EP1421878B1 - Moulded body, expecially cushions - Google Patents

Moulded body, expecially cushions Download PDF

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Publication number
EP1421878B1
EP1421878B1 EP03019425A EP03019425A EP1421878B1 EP 1421878 B1 EP1421878 B1 EP 1421878B1 EP 03019425 A EP03019425 A EP 03019425A EP 03019425 A EP03019425 A EP 03019425A EP 1421878 B1 EP1421878 B1 EP 1421878B1
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EP
European Patent Office
Prior art keywords
shaped body
body according
gel
layer
polyurethane
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.)
Expired - Lifetime
Application number
EP03019425A
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German (de)
French (fr)
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EP1421878A1 (en
Inventor
Adolf Stender
Peter Dr. Gansen
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Technogel GmbH and Co KG
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Technogel GmbH and Co KG
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Publication of EP1421878A1 publication Critical patent/EP1421878A1/en
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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/021—Detachable or loose seat cushions
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/08—Fluid mattresses or cushions
    • A47C27/085—Fluid mattresses or cushions of liquid type, e.g. filled with water or gel
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/08—Fluid mattresses or cushions
    • A47C27/086—Fluid mattresses or cushions with fluid-like particles, e.g. filled with beads
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
    • A47C27/144—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/18—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays in combination with inflatable bodies
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/20—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in foamed material
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/006—Use of three-dimensional fabrics
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61G—TRANSPORT, PERSONAL CONVEYANCES, OR ACCOMMODATION SPECIALLY ADAPTED FOR PATIENTS OR DISABLED PERSONS; OPERATING TABLES OR CHAIRS; CHAIRS FOR DENTISTRY; FUNERAL DEVICES
    • A61G5/00—Chairs or personal conveyances specially adapted for patients or disabled persons, e.g. wheelchairs
    • A61G5/10—Parts, details or accessories
    • A61G5/1043—Cushions specially adapted for wheelchairs
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61G—TRANSPORT, PERSONAL CONVEYANCES, OR ACCOMMODATION SPECIALLY ADAPTED FOR PATIENTS OR DISABLED PERSONS; OPERATING TABLES OR CHAIRS; CHAIRS FOR DENTISTRY; FUNERAL DEVICES
    • A61G5/00—Chairs or personal conveyances specially adapted for patients or disabled persons, e.g. wheelchairs
    • A61G5/10—Parts, details or accessories
    • A61G5/1043—Cushions specially adapted for wheelchairs
    • A61G5/1045—Cushions specially adapted for wheelchairs for the seat portion
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61G—TRANSPORT, PERSONAL CONVEYANCES, OR ACCOMMODATION SPECIALLY ADAPTED FOR PATIENTS OR DISABLED PERSONS; OPERATING TABLES OR CHAIRS; CHAIRS FOR DENTISTRY; FUNERAL DEVICES
    • A61G7/00—Beds specially adapted for nursing; Devices for lifting patients or disabled persons
    • A61G7/05—Parts, details or accessories of beds
    • A61G7/057—Arrangements for preventing bed-sores or for supporting patients with burns, e.g. mattresses specially adapted therefor
    • A61G7/05738—Arrangements for preventing bed-sores or for supporting patients with burns, e.g. mattresses specially adapted therefor with fluid-like particles, e.g. sand, mud, seeds, gel, beads

