GB2413111A - Cover layer for mattress side - Google Patents

Cover layer for mattress side Download PDF

Info

Publication number
GB2413111A
GB2413111A GB0408380A GB0408380A GB2413111A GB 2413111 A GB2413111 A GB 2413111A GB 0408380 A GB0408380 A GB 0408380A GB 0408380 A GB0408380 A GB 0408380A GB 2413111 A GB2413111 A GB 2413111A
Authority
GB
United Kingdom
Prior art keywords
mattress
layer
fabric
elastomeric material
cover 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Withdrawn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
GB0408380A
Other versions
GB0408380D0 (en
Inventor
Charles Bayer
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.)
Silentnight Group Ltd
Original Assignee
Silentnight Group Ltd
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 Silentnight Group Ltd filed Critical Silentnight Group Ltd
Priority to GB0408380A priority Critical patent/GB2413111A/en
Publication of GB0408380D0 publication Critical patent/GB0408380D0/en
Publication of GB2413111A publication Critical patent/GB2413111A/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Withdrawn legal-status Critical Current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
    • B32B5/26—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 also being fibrous or filamentary
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C21/00—Attachments for beds, e.g. sheet holders, bed-cover holders; Ventilating, cooling or heating means in connection with bedsteads or mattresses
    • A47C21/06—Mattress underlays
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0036—Polyester fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/10—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with styrene-butadiene copolymerisation products or other synthetic rubbers or elastomers except polyurethanes
    • 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
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/744—Non-slip, anti-slip
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/04—Vegetal fibres
    • D06N2201/042—Cellulose fibres, e.g. cotton
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/10—Properties of the materials having mechanical properties
    • D06N2209/106—Roughness, anti-slip, abrasiveness

Abstract

A mattress comprises a cover layer constituted by a laminate fabric with a textured elastomeric coating applied thereto. The laminate fabric consists of a densely needled polyester (or other fibre) nonwoven facing inwardly and a woven polyester, cotton or polycotton blend facing outwardly of the mattress body. The woven fabric has the elastomeric coating applied to it, which may be a natural rubber, synthetic rubber or thermoplastic elastomer. The cover layer is manufactured by conveying a woven fabric continuously (or semi continuously) through a printing station at which the elastomer is applied by a rotary screen printing process. The coated fabric is finished in an oven and may subsquently be printed with brand indicia or the like before being adhesively laminated to the nonwoven in a nip between two laminating rollers. The completed laminate is cut to size and stitched to the mattress body.

