EP1901636B1 - Procede pour produire des coussins et des rembourrages avec des maillages d'espacement, des tissus d'espacement ou des tricots d'espacement - Google Patents

Procede pour produire des coussins et des rembourrages avec des maillages d'espacement, des tissus d'espacement ou des tricots d'espacement Download PDF

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Publication number
EP1901636B1
EP1901636B1 EP06724239A EP06724239A EP1901636B1 EP 1901636 B1 EP1901636 B1 EP 1901636B1 EP 06724239 A EP06724239 A EP 06724239A EP 06724239 A EP06724239 A EP 06724239A EP 1901636 B1 EP1901636 B1 EP 1901636B1
Authority
EP
European Patent Office
Prior art keywords
fabric
layers
spacer
fabrics
pillow
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.)
Not-in-force
Application number
EP06724239A
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German (de)
English (en)
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EP1901636A1 (fr
Inventor
Fried-Jan Unger
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MPPS Holding BV
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MPPS HOLDING BV
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Publication of EP1901636A1 publication Critical patent/EP1901636A1/fr
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Classifications

    • 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
    • A47G9/10—Pillows
    • 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
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/02—Pile fabrics or articles having similar surface features
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/02—Pile fabrics or articles having similar surface features
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/022—Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
    • D10B2403/0221—Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics with at least one corrugated ply

Definitions

  • the invention relates to cushions and upholstery.
  • Cushions and upholstery regularly have a strong curvature. The same applies to upholstery. Nevertheless, cushions and upholstery in the middle and on the edge usually have the same flexibility. This results from the cushion filling, which is evenly distributed in the enclosed volume. The same applies to upholstery.
  • a pad assembly which includes a combination of a conventional pad filling with a water filling.
  • the cushion cover has two chambers, one of which is intended for a conventional pillow filling and of which the other is equipped for a water filling.
  • the plastic is usually polyurethane.
  • U.S. Patent 4,896,338 shows a foam layer.
  • the foam layer is formed as a winding.
  • measures are required to stabilize the winding in its position.
  • a backfilling of the gusset spaces is provided. From this, one of ordinary skill in the art concludes that the coil will dissolve without the measures.
  • the viscoelastic polyurethane foam is a significant advancement.
  • This foam has a glass point which is in the range of room temperature, preferably slightly below room temperature.
  • the result is an altered compliance behavior with a slight warming by the person lying. This heating causes a further sinking of the lying People.
  • the concept is based on the realization that the greatest warming takes place where the body has the largest mass.
  • the cushions and upholstery should be made of a spacer knit.
  • spacer fabrics have two spaced layers of fabric which are spaced by filaments or fibers.
  • several layers should be laid one on top of the other and warmed up to a pillow or cushion.
  • the invention has for its object to improve the comfort. According to the invention this is achieved in that the superimposed layers of knitted or woven or knitted fabrics are stepped towards the edge of the pillows and upholstery. The steps result from smaller dimensions of the woven / knitted fabric / knitted layers. Optionally, equal stages are provided. That is, the widths and lengths of the superposed fabric / knitted fabric / knit layers are each reduced by the same amount. The same applies to the diameters of the layers for round cushions and upholstery. The same applies to rounding of the layers for rounded cushions and upholstery.
  • the DE19736951A1 shows the use of a spacer knit, for automobile seats.
  • the section shows the cross section for the installation of the spacer knitted fabric 1 in the seat, wherein the spacer fabric 1 zwichen padding 7 ands a seat cover 6 is installed.
  • Spacer fabrics also called spacer fabrics, are fabrics produced on right / right Raschel machines.
  • the advantage of the spacer fabric 1 is the greater flexibility and ease of fabrication of spacer structure, surface texture, and air permeability.
  • the spacer fabric is intended for the air supply for heating and cooling. About the fact that the use of spacer knits for car seats is known, this document is not apparent.
  • the woven / knitted / knitted layers may themselves be single-ply or multi-ply.
  • the blanks are cut from a web.
  • the web is folded once or several times, so that the material is multi-layered one above the other. Either the folded material can be used unchanged for the cushion structure or upholstery structure.
  • the steps are adapted to the cushion profile or the upholstery profile.
  • the adjustment is made either by the desired cushion profile or upholstery profile on a scale of 1: 1 over the superimposed fabric / knitted fabric / knitted layers is placed.
  • the dimensions of the various layers at the points of contact of the cover layers of the woven / knitted / knitted layers with the pillow profile or upholstery profile are obtained.
  • the points of contact of the centerlines of the superimposed webs / knits / knitted layers can also be used to determine the dimensions of the steps.
  • other lines between the cover layers can be used to determine the dimensions of the steps.
  • the fabrics / knits / knit layers are sized. This is done with the same blanks by appropriate trimming. Preferably, the blanks are made immediately with the dimensions that result from the invention. This significantly reduces the amount of waste.