Definitions

  • the invention relates to a shaped body, in particular for a seat cushion.
  • the invention has for its object to make such a shaped body so that it can be used in particular for a seat cushion and here leads to a high level of comfort compared to conventional seat cushion reduced height and generally for the seating area (armrests, back cushion, neck pillow) and in particular for the vehicle sector can be used, in which a reduction in the height is particularly advantageous, as a result, a higher installation space for technical installations can be created under the vehicle seat.
  • the support in the region of the pressure peaks occurring under load have a closer distance from each other, wherein the support may be preferably formed columnar.
  • the upper support is a Abstandgewirk consisting of two interconnected by spacer threads textile surfaces.
  • the known spacer fabric is composed of a fabric base, a fabric side and from this connecting guide bars.
  • the properties of a spacer knit are essentially influenced by the binding structures, ie the integration of the threads in the surface, the stitch density and the thread thickness. Due to their 3D structure, spacer fabrics offer many technical advantages such as air permeability, low weight, good resilience, shock absorption, heat circulation, recyclability, grade purity and good ductility.
  • the gel layer consists of a polyurethane gel whose chemical structure may consist of long polymer threads and only a few links without added plasticizer.
  • the polyol component for the preparation of the gel from one or more polyols having a molecular weight between 1000 and 12000 and an OH number between 20 and 112, wherein the product of the functionalities of the polyurethane-forming components is at least 5 and the isocyanate Code is between 15 and 60.
  • isocyanates for gel preparation those of the formula Q (NCO) in which n is 2 to 4 and Q is an aliphatic hydrocarbon radical having 8 to 18 carbon atoms, a cycloaliphatic hydrocarbon radical having 4 to 15 carbon atoms. Atoms, an aromatic hydrocarbon radical having 6 to 15 carbon atoms or an araliphatic hydrocarbon radical having 8 to 15 carbon atoms, and when the polyurethane is prepared with isocyanates in pure form or with urethanized, allophanised, biuretized or functionally correspondingly modified isocyanates.
  • the patent EP 57 838 claims gels for the prevention of bedsores, which are characterized by a low characteristic, that is by so-called sub-crosslinking. They are prepared by reacting a polyisocyanate with long-chain polyols, which should be free of short-chain fractions. These dimensionally stable gels made of polyurethane raw materials can be used as mattresses, mattress inserts, automobile seats and as upholstery material.
  • the patent EP 511 570 discloses improved gels of polyols and isocyanates with low characteristic numbers, which are prepared from mixtures of long-chain and short-chain polyethers.
  • the processing technology to produce cheaper Polyol and Polyiscyanatgemische find preferred use as upholstery material in the footwear industry, as editions to prevent or prevent injuries, face masks, as padding of horse saddles and in other applications.
  • the known polyol and isocyanate mixtures always have the disadvantage of the high own weight and the associated high heat capacity for the applications exemplified above. Due to the high weight of about 1.0 g / cm 3 , the use is limited to applications in which the weight plays a minor role in relation to the excellent pressure-distributing properties. In addition, the high heat capacity of the polyurethane gel in direct body contact can be perceived as unpleasant, since body heat to warm up the respective gel masses is clearly removed from the body.
  • the patent DE 43 08 445 A1 mentions various processes and patents (EP-B 0 057 839, WO-88/01878, EP 0 453 286) for the production of gel foams with air, nitrogen and carbon dioxide.
  • the reduction of the specific weight and the associated reduction of the heat capacity are achieved to the desired extent, but the gels have the disadvantage that the cells formed under compressive stress on the cell inner walls due to the very high self-adhesive behavior of always undercrosslinked reaction products based on polyols and polyisocyanates ,
  • the cells are a weakening of the gel matrix, which has a negative effect on the mechanical properties, such as elongation at break and tensile strength.
  • a cellular gel returns more slowly to its original position after loading.
  • shrinkage problems can occur, as they are known from the processing of polyurethane foams.
  • Another disadvantage of the polyurethane gels described is the single-seat behavior. Especially at the first contact, a gel cushion is often felt to be hard, because only with a time delay, the gel flows or flowed into the desired position guaranteeing an optimal pressure distribution.
  • a gel mass that provides a significant reduction in weight, heat capacity and seating comfort while retaining typical gel properties, such as The inclusion of shear forces makes possible a significant technical improvement.
  • the gel masses to be used for the gel layer according to the invention should avoid the above-mentioned disadvantages and combine the typical advantageous gel properties with a low specific weight of an overall lower thermal conductivity as well as good durability and permanently consistent utility model properties. It is therefore advantageous if the gel layer contains elastic hollow microspheres as filler, wherein the hollow microspheres consist of polymeric material, preferably polyolefin, and are coated with a cover layer of an inorganic material, preferably calcium carbonate.
  • the hollow microspheres have a diameter of 10 .mu.m to 150 .mu.m, and if the proportion of Mikrohohokugeln in the gel material is 0.1 to 10 wt .-%.
  • the seating comfort can be improved by distributing coarse-grained solid particles in the gel mass, which consist of cork pieces, cork flour, pieces of wood, wood chips, foam flocks, polystyrene, textile fibers or textile pieces whose diameter is preferably between 0.1 mm and 15 mm.
  • Figure 1 shows in cross-section serving in particular as a seat cushion molding, with a lower, supporting, a lower support surface 1 forming, consisting of a polyurethane gel gel layer 2, on their upper side integral, spaced from each other via expansion channels 4 supports 3, on which a polyurethane foam layer 6 rests, the top 5 is covered by an upper support 7.
  • the integral projections 6a of the polyurethane foam layer 6 extend up to the base 8 of the expansion channels and can be supported thereon. Furthermore, FIG. 3 shows that the polyurethane foam layer 6 fully encloses the gel layer 2 laterally.
  • Figure 4 shows a further modified embodiment, which is a quasi combination of the embodiments according to Figures 1 and 3. Because here are on the one hand expansion channels 4 are provided, which are free of lower approaches of the polyurethane foam layer 6, but immersed with integral lugs 6a in expansion channels lesser depth and smaller cross-section, with these lugs 6a can be supported on the floor 8 of these expansion channels.
  • the gel layer 2 can be glued after removal of a film produced together with her with the polyurethane foam layer 6.
  • the Polyurthan foam layer could also be glued over an applied adhesive to the supports of the gel layer.
  • the upper support 7 is a spacer fabric, which consists of two interconnected by spacer threads textile surfaces.
  • the main advantages of the molding according to the invention can be seen in the increased seating comfort with reduced height, the favorable ventilation properties, the good pressure distribution, a soft Einsitz and in the reduced weight in comparison with a pure gel seat.

