GB2187113A - Improved material for manufacturing mattresses and the like - Google Patents

Improved material for manufacturing mattresses and the like Download PDF

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Publication number
GB2187113A
GB2187113A GB08605015A GB8605015A GB2187113A GB 2187113 A GB2187113 A GB 2187113A GB 08605015 A GB08605015 A GB 08605015A GB 8605015 A GB8605015 A GB 8605015A GB 2187113 A GB2187113 A GB 2187113A
Authority
GB
United Kingdom
Prior art keywords
core
core material
latex
layers
layer
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.)
Withdrawn
Application number
GB08605015A
Other versions
GB8605015D0 (en
Inventor
Kim Hong Lim
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.)
DREAMLAND SPRING MANUFACTURING
Original Assignee
DREAMLAND SPRING MANUFACTURING
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
Application filed by DREAMLAND SPRING MANUFACTURING filed Critical DREAMLAND SPRING MANUFACTURING
Priority to GB08605015A priority Critical patent/GB2187113A/en
Publication of GB8605015D0 publication Critical patent/GB8605015D0/en
Publication of GB2187113A publication Critical patent/GB2187113A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • A47C27/22—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with both fibrous and foamed material inlays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/72—Cured, e.g. vulcanised, cross-linked
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2601/00—Upholstery

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

This invention relates to a material for use in manufacturing mattresses or generally in use as an upholstery material or for cushions etc. The inner core 10 of latex-coated fibrous material is sandwiched between two layers of convoluted polyurethane foam 11 and 12 stuck to the core by adhesive. Outer layers of quilted material 13 consist of a layer of spunbonded polyester lining 14, a layer of polyurethane foam 15 and a layer of damask ticking 16. In manufacture of the core material from rope fibres or from coir the fibres are subjected to an untwisting process to open up the fibres and then needle punched before being sprayed with latex and cured. <IMAGE>

Description

SPECIFICATION Improved material for manufacturing mattresses and the like This invention relates two an improved material for use in manufacturing mattresses and the like. The material can be used not onlyfor mattresses but for cushions and upholstery in general.
An object of the invention is to provide an inexpensive resilient material which can be used as the core material for mattresses and the like and it can also be used in conjunction with foamed plastic or rubber material to form a cushion or mattress which may then be encased, if desired, in a multi-layer quilted covering.
In accordance with one aspect of the invention there isa core material for use in mattresses and the like,the core material consisting of fibrous material, such as twisted rope fibre, which is coated with latex and vulcanised.
The fibre may be derived from any raw and unprocessed fibrous material such as coir ortwisted rope fibre.
Preferably the latex and fibrous materials are in substantially equal amounts so that the core material consists of substantially 50% of latex byweight and 50% offibre byweight.
The fibrous latex-coated core may be sandwiched between layers of foamed polyurethane or otherfoamed plastics or foamed rubber preferably in convoluted form.
The latex-coated fibrous core may be attached to the foam material, which may be in sheet form, by suitable adhesive.
The sandwich so formed may in turn be enclosed in a multi-iayer quilted covering. The covering mayfor example be intheform ofthree layers, an inner layerofspunbonded polyester lining, a middle layer of polyurethanefoam, and an outer layer of damaskticking.
In manufacturing the core material the rope fibre is preferably untwisted and then sprayed with latex and subsequently vulcanised. The core is built up by layers ofthe fibrous sheet so produced and then compressed to reduce thickness and increase density before being fully vulcanised at 100-120" Centigrade.
The resulting core mixture is preferably of the order of 3,500 gm/m2 weight with a standard thickness of 38mm.
In the accompanying drawing is shown a section through a finished mattress material embodying the invention.
In Figure 1, the mattress material comprises an inner core 10 of latex-coated fibrous material sandwiched by two layers of convoluted polyurethane foam 11 and 12, which are stuckto the core material 10 by suitable adhesive, and outer layers of multi-layer quilted material 13 consisting of a layer of spunbonded polyester lining 14, a layer of polyurethane foam 15 and a layer of damask ticking 16 in each ofthe inner and outer quilted layers 13.
In manufacturing the core material rope fibres are subjected to an untwisting process to open up the fibres into curly fibre form, by use of automatic untwisting machines. The fibres are then formed into a needle-punched layer by a web layering process using a picker, a fluted roller, and a second picker and a needle punching thefibresto cause them to form a continuous layer. This may be carried out on a moving conveyor belt.
The layer or sheet of fibrous material thus formed is then subjected to automatic spraying of latex on one side of the sheet. The sheet is then passed through an oven for a pre-curing process. A second automatic latex spraying process is then effected on the other side of the sheet and again the sheet is passed through the oven for pre-curing. The sheet is then cut into a required size and layers of the sheet are built up into a core material which is then compressed to the required thickness.
The built-up core is then subjected to a vulcanising process at 100 to 1 200C and, after cooling, the edges of the finished core are then trimmed.
This core may be used as a central core for mattresses, cushions, upholstery etc. In one example of the manufacture of a mattress using this core material top and bottom polyurethane foam layers, in sheetform, are convoluted and cut to size and then applied to the core material by use of adhesive.
A multi-layer quilt material is then formed from an outer layer ofticking or damask, a middle layer of polyurethane foam, and an inner layer of "Reemay" spunbonded polyester lining. The quilting isthen labelled and hemmed to form a cover and the finished cover is applied overthe combination of core and polyurethane foam layers. The whole is then edged with tape so as to produce a finished mattress.
A similar process can be used to make cushions or the material may be used in the upholstering of furniture and the like. The core densityaimed at is 3,500 gm/m2 weight with a standard thickness of38mm.
The following chart illustrates the process in detail:- Raw Material Rope fibre in coil form Latex (55% latex content) Untwisting process to open up the rope fibre into curly fibre by auto maticuntwisting machines Web layering process by picker l,fluted roller and picker 11 and needle punching machine onto moving conveyor belt First automatic latex spray ing process on one side of the sheet Enter oven curing process Second automaticlatexspray- ing process on the other side of the sheet Re-entryforoven curing process Cut into required dimension Built up layers into the core and compressed to required thickness Vulcanization process at 120"C Finished core Trimming of edges Polyurethane foam Ticking,foam and in sheet form Reemay Convoluting process Top & bottom layers Quilting process and cutting Label & hemming Applying adhesive process Introduce Covering Finished cover Tape edging process Inspection Finished products Packing

