FR3115231A1 - Method of manufacturing fire retardant mattress padding, fire retardant mattress padding and fire retardant mattress - Google Patents

Abstract

------ METHOD FOR MANUFACTURING FIRE RETARDANT MATTRESS FILLING, FIRE RETARDANT MATTRESS FILLING AND FIRE RETARDANT MATTRESS A method of making fire retardant mattress padding (13) includes cutting fire retardant foam sheets (2A, 2B, 2C, 2D) from a roll; disposing a first foam plate (2A) by a side face (5A) in abutment against abutment means (6); apply fire retardant glue (9); arrange a second foam plate (2B) on the first foam plate (2A), with a lateral face (5B) against the abutment means (6) so as to obtain a multilayer fireproof assembly having at least one straight lateral face ( 12); drying the flame retardant glue (9); cutting the other side faces so as to obtain padding (13) having all its side faces uniformly straight (12). Figure to be published with abstract: Figure 6

Description

Method of manufacturing fire retardant mattress padding, fire retardant mattress padding and fire retardant mattress

The present invention relates to the field of mattresses, and relates more particularly to a method of manufacturing a fireproof mattress, to a filling for a fireproof mattress and to a fireproof mattress obtained by said method.

In the field of fireproof mattresses, it is known to combine a fireproof padding with a fireproof casing. Such padding is commonly made of a foam, for example graphite or polyurethane, impregnated with flame retardants. To obtain a mattress with a certain thickness, several foam plates, of the same thickness or of variable thickness, are assembled. The foam sheets are cut from one or more initial rolls, of different thicknesses or characteristics, according to identical dimensions, and glued to each other, to achieve the desired thickness of the mattress. However, the materials commonly used have the disadvantage of having low dimensional stability which leads to variations in size due to cutting and handling, from one plate to another even when they come from the same roll and although they have been cut according to the same dimensions. Thus, the assembly constituting the mattress padding will present irregular side faces, not perfectly straight.

There is therefore a need for a method of manufacturing flame retardant mattress padding which results in padding having uniformly straight side faces.

The Applicant therefore proposes to meet this need by using a process for manufacturing fireproof mattress padding which initially comprises the stacking of foam plates with at least one side face of each plate flush with each other. compared to others.

The subject of the present invention is therefore a process for the manufacture of fireproof mattress padding, characterized in that it comprises:

a) provide one or more rolls of flame retardant foam;

b) cutting slabs of flame retardant foam from the roll or rolls, the slabs having a top face, a bottom face opposite the top face and side faces connecting the top and bottom faces;

c) arranging a first plate of fireproof foam by its underside on a support, and a side face in abutment against abutment means;

d) placing a second fireproof foam plate by its lower face on the upper face of the first foam plate, fireproofing glue being interposed between the first and second foam plates, and a side face of the second foam plate being in abutment against the abutment means so that the second foam plate has at least one side face flush with a side face of the first foam plate, so as to obtain a multilayer fireproof assembly having at least one straight side face;

e) drying the fire-retardant glue;

f) cut the other side faces of the multilayer assembly so as to obtain padding presenting all its side faces uniformly straight.

Thus, the process is suitable for stacking foam sheets of variable thickness, so as to achieve the desired final thickness of the padding.

According to one embodiment of the present invention, the method comprises:

apply the fire-retardant glue to the upper face of the first foam board before placing the first foam board on the support.

According to one embodiment of the present invention, the method comprises:

applying the fire-retardant glue to the upper face of the first foam board after placing the first foam board on the support and before placing the second foam board on the first foam board.

According to one embodiment of the present invention, the method comprises:

repeat step d) at least once before step e).

According to one embodiment of the present invention, the method comprises:

enclose the padding in a fireproof envelope so as to obtain a fireproof mattress.

According to an embodiment of the present invention, the abutment means are configured to bring the foam plates into abutment against them by two lateral faces.

The present invention also relates to a padding for a fireproof mattress, characterized in that it comprises at least two superposed fireproof foam plates, glued to each other by means of a fireproof glue, the padding having uniformly straight side faces, the side faces forming a plane.

The present invention also relates to a fireproof mattress, characterized in that it comprises a fireproof mattress padding, in particular obtained by the above method, and a fireproof envelope in which the fireproof mattress padding is sealed.

The present invention also relates to a process for the manufacture of a fireproof mattress, consisting in manufacturing a padding obtained according to the above process, and in sealing said padding in an envelope.

To better illustrate the object of the present invention, a description will be given below, by way of indication and not of limitation, of several embodiments with reference to the appended drawings.

