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WO2025221216A1 - Système de fabrication de matelas doté d'une unité adhésive permettant l'utilisation d'adhésif entre des couches de matelas - Google Patents

Système de fabrication de matelas doté d'une unité adhésive permettant l'utilisation d'adhésif entre des couches de matelas

Info

Publication number
WO2025221216A1
WO2025221216A1 PCT/TR2024/051154 TR2024051154W WO2025221216A1 WO 2025221216 A1 WO2025221216 A1 WO 2025221216A1 TR 2024051154 W TR2024051154 W TR 2024051154W WO 2025221216 A1 WO2025221216 A1 WO 2025221216A1
Authority
WO
WIPO (PCT)
Prior art keywords
mattress
adhesive
manufacturing system
transfer roller
roller
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/TR2024/051154
Other languages
English (en)
Inventor
Serkan GULER
Orhan GULER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Elektroteks Elektronik Tekstil Sanayi Ve Ticaret AS
Original Assignee
Elektroteks Elektronik Tekstil Sanayi Ve Ticaret AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Elektroteks Elektronik Tekstil Sanayi Ve Ticaret AS filed Critical Elektroteks Elektronik Tekstil Sanayi Ve Ticaret AS
Publication of WO2025221216A1 publication Critical patent/WO2025221216A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts

