example, one or more than one segment.

When "approximately" or "around" is used in the document in conjunction with a measurable quantity, a parameter, a period or moment, etc., it means variations of /-20% or less, preferably /-10% or less, more preferably /-5% or less, even more preferably /-1% or less, and even more preferably /-0.1% or less than and of the cited value, to the extent that said variations apply to the invention that is described. However, it will be clearly understood that the value of the quantity in which the term "about" or "about" is used is itself specified.

The terms "include", "including" and "provide" are synonyms and are inclusive or open terms that indicate the presence of what follows, and that do not exclude or avoid the presence of other components, characteristics, elements, members, stages, known from or described in the state of the art.

Citing numerical intervals by means of endpoints includes all whole, fractional, and/or real numbers between the endpoints, including these endpoints.

The invention relates to a process for producing a breathable mat, preferably a sleeping mat for a children's bed. The method comprising manufacturing a compact three-dimensional woven product by means of a knitting machine, wherein said woven product is maintained under tension during manufacturing; stretching said compact three-dimensional fabric product; and thermally fixing the stretched fabric product.

The term "three-dimensional woven product" in the description of the invention refers to the distinction with a conventional, two-dimensional woven product. Conventional knitting products comprise a layer of textile material consisting, in a simplified embodiment, of a series of rows with a series of stitches. For the manufacture of conventional fabric products comprising a plurality of layers of textile material, different layers of textile material must be sewn together or hemmed must be provided. However, three-dimensional fabric products comprise a plurality of layers of textile material without having to be sewn together and without having to provide one or more hems.

In the description of the present invention, the term "thermal fixation" refers to a process in which fibers, yarns, fabrics, textile materials and/or a fabric product are heat treated to stabilize them.

In a method of the present invention, a compact three-dimensional knitted product is made by means of a knitting machine. By keeping such a fabric product under tension during the manufacturing process, the fabric product is continuously stretched as a result of which stronger and larger stitches can be manufactured than when tension is not maintained. The solidity of the stitches prevents unwanted loosening of the stitches during the further production process or use of the knitted product or sleeping pad produced, while larger stitches cause a larger mesh in the material textile and, consequently, increase the breathability of the fabric product and the ultimately produced sleeping mat. In fact, it is important that the textile material can be stretched later during production to increase the mesh in the textile material and therefore cause a breathable structure in the textile material.

Stretching the three-dimensional knit product during the manufacture of a three-dimensional knit product also brings about the advantage that the knit product is continuously stretched as a result of which stitches, rows of stitches and layers thereof can be applied much more easily. . straighter and more equal.

In particular, a three-dimensional woven product with a honeycomb structure pattern is manufactured. A three-dimensional honeycomb structure pattern offers sufficient support and offers support that extends equally over the entire surface of the respective fabric product. In addition, the tights with the honeycomb structure pattern provide breathability of the fabric. Preferably, the honeycomb structure pattern especially comprises hexagonal conformations.

In particular, in a method of the invention, a tension is applied to the compact three-dimensional fabric product, increasing the width of the respective fabric product by 10% to 50%, compared to when no tension is applied to the fabric product. respective fabric.

By stretching the fabric product only to a limited extent during the manufacturing step, a relatively compact, solid and uniform three-dimensional fabric product is manufactured. This allows the fabric product to be stretched in a more controlled manner in a further step of a process for manufacturing a breathable mattress pad following the invention. In a preferred embodiment, the compact three-dimensional woven product has a width of 180 to 220 cm during manufacturing and under tension. Preferably, the compact three-dimensional woven product has a width of 120 to 150 cm when no tension is applied to the woven product.

The number of needles per inch of a knitting machine is a measure of the fineness of the stitches that can be knitted by the respective knitting machine. The more needles per inch a knitting machine has, the finer the stitches can be.

In a method of the present invention, preferably, fine stitches have to be knitted, since in this way a large number of stitches can be knitted in a relatively small surface and/or volume. This has the advantage that a compact three-dimensional woven product manufactured in accordance with the present invention can exhibit a combination of both large mesh and high fastness.

In particular, a method of the present invention comprises the manufacture of a compact three-dimensional knitted product by means of a knitting machine comprising 12 needles per 2.54 cm (1 inch).

