EP3155933B1 - Noyau d'air, en particulier pour un matelas ou un coussin et son procede de fabrication - Google Patents

Noyau d'air, en particulier pour un matelas ou un coussin et son procede de fabrication Download PDF

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Publication number
EP3155933B1
EP3155933B1 EP15189607.3A EP15189607A EP3155933B1 EP 3155933 B1 EP3155933 B1 EP 3155933B1 EP 15189607 A EP15189607 A EP 15189607A EP 3155933 B1 EP3155933 B1 EP 3155933B1
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EP
European Patent Office
Prior art keywords
laser light
air core
valve
water vapor
layer
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
EP15189607.3A
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German (de)
English (en)
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EP3155933A1 (fr
Inventor
Alexander Haag
Markus Weder
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.)
Gutknecht Peter
Eidgenoessische Materialprufungs und Forschungsanstalt EMPA
Original Assignee
Gutknecht Peter
Eidgenoessische Materialprufungs und Forschungsanstalt EMPA
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Priority to EP15189607.3A priority Critical patent/EP3155933B1/fr
Publication of EP3155933A1 publication Critical patent/EP3155933A1/fr
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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
    • A47C27/08—Fluid mattresses or cushions
    • A47C27/081—Fluid mattresses or cushions of pneumatic type

Definitions

  • the present invention relates to an air core according to the preamble of claim 1 and to a sleep system equipped therewith and to a method for producing the air core.
  • Sleep systems based on an air core are already well known and commercially available.
  • An important advantage over other systems, which are based for example on conventional mattresses or water-filled chambers, is the possibility of continuous adjustment of the degree of hardness.
  • a generic air core is for example in the EP 1416833 B1 described.
  • films of polyurethane have hitherto been welded using a high frequency process.
  • films with a thickness of about 300 microns or more must be used, otherwise no sufficiently airtight seam can be welded.
  • other welding processes such as ultrasonic welding, hot pressing, hot bonding or friction welding airtight constructions are possible, but also here must be used to ensure an airtight joint similar robust films.
  • the breathability ie the removal of moisture, is much lower than would be desirable. For this reason, the conventional air cores must be provided with relatively thick pads that absorb and store body moisture.
  • An object of the invention is therefore to provide an improved air core, which is particularly suitable for a mattress or a pillow.
  • each of the webs has at least one water vapor permeable outer textile layer (A, A ') and an airtight, water vapor permeable inner membrane layer (B, B'), wherein each of the inner membrane layers has a thickness of 1 to 100 ⁇ m.
  • the inner membrane layers and the outer textile layers are formed from thermoplastic polyesters which are compatible in terms of welding and are firmly bonded to one another in the joining zone by the action of laser light and application of pressure, the inner membrane layers and at least one of the outer textile layers and a collar region of the valve being transparent to laser light. and wherein between the webs, at least in the region of the joining zone and the valve, a laser light absorbing middle layer (C) is located.
  • the measures of the invention initially have the consequence that those layers which ensure the significant combination of features of airtightness and water vapor permeability, so here the inner membrane layers, in comparison to the prior art have a smaller thickness.
  • This advantageous combination is made possible by the joining technique used the laser transmission welding, which due to the inventive arrangement with transparent outer layers and transparent valve collar and an absorbent middle layer (C) allows a localized energy input into the interior of the layer stack.
  • thinner layers can be used, it being understood that the desired combination of airtightness and water vapor permeability is achieved by expert choice of suitable materials.
  • the air cores according to the invention are particularly suitable for mattresses and can therefore be integrated into high-quality sleep systems.
  • the inventive air cores are also suitable for pillows of all types and shapes, which include pillows and pfulmen for sleep systems, but also seat cushions, back supports and other cushion elements in living systems. Another important application is the outpatient and inpatient medical field.
  • thermoplastic materials The technique of laser transmission welding of thermoplastic materials is known per se, and accordingly there are already commercially available welding machines for it.
  • the laser radiation used may in principle be in different spectral ranges, for some applications a wavelength in the region around 1 ⁇ m in the near infrared (NIR) has proven to be advantageous.
  • NIR near infrared
  • diode lasers have proven to produce laser light in this spectral region.
  • An application of laser transmission in the textile sector is in EP 2810772 A1 described, where it is about the production of a water vapor permeable but waterproof textilaminate. This comprises as a top layer a plastic fiber threads having open fabric and a lower layer, a film-like water vapor permeable waterproof thermoplastic membrane sheet.
  • the laser welding process is set to the effect that cohesive Verschmelzungsstellen between the membrane web and the raised thread points of the fabric are created.
