The subject-matter of the invention is a device for producing a thermoplastic fibre mattress layer, a method for manufacture of a thermoplastic fibre mattress layer and a mattress comprising said mattress layers.

In accordance with the prior art, industrial manufacture of mattresses requires a number of components (e.g. mattress toppers, chemical foams, springs) and materials to achieve the properties desired for the comfort of the end-user. The design of single -piece mattresses provides for a single component. This group of mattresses includes, for example, latex mattresses made of a single layer of latex or foam mattresses made of polyurethane foam. On the other hand, multi-component mattresses are the ones made of different components (e.g. a combination of foam and springs).

Mattresses made of chemical foam are known from the prior art. For example, utility model description PL68734 Y1 provides for a double-sided foam mattress in a cover, having the form of a rectangular sleeping pad with horizontal channels located longitudinally and transversely crossing each other. Whereby, spatial elements are inseparably attached to the longer sides of the said mattress pad to form rectangular planes of the mattress and its edges, which have the shape of a cuboid, and are made of a foam much more firm than the foam of which the mattress pad is made, and the channels are located on the both opposite surfaces of the mattress pad, the channels on one side of the mattress pad being deeper than the channels located on its other side.

Utility design PL63662 Y 1 describes a mattress consisting of a lower base part (A) made of a traditional resilient polyurethane foam, whose upper surface is formed by evenly distributed depressions and protuberances, with the tops of the protuberances touching the upper part (B), whereby the hollow recesses contain empty spaces; in addition, upper part (B) is made of a foam material, which is characterised by low elasticity with high cushioning capacity and slow return to its original shape after deformation.

On the other hand, Canadian patent application CA2958348 describes a mattress set consisting of a layer of polyurethane foam comprising a porous foam body containing a plurality of air pockets; and a gel and an antimicrobial agent mixed and soaked into the foam in such a way that the gel and the antimicrobial agent occupy the air pockets of the porous foam body. Whereby, the antimicrobial agent comprises a polymer in an amount of 90 to 99.9 weight percent, an oxidant in an amount of 0.004 to 1 weight percent and metallic silver in an amount of 0.002 to 1 weight percent, the weight percent being based on the total weight of the antimicrobial agent. Currently, a number of methods are available for the industrial manufacture of mattresses. For example, document CN111188125 discloses a nano-antimicrobial medical mattress and a method of manufacturing it. Whereby, the disclosed method of producing antimicrobial mattresses includes the following steps: degumming a sheet of coconut fibre and processing it to obtain coconut fibre; immersing the coconut fibre in a methylthiodiazomethane solution, mixing, followed by immersion in solvents and then loading the coconut fibre with methylthiodiazomethane in a heat treatment of the coconut fibre, followed by washing and drying to obtain a modified coconut fibre. The modified coconut fibre is then exposed to the nanosilver dispersion in the conditions with an increased temperature. The fibres are then centrifuged and washed to obtain nanosilver-modified coconut palm fibre composites. The silver- modified coconut fibre composites and kapok fibre were then blended to produce the blended fibres. A board was then produced of the resulting blended fibres together with a polyurethane solution by means of a cold pre-moulding involving a dedicated board followed by a hot moulding process.

International patent application WO2017199474 describes a method of producing a three-dimensional fibre conjugate in which multiple thermoplastic resin fibres (meltblown filaments) in a meltblown state are three-dimensionally combined and bonded together as a cushion or mattress material with high detruding capacities. Furthermore, the document in question discloses a device for producing a three- dimensional filament conjugate. Whereby, the said device includes a device for delivery of fused filament which discharges fused filaments from each of a plurality of nozzles; and a three-dimensional conjugate-forming device for forming a three-dimensional filament conjugate by fusing and bonding the fused filament group discharged from the first device. The device that delivers the fused filament (fibre) includes an opening/closing unit that opens/closes a plurality of specific nozzles, which are a plurality of nozzles arranged in a predetermined direction, and the opening/closing unit includes an aperture element that can move between an open position that opens the aperture and a closed position that closes the aperture and provides sliding on the surface containing the aperture, and the opening and closing is performed by moving the aperture element. The aperture element has an opening corresponding to each of the specified nozzles and is formed so that it can move in a specified direction. The opening position is the position in which the opening overlaps the corresponding specific nozzle. According to this configuration, the three-dimensional conjugate of the filament can be easily produced by adjusting its thickness, hardness or the like dimensions. In contrast, the disclosed method of producing a three-dimensional filament conjugate comprises: extruding a molten thermoplastic resin from a plurality of horizontally arranged nozzles directed vertically downwards, then dropping the molten filament into a cooling water to form a loop, and a three-dimensionally fusing by fusing a plurality of loop-formed molten filaments together. Each molten bonded fibre connected to each other through fusion is transferred to the back side for cooling and a three-dimensional filament conjugate is moulded so that it is continuous in the direction of transfer. The three-dimensional filament conjugate is cut to each of the lengths corresponding to specific product dimensions to obtain a three-dimensional filament conjugate for the product.

