EP1199392A1 - Method and means for production of shaped cushions and upholstery - Google Patents

Method and means for production of shaped cushions and upholstery Download PDF

Info

Publication number
EP1199392A1
EP1199392A1 EP01850069A EP01850069A EP1199392A1 EP 1199392 A1 EP1199392 A1 EP 1199392A1 EP 01850069 A EP01850069 A EP 01850069A EP 01850069 A EP01850069 A EP 01850069A EP 1199392 A1 EP1199392 A1 EP 1199392A1
Authority
EP
European Patent Office
Prior art keywords
cover
fibres
wad
melting point
filled
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP01850069A
Other languages
German (de)
French (fr)
Inventor
Lars-Gunnar Johansson
Ninette Johansson
Mikael Johansson
Andreas Johansson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nila I Nassjo AB
Original Assignee
Nila I Nassjo AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nila I Nassjo AB filed Critical Nila I Nassjo AB
Publication of EP1199392A1 publication Critical patent/EP1199392A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G7/00—Making upholstery
    • B68G7/06—Filling of cushions, mattresses, or the like
    • 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
    • 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
    • D04H1/542—Adhesive fibres
    • D04H1/55—Polyesters

Definitions

  • the present invention is for method and means by manufacture of wad containing cushions and padding for furniture and seats for home, office, public places and chairs and other products for vehicles.
  • the filling of the covers means a manual work which may not be disregarded even if it has been tried to automate the procedure.
  • the covers are often sewn in a special way and may be divided into channels or similar, separate sections. It is also known in the art to shape the cushions by putting a mixture of polyester fibres into a mould. Some of the fibres are so called melt fibres which will melt fully or partially at a consecutive heating and then will bind adjacent fibres.
  • Polyester fibres offer many advantages compared to polyurethane. It is easily recovered and it does not pollute neither the external nor the internal environment during the process of manufacture or during the use of the product. Moreover polyester fibres do not attract moisture or dirt and are neutral to allergy, i.e. it does not cause allergies and is not dangerous to allergic persons.
  • the present invention is for method and means by the manufacture of wad containing cushions and corresponding padding materials having desired weight and density and possibility to obtain different properties at separate sections of the products.
  • the invention makes it possible to shape mould polyester fibre products.
  • a cover from non-woven material having a melting point below 100 °C.
  • the cover is then filled with a mixture of 10-30 % w/w, preferably 20 % w/w meltable fibre and 70-90 % w/w, preferably 80 % w/w of polyester fibres of a material which is non-meltable or which does not melt at the temperatures which may occur during the process. Filling may take place in known manner using vacuum.
  • the filled cover, or the polyester cut to shape is then put into a mould which allows hot air to flow into and through the cover and the filler.
  • the temperature of the air is 120-170 °C, suitably 130-160 °C and preferably 135 °C.
  • Blowing of air goes on for a time interval of 20 s - 10 min, usually 30 s - 5 min and preferably 30 s - 1 min.
  • the surrounding cover and the meltable fibres of the filling will then melt. This gives as result cushions of homogenous material which have a very good shape stability. Textiles may also in this way be fixed by moulding and form a homogenous unit with the filling.
  • the weight per volume of the product when ready may be varied within an interval of at least 20-50 kg/m 3 .
  • This may be made use of by that separate channels or sections within a cover are filled to different weight per volume when manufacturing for example cushioning for vehicle seats, where a softer middle section forms the back and/or seat and more firm side sections form supporting cushions at the sides of the back and/or the seat.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Laminated Bodies (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

The present invention is for method by manufacture of shaped cushions or filling material for furniture and seats where a filling material being a wad is filled into an enclosing cover which comprises fibres of a material having a lower melting point than the wad. Preferably the cover is entirely made from fibres having a melting point below 100 oC. The wad may comprise fibres having two different melting points and the cover may be divided into several separate sections which are intended to be filled with different materials and/or packing density.

