JP3012327B2 - Improvements on bonded nonwoven polyester fiber structures - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to improvements in bonded nonwoven polyester fiber structures, and more particularly, to the polyester fibers and the adhesive fibers, which are less than their load-bearing polyester fibers. A novel bonded polyester by adhering a fiberball blended with a low melting point and softening point to obtain a beneficial and novel through-bonded product with an improved structure A novel method and apparatus for obtaining textile products.

Heat bonded polyester fibrous structures are disclosed in my U.S. Patent No. 4,794,038 (and, for example, U.S. Patent Nos. 4,668,562 and 4,753,693, and June 1986).
It is also disclosed in numerous other documents, including WO 88/00258, which corresponds to the serial number 880,276 filed on 30th). Intimate blending of the adhesive fibers with the loaded polyester fiber, if they are properly activated, will result in true "through-bondein" of the polyester fiber.
g) "can be achieved. "Through bonding" refers to resin-bonding of polyester fibers.
g) provides higher support and better durability than (this is the normal method of bonding), and may also exhibit reduced flammability than conventional resin bonding. For the purpose of manufacturing cotton in furniture, mattresses and similar applications where high support and good durability are required,
Blends of adhesive fibers have already been used. In such end uses, they are rarely used as a single filling material, and normal practice has been to use these polyester fiber cores as a "wrap" around a foam core. The main reason is considered to be that it was difficult to achieve desired properties without using such a foamed core. To achieve the desired resilience and durability, fiber batt which has adhered, it is necessary to achieve a high density in the range of 50 kg / m ³ from 35. Commercially, achieving such high densities was not possible until very recently. Even thereafter, such concentrated (i.e., high density) cotton wool, as found in the European and US markets (e.g., 1987), is non-uniform in density such that the lower layer has a higher density than the upper layer; As a result, a large height loss during use occurred. These high density "block batts" or "fibercores" (often referred to as such) are also characterized by giving the user's body much less comfort. It was attached. This is thought to result from the structure that they have, since these mandrels are made from a set of overlapping parallel layers, and these parallel structures are deformed under pressure. When it does, it tends to be pushed on both sides of the whole structure, rather than being locally deformed, i.e. it tends to adapt to the user's body shape and weight, as well as latex or high quality polyurethane foam It is.

Thus, the performance of existing "block bats" made entirely of bonded polyester fibers was not entirely satisfactory. The difficulty existed in how to combine durability and comfort to the human body in one structure. To obtain durability, the carded web
When using the existing "block bat" obtained from s), one obtains a structure that fits the body with the same comfort as other structures, i.e. structures not entirely made of bonded polyester fibers. It was necessary to increase the density to a point where it was not possible. My co-pending patent application Ser. No. 07 / 290,385 by providing a continuous method and apparatus for producing molded blocks of bonded polyester fibers from a blend of polyester fibers and adhesive fibers. (This disclosure is incorporated herein by reference)
According to the invention of the above, the above problem has been solved.

An essential element of a solution to this problem has been to use the three-dimensional form of the adhesive fiber blend as a fiber ball or as a shaped mass of fibers rather than a flat web. Suitable fiber balls (and their manufacture and bonding) were the subject of my U.S. Pat. No. 4,794,038, cited above (the disclosure of which is incorporated herein by reference); It is understood that fiber balls can also be used.

The continuous method as disclosed in my co-pending application serial no.07 / 290,385 requires a mattress core or similar furniture in flat rectangular shape, or that the cross section of the above furniture style has to be varied substantially. It is excellent for a material whose width is only slightly changed within a limited range so that it can be continuously manufactured on a large scale without any change.

However, the cross-section of some furniture cushion designs is not flat and / or rectangular. Sometimes such specific shapes and / or relatively small scales may be desired. With such a cushion style, a continuous molding method as disclosed in my co-pending application Ser. No. 07 / 290,385 may not always be appropriate. This is excellent for continuous production of structures whose dimensions do not change at all or fall only within a certain range. The methods and apparatus disclosed in this co-pending application are also very useful in the manufacture of concentrated fibrous structures having relatively large sizes, such as mattresses. However, the manufacture of furniture cushions and automotive seats using the continuous method disclosed under my co-application results in significant waste material loss, which is the case today with foam. As such, it is necessary to cut regularly large pieces to produce cushions of various sizes and shapes. This not only increases the cost due to weight loss, but also limits the flexibility of this operation.

Accordingly, it is an object of the present invention to provide a simple, flexible, suitable for the production of cushions, for example by directly molding fiber balls to produce a final shape suitable for cushions or other furniture products if desired. To provide a method and apparatus.