  • the layers welded together ie the inner membrane layers and the outer textile layers, can in principle all be formed from the same thermoplastic polyester.
  • they are formed from weld-compatible thermoplastic polyesters, which usually requires a similar chemical nature and a similar melting temperature.
  • the melting temperatures should differ by at most 20 ° C.
  • the water vapor-permeable outer textile layers (A or A ') can be in the form of woven or knitted fabrics and advantageously have a weight per unit area of 80 to 140 g / m 2 .
  • the air core can have a completely symmetrical layer structure, ie a structure ABCBA, in which the two textile layers A are made of a first thermoplastic polyester and have the same thickness, and in which the two membrane layers B are also made of a second thermoplastic polyester and also have the same thickness.
  • the first and second thermoplastic polyesters are identical, but at least compatible in terms of welding technology.
  • less symmetrical arrangements are possible and expedient in order to achieve the best possible design of serving as the top or bottom of the air core pages.
  • the two textile layers A and A 'of different thermoplastic Be polyesters and they can also have different thicknesses.
  • the inner membrane layers (B, B ') are preferably formed from one and the same thermoplastic polyester, but may have different thicknesses.
  • the two textile layers A or A ' are transparent to laser light, so that the layers to be welded are accessible at all.
  • Another object of the invention is to provide an improved sleep system.
  • This further object is achieved by the sleep system defined in claim 10, which achieves at least one air core according to the invention and a pressure regulator device which can be connected to the closable valve of the air chamber.
  • a sleep system may also include a plurality of air cores, wherein the internal pressure or hardness are suitably controlled independently.
  • Such a multi-chamber system is in itself from the EP 0992206 B1 known, but there for conventional air chambers.
  • the quality of the welding of the airtight, water vapor permeable membrane layers (B) and (B '), including the intermediate absorbent layer (C), is decisive for the required tightness of the air chamber.
  • the welded connection with the fabric layers (A) and (A '), however, is important for the cohesion and mechanical strength of the air chamber.
  • the dimensions of the air core are not subject to any particular restrictions and can therefore be selected according to the desired purpose.
  • the dimensions of the air core must be selected in particular according to the size of the lying surface and the number of air cores installed therein.
  • each of the inner membrane layers (B, B ') has a thickness of 10 to 50 microns, preferably from 20 to 40 microns.
  • the inner membrane layers (B, B ') are formed from a polyether ester. Suitable materials in the form of thin film webs are commercially available, for example under the name Sympatex TM from the company Sympatex Technologies GmbH in Unterfohring (D).
  • At least one of the inner membrane layers has a measured according to ISO 11092 water vapor resistance Ret of at most 20 m 2 Pa / W. Expediently, this is the inner membrane layer which is located on the side facing away from the valve and, when installed in a sleep system, comes to rest on the side facing the person.
  • a middle layer (C) absorbing laser light to be present between the sheets to be fused, that is to say between the two inner membrane layers (B, B ').
  • the middle layer C is heated above the melting point of the thermoplastic polymer, so that under the action of a mechanical pressure, the desired joining zone, i. forms an air-tight weld.
  • the middle layer (C) is formed as a light-absorbing coating of at least one of the inner membrane layers (B, B ').
  • carbon black can be applied as the coating material.
  • commercially available coating agents such as Clearweld TM from Crysta-Lyn Chemical Company, Binghamton, NY (USA) may also be used. Such coatings preferably have a layer thickness of 0.5 to 1 .mu.m.
  • the middle layer (C) as another membrane layer of a laser light absorbing thermoplastic polymer having a thickness of 1 to 50 microns, preferably 10 to 40 microns, and more preferably from 10 to 20 microns formed.
  • a black membrane made of a polyether ester which is available, for example, under the trade name Sympatex Standard Black from the company Sympatex Technologies GmbH.
  • the further membrane layer (C) has a water vapor transmission resistance Ret of at most 20 m 2 Pa / W.
  • the air chamber has airtightness according to EN / ISO 9237 of better than 0.02 Lm -2 s -1 at a pressure difference of 2 mbar. This avoids too frequent refilling of compressed air via the pressure regulator device.
  • the circumferential joining zone has a width of at most 2 mm, preferably from 0.2 to 1 mm. This avoids a potentially annoying stiffness of the air core.
  • a diode laser with a wavelength in the range from 0.9 to 1.1 ⁇ m is preferably used (claim 12).
  • this spectral range there are transparent as well as light-absorbing thermoplastic polymers suitable for laser transmission welding.
  • the contact pressure is applied by means of a transparent to the laser light, preferably air-bearing ball (claim 13). It is typically about 0.5 to 1.5 bar, preferably about 0.9 to 1.1 bar.
  • a transparent to the laser light preferably air-bearing ball (claim 13).
  • a laser beam is focused on the joining zone via an air-bearing, almost friction-free rotatable glass ball.
