DE102007005372A1 - Overfoamed cushion part, e.g. for seating, comprises a layer of superabsorbent materials and an air- and liquid-impermeable film between a cover layer and a foam layer - Google Patents

Abstract

Overfoamed cushion part has an ABCD structure, where A is a cover layer that is permeable to water vapor, B is a layer of superabsorbent material, C is a polymer film that is impermeable to air and to the liquid reactants introduced for overfoaming, and D is the foam layer formed by overfoaming.

Description

The The invention relates to a molded in situ foam backing Upholstered part especially for seats, such as vehicle seats, z. B. motor vehicle seats, but also for other shaped Upholstery elements, such as seat cushions, headrests, armrests, Dashboards, chairs, upholstery or the like. (The term "vehicle" is included within the scope of the invention also aircraft, watercraft, spacecraft, commercial vehicles.)

In the DE 100 59 471 B4 the two mainly used, known techniques for the production of upholstered parts are described. One technique envisages sticking a cover material onto a preformed foam part or applying it using a similar mechanical method. In the other, so-called in-situ technique, the production takes place directly in a mold, which dictates the spatial form of the upholstery part to be created. Here, a cover material blank is inserted with its visible side to the bottom in the mold and z. B. held by deep drawing or suction. Thereafter, a foamable material is introduced into the mold and brought to close the mold for expanding foaming and for bonding with the cover material, resulting in the spatial shape of the cushion part. After opening the mold, the finished upholstery can be removed and reused.

At the In situ method requires it with a barrier layer too prevent components of the foamable and / or foaming components in the material of the cover material blank penetrate and / or penetrate the Bezugmaterialzu section. Known is, between reference blank and the foamable Material a correspondingly dense film or a porous material, which is capable of foaming and / or foaming Material, a penetration of the porous material but does not allow.

padding with the porous intermediate layer usually show clearly noticeable non-uniform or different soft cushion areas on what different levels of penetration of foam material results in the intermediate layer.

padding with a dense barrier film are due to their lack of climatic, z. B. sitzklimatischen property, the so-called. Hygrothermal comfort, usually not accepted anymore.

It An attempt has been made to overcome this deficiency by using films to compensate for the shape of the cushioning part or after made the steaming and air permeable to the foaming process be, for. B. by holes in the film or partially or total destruction of the film.

However, since these processes are production-intensive and / or require high additional material costs because of the special nature of the films ( DE 100 59 471 B4 . DE 37 28923 A1 ), these procedures have not been successful. The in-situ technique has therefore almost come to a standstill, although the process technology of the back-foaming allows a much higher variety of shapes and freedom of design.

task The invention is, with the in-situ method in a simple manner To make upholstery parts, in addition to a uniform Upholstery to ensure outstanding hygrothermal comfort.

These Task is with a cushion part with the features of the claim 1 solved. Advantageous developments of the invention will become in the claims dependent on these claims characterized.

Based the drawing, the invention is exemplified in more detail below explained. Show it:

1 schematically the layered construction according to the invention of an in-situ shaped cushion part;

2 schematically a cross section through a known spacing textiles;

3 schematically a cross section through an inventively usable Abstandstextilie combined with superabsorbent layer.

According to the invention, the object is achieved by the use of a special preferably prefabricated intermediate layer between the outer fabric or cover material and the molded foam part. The intermediate layer can be inserted as a cut in the in-situ process in the mold at the bottom. But the intermediate layer can also with appropriate blanks of the individual layers of Zwi layer in the mold.

A Variant provides that all layers including the upper material individually cut and inserted into the foaming tool become. But more advantageous is that first a composite of decorative material and intermediate layer containing both the superabsorbent and on the back has a barrier layer produced becomes. This composite is then cut to size, positioned in the tool and foamed.

In 1 schematically shows the layered structure of a cushion part produced in-situ process is exemplified.

Accordingly, between the covering material blank layer 1 and the foam part 2 an interlayer element layer 3 arranged under the cover material blank layer 1 towards the foam part 2 successively a first volume material layer 4 , a water vapor or moisture absorbing superabsorbent layer 5 , optionally a second volume material layer 6 , And for the liquid material, which is liquid for backfoaming, required for the foaming material components such as isocyanate and polyol impermeable, airtight film, in particular a water vapor permeable film, in particular a membrane film 7 having. (In the context of the description of the invention, the term "water vapor" means, inter alia, both water vapor and condensation, sweat moisture, humidity or the like.)