Definitions

  • the invention relates to a mattress manufacturing system with at least one adhesive unit for enabling the mattress layers to be adhered together.
  • Mattress manufacturing systems refer to the various technologies and processes used for the production of mattresses. These systems cover all stages from the selection of raw materials to the final form of the mattress. Mattress manufacturing systems can vary depending on the degree of automation on the production line, the materials used, and the types of mattresses produced. These systems are aimed at mass production of mattresses, maintaining quality standards, and increasing productivity. In mattress manufacturing systems, adhering the mattress layers is the process of combining and assembling the different layers of the mattress. This process is a very important step that determines the comfort, support, and durability characteristics of the mattress.
  • Mattress layers are made up of different materials, usually upper comfort layers, support layers, and base layers.
  • Comfort layers are usually made of soft materials such as foam, latex, or wool, while support layers can be made of more rigid and durable materials, such as high-density foam.
  • the base layer forms the lower part of the mattress and usually has a more robust structure to support the other layers of the mattress.
  • the adhesives used are generally selected to be harmless to human health, hypoallergenic, and long-lasting. These adhesives ensure that the layers are bonded tightly and that there is no slipping or separation between the layers when using the mattress.
  • the object of the invention is a system designed for packaging foam products, in which system the first side compressor applies pressure to the first side of the foam product, while the second side compressor applies pressure to the second side of the foam product, reducing the width of the foam product by compression.
  • the system includes a roller device that converts the compressed foam product into a cylindrical packaging product. In this way, the aim is to facilitate the storage and transportation processes of foam products by compressing them to take up less space and turning them into a cylindrical package.
  • Water-based adhesives used in adhering mattress layers in mattress manufacturing systems are preferred for their environmentally friendly and non-harmful properties to human health.
  • Water-based adhesives have longer drying times than other adhesives since the water they contain must evaporate, which can prolong the production process and reduce productivity.
  • water-based adhesives which often have a lower adhesive strength than solvent-based adhesives, may not be ideal for applications that require high durability.
  • These adhesives are also highly affected by moisture. High humidity conditions can adversely affect the adhesion properties, reducing the durability of the product.
  • Water-based adhesives are also sensitive to temperature changes. They can freeze at low temperatures and deteriorate at high temperatures. Storage conditions are also critical for these adhesives; in particular, temperature and humidity levels need to be kept under control, as improper storage conditions can adversely affect the life and performance of the adhesive.
  • the present invention relates to a mattress manufacturing system for eliminating the above-mentioned disadvantages and bringing new advantages to the relevant technical field.
  • the main object of the invention is to introduce a mattress manufacturing system with improved adhesive function.
  • the present invention is a mattress manufacturing system with at least one adhesive unit for enabling the mattress layers to be adhered together. Accordingly, its novelty is that it comprises at least one adhesive feeding system to release, spray adhesive onto the mattress layer on said adhesive unit, at least one transfer roller rotatable around itself on the mattress layer for applying the adhesive flowing from said adhesive feeding system onto the mattress layer, at least one dosing roller positioned adjacent to said transfer roller for homogeneous application of the adhesive to its surface, at least one internal space through which hot fluid can be passed for heating at least one of the transfer roller and dosing roller, and at least one heating tank to which it is connected to supply hot fluid to said internal space.
  • a possible embodiment of the invention is characterized in that the feeding system is positioned to deposit the adhesive between the transfer roller and the dosing roller. Thus, it is ensured that the adhesive is spread homogeneously on the transfer roller and effectively applied on the mattress layer.
  • Another possible embodiment of the invention is characterized in that the transfer roller has a larger diameter than the dosing roller and the transfer roller is configured to contact the mattress layer surface.
  • the adhesive can be spread over a larger area and applied more effectively on top of the mattress layer.
  • Another possible embodiment of the invention is characterized in that the dosing roller is positioned vertically higher than the transfer roller.
  • the dosing roller ensures that the adhesive is uniformly distributed on the transfer roller and does not come into direct contact with the mattress layer.
  • Another possible embodiment of the invention is characterized in that the transfer roller and the dosing roller are positioned side by side, parallel to each other. Thus, effective transfer and distribution of the adhesive between the two rollers is ensured.
  • Another possible embodiment of the invention is characterized in that it comprises at least one adjustment element for changing the distance between the transfer roller and the dosing roller.
  • it is possible to adjust the application density of the adhesive according to the requirements of the mattress layer.
  • Another possible embodiment of the invention is characterized in that it comprises at least one movement mechanism to which the transfer roller and the dosing roller are connected so that they can be positioned vertically in accordance with the mattress layers of different thicknesses.
  • the position of the rollers in accordance with the mattress layers increases the efficiency of the adhering process.
  • Another possible embodiment of the invention is characterized in that it comprises at least one drive conveyor for conveying the mattress layer in the lower adjacent part of the transfer roller. Thus, it is ensured that the mattress layer progresses smoothly and effectively to the adhesive application area.
  • said drive conveyor comprises at least one first part fixed horizontally and at least one second part configured to rotate at least partially with respect to the first part.
  • Another possible embodiment of the invention is characterized in that the internal space is in the form of a channel in the roller, or that the internal space is provided between the diameter space of two pipes interconnected in the rollers.
  • Another possible embodiment of the invention is characterized in that the adhesive is either a PUR-based adhesive or a water-based adhesive.
  • the adhesive is either a PUR-based adhesive or a water-based adhesive.
  • Fig. 1 shows a representative perspective view of the mattress manufacturing system of the invention.
  • Fig. 2 shows a representative perspective view of the adhesive unit in the mattress manufacturing system of the invention.
  • Fig. 3 shows a representative perspective view of the adhesive unit in the mattress manufacturing system of the invention.
  • Fig. 4 shows a representative perspective view of the adhesive unit in the mattress manufacturing system of the invention.
  • Fig. 5 shows another representative perspective view of the adhesive unit in the mattress manufacturing system of the invention.
  • Fig. 6 shows a representative cross-section C-C view of the adhesive unit in the mattress manufacturing system of the invention.
  • Fig. 1 shows a representative perspective view of the mattress manufacturing system (1) of the invention.
  • the mattress manufacturing system (1) of the invention consists of a series of robotic and mechanical units that automate the production and installation process of the mattress layers (Y).
  • the mattress manufacturing system (1) is configured to place the mattress layers (Y) in the correct order and position, apply adhesives, assemble and compress the mattress layers (Y), and cut off excesses.
  • the automated mattress manufacturing system (1) increases the speed and efficiency of the production process, while reducing the error rate and ensuring the consistency of product quality. In this way, the manufacture of mattresses is carried out more economically, quickly, and with high quality.
  • the mattress manufacturing system (1) of the invention comprises a robotic arm (2) that feeds the mattress layers (Y) in a certain order, a straightening conveyor (3) on which said robotic arm (2) places the mattress layer (Y), an adhesive unit (4) which can apply adhesive to the mattress layers (Y) following the straightening conveyor (3), an assembly unit (5) for placing the mattress layers (Y) one on top of the other following the adhesive unit (4).
  • It is configured to comprise a pressing unit (6) for pressing the mattress layers (Y) into a tight adhesion, a cutting unit (7) following the pressing unit (6) for cutting and cleaning the waste parts at the edges of the mattress.
  • Each unit plays a critical role in the production and installation process of the mattress layers (Y) and works in cooperation with each other to increase the efficiency of the production line and product quality.