  • the smallest blank is positioned centrally in the pillows and the larger blanks are placed above and below so that the steps continuously result towards the outer edge of the pillow and the largest blanks form the upper and lower top surfaces.
  • another structure is provided.
  • the smallest blank is positioned at the bottom of the upholstery construction in a variant and the larger blanks placed over it so that the steps continuously result towards the outer edge of the pad and the largest blank forms the upper deck surface.
  • pillows and cushions can be formed with several elevations or depressions. As shown above on a cushion or upholstery with a survey, blanks are then made based on the contour of the cushion or upholstery. This inevitably results in the correct dimensions for the individual layers of upholstery or cushion.
  • the pillows or upholstered superimposed layers are processed without wrapping or with a wrapper.
  • the wrapper regularly enhances the look of the pillow or cushion.
  • the envelope is also made of a woven / knitted or knitted fabric.
  • the sheath is given a small thickness, which is favorable for the edge formation of the pad or pad. Large thicknesses of the cladding rebuild the problem of fringe formation. There, thick layers can only be combined into one edge with considerable compaction. The compression causes a hardening
  • the various layers of material in a cushion or upholstery can already be fixed by a loose cover.
  • a connection between the individual layers in the pillow or cushion is provided.
  • the connection can be made by sewing, knitting or other forms. Corresponding to the needles.
  • gluing or welding can be used.
  • adhesive dots or tape or welding spots or welding strips that are spaced apart, so that flowing gases or liquids are not hindered.
  • spacer fabrics On vehicles, spacer fabrics have already prevailed. Exemplary is on the U.S. Patent 6,629,724 directed. The spacer fabrics are intended to ventilate the seat so that moisture accumulated by sweating evaporates and the steam can be drawn off. The distances can be up to 15 mm. Spacer fabrics are also known in textiles. There they should ventilate waterproof layers. Exemplary is on the U.S. Patent 6,716,778 directed.
  • the spacer fabrics have been known for some time.
  • the US-PS 6687937 , the US-PS 6687935 , the U.S. Patent 6,668,408 , the U.S. Patent 6499157 , the U.S. Patent No. 6460209 , the U.S. Patent 6447874 and the U.S. Patent 6,115,861 describe such spacer materials.
  • the spacer fabrics form part of channels through which the water vapor is removed, which is created by sweating of the person lying. In part, spacer fabrics are provided as continuous layers.
  • single-layer pillows are provided.
  • the spacer fabrics are created in the final form. This can be achieved by changing the weaving or knitting process. In principle, this may result in a change in the programming of the associated manufacturing machines. For large quantities of tissue this includes an optimal solution, also an economic solution. For smaller amounts of tissue, changing the programming is extremely expensive.
  • the assembly according to the invention a small effort is achieved even for small series.
  • spacer fabrics for producing mattresses are deformed by contact with a solid heat transfer medium and by application of a liquid or solid heat transfer medium.
  • Pillows can be made on the way in a desired shape.
  • the layered structure according to the invention can also be processed by hot deformation.
  • the necessary heating of the knitted, woven or knitted fabric can be done in different ways. Radiant heat and / or contact heat of a gaseous or liquid heat carrier is preferably used.
  • the advantageous gaseous heat carriers may also include steam.
  • the steam has a very favorable heat transfer.
  • the steam can also reach temperatures of more than 100 degrees Celsius. In that case steam is used, which is under increased pressure. At higher pressure, the steam can easily be heated well over 100 degrees Celsius.
  • hot gases can be used as heat transfer. With the hot gases all temperatures can be reached, which is required for the thermoforming of eligible plastics. This also applies to the thermoforming of polyester, which has a high melting point. In the form of polyethylene terephthalate (PET), the melting point is 250 degrees Celsius or more.
  • the gaseous or liquid heat transfer medium can penetrate the knitted fabric or knitted fabric well and ensure uniform contact everywhere. This is synonymous with a uniform warming.
  • a non-uniform heating can take place, for example, to leave the tissue parts unchanged, which should experience no or only a small permanent deformation.
  • an oven is suitable, both an intermittently operated oven and a continuously operated oven.
  • Continuously operated furnaces are, for example, tunnel kilns in which the products are continuously passed through. In the ovens, the temperature can be kept arbitrarily or lowered or controlled. The length of a continuous furnace results from the desired duration of the heat treatment and the conveying speed of the furnace.
  • the cooling can be accelerated with a suitable coolant.
  • the coolant may be gaseous or liquid.
  • As a coolant and cooling air is suitable.
  • the cooling air can easily penetrate the knitted fabric, woven or knitted fabric. This ambient air can be used, but also a lower-temperature air, which is produced by appropriate cooling.
  • the knitted, woven or knitted fabric can also be readily cooled with a liquid coolant, in particular with water, because the water flows easily from the knitted fabric, knitted fabric and knits and because the knitted fabric then knits very quickly thereafter.
  • the drying can be promoted with drying air or drying gas.