In these drawings:

is a perspective view of a sheet of foam after the cutting step in a roll;

is a perspective view at a first stage of assembly;

is a perspective view after a bonding step;

is a perspective view at a second stage of assembly;

is a perspective view at a third stage of assembly;

is a perspective view after the assembly cutting step;

is a cross-sectional view of a fireproof mattress comprising padding such as in [Fig. 6]; And

is a perspective view at a third assembly step of [Fig. 5] according to a second embodiment.

The fireproof mattress manufacturing process according to the present invention comprises a first step in which, from a roll 1, a first foam plate 2A is cut, as can be seen in Figure 1. The roll 1 consists by foam impregnated with flame retardants. The foam will, for example, be polyurethane or polyether and the flame retardants will be of the type well known to those skilled in the art. The impregnation process is also well known to those skilled in the art and will not be repeated in detail here. Roll 1 has an M1 fire reaction and resistance classification.

Roll 1 is unrolled and foam sheets 2 are successively cut in the length of roll 1.

Thus, the foam plates 2 have a substantially parallelepipedal shape after cutting and comprise an upper face 3, a lower face 4 opposite the upper face 3 and side faces 5 connecting the upper 3 and lower 4 faces, and substantially perpendicular to those -this.

In the next step, as can be seen in Figure 2, a first foam plate 2A is placed on a support (not shown) with its lower face 4A in contact with the support. The first foam plate 2A is brought with a side face 5A in abutment against abutment means 6. The abutment means 6 will advantageously comprise a support part 7, by means of which the abutment means 6 rest on the support, and a flat abutment part 8, against which the foam plate 2A is brought into abutment by a side face 5A. Advantageously, the abutment means 6 will be able to be secured to the support. The support is, in the embodiment shown, a plate on which is fixed perpendicularly another plate to form an L-shaped corner, the other plate constituting the abutment means.

In the next step, as can be seen in Figure 3, a layer of fire-retardant glue 9 is applied to the upper face 3A of the first foam plate 2A. The glue 9 is applied according to a predefined thickness, so as, on the one hand, to prevent the layers of foam stacked relative to each other from slipping and, on the other hand, to lead to a drying time for the glue 9 optimum. Glue 9 advantageously has an M1 fire reaction and resistance classification and is an aqueous glue of the type well known to those skilled in the art.

It should be noted that the fire-retardant glue 9 may also be applied beforehand to the upper face 3A of the first foam plate 2A before placing the first foam plate 2A on the support.

Furthermore, it should be noted that the step of applying the fire-retardant glue 9, before or after laying the first foam plate 2A on the support, can be carried out manually or by means of an automated process.

In the next step, as can be seen in Figure 4, a second foam plate 2B is placed by its lower face 4B on the upper face 3A of the first foam plate 2A, with the fire-retardant glue 9 interposed between those -this. The second foam plate 2B is oriented similarly to the first foam plate 2A and, like the first foam plate 2A, is brought with a side face 5B in abutment against the abutment part 8 of the abutment means 6. note that the second foam plate 2B can come from the same roll or from a different roll (composition, thickness) of the first plate 2A.

As before, a layer of fire-retardant glue 9 is applied to the upper face 3B of the second foam plate 2B.

The following steps consist in repeating the previous steps, namely stacking other foam plates 2C, 2D on the previous plates, 2A, 2B, with a layer of fire-retardant glue 10 interposed between them, so as to obtain an assembly multilayer 10, as can be seen in Figure 5.

In addition, the foam plates 2C, 2D are arranged so as to bring a side face 5C, 5D into abutment against the abutment part 8 of the abutment means 6.

It should be noted that those skilled in the art will know how to determine the number and the thickness of the foam plates 2A, 2B, 2C, 2D according to the desired final thickness. The foam plates 2A, 2B, 2C, 2D may thus have different thicknesses relative to each other.

Due to the nature of the foam plates 2A, 2B, 2C, 2D, these have low dimensional stability. Thus, frequently, the foam plates 2A, 2B, 2C, 2D are easily deformed during cutting from the roll 1 and/or during their handling. Consequently, the multilayer assembly 10 has non-straight side faces 11. By non-straight face is meant a face which has irregularities, namely projecting areas and recessed areas.

However, thanks to the use of abutment means 6, the multilayer assembly 10 certainly has a straight side face 12, namely a face included in a plane, that defined by the abutment part 8.

The next step consists in letting the multi-layer assembly 10 dry so as to harden the fire-retardant glue 9 and secure the multi-layer assembly 10. The drying time depends on the nature of the fire-retardant glue 9.

The next step is to cut the non-straight side faces 11 of the multilayer assembly 10, so as to obtain a mattress padding 13 which has all its straight side faces 12, as can be seen in Figure 6. The cut will depend on the final dimensions of the desired mattress.

In Figure 7, we can see that there is shown a mattress 14 comprising a padding 13 as obtained previously. The mattress 14 is made by enclosing the padding 13 in a mattress cover 15, the mattress cover 15 is closed by a weld 16 or by gluing or other methods known to those skilled in the art.