From the structure of the interlayer element layer 3 The result is a partial pressure of water vapor pressure in the direction of cover material blank layer 1 and also towards the foam part 2 because in particular the membrane film 7 According to the invention is an impermeable and water vapor permeable membrane film.

Likewise, according to the invention, the layers 1 . 4 and 6 Water vapor permeable and preferably also permeable to air, while the foam part 2 Water vapor receptive and water vapor is capable of delivery.

For the cover material layer 1 is z. B. a decorative fabric, in particular a decorative textile used, wherein the decorative fabric on the first volume material layer 4 is laminated in a conventional manner. As a decorative material advantageously an air- and moisture-permeable fabric is used, which is due to its structure and due to the selected fiber or thread material no moisture or water vapor det, but good moisture is permeable or moisture permeable. Accordingly, the decorative fabric is preferably made of man-made fibers or filaments, e.g. As polyester or polyamide and the textile is z. As a knitted or knitted fabric or fabric or scrim or nonwoven fabric.

When Decorative material will also cover layers of leather, PVC, TPU, PU and / or TPE film used to ensure adequate Moisture or water vapor permeability perforated or water vapor permeable membranes, e.g. B. chemical-physical microperforated materials, e.g. B. Sympatex, Gore, PEBAX od. Like. are.

For lamination, in particular, an adhesive is used which does not bind moisture, wherein an adhesive layer structure is selected which allows moisture to pass through very well. Accordingly, z. B. adhesive fleeces of PES with basis weights of 5 to 50 g / m ² , in particular from 15 to 25 g / m ² used. For the purposes of the invention, the adhesive systems according to the following Table 1 are also used. Table 1 Coating Quantities in g / m ² Hotmelt gravure roll coating 5 to 60, especially 8 to 18 adhesive nets 5 to 60, in particular 12 to 25 Dot coating of a thermoplastic: a) stencil printing 5 to 60, especially 8 to 18 b) powder 3 to 80, especially 8 to 15 c) spraying 3 to 60, especially 8 to 15

The volume material layers 4 and 6 are preferably made of the same material. But they can also consist of different materials.

The Volume material is preferably a Abstandstextilie, z. B. a Spacer fabric or a spacer fabric or a volume nonwoven fabric such as Kunit, Multiknit Struto, Napco nonwoven fabric, being preferably used become spacer knits or kunit or multiknit, or a bulkier one Needle-punched nonwoven.

The Abstandstextilie consists z. B. from man-made fibers or chemical fiber yarns or chemical threads (filaments) or filament yarns, preferably from chemical fibers that do not swell when exposed to moisture or Chemical threads from z. As polyester or polyamide or mixtures from, preferably spacer textiles are used, the only from a single fiber or thread material, for. B. off Polyester or polyamide are made.

For the purposes of the invention are preferably structures and fiber or thread materials of the spacer textile selected, the are permeable to air and do not absorb moisture or adsorb or store, rather pass moisture or let it through without tying it. In this respect are spacer textiles preferably used, their structure moisture or water vapor also not capillary binds and the z. B. of hydrophobic fibers are constructed.

The structures of the bulky spacer nonwovens are known, for. B. off "Nonwovens", by W. Albrecht, H. Fuchs, W. Kittelmann, WILEY-VCH Verlag GmbH ,

The structures of the spacer knitted fabric and spacer knit are z. B. described in the Journal "Mittex", Vol. 1121 (2005), No. 2, p. 26 ; Zeitschrift "Kettenwirk-Praxis", Vol. 38 (2004), No. 4, p. 3 ; "Kettenwirk-Praxis", Vol. 38 (2004), No. 4, p. 19/20 ; "Kettenwirk-Praxis", Vol. 38 (2004), No. 2, p. 30 ; "Warp knitting practice", Bd. 38 (2004), No. 3, pp. 34/35 ; "Melliand Textile Reports", Vol. 85 (2004), No. 3, p. 166, Frankfurt a. M., Verlagsgruppe Dt. Fachverlag ; "Melliand Textile Reports", Vol. 83 (2002), No. 3, pp. 134-136 ; Periodical "Wirkerei und Strickerei-Technik", Vol. 44 (1994), No. 9, pp. 736-738, 740 ; Journal "Tecnica Textile International", Vol. 48 (2004), No. 3, p. 29/30 ,