According to one aspect of the present invention, there is provided a batch method for forming a loaded fiber product having a shape by first heating a blend of an adhesive fiber and a loaded fiber in a mold and then cooling. (1) molding the adhesive fiber and the load fiber to form a fiber ball;
(2) By placing the fiber ball in a mold,
Producing an assembly of fiber balls, (3) activating the adhesive fibers by hot air blowing through the fiber ball assembly in the mold, and wherein:
Sealing means are provided around the fiber ball assembly to ensure that the hot air passes through the assembly. The above methods provide the flexibility to enable and enable some variations, depending on the commercial needs as detailed below. Suitable loading fibers are cut polyester fibers having suitable denier as used in various filling applications.
For they have good resilience and good support. Suitable polyester fiber,
For details of references to adhesive materials and adhesive fibers, reference may be made, for example, to the documents specifically referred to herein as being incorporated by reference. As can be readily appreciated, suitable adhesive fibers include, for example, shell-core or other types of bicomponent adhesive fibers. These cores may be all or part of the loading fibers, as appropriate, depending on the properties desired in the product having the particular end use and shape.

As will become apparent below, a particularly important aspect of the present invention is the novel cushions obtained by the novel method. These new cushions are products having a preferred shape according to the invention. These word cushions are
It is used here to encompass a cushion core that may be broad and used, for example, as a support in the wrapping of one or more layer (s) of other material (s) to provide a different surface aesthetic. As shown here the adhesive, the novel cushion such is characterized by about 18 with a density of about 45 kg / m ^3, and even these, the adhesive material from the entire fiber (using adhesive fibers Loaded fibers). They also have excellent air permeability which they have, i.e. generally at least 1200 L /
m ² / s, preferably air permeability of at least 2000 L / m ² / s,
And / or according to the test methods disclosed herein,
Water transfer using a 10 cm sample, indicated by at least 50% of the 100 mL portion of the water poured over the sample enclosed in the mounting plastic box being collected within 1 minute, or 10 cm above thickness May be limited by a value adjusted to correspond to

Yet another aspect of the present invention is the novel molds and other devices disclosed herein. The mold is particularly adapted for hot air heating, and thus circulates there through hot air for heating for the purpose of activation of the adhesive material, and then for subsequent cooling It is made of grids and / or plates with perforated moving or movable belts for the purpose of circulating cool air.
Preferably, as described in detail below, the mold is mounted on a frame and then heated in an oven.

FIG. 1 is a schematic illustration of a front view of a device according to the invention.

Figures 2A, 2B, 2C and 2D show some illustrations for various parts of an exemplary template according to the invention. 2A and 2B show perspective views of each individual part.
FIG. 2D shows a front view of portions of a representative mold when they are assembled together. FIG.2C is the same as shown in FIG.2D, but exploded so that each part can be seen more clearly with respect to the co-working parts, all of which are described in more detail below. Will be described.

FIG. 3 shows a perspective view of an "open mold" part assembled together, as described in more detail below.

FIG. 4 shows diagrammatically a semi-continuous device according to the invention.

In accordance with the present invention, a product having a predetermined shape and dimensions (often referred to herein as a cushion) is formed from polyester fiber balls, preferably made from a blend of adhesive fibers and loading fibers, wherein Glue fiber, hot air, microwave (MW) or high frequency (HF)
Activate with.

For example, my USP 4,794,038 or Snyder et al. April 1990
The feed fiber was opened using the method disclosed in the prior art of co-pending application Ser. No. 07 / 508,878, filed on the 12th, the disclosure of each of which is specifically incorporated herein by reference. Later, by receiving the rotation action,
The ball can be manufactured from this blend of feed fibers.

Preferably, the fiber balls are rotated sufficiently to produce an effective fiber ball structure having a three-dimensional fiber arrangement. As explained in the text below, the use of fiber balls is important in order to obtain good distribution throughout the molding equipment, as well as uniform density and good resilience and durability for the molded article. Unlike the requirements for other fiber balls, for the purposes of the present invention, often a significant degree of hairiness
, Ie, exhibit a relatively high value on the measure of cohesion disclosed in my earlier U.S. Pat. No. 4,168,531, so that when molded, they adhere well together (fiber ball and fiber ball It is preferred to use fiber balls.

Placing the mold in an oven and preferably attaching it to a frame simplifies the filling and unloading of the mold. The fiber balls may be charged directly into the mold in which they are formed by activating the adhesive, or they may be charged in a ticking contained in the mold. In both cases, the fiber balls can be heated in a sealed mold, i.e. the part of the mold forms the initial dimensions of the cushion and, when it cools, the final dimensions of the cushion. Alternatively, they may first be heated in a confined state, with or without pressure, at a thickness greater than the thickness (ie, height) of the final cushion.
The mold lid may then be depressed, if desired, to a predetermined dimension after the adhesive has been activated, and by drawing air through a mold having the desired dimensions, The above materials are cooled. The above operation results in a higher output because the oven can be used again for the purpose of heating another mold while cooling the previous mold. However, at lower densities, it is possible to heat the fiber balls faster.

It is important to pump air through the fiber ball assembly. This is preferably achieved by sealing the area between the mold and the frame holding the mold (or the wall of the oven if no frame is used).

Providing the cushion with the desired shape, particularly by creating a regular rectangular surface on its sides, may aid, but is not necessary, to use the mold. Molds are highly desirable for the production of cushions intended for direct use as a finished product.

