EP3628638B1

EP3628638B1 - Method and system for making pillows

Info

Publication number: EP3628638B1
Application number: EP19198637.1A
Authority: EP
Inventors: Antonio Caso
Original assignee: Materassificio Montalese SpA
Current assignee: Materassificio Montalese SpA
Priority date: 2018-09-25
Filing date: 2019-09-20
Publication date: 2023-02-01
Anticipated expiration: 2039-09-20
Also published as: EP3628638A1

Description

This invention relates to a method for making pillows and a system for making pillows.
The term "pillow" means an object, rectangular, triangular, circular or of other shapes, which is generally made of fabric and filled with soft materials which can adopt a plurality of different functions.
The pillows are generally covered by linings which can be easily changed and washed.
The paddings of the pillows can be made of a plurality of different materials, for example artificial fibres, wool, feathers, foam rubber or rubber latex.
Currently, the most commonly used materials are synthetic fibres due to their softness, which is similar to feathers, and the relatively low cost. Among the materials used, latex, which avoids the flourishing of mites and gives high standards of hygiene to the pillow, is particularly widespread. Another type of padding recently introduced on the market is the rubber with viscoelastic characteristics which matches the anatomy of the person and supports the weight of the head, guaranteeing a high degree of comfort.
The paddings used often come from processing waste cuttings to favour the sustainability of the process and reduce the production costs.
In particular, the padding consists of a mixture of different materially coming from processing waste cuttings.
The various processing waste cuttings obtained from the various materials are collected in a single container and shredded to obtain the padding.
A predetermined quantity of the padding thus obtained is then introduced into a lining for making the pillow.
Disadvantageously, since it is made from a multiplicity of materials shredded together, the mixture is non-uniform and cannot be predicted, so it is not possible to determine beforehand the characteristics of the pillow which will be obtained.
In particular, it is not possible to set beforehand the bearing capacity of the pillow and the degree of softness to be obtained.
Moreover, very disadvantageously, due to the above-mentioned non-uniform nature of the mixture it is not possible to obtain constant mechanical properties for each pillow of the production batch. A method and system for making pillows are known from US2014053341 A1 .
The aim of this invention is therefore to provide a method for making pillows and a system for making pillows which allows the repeatability of the properties of the pillow obtained from the production cycle to be increased,
in particular which allow pillows having a predetermined bearing capacity to be obtained in a repeatable fashion.
The technical purpose indicated and the aim specified are substantially achieved by a method for making pillows and a system for making pillows, comprising the features set out in one or more of the appended claims.
The dependent claims correspond to possible embodiments of the invention.
Further features and advantages of the invention are more apparent in the non-limiting description which follows of a preferred non-exclusive embodiment of a method for making pillows and a system for making pillows.
The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which:

Figure 1 is a schematic view of a system for making pillows according to the invention.