Description

241311 1
COVER LAYER FOR MATTRESS SIDE
This invention relates to a cover layer attached to one side of a mattress in order to provide improved non-slip properties and greater robustness/durability to the underside of a mattress.
It is a well known problem with existing mattresses, and especially single mattresses supported on a smooth support surface, that they tend to slide relative to the support surface during use, and also when making the bed.
Various attempts have been made to provide an acceptable non-slip base layer for the underside of a mattress, and the present invention develops this concept in a way which 0 provides enhanced non-slip properties, while at the same time providing a carrier layer to which brand identity can readily be applied, if required.
According to the invention there is provided a spring mattress having a flexible textile cover layer attached to one side thereof which, in use, will be the underside of the mattress to be supported by a support surface of a bed base, in which the cover layer is a laminate which comprises a textile fabric layer to which a textured coating of elastomeric material is applied by a screen printing process to provide required non-slip properties for the underside of the mattress, and a layer of needled felt to face the mattress and provide spring insulation properties.
The textured coating preferably is a perforated coating derived from application of the elastomeric material using a perforated printing screen.
For continuous production-line application of the textured coating to the fabric layer, it is preferred to use a perforated rotary printing screen located at a fixed printing station through which the fabric can be conveyed on a continuous or semi-continuous basis.
The elastomeric material employed in carrying out the invention is preferably natural 2s rubber or latex, but it should be understood that the invention includes usage of synthetic elastomeric material, provided that such material is capable of being screen-printed onto the fabric layer, to provide required non-slip properties.
The fabric is preferably made of woven polyester, cotton, or a blend of polyester/cotton.
The needled felt layer is preferably a heavily needled polyester border felt, though other felt s material may be used, provided that it gives required spring insulation properties.
A preferred embodiment of the invention will now be described in detail with reference to the accompanying schematic drawings, in which: Figure I illustrates a first stage in the formation of a laminated cover layer according to the invention, for attachment to the underside of a sprung mattress; and l o Figure 2 illustrates a second stage in the manufacturing process, in which a layer of needled felt (which is intended to face the mattress and provide spring insulation properties) is laminated to a textile fabric layer to which a textured coating of elastomeric material has been applied by a screen printing process provided during the first stage of the manufacturing process.
s Referring now to Figure 1 of the drawings, this is a schematic flow diagram showing one preferred means of the first stage of manufacture of a laminated cover layer which is intended subsequently to be attached to one side of the mattress which, in use, will be the underside of the mattress to be supported by a support surface of a bed base. The first part of the laminate comprises a textile fabric layer to which a textured coating of elastomeric material is applied by a screen printing process, to provide required non-slip properties for the underside of the mattress.
Figure l shows a fabric layer 10 which is conveyed, on a continuous or semi-continuous basis through a printing station 11 at which a perforated rotary printing screen 12 is provided. The screen 12 is located at a fixed position, and is perforated in such a way that 2s it is the reverse image of the required finished product. Textile fabric 10 is passed under the rotating screen 12 on a continuous conveyor belt, and the screen applies a textured coating of elastomeric material, preferably latex, to the surface of the fabric layer by a screen printing process. The textured coating is perforated, and being formed of latex, provides a degree of resilience, but also strong adhesion to the fabric layer, while at the same time via its exposed surface providing required non-slip properties, whereby the underside of the mattress to which the cover layer is attached has strong frictional s resistance to lateral displacement relative to any smooth support surface on which it is laid.
The now coated fabric layer 13 passes to a finishing roll 14 and an oven 15, for final treatment.
The textured coating may have brand identity marking applied subsequently, or during the printing process.
lo To complete the formation of a textile cover layer according to the invention, the coated fabric layer 13 derived from the first stage of the manufacturing process, described above with reference to Figure 1, undergoes a laminating treatment in order to adhere a needled felt layer thereto in a laminating stage described in more detail below with reference to the schematic illustration in Figure 2.
A roll of the textured coating layer 13 is unreeled so as to be fed to a laminating station 14 provided with a pair of nip rollers 15 between which pass the textured coating layer 13, and a layer of needled felt 16 unreeled from a roll 17. The layer 16 preferably comprises a heavily needled polyester border felt, which can provide required spring insulation properties when the finished product is attached to the underside of a mattress, with the felt layer 16 facing the mattress to provide spring insulation properties.
To facilitate the lamination process, conveniently adhesive is applied to the exposed surface of the layer 16, from adhesive dispenser 18, and the layers 13 and 16 then pass through the "nip" between the rollers 15 to be laminated, and then pass to a composite roll 19 of the finished product.
2s The finished laminated fabric is then cut on laying-up tables into individual mattress panels, which are attached to the required side of a mattress case, preferably by stitching.
The process described above endows the laminated textile fabric with a) non-slip properties; b) brand identity; and c) effective spring insulation from the springs in the mattress, making it suitable for use on the intended underside of a mattress, to be laid on all types of sleep base unit, including: s 1. Traditional divans, both sprung and unsprung; 2. Pine slats in bedsteads and bunks; and 3. Sprung beech slats in bedsteads.