Claims (17)

1. A core material for use in mattresses and the like,the core material consisting offibrous material coated with latex and vulcanised.
2. A core material according to claim 1 and in which the fibrous material is derived from coir.
3. A core material according to claim 1 and in which the fibrous material is derived from twisted rope fibre.
4. A core material according to any of claims 1 to 3 and in which the latex and fibrous materials are in substantially equal amounts, so that the core material consists of substantially 50% of latex by weight and 50%offibre byweight.
5. Afibrous latex-coated core material according to any preceding claim sandwiched between layers of foamed plastics or foamed rubber.
6. A core according to claim 5 and in which the foamed plastic is foamed polyurethane in convoluted form.
7. A core according to claim 5 or claim 6 and in which the foamed plastics or rubber is attached to the core material byan adhesive.
8. A core according to any of claims 5 to 7 and in which the core which has been sandwiched between layers of foamed plastics or foamed rubber is then in turn enclosed in a multi-layerquilted covering.
9. Acore according to claim 8 and in which the covering is in the form ofthree layers, an inner layers middie layer, and an outer layer.
10. A core according to claim 9 and in which the inner layer is ofspunbonded polyester.
11. Acore according to claim 9 orclaim 10 and in which the middle layer is of polyurethanefoam.
12. Acore according to claim 9,10 or 11 and in which the outer layer is of damaskticking.
13. A core material according to any preceding claim and in which the fibrous material is rope fibre which is untwisted and the latex material is then sprayed on to the fibre beforevulcanising.
14. A core according to claim 13 built up from a series of layers offibrous sheets produced in accordance with 13 and then compressed in thickness and density before being vulcanised at 1 00-1 200 centig rade.
15. A core material according to any preceding claim in which the basic core material consisting of latex-coated fibre is of the order of 3,500 gm/m2weightwith a standard thickness of 38mm.
16. A core material according to any preceding claim in corporated in a mattress.
17. A core material substantially as hereinbefore particularly described and as illustrated in the accompanying drawing.
GB08605015A 1986-02-28 1986-02-28 Improved material for manufacturing mattresses and the like Withdrawn GB2187113A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08605015A GB2187113A (en) 1986-02-28 1986-02-28 Improved material for manufacturing mattresses and the like

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08605015A GB2187113A (en) 1986-02-28 1986-02-28 Improved material for manufacturing mattresses and the like

Publications (2)

Publication Number Publication Date
GB8605015D0 GB8605015D0 (en) 1986-04-09
GB2187113A true GB2187113A (en) 1987-09-03

Family

ID=10593859

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08605015A Withdrawn GB2187113A (en) 1986-02-28 1986-02-28 Improved material for manufacturing mattresses and the like

