EP0538372B1 - Improvements relating to bonded non-woven polyester fiber structures - Google Patents

Improvements relating to bonded non-woven polyester fiber structures Download PDF

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Publication number
EP0538372B1
EP0538372B1 EP91913401A EP91913401A EP0538372B1 EP 0538372 B1 EP0538372 B1 EP 0538372B1 EP 91913401 A EP91913401 A EP 91913401A EP 91913401 A EP91913401 A EP 91913401A EP 0538372 B1 EP0538372 B1 EP 0538372B1
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EP
European Patent Office
Prior art keywords
mold
fiberballs
air
assembly
cushion
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Expired - Lifetime
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EP91913401A
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German (de)
English (en)
French (fr)
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EP0538372A1 (en
Inventor
Ilan Marcus
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EIDP Inc
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EI Du Pont de Nemours and Co
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G1/00—Loose filling materials for upholstery
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507—Polyesters

Definitions

  • This invention concerns improvements relating to bonded non-woven polyester fiber structures, and more particularly to a new process and apparatus providing novel bonded polyester fiber articles from fiberballs of the polyester fiber blended with binder fibers (of lower melting and softening point than the load-bearing polyester fiber), that are bonded to provide useful new through-bonded articles of improved structure.
  • Binder fibers can be intimately blended into the load-bearing polyester fiber to achieve true "through bonding" of the polyester fiber when they are suitably activated. "Through bonding” has provided higher support and better durability than resin-bonding of polyester fiber (which used to be the conventional method of bonding), and can also provide reduced flammability than conventional resin-bonding.
  • Binder fiber blends had already been used to make batts in furnishing, mattresses and similar uses where high support and good durability were required. They had seldom been used as the only filling material in these end uses, but the common practice was to use the polyester fiber batts as a "wrapping" around a foam core. It is believed that the main reason was that it has been difficult to achieve the desired properties without using such foam core. To achieve the desired resilience and durability, bonded fiber batts would have had to reach high densities, in the 35 to 50 kg/m3 range. Such high densities could not be achieved commercially until more recently. Even then, such condensed (i.e.
  • a continuous process such as we disclosed in our copending application Serial No. 07/290,385 (EP-A-0 378 001) is excellent for producing mattress cores, or similar furnishing products that are flat and rectangular, or whose width varies only slightly within a limited range, so such furniture styles may be continuously produced on a large scale with little variation in cross-section.
  • Some furniture cushions are, however, designed in shapes which are not flat and/or not of rectangular cross-section. The specific shapes may be required infrequently, and/or on a relatively small scale.
  • a continuous molding process such as disclosed in our copending application, Serial No. 07/290,385, (EP-A-0 378 001) may not be so appropriate. It is excellent for producing continuously, a structure whose dimensions are not modified at all, or within certain limits only.
  • the process and the apparatus disclosed in the copending application is also very useful for the production of condensed fiber structures of relatively large size, such as mattresses.
  • EP-A-0268099 discloses polyester fiberfill having spiral crimp that is randomly arranged and entangled in the form of fiberballs with binder fibers.
  • Example fiberballs were packed in a mold with a rectangular base and walls made of wire mesh reinforced with steel bars. The mold was placed in an oven with an air flow across the rectangular base at a temperature of 160°C for 15 minutes to produce a "cushion".
  • FR-A-2542666 discloses the production of panels of variable thickness by placing a stratified assembly of a layer of fibers containing a non-polymerisable binder and a cover sheet between the mold and mold-backing of a molding press. The cover sheet is forced against the mold. Hot air is blown into the fiber layer from the mold surface opposite the cover sheet into the region corresponding to the area of greatest thickness. The direction of the heated air is reversed, maintained and adjusted to secure polymerisation of the binder.
  • the object of the present invention is to provide a simple and flexible process and apparatus suitable for producing cushions, e.g. by directly molding fiberballs into the final shape for the cushion or other furnishing products, if this is desired.
