Claims:We Claim:
1. A three dimensional net or coil like structure comprising an elastic network structure obtained by forming random loops of a continuous linear polymer by curling treatment wherein the apparent density of the network structure is between 0.004 to 0.2 g/cm3; and the polymer is selected to have a specific gravity lower than 0.94 g/cm3 and a diameter in the range 0.2 to 1 mm with density in the range of 0.01 to 0.1g/cm3.

2. The three dimensional net or coil like structure as claimed in claim 1, wherein the structure is made using Polyolefin (PoE) or Polyolefin Elastomer polymer with low specific gravity.

3. The three dimensional net or coil like structure as claimed in claim 1, wherein the polymer has diameter in the range 0.4 to 1 mm with density in the range of 0.03 to 0.08 g/cm3.

4. The process for manufacturing three dimensional net or coil like structure as claimed in claim 1 comprising:
a) converting the pallets of polymeric material into molten state using melt extruder;
b) maintaining the molten polymeric material at 10°C to 80°C above than the melting temperature of the polymeric material;
c) extruding the molten polymeric material in downward or horizontal direction on the two adjacent take-up conveyors with the help of nozzle consisting of multiple orifices arranged in a uniform pattern or in random fashion which form loop pattern of extruded polymer while free falling on conveyors;
d) sandwiching the extruded material between the two conveyors during its molten stage to form three dimensional netted or coiled structure;
e) solidifying the obtained three dimensional netted or coiled structure by a cooling medium;
f) curing the obtained three dimensional netted or coiled structure in controlled environment.

5. The three dimensional net or coil like structure as claimed in claim 1, wherein the netted structure has high heat resistance up to 90°C.

6. The three dimensional net or coil like structure as claimed in claim 1, wherein the netted structure has up to 4% carbon accumulation.

7. The process as claimed in claim 4, wherein the curing in step f) is carried out by chemical additives curing, ultraviolet curing or electron beam curing.
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
THREE DIMENSIONAL NET OR COIL LIKE STRUCTURE FOR COMFORTABLE CUSHIONING AND MATTRESSES.

APPLICANT:
Genex Science and Technologies Pvt. Ltd.,
a company incorporated as per the laws of India,
having address as
1, 2, 3, 'C' Wing, 2nd floor, Tex Centre, Chandivali road,
Andheri (East), Mumbai - 400072

The following specification describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION:

This invention relates to a three-dimensional netted or coiled structure used for a cushioning material, which is easily bendable and is very comfortable for using in automobile seats, medical beds, wheel chair cushioning and for house hold furniture like sofa and bed etc.

BACKGROUND OF THE INVENTION:

As people improve the quality of life, become more focused on the quality of sleep, a good mattress will not only make people comfortable night's sleep, but also good for the body. If the mattress is not ideal, pressure will be induced on body and nerves, affecting the normal circulation of the blood. It can also cause back pain and sciatic nerve pain, etc. Quality mattress on the market varies greatly, now known mostly spring based mattress and foamed urethanes, non-elastic crimped staple stuffing, resin-like stuffing, hard stuffing, etc. obtained majorly by bonding of non-elastic crimped staples are used as a cushioning material for furniture and bedding in trains and automobiles. The adhesives used for bonding components together wear out over the time which causes deformation in shape of cushioning material leading to poor support and comfort. Foam materials exhibit poor ventilation and air circulation plus they have thermal storage tendency because of which the moisture or water entered into the foam remain trapped inside and give the unwanted warm and humid feeling to the user. The carbon accumulation rate of the currently available mattresses is also seen to be high which is hazardous for infants and injurious for adults. Although foamed-cross linking type urethanes have admirable durability as a cushioning material, the foamed cross linking type urethanes have low rebound rate which makes them uncomfortable over the time period. Nevertheless, their manufacturing is not eco-friendly and need high costs in elimination of poisonous gas released during manufacturing. The disposal of these urethanes is another challenge as its incineration releases hazardous chemicals in atmosphere. There are prior arts, US7625629 and US7892991 which disclose about the three dimensional netted structure but get wrinkled and deform unevenly while bending them to fasten on frame of sofa or car seat, therefore they need to be manufactured in different pieces and fasten them to the frame which increases overall cost of manufacturing as separate pieces need to be manufactured due to poor bending property of the product.

