Process and plant for manufacture of latex foam products

• US 6,086,802 A
• Filed: 04/16/1998
• Issued: 07/11/2000
• Est. Priority Date: 04/16/1998
• Status: Expired due to Term

• Current Assignee: Continental Sprayers International, Inc., Sapsa Bedding S.r.l. (Mattress International BV)
• Original Assignee: Sapsa Bedding S.r.l. (Mattress International BV)
• Inventors: Levera, Guido, Herlin, Francis
• Primary Examiner(s): Kuhns, Allan R.
• Application Number:
  US09/061,148
• Time in Patent Office: 817 Days
• Field of Search: 198/795, 264/45.8, 264/51, 425/4 C, 425/817 C
• US Class Current: 264/51
• CPC Class Codes: B29C 33/0033 constructed for making articles provided with holes
• CPC Class Codes: B29C 33/36 continuously movable in one direction, e.g. in a closed circuit B29C49/0021 takes precedence
• CPC Class Codes: B29C 33/424 Moulding surfaces provided with means for marking or patterning for injection moulding B29C45/372
• CPC Class Codes: B29C 39/14 for making articles of indefinite length by depositing material on a substrate and stripping off the shaped article B29C41/24
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 44/28 Expanding the moulding material on continuous moving surfaces without restricting the upwards growth of the foam
• CPC Class Codes: B29C 45/0084 General arrangement or lay-out of plants B29C45/1468 takes precedence
• CPC Class Codes: B29K 2021/00 Use of unspecified rubbers as moulding material
• CPC Class Codes: B29L 2031/737 Articles provided with holes, e.g. grids, sieves nets B29L2028/00
• CPC Class Codes: B29L 2031/751 Mattresses, cushions upholstery B29L2031/58

Abstract

A process and a plant (1) for the manufacture of latex foam products comprising recesses, such as mattresses (2), cushions and the like include a plurality of carriers (9) placed in a ring-like configuration limited by a first, upper stretch (10) between a foam injecting station (3) and a product-removing station (5) and by a second lower stretch (11) for the return of the carriers devoid of foam, to the injecting station.

At any moment the first stretch (10) is filled with carriers (9), touching each other and making a single mold on which foam is injected, while on the second stretch, at least one carrier, or a discrete number of carriers, considerably separated from one another, travel. The carriers (9) of the first and second stretch (10,11) are moved by different and independent operating systems and the speed of the carriers of the second stretch is considerably higher than the one of the carriers of the first stretch, so that, whatever the adopted solution, a carrier (9) can be always present at the injecting station (3), while another carrier leaves the removing station (5).

Claims

1. A continuous process for manufacturing foamed products of unlimited length designed to form mattresses (2) or cushions, the process comprising the steps of:

moving a plurality of laying planes in a ring-like path comprising a first and a second stretch (10,

     11) joined to one another at their ends by means of a third and a fourth stretch shaped as an arc of a circle (16,

     17) respectively, arranged between the exit of the first stretch and the entry of the second stretch and between the exit of the second stretch and the entry of the first stretch;

advancing continuously at a first speed a plurality of laying planes (12) between a first and a second station (3,

     5) between which a vulcanizing station (8) is interposed, said laying planes being of determined sizes;

injecting foam material at the first station until forming over said laying surfaces a layer of determined thickness of said product;

vulcanizing the foam material to form a vulcanized product; and

removing the vulcanized product at the second station;

said process further comprising the steps of;

a) advancing along the second stretch, during the transfer from the first (3) to the second station (5), at a second speed, higher with respect to the first one, at least one of the laying planes devoid of foam material, coming from the exit of the third stretch up to the proximity of the first station (3);

b) pushing by means of said laying planes devoid of foam material the plurality of laying planes placed between the first (3) and the second station (5), said second speed and said pushing transmitted by said laying planes devoid of foam material causing always, between the first (3) and second station (5) a constant plurality of laying planes (12) in contact with one another delimiting a continuous surface for the formation of said products of unlimited length;

c) joining with each other adjacent laying planes from the first station up to the exit of the third stretch;

d) releasing adjacent laying planes after the exit of the third stretch and before the second stretch;

said first and second speed being independent of each other so that the second speed is adjusted in such a way that, even when replacing all of the laying planes, the first stretch is filled with adjacent laying planes joined to each other.

15. The continuous process of claim 1, wherein said latex foam products of unlimited length are manufactured by the process to have recesses.