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  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Laminated Bodies (AREA)
  • Chair Legs, Seat Parts, And Backrests (AREA)

Abstract

A molded article, preferably a seat cushion, comprises a lower bearing surface (1), a gel layer (2), comprising a polyurethane gel, having integral supports (3) separated from each other by extending channels (4), upon which a polyurethane foam layer (6) lies, whose upper face (5) is covered by an outer covering (7).

Description

Die Erfindung betrifft einen Formkörper, insbesondere für ein Sitzpolster.The invention relates to a shaped body, in particular for a seat cushion.

Der Erfindung liegt die Aufgabe zugrunde, einen derartigen Formkörper so zu gestalten, dass er sich insbesondere für ein Sitzpolster verwenden lässt und hier zu einem hohen Sitzkomfort bei gegenüber herkömmlichen Sitzpolstern verringerter Bauhöhe führt und der sich generell für den Sitzmöbelbereich (Armauflagen, Rükkenkissen, Nackenkissen) und insbesondere auch für den Fahrzeugbereich einsetzen lässt, bei denen eine Verringerung der Bauhöhe besonders vorteilhaft ist, da hierdurch unter dem Fahrzeugsitz ein höherer Einbauraum für technische Einbauten geschaffen werden kann.The invention has for its object to make such a shaped body so that it can be used in particular for a seat cushion and here leads to a high level of comfort compared to conventional seat cushion reduced height and generally for the seating area (armrests, back cushion, neck pillow) and in particular for the vehicle sector can be used, in which a reduction in the height is particularly advantageous, as a result, a higher installation space for technical installations can be created under the vehicle seat.

Diese Aufgabe wird in ihrer allgemeinsten Form erfindungsgemäß gelöst durch einen Formkörper mit den Merkmalen des Anspruchs 1.This object is achieved according to the invention in its most general form by a shaped body having the features of claim 1.

Dabei ist es zweckmäßig, wenn die Auflage im Bereich der bei Belastung auftretenden Druckspitzen einen engeren Abstand voneinander aufweisen, wobei die Auflage vorzugsweise säulenförmig ausgebildet sein können.It is expedient if the support in the region of the pressure peaks occurring under load have a closer distance from each other, wherein the support may be preferably formed columnar.

Aus Belüftungszwecken ist es vorteilhaft, wenn die obere Auflage ein Abstandsgewirk ist, das aus zwei durch Abstandsfäden miteinander verbundenen textilen Flächen besteht. Das an sich bekannte Abstandsgewirk setzt sich zusammen aus einer Warengrunde, einer Warenseite und aus diese miteinander verbindende Legebarren. Die Eigenschaften eines Abstandsgewirkes werden im Wesentlichen von den Bindungsstrukturen, also der Einbindung der Fäden in die Fläche, der Maschendichte sowie der Fadenstärke beeinflusst. Durch ihre 3D-Struktur bieten Abstandsgewirke viele technische Vorteile wie Luftdurchlässigkeit, geringes Gewicht, gutes Rückstellverhalten, Schockabsorption, Wärmezirkulation, Recyclingfähigkeit, Sortenreinheit und gute Verformbarkeit.For ventilation purposes, it is advantageous if the upper support is a Abstandgewirk consisting of two interconnected by spacer threads textile surfaces. The known spacer fabric is composed of a fabric base, a fabric side and from this connecting guide bars. The properties of a spacer knit are essentially influenced by the binding structures, ie the integration of the threads in the surface, the stitch density and the thread thickness. Due to their 3D structure, spacer fabrics offer many technical advantages such as air permeability, low weight, good resilience, shock absorption, heat circulation, recyclability, grade purity and good ductility.

Hinsicht spezieller Ausführungsformen der Polyurethan-Schauinstofflage sowie ihrer Verbindung mit der Gellage wird auf die Gegenstände der Ansprüche 6 bis 10 verwiesen.With regard to specific embodiments of the polyurethane Schauinstofflage and their connection with the gel layer is made to the subject matter of claims 6 to 10.

Erfindungsgemäß besteht die Gellage aus einem Polyurethan-Gel, dessen chemische Struktur aus langen Polymer-Fäden und nur wenigen Verkettungen ohne Verwendung zugesetzter Weichmacher bestehen kann.According to the invention, the gel layer consists of a polyurethane gel whose chemical structure may consist of long polymer threads and only a few links without added plasticizer.

