KR20150004812A

KR20150004812A - Method for producing a foam mattress or the like, and mattress or the like thus obtained

Info

Publication number: KR20150004812A
Application number: KR1020147029763A
Authority: KR
Inventors: 마리오 발로타; 다비데 니그로
Original assignee: 에코-티큐엘 에스.알.엘.
Priority date: 2012-03-23
Filing date: 2012-11-09
Publication date: 2015-01-13
Also published as: ITMI20120461A1; JP2015513949A; CN104363794A; WO2013140212A1; EP2833758A1

Abstract

The present invention relates to a method of making a foam comprising the steps of: preparing a basic component of a foam of a mattress or the like; A first amount of a phase change material (PCM) adapted to vary the phase as a function of temperature, and a second amount of a thermo-chromic or thermosensitive pigment adapted to change its color as a function of temperature (TP); Characterized in that it comprises the step of producing the mattress or the like using the basic components and the compound.

Description

METHOD FOR PRODUCING A FOAM MATTRESS OR THE LIKE, AND MATTRESS OR THE LIKE THUS OBTAINED BACKGROUND OF THE INVENTION 1. Field of the Invention [0001]

Explanation

Field of invention

The invention relates to a method of producing a mattress or the like, more precisely to a method of producing a foam mattress or the like and to the field of a mattress or the like obtained thereby.

Background technology

Known foam mattresses have been used for many years due to their high durability as well as their high performance especially in terms of load-carrying capacity. For example, in the case of a latex foam, the mattress typically consists of a solid latex portion having a predetermined density, followed by a through or non-through hole (alveoli). A mattress may be a piece or it may be a separate module joined together using various techniques.

The production process of latex mattresses is generally known, among which there are those called "Dunlop" and "Talalay "; Methods for producing polyurethane mattresses are also known.

There have been many attempts to improve such products to increase user comfort.

A type of material known as "PCM" representing "phase change material " is known to be inserted into a mattress, for example as described in patent US2009288259A1. The material has the property of changing the phase (from solid to liquid and vice versa) according to the external temperature experienced by them. During the phase change, they absorb and then release a significant amount of energy or heat, which exhibit different behaviors in the respective absorption and release stages. The PCM tends not to increase its temperature for a considerably long time while the solid phase is being converted into the liquid phase, for example, due to the temperature increase, in contact with the heat source, Because it is absorbed to cause a phase change; Rather, the release of energy and the return to the solid phase are prone to accelerate.

In the case of a mattress or the like, the addition of such material does not cause the energy released from his / her body to tend to remain cool for a substantial period of time without causing an immediate increase in the temperature of the mattress, There is a tendency to increase comfort.

However, the use of this material is not without its disadvantages, as it can be seen from the fact that a person can hardly detect the benefits obtained from the positive temperature behavior of the mattress, since the phase change resulting from the temperature change is not evident to him / .

Moreover, this difficulty of sensing causes additional problems when designing mattresses, particularly with regard to the selection of the most precise amount and type of PCM product used.

Since the thermal change behavior is different between the latex and the paraffin in the presence of PCM, a system emphasizing its thermal behavior is provided in order to obtain an evaluation system based on whether a product that best meets his / her needs can be selected There is a need. This should be applicable to both the temperature increase and the heat release to return to the initial conditions. Therefore, it is also important to consider the step of returning to the initial condition, in the sense that the warming should occur as long as possible, while the return to the initial condition must be quick.

Summary of the Invention

It is therefore an object of the present invention to provide a method of producing a foam mattress or the like suitable for solving the above-mentioned problems, and to provide a mattress or the like obtained thereby.

According to a key aspect of the present invention there is provided a thermo-chromic pigment or compound thereof having various types of behavior as a function of temperature in relation to color change, in order to obtain improved comfort, product specificity and temperature control. Presence, and concurrent use of PCM has also been found to allow enumeration of the interface between the human body and the foam mattress or the like, which is also evaluated over time. This should take into account both the different temperatures caused by the human body when placed in contact with the foam, and the different pressures of different postures on different parts of the mattress or the like, as well as different steps during the expected lifetime of the mattress.