The aim of the invention is to develop a new device, a method for producing a mattress layer for mattresses and mattresses containing said mattress layer.

The essence of the invention is a device for producing a thermoplastic fibre mattress layer of a mattress, consisting of an extruder unit connected by gearbox to a motor and provided with an auger equipped with heating zones which is connected to a multi-nozzle extruder equipped with built-in heaters; a cooling tank located below the manufacturing nozzles of the extruder and the infeed-receiving unit, characterised in that at least two opposing lateral dispersing nozzles are installed on the housing of the cooling tank, below which at least two opposing outer vertical heaters are mounted, the spacing of the said dispersing nozzles and outer vertical heaters being wider than the spacing of the manufacturing nozzles of the extruder; the cooling tank is provided with moulding rollers, infeed rollers and with an infeed-receiving belt connecting said cooling tank with the post -heating furnace, behind which infeedreceiving unit is situated.

Advantageously, the auger unit is equipped with seven heating zones, each of which is equipped with a cooling fan.

Advantageously, the diameter of each of the plurality of the dispersing nozzles (10) is 0,7 mm.

Another essence of the invention is a method for the continuous manufacture of a thermoplastic fibre mattress layer for a mattress, characterized in that it comprises the following steps: a) thermoplastic granules are supplied to raw material infeed unit (3) of the extruder; b) the granules are heated by heaters (5) of the heating zones (5) of auger (4) of the extruder; c) the fibres are extruded through a plurality of downward-facing manufacturing nozzles (8) of the extruder (7); d) silver ions (9) are dispersed on the surface of the extruded thermoplastic fibres when they exit manufacturing nozzles (8) through at least two opposing lateral dispersing nozzles (10) installed on the cooling tank housing (12) perpendicularly to manufacturing nozzles (8) below their mouth; e) increasing the binding of silver ions (9) to the surface of the thermoplastic fibres by heating the fibres in the outer vertical heaters (11) zone at a temperature of 150°C-285°C; f) transfer of silver ion-coated thermoplastic fibres (9) into the cooling tank (12); g) the fibre conjugate is moulded to take specific shape on moulding rollers (13) of cooling tank (12) for 45 sec. to 5 minutes and the moulded conjugate is fed successively onto infeed rollers (14) and infeed-receiving belt (15) connecting the cooling tank (12) with post-heating furnace; h) the moulded material is transferred to the heating furnace via the infeed-receiving belt (15); i) the moulded conjugate is subjected to a temperature of 120-350 °C in the heating furnace for 45 sec. to 5 minutes; j) the moulded conjugate is received and trimmed at the furnace outlet by infeed-receiving unit (19), which is equipped with edge knives (21).

Advantageously in step e) the heating of the fibres in the outer vertical heaters zone (11) is carried out at a temperature of 230-250 °C.

Advantageously, in step e) the heating of the fibres in the outer vertical heaters zone (11) is carried out at a temperature of 230 °C.

Advantageously, in step i) the moulded conjugate is subjected to a temperature of 200 °C.

Advantageously, in step i) the moulded conjugate is subjected to a temperature of 240 °C.

Advantageously, in step i) the moulded conjugate is subjected to a temperature of 288 °C.

The essence of the invention is a double-sided thermoplastic mattress in the form of a rectangular sleeping pad comprising at least one mattress layer made by the prescribed above method characterised in that its resilience is between 40 and 70%, each layer has a density of 30 to 190 kg/m3 and each fibre of the mattress layer is coated with silver ions.

Advantageously, mattress contains one to three mattress layers.

Advantageously, its permeability to air is 70-98%.

Advantageously, it contains silver in an amount of between 0.0001% and 0.05% by weight of the filling of the entire mattress.

The invention provides the following advantages:

• Each fibre is modified with silver ions, which enriches the mattress material with antibacterial properties;

• coating each fibre with silver ions results in antibacterial properties throughout the mattress, not just on the surface;

• additional moulding in the furnace provides improved bonding between the individual filaments, which results in greater durability of the produced mattress material with long-term use and improves its physical properties - i.e. it provides a better bonding between the filaments that reduces the level of deformation in the mattresses and improves their resilience; - deformability of the mattress after 10 years does not exceed 10%.

A detailed description of the embodiments of the invention is provided below.

Whereby, within the meaning of the invention, phrase "in an embodiment" is to be understood as one or more embodiments. Furthermore, the features present in the various embodiments may be combined with each other. In this application, the descriptions of the embodiments of the invention are provided by way of example and are not intended to limit the scope of the invention. The described embodiments include various features, not all of which are required in all embodiments of the invention. Some embodiments use only some of the features or possible combinations of features. The described variants of the embodiments of the invention and the embodiments of the invention comprising different combinations of the features mentioned in the described embodiments will come to the mind of the persons skilled in the art. The scope of the invention is limited only by the claims.