Description

  • The present invention is for method and means by manufacture of wad containing cushions and padding for furniture and seats for home, office, public places and chairs and other products for vehicles.
  • At the manufacture, repair and renovation of furniture large quantities of polyurethanes are used as push up and padding materials which brings with it several environmental disadvantages at the manufacture of the padding material, such as isocyanates at the foaming, the further handling of it in the production and its use. The advantage of some urethanes is that they may be molded to shape at a comparatively low cost. Wad is also used to an essential extent as a filler material to give the desired shape and comfort to he furniture when used for sitting or lying down. Wad, mostly from polyester fibres, is produced and delivered as blocks or loose wad in bags. In order go give the desired shape and consistency to the padding it has to be filled into covers, for example cushion-cases, where the quantity of the wad has to be carefully controlled. In this way it is possible to produce back cushions of acceptable quality while it is not possible to produce for example seats of acceptable quality for office furniture, especially there is a lack of firmness and durability of shape. The filling of the covers means a manual work which may not be disregarded even if it has been tried to automate the procedure. The covers are often sewn in a special way and may be divided into channels or similar, separate sections. It is also known in the art to shape the cushions by putting a mixture of polyester fibres into a mould. Some of the fibres are so called melt fibres which will melt fully or partially at a consecutive heating and then will bind adjacent fibres.
  • Other known methods to produce shaped cushions and padding material is to cut them, starting with blocks or piece-goods from polyurethane or wad. This method brings considerable disadvantages and a loss of 20-40 % of the material with it.
  • Polyester fibres offer many advantages compared to polyurethane. It is easily recovered and it does not pollute neither the external nor the internal environment during the process of manufacture or during the use of the product. Moreover polyester fibres do not attract moisture or dirt and are neutral to allergy, i.e. it does not cause allergies and is not dangerous to allergic persons.
  • The present invention is for method and means by the manufacture of wad containing cushions and corresponding padding materials having desired weight and density and possibility to obtain different properties at separate sections of the products. The invention makes it possible to shape mould polyester fibre products.
  • To practice the invention one makes a cover from non-woven material having a melting point below 100 °C. The cover is then filled with a mixture of 10-30 % w/w, preferably 20 % w/w meltable fibre and 70-90 % w/w, preferably 80 % w/w of polyester fibres of a material which is non-meltable or which does not melt at the temperatures which may occur during the process. Filling may take place in known manner using vacuum. The filled cover, or the polyester cut to shape, is then put into a mould which allows hot air to flow into and through the cover and the filler. The temperature of the air is 120-170 °C, suitably 130-160 °C and preferably 135 °C. Blowing of air goes on for a time interval of 20 s - 10 min, usually 30 s - 5 min and preferably 30 s - 1 min. The surrounding cover and the meltable fibres of the filling will then melt. This gives as result cushions of homogenous material which have a very good shape stability. Textiles may also in this way be fixed by moulding and form a homogenous unit with the filling. The weight per volume of the product when ready may be varied within an interval of at least 20-50 kg/m3. This may be made use of by that separate channels or sections within a cover are filled to different weight per volume when manufacturing for example cushioning for vehicle seats, where a softer middle section forms the back and/or seat and more firm side sections form supporting cushions at the sides of the back and/or the seat.

Claims (9)

  1. Method and means by the manufacture of shaped cushions or filling material for furniture and seats whereby a filler material being a wad is filled into an enclosing cover characterized in that the cover contains fibres from a material having a lower melting point than the wad.
  2. Method according to claim 1 characterized in that the cover is entirely made from fibres having a lower melting point than the wad.
  3. Method according to claim 1 or 2 characterized in that the cover includes fibres having a melting point below 100 °C.
  4. Method according to any of the preceding claims characterized in that the cover is filled with wad using vacuum and then is put into a mould and treated by through flowing hot air.
  5. Method according to claim 4 characterized in that the temperature of the air is 120-170 °C, preferably about 135 °C.
  6. Method according to any of the preceeding claims characterized in that that the wad comprises fibres having two different melting points.
  7. Method according to any of the preceeding claims characterized in that the mould and the material inside it after the filling is heated so that the fibres having low melting point are melted.
  8. Cover for making cushions and other shaped furniture filling using the method of any of the preceding claims characterized in that the cover comprises polyester fibres having a melting point below 100 °C.
  9. Cover according to claim 8 characterized in that it is divided into several separate sections which are intended to be filled with different materials and/or different packing density.
EP01850069A 2000-10-11 2001-04-18 Method and means for production of shaped cushions and upholstery Withdrawn EP1199392A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0003663A SE515814C2 (en) 2000-10-11 2000-10-11 Methods and means for the manufacture of shaped pillows with cases
SE0003663 2000-10-11

Publications (1)

Publication Number Publication Date
EP1199392A1 true EP1199392A1 (en) 2002-04-24

Family

ID=20281369

Family Applications (1)

Application Number Title Priority Date Filing Date
EP01850069A Withdrawn EP1199392A1 (en) 2000-10-11 2001-04-18 Method and means for production of shaped cushions and upholstery

Country Status (3)

Country Link
EP (1) EP1199392A1 (en)
NO (1) NO20011984L (en)
SE (1) SE515814C2 (en)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4276346A (en) * 1975-04-24 1981-06-30 Imperial Chemical Industries Limited Thermoplastics articles having a surface fused to cloth
EP0344365A2 (en) * 1988-05-28 1989-12-06 Johann Borgers GmbH. & Co. KG Padded member for seating and lying furniture or the like
EP0447090A1 (en) * 1990-03-05 1991-09-18 JOHNSON & JOHNSON INC. Three dimensional non-woven fabric
JPH0810467A (en) * 1994-06-28 1996-01-16 Bridgestone Corp Automotive interior material and production thereof
EP0707820A1 (en) * 1994-10-17 1996-04-24 Hoover Universal,Inc. Process for forming multiple density body from fibrous polymeric material
US5942175A (en) * 1994-07-13 1999-08-24 E. I. Du Pont De Nemours And Company Fiber clusters molding process and equipment
US5951798A (en) * 1995-09-18 1999-09-14 Mercedes-Benz Ag Process for producing a multi-layer web as an upholstery covering material
US6003579A (en) * 1996-03-25 1999-12-21 Lear Corporation Apparatus for bonding a cover material to foam
JP2000037577A (en) * 1998-07-21 2000-02-08 Araco Corp Sheet and its manufacturing method