A method for making pillows according to the invention starts with a step for preparing a plurality of processing waste cuttings, advantageously textile, of different materials suitable for use as padding material.
Preferably, at least one material of the above-mentioned plurality of materials is selected from: foam rubber, polyester, polyurethane, memory foam.
Advantageously, at least one material of the plurality of materials can consist of textile processing waste cuttings thereby favouring the sustainability of the process and reducing the production costs.
The method also comprises a step for shredding the waste cuttings of the plurality of different materials, each material separately from one another, to obtain portions of smaller dimensions than that of the starting waste cuttings.
The starting waste can have a width of between 1 centimetre and 50 centimetres without constraints on the length, since they are often continuous processing waste cuttings, whilst the shredded portions can have dimensions comparable with each other and with volumes in the order to approximately 1-5 cubic centimetres.
The separate shredding of the materials is essential for the reasons expressed below and in particular to obtain a padding during the subsequent mixing steps having the desired design characteristics.
The shredding step is performed without fraying the material, that is to say, making clean cuts without pulling or fraying the material.
In this way the padding material keeps substantially unaltered the particular nature of the material initially prepared to give the pillow a high degree of softness.
Preferably, each shredding step is followed by a respective step for storing separately each shredded padding material in a respective and independent containment volume.
In this way, each containment volume contains one specific padding material obtained from a specific material and therefore having specific mechanical characteristics designed to define the mechanical properties of the pillow.
The individual materials are stored in the respective containment volumes in a shredded form suitable for making a precise and predetermined quantity as a function of the desired final needs and characteristics of the padding.
Each individual shredded material therefore corresponds to a respective containment volume in which any mixing with the other shredded materials is avoided.
After the step for storing different individual materials already shredded, the method according to the invention comprises the step of picking up predetermined quantities of at least two of the different shredded materials from the respective containment volumes.
The above-mentioned quantities are picked up according to predetermined proportions designed to obtain a padding having desired characteristics.
The expression "characteristics of the padding" means, for example, the softness\rigidity of the padding, and also the bearing capacity\compliance.
The method also comprises a step of mixing at least two of the shredded materials, according to the predetermined proportions picked up during the previous step to obtain a padding of the pillow with the desired characteristics.
In particular, the step can be performed by using an automatic mixing device.
The method comprises the step of setting the predetermined proportions as a function of the mechanical properties of each individual material and of the bearing capacity of the padded item to obtain padded items having a constant bearing capacity and repeatability during the entire production process of a multiplicity of pillows.
The padding consists of a plurality of different materials mixed according to precise proportions of the individual materials which allow the mechanical properties of the pillow to be precisely determined.
Preferably, the step can be monitored by a control device which is able to control the quantities of padding material to be used in the mixing step.
The method comprises a step of filling a containment body with the above-mentioned padding to obtain the pillow.
Preferably, the containment body is a lining for the pillow.
The filing step can comprise a sub-step of connecting the containment body to a filling device designed to introduce the padding in the containment body.
Advantageously, the filling device guarantees a high level of precision of the quantity of padding introduced inside the lining and reduces the production cycle times.
After filling the containment body there is a step for closing the containment body.
According to a possible embodiment of the method, the step of closing the containment body can comprise the execution of at least one stitching along a predetermined line on the containment body.
The method also comprises a feed for packaging the pillow inside a wrapper.
Preferably, the packaging step comprises a sub-step of removing a predetermined quantity of gas or air from the above-mentioned wrapper.
In particular, this sub-step can be such as to vacuum pack the padded item.
In this way, it is possible to limit the overall size of the pillow thereby improving the transport efficiency.
In accordance with a further aspect, the invention relates to a system for making pillows, in particular by actuating the method described above.
With reference to the accompanying drawing, the system is indicated in its entirety with reference numeral 1.
The system 1 initially comprises a shredding device 2 designed to shred one material at a time to obtain a specific padding material.
The shredding device allows the material to be shredded without fraying it.
A same shredding device can be used for shredding the various materials, clearly at different times so as not to mix them.
Alternatively, each material can be associated with a respective shredding device in such a way that the shredding devices are independent from each other and do not bring the various shredded materials (or their waste cuttings) into contact with each other, thereby avoiding also the minimum risk of mixing of the various materials before the actual composition of the padded item.
Advantageously, the shredding device 2 keeps unaltered the particular nature of the material to give the padding a high degree of softness.
The system comprises a plurality of storage units 3, each designed to contain a respective padding material separated from the others coming from the shredding device 2.
The system also comprises a mixing device 4 which is operatively connected to the storage unit 3 for receiving independently a plurality of padding materials according to predetermined proportions and for then subsequently mixing them to obtain a padding of the pillow.
Preferably, the system 1 comprises a control device 5 which is able to control the quantities of padding material used by the mixing device 4.
The mixing of the individual shredded material allows padded items to be obtained with predetermined mechanical properties on the basis of the adequate splitting up of the padding materials used.
As illustrated in the accompanying drawing, the system 1 comprises a filling device 6 designed to introduce the padding material in a containment body, preferably a lining.
Downstream of the filling device 6, the system 1 comprises a packaging device 7 designed to package pillow inside a wrapper.
The packaging device 7 can comprise vacuum generating means designed to remove a predetermined quantity of gas/air from the wrapper.
The present invention achieves the preset aims, overcoming the disadvantages of the prior art.
The method and the system according to the invention allow the quality of the production to be increased, guaranteeing a high degree of personalisation of the mechanical properties of the pillow thanks to a precise splitting up of the individual materials used for making the pillow, this splitting up being actuated by shredding (each material independently from the other) and before the mixing of the different materials firstly shredded in clearly defined proportions.
Advantageously, the method according to the invention allows the efficiency of the production cycle to be increased thanks to possibility of using textile waste cuttings as padding material.
Moreover the shredding of the material occurs without altering the particular nature of the material, giving the padding a high degree of softness.
Advantageously, by vacuum sealing the lining it is possible to limit the overall size, thereby improving the transport efficiency.

Claims

A method for making a pillow, comprising the steps of:
- preparing a plurality of processing waste cuttings of different materials suitable for use as padding material for said pillow;

- shredding said waste cuttings of said plurality of different materials, each material separately from one another, to obtain portions of smaller dimensions;

- storing each said different shredded material, separately from each other in respective containment volumes;

- picking up predetermined quantities of at least two of said different shredded materials from said respective containment volumes;

- mixing said predetermined quantities to obtain a padding of said pillow;

- filling a containment body, preferably a lining, with said padding to obtain said pillow;

- closing said containment body;

- packaging said pillow inside a wrapper, characterised in that said shredding step is performed without fraying the material making clean cuts without pulling or fraying the material, and wherein said predetermined quantities of at least two of said different shredded materials are picked up according to predetermined proportions designed to obtain a pillow having desired mechanical characteristics.
The method for making a pillow according to claim 1,
wherein one or more materials of said plurality of materials are selected from: foam rubber, polyester, polyurethane, memory foam.
The method for making a pillow according to any one of the preceding claims, wherein a material of said plurality of materials consists of textile processing waste cuttings.
The method for making a pillow according to any one of the preceding claims, wherein the packaging step comprises a sub-step of removing a predetermined quantity of gas or air from said wrapper.
The method for making a pillow according to claim 4, wherein said sub-step of removing a predetermined quantity of gas or air from said wrapper is such that said pillow is vacuum packed.
The method for making a pillow according to any one of the preceding claims, wherein said step of closing the containment body comprise the step of executing at least one stitching along a predetermined line on said containment body.
The method for making a pillow according to any one of the preceding claims, comprising a step of setting said predetermined proportions as a function of the mechanical properties of each material and of the firmness of the pillow to be made to obtain a pillow having constant firmness to be obtained in a repeatable manner.
A system (1) for making a pillow, comprising:
- a shredding device (2) designed to independently shred one material at a time to obtain a padding material;

- a plurality of storage units (3), each storage unit (3) being designed to contain a single and respective padding material coming from the shredding device;

- a mixing device (4) which is operatively connected to the shredding device (2) for receiving predetermined quantities of each individual shredded material according to predetermined proportions and for mixing said predetermined portions to obtain a padding of said pillow having desired mechanical characteristics;

- a filling device (6) designed to introduce said padding material in a containment body, preferably a lining;

- a packaging device (7) designed to package said pillow inside a wrapper, characterized in that the shredding device (2) is configured for shredding without fraying the material making clean cuts without pulling or fraying the material.
The system for making a pillow according to claim 8, wherein said packaging device (7) comprises vacuum generating means designed to remove a predetermined quantity of gas from said wrapper.