Es ist aber möglich, dass für das Gel ein untervernetztes Polyurethan auf der Basis von Polyolen und Polyisocyanaten oder Polyethern und Polyisocyanaten eingesetzt wird.However, it is possible that an undercrosslinked polyurethane based on polyols and polyisocyanates or polyethers and polyisocyanates is used for the gel.

Erfindungsgemäß ist es zweckmundßig, wenn die Gelmassen mit Rohstoffen bei denen das Produkt der Isocyanat-Funktionalität und der Funktionalität der Polyolkomponente mindestens 5,2, vorzugsweise mindestens 6,5, insbesondere mindestens 7,5 beträgt, hergestellt werden.According to the invention it is zweckmundssig when the gel masses with raw materials in which the product of the isocyanate functionality and the functionality of the polyol is at least 5.2, preferably at least 6.5, in particular at least 7.5, are prepared.

Dabei ist es vorteilhaft, wenn die Polyolkomponente zur Herstellung des Gels aus einem Gemisch aus

  • a) einem oder mehreren Polyolen mit Hydroxylzahlen unter 112 und
  • b) einem oder mehreren Polyolen mit Hydroxyzahlen im Bereich von 112 bis 600 besteht,

wobei das Gewichtsverhältnis der Komponente a) zu Komponente b) zwischen 90:10 und 10:90 liegt, die Isocyanat-Kennzahl des Reaktionsgemisches im Bereich von 15 und 60 liegt und das Produkt aus Isocyanat-Funktionalität und Funktionalität der Polyolkomponente mindestens 6 beträgt.It is advantageous if the polyol component for the preparation of the gel from a mixture of
  • a) one or more polyols having hydroxyl numbers below 112 and
  • b) one or more polyols having hydroxyl numbers ranging from 112 to 600,

wherein the weight ratio of component a) to component b) is between 90:10 and 10:90, the isocyanate index of the reaction mixture in the range of 15 and 60 and the product of isocyanate functionality and functionality of the polyol component is at least 6.

Als Alternativlösung kann vorgesehen sein, dass die Polyolkomponente zur Herstellung des Gels aus einem oder mehreren Polyolen mit einem Molekulargewicht zwischen 1000 und 12000 und einer OH-Zahl zwischen 20 und 112 besteht, wobei das Produkt der Funktionalitäten der polyurethanbildenden Komponenten mindestens 5 beträgt und die Isoeyanat-Kennzahl zwischen 15 und 60 liegt.As an alternative solution it can be provided that the polyol component for the preparation of the gel from one or more polyols having a molecular weight between 1000 and 12000 and an OH number between 20 and 112, wherein the product of the functionalities of the polyurethane-forming components is at least 5 and the isocyanate Code is between 15 and 60.

Schließlich ist es vorteilhaft, wenn man als Isocyanate zur Gelherstellung solche der Formel Q (NCO) einsetzt, in der n für 2 bis 4 steht und Q einen aliphatischen Kohlenwasserstoffrest mit 8 bis 18 C-Atomen, einen cycloaliphatischen Kohlenwasserstoffrest mit 4 bis 15 C-Atomen, einen aromatischen Kohlenwasserstoffrest mit 6 bis 15 C-Atomen oder einen araliphatischen Kohlenwasserstoffrest mit 8 bis 15 C-Atomen bedeutet, und wenn das Polyurethan mit lsocyanaten in reiner Form oder mit urethanisierten, allophanisierten, biurethisierten oder funktionell entsprechend modifizierten Isocyanaten hergestellt ist.Finally, it is advantageous to use as isocyanates for gel preparation those of the formula Q (NCO) in which n is 2 to 4 and Q is an aliphatic hydrocarbon radical having 8 to 18 carbon atoms, a cycloaliphatic hydrocarbon radical having 4 to 15 carbon atoms. Atoms, an aromatic hydrocarbon radical having 6 to 15 carbon atoms or an araliphatic hydrocarbon radical having 8 to 15 carbon atoms, and when the polyurethane is prepared with isocyanates in pure form or with urethanized, allophanised, biuretized or functionally correspondingly modified isocyanates.

