EP1488719A1 - Polsterstruktur - Google Patents

Polsterstruktur Download PDF

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Publication number
EP1488719A1
EP1488719A1 EP04253651A EP04253651A EP1488719A1 EP 1488719 A1 EP1488719 A1 EP 1488719A1 EP 04253651 A EP04253651 A EP 04253651A EP 04253651 A EP04253651 A EP 04253651A EP 1488719 A1 EP1488719 A1 EP 1488719A1
Authority
EP
European Patent Office
Prior art keywords
woven fabric
padded
rolled
structure according
fibres
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Withdrawn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
EP04253651A
Other languages
English (en)
French (fr)
Inventor
David Rooney
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.)
Wellman International Ltd
Original Assignee
Wellman International Ltd
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 Wellman International Ltd filed Critical Wellman International Ltd
Publication of EP1488719A1 publication Critical patent/EP1488719A1/de
Withdrawn legal-status Critical Current

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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
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton

Definitions

  • This invention relates to padded structures and to various articles incorporating said padded structures, with particular, but by no means exclusive, reference to the field of upholstered furniture, commercial seating, transportation vehicle seating, bedding products and general load bearing support structures.
  • cushioning may be incorporated within the body of the article of furniture itself, or may comprise a cushion, which may be attached by way of a zip or other attachment means, or merely placed in contact with the main body of the article of furniture.
  • Particularly important regions from the point of view of cushioning are those portions of the article of furniture which are intended to come into contact with the buttocks and the back of a person using the article of furniture. It is particularly important that such cushioned areas should be compliant enough to provide comfort for a person, yet be resilient enough to provide proper support for the person.
  • the cushioning should be robust enough to retain its properties over the lifetime of the article of furniture.
  • the nature of the cushioning in the seat region of the item of furniture is particularly important in this regard, since this region of an item of furniture should be able to withstand the considerable compression forces placed upon it when persons sit down (often in an uncontrolled manner) upon the item of furniture.
  • Figure 1 shows cross sectional views through a number of prior art cushions 10 which have been used for upholstery purposes.
  • Figure 1(a) shows a cushion 10 which is filled with a horizontally cross lapped fibre that has been carded to produce a web which is built up by cross lapping and then rolled to produce a generally cylindrical configuration 13 which is inserted into a cushion compartment 12.
  • Such cushions exhibit a high degree of compliance, and thus provide a soft feel.
  • cushions of this type do not display great resilience, and do not retain their shape upon repeated use. Rather, the structure of such cushions tends to collapse after repeated use.
  • Figure 1 (b) shows a second cushion construction in which a block of foam 14 is wrapped in carded fibre 16.
  • the foam core 14 is quite effective in preventing collapse of the cushion over a period of time, but unfortunately exhibits attendant drawbacks.
  • the foam core 14 can impart an overly resilient, hard feel to the cushion.
  • a polyurethane foam is used, in which instance there is the added drawback of the flammability of this material.
  • foams comprising a modified urethane which exhibits improved flammability properties.
  • Such materials possess an even greater degree of resiliency, and thus impart an extremely hard feel.
  • Figure 1 (c ) shows a cushion which contains a filling 18 comprising a mixture of feathers and fibre. Typically the fibre is carded but the feather components are not, the feathers being sprinkled onto the web after combing.
  • FIG. 1 (d) depicts a prior art cushion which is filled with a blown fibre 20. In this arrangement, fibre is lightly carded and then blown directly into the cushion compartments. Such arrangements are relatively inexpensive, but are very prone to collapse after repeated use and do not retain their shape at all well. Additionally, it is noted that it is known to provide pillows which have an inner core comprising a rolled up layer of an horizontally lapped non-woven fabric, but this approach is not known in respect of upholstery cushions.
  • a padded structure comprising:
  • Such structures can exhibit an excellent combination of compliance, providing a soft feel and comfort for a user, together with resilience, high load bearing capability, high mechanical strength and durability.
  • padded structures of the invention are convenient and economical to manufacture. Possible areas of application include upholstery cushions, cushions per se, bed mattresses, pillows, and other load bearing applications.
  • the padded structure further comprises a coverstock enclosing the padding material and maintaining the structural integrity of the padded structure.