  • the robotic arm (2) in the mattress manufacturing system (1 ) picks up the mattress layers (Y) using a programmable mechanism and places them on the straightening conveyor (3) in the specified order.
  • the robotic arm (2) By means of the robotic arm (2), the layers that make up the mattress (Y) are continuously fed to the line in order.
  • the robotic arm (2) can precisely carry mattress layers (Y) of different dimensions and weights, minimizing human error.
  • the robotic arm (2) reduces labor costs and increases the speed and repeatability of the production process.
  • the straightening conveyor (3) on which the mattress layers (Y) are placed, allows each mattress layer (Y) to be fed into the adhesive unit in the correct position. For this purpose, there can be pusher units on opposite sides of the straightening conveyor (3) to center the mattress layers (Y). Thus, the centering of the mattress layers (Y) is achieved.
  • the straightening conveyor (3) aligns the edges of the mattress layers (Y) and prepares an ideal surface for the adhering process.
  • Fig. 2 shows a representative perspective view of the adhesive unit (4) in the mattress manufacturing system (1) of the invention.
  • the adhesive unit (4) applies adhesive on the mattress layers (Y) in a controlled manner.
  • the adhesive unit (4) ensures that the adhesive is evenly distributed, helping the layers to form a strong and homogeneous bond with each other.
  • the type and amount of adhesive can be adjusted according to the material properties and adhesion requirements of the mattress layers (Y).
  • the assembly unit (5) allows the adhesive applied mattress layers (Y) to be adhered together by stacking them on top of each other. In this way, it is ensured that the mattresses with mattress layers (Y) are adhered on top of each other to form a whole.
  • the pressing unit (6) compresses the assembled mattress layers (Y) under a certain pressure, allowing the adhesive to penetrate and harden well between the mattress layers (Y). This process helps to strengthen the adhesive bonds and ensure that the mattress layers (Y) adhere firmly to each other.
  • the pressing time and pressure can be adjusted according to the type of adhesive and the properties of the mattress layers (Y).
  • the cutting unit (7) then cuts off the excess edges of the pressed mattress layers (Y) and creates the final dimensions of the mattress. This process ensures that the mattress has clean and smooth edges and enhances the aesthetic appearance of the product.
  • the cutting process is carried out with high precision and can be adjusted according to the dimensions of the mattress.
  • the adhesive unit (4) has at least one chassis (41) and at least one bridge (42) on said chassis (41).
  • Said chassis (41) is the structure that forms the basis of the entire adhesive unit (4). It is preferably made of metal or a similar material and has the function of carrying all other components of the adhesive unit (4).
  • the chassis (41) also ensures that the adhesive unit (4) remains stable against movements and vibrations in the manufacturing environment and increases the precision of the adhering process.
  • the bridge (42) is located on the chassis (41) and is shaped in an inverted U-shape.
  • the bridge (42) carries at least one adhesive feeding system (43), at least one transfer roller (44a)- dosing roller (44b), and at least one movement mechanism (47).
  • the adhesive is released and sprayed on the mattress layer (Y).
  • This adhesive feeding system (43) which can be present in multiple numbers on the bridge (42), applies the PUR (polyurethane) based adhesive onto the mattress layers (Y).
  • PUR based adhesive is solid under normal conditions. To do this, a PUR based adhesive is heated beforehand. To enable this, the adhesive feeding system (43) is associated with at least one heating tank (45).
  • Fig. 6 shows a representative cross-section view of the adhesive unit (4) in the mattress manufacturing system (1) of the invention.
  • One of these rollers is a dosing roller (44b) and a transfer roller (44a).
  • the transfer roller (44a) and the dosing roller (44b) are preferably of different diameters.
  • the transfer roller (44a) is preferably larger in diameter than the dosing roller (44b).
  • the larger diameter transfer roller (44a) is placed in contact with the mattress layer (Y), while the dosing roller (44b) ensures that the adhesive is homogenously spread over the larger diameter transfer roller (44a).
  • the adhesive flowed through the adhesive feeding system (43) is flowed between the transfer roller (44a) and the dosing roller (44b).
  • the distance between the transfer roller (44a) and the dosing roller (44b) can be changed according to the need by means of an adjustment element (46). In this way, the amount of adhesive used per unit area becomes adjustable.
  • the transfer roller (44a) and the dosing roller (44b) are manufactured in different diameters so that the transfer roller (44a) applies the adhesive on the mattress layer (Y) while the dosing roller (44b) allows the adhesive to be homogenously distributed on the transfer roller (44a).
  • the transfer roller (44a) and the dosing roller (44b) may be of equal diameter. In this case, it can be positioned higher vertically to prevent the dosing roller (44b) from coming into contact with the mattress layer (Y). In this way, it can be ensured that only the transfer roller (44a) is contacted on the mattress layer (Y).
  • at least one roller may be associated with a roller drive element (442) for rotating at least one of the rollers around itself. This roller drive element (442) is two pieces, preferably separately for the dosing roller (44b) and the transfer roller (44a).
  • At least one of the transfer roller (44a) and the dosing roller (44b) has at least one internal space (441).
  • Said internal space (441) is sized such that the hot fluid can pass through.
  • the internal space (441) can be in the form of a channel in the roller.
  • the internal space (441) can also be provided between the diameter spaces between the two interconnected pipes of the roller.
  • This internal space (441 ) ensures that the transfer roller (44a) and dosing roller (44b), and thus the mattress layers (Y), are at a homogeneous temperature during the adhering process.
  • the internal space (441 ) is provided in both the transfer roller (44a) and the dosing roller (44b) in the preferred use of the invention.
  • the internal space (441 ) is connected with at least one heating tank (45).
  • the heating tank (45) is the heating device used to ensure that the hot fluid reaches the ideal level of fluidity.
  • the heating tank (45) adjusts the hot fluid in a predetermined manner, which is critical for the adhesive to be applied and spread uniformly between the layers.
  • An interconnection part (49) can be used to ensure flow integrity between the transfer roller (44a) and dosing roller (44b) and the heating tank (45). In this way, it is ensured that a sealed connection can be established therebetween.
  • the movement mechanism (47) allows the vertical height of the transfer roller (44a) and the dosing roller (44b) to be adjusted, adapting to different thickness of mattress layers (Y).
  • the movement mechanism (47) enables the transfer roller (44a) and the dosing roller (44b) to move in the vertical axis, which allows the adhering process to be applied in accordance with the different mattress layers (Y).
  • the movement mechanism (47) has at least one drive element (471 ) positioned on the bridge (42). Said drive element (471 ) moves the transfer roller (44a) and the dosing roller (44b) vertically by means of at least one reducer (472) and the movement transmission arms (473).
  • the transfer roller (44a) and the dosing roller (44b) are associated with at least one ball screw (474) on each opposite side. The vertical movement can be controlled by rotating the ball screw (474) around itself by the drive element (471).
  • the drive conveyor (48) essentially contains a first part (481) and a second part (482) to facilitate maintenance.
  • Said first part (481) is essentially located in the lower vertical adjacent part of the transfer roller (44a) and is kept fixed horizontally.
  • the second part (482) is adjacent to the first part (481 ) and is configured to rotate at least partially.
  • the second part (482) can be rotated at least partially in case of maintenance, allowing the operator to clean the adhesive unit (4).
  • the mattress manufacturing system (1 ) of the invention is notable for its adhesive unit (4), which focuses especially on the use of PUR (polyurethane) based adhesives. Compared to water-based adhesives, PUR-based adhesives offer high adhesion strength and superior durability properties, resulting in tighter and more permanent assembly of the mattress layers (Y).
  • the adhesive unit (4) in the system is designed to apply this special adhesive homogeneously and in the right quantities to the mattress layers (Y).
  • the heated transfer roller (44a), the dosing roller (44b), and the specially configured adhesive feeding systems (43) guarantee that the PUR adhesive is effectively applied to the mattress layers (Y) while maintaining the ideal temperature and viscosity.
  • the mattress manufacturing system (1 ) subject to the invention can also be used for water-based adhesives in alternative embodiments of the invention. This system takes the mattress production process to a new level in terms of efficiency and quality, offering significant advantages to manufacturers and end users.

