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.

1 . A method for producing a bedding product comprising at least a foamed latex layer, said method comprising the steps of:
 pouring liquid latex foam on a conveyor belt;   vulcanizing said liquid latex foam in a vulcanization station to obtain a vulcanized latex foam slab; and   cutting said vulcanized latex foam slab to a desired length and/or width, characterized in that for at least partially vulcanizing said liquid latex foam electromagnetic waves with a frequency ranging between 1 and 50 Mhz are used.   
     
     
         2 . The method according to  claim 1 , wherein vulcanizing the latex foam is performed subsequently by means of electromagnetic waves and by means of steam. 
     
     
         3 . The method according to  claim 1 , wherein vulcanization is solely performed by the means electromagnetic waves whereby the specific power of a electromagnetic wave generator used is chosen between 0.5 and 5 kW/kg latex in the vulcanization station. 
     
     
         4 . The method according to  claim 1 , wherein the liquid latex foam is poured on the carrier to a thickness of 1 cm or more, preferably 6 cm or more, most preferably 8 cm or more. 
     
     
         5 . The method according to  claim 1 , wherein the liquid latex foam is poured on a layer of foam of a material chosen from the group comprising: polyurethane, polyolefin, polystyrene, visco-elastic latex, gelatinized but not fully vulcanized latex and or mixtures thereof. 
     
     
         6 . A slab of vulcanized latex foam for cutting several bedding products therefrom, having a thickness of 6 cm or more, preferably 8 cm or more. 
     
     
         7 . The slab of vulcanized latex foam accordingly to  claim 6  comprising a locally profiled surface. 
     
     
         8 . A bedding product comprising at least a foamed latex layer, said layer having a compression set of less than 10%, preferably less than 6% after compressing the layer to 50% of its initial thickness for 24 hrs at 70° C. 
     
     
         9 . The bedding product according to  claim 8 , wherein the foamed latex layer has a thickness between 1 and 24 cm, preferably a thickness of 6 cm or more, most preferably a thickness of 7 cm or more. 
     
     
         10 . The bedding product according to  claim 9 , wherein the foamed latex layer has a density of less than 60 kg/m 3 . 
     
     
         11 . The bedding product according to  claim 9 , being a mattress or a topper. 
     
     
         12 . A device for continuously vulcanizing latex foam, comprising an endless belt, a device for pouring liquid latex foam on said belt, a vulcanization station provided along said belt comprising a electromagnetic wave generator for electromagnetic waves having a wave length between 1 and 50 Mhz. 
     
     
         13 . The device according to  claim 12  comprising a second vulcanization station provided along said belt and downstream from said first vulcanization station, the second vulcanization station being steam heated.