Another parameter of a knitting machine is the rolling plate distance. The larger the laminating plate distance, the thicker the manufactured fabric product can be; and analogously, the smaller the laminating plate distance, the thinner the fabric product manufactured can be. Depending on other parameters during the manufacture of a compact three-dimensional knitting product, such as the number of needles per inch, the yarn and the knitting pattern, it may be advantageous to adjust the laminating plate distance and therefore the thickness of the product. of manufactured fabric.

In particular, a method of the invention comprises manufacturing a compact three-dimensional knitted product by means of a knitting machine having a laminating plate distance of 3 to 15 mm, preferably 5 to 12 mm and more preferably 8 mm. .

In particular, a method of the invention comprises the manufacture of a compact three-dimensional knitted product by means of a knitting machine comprising at least two rolls of yarns. In one embodiment of the method, the respective thread rolls comprise a different thread.

Using two or more rolls of yarn, possibly comprising a different yarn, allows more complex knitting patterns to be woven. The possibility of weaving more complex patterns allows for the production of three-dimensional woven products and, ultimately, produced mats, which have a greater degree of variation, adaptation and/or customization.

In particular, the three-dimensional woven product is manufactured at a speed of 12 to 18 meters per hour.

After manufacturing a three-dimensional knitted product, the manufactured compact three-dimensional knitted product is stretched.

A manufactured three-dimensional fabric product experiences unwanted deformations when no tension is maintained. Stretching the fabric product manufactured such as in a process of the invention makes it possible to avoid and eliminate said deformations, and makes it possible to give and maintain the desired fabric product in a more desired conformation.

As stated above, the compact three-dimensional woven product stretches only slightly during the manufacturing stage. As a result, a relatively compact woven product is manufactured that still has great potential to stretch. In a method of the present invention, the compact three-dimensional woven product is substantially stretched after the manufacturing process so that the meshes in the textile structure of the woven product are enlarged. Larger meshes increase the breathability of the knitted product.

More specifically, stretching of the woven product is performed by causing and maintaining similar tensile forces on both the longitudinal sides and the width of the compact three-dimensional woven product. In this way, a stretched fabric product is obtained that stretches on all sides in similar proportions and therefore has a uniform textile structure and pattern over the entire stretched fabric product. Possibly, the thickness of the tightly woven product is also stretched in an analogous manner. Said uniform textile structure would not be obtained when large tension and/or traction forces were already maintained during the manufacture of the compact three-dimensional fabric product. The separation of the manufacturing step of a compact three-dimensional fabric product and the stretching step of the respective fabric product allows a controlled stretching of the fabric product.

In particular, the fabric product is stretched when a mesh is obtained in the textile material of 0.5 to 10 mm and, preferably, 2 to 4 mm. The respective mesh allows the stretched fabric product to be both sufficiently breathable and supportive, and at the same time feel comfortable for a user of an ultimately produced breathable mat. Larger meshes would feel less uniform or even wavy and therefore unpleasant for a user.

In particular, the stretched fabric product has a thickness of 3 to 15 mm, more preferably 5 to 12 mm and most preferably 8 mm. A sleeping pad of limited thickness has the advantage that it takes up less volume and is easy to transport and store. In addition, a small thickness of a mat ensures that it is easy to wash. However, it is important that the final produced sleeping pad be thick enough to offer sufficient support to a user.

In a method according to the present invention, a stretched fabric product will be thermally set to stabilize the structure, conformation and dimensions thereof. More particularly, thermal fixation of a stretched fabric product makes it possible to maintain the shape and dimensions of the fabric product that have been obtained by stretching the compact three-dimensional fabric product. In this way, the stretched fabric product is prevented from shrinking and returning to the dimensions of the compact three-dimensional fabric product when the fabric product is no longer subjected to stretching forces.

Additionally, heat setting a knitted fabric product often results in increased bulk and increased folding, wrinkling, and/or temperature resistance of the resulting knitted product.

In a method of the present invention, the stretched fabric product is possibly thermally set when tensile forces are maintained in the respective compact three-dimensional fabric product. In this way, the conformation, dimensions and/or structure of the thermally set fabric product are prevented from deviating from the conformation, dimensions and/or structure of the stretched fabric product.