  • a batch process for molding shaped articles of load-bearing fibers by first heating and then cooling in a mold a blend of binder fibers and load-bearing fibers, wherein (1) the binder fibers and load-bearing fibers are formed into fiberballs, (2) the fiberballs are loaded into a mold, to form an assembly of fiberballs, (3) the binder fibers are activated by hot air which is forced through the assembly of fiberballs in the mold in a direction perpendicular to the base of said assembly, and wherein sealing means are provided around the assembly of fiberballs to ensure passage of the hot air through said assembly.
  • load-bearing fibers are cut polyester fibers of suitable denier such as have been used in various filling applications, because of their resilience and the good support provided.
  • suitable polyester fibers, binder materials and binder fibers include bicomponent binder fibers, e.g. of sheath-core or other type. The cores thereof may provide all or part of the load-bearing fibers, as desirable according to the particular end-use and properties desired in the shaped article.
  • cushions are preferred shaped articles according to the invention.
  • the term cushions is used broadly herein, including, for instance cushion cores that may be used as support within a wrapping of one or more layer(s) of other material(s) to provide different surface aesthetics.
  • such new cushions may be characterized by a density from about 18 to about 45 kg/m3, and yet be entirely derived from fibers (load-bearing fibers bonded by the binder material from the binder fiber used).
  • They may also be defined by their superior air permeability, generally at least 1200 l/m2/sec, and preferably at least 2000 l/m2/sec, and/or water transport as shown by recovery within 1 minute of at least 50% of a portion of 100 ml of water poured onto a sample enclosed in a fitting plastic box, by the test method disclosed herein, using samples 10 cm thick, or values adjusted to correspond with such a thickness of 10 cm.
  • Such molds are particularly adapted for heating with hot air, and so are formed from grids and/or plates, including moving or movable belts, that are perforated to permit circulation of hot air therethrough for heating to activate the binder material, and then for cool air for subsequent cooling.
  • the molds are preferably supported on frames, and heated in ovens, as more particularly described hereinafter.
  • Figure 1 illustrates schematically an elevation view of an apparatus according to the invention.
  • Figures 2A, 2B, 2C, and 2D show several views of various parts of representative molds according to the invention.
  • Figures 2A and 2B shows perspective views of individual parts separately.
  • Figure 2D shows an elevation view of the parts of a representative mold as they would be assembled together.
  • Figure 2C shows the same parts as in Figure 2D, but exploded, so each part may be seen more clearly in relation to cooperating parts, all as described more particularly hereinafter.
  • Figure 3 shows a view in perspective of the parts of an "open mold” assembled together, as described hereinafter in more detail.
  • Figure 4 illustrates schematically a semi-continuous apparatus according to the invention.
  • articles having a predetermined shape and dimensions are molded from polyester fiberballs, preferably made from blends of binder fiber and load-bearing fibers, the binder fiber being activated by hot air, microwave (MW) or high frequency (HF).
  • MW microwave
  • HF high frequency
  • the balls may be made from a blend of the feed fiber by opening the feed fiber and then submitting to a rolling action by methods disclosed in the art; e.g. our USP 4,794,038 or copending application Serial No. 07/508,878 filed April 12, 1990 by Snyder et al, (corresponding to EP-A-0 524 221) the disclosures of each of which is hereby specifically incorporated herein by reference.
  • the fiberballs are preferably sufficiently rolled to produce an effective fiberball structure with a three dimensional fiber arrangement.
  • the use of fiberballs is important to provide good distribution throughout the molding apparatus, and uniform density and good resilience and durability in the molded articles, as indicated later herein. Unlike requirements for other fiberballs, for the purposes of the present invention it is often preferable to use fiberballs having a significant degree of hairiness, i.e. a relatively high cohesion measurement as described in my earlier U.S. Patent No. 4,168,531, so that, when molded, they bond well together (good fiberball to fiberball bonding).
  • the mold is placed in an oven, and is preferably supported by a frame, to simplify loading and unloading of the mold.
