Process and plant for the continuous manufacturing of at least a layer of latex foam with recesses

Process for the continuous manufacture of at least a continuous layer of latex foam with recesses of unlimited length to be subdivided in a plurality of blocks (B) of latex foam by transverse cuts having thickness of 10 cm and or more, comprising the steps of:

• advancing along a predetermined longitudinal direction (F) a metal laying surface provided with protuberances between a first and a second station, the protuberances having ends laying on a horizontal plane (S) and being placed along horizontal rows pointed towards said longitudinal direction (F) and transverse rows,
• depositing the continuous layer of said latex foam in said first station on said laying surface while said laying surface is continuously advancing,
• gelating said continuous layer,
• curing said continuous layer,
• extracting said cured continuous layer in said second station;
• the process further comprising:
• a) before depositing the latex foam, inserting by interference fit supporting elements of resilient deformability between pairs of protuberances of said horizontal rows, said supporting elements having predetermined thickness and being of unlimited length;
• b) carrying away the supporting elements with the advancing laying surface between said first and second station;
• c) embedding with latex foam said supporting elements;
• and
• d) maintaining the lower ends of said supporting elements placed between said pair of protuberances at distance (b) from said laying surface.