However, in the normal practice of furniture, the core is wrapped with fiber core cotton (until now such cores have usually been foamed). In such a case, it is not necessary to impart aesthetic perfection to the sides of the cushion, so that another (lower cost) technique ("open molding") can be used as follows: ) Can be used. After sucking the fiber ball into a non-woven or similar ticking and sealing the "cushion", puncture the entire area around the "cushion" while keeping it sealed with plastic foil or other heat resistant material. Place on plate. An upper perforated plate is secured on the cushion at a predetermined distance from the lower plate. Next, hot air is blown through this structure. As with the sealed molding technique, the cushion is either heated or cooled directly to its final thickness without changing its dimensions, or the upper perforated plate (this is the " It can be shaped by lowering it, which acts like a "lid", i.e. it has little or no sidewalls when heated, as it has no side walls. . Another possible variant is to cool the cushion with a lid having the desired shape, for example a curved or specially carved surface.

Place the mold in an oven with an air inlet on one side (preferably below the mold) and an air outlet on the other side (preferably above the mold). Put (fill). Filling and unloading
Suitably, it takes place horizontally, for example by means of a sliding door connected to a filling and unloading mechanism. Preferably, the oven is positioned such that the air inlet is centrally located and the air is vertically directed to the mold and the air outlet is symmetrical with the inlet.

It is generally desirable to use a highly directional air flow in order to make good adjustments to this air flow, and thus to temperature. However, in order to ensure a good and uniform adhesion of the cushion with a large area, a number of perforated plates are provided between the air inlet and the mold, which are provided with air holes arranged opposite one another. This air is more evenly distributed by layering and dividing the air flow.

The system allows direct molding of fiber balls to produce a cushion without material loss by cutting the cushion to produce a shape if desired, which comprises: It can constitute a major economic advantage. These cushions also differ from cushions molded from cotton wool (cushions made from similar fiber blends), which generally have significantly higher densities in valleys than in crests, Can be manufactured to have a uniform density even when they have exactly the engraved surface.

The method and apparatus are inexpensive and flexible, and as a result, allow for the manufacture of custom made cushions having various shapes and sizes simultaneously. In custom molding,
A custom mold (having the desired dimensions) manufactured from a perforated plate or grid is used and is heat resistant, having a suitable size such that there is no gap between the frame and the mold. It rests on a frame consisting of metal bars supporting relatively thick plastic foil or a metal "skirt". This skirt allows hot air to flow through the mold, thus making it possible to produce a variety of cushions of different sizes and / or shapes using a standard frame in the same oven.

The same principle applies to "open molding", whereby whatever size is desired, the "cushion" is placed on a perforated plate or grid, and a suitably sized metal or heat-resistant plastic The area around the base may be sealed with a skirt made of air, and air may be pumped into the cushion. This lower perforated plate may be replaced by a perforated belt,
For example, by intermittently moving into the oven, stopping there for a period of time, and then moving forward, it may serve to fill and unload the cushions. For example, the belt may serve to carry the cushion to a cooling area and remove it therefrom to an area. The upper plate may create the upper shape of the cushion in a cooling zone prior to cooling and solidifying the structure.
The skirt may be conveniently located directly below the belt, and they are made of polyester, polyamide, certain rubbers and other materials capable of withstanding hot air having a temperature of about 150 to about 180 ° C. Is also good.

The above devices and techniques are simple and flexible, require little investment, and can be increased in capacity as desired.

The resulting cushions are characterized by outstanding durability, which can be achieved at lower densities than with the same feed fiber and with concentrated cotton wool. The cushions are also characterized by a high support showing good fit to the user's body. These advantages are believed to result from the internal structure of the cushions, i.e., the fiber arrangement in each of the fiber balls, which arrangement is stabilized by bonding, has a significant vertical component; This provides support even though the adhesion between the fiber balls is low, and
If desired, limited relative movement of the fiber balls within the structure may be possible.

The cushions also exhibit much better (higher) water movement through these cushions and their air permeability at least comparable to concentrated cotton made from the same feed fiber having the same density. Are characterized by It is believed that this improvement relates, for example, to the space between these fiber balls, and more generally to improved fiber placement. This water transfer was developed in my earlier US Patent No. 4,783,364
B) and 4,818,599 (DP-4155), and March 1, 1989
My co-pending application serial no. 07 / 435,513 filed on the 7th
(DP-4349A), the disclosure of each of which is specifically incorporated herein by reference, for example, by coating the fibers with a hydrophilic permanent coating.

Due to these properties of the cushions, they are particularly suitable for furniture and garden applications, for example, for example used in homes and automobiles.

In accordance with one embodiment of the present invention, these fiber balls may be sucked or blown into a ticking, then closed and placed on the bottom of a perforated mold.