  • the fiberballs may be fed directly into the mold, where they are molded by activation of the binder, or be fed into a ticking which is placed in the mold. In both cases, the fiberballs may be heated in the closed mold, i.e. the parts of the mold form the initial and final dimensions of the cushion, as it cools. Alternatively, they may first be heated while confined under a low pressure, or no pressure at all, at a higher thickness (i.e. height) than the final cushion thickness.
  • the lid of the mold may be pushed down, as desired, to the predetermined dimensions after the binder has been activated, and the material is cooled by sucking air through the mold with the desired dimensions.
  • molds may be of help, by giving a desired shape to a cushion, and particularly to its sides, by producing a good, regular, surface, it is not essential.
  • a mold is highly desirable for forming cushions which are going to be used directly as the finished product.
  • the mold is placed (loaded) in an oven having an air inlet on one side of the mold (preferably below the mold) and an air outlet on the other side (preferably above the mold).
  • Loading and unloading is preferably done horizontally, e.g. by a sliding door which is coupled with the loading and unloading mechanism.
  • the oven is preferably arranged so that the air inlet is centered and the air is directed perpendicularly to the mold, and the air outlet is symmetric to the inlet.
  • the system allows fiberballs to be molded directly into cushions, if desired, without losing material by cutting the cushion to shape, which can constitute a major economic advantage.
  • the cushions also can be made with uniform density even when they have a very sculptured surface, unlike cushions that have been molded from batts (made from similar fiber blends), which generally have a significantly higher density in the troughs than in the peaks.
  • the process and equipment are inexpensive and flexible, allowing one to custom-produce cushions with various shapes and sizes at the same time.
  • a custom-mold (of the desired dimensions) made from perforated plates or grids, and mounted on a frame of metal bars supporting a "skirt" made of a temperature-resistant relatively thick plastic foil, or of metal, of appropriate size so as to avoid leaving any gap between the frame and the mold.
  • This skirt forces the hot air to pass through the mold and thus allows one to produce a variety of cushions which differ from each other in size and/or shape in the same oven using a standard frame.
  • the same principle applies to "open molding", whereby a "cushion" of whatever dimensions desired may be placed on a perforated plate or a grid, with the area around its base sealed by an appropriately sized metal or a heat-resistant plastic skirt, to force the air through the cushion.
  • the lower perforated plate may be replaced by a perforated belt, which may serve to load and unload the cushions, e.g. by intermittently moving into the oven, stopping there for a timed period, and then moving on.
  • the belt may serve to bring the cushion to a cooling zone and from there to an unloading zone.
  • the upper part of the cushion can be shaped by the upper plate in the cooling zone prior to cooling and consolidating the structure.
  • the skirt may conveniently be located just beneath the belt and can be made of polyester, polyamide, special rubber or other materials which can resist hot air at temperatures of about 150° to about 180°C.
  • the resulting cushions are characterized by outstanding durability, that is achievable at lower density than from condensed batts using the same feed fibers.
  • My cushions are also characterized by high support, with good conformation to the user's body. I believe that these advantages result from the internal structure of these cushions: the fiber arrangement within each fiberball (which arrangement has been stabilized by the bonding) has a significant vertical component which provides support, while the bonding forces between the fiberballs may be lower, and may allow limited relative movements of the fiberballs within the structure, if desired.
  • My cushions are characterized also by much better (higher) water transport through the cushions than condensed batts made from the same feed fibers at the same density and the air permeability is at least comparable.
  • the improvement is believed to be related to the interstices, e.g. between the fiberballs, and the improved fiber arrangements, more generally.
  • the water transport can be enhanced by coating the fibers with hydrophilic permanent coatings, such as those disclosed in my earlier U.S. Patents Nos. 4,783,364 (DP-3720-B) and 4,818,599 (DP-4155) and my co-pending application (DP-4349A), Serial No. 07/435,513, filed March 17, 1989, the disclosures of each of which is hereby specifically incorporated herein by reference.
