WO2008087531A1

WO2008087531A1 - Structure for mattresses and the like, undulated felt sheet for mattresses and the like, apparatus and method for the production of an undulated felt sheet

Info

Publication number: WO2008087531A1
Application number: PCT/IB2008/000093
Authority: WO
Inventors: Vittorio Casini
Original assignee: Manifattura Maiano S.P.A.
Priority date: 2007-01-17
Filing date: 2008-01-15
Publication date: 2008-07-24

Abstract

Structure for mattresses and the like for bearing a user, comprising a first user's bearing layer permeable to the air, a second layer disposed below said first layer in correspondence of a common plane and comprising aeration paths parallel to said common plane.

Description

"STRUCTURE FOR MATTRESSES AND THE LIKE, UNDULATED FELT SHEET FOR MATTRESSES AND THE LIKE, APPARATUS AND METHOD FOR

THE PRODUCTION OF AN UNDULATED FELT SHEET"

*********** Technical Field

The present invention relates to a user' s bearing structure for mattresses and the like.

Background Art

Structures for mattresses are^' known which comprise a linear felt layer interpos.ed between two layers of latex, rubber, sponge rubber or the like. The felt layer, in addition to be a component of high transpiration capacity, it performs also a structure-bearing function.

Since the latex is a material impervious to air and humidity, the whole transpiration capacity of the mattress is improved by forming vertical holes in at least one of the two latex layers, so as to create some aeration inside the mattress.

The structure for mattresses above described, however, are not without drawbacks.

A first drawback lies in the. fact that, even when air is made to flow-in through the vertical aeration paths formed in the latex- layer and toward the central felt layer, and although the felt itself is a material having a high transpiration capacity, the use of the known structures does not allow the obtainment of high transpiration capacity in the whole.

This drawback is due to the fact that the flow for the aeration of a mattress provided with a structure of known type, results directed mostly vertically and, for this reason, does not ensure a satisfactory escape of the air.

Disclosure of the Invention

The object of the present invention is therefore to overcome these drawbacks by providing a structure for mattresses and the like having high transpiration capacity. A further, second aspect of the present invention, relates to an undulated felt sheet for the production of mattresses and the like, an apparatus and a method for the production of an undulated felt sheet. At present, devices for hot forming of felt sheets are known to operate outside the production line of said felt. For the hot forming of felt by the known devises it is therefore necessary to provide a production line independent of the felt's manufacturing process, which implies increased operation costs and times.

It is thus long required the possibility of performing a continual hot forming of felt sheets within the production line of said felt. The known systems further exhibit the drawback of not allowing the formation of felt sheets with bearing characteristics and varying dimensions, at least in the development direction.

A second object of the present invention is therefore to provide an apparatus and a method for continual hot forming of felt sheets which can be used as a resistant layer in mattresses and the like, or wherever it is desired to have a support offering both mechanical strength and transpiration capacity. According to the invention, this object is achieved by means of a structure for mattresses and the like, an undulated felt sheet for mattresses and the like, an apparatus and a method for the production of an undulated felt sheet according to the appended claims . The technical characteristics of the invention, according to the above objects, are clearly set forth in the appended claims, the advantages of the same invention being more evident from the detailed description that follows with reference to the accompanying drawings, which show an exemplary and non-limiting embodiment thereof. In the drawings: Fig. 1 is a perspective view of a structure for mattresses and the like, according to the present invention;

- Fig. 2 is a sectional view of a mattress provided with a structure according to the present invention;

- Fig. 3 is a front view of an apparatus for hot forming of felt sheets for mattresses and the like according to the present invention;

- Fig. 4 shows a detail of the apparatus of Fig. 1 during the formation of the felt sheet;

- Fig. 5 is a side view of the apparatus during the step shown in Fig. 4;

- Fig. 6 is a side view of a felt sheets' production line provided with an apparatus according to the present invention;

Fig. 7 shows a second embodiment of an apparatus according to the present invention;

- Fig. 8 shows a detail of the apparatus of Fig. 7 during the felt sheet-forming step; - Fig. 9 is a first sectional view of the apparatus in the configuration shown in Fig. 8;

- Fig. 10 is a second sectional view of the apparatus in the configuration shown in Fig. 8; and

- Fig. 11 is a side view of a felt sheets' production line provided with an apparatus as shown in the previous figures

7 to 10.

Described herebelow with reference to the accompanying drawings and in particular to Fig. 1, is a structure for users' bearing mattresses and the like, the structure comprising a first user-resting layer 1 permeable to the air, and a second layer 2 disposed below the first layer 1 in correspondence of a plane ^λλP".

The second layer 2 is preferably of a material having a high transpiration capacity, such as the felt, and comprises a plurality of aeration paths 3 parallel to the same plane ^λλP" .

