METHOD FOR PRODUCING A BREATHABLE MAT

Description

TECHNICAL DOMAIN

[0001] The invention relates to a method for producing a breathable mat, in particular a breathable lying mat for a child's bed.

STATE OF THE ART

[0002] The invention relates to a method for producing a breathable mat, and a breathable mat obtained by a method according to the invention.

[0003] Sometimes, it happens that the respiration of babies or toddlers is strongly obstructed, because they roll onto their belly and do not yet have the reflex to turn again.
Nevertheless, sufficient sleeping is part of a healthy life style, and ensures - especially for babies and young children - a good psychic and physical development. Moreover, sleeping contributes to the release and relaxation of body and mind. The number of sleeping hours per day that is necessary for being sufficiently well rested depends from person to person. Moreover, the average number of sleeping hours one needs for sleeping sufficiently, decreases as one gets older. For example, an adult aged 30 year needs in average 7 to 9 hours of sleep per day, while a new-born baby aged 0 to 3 months needs in average 14 to 17 hours of sleep per day.

[0004] People, and especially babies, thus spend a substantial part of their day while sleeping. Therefore, it is important that one takes a healthy, safe and comfortable position while sleeping.

[0005] Thus, it is important that parts of the body that are in contact with a mattress while sleeping, are sufficiently ventilated to prevent overheating and damage or discomforts at the respective parts of the body. This is certainly also important with respect to bedridden persons.

[0006] It is also known that sufficient, and possibly adaptive, support of the parts of the body such as the neck and back is essential for a good night rest. The present state of the art already describes personalized mattresses that are modified based on person-specific anatomy.

[0007] Although the present state of the art already describes one or more lying mats that can solve part of these problems, there is still a need for alternatives and/or optimization for solving these problems.

[0008] There is also a need for an efficient and performant method for producing a mattress which can offer a solution for one or more of the above-said problems.

[0009] The present invention aims to find a solution for at least some of the above-mentioned problems.

SUMMARY OF THE INVENTION

[0010] The invention relates to a method for producing a breathable mat according to claim 1. More in particular, the invention relates to a method for producing a breathable mat, preferably a lying mat for a child's bed, comprising:

• fabricating a compact three-dimensional knitting product by means of a knitting machine, in which said knitting product is kept under tension during the fabrication;
• stretching said compact three-dimensional knitting product; and
• thermally fixing the stretched knitting product.

[0011] In a second aspect, the invention relates to a mat according to claim 13. More in particular, the invention relates to a breathable mat for use as a lying mat, characterised in that said mat is fabricated by means of a method according to the present invention.

DETAILED DESCRIPTION

[0012] The invention relates to a method for producing a breathable mat, in particular a breathable lying mat for a child's bed. Moreover, the invention relates to a breathable mat for use as a lying mat.

[0013] Unless otherwise specified, all terms used in the description of the invention, including technical and scientific terms, shall have the meaning as they are generally understood by the skilled person in the technical field of the invention. For a better understanding of the description of the invention, the following terms are explained specifically.

[0014] "A", "an" and "the" refer in the document to both the singular and the plural form unless clearly understood differently in the context. "A segment" means for example one or more than one segment.

[0015] When "approximately" or "about" are used in the document together with a measurable quantity, a parameter, a period or moment, etc., variations of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, still more preferably +/-1% or less, and even still more preferably +/-0.1% or less than and of the cited value are meant, as far as such variations apply to the invention that is described. It will however be clearly understood that the value of the quantity at which the term "approximately" or "about" is used, is itself specified.

[0016] The terms "include", "including" and "provide with" are synonyms and are inclusive or open terms that indicate the presence of what follows, and that do not exclude or prevent the presence of other components, characteristics, elements, members, steps, known from or described in the state of the art.

[0017] The citation of numeric intervals by means of end points includes all integers, fractions and/or real numbers between the end points, including these end points.

[0018] In a first aspect, the invention relates to a method for producing a breathable mat, preferably a lying mat for a child's bed. The method comprising fabricating a compact three-dimensional knitting product by means of a knitting machine, in which said knitting product is kept under tension during fabrication; stretching said compact three-dimensional knitting product; and thermally fixing the stretched knitting product.

[0019] The term "three-dimensional knitting product" in the description of the invention refers to the distinction with a conventional - bi-dimensional - knitting product. Conventional knitting products comprise one layer of textile consisting of - in a simplified embodiment - a number of rows with a number of stitches. For fabricating conventional knitting products comprising a plurality of layers of textile, different textile layers must be sewn to each other, or hems must be provided for. Three-dimensional knitting products however comprise a plurality of textile layers without having to sew them to each other and without one or several hems having to be provided for.