A preferred spacer fabric 10 ( 2 ) has z. B. a technical-textile, knitted surface 11 (Upper binding) and a technical-textile, knitted lower surface 12 (Ligation) on, by dense nebeneinan arranged, arcuately extending, elastically responsive in the outer surfaces elastically integrated threads 13 (Monofilament webs) are kept at a defined distance. The arcuate threads ensure the desired compressive elasticity and bulkiness according to their thickness, their distance from each other and their length, while the surface structures of the outer surfaces 11 . 12 essentially cause the desired strengths in the surface.

Preference is given to the spacer textiles with basis weights above 60 g / m ² and below 1200 g / m ² , ins particular between 120 and 600 g / m ² , used.

Instead of the spacer textiles, a reticulated foam body can also be used. Such solidified foam body, z. Example of polyurethane or polyurethane esters, should have a basis weight of 80-500, in particular from 100 to 300 g / m ² and a thickness of 2.5-30 mm, in particular from 3.5 to 5 mm.

According to the invention is between the first volume Matriallage 4 and the second volume material layer 6 a superabsorbent layer 5 arranged. The superabsorbent layer 5 has at least one superabsorbent material or contains at least one superabsorbent material. Superabsorbent material is known and is z. B. in the DE 41 27 337 A1 or WO00 / 64311 described. The superabsorbent material can be used as loose superabsorbent granulate between the layers 4 and 6 or with at least one of the layers 4 . 6 combined present.

A particular embodiment of the invention provides the use at least one spacer textile, with a separate, the superabsorbent material containing textile fabric combined.

Such a spacer textile is in 3 displayed. The spacer textile is with a functional textile 15 connected, in particular glued, expediently an adhesive layer 14 is used, which is permeable to moisture and expediently also permeable to air. Accordingly, in particular so-called adhesive fleeces with fibers of thermoplastic material are used with basis weights of 5 to 50 g / m ² , in particular of 15 to 25 g / m ² . Furthermore, it is also possible to use other adhesives which produce a moisture-permeable bond or lamination. For example, adhesions shown in Table 1 are used.

The functional textiles 15 has a relatively thin textile fabric compared to the spacer textile 16 , z. As a nonwoven fabric, a woven fabric, a knitted fabric or knit or scrim, in the structural clearances between the threads and / or on the threads or fibers and possibly also on the top and / or bottom surface at least one superabsorbent material 17 z. B. is arranged tightly. The superabsorbent material is in a separate process step in the textile or on the textile z. B. introduced or applied by spraying or impregnation or knife coating or spreading and is then connected to the textile threads or textile fibers adherent.

The Quantity and type of each superabsorbent material is determined according to the absorption capacity of the textile and according to the required properties of the final product.

to Combination of the superabsorbent material with the textile fabric are preferably bright textiles, especially gray to white Textiles used and the superabsorbent material sprayed or sprinkled. Subsequently, a polymerization takes place. Polymerizing on a light textile gives a particular good adhesion of the superabsorbent material to the threads or Fibers of light to white threads or fibers the textile.

On the functional textiles 15 is the membrane film 7 stuck, z. B. glued, arranged.

The textile fabric 16 with the superabsorbent material 17 corresponds to the superabsorbent layer 5 ,

Conveniently, the layers 1 to 6 prefabricated, taking on the textile fabric 16 over another adhesive layer 14 another, preferably the same spacer textiles is applied.