  • the fiberballs may be sucked or blown into a ticking, which is then closed and placed in the bottom of a perforated mold.
  • the mass of the fiberballs may be heated without any pressure applied, the heated mass may then be pressed to the predetermined shape and dimensions by the upper part of the mold, which may also be perforated, and cooled by sucking cold air through the mold.
  • the cushion is then taken out of the mold and can either be used directly or, if so desired, the ticking can be recovered and recycled.
  • the ticking filled with the fiberballs may be placed in a closed mold and the binder fiber is activated, to produce the cushion to its final dimensions.
  • the filled ticking may be placed on a perforated plate or a grid with the area between the cushion and oven walls completely closed.
  • the binder fiber may then be activated by hot air and the cushion is cooled between two perforated plates or in a mold to shape it.
  • the cushion can also be heated between two perforated plates. The presence of the upper plate will usually make the upper part of the cushion firmer and will improve the bonding of the sides of the cushion.
  • the fiberballs may be sucked directly into the bottom of the mold, the binder may be activated and the mass of fiberballs may be compressed to its final dimensions and cooled by sucking air through the mold.
  • the bottom part of the mold should preferably have a removable base, which can be pushed upwards to free the molded piece.
  • the binder fiber is preferably activated by hot air.
  • This hot air may be forced through the mass of fiberballs in the mold to achieve effective bonding within a short heating cycle.
  • To ensure that the air passes through the fiberballs within the mold their periphery around the mold should be completely sealed. This can be achieved by surrounding the mold with a heat-resistant plastic sheet or metal plate to fill any gap between the mold and the frame which carries it.
  • the hot air is introduced from the bottom or the upper part of the perpendicular oven and forced to pass through the mold, by sealing the space between the mold and the carrying frame.
  • the frame is introduced through a sliding door into the oven and the hot air is injected.
  • the hot air can be collected, re-heated to the working temperature, and recycled.
  • the heating cycle depends on many factors: The density of the fiberball mass, the air temperature, the air flow, the resistance of the mold and the perforated plates to the air flow, and the temperature of the oven chamber.
  • the mold is unloaded, the upper part of the mold is pressed down to the desired height of the cushion and cold air is sucked through the structure to cool the cushion to about the room temperature.
  • the working temperature depends on the binder fiber and is preferably not higher than 185°C. For economic reasons it is desirable to work with a high air flow, and thus to minimize the duration of the heating cycle.
  • a frame carries the mold and provides a large amount of open space.
  • the frames can be interconnected, mounted on chains, or a rotating system, so that a continuous or a semi-continuous process can be achieved.
  • the frames carry the lower part of the molds, which may be supported directly by such frame, or conveniently lay on bars which extend from the mold.
  • the space between the mold and the frame is covered by sealing means, preferably a metal or plastic sheet which is welded, glued or otherwise bonded to the support bars.
  • the frame simply supports the perforated plate and the cushion, while the gap between the oven walls and the cushion is sealed by a plastic foil or metal sheet or a similar material.
  • This may be provided by using a belt, for transplanting the cushions, such belt being perforated, e.g. perforated metal plates, or a grid made of aramid fibers, suitably coated, if desired, e.g. with a "non-stick” coating.
  • the frames are placed in an oven, equipped with a precise control of the air flow and air temperature.
  • the oven may also be equipped with thermocouples to monitor and provide means to control the air temperature at different parts of the oven. I have found that the key points to place these thermocouples are the air inlet, preferably just below the mold, and the air outlet. Other thermocouples can be placed at other parts of the mold to allow control of the temperature uniformity. To achieve good control of the temperature and the flow it may be necessary to direct the air flow.
  • each mold may be equipped with metal bars which bridge the space between the mold and the frame which carries it.
  • a plastic skirt made of a thin heat resistant film, which fills the gap between the mold and the frame, may be fixed on the metal bars.