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un système de fabrication de matelas (1) avec au moins une unité adhésive (4) pour permettre aux couches de matelas (Y) d'être collées ensemble. La nouveauté de l'invention est caractérisée par le fait qu'elle comprend au moins un système d'alimentation en adhésif (43) pour libérer, pulvériser de l'adhésif sur la couche de matelas (Y) sur ladite unité adhésive (4), au moins un rouleau de transfert (44a) pouvant tourner sur lui-même sur la couche de matelas (Y) pour appliquer l'adhésif s'écoulant dudit système d'alimentation en adhésif (43) sur la couche de matelas (Y), au moins un rouleau de dosage (44b) positionné de manière adjacente audit rouleau de transfert (44a) pour une application homogène de l'adhésif sur sa surface, au moins un espace interne (441) à travers lequel un fluide chaud peut être passé pour chauffer le rouleau de transfert (44a) et/ou le rouleau de dosage (44b), et au moins un réservoir de chauffage (45) auquel il est relié pour fournir du fluide chaud audit espace interne (441).
PCT/TR2024/051154 2024-04-18 2024-10-08 Système de fabrication de matelas doté d'une unité adhésive permettant l'utilisation d'adhésif entre des couches de matelas Pending WO2025221216A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2024/004692 2024-04-18
TR2024/004692A TR2024004692A1 (tr) 2024-04-18 2024-04-18 Yatak katmanlari arasinda yapiştirici kullanimina i̇mkan veren bi̇r yapiştirma üni̇tesi̇ne sahi̇p yatak i̇malat si̇stemi̇