  • a drying gas for example, the exhaust gas from a heating of the knitted fabric, fabric or knitted fabric with gas as the heat transfer medium. That is, it may be advantageous to first heat the knitted fabric, woven fabric or knitted fabric with a gaseous heat transfer medium for hot deformation, to cool it after deformation with water and then to bring about drying with the exhaust gas from the first heating. It may be appropriate to bring the exhaust gas by mixing with ambient air to a lower temperature for the drying of the fabric, knitted or knitted fabric.
  • the heating can be controlled very precisely. This applies both to the duration of the heating and to the course of the heating and also to the height of the outside of the filaments, fibers, etc. temperature applied.
  • a temperature is set at the parts to be deformed, which is at least 5, preferably at least 10 and more preferably up to 20% below the temperature of the melting point.
  • the gaseous or liquid heat carrier is introduced between the spaced outer layers.
  • the heat transfer agents transfer the heat to the filaments, fibers and threads that connect the outer layers.
  • the heating may take place before deformation or during deformation or after preforming. It is favorable to heat before deformation, because the supply of the gaseous or liquid heat carrier is thereby simplified and because the resistance to deformation is then very low. It is also favorable to supply the gaseous or liquid heat carrier after deformation, because the energy consumption is then particularly low.
  • heating filaments, fibers and filaments relax and remain in the deformed state after subsequent cooling. That is, the knitted, woven and knitted fabric retains the desired shape after release.
  • the gaseous or liquid heat transfer medium are abandoned intermittently. Then, the heating process is prolonged and the heating process can be well controlled by the number of impacts of the heat carrier.
  • the overpressure is preferably at least 1 bar, more preferably at least 2 bar and most preferably at least 3 bar.
  • the desired pressure can be established with a pump. There are heat resistant pumps. But it can also be built up pressure first and then take place heating of the gaseous or liquid heat carrier, so that there is no significant heat load on the pump.
  • the woven, knitted and knitted fabrics can be loaded at any desired point with the gaseous or liquid heat carrier. This is possible on both the spaced layers and the side surfaces between the spaced layers.
  • the gaseous or liquid heat carrier then flows through the fabric or knitted fabric or knits to emerge at a predetermined location again. With the outlet opening or the outlet openings, the flow can be directed. In addition, the flow can be influenced by applying a negative pressure to the outlet opening or outlet openings.
  • the gaseous or liquid heat carrier can be carried directly into the gap.
  • a lateral entry between the spaced layers of knitted or woven or knitted fabric is possible.
  • the apertured windows include a wall having a plurality of apertures disposed therein.
  • the openings can be free of a nozzle effect or develop a nozzle effect to a lesser or to a great extent.
  • the openings can be evenly distributed. Then a grid structure is created.
  • the openings may also be unevenly distributed in order to provide the heat transfer medium in the deformation areas with a high concentration of fibers and filaments to a large extent necessary.
  • lances can be used to enter the heat carrier.
  • the lances can direct the heat transfer to the required locations.
  • the lances may be of small diameter and have a point so that the lances will not damage the knit, fabric or knit as they penetrate the knit, fabric or knit.
  • the lances may be provided with one or more openings. With a small diameter and appropriate length, the lances have the shape of nails.
  • the nail-shaped lances are also forced through the spaced layers into the space between the spaced layers.
  • all areas of the knitted fabric, fabric, knitted fabrics can be reached.
  • it is possible to isolate the lances dealt with unwanted place heating of the spacer knitted fabric, knitted fabrics.
  • Sufficient insulation can already arise because the lances are surrounded by a protective tube at a short distance.
  • the deformation of the knitted, woven, knitted fabric can take place in a mold.
  • the shape can be completely or partially closed. As far as the form is partially open and with a gaseous heat transfer medium is working, however, a burden on the environment can be prevented by means of a take-off device.
  • a train is therefore wholly or partially applied to the spaced layers, which lie opposite the pressure region.
  • the train can be applied mechanically by being attacked on the outer layers.
  • An attack with hooks and / or tongs is possible.
  • the hooks or tongs may be slidable in shape and, if necessary, extended out of the mold to grip the knit, fabric and knit. Conveniently, there are movable hooks that can open to release the deformed knitted fabrics, fabrics and knits.
  • the foil pieces are yielding.
  • the compliance is not required in various applications.
  • less flexible platelets or pieces of plates can also be used.
  • These parts can be equipped with additional functions, for example with the attachment to the chair structure or the sofa construction. So far, such constructions consist almost exclusively of wood. This has cost reasons, but also mounting reasons, because the pad can then be attached to the construction by nailing or staples.
  • the knitted fabrics, woven fabrics, knits according to the invention can be nailed to the construction with the parts described above or staples. At least with the brackets, the knitted fabric, woven fabric, knitted fabrics can also be fastened without the above-described upholstery.
  • a clean finish can be achieved by a hidden seam or by a piping.
  • the hidden seam the upper layers of the pillow are detected, turned inwards and welded together.