Country Status (1)

Country Link
GB (1) GB2187113A (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2641456A1 (en) * 1989-01-11 1990-07-13 Lacotte Philippe FLEXIBLE MATTRESS BASED ON VEGETABLE FIBERS
US5787525A (en) * 1996-07-09 1998-08-04 Life Energy Industry Inc. Layered fabric mattress
US6295674B1 (en) * 2000-01-21 2001-10-02 Sleeper Solutions Foldable sleeper sofa mattress and method of manufacturing
US20120005836A1 (en) * 2010-07-07 2012-01-12 Jason Cik Corrugated foam mattress and method of making same
US9103470B2 (en) 2010-07-07 2015-08-11 Bj2, Llc Apparatus and method for making a corrugated product
CN112497802A (en) * 2020-12-15 2021-03-16 长春一汽四环总装福利包装有限公司 Production process of composite pad
US20220095806A1 (en) * 2020-08-28 2022-03-31 Avocado Green Brands, LLC Multiple zone layered mattress

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB226545A (en) * 1923-12-17 1925-08-06 George S Frazier Improvements in chair-seat pads or cushions
GB341936A (en) * 1929-09-24 1931-01-26 Arthur Ernest Weber Improvements in resilient surfaces for seats, cushions and upholstery
GB387547A (en) * 1931-04-20 1933-02-09 Frederik Wernersson Process for the manufacture of a substance resembling curled hair
GB389487A (en) * 1931-09-15 1933-03-15 Dunlop Rubber Co Improvements in or relating to a method for the production of upholstery, mattressesand the like articles of resilient nature
GB403375A (en) * 1931-07-24 1933-12-18 Anode Rubber Co Ltd Upholstering material made of rubberised fibres and process for its production
GB707433A (en) * 1951-02-16 1954-04-14 Pio Reggiani Improvements relating to springs of rubberised fabric in strip form adapted to be stressed in tension

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB226545A (en) * 1923-12-17 1925-08-06 George S Frazier Improvements in chair-seat pads or cushions
GB341936A (en) * 1929-09-24 1931-01-26 Arthur Ernest Weber Improvements in resilient surfaces for seats, cushions and upholstery
GB387547A (en) * 1931-04-20 1933-02-09 Frederik Wernersson Process for the manufacture of a substance resembling curled hair
GB403375A (en) * 1931-07-24 1933-12-18 Anode Rubber Co Ltd Upholstering material made of rubberised fibres and process for its production
GB389487A (en) * 1931-09-15 1933-03-15 Dunlop Rubber Co Improvements in or relating to a method for the production of upholstery, mattressesand the like articles of resilient nature
GB707433A (en) * 1951-02-16 1954-04-14 Pio Reggiani Improvements relating to springs of rubberised fabric in strip form adapted to be stressed in tension

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2641456A1 (en) * 1989-01-11 1990-07-13 Lacotte Philippe FLEXIBLE MATTRESS BASED ON VEGETABLE FIBERS
EP0378467A1 (en) * 1989-01-11 1990-07-18 Philippe Georges Victor Lacotte Flexible mattress based on vegetable fibres
US4985951A (en) * 1989-01-11 1991-01-22 Lacotte Phillipe G V Flexible mattress including vegetable fibers
US5787525A (en) * 1996-07-09 1998-08-04 Life Energy Industry Inc. Layered fabric mattress
US6295674B1 (en) * 2000-01-21 2001-10-02 Sleeper Solutions Foldable sleeper sofa mattress and method of manufacturing
US20120005836A1 (en) * 2010-07-07 2012-01-12 Jason Cik Corrugated foam mattress and method of making same
US8726438B2 (en) * 2010-07-07 2014-05-20 Bj2, Llc Corrugated foam mattress and method of making same
US9004133B2 (en) 2010-07-07 2015-04-14 Bj2, Llc Apparatus and method for making a corrugated product
US9103470B2 (en) 2010-07-07 2015-08-11 Bj2, Llc Apparatus and method for making a corrugated product
US10035299B2 (en) 2010-07-07 2018-07-31 Bj2, Llc Apparatus and method for making a corrugated product
US20220095806A1 (en) * 2020-08-28 2022-03-31 Avocado Green Brands, LLC Multiple zone layered mattress
CN112497802A (en) * 2020-12-15 2021-03-16 长春一汽四环总装福利包装有限公司 Production process of composite pad

Also Published As

Publication number Publication date
GB8605015D0 (en) 1986-04-09

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)