• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of manufacturing a bed product comprising at least one foam rubber layer. Said method comprises the following steps: - pouring liquid foam rubber onto a conveyor belt; vulcanizing said liquid foam rubber in a vulcanization station to obtain a vulcanized foam rubber slab; - cutting said vulcanized slab of foam rubber into the desired length and / or width, characterized in that electromagnetic waves with a frequency between 1 and 50 MHz are used for at least partially vulcanizing said liquid foam rubber.
    公开号:BE1022492B1
    申请号:E2013/0706
    申请日:2013-10-21
    公开日:2016-05-04
    发明作者:
    申请人:Latexco Nv；
    IPC主号:
    专利说明:

    PRODUCT FOR BEDS CONTAINING A FOAM RUBBER LAYER, A SLICE OF SUCH FOAM RUBBER LAYER TO CUT A BED PRODUCT THEREOF AND A METHOD OF MAKING IT
    TECHNICAL FIELD
    This invention relates to products for beds, in particular mattresses and cover mattresses which contain a foam rubber layer.
    BACKGROUND OF THE INVENTION
    Products for beds such as top mattresses (mattress topper) and mattresses made of foam rubber are usually produced by vulcanization with steam. Cover mattresses with a maximum thickness of 6 cm are known that are produced in a continuous vulcanization process, in which liquid foam rubber is poured onto an endless belt and then passed through a steam oven. With a thickness of more than 6 cm, vulcanization is not possible because heat cannot be introduced into the core of the latex quickly enough since the conveyor belt has no aluminum pins.
    Moreover, it has been found that when foam rubber layers are produced by steam vulcanization, the diameter of the foam cell and the foam density vary with the thickness of the layer. This is undesirable when adjusting the properties of the foam layer, such as the values for pressure distortion and compression hardness.
    To overcome the aforementioned disadvantages, EP 1 904 570 discloses a composite foam consisting of an upper layer of foam rubber and a second layer of a foam of either foam rubber or another type of foam. CA 2 007 548 discloses a method for making foam mattresses to a thickness of 15 cm in a batch process, wherein liquid foam rubber is poured into a mold which is then placed in a microwave field with a frequency of 2.45 GHz ( Example 1) and a power of 1.2 kW / kg of latex.
    Thus, there remains a need for a continuous method of making a latex layer with a uniform cell diameter, an even foam density and low values for pressure deformation and compression hardness, which can be produced in a thickness ranging from about 1 cm to 24 cm or more.
    DETAILED DESCRIPTION OF THE INVENTION DEFINITIONS:
    Deck mattresses (topper mattress) for use in beds or seating furniture are known. These mattresses extend over the entire width and length of the specific bed or seating furniture. If the specific product or seating furniture is a mattress, such a mattress topper is usually placed on one side of the mattress core, especially at the top of the mattress, which is the side that is intended to lie on. A second cover mattress can also be placed on the other side of the mattress core, whereby the mattress core is in fact clamped. This combination is then usually covered with a fabric covering. "Latex" is herein defined as a dispersion of polymer particles in a continuous phase. Preferably the polymer particles have a size of 10 to 1000 nm. The foam rubber material can be made from natural rubber latex or from one or more synthetic latex types such as polybutadiene / styrene latex, polybutadiene / acrylonitrile latex, polychlorprene latex and the like, or from a mixture of natural rubber latex and one or more of such synthetic latexes. The foam rubber comprises conventional foam rubber and visco-elastic foam rubber.
    The dry matter content of suitable water latex is 20 to 75% by weight. The latex preferably has a dry matter content of 50 to 75% by weight.
    Suitable types of polymer latex are all dispersions in which the solids are dispersed in a liquid phase and in which this phase in turn forms an emulsion with a further liquid phase. Examples are types of latex of polymers that consist of diene or olefinically unsaturated monomers and copolymers thereof, such as polystyrene butadiene latex, polybutadiene latex, polyisoprene latex, natural rubber latex, acrylonitrile butadiene latex, polychloroprene latex, polydichlorbutadiene, copolymer latex, latex, and latex chloride. or (meth) acrylate latex. However, dispersions of polyurethanes or other dispersions in which polymers are dispersed in water with the aid of emulsifiers or dispersants are also suitable.