Das Patent EP 57 838 beansprucht Gele zur Vermeidung von Dekubitus, welche durch eine niedrige Kennzahl, das heißt durch sogenannte Untervernetzung gekennzeichnet sind. Sie werden durch Umsetzung eines Polyisocyanates mit langkettigen Polyolen, die frei von kurzkettigen Anteilen sein sollen, hergestellt. Diese formstabilen Gele aus Polyurethan-Rohstoffen können als Matratzen, Matratzeneinlagen, Automobilsitze und als Polstermaterial zum Einsatz kommen. Das Patent EP 511 570 offenbart verbesserte Gele aus Polyolen und Isocyanaten mit niedrigen Kennzahlen, die aus Gemischen von langkettigen und kurkettigen Polyethern hergestellt werden. Die verarbeitungstechnisch günstiger herzustellen Polyol- und Polyiscyanatgemische finden bevorzugte Anwendung als Polstermaterial in der Schuhindustrie, als Auflagen zur Vermeidung von bzw. Verhinderung von Verletzungen, Gesichtsmasken, als Abpolsterungen von Pferdesätteln sowie in weiteren Anwendungen.The patent EP 57 838 claims gels for the prevention of bedsores, which are characterized by a low characteristic, that is by so-called sub-crosslinking. They are prepared by reacting a polyisocyanate with long-chain polyols, which should be free of short-chain fractions. These dimensionally stable gels made of polyurethane raw materials can be used as mattresses, mattress inserts, automobile seats and as upholstery material. The patent EP 511 570 discloses improved gels of polyols and isocyanates with low characteristic numbers, which are prepared from mixtures of long-chain and short-chain polyethers. The processing technology to produce cheaper Polyol and Polyiscyanatgemische find preferred use as upholstery material in the footwear industry, as editions to prevent or prevent injuries, face masks, as padding of horse saddles and in other applications.

Die bekannten Polyol- und Isocyanatgemische weisen für die oben beispielhaft genannten Anwendungen stets den Nachteil des hohen Eigengewichtes und die damit verbundene hohe Wärmekapazität auf. Aufgrund des hohen Eigengewichtes von etwa 1,0 g/cm3 ist der Einsatz auf Anwednungen beschränkt, bei denen das Gewicht in Relation zu den hervorragenden druckverteilenden Eigenschaften eine untergeordnete Rolle spielt. Darüber hinaus kann die hohe Wärmekapazität des Polyurethan-Gels im direkten Körperkontakt als unangenehm empfunden werden, da Körperwärme zum Aufwärmen der jeweiligen Gelmassen deutlich wahrnehmbar dem Körper entzogen wird.The known polyol and isocyanate mixtures always have the disadvantage of the high own weight and the associated high heat capacity for the applications exemplified above. Due to the high weight of about 1.0 g / cm 3 , the use is limited to applications in which the weight plays a minor role in relation to the excellent pressure-distributing properties. In addition, the high heat capacity of the polyurethane gel in direct body contact can be perceived as unpleasant, since body heat to warm up the respective gel masses is clearly removed from the body.

Im Patent DE 43 08 445 A1 werden verschiedene Verfahren bzw. Patentschriften (EP-B 0 057 839; WO-88/01878; EP 0 453 286) zur Herstellung von Gelschäumen mit Luft, Stickstoff und Kohlendioxid genannt. Die Reduzierung des spezifischen Gewichts und damit verbundene Verringerung der Wärmekapazität sind im gewünschten Maße erreicht, die Gele weisen aber den Nachteil auf, dass die gebildeten Zellen bei Druckbeanspruchung an den Zellinnenwänden aufgrund des sehr hohen Selbstklebeverhaltens der stets untervernetzten Reaktionsprodukte auf Basis von Polyolen und Polyisocyanaten verkleben. Darüber hinaus stellen die Zellen eine Schwächung der Gelmatrix dar, die sich negativ auf die mechanischen Eigenschaften, wie Bruchdehnung und Zugfestigkeit auswirkt. Auch kehrt ein zelliges Gel nach Belastung langsamer in seine Ausgangsposition zurück. Des Weiteren können Schrumpfprobleme auftreten, wie sie aus der Verarbeitung von Polyurethanschaumstoffen bekannt sind.The patent DE 43 08 445 A1 mentions various processes and patents (EP-B 0 057 839, WO-88/01878, EP 0 453 286) for the production of gel foams with air, nitrogen and carbon dioxide. The reduction of the specific weight and the associated reduction of the heat capacity are achieved to the desired extent, but the gels have the disadvantage that the cells formed under compressive stress on the cell inner walls due to the very high self-adhesive behavior of always undercrosslinked reaction products based on polyols and polyisocyanates , In addition, the cells are a weakening of the gel matrix, which has a negative effect on the mechanical properties, such as elongation at break and tensile strength. Also, a cellular gel returns more slowly to its original position after loading. Furthermore, shrinkage problems can occur, as they are known from the processing of polyurethane foams.

Ein weiterer Nachteil der beschriebenen Polyurethan-Gele ist das Einsitzverhalten. Insbesondere beim ersten Kontakt wird ein Gel-Kissen häufig als hart empfunden, weil erst mit einer Zeitverzögerung das Gel in die gewünschte eine optimale Druckverteilung garantierende Position fließt bzw. geflossen ist.Another disadvantage of the polyurethane gels described is the single-seat behavior. Especially at the first contact, a gel cushion is often felt to be hard, because only with a time delay, the gel flows or flowed into the desired position guaranteeing an optimal pressure distribution.