  • a cord or the like is used as piping in the seam on the edge or in the edge.
  • the Fig. 1 shows the spacer fabric for a pillow or cushion lying on his head. Both layers 1 and 2 are connected to each other by filaments 3. In addition, starting from the layer 2, further filaments 4 are provided whose length is less than the distance between the layers 1 and 2. In case of a compression, the filaments 3 immediately take on load. However, the filaments 4 participate only in the load bearing when they touch the layer 1.
  • the embodiment according to Fig. 2 differs from the embodiment according to Fig. 1 in that instead of the filaments 4 wound filaments 5 are provided.
  • the wound filaments 5 are better supported on the layer 1.
  • the embodiment according to Fig. 3 differs from the embodiment according to Fig. 1 in that, instead of the filaments 4, other filaments 6 are provided, which are connected to an intermediate layer 7. By the intermediate layer 7 even better support is achieved.
  • the embodiment according to 4 and 5 is in Fig. 4 also shown lying on his head.
  • the embodiment has an upper fabric layer 10 from which filaments 13 and 14 extend.
  • the filaments 13 hold fabric strips 11, the filaments 14 hold fabric strips 12.
  • the filaments 14 are shorter than the filaments 13 so that the spacing of the strips 12 from the layer 10 is less than the spacing of the strips 11 from the layer 10.
  • the strips 11 together with the filaments 13 webs, as are the strips 12 with the filaments 14th In the case of the compression of the spacer fabric, first the webs with the strips 11 take up the load until their distance from the layer 10 is equal to the distance between the strips 12 and the layer 10. Then the webs participate with the strips 12 on the load-carrying.
  • FIG. 6 is a modification of the in 4 and 5 shown system represented by webs.
  • the webs 21 extend so that a honeycomb structure is formed.
  • Each honeycomb 20 encloses a nub 22.
  • the webs 21 have in the embodiment, the function of the webs 11, the nubs the function of the webs 12. Accordingly, the webs 11 at the illustrated end of fabric strips which are connected by filaments with an opposite layer of fabric of the spacer fabric ,
  • the knobs 22 also have a fabric layer which is connected by filaments to the opposing fabric layer of the spacer fabric.
  • Fig. 10 shows a schematic drawing of the hot deformation according to the invention.
  • the resulting spacer fabric is placed in a heating station. There it is brought to an outside temperature with hot air, which is 5 to 10% below the temperature of the melting point.
  • the heating is carried out in the manner described below at a hot gas temperature which is 10 to 30% higher than the temperature of the melting point.
  • a hot gas temperature which is 10 to 30% higher than the temperature of the melting point.
  • the fabrics are fed to a deformation station 46. There the fabrics experience a desired deformation. Matrices can be used as tools.
  • the deformed tissues are still cooled in the mold until there is also a temperature at the outside of the filaments and fibers, eg room temperature, at which the tissue has permanently assumed the acquired shape.
  • the Fig. 7 to 9 show examples of shaping the tissues.
  • the fabrics 30 have molded hinge points 31. At the impressions a compression of the filaments, fibers, etc. is shown schematically.
  • the blanks of spacer fabric delivered with a uniform cross section are heated with hot air at the intended joints.
  • a board or the like is pressed with the narrow side in the heated area of the molding. After reaching the desired penetration depth of the molding with cooling air is applied until the filaments, fibers, etc. have reached room temperature again. After that, the board is removed.
  • the Fig. 8 shows a seat cushion 35 with a curvature 36 at the top.
  • the seat cushion is made of a molded piece of spacer fabric supplied with a uniform cross-section.
  • the molding is subjected to hot air. Unlike the procedure according to Fig. 7 however, the hot air is injected between the spaced tissues. The thus heated molding is compressed between a die and a male until the in Fig. 8 shown form is reached.
  • Fig. 9 shows a U-shaped pad 40 for an armrest with legs 41, which should include the armrests of a chair on both sides.
  • the heating, shaping and cooling takes place as in the exemplary embodiment Fig. 8 ,
  • a pad is made in place of the pad in the same manner as the pad.
  • the molding is immediately inserted into a mold and also takes place in the heating of the mold.
  • the mold then has nozzle surfaces at the respective locations, through which heating means and coolant can penetrate into the mold cavity.
  • openings are provided at opposite points at which spent heating medium and spent coolant can escape again.
  • the openings are selectively closable in order to set a desired pressure level in the mold can.
  • Fig. 11 shows a molded article 52 of a spacer fabric with two spaced layers 53 and 54, which are connected by filaments 55 together.
  • the molding 52 lies between two shaping plates 50 and 51.
  • the molding is provided with a film 57.
  • the foil is laminated.
  • Into the plate 50 are suction with suction channels 56. Through the suction and suction channels, a negative pressure is applied to the film 57, so that the film 57 closes against the contour of the plate 50 applies.
  • the blank 52 is flowed through with hot gas from the direction 58, so that the filaments 55 soften.