Preferably, however, on the functional textiles 15 already the slide 7 arranged so that a second Abstandststextilie deleted. ( 3 )

The technical-textile superabsorber-containing interlayer element layer 3 ensures an additional cushioning effect through the spacer textiles and is therefore particularly well suited for combination with the cover material and the foam part 2 ,

Preference is given to superabsorbent material carrier textiles 16 with basis weights over 10 g / m ² to less than 300 g / m ² , in particular between 50 and 200 g / m ² used. The carrier textile 16 is z. As a nonwoven or woven or knitted fabric or knit or scrim z. B. from the action of moisture not quel lend chemical fibers or chemical threads, in particular of polyester but also of polyamide or polyurethane. Also usable according to the invention are natural fibers or natural yarns.

The basis of the 3 described with a superabsorber combined intermediate layer element layer 3 can be over an adhesive layer 14 with the reference material blank layer 1 , as shown, be connected. The Zwischenschichtele mentlage 3 Accordingly, it is expediently produced from a prefabricated sheet. In 3 only one blank is shown, which is the first volume material layer 4 having. The combination with the second volume material situation 6 can be done in the same way by adding to the Funktionsmitteltextilie 15 over z. B. an adhesive layer 14 the second volume material situation 6 is applied, which preferably consists of the same material as the first volume material layer 4 ,

The thickness of the interlayer element layer 3 is suitably 1.5 to 80 mm, in particular 2.5 to 5.5 mm. The thickness of the first and in particular the second volume material layer 4 . 6 is in particular 0.8 to 60 mm, preferably 1.0 to 3.0 mm. In the case of using a spacer fabric, the fibers or threads z. B. from PES or PA or other chemical fibers or filaments. The knitted fabric preferably has a weight per unit area of 80 to 1200 g / m ² , in particular of 200 and 600 g / m ² .

It is within the scope of the invention, the cover material Zuschnittlage 1 against the superabsorbent functional textiles 15 to conceal and the membrane 7 on the other side of the first volume material situation 4 to arrange. It is also within the scope of the invention, on the second volume material layer 6 to dispense and the membrane 7 between the functional textiles 15 and the upholstery part 2 to arrange.

The arrangement of the membrane 7 at the intermediate layer element layer 3 preferably also takes place with an adhesive layer 14 , As a water vapor permeable membranes z. B. chemico-physically microperforated materials, eg. B. Sympatex, Gore, PEBAX od. Like. Used. These membranes form a Schaummaterial-, especially when using PU foam material and a Isocya natsperre so that during the foaming neither isocyanate nor other foam material can penetrate the membrane.

It is surprising that the invention does not succeed with absolutely dense membranes which have hitherto been used and which are impermeable to water vapor and isocyanate. Apparently, it must be ensured that moisture is above the reference material layer 1 , the interlayer element layer 3 and the membrane 4 penetrates, up to the foam part 2 can get on and on the foam part 2 is reversibly stored or attached. This moisture travels the same way back as the corresponding water vapor partial pressure gradient is established. In the foam material of the foam part 2 It is usually a closed-cell foam that normally does not absorb and store water. Apparently, however, water vapor is deposited on free surfaces of the foam part 2 so that in this case is stored in an oversupply of steam.

The foam part 2 , which preferably consists of polyurethane foam, has a density or a molding density of 20 to 80, in particular from 30 to 55 kg / m ³ . It is produced in a manner known per se in the in-situ process. Here, first of all, a blank of the individual layers and the absorbent material or the blank of a combined layer containing the absorbent material are placed and held at the bottom in the casting mold. Subsequently, the material to be foamed is introduced into the mold and the mold is closed. There is the foaming of the material. After the foaming process, the mold is opened and the finished upholstery part removed.

It is expedient if the superabsorbent layer 5 forming a separate layer and the superabsorbent material is not within the structure of either or both of the volume materials 4 . 6 located. In this way it is ensured that the desired cushioning effect is not affected over the entire surface.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 10059471 B4 [0002, 0007]
• - DE 3728923 A1 [0007]
• - DE 4127337 A1 [0032]
• WO 00/64311 [0032]

