Bedding Product Comprising a Foamed Latex Layer, Slab of Such Foamed Latex Layer for Cutting a Bedding Product Therefrom and Method of Manufacturing Thereof

Abstract

A method for producing a bedding product is disclosed which has at least a foamed latex layer. The method includes pouring liquid latex foam on a conveyor belt. The liquid latex foam is vulcanized in a vulcanization station to obtain a vulcanized latex foam slab. The vulcanized latex foam slab is cut to a desired length and / or width. Electromagnetic waves with a frequency ranging between 1 and 50 Mhz are used for at least partially vulcanizing the liquid latex foam.

Description

TECHNICAL FIELD

[0001] The present invention concerns bedding products and in particular mattresses and toppers, comprising a foamed latex layer.BACKGROUND OF THE INVENTION

[0002] Bedding products such as toppers and mattresses made of latex foam are generally manufactured by steam vulcanization. Toppers having a thickness of maximally 6 cm are known which are produced in a continuous vulcanization process, whereby liquid latex foam is poured onto an endless belt or carrier and is subsequently passed through a steam oven. Above 6 cm thickness, continuous vulcanization is not possible because heat cannot be introduced into the core of the latex material sufficiently quickly due to the absence of aluminium pins on the conveyor belt.

[0003] Furthermore, when manufacturing latex foam layers by steam vulcanization it has been observed that the foam cell diameter and the foam density varies throughout the thickness of the layer which is undesirable for fine-tuning the properties of the latex fo...