  • the invention allows one to have one set of frames installed permanently with their loading and unloading system and produce whatever cushions are required by changing the mold, or the shape of the filled cushion. The sealing of the system is ensured by the mold's skirt. The skirt can be easily cut from an appropriate plastic film.
  • the apparatus generally, may be referred to as an oven 10, within which is located a mold 11.
  • the frame 12 is itself supported by lugs 20 or other suitable fixed supports attached to the internal wall of ovens 10.
  • a fitting skirt 13 is provided to seal the space around the periphery of mold 11.
  • the skirt 13 overlaps the frame 12, and is held in place by the bars 14.
  • Mold 11 has a removable base 16 that is perforated to allow air to pass through the mold from an inlet 21, being supported by a lower fan 24, after being heated by a heater 23, and is exhausted at the top through an outlet 22.
  • Perforated plates 25 are provided to act as baffles and provide better distribution and uniformity of the air flow, because of the lateral displacement of the perforations.
  • Figure 2D shows the various parts assembled more or less as in Figure 1, while Figure 2C shows an exploded view of the same parts (which are shown individually, in perspective, in Figure 2A).
  • frame 12 supports skirt 13, on which rest bars 14 protruding from mold 11, which is shown also with lid 15, and removable base 16, both of which are perforated (such perforations not being shown).
  • Mold 11 and skirt 13 are each shown in figure 2A as having an essentially square cross-section, but different cross-sections may be used as shown, for instance, in Figure 2B.
  • Figure 2B shows mold 11 with a cross-section like a 4-leaf clover, and with correspondingly shaped skirt 13.
  • Figure 3 shows a perspective view of the "open mold” concept, whereby the fiberballs are first loaded into a ticking of the dimensions desired (these may be those desired for he final cushion), and then the binder fiber is activated by hot air as the cushion is located between upper and lower perforated plates, or grids if desired.
  • frame 12 is shown supporting skirt 13 as before, with a perforated plate 16' acting as a base for cushion 17 (before activating the binder with hot air, this is generally ticking loaded with fiberballs and then closed) that is located between upper plate 15' and lower plate 16', which may be secured together at each corner by threaded rods 18 that are adjusted to the same length (so as to maintain uniform thickness for the fiberball assembly, i.e. the cushion) by adjusting the positions of butterfly nuts 18A, as shown.
  • Perforations 19 are provided in both upper plate 15' and lower plate 16' (only some representative perforations being shown in the drawing).
  • Suitable dimensions may be as follows: frame 12, of thickness 10 mm and shaped as an open square in cross-section, with an outside length of 800 mm and an inside length of 650 mm; skirt 13, of thickness 50 mm and shaped as another open square in cross-section, with an outside length of 750 mm and an inside length of 600 mm; lower perforated plate 16' of thickness 1.5 mm, and being a square, each side being of length 700 mm, and with perforations of diameter about 3 mm, spaced 2 mm apart; cushion 17 being of square cross-section with sides 600 mm long (to fit the inside length of skirt 13), and of whatever thickness is desired; upper plate 15' may be like bottom plate 16'.
  • the open mold concept can easily be automated to reduce labor cost by replacing the lower plate 16' by a belt, e.g., as shown in Figure 4.
  • This process concept allows one to use separate zones, as shown by heating zone 47, and cooling zone 52 with a belt 45, going through, transporting the cushion 41 from loading zone 42 to the heating zone 47, then to the cooling zone 52 and finally to unloading zone 54.
  • the molding is done by injecting hot air (using, for example, fan 43) through the belt 45 into the cushion which is between the belt and upper plate 46, attached to a piston 48 to lower and release the upper plate as required by the operation.
  • the upper plate is usually a perforated metal plate which can be either flat or shaped to the shape of the cushion, depending on the cushion design. Usually, for designs with a small to moderate difference between the highest and the lowest points on the cushion surface, it is not necessary to use a shaped upper plate. For such cushions it is possible to achieve satisfactory results by heating the cushion between the belt and a flat plate and forming it prior to cooling in the cooling zone.