    Preferred types of latex include natural rubber latex, styrene butadiene rubber (SBR), low styrene content (up to 27%), nitrile rubber (NBR), isoprene rubber, neoprene rubber, polybutadiene rubber, isobutylene isoprene rubber (IIR), acrylonitrile copolymers , methacrylonitrile, acrylates, methacrylates, vinyl pyridine with butadiene or 2-chloro-1, 3-butadiene and chlorinated polyethylene or mixtures thereof.
    By far the preferred types of latex are natural rubber, styrene-butadiene rubber, nitrile rubber, polybutadiene rubber, isoprene rubber or copolymers containing acrylates.
    Types of latex containing polymers such as, for example, SBR (styrene-butadiene rubber) or NBR (acrylonitrile rubber), polychloroprene, polybutadiene, polyisoprene, natural rubber latex, polyvinyl chloride, (meth) acrylate dispersions or dispersions of copolymers thereof, are usually commercially available with a dry matter content of more than 50%.
    These levels can be achieved by, for example, increasing the concentration of low-concentration polymer latex. For example, the concentration of natural rubber latex is increased from 30% to 60% dry matter.
    Other preferred types of latex are combinations of synthetic and natural latex. The preferred ratio of natural latex and synthetic latex can be varied from 1: 4 to 6: 4. The best ratio of natural latex to synthetic latex is greater than 1: 1.
    The optimum ratios must be determined depending on the latex used. Π
    A method according to the present invention can be carried out with the aid of an apparatus comprising an endless belt, a means for pouring liquid foam on said belt and a vulcanization station along said belt comprising an electromagnetic wave generator for electromagnetic waves with a wavelength between 1 and 50 MHz.
    The device may optionally include a second vulcanization station along said band and downstream from said first vulcanization station. The second vulcanization station is heated with steam.
    The method according to the present invention for producing a product for beds comprises at least one foam layer. The said method comprises the following steps: - pouring liquid foam rubber onto a conveyor belt; - vulcanizing said liquid foam rubber in a vulcanization station to obtain a vulcanized slab of foam rubber; - cutting said vulcanized slab of foam rubber into the desired length and / or width, wherein electromagnetic waves with a frequency between 1 and 50 Mhz are used for at least partially vulcanizing said liquid foam rubber.
    According to a first method, the liquid foam rubber is vulcanized to a desired level solely through the use of electromagnetic waves, preferably in a single vulcanization station through which the conveyor belt is passed.
    In this first method, vulcanization can be achieved within a few minutes by applying the specific power of an electromagnetic wave generator that is between 0.5 and 5 kW / kg of latex in the vulcanization station.
    It is also possible to perform the vulcanization by means of electromagnetic waves to a point where the foam layer is dimensionally stable and then complete the vulcanization in a second vulcanization station in which, for example, steam is used to heat the foam rubber.
    The use of the electromagnetic waves for at least partially vulcanizing the foam rubber is favorable because foam layers with a thickness ranging from 1 cm to more than 6 cm, preferably even more than 8 cm and, even better, to even 24 cm, are vulcanized and can show good performance in terms of an even cell diameter, even foam density and low values for pressure distortion (less than 10%) and impression hardness. A foam density of only 40 kg / m3 can be achieved with the method according to the present invention.
    With an alternative method, the liquid latex layer can be deposited on a preformed foam layer with which the endless conveyor belt is equipped. Said preformed foam layer is made of a material selected from the group consisting of: polyurethane, polyolefin, polystyrene, visco-elastic latex, gelatinized but not fully vulcanized latex with stable dimensions and / or mixtures thereof.
