Sapsa Bedding S.r.l.

Renzo Villa

Luciano Abrigo

Pasquale De Michele

Alain Bruno Serge Marié

Régis Francois Jean Marie Vernet

Bruno Macció

Bruno Maccio'

Régis François Jean Marie Vernet

Abrigo Luciano

Continuous manufacture of at least a layer of latex foam with recesses of unlimited length to be divided in a plurality of blocks of latex foam by transverse cuts. The layer has a thickness between 10 and 20 cm and more. The process includes advancing along a predetermined longitudinal direction a metal laying surface provided with protuberances, gelating, curing. The process includes: a) Before depositing the latex foam inserting, by interference fit, supporting elements of resilient deformability having a predetermined thickness between pairs of protuberances of horizontal rows, the supporting elements of unlimited length; b) Carrying away the supporting elements with the advancing laying surface between an injection latex foam station and a layer extracting station; c) Embedding with latex foam the supporting elements. Advantageously the process forwards the blocks to a washing station and squeezes the blocks to a thickness reduction between 3% and 5% of their initial thickness.

Process and plant for the continuous manufacturing of at least a layer of latex foam with recesses

A plant for manufacturing a continuous latex foam layer () to form mattresses () provided with cells (). The plant comprises a plurality of laying planes () provided with a plurality of separate tables () separately arranged side by side to form a surface for the foam deposit. Each table comprises protuberances () and the arrangement of the protuberances on a table can differ from that of the juxtaposed tables in order to create supporting areas for the different body parts of the user. Preferably the tables () with their protuberances () are slidably fitted onto the laying planes () and can be easily and quickly replaced with separately provided tables having protuberances () differently arranged in order to meet the support capacity values required by different users.

Plant for continuously manufacturing a foam layer to form rest articles

A panel for a mattress including first and second fabric layers joined together along their edges and a padding material between said fabrics. The padding material includes at least a layer of resilient foam provided with through-holes. The foam layer is quilted between the first and second fabric layers. A method of manufacturing the panel includes forming a resilient foam body provided with recesses, horizontally cutting a plurality of single layers in the body in the recesses portion to result in at least one layer with through-holes, sandwiching at least one of the single layers provided with through-holes in each panel between the first and second fabric layers.

Method of manufacturing a panel for a mattress

Process for continuous manufacture of an unlimited length latex foam block including at least two layers to form after successive cross cuts resting articles such as mattresses, cushions and parts of such articles. At least a first and second latex foam mixture with different characteristics among them are separately prepared and sent consecutively at a predetermined distance from each other on a laying surface in continuous progress. The second mixture is deposited on the already shaped first layer. The first and the second layers are gelatinized concurrently at the same place. The two layers are directly joined to each other along the contact surface by mechanical co-penetration of appendices of the one into micro-cavities of the other and by reciprocal tack of the two layers latex particles following breaking of the protective barrier between particles during gelatinizing.

Process and plant for continuous manufacture of resting articles of latex foam

Process for continuous manufacture of latex foam rest articles such as mattresses, cushions and the like comprising a part able to participate to the manufacture steps and to remain embedded in the article with consequent improvements of final performances. A flexible perforated band, preferably a flat polymeric material net with longitudinal and cross reinforcement members, is placed over a foam laying surface provided with protuberances and in continuous advancement between a foam laying station and an unlimited length article extraction station. The latex foam passes through net holes forming an upper portion and a lower portion relative to said net. The net continuously opposes contraction forces and weight force exerted from upper portion on lower portion. The unlimited length article is subjected to successive cross cuts originating rest articles wherein a foam embedded net is arranged on ends of recesses originated by the protuberances.

Growing community of inventors

Cassano d'Adda, Italy

Renzo Villa