  • the glass ball acts on the one hand as an optical element for focusing the laser beam and on the other hand serves as a mechanical Pressure means. While the ball rolls on the joining zone, a permanent and punctual contact pressure is exerted. With such an arrangement, the thermal energy of the laser is introduced only where a contact pressure is applied.
  • a film of polyethylene (PE) with a thickness of 150 to 400 microns is preferably used, which is characterized by good elasticity and stability and has good transparency for radiation in the range of 0.9 to 1.1 microns .
  • a film of polytetrafluoroethylene (PTFE) having a thickness of 100 to 300 microns can be used.
  • Fig. 1 to 6 not shown to scale, but the thicknesses of different components or the vertical distances between components are shown greatly enlarged.
  • the Indian Fig. 1 illustrated air core 2 comprises an air chamber 4 with an airtight, water vapor permeable casing 6, which is formed by in a circumferential joining zone 8 welded together webs 10, 12.
  • the air chamber is provided with a lockable valve, not shown here for the inlet and outlet of air.
  • Each web is formed by a water vapor permeable outer textile layer A or A 'of a polyester and an airtight, water vapor permeable inner membrane layer B or B' of one and the same thermoplastic polymer.
  • the inner membrane layers are welded together in the joining zone 8 by the action of laser light and application of pressure cohesively.
  • the lower membrane layer B is provided near the edge of the layer stack with a laser light absorbing coating C, which is required to form the joining zone 8 by means of laser transmission welding. For the same reason, at least the layers A 'and B' lying above the joining zone must be transparent to the laser light.
  • the Fig. 1 shows only the near-edge parts of the air core 2, and in particular the lockable valve is not shown.
  • the Fig. 3 shows a central portion of the air core of Fig. 2 , In particular, this is the valve 14 guided through a punched-out region of the film layer.
  • This has a collar part 16 made of a thermoplastic material which is transparent to the laser light.
  • the schematically illustrated laser beam L can be focused on the absorbent layer C through the collar portion.
  • the laser beam is transmitted through an air-bearing, transparent to the laser light glass ball K and focused.
  • the glass ball also serves as a means for exerting a contact pressure P, which presses the collar member 16 against the underlying layer CBA.
  • Such laser transmission welding forms a circumferential sealing zone 18 between the collar part 16 and the layer stack CBA. This is in the representation of Fig. 3 already formed in the right part and is formed straight in the left part.
  • the support table comprises a table plate 22 provided with through holes 20 and a support plate 24 thereon, which advantageously consists of aluminum.
  • the support plate 24 is provided with a central recess 26.
  • a passage for the valve 14 is punched out in a central region of the first path, and then the first web is placed together with the valve on the support plate 24 so that the edges of the first web over the support plate 24 protruding on the table top 22 and rest the valve is inserted into the recess 26 while its collar portion 16 is above the laid-up web.
  • the suction means are turned on, whereby air is withdrawn through the through holes 20 and thereby the first web ABC is fixed to the table top 22.
  • the valve collar is welded by means of laser transmission welding with the first web ABC to form the circumferential sealing zone 18 as already in connection with the Fig. 3 explained.
  • a second web formed by a second airtight, water vapor permeable membrane layer B 'and, overlying, a second water vapor permeable fabric layers A 'launched, whereby a layer stack (A', B ', C, B, A) is formed.
  • a transparent laser-transparent vacuum-tight holding film D is applied over the entire stack of sheets and clamped against the table top 22 to fix the stack of sheets.
  • the circumferential joining zone 8 in turn formed by laser transmission welding.
  • the laser beam is transmitted through an air-bearing, transparent to the laser light glass ball K and focused on the absorbent layer C.
  • the glass ball also serves as a means for exerting a contact pressure P, which presses the layers (A ', B', C, B, A) against the underlying support plate 24.
  • the circumferential joining zone 8 is formed. This is in the representation of Fig. 6 already formed in the right part and is formed straight in the left part.
  • Air cores of various dimensions were produced by the method described above, using a device with airborne spherical optics "GloboOptik” from Leister Technologies AG, Kägiswil, Switzerland, for laser transmission welding.
  • the laser source was a laser diode with an emission wavelength of 940 nm.
  • the optics were mounted on an XY vacuum table, which prevents shifting of the layers during welding.
  • all joint lines can be realized, which can be identified with a CAD editing program in a two-dimensional surface. In particular, it can be used to control circumferential joint lines in a circular or rectangular shape.
  • the process parameters must be selected according to the thickness and the optical and thermal properties of the materials used. It may therefore be necessary in preliminary experiments to determine the minimum laser energy with which the layers fuse together and have the desired strengths, but undergo no thermal damage.
  • the measured airtightness according to EN / ISO 9237 at a pressure difference of 2 mbar was better than 0.02 Lm -2 s -1 .