In an embodiment of the invention, the device according to the invention is designed to produce a mattress layer made of thermoplastic fibres and comprises a device for producing a mattress layer from thermoplastic fibres, which comprises an extruder unit, a cooling tank, a post-heating furnace and an infeed-receiving unit.

In an embodiment of the invention, the infeed-receiving unit is followed by a receiving-infeed unit equipped with an infeed-measuring unit, behind which a cross-cutting device ending in a receiving belt to receive the ready material layers is located.

In an embodiment of the invention, the extruder unit comprises a raw material feed unit connected to a tripartite auger where the second leg is connected to a gearbox connected to a three-phase motor and the third leg of the tripartite auger is elongated and equipped with multiple heating zones and cooling fans. The last heating zone of the auger is connected to the extruder by a connector (e.g. an elbow).

In one version, each of the heating zones is equipped with a cooling fan.

In one version, the auger contains seven heating zones, each of which is equipped with a cooling fan.

The extruder includes inside built-in heaters and ends in a plurality of manufacturing nozzles (e.g., may include 1000 nozzles) aligned vertically downwards. In one design, the extruder is equipped with nozzles, each with a diameter of 0.7 mm.

Below the manufacturing nozzles of the extruder there is a cooling tank filled with coolant. In an advantageous design, the coolant may be water. According to the invention, the temperature of the coolant in the cooling tank should be kept at 2 - 8 °C. In an advantageous embodiment of the invention, the coolant in the cooling tank is kept at 5-8 °C. In an advantageous embodiment of the invention, said coolant is water. Whereby, on the housing of the cooling tank, two opposing lateral dispersing nozzles are installed to potentially disperse silver ions as a mist. Whereby, the spacing of the said dispersing nozzles is wider than the spacing of the manufacturing nozzles unit of the extruder. This arrangement allows the spray mist of silver ions to cover on both sides the fibres extruded by the manufacturing nozzles.

Below the dispersing nozzles, opposing outer vertical heaters are installed on the housing of the cooling tank to infuse silver ions into the extruded fibres and to cure the fibres coated with silver ions. Whereby, the spacing of said outer vertical heaters is wider than the spacing of the extruder manufacturing nozzles.

According to the invention, the cooling tank is provided with moulding rollers whose task is to form the extruded fibres. Below the moulding rollers there are feed rollers whose function is to keep the moulded conjugate below the surface of the coolant and to feed it to an infeed-receiving belt connecting the said cooling tank with a post-heating furnace, which is equipped with built-in heaters to cure the conjugate and fans to mix the air inside the furnace. The aforementioned post-heating furnace is equipped with cooling fans. A infeed-receiving belt runs through the entire working space of the post-heating furnace, transporting the moulded conjugate from the cooling tank to the infeed-receiving unit located downstream the post-heating furnace.

In an advantageous embodiment of the invention, the infeed-receiving unit located downstream of the post-heating furnace is equipped with pressure rollers and edge knives which cut the cured conjugate to the desired width. Whereby, owing to the pressure rollers the material is cut evenly by the edge knives. If it were not for the pressure rollers in the manufacturing process, the edge knives might translocate the material.

In an advantageous embodiment of the invention, the infeed-receiving unit is followed by a receivinginfeed unit equipped with an infeed-measuring unit, behind which a cross-cutting device ending in a receiving belt to receive the ready material layers is located.

In one embodiment, the receiving-infeed unit is equipped with an infeed-measuring unit and a distance sensor, whose task is to measure the mattress layer at an appropriate spacing to be cut to the designated length by the cross-cutting device located downstream the receiving-infeed unit and equipped with a cross-cutting knife, actuators to press the material being cut and a receiving belt to receive the ready mattress layers.

Advantageously, the method for manufacturing the thermoplastic fibre mattress layer according to the invention is a continuous process.

Advantageously, the input raw material constituting the material for the manufacture of the mattress layer can be Affinity 1280G, LLDPE, another thermoplastic raw material or various combinations of known thermoplastic raw materials. In advantageous exemplary embodiment of the method according to the invention, the granulate in the heating zones of the extruder auger is heated at a temperature between 145 °C and 280 °C for a minimum of 2 minutes so as to melt the granulate.

The next stage is the extrusion of fibres through a plurality of directed downwards dispersing nozzles of the extruder. A silver ions are dispersed onto the surface of the newly extruded thermoplastic fibres as a mist. Coating each fibre individually with silver ions affords antibacterial properties to it and to the entire mattress evenly throughout its body rather than just the surface.