  • the padding material forms an outer core which is disposed around the core of the rolled, vertically lapped non-woven fabric.
  • the padding material may form an inner core, with the rolled, vertically lapped non-woven fabric being disposed around the inner core.
  • the padding material may be incorporated within the core of the rolled, vertically lapped non-woven fabric, for example by i) providing a two layer arrangement comprising a layer of padding material and a layer of vertically lapped, non-woven fabric and ii) rolling the two layer arrangement up into a spiral configuration.
  • a padded structure may comprise an inner core of a padding material, a middle core of the rolled up, vertically lapped non-woven fabric disposed around the inner core, and an outer core of a padding material disposed around the middle core.
  • the rolled, vertically lapped non-woven fabric may be substantially cylindrical.
  • the fabric is rolled so as to provide a single walled structure of substantially circular transverse cross sectional form.
  • the fabric may be rolled in a spiral transverse cross sectional form so as to provide a multiple walled arrangement (at least over a portion of the perimeter of the inner core).
  • Other transverse cross sectional forms such as a substantially elliptical form, may be employed.
  • the rolled, vertically lapped non-woven fabric may comprise polyester or modified polyester fibres.
  • Other natural, re-engineered or synthetic fibres may be used, such as acrylic, viscose, wool, polycyclohexlenedimethylene terephthalate, polyolefins, polyamides, polyvinylchlorides and polylactic acid.
  • the rolled, vertically lapped non-woven fabric may comprise an arrangement of bonded matrix fibres.
  • the rolled, vertically lapped non-woven fabric may further comprise bonding fibres which are at least partially melted so as to bond the matrix fibres.
  • the bonding fibres may be bi-component fibres.
  • the matrix fibres may be bonded with a bonding agent, such as a resin or in other ways.
  • the bonded matrix fibres may comprise polyester or modified polyester fibres.
  • the padding material may comprise a fibrous material.
  • the padding material may comprise a carded fibrous material.
  • the padding material may comprise a foam or feathers.
  • the padding material may comprise polyester or modified polyester fibres.
  • Other natural, re-engineered or synthetic fibres may be used, such as polycyclohexlenedimethylene terephthalate, polyolefins, polyamides, acrylics, polyvinylchlorides, polylactic acid, viscose and wool.
  • an item of furniture or seating comprising at least one padded structure, in which the padded structure comprises:
  • the padding material may form an outer core which is disposed around the core of the rolled, lapped non-woven fabric.
  • the item of furniture or seating may comprise at least one padded structure according to the first aspect of the invention.
  • This arrangement is preferred, since it provides greatest resilience and load bearing capacity.
  • the use of differently lapped non-woven fabric, eg, horizontally lapped non-woven fabric, is possible.
  • An item of furniture or seating may be a sofa or a chair.
  • Seating may comprise seating for automotive vehicles.
  • the padded structure may be disposed in a seat region of the item of furniture or seating.
  • the padded structure may form part of a cushion, which cushion is detachable from the item of furniture or seating.
  • a bed mattress comprising at least one padded structure, in which the padded structure comprises:
  • the padding material may form an outer core which is disposed around the core of the rolled, lapped non-woven fabric.
  • the bed mattress may comprise at least one padded structure according to the first aspect of the invention. This arrangement is preferred, since it provides greatest resilience and load bearing capacity. However, the use of differently lapped non-woven fabric, eg, horizontally lapped non-woven fabric, is possible.
  • a cushion comprising a padded structure according to the first aspect of the invention and at least one cushion cover enclosing said padded structure.
  • a pillow comprising a padded structure according to the first aspect of the invention and at least one pillow cover enclosing said padded structure.
  • a cushion according to the fourth aspect of the invention to support the buttocks or back of a person.
  • a seventh aspect of the invention there is provided the use of a pillow according to the fifth aspect of the invention on a bed to support the head or neck of a person.
  • FIG 2 (a) shows a seat cushion 30 of the present invention.
  • the seat cushion 30 comprises a cushion cover 32 and, as shown in Figure 2 (b), an interior structure which comprises a plurality of padded structures 34.
  • Each padded structure 34 comprises an inner core of a lapped non-woven fabric 36 and an outer core of a padding material 38.
  • the inner core 36 is of a substantially cylindrical configuration. Such a configuration can be obtained by rolling a substantially planar sheet of a lapped non-woven fabric into a cylindrical shape.
  • the substantially circular cross sectional shape of the inner core 36 imbues the padded structure with enhanced properties, in particular enhanced mechanical properties which can be associated with the circular cross sectional symmetry of the inner core 36.