According to another embodiment of the present invention, the mass of the fiber ball is heated without any pressure and the heated mass is then placed on top of the mold (which may also be perforated). Press down to a predetermined shape and size and cool by drawing cool air through the mold. The cushion is then removed from the mold and used directly or, if desired, the ticking can be recovered and reused. According to another embodiment of the present invention,
The ticks packed with the fiber balls may be placed in a sealed mold and the adhesive fibers activated to give the cushion its final dimensions.

According to another variant of the invention, the packed ticks may be placed on a perforated plate or grid to completely seal the area between the cushion and the oven wall. Next, the adhesive fibers are activated with hot air and then given a shape by cooling the cushion between two perforated plates or in a mold. The cushion may also be heated between two perforated plates.
The presence of this top plate usually makes the upper portion of the cushion stiffer and improves the adhesion of the cushion sides.

According to yet another embodiment of the present invention, the fiber ball may be sucked directly into the bottom of the mold, and after activating the adhesive, the mass of the fiber ball is compressed to yield its final dimensions. And may be cooled by drawing air through the mold. To facilitate mold removal of the cushion, preferably the bottom of the mold should be provided with a removable base from which the molded piece can be removed by pushing it up.

The adhesive fibers are preferably activated with hot air.
By feeding this hot air into the fiber ball mass in the mold, it is possible to achieve effective bonding within a short heating cycle. To ensure that air passes through the fiber balls in the mold, their perimeters around the mold should be completely sealed. This can be achieved by surrounding the mold with a heat-resistant plastic sheet or metal plate, eliminating any gaps between the mold and the frame holding it.

Furniture cushions come in a variety of shapes and sizes, and the number of cushions of each size and shape that can be manufactured is limited. Avoiding all gaps between and can be complicated. In commercial operation, it is also possible to manufacture plates and frames that fit each and every cushion to be manufactured and keep them in storage, including sufficient frames and plates, and manufacturing and Replacement costs and time are required. Therefore, a solution to this problem has been developed, which ensures that the gap between these molds and the oven walls is sealed and has a different plate or frame for each and every cushion It reduces the need for The present invention also provides a system that allows the cushion shape to be easily changed, or if desired, to produce cushions having completely different shapes. A special oven for forming fiber balls according to the invention has also been developed. The oven consists of two chambers with a frame and a mold located between them. The oven is preferably vertical.

After hot air is introduced from the bottom or top of the vertical oven, the hot air is passed through the mold by sealing the gap between the mold and the holding frame. After introducing the frame into the oven through a sliding door, hot air is injected. For the purpose of saving energy, the hot air may be collected and then reheated to its working temperature for reuse. This heating cycle depends on a number of factors, including: The density of the fiber ball mass, air temperature, air flow, the resistance of the mold and perforated plate to the air flow, and the temperature of the oven chamber. After the heating cycle is over, the mold is removed, the top of the mold is pressed down to the desired height for the cushion, and then the cushion is removed by drawing cool air through the structure. Cool to approximately room temperature. This working temperature depends on the adhesive fiber and is preferably below 185 ° C. For economic reasons, it is desirable to work with a high air flow, thereby minimizing the duration of this heating cycle.

Preferably, in accordance with the present invention, a frame is used to hold the mold and thereby provide a large open space. These frames may be connected and chained together or may be a rotating system so that a continuous or semi-continuous method can be achieved. These frames support the lower part of the mold, which may be supported by the frame or conveniently rested on rods extending from the mold.
The gap between the mold and the frame is covered with a sheet of metal or plastic welded, glued or glued to the sealing means, preferably the support bar.

When using this "open mold" technique, the frame simply supports the perforated plate and the cushion, and the gap between the oven wall and the cushion is:
Sealed by plastic foil or metal sheet or similar material. This can be provided by using a belt to move the cushion, wherein the belt is perforated, for example a perforated metal plate,
Or, if desired, for example, a grid of aramid fibers suitably coated with a "non-stick" coating.

Place the frame in an oven equipped with devices for precisely controlling the air flow and air temperature. The oven may also be equipped with thermocouples to monitor and adjust the air temperature in different parts of the oven. The key points in placing these thermocouples have been found to be the air inlet, preferably the air inlet located just below the mold, and the air outlet. Other thermocouples may be placed in other parts of the mold to allow this temperature uniformity to be adjusted. To achieve good control of this temperature and flow,
The airflow needs to be directed. However, if this results in uneven heating of the cushion, resulting in uneven stiffness, disrupting this air flow between the air inlet and the mold, as is known in the art. It is possible to circumvent this problem by using a set of appropriately spaced parallel perforated plates with holes arranged facing each other. The bottom of each mold may be provided with a metal rod bridging the gap between the mold and the frame holding it. A plastic skirt made of a heat-resistant thin film that fills a gap between the mold and the frame may be fixed on the metal bar. The present invention allows the use of a set of frames with a permanent filling and unloading system and is required by replacing the mold or changing the shape of the filled cushion. Any cushion that is available. The sealing of the system is ensured by the skirt provided on the mold. This skirt can be easily cut from a suitable plastic film.