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  • Lining Or Joining Of Plastics Or The Like (AREA)

Claims (13)

  1. Noyau pneumatique (2), en particulier pour un matelas ou un coussin comprenant au moins une chambre à air (4) équipée d'une enveloppe étanche à l'air et perméable à la vapeur d'eau qui est formée par des bandes soudées les unes aux autres dans une zone d'assemblage (8), la chambre à air étant équipée d'une soupape (14) pouvant être fermée, permettant l'entrée et la sortie d'air qui est soudée dans l'une des bandes,
    caractérisé en ce que
    chacune des bandes comporte au moins une couche textile externe (A, A') perméable à la vapeur d'eau et une couche membranaire interne (B, B') étanche à l'air et perméable à la vapeur d'eau, chacune des couches membranaires internes ayant une épaisseur de 1 à 100 µm, les couches membranaires internes et les couches textiles externes étant réalisées en un polyester thermoplastique compatible avec la technique de soudage et étant soudées les unes aux autres par une liaison par la matière dans la zone d'assemblage sous l'action d'un rayonnement laser et avec utilisation de pression, les couches membranaires internes ainsi qu'au moins l'une des couches textiles externes et une zone de collerette (16) de la soupape étant transparentes à la lumière laser, et entre les bandes, au moins dans la zone de la zone d'assemblage (8) et de la soupape (14) étant située une couche médiane (C) absorbant le rayonnement laser.
  2. Noyau pneumatique conforme à la revendication 1,
    dans lequel chacune des couches membranaires internes (B, B') a une épaisseur de 10 à 50 µm, de préférence de 20 à 40 µm.
  3. Noyau pneumatique conforme à la revendication 1 ou 2,
    dans lequel chacune des couches membranaires internes (B, B') est réalisée en un ester de polyéther.
  4. Noyau pneumatique conforme à l'une des revendications 1 à 3, dans lequel au moins l'une des couches membranaires internes (B, B') a une résistivité volumique vis-à-vis de la vapeur d'eau Ret égale au maximum à 20 m2Pa/W.
  5. Noyau pneumatique conforme à l'une des revendications 1 à 4, dans lequel la couche médiane (C) est réalisée sous la forme d'un revêtement absorbant la lumière d'au moins l'une des couches membranaires internes (B, B').
  6. Noyau pneumatique conforme à l'une des revendications 1 à 4, dans lequel la couche médiane (C) est réalisée sous la forme d'une autre couche membranaire réalisée en un polyester thermoplastique absorbant le rayonnement laser compatible vis-à-vis de la technique de soudage avec les couches membranaires internes, ayant une épaisseur de 1 à 50 µm, de préférence de 10 à 20 µm.
  7. Noyau pneumatique conforme à la revendication 6,
    dans lequel l'autre couche membranaire (C) a une résistivité volumique vis-à-vis de la vapeur d'eau Ret égale au maximum à 20 m2Pa/W.
  8. Noyau pneumatique conforme à l'une des revendications 1 à 7, dans lequel la chambre à air a une étanchéité à l'air selon la norme EN/ISO 9237 meilleure que 0,02 Lm-2s-1 pour une différence de pression de 2 mbar.
  9. Noyau pneumatique conforme à l'une des revendications 1 à 8, dans lequel la zone d'assemblage périphérique a une largeur au plus égale à 2 mm, de préférence comprise entre 0,2 et 1 mm.
  10. Système de couchage comprenant au moins un noyau pneumatique conforme à l'une des revendications précédentes ainsi qu'un dispositif de régulation de la pression pouvant être relié à la soupape pouvant être fermée de la chambre à air.
  11. Procédé de fabrication d'un noyau pneumatique conforme à l'une des revendications 1 à 9, comprenant les étapes suivantes consistant à :