A particular aim of the present invention is to provide a method of making a base component of a foam, such as a mattress or the like; A first amount of a phase change material (PCM) adapted to vary the phase as a function of temperature, and a second amount of a thermo-chromic or thermosensitive pigment adapted to change its color as a function of temperature (TP); The method comprising producing the mattress or the like using the basic components and the compound.

According to a first variant of the process, the compound is added to the basic component in the entire mattress or the like, or a part thereof, during the production of the mattress or the like.

According to a second variant of the process, the compound is applied to the exterior surface of the mattress or the like, either over the exterior surface or on a part thereof, after the mattress or the like is produced with the basic component.

A further object of the present invention is to provide a mattress, or pillow, armchair, sofa or sofa-bed, or a portion thereof, obtained using the method.

It is a particular object of the invention to provide a method of producing a foam mattress or the like as well as a mattress or the like obtained therefrom, as disclosed in the claims which is an integral part of this description.

Brief Description of Drawings

Additional objects and advantages of the invention will be apparent from the detailed description of embodiments of the appended drawings, provided by way of non-limitative example only, and the following detailed description.

1 to 4 show various graphs of the color change C occurring in the foam mattress or the like as a function of the temperature T. Fig.

Figures 5 and 6 illustrate some examples of devices used to implement a second variant of the method, particularly in a spray air brush and a drying oven, respectively.

In the drawings, the same reference numbers and characters denote the same items or components.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

Thermo-chromic or thermosensitive pigment TP is a material of a type known per se that includes a thermosensitive material having properties that change its color (as a function of temperature) in a reversible manner The material is usually enclosed in a water insoluble spherical capsule in the form of a dispersion or powder. Typically, the diameter of the microcapsules is 1-30 microns.

When the pigment reaches a so-called "color change temperature" period indicated by a section T0 - T1 in the figure, they start to change in color. The color change temperature is representative of the pigment: for example, the pigment is known to have a color change temperature of -15 ° C to 65 ° C.

For use in a mattress or the like, the color change temperature of the thermo-chromic or thermosensitive material is preferably, for example, 28 ° C, that is, close to the average body temperature.

Thermochromic or thermochromic pigments TP can have different types of behavior with respect to color change as a function of temperature, for example:

In the first type (FIG. 1), the pigment is colored in a saturated manner under the color change temperature, whereas at the color change temperature, the pigment starts the color loss process leading to the color change, and when the color change temperature is higher than the color change temperature, ;

In the second type (FIG. 2), the opposite phenomenon occurs;

In the third type (Fig. 3), the color change is also dependent on the temperature gradient and follows a different path during the two steps of temperature increase and decrease.

In the fourth type (Fig. 4), the pigment is colored within the color change temperature range, while the pigment loses color and becomes colorless outside the above range.

In addition to temperature, there is also an additional type in which the color is changed as a function of pressure: at normal pressure (about 1 bar) the pigment is colorless, whereas when the pressure is increased the pigment gets color; As long as the temperature is concerned, this behaves like the first type.

Various types of compounds of thermo-chromic or thermosensitive pigments TP with various color tones can be obtained which are mixed with ordinary non-thermo-chromic pigments such as those already used in the traditional coloring of mattresses or the like So that the coloring effect of various characteristics can be achieved. For example, it is possible to have only the color of the thermochromic or thermosensitive pigment TP at room temperature, or only the traditional color, while the other color appears when the temperature increases or vice versa.

In a mattress or the like, the thermal environment can be a microcapsule or microsphere, which may vary in diameter, for example from 3 to 15 microns, preferably a PCM material, typically in the form of a high density paraffin, Lt; / RTI >

Different types of PCMs are commercially available and they are also characterized by a temperature at which a phase change occurs, also known as the "color change temperature" or "melting point ".

For use in mattresses or the like, the color change temperature of the PCM is preferably, for example, 28 ° C, in other words, close to the average body temperature, which is a good compromise between room temperature and body temperature.

According to a first variant of the process of the present invention, during the process of producing a mattress or the like, a given amount of phase change material (PCM) and of a type of component material known as a thermochromic or thermosensitive pigment (TP) A suitable compound is added to the base foam component.

Thus, during the process of producing a mattress or the like, the liquid compound is prepared starting from the latex, and the compound of PCM and TP is then added as a dispersion or powder.