With reference to the figures in more detail, a preferred apparatus according to the invention is schematically illustrated in FIG. This device can be generally referred to as an oven 10 in which a mold 11 is located. The frame 12 itself is supported by lugs 20 or by other suitable fixed supports mounted on the inner wall of the oven 10. By providing the mounting skirt 13, the gap existing around the periphery of the mold 11 is sealed. This skirt 13 is
And are held in place by rods 14. The mold 11 is provided with a movable base 16 which is perforated to allow air after being heated by a heater 23 to pass through the mold through an inlet 21 supported by a fan 24 below. , And vented from the top through outlet 22. Equipped with perforated plates 25 to serve as baffles, whereby an improved distribution and uniformity of the air flow is obtained, since there is a lateral displacement with respect to these perforations.

The various parts associated with template 11 are shown in detail in FIGS. 2A, 2B, 2C and 2D. FIG. 2D shows the various parts somewhat assembled as in FIG. 1, while FIG. 2C shows an exploded view of these same parts (these are shown individually and in perspective in FIG. 2A). Has been). In FIG. 2D, a frame 12 supports a skirt 13, on which a bar 14 protruding from a mold 11 (also shown with a lid 15), and a removable base 16 (these Both have holes, but the holes are not shown). Although mold 11 and skirt 13 are each shown in FIG. 2A as having to have a square cross-section, different cross-sections may be used, for example, as shown in FIG. 2B. FIG. 2B shows a mold 11 having a cross section like a four-leaf clover, and a skirt having a shape corresponding thereto.
13 is shown. Thus, it will be appreciated that it is possible to produce a wide variety of differently shaped cushions in the same oven simply by changing the shape of the mold and matching it to the peripheral skirt.

FIG. 3 shows a perspective view of the "open mold" concept, in which the fiber balls are initially sized as desired (this may be the size desired for the final cushion). After filling in the ticking with hot air, the adhesive fibers are activated with hot air while the cushion is located between the upper and lower perforated plates or, if desired, between the grids. in this way,
Starting from the bottom in FIG. 3, as before, the frame 12 supporting a skirt 13 is shown, which is provided with a perforated plate 16 'serving as a base for a cushion 17 (with hot air the adhesive Prior to activation, generally tick-fill it with a fiber ball and then seal), and the cushion is located between upper plate 15 'and lower plate 16', and these plates are held together. At each corner, the threaded rod 18 is adjusted to the same length by adjusting the position of the bow nut 18A shown here (to maintain a uniform thickness for this fiber ball assembly, i.e., cushion). It may be fixed. Upper plate 15 'and lower plate 1
Holes 19 are open in both 6 '(only some representative holes are shown in the figure). Suitable sizes may be as follows. Frame 12 with a thickness of 10 mm, whose cross section is formed as an open square, with an outer length of 800 mm and an inner length of 650 mm; an outer length of 750 mm and an inner length of 600 mm Skirt 13; 2 with a thickness of 50 mm, whose cross section is shaped as another open square
1.5 mm thick perforated plate 16 ′ with holes about 3 mm in diameter and about 3 mm in diameter and each piece being 700 mm long; any desired thickness Has a square cross section with a piece length of 600 mm (skirt 1
3) cushion 17; upper plate 15 ', which may be similar to bottom plate 16', to accommodate the inner length of 3;

The concept of the open mold can be easily automated and labor costs reduced by replacing the lower plate 16 'with a belt, for example as shown in FIG. The concept of this process is that heating zone 47
And a cooling zone 52 provided with a belt 45 which moves the cushion 41 from the filling zone 42 to the heating zone 47 and then moves from the cooling zone 52 to the final removal zone 54. Can be used.

Hot air (e.g., fan 43) is applied to the cushion present between the belt and the upper plate 46 attached to the piston 48 which lowers and releases the upper plate required for this operation. Use) the belt
This is done by pouring through 45. The upper plate is typically a perforated metal plate that may be flat or shaped to have the shape of the cushion, depending on the design of the cushion. Usually, in designs where there is a small to intermediate change between the maximum and minimum points on the cushion surface, it is not necessary to use a shaped upper plate. For such cushions, satisfactory results can be achieved by heating the cushion between the belt and the flat plate and then shaping it in a cooling zone prior to cooling.

As with the open mold disclosed in FIG. 3, in order to achieve rapid and effective molding, sealing means for blocking the escape of hot air from the part of the belt surrounding the cushion, for example the skirt 44 It is important to use This skirt may be made of polyester, polyamide sheets, special rubber, or other materials that can withstand temperatures up to about 180 ° C. This is conveniently located below the belt in the heating zone and fixed on a metal frame that can slide into a horizontal slot located directly below the belt. Or a single continuous sheet that can be wound and unwound perpendicular to the belt so that the appropriate skirt is in place under the belt. Is also good.

For the purpose of saving energy, automatic sliding doors 53 may be installed in both the heating and cooling zones, which open and remove the cushions and close during heating and cooling operations. An advantage of this embodiment is that it allows heating and cooling to be performed simultaneously on two different cushions.