It should be noted that any method of joining padding and cover to form a mattress and suitable will be suitable. Those skilled in the art may advantageously refer to the method described in French patent application FR 2 964 025 A1.

Advantageously, the mattress cover 15 has an M1 fire reaction and resistance classification. Thus the mattress 14, comprising padding comprising a stack of foam plates 2A, 2B, 3C, 2D classified M1, glued with an adhesive classified M1, and wrapped in a cover classified M1, has a fire reaction and resistance classification M1.

According to a second embodiment, the abutment means 107 are configured to abut against them two side faces 5A, 5B, 5C, 5D of the foam plates 2A, 2B, 2C, 2D.

The abutment means 106 are similar to the abutment means 6 according to the first embodiment described above. The elements of the abutment means which are identical or similar to the elements of the abutment means of the first embodiment described with reference to FIG. 8 will bear the same reference numeral increased by 100, and will not be described in more detail here.

In Figure 8, it can be seen that the abutment means 106 comprise two flat abutment parts 108A, 108B, arranged one relative to the other so as to form a corner of 90° angle, as most often encounter. Each abutment part 108A, 108B is connected to a support part 107A, 107B, by means of which the abutment means 106 rest on the support. During the steps of arranging the foam plates 2A, 2B, 2C, 2D on top of each other, these are brought with two adjacent side faces 5A, 5B, 5C, 5D into abutment against the abutment means 106. Thus, the multilayer assembly 110 obtained certainly has two straight side faces 112. This reduces the number of cutouts of the non-straight side faces 111.

It should be noted that this second embodiment is particularly advantageous when the foam plates 2A, 2B, 2C, 2D have two successive side faces 5A, 5B, 5C, 5D at right angles.

It is understood that the embodiments which have just been described have been given by way of indication and are not limiting and that embodiments can be added thereto without thereby departing from the scope of the present invention. .

Claims (8)

– Method of manufacturing fireproof mattress padding (13), characterized in that it comprises:
a) providing one or more rolls of flame retardant foam (1);
b) cutting fireproof foam plates (2A, 2B, 2C, 2D) from the roll or rolls (1), the plates (2A, 2B, 2C, 2D) having an upper face (3A, 3B, 3C, 3D ), a lower face (4A, 4B, 4C, 4D) opposite the upper face (3A, 3B, 3C, 3D) and side faces (5A, 5B, 5C, 5D) connecting the upper faces (3A, 3B, 3C, 3D) and lower (4A, 4B, 4C, 4D);
c) arranging a first fireproof foam plate (2A) by its lower face (4A) on a support, and a lateral face (5A) in abutment against abutment means (6; 106);
d) placing a second fireproof foam plate (2B) by its lower face (4B) on the upper face (3A) of the first foam plate (2A), fireproof glue (9) being interposed between the first (2A ) and second (2B) foam plates, and a side face (5B) of the second foam plate (2B) being in abutment against the abutment means (6; 106) so that the second foam plate (2B) has at least one side face (5B) flush with a side face (5A) of the first foam plate (2A), so as to obtain a multilayer fireproof assembly (10; 110) having at least one straight side face (12 ;112);
e) drying the fire-retardant glue (9);
f) cutting the other side faces (11; 111) of the multilayer assembly (10; 110) so as to obtain padding (13) presenting all its side faces uniformly straight (12; 112). - Process according to claim 1, characterized in that it comprises:
apply the fire-retardant glue (9) on the upper face (3A) of the first foam plate (2A) before placing the first foam plate (2A) on the support. - Process according to claim 1, characterized in that it comprises:
apply the fire-retardant glue (9) on the upper face (3A) of the first foam plate (2A) after having placed the first foam plate (2A) on the support and before placing the second foam plate (2B) on the first foam plate (2A). – Method according to one of claims 1 to 3, characterized in that it comprises:
repeat step d) at least once before step e). - Method according to one of claims 1 to 4, characterized in that it comprises:
enclosing the padding (13) in a fireproof envelope (15) so as to obtain a fireproof mattress (14). - Method according to one of claims 1 to 5, characterized in that the abutment means (106) are configured to abut against them the foam plates (2A, 2B, 2C, 2D) by two faces side (5A, 5B, 5C, 5D). – Padding for a fireproof mattress (13), characterized in that it comprises at least two sheets of fireproof foam (2A, 2B, 2C, 2D) superimposed, glued to each other by means of a fire-retardant glue (9), the padding having uniformly straight side faces (12; 112). – Fireproof mattress (14), characterized in that it comprises a fireproof mattress padding (13) according to claim 7, and a fireproof envelope (16) in which the fireproof mattress padding (13) is sealed.