Cited non-patent literature

• "Nonwovens", by W. Albrecht, H. Fuchs, W. Kittelmann, WILEY-VCH Verlag GmbH [0027]
• - Zeitschrift "Mittex", Vol. 1121 (2005), No. 2, p. 26 [0028]
• - Zeitschrift "Kettenwirk-Praxis", Vol. 38 (2004), No. 4, p. 3 [0028]
• - "Kettenwirk-Praxis", Vol. 38 (2004), No. 4, p. 19/20 [0028]
• - "Warp knitting practice", Vol. 38 (2004), No. 2, p. 30 [0028]
• - "Kettenwirk-Praxis", Vol. 38 (2004), Issue 3, p. 34/35 [0028]
• - "Melliand Textile Reports", Vol. 85 (2004), No. 3, p. 166, Frankfurt a. M., Verlagsgruppe Dt. Fachverlag [0028]
• - "Melliand Textile Reports", Vol. 83 (2002), No. 3, pp. 134-136 [0028]
• - Zeitschrift "Wirkerei und Strickerei-Technik", Vol. 44 (1994), No. 9, pp. 736-738, 740 [0028]
• - Journal "Tecnica Textil International", Vol. 48 (2004), No. 3, p. 29/30 [0028]

Claims (31)

Foam-backed, multi-layered upholstered part having a water vapor permeable covering material blank layer ( 1 ) and a foam part ( 2 ), in particular of polyurethane, and in between a plastic film, characterized in that a) the plastic film a for the liquid foam in the backfilling, required for the foaming material components such as isocyanate and polyol impermeable airtight film, in particular a water vapor permeable membrane film ( 7 ) and b) between the film and the coverstock layer ( 1 ) an intermediate layer element layer comprising superabsorbent material ( 3 ) is arranged. Upholstery part according to claim 1, characterized in that the superabsorbent material in the form of a superabsorbent material layer ( 5 ) is trained. Upholstered part according to claim 2, characterized in that the superabsorbent material layer ( 5 ) in layers with at least one water vapor permeable volume material layer ( 4 . 6 ) is combined. Upholstered part according to claim 3, characterized in that the superabsorbent material layer ( 5 ) between two water vapor permeable volume material layers ( 4 . 6 ) is arranged. Upholstery part according to one or more of claims 1 to 4, characterized in that the superabsorbent material is a material which is in the DE 41 27 337 A1 or WO 00/64311 is described. Upholstered part according to one or more of claims 1 to 5, characterized in that the superabsorbent material as a loose superabsorbent granules between the layers ( 4 . 6 ) is arranged. Upholstered part according to one or more of claims 1 to 5, characterized in that the superabsorbent material with a textile fabric ( 16 ), z. B. a nonwoven fabric, a woven fabric, a knitted fabric, a knit or scrim is combined, in which in their structural clearances between the threads and / or on the threads or fibers and possibly also on the top and / or bottom surface at least one superabsorber material ( 17 ) z. B. is arranged tightly. Upholstered part according to claim 7, characterized in that from the sheet ( 16 ) and the superabsorbent material ( 17 ) resulting functional textiles ( 15 ) on one or both volume material layers ( 4 . 6 ) is laminated as a functional text location. Upholstered part according to claim 7 and / or 8, characterized that there is more than one function text location. Upholstered part according to one or more of claims 7 to 9, characterized in that the functional textile ( 15 ) between the covering material blank layer ( 1 ) and the volume material layer ( 4 ) or between a volume material layer ( 4 . 6 ) and the membrane film ( 7 ) is arranged. Upholstered part according to one or more of claims 7 to 10, characterized in that the functional textile ( 15 ) between the covering material blank layer ( 1 ) and a volume material layer ( 4 ) and / or between two volume material layers ( 4 . 6 ) and / or between a volume material layer ( 6 ) and the membrane film ( 7 ) is arranged. Upholstered part according to one or more of claims 7 to 11, characterized in that the support textile ( 16 ) has a basis weight over 10 g / m ² to less than 300 g / m ² , in particular between 50 and 200 g / m ² and z. B. a nonwoven fabric or woven or knitted or knitted fabric or scrim, z. B. from the action of moisture non-swelling man-made fibers or chemical threads, in particular of polyester but also polyamide or polyurethane. Upholstered part according to one or more of claims 1 to 12, characterized in that for the cover material blank layer ( 1 ) a decorative fabric, in particular a decorative textile is used, which is expediently permeable to air and moisture and no moisture or water vapor