The silver ion coated thermoplastic fibres are then moved downwards to the outer vertical heaters situated below. The high temperature treatment of the thermoplastic fibres primarily prevents them from losing temperature on their way from the nozzle to the water. Whereby, in an embodiment of the method according to the invention, the outer vertical heaters are heated up to a temperature of 150°C-285°C. In an advantageous embodiment of the method according to the invention, the outer vertical heaters are heated up to a temperature of 230-250 °C. In another advantageous embodiment, the outer vertical heaters are heated up to 230 °C.

The method according to the invention provides that after passing through the outer vertical heaters, the thermoplastic fibres are transferred to a cooling tank containing a coolant kept at 2 - 8 °C, and the fibres are loosened and formed for 45 sec. to 5min. on the moulding rollers of the cooling tank, yielding thus a conjugate of a predetermined thickness. In an advantageous embodiment of the invention, the coolant in the cooling tank is kept at 5 - 8 °C. In an advantageous embodiment of the invention, the said coolant is water.

The conjugate moulded to the desired thickness is then transferred to the feed rollers that hold the conjugate under the surface of the coolant, and then to the infeed-receiving belt connecting the cooling tank with the post-heating furnace.

The method according to the invention provides that the moulded conjugate passes through the postheating furnace for 45 sec to 5 minutes, where it is subjected to a temperature of 120 to 350 °C. The additional formation of the conjugate in the post-heating furnace in accordance with the method according to the invention provides improved bonding between the individual filaments of the conjugate to ensure a higher durability of the manufactured mattress material upon long-term use and provides improved fibre bonding, which reduces the level of deformation of the mattresses and improves their resilience.

In an advantageous embodiment of the method according to the invention, a temperature of 200, 240 or 288 °C is applied. After passing through the post-heating furnace, the conjugate is trimmed to a predetermined width by the edge knives of the infeed-receiving unit. Subsequently, the infeed-measuring unit with a distance sensor measures the pre-set length of the mattress layer, after which the conjugate is cut to the designated length by a cross-cutting device located downstream the infeed-receiving unit and equipped with a crosscutting knife actuator pressing the cut material. After being cut to the pre-set length, the resulting mattress layer is transferred to a receiving belt to receive the ready mattress layers.

Mattress layers according to the invention produced by the method according to the invention are widely used in industry. In particular, they can be used for the manufacture of mattresses for humans and for the manufacture of animal beds. In some embodiments, each fibre of the mattress layer is coated with silver ions. In some embodiments, the mattress according to the invention comprises silver in an amount ranging from 0.0001% to 0.05% by the weight of the filling of the entire mattress.

In an advantageous exemplary embodiment of the invention, the mattress layers according to the invention were used to manufacture a double-sided mattress. The mattress layers can be placed in a cover.

In an advantageous exemplary embodiment of the invention, the double-sided mattress made of thermoplastic materials comes in the form of a rectangular sleeping pad, which can be intended both for human or animal use, in particular for pets (such as, for example, dogs or cats).

The mattress according to the invention comprising mattress layers manufactured using the method according to the invention consists of at least one mattress layer.

In an advantageous exemplary embodiment, the mattress may consist of a single mattress layer. In another embodiment, the mattress according to the invention consists of two mattress layers. In another embodiment, the mattress according to the invention consists of three mattress layers. In another embodiment of the invention, the mattress according to the invention consists of six mattress layers. Whereby, it is also possible to manufacture mattress consisting of more mattress layers.

Whereby, in accordance with the invention, a single mattress may comprise the same or different mattress layers. Whereby, the said different mattress layers may differ from each other in e.g. dimensions (i.e. length, width, density), resilience or density.

Furthermore, the individual mattress layers can be stacked on top of each other, side by side or in a combination of these ways.

In an advantageous exemplary embodiment of the invention, the mattress layer produced using the method according to the invention is used to produce a double-sided mattress according to the invention with a modular structure, where a mattress layer produced by the method according to the invention, which performs the function of a panel, is referred to as a "module". Several panels arranged in one plane make it possible to select different modules as desired. The multiple panels may also be arranged in multiple layers, each of which may contain two or more panels.

In an exemplary embodiment, the mattress is made of six modules (panels), each of which is a mattress layer made using the method according to the invention. Whereby, the said six modules are arranged in two layers (three modules in each layer).

In an exemplary embodiment, the mattress is made of six modules (panels), each of which is a mattress layer made using the method according to the invention. Whereby, said six modules are arranged in two layers (three modules in each layer) and the middle module (panel) of the upper layer has an increased density with respect to the other two panels of the upper layer. This is for the sake of a lesser sinking of the lumbar section and an increased comfort for some people.

In an exemplary embodiment, the mattress is made of six modules (panels), each of which is a mattress layer made using the method according to the invention. Whereby, said six modules are arranged in two layers (three modules in each layer) and the middle module (panel) of the upper layer has an increased density with respect to the other two panels of the upper layer. In contrast, the middle panel of the bottom layer has a reduced density relative to the other two panels of the bottom layer.