Claims (7)

1. A sprung mattress having a flexible cover layer attached to one side thereof which, in use, will be the underside of the mattress to be supported by a support surface of a bed base, in which the cover layer is a laminate which comprises a textile fabric layer to which a textured coating of elastomeric material is applied by a screen printing process, to provide required non-slip properties for the underside of the mattress, and a layer of needled felt to face the mattress and provide spring insulation properties.
2. A mattress according to claim 1, in which the textured coating is a perforated l o coating derived from application of the elastomeric material using a perforated printing screen.
3. A mattress according to claim 1 or 2, in which the elastomeric material is natural rubber or latex.
4. A mattress according to claim 1 or 2, in which the elastomeric material is synthetic material.
5. A mattress according to any one of claims 1 to 4, in which the fabric is made of woven polyester, cotton, or a blend of polyester/cotton.
6. A mattress according to any one of claims 1 to 5, in which the layer of needled felt is a heavily needled polyester border felt.
7. A method of applying a textured coating to a fabric layer which is intended to form a non-slip underside of a mattress to which it is attached, in which the fabric layer is conveyed through a fixed printing station at which a perforated rotary printing screen is located, such screen applying a textured coating of elastomeric material to the fabric layer by a screen printing process.
GB0408380A 2004-04-15 2004-04-15 Cover layer for mattress side Withdrawn GB2413111A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0408380A GB2413111A (en) 2004-04-15 2004-04-15 Cover layer for mattress side

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0408380A GB2413111A (en) 2004-04-15 2004-04-15 Cover layer for mattress side

Publications (2)

Publication Number Publication Date
GB0408380D0 GB0408380D0 (en) 2004-05-19
GB2413111A true GB2413111A (en) 2005-10-19

Family

ID=32320852

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0408380A Withdrawn GB2413111A (en) 2004-04-15 2004-04-15 Cover layer for mattress side

Country Status (1)

Country Link
GB (1) GB2413111A (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2292337A1 (en) * 2006-02-09 2008-03-01 Pikolin, S.A. Obtaining method for composite material of latex foam and multilayer polyester sheet, which is used in equipment such as rest mattresses, involves employing composite material base plate to obtain thin and continuous elongated laminar body
CN110143562A (en) * 2019-06-05 2019-08-20 浙江安吉美佳琪家居用品有限公司 A kind of mattress production processing technology

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0640307A2 (en) * 1993-08-26 1995-03-01 Jacques H Dehondt Non-slip cushion and method
US5542137A (en) * 1994-03-16 1996-08-06 Western Fibres Limited Friction fitted contour skirt for mattress pads and covers
US5896603A (en) * 1997-12-18 1999-04-27 Klear-Vu Corporation Articles with gripping surfaces
WO2003078720A2 (en) * 2002-03-19 2003-09-25 Francis Norbert Marie Lampe A mattress cover and a method of manufacturing the same, as well as a mattress

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0640307A2 (en) * 1993-08-26 1995-03-01 Jacques H Dehondt Non-slip cushion and method
US5542137A (en) * 1994-03-16 1996-08-06 Western Fibres Limited Friction fitted contour skirt for mattress pads and covers
US5896603A (en) * 1997-12-18 1999-04-27 Klear-Vu Corporation Articles with gripping surfaces
WO2003078720A2 (en) * 2002-03-19 2003-09-25 Francis Norbert Marie Lampe A mattress cover and a method of manufacturing the same, as well as a mattress

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2292337A1 (en) * 2006-02-09 2008-03-01 Pikolin, S.A. Obtaining method for composite material of latex foam and multilayer polyester sheet, which is used in equipment such as rest mattresses, involves employing composite material base plate to obtain thin and continuous elongated laminar body
CN110143562A (en) * 2019-06-05 2019-08-20 浙江安吉美佳琪家居用品有限公司 A kind of mattress production processing technology
CN110143562B (en) * 2019-06-05 2020-11-20 阜阳皖春家俬有限公司 Mattress production and processing technology

Also Published As

Publication number Publication date
GB0408380D0 (en) 2004-05-19

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