One example of an embodiment of a first variant of the production process using latex which may be of the known type, whether natural or synthetic in the following, will be described in detail, wherein the compound is subjected to mechanical foaming and then treated with sodium fluorosilicate Gelled, and steam cured at 100 占 폚 for about 30 minutes in the mold. A closed mold can be used, and the latex is injected therein according to a process known in the art, such as "Dunlop" or "Talalay ".

The mold may contain an inner protrusion of a shape suitable for obtaining an empty portion of the mattress (alveoli).

By adding a phase change material (PCM) and a thermochromic pigment (TP) to the latex foam, the desired compound is obtained.

For example, in the case of a compound obtained by the Dunlop process, the following steps are carried out

1. Preparation of PCM dispersion

- 1000 g water

- 500 g Lurapret® TX PCM 28

- 10 g potassium ricinate

- 40 g CMC

- rapid stirring for 5 minutes

2. Preparation of TP dispersion

- 500 g TP

- 50 g water

- rapid stirring for 5 minutes

- Tin: TPs can be homogeneous or a mixture of TPs with different characteristics; These are commercially available, in which case those having a color change temperature of about 28 占 폚 are used.

3. PCM and TP dispersions were mixed and quickly stirred for 5 minutes to homogenize them.

4. The dispersion obtained in step 3 was mixed with latex compounds in an amount of 5% to 15% of the compound.

The process described above can also be applied, for example, to portions of the mattress, by dividing the latter into layers in the thickness direction and applying PCM and TP to one or two side layers.

Conventional fixed color pigments may be coupled with TPs to achieve the desired gradation.

Thus, in effect, only standard pigments can be achieved visibly at high temperatures, since TP is transparent, whereas at low temperatures only TP can be seen.

According to a second variant of the process of the invention, a known process for producing a mattress or the like having a basic foam component (latex or polyurethane) is first carried out to obtain a conventional type of foam mattress. Followed by the application of a surface layer comprising a compound of PCM and TP components onto the mattress.

The surface layer can be applied by spraying or immersion in a suitable bath.

The application may relate to the entire surface of the mattress or only a portion thereof, such as a major site where contact with the body occurs.

An example of a concrete example of a second modification of the production method will be described in detail below.

A mattress, such as a latex mattress, is first produced as described above for the first variant by using a latex which may be of the known type, natural or synthetic. According to the method, the compound is then gelled with sodium fluorosilicate after mechanical foaming, and steam cured at 100 < 0 > C for about 30 minutes in the mold.

A closed mold can be used, and the latex is injected therein according to a process known in the art, such as "Dunlop" or "Talalay ". The mold may contain an inner protrusion of a shape suitable for obtaining an empty portion of the mattress (alveoli).

After obtaining a mattress or the like, a second step is carried out, wherein a surface layer comprising a compound of PCM and TP components is applied.

For spray applications, the PCM and TP components are applied using a latex-based colloidal dispersion with adhesion properties.

Preferably, then a drying step is followed.

For example, the following steps are carried out for spray application on a mattress of normal size:

1. - 320 g TP powder;

- Preparation of a dispersion of TP material consisting of 520 g water.

2. 100 g PCM powder;

- Preparation of a dispersion of PCM material consisting of 200 g water.

3. - 300 g polychloroprene latex;

- 60 g TP dispersion;

- Preparation of total dispersion of 60 g PCM dispersion.

The final compound was applied by spraying, e.g., using an airbrush 51 (Figure 5) and passed across the surface of the mattress 52. The airbrush has a series of spray nozzles 53 that atomize the entire dispersion, preferably at room temperature, with compressed air. The movement of the airbrush is usually controlled at a constant rate so that the dispersion can evenly be applied on the mattress surface; However, the application may also be uneven. The dispersion to be applied may be contained in a suitable tank connected to the airbrush.

Instead of using an airbrush, spraying can also be performed manually.

The drying step is then preferably carried out, for example, by air, UV radiation or infrared radiation. The mattress is conveyed to a suitable drying oven 61 of the type that is preferably non-ventilated at a temperature that may be higher than room temperature, for a shorter drying time, or at room temperature (FIG. 6) to avoid dispersion desorption phenomena.

Optionally, additional steps for applying text or illustrations superimposed on the surface of the mattress or the like may be performed for its possible customization.