  • the inner core 36 comprises a vertically lapped non-woven fabric.
  • a strut like arrangement is produced in which the lapped layers 39 of the non-woven fabric act in a manner somewhat akin to the spokes of a wheel to provide a structure which is mechanically strong, particularly with respect to axial loading.
  • the construction employing vertically lapped non-woven fabric in the inner core 36 provides excellent resilience and load bearing capability.
  • the lapped non-woven fabric used to form the inner core of the padded structure should possess suitable mechanical properties in order to provide a padded structure of the desired degree of resilience.
  • the lapped non-woven fabric comprises a bonded non-woven web.
  • a suitable bonded non-woven web can be produced from a mixture of matrix fibres and low melt fibres, the latter being melted so as to bond to the matrix fibres and thus provide a strong structure.
  • Bi-component low melt fibres which comprise a core fibre and an outer sheath of a relatively low melting point material, are particularly suitable in this regard.
  • the bi-component fibres comprise polymeric materials which soften or melt at temperatures in excess of 60°C, preferably with melting points in the range 90 to 190°C.
  • the bi-component fibres are present in relatively low proportions, such as 70% matrix fibre to 30% bi-component fibre.
  • bi-component fibres Such processes are well known in the art, and thus greater detail is not provided herein. It should be noted that whilst the use of bi-component fibres is convenient, the invention is certainly not limited in this regard.
  • a bonding agent such as a resin may be used to bond matrix fibres together. Fibres which have been pre-coated with a suitable bonding agent might be used to form the non-woven fabric. Alternatively still, it may be possible to impart suitable structure to the non-woven fabric through the use of other techniques such as needling.
  • a non-woven fabric comprising 12 denier fibre might be used, although the invention is not limited in this regard. Polyester matrix fibres are typically used.
  • FIG. 1 An example of a vertically lapped non-woven fabric which is suitable for use in the present invention is available from Struto International Inc of 2021 Midwest Road, Suite 200, Oak Brook, IL 60523, USA under the tradename Struto (RTM). Additionally, Struto (RTM) is manufactured under licence by Granstand Limited, Lexington Mills, Wormald Street, Heckmondwike, West Yorkshire WF 15 6AR, UK (amongst others).
  • the Struto (RTM) material is produced in a substantially planar form.
  • Figure 3 (a) shows a cross sectional view through the plane of the Struto (RTM) material. It can be seen that the material comprises a plurality of layers 40 which are aligned substantially perpendicularly to the plane of the material.
  • Figure 3 (b) shows a cross sectional view through the plane of a horizontally lapped (or cross layered) non-woven fabric. It can be seen that the horizontally lapped non-woven fabric comprises a plurality of layers 42 which extend in parallel with the plane of the material.
  • Figure 3 (c ) is a cross sectional view of a vertically lapped non-woven fabric when rolled so as to produce a single walled inner core of the type described above. It can be seen that in the rolled configuration, the vertical layers of the planar material assume a radial configuration which provides excellent resilience and load bearing capability with respect to axially applied forces.
  • the padding material 38 is chosen to provide a desired degree of compliance.
  • carded fibres such as carded polyester fibres are used, in which instance the inner core 36 may be wrapped with carded fibre.
  • suitable fibre deniers is 1 to 50.
  • Padded structures of the present invention can be incorporated into a variety of end uses. It will be appreciated that typically a plurality of padded structures is used to produce an upholstery cushion. However, there may be some applications in which a single padded structure might be used, such as a padded roll for supporting the neck or head of a person. In upholstery applications, padded structures of the present invention might be incorporated directly into the main body of an item of furniture rather than into a cushion. Thus, padded structures of the invention may be disposed in a back panel of an item of furniture (so as to support the back region of a person sitting upon the item of furniture) or in a seat portion of an item of furniture (so as to support the buttocks of a person using the item of furniture).
  • padded structures of the present invention renders such padded structures particularly useful for seat applications in which a great deal of wear and tear is experienced due to repeated application of the forces associated with persons sitting down upon the item of furniture.
  • Padded structures of the present invention might also be incorporated into other forms of cushions, pillows, and bed mattresses, and used in other load bearing structures and applications.
  • the configuration of the inner core might be varied in a number of ways. It may be possible to roll the non-woven fabric around a central axle formed from another material.
  • the central axle may be formed from a padding material, in which instance the outer core of padding material may be dispensed with.