  • the hot gas exits the molding at 59.
  • cooling takes place. The cooling is done abruptly in the embodiment with cooling water. Thereafter, the molding remains in the new form.
  • Fig. 12 The embodiment according to Fig. 12 is different from that Fig. 11 through another feeder of the H devisgaes.
  • a plate 60 is provided with hot gas supply 61, which protrude in the exemplary embodiment of the plate 60 nail-shaped and penetrate into the molding 52.
  • a targeted hot gas supply takes place in the area of deformation. A small amount of hot gas is required. The molding is less affected by the hot gas.
  • the embodiment according to Fig. 13 differs from the embodiments according to FIGS. 11 and 12 in that, instead of a film 57 on the molding 52, a plurality of uniformly distributed film patches 65, are provided. The stains are placed so that they lie exactly on the intake in the upcoming deformation, the molding.
  • the spots 65 and the suction openings cause, as in the exemplary embodiments 11 and 12, a concern with the contour of the plate 50.
  • Fig. 14 shows a cushion profile 80.
  • the cushion profile 80 stands for a pillowcase.
  • the pillowcase is square. With the pillow filling results in a bulge of the pillow.
  • the pillow edges also form approximately a square with the pillow filling.
  • the cushion filling should be represented by layered spacer fabric 70,71,72,73,74,75.
  • the spacer fabrics are in Fig. 14 match each other.
  • the spacer fabrics 70 to 75 form different squares.
  • the central square spacer fabrics 70 and 71 are the same and the largest. Above and below the smaller, square Abstandsgewirke 72 and 73 are arranged. Outside even smaller, square Abstandsgewirke 74 and 75 are arranged.
  • the dimensions of the knitted fabric 72 to 75 have been determined in the embodiment based on the cushion contour.
  • the cushion contour 1: 1 1 has been recorded and the knitted fabric has been placed with a narrow side on the contour. Where the outer edges of the knitted fabrics 72 to 75 will touch the cushion contour, the edge length for these knitted fabrics 72 to 75 is derived.
  • the knits 70 and 71 are other sizes. Their dimension has been determined by the associated cushion circumferential length. The circumferential length is much larger than the edge length of the filled pad. Therefore, the knits 70 and 71 protrude as shown Fig. 14 beyond the cushion contour 80.
  • the various knits form steps which have different pitches from the center of the pillow and extend from the center of the pillow to the outside, or vice versa.
  • the various knits are brought by hot deformation to a cushion filling in a contour corresponding to the contour 80.
  • the different knitted fabrics are layered differently, as in Fig. 16 shown.
  • the small knits 74 and 75 are in the middle.
  • the larger knitted fabrics 72 and 73 and outside are the knitted fabrics 70 and 71.
  • the hot deformation takes place in a mold whose cavity has the contour 80 of the pad in the manner described above with hot gas.
  • the in Fig. 15 illustrated deformation of the knitted fabric.
  • the knits 70 and 71 abut in the middle.
  • the knitted fabrics 70 and 71 enclose the intermediate knitted fabric between them, as in FIG Fig. 15 is shown.
  • Fig. 18 shows a folded spacer knitted fabric.
  • the individual layers of the fold are designated 91, 92 and 93.
  • the fold is designed such that the layer 92 is smaller than the layer and the layer 93 is smaller than the layer 92. With such folds a cushion filling can be represented, which is much thinner at the edge than in the middle.
  • Fig. 19 shows a padding filling consisting of spacer fabric with superimposed layers 95, 96 and 98 and a surrounding outer layer 97. Due to the layer structure and the arrangement of the outer layers 98, the cushion filling has the shape of a neck support with lateral bulges and central recess. The lateral bulges have a thickness of up to 15cm. The existing between the bulges Kuhle includes in the exemplary embodiment, a thickness reduction to 50%.
  • Fig. 17 shows a cushion pad of spacer fabric 85 with a skirt 87 of the edge and a pillow cover 86, which is provided for removing and inserting the pillow filling with a side zipper.
  • the pillow cover encloses the pillow filling, so that the pillow filling can also have a large appearance.
  • the cushion filling is provided with a fine exterior. This is achieved by the fact that large layers are provided on the outside, which surround the remaining part of the cushion filling like a pillowcase. In contrast to the pillowcase, these layers can not be peeled off.
  • various hardnesses in the layers, different thicknesses and different densities of the spacer knitted fabric are provided.
  • the layers can have a wide variety of construction, with the filaments and surface structure of the individual layers, in terms of their elasticity, diameter, length, position, number and laying, being used to produce cushions with specific deformation properties.
  • the topmost layer may be made softer or harder at a predetermined location.
  • lower layers can be provided with a shear strength which prevents so-called floating of the cushions.
  • the desired shear strength is created, for example, by criss-crossing the webs connecting the spaced layers.
  • the spacer fabrics are also made of a viscoelastic plastic that changes its compliance behavior under body heat.