The application is carried out by spraying, by using a pre-formed mask as an outline, according to two possible variants:

- after main spraying, spraying a special amount of thermo-chromic material at the same site as the main spray, in particular in larger amounts, possibly in different hues,

- Spray non-thermochromic material directly on the mattress before main spraying.

Thus, as the contact temperature increases, the thermo-chromic material will become transparent, thereby highlighting overlapping or underlying text or illustration that can have a distinct color, while at room temperature the thermo- It will hide the text or illustrations.

As mentioned above, the main spray may be replaced by soaking the mattress in a suitable bath containing the materials described above.

The method of producing latex mattresses with the variations described above can also be applied to pillows and other types of products, such as padding of armchairs, sofas or sofa-beds.

The advantages of the present invention are apparent.

A simple and effective system for increasing the performance of a mattress or the like is thus obtained in that the user can more easily perceive the thermal effect and the design of the mattress or the like is also improved.

From the above description, those skilled in the art will be able to provide the object of the present invention without introducing any further explanation.

In particular, machines and apparatus known in the production of both semi-finished and finished articles can be used.

However, the elements and features disclosed in the various preferred embodiments can be combined without departing from the scope of protection of the present invention.

Claims

Fabricating a base component of a foam of a mattress or the like;
A first amount of phase change material (PCM) adapted to vary the phase as a function of temperature, and a second amount of thermo-chromic material adapted to change its color as a function of temperature ) Or a compound of a thermosensitive pigment (TP);
Characterized in that it comprises the step of producing the mattress or the like using the basic components and the compound.

The method of claim 1 wherein the compound is added to the base component in the entire mattress or the like, or a portion thereof, during production of the mattress or the like.

3. The method of claim 2, wherein the portion of the mattress conforms to at least one layer of the mattress in the thickness direction.

4. The composition of claim 1, wherein the compound is a foam mattress or the like, which is applied to the exterior surface of the mattress or the like, either over the exterior surface or on a portion thereof, after the mattress or the like is produced with the basic component How to produce.

5. The method of claim 4, wherein the compound is applied via a first spray or through dipping into a suitable bath.

6. The method of claim 5, wherein the first spray is applied to the mattress surface using a colloidal dispersion, preferably performed automatically using an airbrush.

6. The method of claim 5, wherein after the first spraying, the drying step is performed using, for example, air, UV radiation or infrared radiation.

6. The method of claim 5, further comprising applying the overlaid text or illustration onto a surface of the mattress or the like through a second spray performed using a preformed mask as an outline Way.

9. The method of claim 8, wherein said additional step of applying a text or illustration is after said first spray, and wherein said further step comprises applying various special amounts of thermo-chromic material to said same area relative to said first spray A foam mattress or the like.

9. A foam mattress according to claim 8, wherein said further step of applying a text or illustration is preceded by said first spray, and said further step is carried out directly on a mattress or the like by using a non-thermochromic material. Or analogs thereof.

11. A method according to any one of claims 1 to 10, wherein the phase change material (PCM) and the thermochromic or thermosensitive pigment (TP) are selected such that their respective phases and color changes occur at temperatures close to the average body temperature &Lt; RTI ID = 0.0 > and / or < / RTI >

12. A method according to any one of claims 1 to 11, wherein the at least one second amount of thermo-chromic or thermosensitive pigment (TP) is of a different type of thermochromic or sensory A method of producing a foam mattress or the like, comprising a thermochromic pigment (TP).

13. A method as claimed in any one of the preceding claims wherein the at least one second amount of thermo-chromic or thermosensitive pigment (TP) is of the type of thermo-crossover type with additional characteristics of color change as a function of pressure Mica or thermosensitive pigment (TP).

14. The method according to any one of claims 1 to 13, wherein said basic component of a foam of a mattress or the like comprises one or more pigments of a non-thermosensitive type.

15. The method according to any one of claims 1 to 14, wherein the foam is essentially a latex foam or a polyurethane foam.

17. A mattress produced using the method of any one of claims 1 to 15.

17. A pillow produced using the method of any one of claims 1 to 15.

16. A armchair padding portion produced using the method of any one of claims 1 to 15.

15. A sofa or sofa-bed padding portion produced using the method of any one of claims 1 to 15.