[0020] In the description of the present invention, the term "thermally fixing" refers to a process in which fibres, yarns, fabrics, textile and/or a knitting product are treated with heat for stabilising it.

[0021] In a method of the present invention, a compact three-dimensional knitting product is made by means of a knitting machine. By keeping said knitting product under tension during the fabrication process, the knitting product is continuously stretched as a result of which more robust and larger stitches can be fabricated than when no tension would be maintained. The robustness of stitches prevents that stitches come loose in an undesired way during the further production process or use of the knitting product or the produced lying mat, while larger stitches induce a larger mesh in the textile and consequently increase the breathability of the knitting product and the finally produced lying mat. It is indeed important that the textile can be stretched later during the production in order to increase the mesh in the textile and thus induce a breathable structure in the textile.

[0022] The stretching of the three-dimensional knitting product during the fabrication of a three-dimensional knitting product also induces the advantage that the knitting product is stretched continuously as a result of which stitches, rows of stitches and layers thereof can be applied much more easily, straighter and more equal.

[0023] In particular, a three-dimensional knitting product is fabricated in a pattern of a honeycomb structure. A three-dimensional honeycomb structure pattern offers sufficient support and offers a support that is equally spread over the complete surface of the respective knitting product. Moreover, the meshes in the honeycomb structure pattern provide for a breathability of the textile. Preferably, the honeycomb structure pattern especially comprises hexagonal shapes.

[0024] In particular, in a method of the invention, a tension is applied to the compact three-dimensional knitting product, increasing the width of the respective knitting product with 10% to 50%, compared to when no tension would be applied to the respective knitting product.

[0025] By stretching the knitting product only in a limited way during the fabricating step, a relatively compact, robust and uniform three-dimensional knitting product is fabricated. This allows to stretch the knitting product in a more controlled way in a further phase of a method for fabricating a breathable mat following the invention.

[0026] In a preferred embodiment, the compact three-dimensional knitting product has a width of 180 to 220 cm during the fabrication and under tension. Preferably, the compact three-dimensional knitting product has a width of 120 to 150 cm when no tension is applied to the knitting product.

[0027] The number of needles per inch of a knitting machine is a measure for the fineness of the stitches that can be knitted by means of the respective knitting machine. The more needles per inch a knitting machine comprises, the finer the stitches can be knit.

[0028] In a method of the present invention, preferably, fine stitches have to be knitted, as in this way, a large number of stitches can be knitted at a relatively small surface and/or volume. This has the advantage that a compact three-dimensional knitting product fabricated according to the present invention can show a combination of both a large mesh and a high robustness.

[0029] In particular, a method of the present invention comprises the fabrication of a compact three-dimensional knitting product by means of a knitting machine comprising 12 needles per inch.

[0030] Another parameter of a knitting machine is the mill plate distance. The larger the mill plate distance, the thicker the fabricated knitting product can be; and analogously, the smaller the mill plate distance, the thinner the fabricated knitting product can be.

[0031] Depending on other parameters during the fabrication of a compact three-dimensional knitting product - such as the number of needles per inch, the yarn and the knitting pattern - it can be advantageous to adjust the mill plate distance, and thus the thickness of the fabricated knitting product.

[0032] In particular, a method of the invention comprises the fabrication of a compact three-dimensional knitting product by means of a knitting machine having a mill plate distance of 3 to 15 mm, preferably 5 to 12 mm and more preferably of 8 mm.

[0033] In particular, a method of the invention comprises the fabrication of a compact three-dimensional knitting product by means of a knitting machine comprising at least two rolls of yarns. In an embodiment of the method, the respective rolls of yarns comprise a different yarn.

[0034] The use of two or more rolls of yarns, possibly comprising a different yarn, allows to knit more complex knitting patterns. The possibility to knit more complex patterns allows to produce three-dimensional knitting products - and finally produced mats - having a higher degree of variation, adaptation and/or personalisation.

[0035] In particular, the three-dimensional knitting product is fabricated at a speed of 12 to 18 meter per hour.

[0036] After fabricating a three-dimensional knitting product, the fabricated compact three-dimensional knitting product is stretched.

[0037] A fabricated three-dimensional knitting product undergoes undesired deformations, when no tension is maintained. The stretching of the fabricated knitting product such as in a method of the invention, allows to prevent and remove such deformations, and allows to bring and maintain the desired knitting product in a more desired shape.