  • the number of layers can be up to 5 or 10 or even more.
  • Suitable materials are, for example, polyesters, polyamides, polybutylene terephthalate, polyethylene terephthalate, PPT.
  • the layer thickness can be from a few millimeters up to 50 mm and more.
  • the layer thickness is preferably up to 35 mm, more preferably up to 25 mm.
  • the outer layers of the pad filling with the other layers of the pad filling are connected in the same or different manner as the layers with each other.
  • the outer layer of the cushion filling also forms the cushion cover. This is possible because the pad filling according to the invention can be washed easily. From a hygienic point of view, this is much more advisable than a replacement of the used cushion cover against a washed cushion cover and continued use of an unwashed pillow filling. This is particularly important for the use of cushions for patients or nursing cases.
  • the cushion cover is peelable to appeal to traditional customers who wish to wash the pillow cover more frequently than the pillow fill.
  • the cushions in the initial shape width dimensions and length dimensions which vary from 30cm to 100cm arbitrarily and can be combined.
  • the dimensions of different pads differ by at least 10cm.
  • the thickness of the pads is preferably 10 to 25 cm.
  • the pads are composed of knit fabrics which may have a basis weight of from 100 grams per square meter to 600 grams per square meter.
  • a higher grammage of fabric layers per square meter (specific basis weight) is not necessarily equivalent to greater thickness of the fabric layers.
  • a lower specific basis weight is not necessarily synonymous with a smaller thickness.
  • the cushions can also be shaped as designated support cushions.
  • one of the cushion surfaces on the body side is adapted to the body part to be supported.
  • These include cervical pillows, back cushions, hip pads and knee pads.
  • the compressive strength and the thickness of the cushions is preferably selected so that a person to be supported with at least a body weight of 50 kg does not pass through the relevant body part. Even more preferably, this also applies to persons with a body weight of at least 100 kg.
  • Sleeping means The user feels a firm pad under the pillow.
  • Cushions can exhibit spacer fabric layers according to the invention with significantly higher specific basis weights than cushions.
  • the specific basis weights can be up to 1500 grams per square meter and more.
  • upholstery can have a much higher compressive strength than the pillows.
  • the thickness of the upholstery is usually less than the thickness of the pillows.
  • the sagging applies in the corresponding application on seats. That is, the upholstery should carry people with a body weight of at least 50 kg, preferably at least 100 kg, without the people sitting through the pad.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Otolaryngology (AREA)
  • Pulmonology (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Knitting Of Fabric (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Bedding Items (AREA)

Claims (44)

  1. Procédé pour fabriquer des corps moulés (40, 41 ; 52) pour le remplissage de coussins et de rembourrages (40, 41), caractérisé par l'utilisation de maillages d'espacement, des maillages d'espacement souples (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), des tissus d'espacement ou des tricots d'espacement étant utilisés qui sont en matériau thermoplastique et qui possèdent respectivement deux couches espacées qui sont reliées ensemble par des éléments tels que des filaments (3), des fibres ou des fils, les maillages (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissus ou tricots étant découpés à partir d'une nappe de matériau et les découpes (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98) étant placées à plusieurs les unes au-dessus des autres, les bords des découpes (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98) fournissant le contour (80) du coussin ou du rembourrage (40, 41), et/ou les maillages d'espacement (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissus d'espacement ou tricots d'espacement étant adaptés, au niveau du bord, par déformation thermoplastique (46) du contour (80) au coussin ou rembourrage (40, 41).
  2. Procédé selon la revendication 1, caractérisé par l'utilisation de couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93)
    a) qui, de par des dimensions différentes, en longueur et/ou largeur et/ou diamètre et/ou arrondi, forment les niveaux.
  3. Procédé selon la revendication 2, caractérisé par l'utilisation de couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93) avec des niveaux qui, dans la section transversale des coussins ou rembourrages (40, 41), au niveau du contour (80), passent, en continu, du milieu vers l'extérieur.
  4. Procédé selon l'une des revendications 1 à 3, caractérisé par l'utilisation de couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93), parmi lesquelles
    a) la couche la plus grande en termes de dimensions (70, 71, 72, 73, 74, 75 ; 91, 92, 93) est située au milieu et les couches (70, 71, 72, 73, 74, 75; 91, 92, 93) plus petites sont placées dessus,
    ou
    b) la couche la plus grande en termes de dimensions est située à l'extérieur et forme en tout ou partie le contour (80) du coussin ou le contour (80) du rembourrage, sachant que les couches plus petites en termes de dimensions (70, 71, 72, 73, 74, 75 ; 91, 92, 93) sont entourées par la plus grande couche (70, 71, 72, 73, 74, 75 ; 91, 92, 93).
  5. Procédé selon l'une des revendications 1 à 4, caractérisé par l'utilisation de découpes (91, 92, 93) monocouches ou multicouches et/ou l'utilisation de découpes (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98) qui possèdent en tout ou partie un comportement élastique différent.