Eine Gelmasse, die eine deutliche Reduzierung des Gewichtes, der Wärmekapazität und des Einsitzkomforts unter Beibehaltung der typischen Geleigenschaften, wie z.B. der Aufnahme von Scherkräften möglich macht, bedeutet eine deutliche technische Verbesserung.A gel mass that provides a significant reduction in weight, heat capacity and seating comfort while retaining typical gel properties, such as The inclusion of shear forces makes possible a significant technical improvement.

Die für die erfindungsgemäß vorgesehene Gellage zu verwendenden Gelmassen sollten die vorstehend genannten Nachteile vermeiden und die typischen vorteilhaften Geleigenschaften mit einem niedrigen spezifischen Gewicht einer insgesamt niedrigeren Wärmeleitfähigkeit sowie guter Haltbarkeit und dauerhaft gleich bleibenden Gebrauchsmustereigenschaften verbinden. Es ist daher vorteilhaft, wenn die Gellage elastische Mikrohohlkugeln als Füllstoff enthält, wobei die Mikrohohlkugeln aus polymerem Material, vorzugsweise Polyolefin bestehen und mit einer Deckschicht aus einem anorganischen Material, vorzugsweise Calciumkarbonat, beschichtet sind.The gel masses to be used for the gel layer according to the invention should avoid the above-mentioned disadvantages and combine the typical advantageous gel properties with a low specific weight of an overall lower thermal conductivity as well as good durability and permanently consistent utility model properties. It is therefore advantageous if the gel layer contains elastic hollow microspheres as filler, wherein the hollow microspheres consist of polymeric material, preferably polyolefin, and are coated with a cover layer of an inorganic material, preferably calcium carbonate.

Es ist vorteilhaft, wenn die Mikrohohlkugeln einen Durchmesser von 10 µm bis 150 µm besitzen, und wenn der Anteil der Mikrohohokugeln in dem Gelwerkstoff 0,1 - 10 Gew.-% beträgt.It is advantageous if the hollow microspheres have a diameter of 10 .mu.m to 150 .mu.m, and if the proportion of Mikrohohokugeln in the gel material is 0.1 to 10 wt .-%.

Der Sitzkomfort lässt sich insgesamt noch dadurch verbessern, dass in der Gelmasse grobkörnige Feststoffteilchen verteilt sind, die aus Korkstückchen, Korkmehl, Holzstückchen, Holzspänen, Schaumstoffflocken, Styropor, Textilfasern oder Textilstücken bestehen, deren Durchmesser vorzugsweise zwischen 0,1 mm und 15 mm liegt.Overall, the seating comfort can be improved by distributing coarse-grained solid particles in the gel mass, which consist of cork pieces, cork flour, pieces of wood, wood chips, foam flocks, polystyrene, textile fibers or textile pieces whose diameter is preferably between 0.1 mm and 15 mm.

Erfindungsgemäß wird der Einsitz-Komfort durch die obenliegende Polyurethan-Schaumstofflage wesentlich verbessert.According to the seat comfort is substantially improved by the overhead polyurethane foam layer.

In der Zeichnung sind einige als Beispiele dienende Ausführungsformen der Erfindung dargestellt. Es zeigen:

Figur 1 -
im Querschnitt einen Formkörper mit einer unteren Gellage und einer oberen Schaumstofflage;
Figur 2 -
in einer Darstellung gemäß Figur 1 eine mit unteren Ansätzen in Ausdehungskanäle der Gellager eintauchende Schaumstofflage;
Figur 3 -
in einer Darstellung gemäß Figur 2 eine die Gellage seitlich einfassende Schaumstofflage, deren untere Ansätze sich bis auf den Boden der Ausdehnungskanäle erstrecken; und
Figur 4 -
in einer Darstellung gemäß Figur 2 eine untere Gellage mit unterschiedlich gestalteten Ausdehnungskanälen.
In the drawing, some exemplary embodiments of the invention are shown. Show it:
FIG. 1 -
in cross section a molded body with a lower gel layer and an upper foam layer;
FIG. 2 -
in a representation according to FIG. 1, a foam layer dipping with lower lugs into expansion channels of the gel bearings;
FIG. 3 -
in a representation according to FIG. 2, a foam layer which laterally surrounds the gel layer and whose lower extensions extend as far as the bottom of the expansion channels; and
FIG. 4 -
in a representation according to Figure 2, a lower gel layer with differently shaped expansion channels.