[0038] As said above, the compact three-dimensional knitting product is stretched only slightly during the fabrication step. As a result, a relatively compact knitting product is fabricated having still a lot of potential for being stretched out. In a method of the present invention, the compact three-dimensional knitting product is stretched substantially after the fabrication process for the meshes in the textile structure of the knitting product being enlarged. Larger meshes increase the breathability of the knitting product.

[0039] More specifically, the stretching of the knitting product is made by inducing and maintaining similar tractive forces at both the longitudinal and the width sides of the compact three-dimensional knitting product. In this way, a stretched knitting product is obtained which is stretched out at all sides in similar extents, and thus, having a uniform textile structure and pattern over the complete stretched knitting product. Possibly, the thickness of the compact knitting product is also stretched in an analogous way. Said uniform textile structure would not be obtained when already large tension and/or tractive forces were already maintained during the fabrication of the compact three-dimensional knitting product. The separation of the fabrication step of a compact three-dimensional knitting product and the stretching step of the respective knitting product allows for a controlled stretching-out of the knitting product.

[0040] In particular, the knitting product is stretched when a mesh in the textile is obtained from 0,5 to 10 mm, and preferably 2 to 4 mm. The respective mesh allows the stretched knitting product to be both sufficiently breathable and supportive, and at the same time to feel comfortable for a user of a finally produced breathable mat. Larger meshes would feel less even - or even corrugated - and thus unpleasant for a user.

[0041] In particular, the stretched knitting product has a thickness of 3 to 15 mm, more preferably 5 to 12 mm, and most preferably 8 mm. A lying mat with limited thickness has the advantage that it takes less volume and is easy to transport and to store. Moreover, a small thickness of a mat ensures that it is easy to wash. Nevertheless, it is important that a final produced lying mat is sufficiently thick for offering sufficient support to a user.

[0042] In a method according to the present invention, a stretched knitting product will be thermally fixed for stabilising the structure, shape and dimensions thereof. More in particular, the thermal fixing of a stretched knitting product allows to maintain the shape and dimensions of the knitting product that have been obtained by stretching the compact three-dimensional knitting product. In this way, it is prevented that the stretched knitting product shrinks and again takes the dimensions of the compact three-dimensional knitting product when the knitting product is no longer subjected to stretching forces.

[0043] Also, thermal fixation of a knitting product often induces a higher volume, and a larger folding, wrinkling and/or temperature resistance of the resulting knitting product.

[0044] In a method of the present invention, the stretched knitting product is possibly fixed thermally when tensile forces are maintained at the respective compact three-dimensional knitting product. In this way, it is prevented that the shape, dimensions and/or structure of the thermally fixed knitting product deviate from the shape, dimensions and/or structure of the stretched knitting product.

[0045] Nevertheless, it is possible to fix the stretched knitting product in the absence of tensile forces. In order to avoid in such embodiments that the shape, dimensions and/or structure of a thermally fixed knitting product substantially deviate from the shape, dimensions and/or structure of the stretched knitting product, the stretched knitting product must be subjected to tensile forces inducing permanent shape and structural changes of the knitting product.

[0046] In particular, the stretched knitting product is fixed thermally at a temperature of 150-200°C, and more in particular, the knitting product is fixed thermally for 3 to 5 minutes.

[0047] The inventors of the invention have found that a thermal fixation at 150-200°C induces a high degree of stabilisation of the textile of the stretched knitting product as a result of which the stretched knitting product maintains its shapes, volume and dimensions for a long time and during intensive use. Also, thermal fixation at such elevated temperatures allows that the stretched knitting product must be fixed thermally only during a short time, and that in this way, a fast production of a mat is possible. Thermal fixation at a higher temperature or for a longer time results in a decrease of resistance of the knitting product, while thermal fixation at a lower temperature or for a shorter time results in insufficient fixation, and thus stability, of the knitting product.

[0048] Preferably, the thermally fixed knitting product is at the lower side provided with one or a plurality of additional layers. In particular, an absorbent layer is provided at the thermally fixed knitting product. Such a layer ensures that the bodily fluid is absorbed, such as in non-limiting examples sweat, urine and saliva, of a user.

[0049] In a further embodiment, the fixed knitting product (whether or not provided with an absorbent layer) will at the bottom be provided with an impermeable layer that is attached to the knitting product by means of a lamination process, or - if absent - at the absorbent layer. This impermeable layer preferably comprises polyurethane. This impermeable layer ensures that the mat remains moisture-proof. In a preferred embodiment, the lamination process takes place at a temperature between 140°C and 160°C. The provision of an impermeable layer at the bottom of the thermally fixed knitting product has the advantage that the base - preferably a mattress - is protected against bodily fluids such as sweat, urine and blood, and bacteria coming from a user. In this respect, the mat which is produced according to the present method also functions as a protection of the base or mattress and said mat ensures the hygiene of the base or mattress. In this way, a breathable mat is produced ensuring cleanliness, safely and comfort.