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4276346A (en) * 1975-04-24 1981-06-30 Imperial Chemical Industries Limited Thermoplastics articles having a surface fused to cloth
EP0344365A2 (en) * 1988-05-28 1989-12-06 Johann Borgers GmbH. & Co. KG Padded member for seating and lying furniture or the like
EP0447090A1 (en) * 1990-03-05 1991-09-18 JOHNSON & JOHNSON INC. Three dimensional non-woven fabric
JPH0810467A (en) * 1994-06-28 1996-01-16 Bridgestone Corp Automotive interior material and production thereof
US5942175A (en) * 1994-07-13 1999-08-24 E. I. Du Pont De Nemours And Company Fiber clusters molding process and equipment
EP0707820A1 (en) * 1994-10-17 1996-04-24 Hoover Universal,Inc. Process for forming multiple density body from fibrous polymeric material
US5951798A (en) * 1995-09-18 1999-09-14 Mercedes-Benz Ag Process for producing a multi-layer web as an upholstery covering material
US6003579A (en) * 1996-03-25 1999-12-21 Lear Corporation Apparatus for bonding a cover material to foam
JP2000037577A (en) * 1998-07-21 2000-02-08 Araco Corp Sheet and its manufacturing method

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 1996, no. 05 31 May 1996 (1996-05-31) *
PATENT ABSTRACTS OF JAPAN vol. 2000, no. 05 14 September 2000 (2000-09-14) *

Also Published As

Publication number Publication date
SE0003663L (en) 2001-10-15
SE515814C2 (en) 2001-10-15
NO20011984D0 (en) 2001-04-23
NO20011984L (en) 2002-04-12
SE0003663D0 (en) 2000-10-11

Similar Documents

Publication Publication Date Title
US4726086A (en) Composite foam seat cushion and method of preparation
CN113930900B (en) A thermoplastic fiber net structure and automotive interior parts
US6063461A (en) Multi-density seating cushion
US4405681A (en) Foam article and method of preparation
US7216936B2 (en) Cushion construction for seating unit
US5801211A (en) Resilient fiber mass and method
CA1141042A (en) Seat cushions
US20070001336A1 (en) Cushion material formed of spring-structured resin-molded product, manufacturing method for the cushion material, and mold used for the manufacturing method
US20140053341A1 (en) Foam fiber structure and method of making same
JP2002061059A (en) Spring-structured resin molded product and method of manufacturing the same
JPH0861414A (en) Cushion body and manufacture therefor
US3894973A (en) Use of pneumacel in rebonded structures comprising polyurethane scrap
US4014826A (en) Process for preparing rebonded foam structures
US20030026970A1 (en) Method of manufacturing a soft trim assembly and resultant article
AU595346B2 (en) Process for preparing polyurethane foams having zones of different hardness
EP1199392A1 (en) Method and means for production of shaped cushions and upholstery
DE69110127T2 (en) METHOD FOR PRODUCING A PADDED ELEMENT.
EP0228350A2 (en) Items composed of a steel frame with steel springs, behaving as elastic support, for the manufacturing of mattresses and cushions
US2932121A (en) Welding materials and upholstered or other fabric structures comprising same
RU2342895C2 (en) Method for manufacture of cushioning material from molded polymer product (versions) and cushioning material (versions)
EP1170170A1 (en) An upholstery item for a motor vehicle
US4989916A (en) Upholstered article of furniture
JPH05269264A (en) Molded body for sheet and manufacturing method thereof
CA2512592A1 (en) Textile mat and cushion made thereof and a method of making a cushion
US20250121567A1 (en) Self-rising board molding

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LI LU MC NL PT SE TR

AX Request for extension of the european patent

Free format text: AL;LT;LV;MK;RO;SI

17P Request for examination filed

Effective date: 20021024

AKX Designation fees paid

Free format text: AT BE CH CY DE DK ES FI FR GB GR IE IT LI LU MC NL PT SE TR

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

RTI1 Title (correction)

Free format text: METHOD FOR PRODUCTION OF SHAPED CUSHIONS AND UPHOLSTERY

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

GRAJ Information related to disapproval of communication of intention to grant by the applicant or resumption of examination proceedings by the epo deleted

Free format text: ORIGINAL CODE: EPIDOSDIGR1

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 20081101