  • skirts 44 As in the case of the open mold disclosed in Figure 3, to achieve a fast and effective molding it is important to use a sealing means, such as skirts 44, to block the hot air from escaping through the part of the belt which surrounds the cushion.
  • the skirt can be made of polyester, polyamide sheets, special rubber, or other materials which resist a temperature of up to about 180°C. It is conveniently placed beneath the belt in the heating zone and can be either fixed on metal frames, which can be slided into a horizontal slot located just beneath the belt, or can be cut in a roll of continuous sheet which can be rolled and unrolled, perpendicularly to the belt, to position the appropriate skirt beneath the belt.
  • both the heating and the cooling zones can be equipped with automatic sliding doors 53 which open to let the cushion in and out and close during the heating and cooling operation.
  • An advantage of this embodiment is that heating and cooling can be done at the same time on two different cushions.
  • the upper part of the cushion can be shaped prior to and during cooling, using a shaped upper plate 50 in the cooling zone.
  • the upper plate 50 is attached to a piston 51, which allows the plate to move up and down to shape the cushion prior and during cooling and then release it after the cooling cycle.
  • the cooling zone 52 may be equipped similarly to the heating zone, e.g., with fan 49, and another skirt 44.
  • Support bulk (SB or 7.5 N): the height under a 7.5 N force.
  • the softness is calculated both in absolute terms (AS, i.e. IH2-7.5 N) and in relative terms as a percentage of the initial height (RS, i.e. AS expressed in percent of IH2).
  • a firm cushion corresponds to a high support bulk, i.e. inversely with softness.
  • Resilience is measured as work recovery (WR), i.e. the ratio of the area under the whole recovery curve calculated as a percent of that under the whole compression curve. The higher the WR, the better the resilience.
  • Each cushion was covered with a polyester spun bonded non-woven, weight 18 g/m2.
  • the object of this test is to measure how fast water runs through the structure.
  • a high value can be important for such applications as garden furniture cushions, boat cushions, and car seats.
  • the following method was developed by modifying a geotextile test. With thick products of the invention, foam blocks or similar products, the water would tend to run out through the sides of the block, rather than pass through. So, the equipment was modified, and the test piece of cushion was a plastic box, as described below. Before introducing the cushion, the side walls of the plastic box are covered with a thin layer of high viscosity silicone oil. A 15 x 15 cm block, 10 cm thick, is cut from the material to be tested and placed in the plastic box in the equipment.
  • the box is then closed by a plastic lid having a hole with a diameter of 150 mm.
  • 100 ml of water are poured in one shot through this hole onto the upper part of the test block, the water is collected into a measuring glass cylinder and the amount of water collected is recorded as a function of time.
  • cushions according to the invention that have had sufficient water transportability to allow within one minute more than 50% of such 100 ml of water, which is an excellent result and superior to the prior art.
  • a similar block of the cushion to be tested having dimensions of 15 x 15 x 10 cm is placed in a plastic box of 15 x 15 cm, having a round hole in its base of diameter 15 mm.
  • the box is closed with an upper part which closes hermetically on the bottom part, and has a round hole with a similar diameter of 15 mm. Air is sucked through the hole in the base after inserting a flexible plastic tube (diameter 40 mm) connected to an Air Permeability Tester (produced and sold commercially by Textil Testing Instruments in Zurich, Switzerland).
  • the air permeability is measured under the standard conditions used for measuring the air permeability of fabrics, and is recorded as l/m2/sec (i.e., liters per square meter per second) for such a thickness of 10 cm.
  • l/m2/sec i.e., liters per square meter per second
  • High air permeability is generally desirable, so long as the cushion provides adequate support.
  • a blend of 80% of a 13 dtex commercial 4-hole (25% void) polyester fiberfill and 20% of a 17 dtex commercial sheath-core polyester binder fiber (50% core/50% sheath by weight) was processed on standard commercial garnetting equipment to produce a batt of density about 450 g/m2.
