Process and plant for continuous manufacture of latex foam articles

Process for the continuous manufacture of an unlimited length latex foam block to be subdivided in a plurality of mattresses by cuts transversely to said unlimited length, comprising the steps of:

• advancing along a predetermined longitudinal direction a laying surface provided with protuberances, having tapered ends to form recesses in said mattresses, said laying surface advancing between a first and a second station,
• laying in said first station a latex foam mixture on said laying surface in continuous advancement, and
• further comprising:
• a) providing proximate to said first station a substantially flat flexible band of unlimited length and provided with a plurality of through openings;
• b) laying said flexible band on said laying surface protuberances;
• c) advancing continuously said flexible band with that laying surface;
• d) introducing said mixture in said band openings, downwardly passing a portion of the mixture through the openings;
• e) forming from the mixture a continuous latex foam layer comprising a lower portion and an upper portion respectively below and above said band, the latex foam mainly comprising open cells;
• f) pressing with said upper portion weight said band against said laying surface protuberances;
• g) gelating, vulcanising, drying said foam layer incorporating said band to form said foam block of continuous latex foam incorporating said band;
• h) cutting said foam block of continuous latex foam incorporating said band with consecutive cross cuts at a predetermined distance from each other.