However, it is possible to fix the stretched fabric product in the absence of tensile forces. To prevent in said embodiments the conformation, dimensions and/or structure of a thermally set fabric product from substantially deviating from the conformation, dimensions and/or structure of the stretched fabric product, the stretched fabric product must be subjected to tensile forces that cause permanent conformational and structural changes of the fabric product.

In particular, the stretched fabric product is thermally set at a temperature of 150-200°C, and more particularly, the fabric product is thermally set for 3 to 5 minutes.

The inventors of the invention have discovered that a thermal fixation at 150-200 °C causes a high degree of stabilization of the textile material of the stretched fabric product as a result of which the stretched fabric product maintains its conformations, volume and dimensions for a period of time. long time and during intensive use. Furthermore, heat setting at such high temperatures allows the stretched fabric product to be heat set only for a short time, thus making rapid production of a mat possible. Heat setting at a higher temperature or for a longer time results in a decrease in the strength of the fabric product, while heat setting at a lower temperature or for a shorter time results in insufficient fixation and therefore therefore, stability, of the fabric product.

The thermally set fabric product is provided on the underside with a plurality of additional layers. In particular, an absorbent layer is provided in the thermally set fabric product. Such a layer ensures that body fluid, such as in non-limiting examples, sweat, urine and saliva, from a user is absorbed.

The fixed fabric product will be provided at the bottom with a waterproof layer that is bonded to the fabric product by means of a lamination process. This waterproof layer preferably comprises polyurethane. This waterproof layer ensures that the mat remains moisture-proof. In a preferred embodiment, the lamination process takes place at a temperature between 140°C and 160°C. The provision of a waterproof layer at the bottom of the thermally set fabric product has the advantage that the base, preferably a mattress, is protected against body fluids such as sweat, urine and blood, and bacteria coming from a user. In this regard, the mat produced according to the present process also functions as protection of the base or mattress and said mat guarantees the hygiene of the base or mattress. In this way, a breathable mat is produced that guarantees cleanliness, safety and comfort.

The final product produced will be composed of three layers. A first layer comprises the breathable layer (the thermally set fabric product) which is provided on the bottom with a waterproof layer. Between the breathable layer and the waterproof layer, a moisture absorbing layer is provided.

In this way, a breathable mat for use as a sleeping mat is obtained by means of a method according to the present invention.

A breathable mat obtained by means of a process of the present invention guarantees comfort, support and safety for a user, preferably a baby or child. By stretching a compact three-dimensional woven product and thermal fixation of the stretched woven product, a mat is highly breathable. In this way, a mattress allows that when a baby or child rolls onto their stomach, and more particularly when they are lying on their stomach, they can still breathe and not suffocate. Furthermore, a high breathability of a mattress also ensures that the parts of a user's body, preferably a baby or child, that are in contact with the mat, are sufficiently ventilated and do not overheat. However, said mat offers enough support for a user, preferably a baby or child, to lie down in a comfortable, safe and healthy position.

The breathable mat comprises an extended honeycomb structure pattern. As described above, a honeycomb structure pattern allows for both sufficient and comfortable support and sufficient breathability.

The breathable mat is made of breathable textile material. Although the mesh of the mattress, and more particularly the fabric product, causes breathability, a breathable textile material ensures that a mattress is even more breathable. In addition, a breathable textile material ensures better ventilation of the parts of the body that are in contact with the mat, and the breathable material also guarantees more cooling and less risk of overheating of the respective body parts.

The breathable mat comprises a moisture-absorbing layer at the bottom of the mat, whether or not provided with a waterproof layer. As stated above, a moisture absorbing layer ensures that body fluid, such as sweat, blood, saliva and urine, of a user is absorbed, as a result of which the thermally set fabric product of the mat is protected. A waterproof layer guarantees protection of the base, preferably a mattress, against human liquids such as blood, sweat and urine, and bacteria. A waterproof layer prevents unwanted human liquids and/or bacteria from penetrating the base, or the underlying mattress, thus preventing damage or contamination of the base.

In some configurations, a breathable mat comprises flannel on at least one of its outer surfaces.