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
EP04253651A 2003-06-20 2004-06-18 Polsterstruktur Withdrawn EP1488719A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0314406A GB0314406D0 (en) 2003-06-20 2003-06-20 Padded structure
GB0314406 2003-06-20

Publications (1)

Publication Number Publication Date
EP1488719A1 true EP1488719A1 (de) 2004-12-22

Family

ID=27637009

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04253651A Withdrawn EP1488719A1 (de) 2003-06-20 2004-06-18 Polsterstruktur

Country Status (2)

Country Link
EP (1) EP1488719A1 (de)
GB (1) GB0314406D0 (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007058937A2 (en) * 2005-11-19 2007-05-24 Illinois Tool Works Inc. Seat cushion using vertically lapped fiber
WO2012038737A1 (en) * 2010-09-20 2012-03-29 John Cotton Group Limited A padding layer
WO2023059475A1 (en) * 2021-10-05 2023-04-13 Piana Nonwovens, Llc Consumer goods made with pieces of vertically lapped nonwoven

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB403175A (de) * 1900-01-01
US992354A (en) * 1910-09-01 1911-05-16 Wallace T Heermans Mattress.
US1256088A (en) * 1917-04-23 1918-02-12 Frederick P Woll Upholstery material.
US1992603A (en) * 1931-09-18 1935-02-26 Burton Dixie Corp Upholstery pad
US2638960A (en) 1952-12-18 1953-05-19 Bigelow Sanford Carpet Co Apparatus for producing a nonwoven soft-surface floor covering
US2678686A (en) * 1947-12-22 1954-05-18 William M Schulz Padding for upholstery and the like
FR1435168A (fr) * 1965-02-27 1966-04-15 Lihaut Et Fils Ets Perfectionnements apportés à la fabrication d'articles tels que coussins, oreillers ou analogues au moyen de produits en nappes ou en feuilles
US3373455A (en) * 1965-09-10 1968-03-19 Kaplan Julius Filling material for pillows
CS235494B1 (cs) 1983-01-04 1985-05-15 Jaroslav Hanus Vlákenná vrstva, způsob její výroby a zařízení k provádění způsobu výroby vlákenné vrstvy
CS269300B1 (en) 1988-06-13 1990-04-11 Krcma Radko Device for bulky fibrous layer production
DE29715153U1 (de) * 1997-08-23 1997-10-23 Inhoffen, Martin, 79117 Freiburg Matratze zur Aufnahme von Vliesstoffbahnen
JPH10215984A (ja) * 1997-02-07 1998-08-18 Paramount Bed Co Ltd 伸縮マットレス
WO1999061693A1 (en) 1998-05-25 1999-12-02 I.N.T., Krc^¿Ma Radko A device for perpendicular stratification of planary fibrous shapes

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB403175A (de) * 1900-01-01
US992354A (en) * 1910-09-01 1911-05-16 Wallace T Heermans Mattress.
US1256088A (en) * 1917-04-23 1918-02-12 Frederick P Woll Upholstery material.
US1992603A (en) * 1931-09-18 1935-02-26 Burton Dixie Corp Upholstery pad
US2678686A (en) * 1947-12-22 1954-05-18 William M Schulz Padding for upholstery and the like
US2638960A (en) 1952-12-18 1953-05-19 Bigelow Sanford Carpet Co Apparatus for producing a nonwoven soft-surface floor covering
FR1435168A (fr) * 1965-02-27 1966-04-15 Lihaut Et Fils Ets Perfectionnements apportés à la fabrication d'articles tels que coussins, oreillers ou analogues au moyen de produits en nappes ou en feuilles
US3373455A (en) * 1965-09-10 1968-03-19 Kaplan Julius Filling material for pillows
CS235494B1 (cs) 1983-01-04 1985-05-15 Jaroslav Hanus Vlákenná vrstva, způsob její výroby a zařízení k provádění způsobu výroby vlákenné vrstvy
CS269300B1 (en) 1988-06-13 1990-04-11 Krcma Radko Device for bulky fibrous layer production
JPH10215984A (ja) * 1997-02-07 1998-08-18 Paramount Bed Co Ltd 伸縮マットレス
DE29715153U1 (de) * 1997-08-23 1997-10-23 Inhoffen, Martin, 79117 Freiburg Matratze zur Aufnahme von Vliesstoffbahnen
WO1999061693A1 (en) 1998-05-25 1999-12-02 I.N.T., Krc^¿Ma Radko A device for perpendicular stratification of planary fibrous shapes

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007058937A2 (en) * 2005-11-19 2007-05-24 Illinois Tool Works Inc. Seat cushion using vertically lapped fiber
WO2007058937A3 (en) * 2005-11-19 2007-07-05 Illinois Tool Works Seat cushion using vertically lapped fiber
GB2445899A (en) * 2005-11-19 2008-07-23 Illinois Tool Works Seat cushion using vertically lapped fiber
GB2445899B (en) * 2005-11-19 2009-05-20 Illinois Tool Works Seat cushion using vertically lapped fiber
WO2012038737A1 (en) * 2010-09-20 2012-03-29 John Cotton Group Limited A padding layer
GB2498302A (en) * 2010-09-20 2013-07-10 John Cotton Group Ltd A padding layer
GB2498302B (en) * 2010-09-20 2015-05-06 John Cotton Group Ltd A padding layer
WO2023059475A1 (en) * 2021-10-05 2023-04-13 Piana Nonwovens, Llc Consumer goods made with pieces of vertically lapped nonwoven

Also Published As

Publication number Publication date
GB0314406D0 (en) 2003-07-23

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