Thanks to the modular construction with the use of panels, we can facilitate transport of the mattress and, in a modular way, choose which density of the mattress is best for which part of the body. This ensures that the user of the mattress can select the modules as desired. For example, a person may choose that the “top” section, on which the head and shoulders of a person normally rest during sleep, has a greater firmness and lower resilience than the section on which the person's feet are located.

In the advantageous exemplary embodiment, the modular mattress contains two layers, with three panels in each layer.

In an advantageous exemplary embodiment, a mattress comprising mattress layers made using the method according to the invention exhibits a resilience of 40 to 70%. Furthermore, each layer of the said mattress has a density ranging from 30 to 190 kg/m3, whereby each fibre of the mattress layer is coated with silver ions. The air permeability of the mattress according to the invention will be 100%.

However, in an exemplary embodiment, the mattress according to the invention has an air throughput between 70% and 98%. In another exemplary embodiment, the mattress according to the invention is characterised by an air throughput of 80-94%. In one exemplary embodiment, a double-sided mattress measuring 120x200 cm with a resilience of 55% contains a single mattress layer made according to the invention with a thickness of 11 cm and a density of 80 kg/m3. Its air throughput, on the other hand, is 92%.

In one exemplary embodiment, a double-sided mattress measuring 180x200 cm with resilience of 60% contains two mattress layers made according to the invention with the thickness of 25 cm and density of 120 kg/m3.

In one exemplary version, a double-sided mattress measuring 120x60 cm with a resilience of 50% contains a single mattress layer made according to the invention with the thickness of 11 cm.

In another exemplary embodiment, the mattress according to the invention is a double-sided mattress measuring 1.40 x 0.66 m with a resilience of 48% containing two mattress layers each fibre of which is coated with silver ions. Whereby, each layer has a thickness of 6 cm and a density of 100 kg/m3. Its air throughput, on the other hand, is 90%.

In a further exemplary embodiment, the mattress according to the invention is a double-sided mattress measuring 120x200 cm with a resilience of 60%, containing a single mattress layer with a thickness of 11 cm and a density of 120 kg/m3. Whereby, each fibre of the mattress layer is coated with silver ions. Its air throughput, on the other hand, is 88%.

In a further exemplary embodiment, the mattress according to the invention is a double-sided mattress measuring 180x200cm with a resilience of 60%. The mattress contains three mattress layers with a total thickness of 25 and a density of 120 kg/m3 (two layers each 10 cm thick and one having a thickness of 5 cm). The mattress consists of three layers stacked on top of each other and has an air throughput of 82%.

In addition, the inventors carried out a number of tests to check the durability of the mattress according to the invention. The ageing tests carried out showed that the deformation rate of the mattress according to the invention containing mattress layers made using the method according to the invention does not exceed 10% after 10 years.

The subject-matter of the invention is depicted in the embodiment shown in the drawing wherein fig. 1 presents a diagram of the heating zones, the infeed unit and the extruder motor of the device according to the invention; fig. 2 presents a diagram of a section of the device according to the invention with particular reference to the location of the nozzles dispersing silver ions and the outer heaters placed vertically towards the outlet of the manufacturing nozzles of the extruder; fig. 3 presents, on a diagram, the juxtaposition of the extruder with the cooling tank of the device according to the invention; fig. 4 shows a diagram of the post-heating furnace of the device according to the invention; fig. 5 presents, on a diagram, the infeed- receiving unit with edge knives; fig. 6 depicts a receiving-infeed unit with an infeed-measuring unit; fig. 7 shows a cross-cutting device; fig. 8 shows a mattress according to the invention in an embodiment containing a single mattress layer made by the method according to the invention; fig. 9 depicts a mattress according to the invention in an embodiment containing two mattress layers manufactured using the method according to the invention; fig. 10 shows a mattress according to the invention in a two-layer embodiment, where each layer consists of three panels constituting mattress layers manufactured using the method according to the invention in a variant with an alternate arrangement of panels of different resilience in a single layer; fig. 11 shows a mattress according to the invention in a two-layer embodiment, where each layer consists of three panels constituting mattress layers manufactured using the method according to the invention in a variant in which the panels of the upper layer exhibit higher resilience than those of the lower layer.

Example 1.