Advantageously, the aeration paths 3 are directly obtained by bellows-like folding the felt, without the need of any additional component. To improve the total transpiration capacity of the structure it is of advantage that the first layer 1 too be made to include a plurality of aeration paths 4, but perpendicularly to the plane ^XλP" in order to cause air to flow in correspondence of the horizontal aeration paths 3. Again with reference to Fig. 1, the structure for mattresses may comprise also a third layer 5 disposed below the second layer 2 and defining with the latter a second plane "Q" parallel to the first common plane "P". Advantageously, also the third layer 5 is made of latex and comprises aeration paths 4 disposed perpendicularly to the plane "Q"; the latter also having the purpose of flowing air into the felt central layer 2.

In particular, the aeration paths 4 formed on the layers 1 and 5 are preferably made to face the paths 3 formed on the felt layer 2.

A further aspect of the present invention described herebelow with reference to Fig. 2 is a mattress which comprises a cover 6 having thereinside a structure as above described. Preferably, the cover 6 is made up of wad and fabric and is caused to adhere to the structure through fixing techniques known per se and, therefore, not to be further described herein. Also in Fig. 2 it is possible to note that the vertical aeration paths 4 formed on the layers 1 and 5 lead advantageously into the horizontal paths 3 on the felt layer 2.

In this way, air is made to flow inside the mattress through the vertical paths 4 and to escape therefrom through the horizontal paths 3. Although the description relates to a mattress, it is understood that a structure according to the present invention can find application in the production of vehicle seats and, in general, in the sector of padded furniture for internal furnishing.

Described herebelow, with reference to figures 3 to 11, is a second aspect of the invention relating to an apparatus for continual hot forming of felt sheets comprising a line for feeding the hot felt sheet 11 along a direction ^λλD", at least a first forming surface 8 disposed for interfering with the feeding direction "D" of sheet 11, and at least a second forming surface 10, 15 to deform the sheet 11 in cooperation with the first surface 8. In the apparatus according to the present invention, the first 8 and second 10, 15 surfaces cooperate continually during a displacement of the hot sheet 11 in ^λλD" direction, in order to define a generally undulated deformation profile "F" of the formed sheet 11. The first forming surface 8 comprises a cylinder 7 having longitudinal axis ^λλx" and one or more discs 8 also having axis ^λλx" and engaged to the cylinder 7 and defining gaps 13.

In a first preferred embodiment, reference being made to Figs. 3 to 6, the second forming surface 10 may comprise a rake 9 having a plurality of teeth 10 counter shaped to the discs 8, disposed on the cylinder 7 and able to fit into the gaps 13.

Preferably, the discs 8 and teeth 10 can be removed respectively from the cylinder 7 and from the rake 9, so as to allow the user to determine the number and depth of the corrugations formed on the sheet 11.

To achieve a further adjustment of the deformation on the felt sheet 11 transiting between the cylinder 7 and rake 9, the latter can be pivotally engaged to a frame by means of a hinge having axis "y". In this way, it is possible to change the distance of the teeth 10, formed on the rake 9, from the discs 8 formed on the cylinder 7, thereby changing the deformation profile ^λλF" of the felt sheet 11. Described with reference to Figs. 7-11 is a second embodiment of an apparatus according to the present invention.

In this second embodiment, the second forming surface 15 may comprise a second cylinder 14 having also a plurality of discs 15 counter shaped with respect to discs 8 disposed on the first cylinder 7.

Also in this embodiment the discs 15 are removable from the cylinder 14 so as to allow the user to determine the number and depth of the corrugations formed on the sheets 11. For more clarity, Figs. 9 and 10 are cross-sections, respectively taken on line "VII" and "VIII", showing the forming patterns of the felt sheet 11 with reference to the configuration Fig. 8. Described herebelow is an another aspect of the present invention relating to a method for continual hot forming of felt sheets 11, the method comprising the step of:

- feeding the hot felt sheet 11 in a direction "D";

- heating the sheet 11, for example by means of a hot-air furnace 12; - deforming the heated sheet 11 by at least a first forming surface 8 disposed for interfering with the feeding direction "D" of the sheet 11, and at least a second forming surface 10, 15 cooperating with said first surface 8. Advantageously, the felt sheet 11 comprises fibres of thermoplastic material which exhibit - after reaching the melting temperature and subsequent cooling/hardening - a suitable cohesion with the felt fibres. Referring now in particular to Fig. 11, an apparatus according to the present invention is advantageously disposed within a production line for continually forming felt sheets, especially interposed between a heating furnace 12 and a cooler.

This disposition results advantageous inasmuch as, during the transit in the furnace, the felt sheet 11, preferably including fibres of thermoplastic material as an additive, becomes soft and thus able to be easily deformed by the forming surfaces 8, 10, 15. Yet another aspect of the present invention is therefore a line for continual production of a felt sheet 11 starting from scattered fibres, wherein, downstream of the units for carding, lap forming and heating the same fibres, it comprises an apparatus for a forming process as above described. The invention according to the present invention offers several advantages.