Figur 1 zeigt im Querschnitt einen insbesondere als Sitzpolster dienenden Formkörper, mit einer unteren, tragenden, eine untere Auflagefläche 1 bildenden, aus einem Polyurethan-Gel bestehenden Gellage 2, die auf ihrer Oberseite integrale, voneinander über Ausdehnungskanäle 4 beabstandete Auflager 3 aufweist, auf denen eine Polyurethan-Schaumstofflage 6 aufliegt, deren Oberseite 5 durch eine obere Auflage 7 abgedeckt ist.Figure 1 shows in cross-section serving in particular as a seat cushion molding, with a lower, supporting, a lower support surface 1 forming, consisting of a polyurethane gel gel layer 2, on their upper side integral, spaced from each other via expansion channels 4 supports 3, on which a polyurethane foam layer 6 rests, the top 5 is covered by an upper support 7.

Bei der in Figur 2 dargestellten abgewandelten Ausführungsform weist die Polyurethan-Schaumsttifflage 6 auf ihrer Unterseite integrale Ansätze 6a auf, die in die Ausdehnungskanäle 4 der Gellage 2 eintauchen.In the modified embodiment shown in Figure 2, the polyurethane Schaumsttifflage 6 on its underside integral lugs 6a, which dive into the expansion channels 4 of the gel layer 2.

Bei der Ausführungsform gemäß Figur 3 erstrecken sich die integralen Ansätze 6a der Polyurethan-Schaumstofflage 6 bis auf den Boden 8 der Ausdehnungskanäle und können sich auf diesen abstützen. Ferner zeigt Figur 3, dass die Polyurethan-Schaumstofflage 6 die Gellage 2 seitlich vollständig einfasst.In the embodiment according to FIG. 3, the integral projections 6a of the polyurethane foam layer 6 extend up to the base 8 of the expansion channels and can be supported thereon. Furthermore, FIG. 3 shows that the polyurethane foam layer 6 fully encloses the gel layer 2 laterally.

Figur 4 zeigt eine weiterhin abgewandelte Ausführungsform, die quasi eine Kombination der Ausführungsformen gemäß den Figuren 1 und 3 darstellt. Denn hier sind einerseits Ausdehnungskanäle 4 vorgesehen, die frei von unteren Ansätzen der Polyurethan-Schaumstofflage 6 sind, die aber mit integralen Ansätzen 6a in Ausdehnungskanäle geringerer Tiefe und kleineren Querschnitts eintaucht, wobei sich diese Ansätze 6a auf dem Boden 8 dieser Ausdehnungskanäle abstützen können.Figure 4 shows a further modified embodiment, which is a quasi combination of the embodiments according to Figures 1 and 3. Because here are on the one hand expansion channels 4 are provided, which are free of lower approaches of the polyurethane foam layer 6, but immersed with integral lugs 6a in expansion channels lesser depth and smaller cross-section, with these lugs 6a can be supported on the floor 8 of these expansion channels.

Die Gellage 2 kann nach Abziehen einer zusammen mit ihr hergestellten Folie mit der Polyurethan-Schaumstofflage 6 verklebt sein. Alternativ könnte die Polyurthan-Schaumstofflage auch über einen aufgetragenen Kleber mit den Auflagern der Gellage verklebt sein.The gel layer 2 can be glued after removal of a film produced together with her with the polyurethane foam layer 6. Alternatively, the Polyurthan foam layer could also be glued over an applied adhesive to the supports of the gel layer.

Bei allen Ausführungsformen ist die obere Auflage 7 ein Abstandsgewirk, das aus zwei durch Abstandsfäden miteinander verbundenen textilen Flächen besteht.In all embodiments, the upper support 7 is a spacer fabric, which consists of two interconnected by spacer threads textile surfaces.

Die wesentlichen Vorteile des erfindungsgemäßen Formkörpers sind zu sehen in dem erhöhten Sitzkomfort bei verringerter Bauhöhe, den günstigen Belüftungseigenschaften, der guten Druckverteilung, einem weichen Einsitzverhalten und in dem reduzierten Gewicht im Vergleich mit einem reinen Gelsitz.The main advantages of the molding according to the invention can be seen in the increased seating comfort with reduced height, the favorable ventilation properties, the good pressure distribution, a soft Einsitzverhalten and in the reduced weight in comparison with a pure gel seat.