The device according to the invention is shown in the drawing in which 1 denotes the three-phase motor of the extruder unit; 2 denotes the gearbox of the extruder unit; 3 denotes the raw material infeed unit; 4 denotes the auger of the extruder unit; 5 denotes the heating zones of the extruder auger; 6 denotes the coupling; 7 denotes the extruder; 8 denotes manufacturing nozzles; 9 denotes silver ions; 10 denotes dispersing nozzles; 11 denotes outer vertical heaters; 12 denotes cooling tank; 13 denotes moulding rollers; 14 denotes feed rollers; 15 denotes infeed-receiving belt; 16 denotes furnace built-in heaters; 17 denotes post-heating furnace cooling fans; 18 denotes post-heating furnace mixing fans; 19 denotes infeed-receiving unit; 20 denotes pressure rollers; 21 denotes edge knives; 22 denotes an infeedmeasuring unit; 23 denotes distance sensor; 24 denotes infeed-receiving unit with a transverse knife; 25 denotes transverse knife; 26 denotes pressure cylinders for cutting material; 27 denotes finished material receiving belt; Urzqdzenie wedlug wynalazku jest przeznaczone do wytwarzania warstwy materacowej z wlokien termoplastycznych i sklada si? z zespolu wytlaczarki, zbiornika chlodzqcego 12, pieca dogrzewajqcego oraz zespolu podawczo-odbiorczego 19.

As shown in fig. 1, the extruder unit comprises raw material infeed unit 3, which is connected to the first leg of tripartite auger 4. The second leg of tripartite auger 4 is connected to gearbox 2 connected to three-phase motor 1. On the other hand, the third leg of the tripartite auger 4 comprises heating zones 5 equipped with cooling fans. Whereby, in this exemplary embodiment, auger 4 contains seven heating zones 5, each of which is equipped with a cooling fan.

The last heating zone 5 of auger 4 is connected by connector 6 in the form of an elbow to extruder 7 (fig. 2) with inside built-in heaters, which ends in a number of manufacturing nozzles 8 positioned vertically downwards.

In this exemplary embodiment, extruder 8 is equipped with one thousand manufacturing nozzles 8, each of which has a diameter of 0,7 mm. Below manufacturing nozzles 8 of extruder 7 there is cooling tank 12 filled with coolant (fig. 3). The temperature of the coolant should be kept between 5 and 8 °C. In this exemplary embodiment, the coolant is water at a temperature of 5 °C.

As shown in fig. 2 and 3, two opposing lateral dispersing nozzles 10, which disperse silver ions 9 as a mist, are mounted on the housing of cooling tank 12. Whereby, the spacing of said dispersing nozzles 10 is wider than the spacing of manufacturing nozzles 8 of extruder 7. This arrangement makes it possible for the sprayed mist of silver ions 9 to cover, on both sides, the fibres extruded by the manufacturing nozzles 8.

Below dispersing nozzles 10, opposing outer vertical heaters 11 are mounted on the housing of the cooling tank 12, which infuse the silver ions 9 into the surface of the extruded fibres and cure the fibres coated with silver ions. Whereby, the spacing of the said outer vertical heaters 11 is wider than the spacing of the manufacturing nozzles 8 of the extruder 7.

As shown in fig. 3, the cooling tank 12 is provided with moulding rollers 13 whose function is to form the extruded fibres. Below the moulding rollers, there are feed rollers 14 whose function is to keep the moulded conjugate below the surface of the coolant and to feed it to infeed-receiving belt 15 connecting the said cooling tank 12 with the post-heating furnace, which is presented as a diagram in fig. 4.

As shown in fig. 4, the post-heating furnace is equipped with built-in heaters 16 to cure the conjugate and fans 18 to mix the air inside the furnace. The said post -heating furnace is equipped with cooling fans 17. On the other hand, through the entire working space of the post-heating furnace runs infeedreceiving belt 15 transporting the moulded conjugate from cooling tank 12 to infeed-receiving unit 19, located downstream the post-heating furnace. In addition, terminal hot air nozzles 28 are located at the outlet of the post-heating furnace.

As shown in fig. 5, feed-receiving unit 19 located downstream the post-heating furnace is equipped with pressure rollers 20 and edge knives 21, which cut the cured conjugate to the desired width. Whereby, pressure rollers 20 ensure that the material is cut evenly by the edge knives. If it were not for pressure rollers 20 in the production process, edge knives 21 might translocate the material. As shown in figs. 6, after the infeed-receiving unit there is a receiving-infeed unit equipped with an infeed-measuring unit 22 and a distance sensor 23, which serves to measure the correct length of the mattress layer to be cut to the designated length by the cross-cutting device (fig. 7) located downstream the receiving-infeed unit and equipped with a transverse cutter 25, actuators to press the cut material 26 and a receiving belt 27 to receive the ready mattress layers.

Example 2.

The device as in embodiment 1 can be used to produce a mattress layer of thermoplastic fibres. The method for producing a thermoplastic fibre mattress layer according to the invention is a continuous process, the first step of which is the supply of the thermoplastic granulate to raw material infeed unit 3 of the extruder.

In this non-limiting exemplary embodiment, the thermoplastic material is LLDPE. Whereby, other thermoplastic materials e.g. (LLDPE, polyolefin plastomer, e.g. Affinity 1280G) or combinations of thermoplastic materials can also be used as feedstock.