  6. Procédé selon la revendication 5, caractérisé en ce que les couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93) sont pliées à partir de nappes de matériau qui sont confectionnées avant ou après.
  7. Procédé selon la revendication 5, caractérisé en ce que les fils, fibres et filaments (3) sont différents des uns des autres, en nombre et/ou en longueur et/ou en diamètre et/ou en position et/ou en qualité de matériau.
  8. Procédé selon l'une des revendications 1 à 7, caractérisé en ce que l'augmentation de température pour le façonnage à chaud (46) des matériaux composant le maillage (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissu ou tricot ou similaire est réalisée avec un fluide caloporteur solide et/ou liquide et/ou gazeux.
  9. Procédé selon la revendication 8, caractérisé en ce que le maillage (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissu ou tricot ou similaire est traversé par le fluide caloporteur à l'état liquide et/ou gazeux et/ou est mis en contact avec une matière solide servant de fluide caloporteur, de préférence, placée dans un moule.
  10. Procédé selon l'une des revendications 1 à 9, caractérisé en ce que l'augmentation de température de la matière plastique se produit à une température qui est au moins 5 %, de préférence au moins 10 % inférieure, de préférence jusqu'à 20 % inférieure à la température du point de fusion.
  11. Procédé selon la revendication 10, caractérisé en ce que la température du gaz chaud est, en tant que fluide caloporteur, au moins 10 %, de préférence au moins 20 %, de préférence jusqu'à 30 %, supérieure à la température du point de fusion.
  12. Procédé selon l'une des revendications 1 à 11, caractérisé en ce que le maillage d'espacement (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), le tissu d'espacement ou le tricot d'espacement est exposé entre les couches espacées (70, 71, 72, 73, 74, 75 ; 91, 92, 93) et/ou de l'extérieur, au niveau des couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93), au fluide caloporteur à l'état liquide et/ou gazeux.
  13. Procédé selon l'une des revendications 1 à 12, caractérisé par l'utilisation de fluides caloporteurs à l'état liquide et/ou gazeux, à une pression de 1 bar, de préférence d'au moins 2 bar et d'avantage encore, de préférence d'au moins 3 bar, par rapport à l'environnement.
  14. Procédé selon l'une des revendications 1 à 13, caractérisé en ce que les fluides caloporteurs à l'état liquide et/ou gazeux employés sont aspirés en dépression.
  15. Procédé selon l'une des revendications 1 à 14, caractérisé par un recuit après le façonnage à chaud (46).
  16. Procédé selon la revendication 15, caractérisé par l'utilisation d'un four continu pour le recuit.
  17. Procédé selon l'une des revendications 1 à 16, caractérisé par un refroidissement du plastique recuit et/ou façonné à chaud.
  18. Procédé selon la revendication 17, caractérisé par l'exposition à un agent réfrigérant liquide ou gazeux.
  19. Procédé selon la revendication 18, caractérisé en ce que le maillage (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissu ou tricot est traversé par l'agent réfrigérant.
  20. Procédé selon l'une des revendications 17 à 19, caractérisé par un séchage du maillage (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissu ou tricot, après refroidissement, avec un agent réfrigérant liquide.
  21. Procédé selon la revendication 20, caractérisé par l'utilisation de gaz d'échappement provenant de l'augmentation de température antérieure avec le fluide caloporteur sous forme gazeusé pour le séchage.
  22. Procédé selon l'une des revendications 1 à 21, caractérisé par l'utilisation d'un moule qui peut admettre un agent réfrigérant et/ou chauffant.
  23. Procédé selon l'une des revendications 1 à 22, caractérisé en ce que l'agent réfrigérant et/ou chauffant est introduit à l'aide de lances entre les couches espacées (70, 71, 72, 73, 74, 75 ; 91, 92, 93).
  24. Procédé selon la revendication 23, caractérisé en ce que les lances présentent la forme de clous et pénètrent à travers les couches espacées dans l'espace intermédiaire.
  25. Procédé selon la revendication 23 ou 24, caractérisé par l'utilisation de plaques et de pièces moulées qui sont munies de lances en forme de clous pour l'amenée des agents réfrigérants et/ou chauffants.
  26. Procédé selon l'une des revendications 1 à 25, caractérisé par l'utilisation d'un moule avec des ouvertures d'amenée pour des fluides caloporteurs à l'état liquide et/ou gazeux et des ouvertures d'évacuation pour des fluides caloporteurs à l'état liquide et/ou gazeux.
  27. Procédé selon la revendication 26, caractérisé par l'utilisation d'un moule avec une multitude d'ouvertures disposées les unes à côté des autres.
  28. Procédé selon la revendication 27, caractérisé par une structure en grille ou une structure d'une plaque perforée pour l'arrivée ou l'évacuation.
  29. Procédé selon l'une des revendications 26 à 28, caractérisé par l'utilisation d'un moule avec des ouvertures pouvant être obturées.