A first advantage lies in the fact that by the use of a mattress comprising a structure as above described it is possible to achieve an elevated internal aeration and, thus, an elevated transpiration capacity of the same mattress.

A second advantage lies in the fact that by the use of a structure according to the present invention it is possible to achieve a light-weight mattress having at the same time a high structural sturdiness.

Yet another advantage lies in the fact that the use of an apparatus for the hot forming of felt sheets 11 for mattresses and the like according to the present invention, allows carrying out the felt-forming operation within the production line for said felt.

In this way it is possible to simplify, speed up and consequently reduce the whole treatment operations performed on the felt. A further advantage lies in the fact that an apparatus according to the present invention allows making felt sheets having high bearing characteristics and various dimensions, at least in one direction of development, said sheets being suited, for example, for structures of mattresses like those of the present invention. The invention thus conceived is evidently suited for industrial application; the same invention can also be subjected to several modifications and changes falling within the scope of the inventive idea; moreover, all the parts may be replaced by other elements technically equivalent.

Claims

CIAIMS

1. Structure for mattresses and the like for bearing a user, comprising: a first user's bearing layer (1) permeable to the air, a second layer (2) disposed below said first layer (1) in correspondence of a common plane (P) , characterized in that said second layer (2) comprises aeration paths (3) parallel to said common plane (P) .

2. Structure according to claim 1, wherein said second layer (2) is made of felt.

3. Structure according to claim 2, wherein said aeration channels (3) comprise folds of said felt.

4. Structure according to claim 3, wherein said folds of said felt are bellows-like.

5. Structure according to any of the preceding claims, wherein said first layer (1) comprises paths (4) disposed perpendicularly to said common plane (P) to direct the flow of air to said aeration paths (3) .

6. Structure according to any of the preceding claims, further comprising a third layer (5) disposed below said second layer (2) , said third layer (5) defining with the latter a second plane (Q) parallel to said common plane

(P) •

7. Structure according to any of the preceding claims, wherein said first (1) and said third (5) layers are made of a material selected from latex, rubber or sponge rubber.

8. Mattress characterized in that it comprises a cover (6) having thereinside a structure according to any of previous claims 1 to 7.

9. Seat for vehicles, characterized in that it comprises a structure according to any of previous claims 1 to 7.

10. Padded furniture characterized in that it comprises a structure according to any of previous claims 1 to 7.

11. Apparatus for continual hot forming of felt sheets (11) comprising: a line for feeding said hot felt sheet (11) in a direction (D) ; at least a first forming surface (8) disposed for interfering with the feeding direction (D) of the sheet (11); at least a second forming surface (10, 15) to deform said sheet (11) in cooperation with said first surface (8); wherein said first (8) and second (10, 15) surfaces operate in continuous during the displacement of said hot sheet (11) in the direction (D) to define a generally undulated deformation profile (F) of the formed sheet (11).

12. Apparatus according to claim 11, wherein said first forming surface (8) comprises a cylinder (7) having longitudinal axis (x) and one or more discs (8) also having axis (x) , said one or more discs (8) being engaged to the cylinder (7) and defining gaps (13) .

13. Apparatus according to any of the preceding claims, wherein said second forming surface (10) comprises a rake

(9) having a plurality of teeth (10) counter shaped to the discs (8) and able to fit into the gaps (13) .

14. Apparatus according to any of the preceding claims, wherein said one or more discs (8) are removable from said cylinder (7) .

15. Apparatus according to any of the preceding claims, wherein said teeth (10) are removable from said rake (9) .

16. Apparatus according to any of the preceding claims 13 to 15, wherein said rake (9) is pivotally engaged to a hinge having axis (y) to change the deformation of said felt sheet (11) .

17. Apparatus according to any of the preceding claims 11, 12 or 14, wherein said second forming surface (15) comprises a cylinder (14) having a plurality of discs (15) counter shaped to said discs (8) of said cylinder (7) and able to fit into said gaps (13) .

18. Apparatus according to claim 17, wherein said plurality of discs (15) are removable from said cylinder (14) .

19. Apparatus according to any of the preceding claims, wherein said apparatus is located within a production line for continually forming felt sheets (11) and is interposed between a heating furnace (12) and a cooler.

20. Method for continual hot forming of felt sheets, the method comprising the step of: feeding the hot felt sheet (11) in a direction (D) ; heating said sheet (11); continually deforming said hot sheet (11) .

21. Method according to claim 20, wherein said step for deforming said sheet (11) is carried out by means of at least a first forming surface (8) disposed for interfering with the feeding direction (D) of the sheet (11), and at least a second forming surface (10, 15) cooperating with said first surface (8).

22. Method according to any of preceding claims 20 or 21, wherein said felt sheet (11) comprises fibres of thermoplastic material.

23. Line for continual production of a felt sheet (11) comprising an apparatus according to any of the preceding claims 11 to 19, said apparatus being disposed downstream of a unit (12) for heating said felt sheet (11) .