Functionalized latex based foam
An integral latex foam having a first layer foam and a second and/or subsequent layer of latex foam is disclosed. The first layer foam contains an additive that is applied in the form of a solution, emulsion or dispersion. The first layer has a thickness from 0.01 to 9 mm.
1. A single integral slab or mold of latex foam comprising a first layer of latex foam and a second and/or subsequent layer of latex foam characterized in that said first layer is impregnated with an additive that is applied in the form of a solution, emulsion or dispersion onto said first layer during a post-vulcanization step and whereby the first layer has a thickness from 0.01 to 9 mm.
2. The single integral slab or mold of latex foam according to claim 1 , wherein the second and/or subsequent layer of said foam is free of said additive.
3. The single integral slab or mold of latex foam according to claim 1 , comprising a third layer containing an additive in which the additive is applied in the form of a solution, emulsion or dispersion and whereby the third layer has a thickness from 0.01 to 9 mm.
4. The single integral slab or mold of latex foam according to claim 3 , wherein said first layer and/or third layer is colored.
5. The single integral slab or mold of latex foam according to claim 1 , wherein the additive is selected from the group consisting of i) phase change material, ii) fire retardant, iii) an antimicrobial active agent, iv) an antifungal agent, and combinations comprising at least one of the foregoing.
6. The single integral slab or mold of latex foam according to claim 5 , wherein said first layer and/or subsequent layer is colored.
7. The single integral slab or mold of latex foam according to claim 1 , wherein the additive is a phase change material.
8. The single integral slab or mold of latex foam according to claim 1 , wherein the impregnation is achieved by a spraying technique.
9. A process for manufacturing a single integral slab or mold of latex foam as identified in claim 1 , the process comprising the steps of:
a. pouring latex foam;
b. vulcanizing the poured latex foam; and
c. dosing an additive to the vulcanized latex foam in which the additive is dosed in the form of a solution, emulsion or dispersion.
10. A bedding product comprising a single integral slab or mold of latex foam having a first layer of latex foam and a second and/or subsequent layer of latex foam characterized in that said first layer is impregnated with an additive that is applied in the form of a solution, emulsion or dispersion onto said first layer during a post-vulcanization step and whereby the first layer has a thickness from 0.01 to 9 mm.
11. The bedding product according to claim 10 , wherein said product is a mattress topper.
12. The bedding product according to claim 11 , wherein said mattress topper has a thickness of from 2 to 20 cm.
13. The process according to claim 12 , wherein the dosing is achieved by a spraying technique.
14. A kit in parts of a vulcanized latex foam and an application kit comprising a solution, emulsion or dispersion of an additive to be applied on a surface of the foam layer.
15. The kit in parts according to claim 14 , wherein the additive is selected from the group consisting of i) phase change material, ii) fire retardant, iii) an antimicrobial active agent, iv) an antifungal agent, v) a perfume and combinations comprising at least one of the foregoing.