The materials disclosed for and used in earlier cushioning were not compatible with antibacterial sprays and cleansing materials. Most of them were prone to the reactions with chemicals used in such sprays and cleansing materials causing potency loss of such materials as well as the degradation of the cushioning materials. There is a need of an inert material to be used for manufacturing cushioning products.

An object of the invention is to provide a smoothly-bendable and comfortable three-dimensional net or coil like structure made from elastomeric polymer material. The object of invention is also to make cushioning more comfortable for bed mattresses, furniture cushioning like in sofas and chairs and automotive seat, etc. and reducing cost of manufacturing.

SUMMARY OF THE INVENTION:

The present invention provides suitable solution for human sleep and resting comfort. Accordingly current invention provides a three dimensional netted or coiled structure for comfortable cushioning and mattresses. It is made of a material stack up layers.
The present invention provides a three dimensional netted or coiled structure comprising an elastic network structure obtained by forming random loops of continuous linear polymers by curling treatment. As the polymers having a specific gravity exceeding 0.94 g/cm3 hardens the obtained cushioning material, preferably the polymer having specific gravity lower than this and more specifically the polymer with specific gravity of 0.92g/cm3are used. The network structure is formed to give apparent density of 0.03 to 0.08g/cm3.
The polymer for netted structure of present invention has diameter in the range 0.4 to 1 mm with density in the range of 0.03 to 0.08g/cm3. Preferably, the structure is made using Polyolefin (PoE) or Polyolefin Elastomer polymer with low specific gravity.

DESCRIPTION OF THE INVENTION:

According to present invention, there is provided a three-dimensional net or coil like structure prepared without using any adhesive, having good ventilation, low carbon accumulation, good water permeability, and lower thermal storage capacity and which is compatible with antibacterial sprays and cleansing materials. This three dimensional netted or coiled structure is ideal for comfortable cushioning.

In the first aspect of the invention, a three dimensional netted or coiled structure is provided comprising an elastic network structure obtained by forming random loops of a continuous linear polymers by curling treatment wherein the apparent density of the network structure is between 0.004 to 0.2 g/cm3; and the polymer is selected to have a specific gravity lower than 0.94 g/cm3 and a diameter in the range 0.4 to 1 mm with density in the range of 0.03 to 0.08g/cm3.

The apparent density of less than 0.004g/cm3 fails to provide repulsive force, and the elastic network structure is unsuitable as a cushioning material, to the contrary the apparent density exceeding 0.2 g/cm3 gives great elasticity, and reduces comfortableness, leading to an unsuitable cushioning material.

As the polymers having a specific gravity exceeding 0.94 g/cm3 hardens the obtained cushioning material, preferably the polymer having specific gravity lower than this and more specifically the polymer with specific gravity of 0.92g/cm3are used. The network structure is formed to give apparent density of 0.03 to 0.08g/cm3.

The suitable polymers for use in present invention are selected from Polyolefin (PoE) or Polyolefin Elastomer which does not interfere with the advantageous effects of the invention.

The air pockets created by using three dimensional netted or coiled structure make it more breathable and due to passing of more air through the cavities, mattress are excellent at maintaining freshness even after long period of use. In present invention carbon accumulation is also lowered which is advantageous for health. More preferably it is advantageous for infants which are prone to problems related with high carbon accumulation in mattresses. The structure of present invention has only 3%-4%carbon accumulation which helps in better health of infants.

The polymers listed above possess lower thermal resistance of about 3.2° KCm2/W or less, which prevents overheating of the mattress, hyperthermia and improves thermal comfort. This being inert materials does not react and produce poisonous gases when cleansing and antibacterial sprays are applied to the prepared netted or coiled structure.

While sleeping most of the human weight is concentrated at two regions, chest region concentrating up to 35% and hip region concentrating to 45% which causes bedsore. The netted or coiled structure of present invention mitigate this problem by providing the rebound and recovery rate of at least 96% which can go up to 98%which offer superior weight distribution during sleep.