[0050] In a most preferred embodiment, the produced final product will be composed of three layers. A first layer comprises the breathable layer (the thermally fixed knitting product) that is provided at the bottom with an impermeable layer. Between the breathable layer and the impermeable layer, a humidity-absorbing layer is provided.

[0051] In a second aspect, the invention relates to a breathable mat for use as a lying mat, characterised in that the respective mat is obtained by means of a method according to the present invention.

[0052] A breathable mat obtained by means of a method of the present invention ensures comfort, support and safety for a user, preferably a baby or child. By stretching a compact three-dimensional knitting product and the thermal fixation of the stretched knitting product, a mat according to the present invention is highly breathable. In this way, a mattress according to the present invention allows that when a baby or a child rolls onto his or her belly, and more in particular when he or she is laying on his or her face, he/she can still breathe and does not suffocate. Moreover, a high breathability of a mattress according to the present invention also ensures that parts of the body of a user, preferably a baby or child, that are in contact with the mat, are sufficiently ventilated and to not overheat. Nevertheless, a mat according to the present invention offers sufficient support for a user, preferably a baby or a child, to lie in a comfortable, safe and healthy position.

[0053] In an embodiment, the breathable mat comprises an extended honeycomb structure pattern. As described above, a honeycomb structure pattern allows both sufficient and pleasant support and sufficient breathability.

[0054] In an embodiment, a breathable mat is made of a breathable textile. Although the mesh of the mat, and more in particular of the knitting product, induces breathability, a breathable textile ensures that a mattress according to the invention is even more breathable. Also, a breathable textile ensures a better ventilation of parts of the body that are in contact with the mat, and the breathable material also ensures more cooling and less risks for overheating of respective parts of the body.

[0055] In a preferred embodiment, a breathable mat according to the present invention comprises a humidity-absorbing layer at the bottom side of the mat, whether or not provided with an impermeable layer. As said above, a humidity-absorbing layer ensures that the bodily fluid is absorbed, such as sweat, blood, saliva and urine, of a user as a result of which the thermally fixed knitting product of the mat is protected. An impermeable layer ensures a protection of the base - preferably a mattress - against human fluids such as blood, sweat and urine, and bacteria. An impermeable layer avoids that undesired human fluids and/or bacteria penetrate into the base - or the underlying mattress - and avoids in this way damage or pollution of the base.

[0056] In an embodiment, a breathable mat comprises flannel at at least one of its outer surfaces.

[0057] Flannel is capable of absorbing lots of (bodily) fluid and can be washed at high temperatures. Therefore, flannel is used often as a fabric for blankets, sheets and cloths. Preferably, at least the side with which parts of the body of a user of the mat, preferably a baby or a child, make most of the contact, comprises flannel.

[0058] In an embodiment, a breathable mat comprises means for allowing attachment of the mat to a base, preferably a mattress. More preferably, a mat comprises means for allowing reversible attachment of the mat to a base, more preferably a mattress.

[0059] Attachment of a breathable mat to a mattress avoids movement of the mat with respect to the mattress. This is essential with respect to the comfort of a user, but it also plays an important role as to the safety of a user. Thanks to attachment of a mat to a mattress, it is avoided that the mat moves or shifts in such way with respect to the mattress that a user of the mattress - or mat - rolls or falls and gets hurt. The provision of a reversible attachment of the mat to a mattress allows to loosen the respective mat of one mattress and to attach it to another mattress. This has the advantage that only the mat - and not the complete mattress - has to be transported, and that, when buying a new or another mattress, the same mat can be attached and used. Furthermore, the reversibility of the attachment allows to wash only the mat, without having to wash the complete mattress.

[0060] In a preferred embodiment, the breathable mat can be washed at a temperature up to 60°C. Consequently, a mat according to the present invention can be washed by a machine. This allows a respective mat to be washed regularly as a result of which the cleanliness and hygiene of the mat is maintained.

[0061] In a preferred embodiment, a breathable mat which is part of a mattress, has a length and/or width that is equal to or is larger than the length and/or width of the respective mattress. This has the advantage that a mat according to the present invention covers, and possibly protects, the whole surface of the respective mattress.

[0062] It is obvious that a breathable mat according to the present invention is not limited to attachment or provision to a mattress, but that a mat according to the present invention can be attached or provided at any base, device or apparatus supporting one or a plurality of babies.