Claims (24)

  1. Shaped body, in particular for a seat cushion, having a lower, supporting gel layer (2) which forms a lower covering surface (1), consists of a polyurethane gel and, on its upper side, has integral supports (3) which are spaced apart from one another via expansion channels (4) and on which a polyurethane foam layer (6) rests, the upper side (5) of which layer is covered by an upper covering (7).
  2. Shaped body according to Claim 1, characterized in that the supports (3) are at a narrower distance from one another in the region of the pressure peaks which occur under load.
  3. Shaped body according to Claim 1 or 2, characterized in that the supports (3) are of columnar design.
  4. Shaped body according to Claim 1, 2 or 3, characterized in that the polyurethane foam layer (6) has, on its lower side, integral projections (6a) which enter into the expansion channels (4) of the gel layer (2).
  5. Shaped body according to one of the preceding Claims, characterized in that the upper covering (7) is a spacer knit which consists of two textile surfaces connected to each other by spacer threads.
  6. Shaped body according to one of the preceding Claims, characterized in that the polyurethane foam layer (6) completely or partially laterally encloses the gel layer (2).
  7. Shaped body according to one of the preceding Claims, characterized in that the gel layer (2), after a film has been produced together with it pulled off, is bonded to the polyurethane foam layer (6).
  8. Shaped body according to one of Claims 1 to 6, characterized in that the polyurethane foam layer (6) is bonded to the supports (3) of the gel layer (2) by an applied adhesive.
  9. Shaped body according to one of Claims 4 to 8, characterized in that the integral projections (6a) of the polyurethane foam layer (6) extend as far as the bottom (8) of the expansion channels (4).
  10. Shaped body according to Claim 9, characterized in that the projections (6a) of the polyurethane foam layer (6) are supported on the bottom (8) of the expansion channels (4).
  11. Shaped body according to one of the preceding Claims, characterized in that the chemical structure of the polyurethane gel consists of long polymer threads and only a few linkages without added plasticizers being used.
  12. Shaped body according to one of Claims 1 to 10, characterized in that an undercrosslinked polyurethane based on polyols and polyisocyanates or polyethers and polyisocyanates is used for the gel.
  13. Shaped body according to Claim 12, characterized in that the gel compounds are produced using starting materials, in the case of which the product of the isocyanate functionality and the functionality of the polyol component is at least 5.2, preferably at least 6.5, in particular at least 7.5.
  14. Shaped body according to Claim 12 or 13, characterized in that the polyol component for producing the gel consists of a mixture of
    a) one or more polyols having hydroxyl numbers under 112, and
    b) one or more polyols having hydroxyl numbers in the range of from 112 to 600,

    the weight ratio of component a) to component b) being between 90:10 and 10:90, the characteristic isocyanate number of the reaction mixture lying in the range of from 15 to 60, and the product from the isocyanate functionality and functionality of the polyol component being at least 6.
  15. Shaped body according to Claim 12 or 13, characterized in that the polyol component for producing the gel consists of one or more polyols having a molecular weight of between 1000 and 12 000 and an OH number of between 20 and 112, the product of the functionalities of the polyurethane-forming components being at least 5 and the characteristic isocyanate number being between 15 and 60.
  16. Shaped body according to one of Claims 12 to 15, characterized in that, the isocyanates used for the production of the gels are those of the formula Q (NCO) in which N is 2 to 4 and Q is an aliphatic hydrocarbon radical having 8 to 18 C atoms, a cycloaliphatic hydrocarbon radical having 4 to 15 C atoms, an aromatic hydrocarbon radical having 6 to 15 C atoms or an araliphatic hydrocarbon radical having 8 to 15 C atoms.
  17. Shaped body according to one of Claims 12 to 16, characterized in that the polyurethane is produced with isocyanates in a pure form or with urethanized, allophanisized, biurethisized or functionally correspondingly modified isocyanates.
  18. Shaped body according to one of the preceding Claims, characterized in that the gel layer (2) contains elastic hollow microbeads as filler.
  19. Shaped body according to Claim 18, characterized in that the hollow microbeads consist of polymeric material, preferably polyolefin.
  20. Shaped body according to Claim 18 or 19, characterized in that the hollow microbeads are coated with a covering layer of an organic material, preferably calcium carbonate.
  21. Shaped body according to Claim 18, 19 or 20, characterized in that the hollow microbeads have a diameter of 10 µm to 150 µm.
  22. Shaped body according to one of Claims 18 to 21, characterized in that the content of hollow microbeads in the gel material is 0.1 to 10% by weight.
  23. Shaped body according to one of the preceding Claims, characterized in that coarse-grained solid particles consisting of small pieces of cork, cork powder, small pieces of wood, wood shavings, foam flakes, styropor, textile fibres or pieces or textile are distributed in the gel compound.
  24. Shaped body according to Claim 23, characterized in that the diameter of the solid particles is between 0.1 and 15 mm.
EP03019425A 2002-11-22 2003-08-28 Moulded body, expecially cushions Expired - Lifetime EP1421878B1 (en)

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DE10254678 2002-11-22
DE10254678A DE10254678B4 (en) 2002-11-22 2002-11-22 Shaped body, in particular for a seat cushion

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DE10254678B4 (en) 2005-11-17
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EP1421878A1 (en) 2004-05-26
ATE317655T1 (en) 2006-03-15

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