  • the batt was heated at 165°C for about 3 minutes and calendered to 40 mm thickness.
  • the batts were cut to squares measuring 50 x 50 cm, and five and a half of these squares, in layers, layer split horizontally through the middle were piled on the bottom part of the mold, to make 5 layers, plus one layer split horizontally through the middle.
  • the mold was closed with its upper part to form a chamber with an internal height of 10 cm, and was placed on a frame, which was then put in the oven described in Figure 1. Hot air at a temperature of 170°C was injected for 30 seconds (using the Leister lufthitzer type 40,000). The mold was unloaded and cooled with air until it reached 30°C and the mold was opened to produce a molded cushion with a density of about 25 kg/m3 and dimensions of 50 x 50 x 10 cm.
  • a blend of 80% of 13 dtex 4-hole 25% void polyester fiberfill, coated with 0.5% of a (hydrophilic) co(polyether polyester) and 20% of a 17 dtex sheath-core polyester binder fiber (50% core/50% sheath by weight) was processed on standard commercial garnetting equipment to produce a batt of about 450 g/m2.
  • the batts were then processed as in Comparison A, but with the hydrophilic coating on the load-bearing fibers.
  • a fiber blend as in Comparison C (but with a cut length of 50 mm) was opened and processed on modified card equipment at a throughput of about 50 kg/m3 to produce fiberballs with an average diameter of 5 mm.
  • the fiberballs were baled to form a bale with a density of 80 kg/m3.
  • 625 g of the fiberballs were sucked into a light weight spun bonded polyester ticking, having the shape of the cushion to be molded, and the ticking was closed.
  • the filled ticking was loaded into the bottom part of the same mold and the mold was closed at the predetermined height, as in Comparison C, to form a cushion with 10 cm thickness.
  • the mold was heated for 30 seconds, then cooled by sucking cold air through the mold.
  • the mold was opened, and the ticking opened to free the 10 cm thick 25 kg/m3 cushion.
  • Example 5 The fiberballs used in Example 5 were molded in the same mold following the same procedure, but using lOOOg of the fiberballs, to produce a cushion with the same dimensions, but with a density of 40 kg/m3.
  • Table 1 Item Density (kg/m3) Air permeability (l/m2/sec) Comparison A 25 3333 Comparison B 45 1000 Comparison C 25 3889 Comparison D 45 1528 Example 1 25 4028 Example 2 40 1528 PU foam 25 1666 PU foam 45 1069
  • Table 1 shows air permeability measurements for the above products and foams of comparable density. There was no difference between the air permeability of the densified batt, Comparison D, and the corresponding fiberball block of the same density, Example 2, and there was little difference between Comparison C and Example 1. Comparisons A and B have lower air permeabilities (although they were made from fibers with the same denier), because these fibers were not slickened.
  • Comparison A and B (like the foams) retained the water completely and did not let anything pass through, even when the experiment was extended to 15 minutes. The reason is that, due to the hydrophobic character of these fibers, their wetting was poor and the water was retained in the structure, and did not run through. In Comparisons C and D, the water ran through almost immediately. As could be expected the rate was higher for the 25 kg/m3 (Comparison C) than for the 45 kg/m3 bolt (Comparison D).
  • the difference from Comparisons A and B was essentially due to the hydrophilic coating of the fibers of Comparisons C and D.
  • the products of the invention (made by molding fiberballs made from the same fibers) gave very significantly faster water transport.
  • the 25 kg/m3 Example 5 retained only 38% of the water after 3 minutes, versus 50% for Comparison C. The transport of the water was almost instantaneous for Example 1, 50% of the water being collected after only 10 seconds versus only 20% for Comparison C.
  • the water transport of the cushions of the invention depends less on the density, as there is very little difference between the amount of water collected after 3 minutes with the 25 kg/m3 (Example 1) and the 40 kg/m3 (Example 2).
  • Example 1 (the cushion of the invention at 25 kg/m3 had a higher support than Comparison D (the condensed batt made from the same fibers at 45 kg/m3).