As with the open mold disclosed in FIG. 3, the upper portion of the cushion can be given a shape before or during cooling by using a shaped upper plate 50 in the cooling zone. Like the heating zone, the upper plate 50 is attached to a piston 51, which moves the plate up and down to give the cushion before and during cooling, and after this cooling cycle, Release it. This cooling zone
52 may be provided with a fan 49 and another skirt 44, for example, as well as the heating zone.

Description of test method Bulk measurement using an Instron device according to the usual method shows that the cushion (size 50 cm x 50 cm x 10 cm) has a function as a function of compression force when compressed with a foot having a diameter of 10 cm. The height (expressed in mm) was measured. After one compression cycle (no measurements taken during this time), during the second compression cycle the following values are recorded: H2: initial height, ie the height of the cushion at the beginning of the second cycle.

 Support Bulk (SB or 7.5N): Height under 7.5N force.

 Bulk 60N (B or 60N): Height under 60N force.

Absolute term (AS, ie, IH2-7.5N) and relative term (RS, ie, expressed as a percentage of IH2,
S) Both, calculate the softness.

A stiff cushion corresponds to a high support bulk, ie, opposite to softness.

Resilience, work recovery (W
R), ie, the area ratio under the total recovery curve, calculated as the percentage of the area under the total compression curve. this
The higher the WR, the better this resilience.

Durability Each cushion has a polyester spun bonded nonwoven cover, weighs 18g /
m ^2.

The various compression values these cushions have are measured and recorded (as BF before bending) and are shown in Table 3A. Next, the cushion was subjected to 10,000 continuous bendings at a rate of 1400 cycles / hour under a pressure of about 133 g / cm ² , and the compression value was measured and recorded again (after bending).
AF). These changes are shown in Table 3B as percent loss from the BF value.

Measuring Water Movement The purpose of this test is to measure how fast water flows through the structure. For applications such as garden fixture cushions, boat cushions and car seats, it may be important that this value be high. Because there was no standard method for measuring this property for the above mentioned heavy goods, the geotextile test (geotextile tes)
The following method was developed by modifying t). With the thick products, foam blocks or similar products of the present invention, water tends to flow through both sides of the block rather than through the block. Therefore, the device was modified so that the cushion specimen was placed in a plastic box as described below. Prior to introducing the cushion, the side walls of the plastic box were covered with a thin layer of high viscosity silicone oil.
A 15 cm x 15 cm block of 10 cm thickness is cut from the test material and placed in a plastic box in the device. The box is then closed with a plastic lid with a 150 mm diameter hole. Pour 100 mL of water at a time through the hole into the top of the test block, collect the water in a measuring glass cylinder, and record the amount of water collected as a function of time. The cushions made according to the present invention have sufficient water transfer to allow more than 50% of the 100 mL of water to be within one minute, which is an excellent result and superior to the prior art. ing.

Measurement of air permeability Again, there is no existing method for measuring the thick blocks. Therefore, by placing the block in a sealed box with air inlets and outlets with small diameters to allow the flow of air through the block and avoid the air flow through both sides of the block Improved air permeability test for textiles.

15x15 with a round hole 15mm in diameter at its base
In a plastic box of cm, the same dimensions 15 × 15 ×
Place a block of test cushion having 10 cm. The upper part, which is sealed at its bottom part and provided with a round hole also having a diameter of 15 mm, seals the box. Air permeability testing equipment (Texitl Testing Instruments, Zuric
h. Insert a soft plastic tubing (40 mm diameter) connected to a commercialized and manufactured by Swisserland), then inhale air through the hole in the base. Measure the air permeability under the standard conditions used for measuring the air permeability of the fabric and record as L / m ² / sec for the 10 cm thickness above (ie liter per square meter per second) . Cushions made in accordance with the present invention exhibited an air permeability greater than the excellent value of 1200 L / m ² / sec (for the 10 cm pressure above).

As long as this cushion provides adequate support,
High air permeability is desirable.

The invention is further described in the following examples. It is noted that for comparison purposes, cushions were made from a similar blend without the initial fiber ball production, and each of these was labeled "Compare." All parts and percentages are herein by weight on a fiber basis unless otherwise specified. The molds used in these tests were provided with flat upper and lower portions and had a rectangle with rounded corners and edges. For the purpose of demonstrating the advantages of the cushions made in accordance with the present invention with respect to the above properties, the above-mentioned shape was used which facilitates measurement of air permeability and water movement for the resulting cushion.

Comparison A This section is not in accordance with the invention, but is merely for comparison purposes.

Using a commercially available standard garnet device,
dtex4 hole (25% void) polyester fiber fill (f
iberfill) and a 20% blend of commercially available 17dtex shell-core polyester adhesive fibers (50% core / 50% shell) with a density of about 450 g / m ²
Made of cotton wool. The cotton wool was heated at 165 ° C. for about 3 minutes and calendered to a thickness of 40 mm. The cotton wool is cut into squares measuring 50 × 50 cm, and five and half of these squares (layer split horizontally through the middle) are layered on top of the bottom of the mold. To give 5 layers and one layer split horizontally through the middle part.