2. A continuous process for manufacturing foamed products of unlimited length to form mattresses (2) or cushions, including the steps of:

moving forward continuously at a first speed a plurality of laying planes (12) between a first and a second station (3,5) between which a vulcanizing station (8) is interposed, said laying planes being of determined sizes,

injecting foam material at the first station until foaming on said laying planes a layer of determined thickness of said article

vulcanizing;

removing the vulcanized product at the second station,

a) advancing, during the movement of laying planes from the first to the second station, at a second speed higher than the first one, at least one of the laying planes, devoid of foam material, coming from the exit of the second station unto close to the first station

b) pushing by said laying planes devoid of foam the plurality of laying planes placed between the first and the second station,

said second speed and said pushing given by said laying planes devoid of foam determining always between the first and the second station a constant plurality of laying planes mutually touching each other delimiting a continuous surface for the formation of said articles of unlimited length.

3. A continuous process for manufacturing latex foam products of unlimited length designed to form mattresses (2) or cushions, the process comprising the steps of:

moving a plurality of laying planes in a ring-like path comprising a first and a second stretch (10,11), joined to one another at their ends by means of a third and a fourth stretch shaped as an arc of a circle (16,

     17) respectively arranged between the exit of the first stretch and the entry of the second stretch and between the exit of the second stretch and the entry of the first stretch,

advancing continuously at a first speed a plurality of laying planes (12) between a first and a second station (3,5) between which a vulcanizing station (8) is interposed, said laying planes being of determined sizes,

injecting latex foam material at the first station until forming over said laying surfaces a layer of determined thickness of said product;

vulcanizing the foam material to form a vulcanized product; and

removing the vulcanized product at the second station;

said process further comprising the steps of;

a) advancing along the second stretch, during the transfer from the first (3) to the second station (5), at a second speed, higher with respect to the first one, at least one of the laying planes devoid of foam material, coming from the exit of the third stretch up to the proximity of the first station (3);

b) pushing by means of said laying planes devoid of foam material the plurality of laying planes placed between the first (3) and the second station (5), said second speed and said pushing transmitted by said laying planes devoid of foam material causing always, between the first (3) and second station (5) a constant plurality of laying planes (12) in contact with one another delimiting a continuous surface for the formation of said products of unlimited length;

c) joining with each other (24,

     29) adjacent laying planes from the first station up to the exit of the third stretch;

d) releasing adjacent laying planes after the exit of the third stretch and before the second stretch;

e) removing (53,

     54) close to a fourth station laying planes coming out from the second station devoid of foam material without stopping the manufacturing cycle when new manufacturing necessities of the products or maintenance operations are requested;

f) changing or repairing said removed laying planes;

g) moving forward at said second speed the change or repaired laying planes up to the proximity of the first station, and repeating step b).

4. A process according to claim 3, wherein the laying planes advance in a ring-like configuration in a vertical plane.

5. A process according to claim 3, wherein the injection of the material and the removal of the product of unlimited length are carried out at opposite ends of the first stretch.

6. A process according to claim 3, wherein the laying planes devoid of foam material are reciprocally connected close to the entry of the fourth stretch.

7. A process according to claim 3, wherein the first stretch being at any moment occupied by a plurality of laying planes, equal to the distance between the first and the second station and, simultaneously, rotating in the third and fourth stretch a number of laying planes positioned substantially as chords of an arc of a circle and maintaining in the second stretch a number of laying planes only close to the third and fourth stretches in such a way that the laying planes close to said fourth stretch, driven at said second speed, maintain said plurality of laying planes in the first rectilinear stretch unchanged at any moment.

8. A process according to claim 3, wherein the transferring step along two successive first and second sections of the second stretch separated from one another by an interposed area of size substantially corresponding to the size of a laying plane, comprises:

advancing said at least one laying plane along said first and second sections and the interposed area, and

maintaining always a speed higher then that of the first speed.

9. A process according to claim 3, wherein changing at least one of said laying planes without interrupting the manufacturing cycle along successive first and second sections of the second stretch and an interposed area between the two sections, comprises:

advancing said at least one laying plane from said first section to the interposed area maintaining always a speed higher then that of the first speed;

shifting transversely to the second stretch from the interposed area said at least laying plane to be changed;

inserting the changed laying plane in the interposed area; and

advancing the changed laying plane from the interposed area to the second section always maintaining a speed higher than that of the first speed.

10. A process according to claim 8 for manufacturing latex foam products provided with recesses, wherein all of the laying planes devoid of foam material are changed to form recesses of new sizes.

11. A process according to claim 3, wherein said second speed in the second stretch is adjusted such that even when changing a laying plane with a modified one, the first stretch remains filled with laying planes.

12. A process according to claim 4, wherein the laying planes have a length of from 40 cm to 100 cm for manufacturing mattresses having a thickness of from 14 cm to more than 20 cm.

13. A process according to claim 3, wherein the latex foam material injected on the laying planes is heated before the step of vulcanizing.

14. The continuous process of claim 3, wherein said latex foam products of unlimited length are manufactured by the process to have recesses.