Flannel can absorb many (body) liquids and can be washed at high temperatures. Therefore, flannel is often used as a fabric for blankets, sheets and cloths. Preferably, at least the side with which the body parts of a user of the mat, preferably a baby or child, make most of the contact, comprises flannel.

In some configurations, a breathable mat comprises means to allow 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. Attaching a breathable mat to a mattress prevents movement of the mat relative to the mattress. This is essential with respect to a user's comfort, but also plays an important role in regards to a user's safety. By attaching a mat to a mattress, the mat is prevented from moving or shifting in such a way with respect to the mattress that a user of the mattress, or mat, would roll or fall and injure themselves. The provision of a reversible mat-to-mattress attachment allows the respective mat to be loosened from one mattress and attached to another mattress. This has the advantage that only the mat has to be transported, and not the entire mattress, and that when buying another mattress or a new one, the same mat can be joined together and used. In addition, the reversibility of the union allows you to wash only the mattress pad, without having to wash the entire mattress.

The breathable mat can be washed at a temperature of up to 60°C. Consequently, such a mat can be machine washed. 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 that is part of a mattress has a length and/or width that is equal to or greater than the length and/or width of the respective mattress. This has the advantage that the mat covers and possibly protects the entire surface of the respective mattress.

It is obvious that the breathable mat is not limited to its attachment or provision on a mattress, but the mat can be attached or provided on any base, device or apparatus that supports one or a plurality of babies.

In a preferred configuration, the breathable mat is selected from the group consisting of 31 x 71 cm, 34 x 75 cm; 40x80cm; 40x90cm; 40x60cm; 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.

Claims (14)

1. A method for producing a breathable mat comprising a breathable layer, an absorbent layer and a waterproof layer, said method comprising: - manufacturing, by means of a knitting machine, a compact three-dimensional knitted product with a honeycomb structure pattern comprising hexagonal conformations, wherein said knitted product is maintained under tension during manufacturing, - further stretching the fabric product obtained, compared to when no tension is applied, - thermally fixing said stretched product, characterized in that in said stretching step, the fabric product obtained is stretched through the application of similar tensile forces on both the longitudinal and width sides of the fabric product, and to such an extent that both the length and width of knitting products are increased by 10% to 50%, and - further providing an absorbent layer and a waterproof layer on a bottom side of the thermally set fabric product. 2. Method according to claim 1, characterized in that the compact three-dimensional fabric product, which is kept under tension during manufacturing, has a width of 180 to 220 cm. 3. Method according to any one of the previous claims, characterized in that the compact three-dimensional fabric has a width of 120 to 150 cm when no tension has been applied to the respective compact three-dimensional fabric product. 4. Method according to any one of the previous claims, characterized in that the compact three-dimensional knitted product is manufactured by means of a knitting machine comprising 12 needles per 2.54 cm (1 inch). 5. Method according to any one of the previous claims, characterized in that the compact three-dimensional knitted product is manufactured by means of a knitting machine having a laminating plate distance of 3 to 15 mm. 6. Method according to claim 5, characterized in that said laminating plate distance is between 5 and 12 mm, when the compact three-dimensional fabric product is manufactured. 7. Method according to claim 5 or 6, characterized in that said laminating plate distance is 8 mm when the compact three-dimensional fabric product is manufactured. 8. Method according to any one of the previous claims, characterized in that the knitting machine comprises at least two rolls of threads, when the compact three-dimensional fabric product is manufactured. 9. Method according to claim 8, characterized in that the respective thread rolls comprise a different thread. 10. Method according to any one of the previous claims, characterized in that the three-dimensional fabric product is manufactured at a speed of 12 to 18 meters per hour. 11. Method according to any one of the previous claims, characterized in that the compact three-dimensional fabric product is stretched until the stretched fabric product has a mesh width of 0.5 to 10 mm. 12. Method according to claim 11, characterized in that the compact three-dimensional fabric product is stretched until the stretched fabric product has a mesh width of 2 to 4 mm. 13. Method according to any one of the previous claims, characterized in that the stretched fabric product has a thickness of 3 to 15 mm. 14. Method according to any one of the previous claims, characterized in that the thermally fixed fabric product has a thickness of 5 to 12 mm.