The mold was closed at the top of the mold to create a chamber with an inner height of 10 cm, then placed on a frame and placed in the oven shown in FIG. Hot air at a temperature of 170 ° C was injected for 30 seconds (Leister lufthitze
r Type 40,000 used). After removing this mold, 30 ℃
Air-cool until it reaches
A molded cushion of 25 kg / m ³ and dimensions of 50 × 50 × 10 cm was obtained.

Comparative B Using the same blend as Comparative A, but with the same mold, molding equipment and procedure, but using 10 layers of cotton, a cushion having the same dimensions but a density of 45 mg / m ³ was obtained. .

Comparative C 13 dtex 4 hole 25% void polyester fiber fill coated with 0.5% (hydrophilic) co (polyether polyester) 80% and 17 dtex shell-core polyester bond using standard garnet equipment available commercially A 20% blend of agent fiber (50% core / 50% shell) was processed to produce about 450 g / m ² cotton wool. These cotton wools were then processed as in Comparative A, except that the hydrophilic coating on the loaded fibers was used.

Comparative D Using the same blend as Comparative C with the same mold, molding equipment and operation except using 10 layers of cotton wool,
As in Comparative B, have the same dimensions but a density of 45 kg / m
^Three cushions were obtained.

Example 1 Open the same fiber blend as in Comparative C (but cut to 50 mm length) and use a modified carding device to about 50 kg / m
Processing at a production volume of ³ produced a fiber ball with an average diameter of 5 mm. These fiber balls were packed to generate a dust having a density of 80 kg / m ³ . After sucking 625 g of the fiber ball into a lightweight spunbonded polyester ticking having the shape of the cushion to be molded, the ticking was closed. After placing the filled ticks in the bottom of the same mold, the mold was closed at a predetermined height, as in Comparative C, to produce a 10 cm thick cushion. After heating the mold for 30 seconds, it was cooled by drawing cool air through the mold. By opening the mold and opening the tick, the thickness is reduced
A 25 cm / m ³ cushion of 10 cm was taken out.

Example 2 A fiber ball having the same dimensions but having a density of 40 was formed by molding the fiber ball used in Example 2 in the same mold in the same manner except that 1000 g of fiber ball was used.
A cushion of kg / m ³ was obtained.

Table 1 shows air permeability measurements for the above products and foams having comparable densities. There was little difference between the concentrated cotton wool (Comparative D) and the corresponding fiber ball block of the same density (Example 2), and there was little difference between Comparative C and Example 1. Because the fibers of Comparatives A and B are not smooth, they show lower air permeability (even though they were made from fibers having the same denier).

The foam showed much lower air permeability than the same density product made according to the present invention. The improved air permeability helps to dissipate the excess body heat and thus improves the comfort of the user.

Comparatives A and B (similar to foam) retained the water completely and did not pass through when extending the experiment to 15 minutes. The reason for this is that due to the hydrophobic character of these fibers, they are moist and do not pass through due to the retention of water in their structure. In comparisons C and D, water passed almost immediately. As expected, the rate for 25 kg / m ³ cotton (Comparative C) was higher than for 45 kg / m ³ cotton (Comparative D). The difference between Comparatives A and B was essentially due to the hydrophilic coating of the fibers of Comparatives C and D. The product of the present invention (made using molding fiber balls made from the same fibers) gave significantly more rapid water transfer. After 3 minutes, the water retention of 25 kg / m ³ of cotton wool (Example 1) was only 38% compared to 50% for Comparative C. The water transfer for Example 1 was almost instantaneous, only 20% in Comparative C, even after only 10 seconds.
50% of the water was collected.

The water transfer exhibited by the cushion of the present invention is almost independent of density, since there is little difference in the amount of water collected after 3 minutes, 25 kg / m ³ (Example 1). 40k
g / m ³ (Example 2).

The data in Table 3A clearly shows that the products according to the invention have a high support and resilience (WR).

Example 1 (25 kg / m ³ of the cushion according to the invention)
Comparative D (45 kg / m ³ concentrated cotton wool manufactured from the same fiber)
Higher support. The resilience (WR) of Example 1 was substantially higher than that of Comparative B or D manufactured to a density of 45 kg / m ³ . Another advantage of the products according to the invention is their durability. Again, Example 1 generally had better durability than any of Comparatives A through D, even though the density of Comparatives B and D was 45 kg / m ³ . Product of the invention prepared according to Example 2 (density of 40 kg / m ³ )
Showed negligible bulk loss. A clearly higher change in percent softness corresponds to an absolute change of less than 5 mm.

These results show that the cushions according to the invention at 25 kg / m ³ give better support and durability than the comparison (even at a density of 45 kg / m ³ ). This is an important economic advantage of the product, in addition to the low cost of performing the method of the invention.