    a) se procurer une table de support (22,24) équipée de moyens d'aspiration commutables (20) et d'un évidement (26) de réception de la soupape,
    b) appliquer une première bande formée par une première des couches textiles (A) perméables à la vapeur d'eau, et, au-dessus une première des couches membranaires (B) étanches à l'air et perméables à la vapeur d'eau, et au-dessus, une couche (C) absorbant le rayonnement laser,
    c) insérer les moyens d'aspiration pour fixer la première bande,
    c) découper à la matrice la bande appliquée sur l'évidement et insérer une soupape (14) dans l'évidement, la zone de la collerette (16) de la soupape venant se positionner sur la bande appliquée,
    d) souder la soupape sur la bande appliquée en déplaçant le long de la périphérie de la zone de la collerette un rayonnement laser (L) au travers de la zone de la collerette, focalisé sur la couche absorbante (C), en utilisant simultanément une pression d'appui (P), une zone d'étanchéité périphérique (18) étant formée entre la soupape (14) et la bande appliquée,
    e) appliquer une seconde bande formée par une seconde des couches membranaires (B') étanches à l'air et perméables à la vapeur d'eau, et au-dessus, une seconde des couches textiles (A') perméables à la vapeur d'eau, de façon à former une pile de couches (A', B', B, A ou A', B', C, B, A),
    f) appliquer une feuille de retenue (D) transparente au rayonnement laser et étanche au vide sur la pile de couches et la fixer en sollicitant la feuille de retenue contre la table de support,
    g) former une zone d'assemblage périphérique (8) en guidant un rayonnement laser (L) focalisé sur la couche absorbante, le long d'une ligne d'assemblage correspondante en utilisant simultanément une pression d'appui (P).
  12. Procédé conforme à la revendication 11,
    selon lequel le rayonnement laser a une longueur d'onde de 0,9 à 1,1 µm.
  13. Procédé conforme à la revendication 11 ou 12,
    selon lequel la pression d'appui est appliquée au moyen d'une sphère transparente au rayonnement laser de préférence à coussin d'air.
EP15189607.3A 2015-10-13 2015-10-13 Noyau d'air, en particulier pour un matelas ou un coussin et son procede de fabrication Not-in-force EP3155933B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP15189607.3A EP3155933B1 (fr) 2015-10-13 2015-10-13 Noyau d'air, en particulier pour un matelas ou un coussin et son procede de fabrication

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP15189607.3A EP3155933B1 (fr) 2015-10-13 2015-10-13 Noyau d'air, en particulier pour un matelas ou un coussin et son procede de fabrication

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EP3155933A1 EP3155933A1 (fr) 2017-04-19
EP3155933B1 true EP3155933B1 (fr) 2018-06-06

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Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
CH715194A1 (de) * 2018-07-23 2020-01-31 Mammut Sports Group Ag Textiles Lagenkonstrukt zur Herstellung eines Kleidungsstücks.

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH687905A5 (de) 1992-05-06 1997-03-27 Airlux Ag Luftversorgungsvorrichtung fuer eine Matratze oder ein Polster mit einer Luftkammer.
DE59807978D1 (de) 1998-10-05 2003-05-22 Aqua Dynamic Ag Rapperswil Luftbett-Pumpe und Aufteilung für mehrere unabhängige Kammern eines Luftbettes
DE20112764U1 (de) 2001-08-08 2001-10-31 Brun, Andreas, Zürich Luftmatratze
EP2810772A1 (fr) 2013-06-07 2014-12-10 Leister Technologies AG Laminé textile étanche à l'eau mais perméable à la vapeur d'eau et son procédé de fabrication

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* Cited by examiner, † Cited by third party
Title
None *

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