The netted or coiled structure has high heat resistance up to 90°c, which make it washable by hot water.
In another aspect of the invention the process of manufacturing three dimensional netted or coiled structure is described hereinafter;
a) converting the pallets of polymeric material into molten state using melt extruder;
b) maintaining the molten polymeric material at 10°C to 80°C above than the melting temperature of the polymeric material;
c) extruding the molten polymeric material in downward or horizontal direction on the two adjacent take-up conveyors with the help of nozzle consisting of multiple orifices arranged in a uniform pattern or in random fashion which form loop pattern of extruded polymer while free falling on conveyors;
d) sandwiching the extruded material between the two conveyors during its molten stage to form three dimensional netted or coiled structure;
e) solidifying the obtained three dimensional netted or coiled structure by a cooling medium;
f) curing the obtained three dimensional netted or coiled structure in controlled environment.

More specifically, the pallets of polymeric material of suitable nature and characteristics used as raw materials are converted into molten state using common melt extruder; the molten polymeric material is maintained 10°C to 80°C above than the melting temperature of the polymeric material. The molten polymeric material is extruded in downward or horizontal direction with help of nozzle consisting of multiple orifices which can be arranged in uniform pattern or in random pattern, which form loop pattern of extruded material while free falling. The extruded material falls on the two adjacent take-up conveyors and it is sandwiched between them to form three dimensional netted or coiled structure. It is further solidified by cooling medium. The cooling can also be achieved by simultaneously passing the conveyors holding the sandwiched netted or coiled structure through cooling medium. The diameter and fineness of pattern obtained is determined by adjusting distance between nozzle and take-up conveyor, viscosity of molten polymeric material, hole size of orifice and discharge rate. The pair of conveyors has spacing between them which sandwich the filament during its molten stage to form netted or coiled structure. By adjusting spacing between the holes of orifice the discharging filaments are brought in contact. The contact between the loops while in molten stage weld them to form random three dimensional structures. The obtained three dimensional structure is passed through the cooling medium and solidified forming an elastic network structure. Further, the solidified elastic network structure is cured for increasing quality and durability. The methods used for curing are commonly known methods namely; chemical additives curing, ultraviolet curing and electron beam curing etc. Curing process is carried out in controlled environment which does not affect the specific dimensions of the product during curing process. The obtained network structure is cut into desired length and shape. The obtained product is moulded and laminated for using as cushioning material.

According to one embodiment design of three dimensional netted or coiled structure is such that it is easy for user to wash and dry. The breathable cavities formed help in quicker drying of mattress and spraying anti-bacterial sprays is also possible, it can also be disinfected using alcohol based disinfectants and lower-concentration bleaching liquids. In present invention as breathable cavities are present they help in proper ventilation of bed and removing unwanted odour in the ventilation process. Yet another advantage of three dimensional netted or coiled structure of present invention is, it prevents user from suffocating while sleeping in face down position as proper ventilation is provided in the mattress structure. More than 95% of surrounding air passes through the cavities present in product which prevent in humidity to be trapped inside of mattress.

Another embodiment shows that mould and bacteria formation is lowered due to superior air circulation. Air circulation between user and bed surface evaporate the sweat faster. The three dimensional netted or coiled structure of present invention has high resistance to heat; it can resist heat up to 90°C which makes it suitable for washing with hot water. Due to high heat resistance electrical blankets can be used safely without any overheating and fire hazard. Materials used in manufacturing of bed are recyclable which makes product eco-friendly and helps in reducing manufacturing cost of the product.

Three dimensional netted or coiled structure of current invention has the following advantages: odourless because of superior air-circulation through the structure, the structure has superior ventilation which makes it breathable and thermally comfortable, easy to wash and cleanse using disinfectants, can be broken down and recycled and structure provides multiple points supporting the human body according to the pressure per unit area to provide support to the human skeleton which keeps body in a completely relaxed state.

Although the embodiments of the present invention is to describe the actual program, but is not construed to limit the meaning of the present invention.