The above examples gave very good results. However, the automatic open mold concept as disclosed and described, for example, in FIG. 4, is also preferred in view of economic considerations. Such methods and apparatus may be preferred,
Here, the ticks filled with fiber balls are first placed on a perforated plate (or grid), then the supporting plate is placed into the heating chamber (automatically) and then (after the heating cycle). ), Removing the plate supporting the resulting cushion from the heating chamber and transferring it to the cooling zone. As support for the ticking (and resulting cushion), a belt can be used if desired. Suitable equipment may include means for simultaneous filling and unloading of the mold, means for placing and removing the mold resting on the support from the oven, and, if desired, a cooling location.

Claims (20)

(57) [Claims] The present invention relates to: (1) forming an adhesive fiber and a load fiber to form a fiber ball; (2) placing these fiber balls in a mold to form a fiber ball assembly; ) Hot air blowing through the fiber ball assembly in the mold activates the adhesive fibers, and wherein sealing means for ensuring that the hot air passes through the assembly is provided around the fiber ball assembly. A batch method for forming a shaped loaded fiber product by first heating a blend of adhesive fiber and loaded fiber in a mold, followed by cooling. 2. The fiber ball is placed in a perforated plate or a mold containing a grid exhibiting high air permeability, wherein the sealing means is a metal which is thermally stable at 180 ° C. Or a plastic sheet,
The method of claim 1. 3. The mold of claim 1, wherein the mold includes a base and a lid, and wherein at least a portion of the base is movable to facilitate removal of the molded article from the remainder of the mold. The method of range 1. 4. The method according to claim 1, wherein after filling the fiber ball into a ticking, the filled ticking is put into the mold before activating the adhesive fiber. The method described in the section. 5. The method according to claim 1, wherein the mold is cooled without changing the dimensions of the mold after sending the hot air through the fiber balls. 6. Activating the adhesive to reduce the thickness of the product by depressing the top of the mold prior to cooling the fibers to produce their final shape; A method according to any one of claims 1 to 3. 7. The mold includes a bottom and a lid, wherein the filled ticking is placed in the bottom of the mold and after activating the adhesive fibers, the adhesive is bonded to the adhesive. The shape is given to the product by pushing the lid down while at or above temperature to produce the predetermined shape and dimensions for the product, and then the cooling by cooling the fibers. 7. A method according to claim 6, wherein they are cured in the form of broken products. 8. After filling the fiber ball into a ticking, the filled ticking is placed on a perforated plate, and the area around the filled ticking is sealed with a plastic or metal sheet. 3. The method of claim 2 wherein said means is sealed by means and forcing said air through said assembly. 9. The method of claim 8, wherein said assembly is shaped during molding by defining an upper side of said assembly with a perforated plate. 10. After activating the adhesive and before cooling the assembly to produce its final shape.
9. The method of claim 8, wherein the assembly is given a shape. 11. The mold includes a bottom and a lid, wherein the fiber balls are directly filled into the bottom of the mold, and then the lid is pressed to achieve the desired size of the molded article. The method of claim 1 wherein the assembly is cooled after producing a final thickness and activating the adhesive fibers. 12. The mold includes a bottom and a lid, and after filling the fiber balls to the bottom of the mold, heats the assembly to a thickness greater than the final thickness desired for the molded article. 3. The method of claim 1 or 2, wherein the assembly is cooled after the lid is depressed to a predetermined desired thickness. 13. Characterized by being for use in furniture, car seats, garden fixtures and the like, and characterized by exhibiting an air permeability of at least 1200 L / m ² / sec per 10 cm thickness. , Cushions molded from fiber balls. 14. The cushion according to claim 13, characterized by having a density of about 18 to about 45 kg / m ³ . 15. Air permeability per 10 cm thickness is at least
15. The cushion according to claim 13 or 14, characterized by being at 2000 L / m ² seconds. 16. A method wherein at least 50% of 100 mL poured over a 10 cm thick sample placed in a plastic mounting box has a water transfer value at least sufficient to be recovered within one minute. The cushion according to claim 13, 14 or 15, which is attached. 17. The base (16) is one or more grids or plates, provided with holes (19) for allowing the passage of heating air therethrough and resting on a frame (12). And a skirt (13) adapted to provide an air seal around the periphery of the mold to prevent the heating air from passing through the side of the mold.
A mold (11), characterized by comprising: 18. A mold (11) having a hole (19) adapted to pass heating air therethrough, an air inlet (21) located on one side of the mold (11), the mold An air outlet (22) located on the other side of (11) and at least two layers of perforations present between the air inlet (21) and the mold (11) Plate (25)
And wherein the holes of said plate (25) are arranged in relation to each other for the purpose of improving the uniformity of the air distribution.
An apparatus for forming a fiber ball to produce a molded article, comprising: 19. An air recycling system for heating the air to a desired temperature.
19. The device according to claim 18. 20. The method according to claim 18, further comprising means for opening and closing said heating chamber as said mold is charged and removed from said heating chamber.
Or the device according to 19.