    If the second layer is a gelatinized but not fully vulcanized latex layer, then the vulcanization of the second layer can be achieved in the vulcanization station used to vulcanize the poured, liquid foam rubber layer.
    EXAMPLES
    Example 1:
    Natural foam rubber was made according to a known formula and deposited on a continuous conveyor belt between two 26 centimeters high edges, along which a vulcanization station is placed that is fed by an electromagnetic wave generator set at 2.7 Mhz and with a specific power of 2 kW / kg of the latex present in the vulcanization station. The vulcanization station is 8 meters long and the continuous conveyor belt moves at a speed of 0.4 m / minute.
    When leaving the vulcanization station, the vulcanized foam layer has a thickness of 24 cm and is cut into cover mattresses of 1 by 2 meters. Several cover mattresses were analyzed and showed little pressure distortion and an even foam density (the weight of different cover mattresses was very close together). The pressure distortion was measured by pressing the mattress cover at a temperature of 70 ° C for 24 hours to 50% of the original thickness and then releasing the pressure. The thickness was then measured after 0.5 hours. Pressure distortion is defined as the loss in thickness after impressions expressed in%. All results were between 5 and 6% weight loss.
    权利要求:
    Claims (12)
    [1]
    CONCLUSIONS
    A method of producing a bed product comprising at least one foam layer, the method comprising the steps of: - pouring liquid foam rubber onto a conveyor belt; - vulcanizing said liquid foam rubber in a vulcanization station to obtain a vulcanized sheet of foam rubber; - cutting said vulcanized foam sheet into the desired length and / or width, characterized in that electromagnetic waves with a frequency between 1 and 50 Mhz are used to at least partially vulcanize said liquid foam rubber.
    [2]
    The method according to claim 1 wherein the vulcanization of the foam rubber is done by means of electromagnetic waves and then by means of steam.
    [3]
    The method according to claim 1, wherein the vulcanization is carried out exclusively by means of electromagnetic waves, the specific power of an electromagnetic wave generator being selected between 0.5 and 5 kW / kg of latex in the vulcanization station.
    [4]
    The method of claim 1 wherein the liquid foam rubber is poured onto the belt to a thickness of 1 cm or more, preferably 6 cm or more and most preferably 8 cm or more.
    [5]
    The method according to claim 1 wherein the liquid foam rubber is poured onto a layer of foam made from a material selected from a group comprising: polyurethane, polyolefin, polystyrene, visco-elastic latex, gelatinized but not fully vulcanized latex and / or mixtures thereof.
    [6]
    6. A vulcanized foam rubber sheet intended to cut different bed products therefrom, with a thickness of 6 cm or more and preferably of 8 cm or more.
    [7]
    A bed product comprising at least one foam rubber layer, said layer having a pressure distortion of less than 10%, preferably less than 6% after the layer has been compressed for 24 hours at 50 ° C of the original thickness at 70 ° C.
    [8]
    The bed product according to claim 6, wherein the foam rubber layer has a thickness of 1 to 24 cm, preferably a thickness of 6 cm or more and most preferably a thickness of 7 cm or more.
    [9]
    The product for beds according to claim 8, wherein the foam rubber layer has a density of less than 60 kg / m3.
    [10]
    The product for beds according to claim 8, being a mattress or a mattress topper.
    [11]
    A device for continuously vulcanizing foam rubber comprising an endless belt, a means for pouring liquid foam on said belt, and a vulcanization station along said belt comprising an electromagnetic wave generator for electromagnetic waves with a wavelength between 1 and 50 MHz.
    [12]
    The apparatus according to claim 11 comprising a second vulcanization station along said belt and downstream from said first vulcanization station, wherein the second vulcanization station is heated with steam.
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    EP121896088|2012-10-23|
    EP12189608.8A|EP2724834A1|2012-10-23|2012-10-23|Method and device for producing a bedding product comprising a foamed latex layer, slab of such foamed latex layer for cutting a bedding product and bedding product obtained|
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