[0063] In a preferred embodiment, a breathable mat according to the present invention is selected from the group consisting of 31 x 71 cm, 34 x 75 cm; 40 x 80 cm; 40 x 90 cm; 40 x 60 cm; 60 x 120 cm, 70 x 140 cm, 70 x 150 cm, 70 x 160 cm, 75 x 95 cm, 97 x 97 cm, and 90 x 200 cm.

Claims

1. A method for producing a breathable mat, preferably a lying mat for a child's bed, comprising:

- fabricating a compact three-dimensional knitting product by means of a knitting machine, in which said knitting product is kept under tension during the fabrication;

- stretching said compact three-dimensional knitting product; and

- thermally fixing the stretched knitting product.

2. Method according to claim 1, characterised in that the compact three-dimensional knitting product comprises a honeycomb structure.

3. Method according toclaim 1 or 2, characterised in that the compact three-dimensional knitting product that is kept under tension during the fabrication has a width of 180 to 220 cm.

4. Method according to any one of the previous claims, characterised in that the compact three-dimensional knitting has a width of 120 to 150 cm when no tension has been applied over the respective compact three-dimensional knitting product.

5. Method according to any one of the previous claims, characterised in that the compact three-dimensional knitting product is fabricated by means of a knitting machine comprising 12 needles per inch.

6. Method according to any one of the previous claims, characterised in that the compact three-dimensional knitting product is fabricated by means of a knitting machine having a mill plate distance of 3 to 15 mm.

7. Method according to claim 12, characterised in that the knitting machine has a mill plate distance of 5 to 12 mm when fabricating the compact three-dimensional knitting product.

8. Method according to claim 6 or 7, characterised in that the knitting machine has a mill plate distance of 8 mm when fabricating the compact three-dimensional knitting product.

9. Method according to any one of the previous claims, characterised in that the knitting machine comprises at least two rolls of yarns, when fabricating the compact three-dimensional knitting product.

10. Method according to claim Error! Bookmark not defined., characterised in that the respective rolls of yarns comprise a different yarn.

11. Method according to any one of the previous claims, characterised in that the three-dimensional knitting product is fabricated with a speed of 12 to 18 meter per hour.

12. Method according to any one of the previous claims, characterised in that the compact three-dimensional knitting product is stretched until the stretched knitting product has a width of mesh of 0,5 to 10 mm.

13. Method according to claim 13, characterised in that the compact three-dimensional knitting product is stretched until the stretched knitting product has a width of mesh of 2 to 4 mm.

14. Method according to any one of the previous claims, characterised in that the stretched knitting product has a thickness of 3 to 15 mm.

15. Method according to any one of the previous claims, characterised in that the thermally fixed knitting product has a thickness of 5 to 12 mm.

16. Method according to any one of the previous claims, characterised in that the stretched knitting product has a thickness of 8 mm.

17. Method according to any one of the previous claims, characterised in that the stretched knitting product is fixed thermally at a temperature of 150-200°C.

18. Method according to claim 13, characterised in that the stretched knitting product is fixed thermally during 3 to 5 minutes.

19. Method according to any one of the previous claims, characterised in that an impermeable layer is provided at the bottom of the thermally fixed knitting product.

20. Method according to claim 13, characterised in that the impermeable layer is applied by means of a lamination process.

21. Method according to claim 20, characterised in that a humidity-absorbing layer is provided between the thermally fixed knitting product and the liquid impermeable layer.

22. A breathable mat for use as a lying mat, characterised in that said mat is obtained by means of a method according to any one of the claims 12-13.

23. Breathable mat according to claim 13, characterised in that said breathable mat comprises a knitted honeycomb structure pattern.

24. Breathable mat of claim 13 or 13, characterised in that the mat is fabricated of a breathable fabric.

25. Breathable mat according to any one the claims 13-13, characterised in that the mat comprises an impermeable layer provided at the bottom side of the thermally fixed knitting product.

26. Breathable mat according to claim 13, characterised in that between the thermally fixed knitting product and the liquid impermeable layer, a humidity-absorbing layer is provided.

27. Breathable mat according to any one of the claims 13-26, characterised in that at least one of the outer surfaces of the mat comprises molleton.

28. Breathable mat according to any one of the claims 13-14, characterised in that the mat comprises one or a plurality of means allowing attachment to a mattress.

29. Breathable mat according to any one of the claims 13-14, characterised in that the mat comprises one or a plurality of means allowing reversible attachment to a mattress.

30. Use of a breathable mat according to any one of the claims 13-14 as a mattress protection.