binds and in particular from man-made fibers or chemical threads, eg. B. made of polyester or polyamide and the textile z. B. a knitted fabric or fabric or scrim or nonwoven fabric. Upholstered part according to one or more of claims 1 to 12, characterized in that the cover material blank layer ( 1 ) made of leather, PVC, TPU, PU and / or TPE film, which are perforated to ensure a sufficient moisture or water vapor permeability. Upholstered part according to one or more of claims 1 to 12, characterized in that the blank layer ( 7 ) a water vapor permeable membrane of z. B. a chemico-physically microperforated material. Upholstery part according to one or more of claims 1 to 15, characterized in that the volume material layers ( 4 . 6 ) consist of the same material. Upholstery part according to one or more of claims 1 to 15, characterized in that the volume material layers ( 4 . 6 ) consist of different materials. Upholstered part according to one or more of the claims 1 to 17, characterized in that the volume material is a Spacer textile, z. B. a spacer fabric or a spacer knitted fabric or a bulk nonwoven such as Kunit, Multiknit Struto or Napco Nonwoven or needled nonwoven fabric. Upholstered part according to claim 18, characterized that the spacer textile made of man-made fibers or chemical fiber yarns or chemical threads (filaments) or filament yarns, in particular from non-swelling chemical fibers when exposed to moisture or chemical threads. Upholstered part according to claim 19, characterized that the spacer textile consists of a single fiber or thread material, z. B. of polyester or polyamide is formed. Upholstered part according to one or more of claims 16 to 20, characterized in that the volume material ( 4 . 6 ) a spacer knitted fabric ( 10 ), which is a technically-textile knitted surface ( 11 ) and a technically-textile knitted lower surface ( 12 ), which by closely juxtaposed arcuate, elastically reacting in the outer surfaces elastically bound threads ( 13 ) (Monofilament webs) are kept at a defined distance. Upholstered part according to one or more of claims 16 to 21, characterized in that the spacer textile has a basis weight over 60 g / m ² and less than 1200 g / m ² , in particular between 120 and 600 g / m ² . Upholstered part according to one or more of claims 1 to 17, characterized in that the volume material ( 4 . 6 ) a reticulated foam body z. B. polyurethane ether or polyurethane ester is z. B. basis weights of 80 to 500, in particular from 100 to 300 g / m ² and a thickness of 2.5 to 30, in particular from 3.5 to 15 mm. Upholstered part according to one or more of claims 1 to 23, characterized in that the foam part ( 2 ) has a density or a molding density of 20 to 80, in particular from 30 to 55 kg / m ³ . Upholstered part according to one or more of claims 1 to 23, characterized in that at least one of the layers ( 1 . 4 . 6 and 7 ) respectively. ( 3 ) are laminated against each other. Upholstered part according to claim 25, characterized in that the lamination by means of an adhesive layer ( 14 ) is done. Upholstered part according to claim 26, characterized in that the adhesive layer ( 14 ) permeable to moisture and expediently also permeable to air. Upholstered part according to claim 27, characterized in that the adhesive layer ( 14 ) is formed from an adhesive fleece with fibers of thermoplastic material, in particular with basis weights of 5 to 60 g / m ² , in particular from 15 to 25 g / m ² . Upholstered part according to claim 27, characterized in that the adhesive layer ( 14 ) is formed from a hot melt gravure roll coating in amounts of 5 to 60, in particular 8 to 18 g / m ² , or with adhesive tackles in amounts of 5 to 60, in particular 12 to 25 g / m ² , or with dot coatings a thermoplastic z. B. in stencil printing with amounts of adhesive from 5 to 60, in particular from 8 to 18 g / m ² , or with a powder coating with adhesive amounts of 3 to 80, in particular 8 to 25 g / m ² , or by spraying with adhesive amounts of 3 to 50 , in particular 8 to 15 g / m ² . Upholstered part according to one or more of claims 1 to 28, characterized in that at least two layers, in particular the layers ( 1 and 3 ) or ( 1 to 7 ) are prefabricated by lamination and cutting. Upholstered part according to one or more of claims 1 to 30, characterized in that the thickness of the intermediate layer element layer ( 3 ) Is 1.5 to 80, especially 2.5 to 5.5 mm.