  30. Procédé selon l'une des revendications 1 à 29, caractérisé par le formage de coussins de l'extérieur et/ou de l'intérieur.
  31. Procédé selon l'une des revendications 1 à 30, caractérisé par le formage de pliures.
  32. Procédé selon l'une des revendications 1 à 31, caractérisé par le façonnage et/ou le formage d'arrondis et/ou de bords.
  33. Procédé selon l'une des revendications 1 à 32, caractérisé par l'utilisation de maillages (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissus ou tricots en tant qu'agglomérés, munis, au moins d'un côté, en tout ou partie, d'une surface d'aspiration, au niveau de laquelle une dépression est appliquée afin de disposer l'aggloméré au niveau d'un contour (80) façonnant.
  34. Procédé selon la revendication 33, caractérisé par l'application de pellicules (52) en tant que surface d'aspiration.
  35. Procédé selon la revendication 34, caractérisé par l'utilisation de pellicules (52) contrecollées et par la disposition d'ouvertures d'aspiration au niveau des surfaces correspondantes dans le moule.
  36. Procédé selon la revendication 34 ou 35, caractérisé par l'utilisation de taches de pellicules ou de parties de pellicules dont la taille et/ou forme et/ou espacement n'est pas préjudiciable à la perméabilité du maillage (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissu ou tricot et par la disposition d'ouvertures d'aspiration au niveau des surfaces correspondantes dans le moule.
  37. Procédé selon l'une des revendications 1 à 36, caractérisé par l'utilisation de couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93) d'un poids surfacique maximal de 600 grammes par mètre carré pour des coussins et/ou d'un poids surfacique maximal de 1500 grammes par mètre carré pour des rembourrages (40, 41).
  38. Procédé selon l'une des revendications 1 à 37, caractérisé par l'utilisation de couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93) en maillage (70, 71, 72, 73, 74, 75 ; 91, 92, 93 ; 85, 96, 98), tissu ou tricot d'une épaisseur maximale de 50 mm, de préférence inférieure à 35 mm et d'avantage encore, de préférence, inférieure à 25 mm.
  39. Procédé selon l'une des revendications 1 à 38, caractérisé par l'utilisation de couches (70, 71, 72, 73, 74, 75; 91, 92, 93) d'épaisseur différente et/ou de résistance à l'écrasement différente.
  40. Procédé selon l'une des revendications 1 à 39, caractérisé en ce que les coussins, en tant que coussins d'appui, ne se détériorent pas, sous un poids corporel d'au moins 50 kg, de préférence sous un poids corporel d'au moins 100 kg, d'une personne, et en ce que les rembourrages (40, 41) ne s'usent pas sous un poids corporel d'au moins 50 kg, de préférence sous un poids corporel d'au moins 100 kg, d'une personne.
  41. Procédé selon l'une des revendications 1 à 40, caractérisé par l'utilisation d'une matière de remplissage pour coussin et d'une enveloppe de coussin, sachant que la matière de remplissage pour coussin présente, côté extérieur, des couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93) de grande surface qui entourent la partie restante de la matière de remplissage pour coussin comme une enveloppe de coussin.
  42. Procédé selon l'une des revendications 1 à 41, caractérisé en ce que les couches (70, 71, 72, 73, 74, 75 ; 91, 92, 93) d'un coussin ou rembourrage (40, 41) sont assemblées ensemble par des coutures et/ou aiguilletages et/ou soudures et/ou collages.
  43. Procédé selon l'une des revendications 1 à 42, caractérisé en ce que sont utilisés des coussins dont la couche extérieure de la matière de remplissage pour coussin forme à la fois la housse de coussin.
  44. Procédé selon l'une des revendications 1 à 43, caractérisé en ce que la matière de remplissage pour coussin est lavée à la fois avec la housse de coussin.
EP06724239A 2005-05-15 2006-04-11 Procede pour produire des coussins et des rembourrages avec des maillages d'espacement, des tissus d'espacement ou des tricots d'espacement Not-in-force EP1901636B1 (fr)

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DE102005023197 2005-05-15
DE102005034797 2005-07-21
DE102006002098A DE102006002098A1 (de) 2005-05-15 2006-01-14 Kissen und Polster
PCT/EP2006/003317 WO2006122614A1 (fr) 2005-05-15 2006-04-11 Procede pour produire des coussins et des rembourrages avec des maillages d'espacement, des tissus d'espacement ou des tricots d'espacement

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JP2008540001A (ja) 2008-11-20
DE502006009113D1 (de) 2011-04-28
EP1901636A1 (fr) 2008-03-26
CA2645673A1 (fr) 2006-11-23
DE102006002098A1 (de) 2006-11-16
KR20080007614A (ko) 2008-01-22
CN101203161A (zh) 2008-06-18
ATE501657T1 (de) 2011-04-15
WO2006122614A1 (fr) 2006-11-23
US20080209638A1 (en) 2008-09-04

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