From the infeed unit, the granulate enters heating zones 5 of extruder auger 4, where the granulate is heated at 280°C for 2 minutes so that it is melted. After passing through heating zones 5, the melted material enters, through connector 6, extruder 7 equipped with built-in heaters and manufacturing nozzles 8 directed vertically downwards. The next stage is the extrusion of the fibres through multiple downward facing manufacturing nozzles 8 of extruder 7.

Subsequently, lateral dispersing nozzles 10 located below the mouth of manufacturing nozzles 8 disperse silver ions 9 onto the surface of the newly extruded thermoplastic fibres. In this step, each fibre is being coated with silver ions 9 so that the mattress layer acquires antibacterial properties throughout its entire body rather than only on its surface.

Thermoplastic fibres coated with silver ions 9 are then transferred downwards to outer vertical heaters

11 below, which operate at 250 °C. The treatment of the thermoplastic fibres coated with silver ions 9 allows them to harden and the silver to be infused into the fibre structure.

After passing through the outer heaters, the vertical thermoplastic fibres are transferred to cooling tank

12 containing water at 5 °C, where the cured fibres are loosened and formed for 45 seconds on moulding rollers 12 into a conjugate of a predetermined thickness, from which it is transferred to feed rollers 14 holding it below the surface of the coolant and then to infeed-receiving belt 15 connecting cooling tank 12 to the post-heating furnace.

While it passes through a post-heating furnace, the moulded conjugate is subjected to a temperature of 350 °C for 45 seconds. The additional moulding in the furnace provides improved bonding between the individual filaments of the conjugate, which ensures greater durability of the manufactured mattress material over its long-term use and provides better fibre bonding, which reduces the deformation rate of mattresses and improves their resilience.

After passing through the post-heating furnace, the conjugate is received by an infeed-receiving unit equipped with edge knives 21, which cut the conjugate to a pre-set width. On the other hand, pressure rollers 20 of the feed-receiving unit cause the conjugate to be cut evenly by the edge knives. The conjugate cut to the pre-set width is then fed to the receiving-infeed unit, where infeed-measuring unit 22 together with a distance sensor measures the pre-set length of the mattress layer. The conjugate is then cut to the designated length by a cross-cutting device (fig. 7) located downstream the receivinginfeed unit and equipped with transverse cutter 25, and actuators 26 to press the cut material. After being cut to the pre-set length, the obtained mattress layer is transferred to receiving belt 27 designated to receive the ready mattress layers.

Example 3.

Method as in embodiment 2, except that from the infeed unit the granulate goes to the heating zones 5 of the auger 4 of the extruder, where the granulate is heated at 145 °C for 5 minutes so that it melts. On the other hand, after being coated with silver ions 9, the thermoplastic fibres are subjected to a temperature of 150 °C provided by outer vertical heaters 11. The temperature of the water in cooling tank 12 is 8 °C, and the fibres are moulded for 5 minutes on moulding rollers 12 into a conjugate of a pre-set thickness. On the other hand, while passing through the post-heating furnace, the moulded conjugate is subjected to a temperature of 120 °C for 5 minutes.

Example 4.

Method as in embodiment 2, except that the thermoplastic material is Affinity 1280G polyolefin plastomer. Furthermore, the granulate from the infeed unit is transferred to heating zones 5 of extruder auger 4, where it is heated at 250 °C for 3 minutes so that it melts. On the other hand, after being coated with silver ions 9, the thermoplastic fibres are subjected to a temperature of 230 °C provided by outer vertical heaters 11. The temperature of the water in cooling tank 12 is 2 °C, and the fibres are moulded for 2 minutes on moulding rollers 12 into a conjugate of a pre-set thickness. On the other hand, while passing through the post-heating furnace, the moulded conjugate is subjected to a temperature of 200 °C for 3 minutes.

Example 5.

Method as in embodiment 2, except that after coating with silver ions 9, the thermoplastic fibres are subjected to a temperature of 240 °C provided by outer vertical heaters 11. The temperature of the water in cooling tank 12 is 5 °C, and the fibres are moulded for 3 minutes on moulding rollers 12 into a conjugate of a pre-set thickness. On the other hand, while passing through the post-heating furnace, the moulded conjugate is subjected to a temperature of 288 °C for 1 minute.

Przyklad 6.

Method as in embodiment 2, except that after coating with silver ions 9, the thermoplastic fibres are subjected to a temperature of 230 °C provided by outer vertical heaters 11. The temperature of the water in cooling tank 12 is 4 °C, and the fibres are moulded for 1 minute on moulding rollers 12 into a conjugate of a pre-set thickness. On the other hand, while passing through the post-heating furnace, the moulded conjugate is subjected to a temperature of 240 °C for 2 minutes.