Publications (1)

Publication Number Publication Date
WO2025221216A1 true WO2025221216A1 (fr) 2025-10-23

Family

ID=97404103

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/TR2024/051154 Pending WO2025221216A1 (fr) 2024-04-18 2024-10-08 Système de fabrication de matelas doté d'une unité adhésive permettant l'utilisation d'adhésif entre des couches de matelas

Country Status (2)

Country Link
TR (1) TR2024004692A1 (fr)
WO (1) WO2025221216A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8337980B2 (en) * 2005-05-20 2012-12-25 Charlie Hubbs Silicone-impregnated foam product and method for producing same
US20130101805A1 (en) * 2010-07-07 2013-04-25 3M Innovative Properties Company Patterned air-laid nonwoven fibrous webs and methods of making and using same
US10172474B2 (en) * 2015-01-23 2019-01-08 Dreamwell, Ltd. Mattress manufacturing process and apparatus

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8337980B2 (en) * 2005-05-20 2012-12-25 Charlie Hubbs Silicone-impregnated foam product and method for producing same
US20130101805A1 (en) * 2010-07-07 2013-04-25 3M Innovative Properties Company Patterned air-laid nonwoven fibrous webs and methods of making and using same
US10172474B2 (en) * 2015-01-23 2019-01-08 Dreamwell, Ltd. Mattress manufacturing process and apparatus

Also Published As

Publication number Publication date
TR2024004692A1 (tr) 2025-08-21

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