  • the resilience (W.R.) of Example 1 was substantially higher than that of Comparison B or D, made with a density of 45 kg/m3.
  • Another advantage of the products according to the invention is their durability.
  • Example 1 had an overall better durability than any of Comparisons A to D, although B and D had a density of 45 kg/m3.
  • the product of the invention made according to Example 2 (at a density of 40 kg/m3) had negligible bulk losses.
  • the apparent high change in percent of the softness corresponds to an absolute change of less than 5 mm.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
  • Reinforced Plastic Materials (AREA)
  • Multicomponent Fibers (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
EP91913401A 1990-07-09 1991-06-18 Improvements relating to bonded non-woven polyester fiber structures Expired - Lifetime EP0538372B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US54984790A 1990-07-09 1990-07-09
US549847 1990-07-09
PCT/US1991/004134 WO1992001104A1 (en) 1990-07-09 1991-06-18 Improvements relating to bonded non-woven polyester fiber structures

Publications (2)

Publication Number Publication Date
EP0538372A1 EP0538372A1 (en) 1993-04-28
EP0538372B1 true EP0538372B1 (en) 1995-07-26

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EP91913401A Expired - Lifetime EP0538372B1 (en) 1990-07-09 1991-06-18 Improvements relating to bonded non-woven polyester fiber structures

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EP (1) EP0538372B1 (es)
JP (1) JP3012327B2 (es)
KR (1) KR0158667B1 (es)
AU (1) AU8283691A (es)
CA (1) CA2086840C (es)
DE (1) DE69111608T2 (es)
ES (1) ES2076539T3 (es)
IE (1) IE912262A1 (es)
MX (1) MX9100124A (es)
WO (1) WO1992001104A1 (es)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995014801A1 (en) * 1993-11-23 1995-06-01 E.I. Du Pont De Nemours And Company Improvements relating to bonded non-woven polyester fiber structures
MX9700357A (es) * 1994-07-13 1997-04-30 Du Pont Proceso y equipo para moldeos de grupos de fibras.
US5454992A (en) * 1994-07-13 1995-10-03 E. I. Du Pont De Nemours And Company Fiber clusters molding process and equipment
WO1998024958A1 (fr) * 1996-12-05 1998-06-11 Teijin Limited Procede de moulage d'agregats de fibres
WO2003021025A1 (fr) 2001-09-03 2003-03-13 Teijin Limited Procede et appareil de formation d'un agregat de fibres
EP3245053A1 (en) * 2015-01-16 2017-11-22 Schukra Gerätebau GmbH Method, tool and system for producing a product from fiber material
CN109898237B (zh) * 2019-04-19 2020-07-21 武汉纺织大学 一种纺织体的线型直轨式生产系统

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2587814A (en) * 1946-11-09 1952-03-04 Owens Corning Fiberglass Corp Method and apparatus for making a fibrous preform
US4794038A (en) * 1985-05-15 1988-12-27 E. I. Du Pont De Nemours And Company Polyester fiberfill
FR2542666B1 (fr) * 1983-03-17 1986-06-20 Saint Gobain Isover Panneaux composites moules
US4940502A (en) * 1985-05-15 1990-07-10 E. I. Du Pont De Nemours And Company Relating to bonded non-woven polyester fiber structures

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CA2086840A1 (en) 1992-01-10
DE69111608D1 (de) 1995-08-31
DE69111608T2 (de) 1996-03-21
IE912262A1 (en) 1992-01-15
JPH05508198A (ja) 1993-11-18
ES2076539T3 (es) 1995-11-01
MX9100124A (es) 1992-02-28
KR0158667B1 (ko) 1998-12-01
JP3012327B2 (ja) 2000-02-21
KR930701649A (ko) 1993-06-12
CA2086840C (en) 2001-01-16
EP0538372A1 (en) 1993-04-28
WO1992001104A1 (en) 1992-01-23
AU8283691A (en) 1992-02-04

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