Przyklad 7.

Method as in embodiment 2, except that after coating with silver ions 9, the thermoplastic fibres are subjected to a temperature of 285 °C provided by outer vertical heaters 11. The temperature of the water in cooling tank 12 is 8 °C, and the fibres are moulded for 5 minutes on moulding rollers 12 into a conjugate of a pre-set thickness. On the other hand, while passing through the post-heating furnace, the moulded conjugate is subjected to a temperature of 240 °C for 2 minutes.

Przyklad 8.

Method as in embodiment 2, except that after coating with silver ions 9, the thermoplastic fibres are subjected to a temperature of 230 °C provided by outer vertical heaters 11. The temperature of the water in cooling tank 12 is 5 °C, and the fibres are moulded for 4 minutes on moulding rollers 12 into a conjugate of a pre-set thickness. On the other hand, while passing through the post-heating furnace, the moulded conjugate is subjected to a temperature of 300 °C for 5 minutes.

Example 9.

The mattress layer (fig. 8) produced by the method according to the invention can be used to manufacture mattresses according to the invention for humans and for making animal beds.

In this non-limiting exemplary embodiment, the mattress layers were used to produce a double-sided mattress measuring 1.40 x 0.66 m, which is presented on a diagram in fig. 9. In this exemplary embodiment, the mattress comprises two mattress layers, each with a thickness of 6 cm and a density of 100 kg/m ³ . Whereby, each fibre of the mattress layer is coated with silver ions. In this exemplary embodiment, the mattress according to the invention has an air throughput of 90% and a resilience of 48%.

Example 10.

In this non-limiting exemplary embodiment, to produce a double-sided mattress measuring 120x200cm, a single mattress layer (fig. 8) with a thickness of 11 cm and a density of 80 kg/m ³ was used. The resilience of the resulting mattress is 55%. Whereby, each fibre of the mattress layer is coated with silver ions and the silver content of the mattress is 0.0001 % by weight of the filling of the entire mattress. Furthermore, in this non-limiting exemplary embodiment, the mattress according to the invention has an air throughput of 92%.

Example 11. In this non- limiting exemplary embodiment, a single mattress layer with a thickness of 11 cm and a density of 120 kg/m ³ was used to manufacture a double-sided mattress measuring 120x200 cm. The resilience of the resulting mattress is 60%. Whereby, each fibre of the mattress layer is coated with silver ions. In addition, the mattress has an air throughput of 88%.

Example 12.

In this non-limiting exemplary embodiment, the mattress layers were used to produce a double-sided mattress measuring 180x200 cm, with the resilience of 60%. As indicated in fig. 10 the mattress consists of six mattress panels (i.e. six mattress layers made by the method according to the invention) arranged in two layers with a total thickness of 25 cm and a density of 120 kg/m ³ . Whereby, in this exemplary embodiment, the middle panel of the upper layer has an increased density relative to the other panels of the upper layer. This is for the sake of a lesser sinking of the lumbar section and an increased comfort for some people. Whereby, each fibre of each panel (i.e. the mattress layers made by the method according to the invention) is coated with silver ions. Furthermore, in this exemplary embodiment, the mattress has an air throughput of 85%.

Example 13.

In this non-limiting exemplary embodiment, the mattress layers were used to produce a double-sided mattress measuring 180x200 cm with its resilience of 60% In this exemplary embodiment, the mattress contains three mattress layers with a total thickness of 25 cm and a density of 120 kg/m ³ (two layers each 10 cm thick and one having a thickness of 5 cm). The mattress consists of three layers stacked on top of each other. Whereby, each fibre of the mattress layer is coated with silver ions. The silver content of the mattress represents 0,05 % by weight of the filling of the entire mattress. Furthermore, in this exemplary embodiment, the mattress according to the invention has an air permeability of 82%.

Example 14.

In this non-limiting exemplary embodiment, the mattress layer produced by the method according to the invention was used to produce a double-sided mattress measuring 120x60cm with a resilience of 50%. The mattress was created from a single mattress layer with a thickness of 11cm. Whereby, each fibre of the mattress layer is coated with silver ions. However, the silver content of the mattress represents 0.0001 % by weight of the filling of the entire mattress.

Example 15.

In this non-limiting exemplary embodiment, the mattress layer produced by the method according to the invention was used to produce a double-sided mattress with a modular structure. As shown in figs. 11 the mattress according to the invention is a two-layer mattress made of a total of six panels arranged in two mattress layers made by the method according to the invention in a variant in which the panels of the upper layer show higher resilience than the panels of the lower layer. The dimensions of the mattress are 120x60cm.

The use of the panel variant of the mattress according to the invention may facilitate transport of the mattress and in a modular way choose which density of the mattress is best for which part of the body. This provides the customer with the possibility to select the modules as desired.