WO2011014603A1 - Matériau de siège et procédé de formation - Google Patents

Matériau de siège et procédé de formation Download PDF

Info

Publication number
WO2011014603A1
WO2011014603A1 PCT/US2010/043624 US2010043624W WO2011014603A1 WO 2011014603 A1 WO2011014603 A1 WO 2011014603A1 US 2010043624 W US2010043624 W US 2010043624W WO 2011014603 A1 WO2011014603 A1 WO 2011014603A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
fiber web
polyester
web pad
surface material
Prior art date
Application number
PCT/US2010/043624
Other languages
English (en)
Inventor
Gregg Laframboise
Original Assignee
Johnson Controls Technology Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Controls Technology Company filed Critical Johnson Controls Technology Company
Publication of WO2011014603A1 publication Critical patent/WO2011014603A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • B32B5/145—Variation across the thickness of the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2601/00—Upholstery

Definitions

  • the present invention is directed to a seating material and method of forming materials for use in vehicle seats. More specifically, the present invention is directed to an environmentally friendly upholstery material and method of forming that reduces or eliminates the use of adhesive while increasing the use of post-consumer and post-industrial waste materials.
  • Vehicle seats and other upholstery products generally include a cushion portion or plus pad that is surrounded and shaped by a surface material that forms the seating surface, outer surface face material or Class A surface of the seat.
  • This face material may be formed from a variety of materials, and is commonly a cloth material formed from polyester or other material which is not polyurethane.
  • the plus pad is commonly formed from a polyurethane material and adhered to or laminated with adhesive foam to the class A surface.
  • the polyurethane foam plus pad may receive a scrim coating, opposed to the face or surface material further shape the plus pad, or to allow for easier assembly. To ensure proper assembly, these materials especially when they are formed from dissimilar materials, are generally laminated together with adhesive, and are generally laminated with adhesive when both are formed from polyester.
  • the present invention is directed to an upholstered material and more particularly, a seating material and method of forming materials for use in upholstered products, such as vehicle seats. More specifically, the present invention is directed to an environmentally friendly seating material and method of forming that reduces or eliminates the use of adhesive while increasing the use of post-consumer and post-industrial waste materials.
  • the present invention eliminates the need for an adhesive and allows bonding of materials through heat lamination that was previously not possible, and in particular, allows the use of more environmentally friendly materials without the use of adhesive. More specifically the present invention, through controlling of placement of fibers of differing melt temperatures or open melt times in a fiber web pad allows heat lamination of the fiber web pad to a class A surface, without the use of adhesive.
  • FIG. 1 illustrates a method of forming a fiber web pad of non-woven fibers
  • FIG. 2 illustrates an exemplar process of bonding a face material with a fiber web pad
  • FIG. 3 is an enlarged schematic cross section of the bonded material
  • FIG. 4 illustrates an exemplary process of bonding a face material with a fiber web pad
  • FIG. 5 is an enlarged schematic cross section of the bonded material
  • FIG. 6 illustrates an exemplary process of flame lamination
  • FIG. 7 illustrates an exemplary process of flame lamination.
  • the present invention is generally directed to a surface material 10 as well as a method of forming the surface material 10.
  • the surface material 10 may be used in many industries and has broad applicability in many industries for surface materials and seat coverings, along with the method of forming.
  • the present invention may be used in vehicle seats, soft surface materials for door panels and other trim components of vehicles, furniture, including office, commercial and home and any other industry or product where a surface material is typically bonded or adhered to a foam or cushion material.
  • the surface material 10 in its final assembled state has dimension and depth such that it is more than just a surface but also typically provides some structure and cushion, such that when one presses on the class A material, the surface material moves as desired.
  • the surface material 10 is generally formed from a fiber web pad 20 and a face material 30 that forms the class A surface.
  • a backing or scrim material 40 which is bonded or laminated to the fiber web pad 20 generally on the opposing side to that of the face material 30.
  • the finished product of surface material 10 is generally referred to as an interface fabric.
  • the face material 30 and fiber web pad 20 are generally formed from polyester, preferably polyester fibers, and the fiber web pad 20 is more preferably, formed from air or gravity laid fibers. More particularly, the present invention includes a process and materials that allow the face material 30 and fiber web pad 20 to be formed from a high content of post-consumer and post-industrial recycled material.
  • the method of the present invention makes it possible to bond together materials with high- recycled content without the use of adhesive.
  • the fiber web pad 20 and face material 30 are heat bonded without the use of an added adhesive.
  • manufacturers were not able to bond such materials together without the use of an added adhesive.
  • the fiber web pad 20 is formed by airlaying or gravity laying polyester fibers, as illustrated in FIG. 1 into a cohesive unitary product having the desired density and deflection rates.
  • the fibers may be distributed by melting point or open melt times, such that the outer surfaces or surface of the fiber web pad 20 may have a lower melting point than the core of the fiber web pad 20 or locations removed from a surface configured for heat bonding.
  • Such control over the placement of fibers allows variations within the fiber web pad 20, such as controlling where certain fibers are placed based upon their with different melting points or open melt times and also controlling the amounts of each type of fiber in a specified area of the foam web pad 20.
  • This control allows predictable and consistent melting temperatures and open melt times of the fiber web pad. More specifically, adjustments to the open melt time and melt temperature as well as strength of any bond formed with the face fabric 30 may be controlled by this variation and control of fiber.
  • the melt temperature and time to melting point from when heat is applied as well as the open melt time may be varied. Therefore, not only does air or gravity laying the fibers allow control of loft and density but also control of the placement of different fibers and in particular control of the placement of fibers having different melting points or open melt times, or different times to reach melting point, as well as the blend of fibers having different melting points in a given area, and even allow control of the placement of fibers having different chemical compositions.
  • the overall bonding characteristics such as the open melt time, bonding strength and temperature at which bonding occurs may be adjusted. For example, it may be preferable to provide 80% of a standard mix of fibers and 20% fibers of lower melting temperature fibers or less time until melting point is reached than the standard mix of fibers.
  • An exemplary fiber could have various lengths and the size and diameter of the fibers may vary, all affecting the melting time, melting point and open melt time characteristics of the fibers.
  • the system allows for the weaving of a flat layer in a desired thickness as well as placement of certain blends of fibers to create the fiber web pad 20 that replaces the typical polyurethane foam plus pad that have been heat laminated previously to face fabric.
  • heat is applied to the fibers as they are laid or after they are laid such that the fibers heat bond together to create a single porous pad of the desired density, deflection and other characteristics as discussed above.
  • polyester fibers have a large tacky range such as polyurethane. Therefore, it was difficult to control when polyester becomes tacky such that it was difficult or inconsistent when heat bonded to other polyester materials.
  • polyurethane has a large range of temperatures and times where it becomes tacky and is easily bonded to other materials.
  • using standard polyester fibers without using the present invention to place polyester fibers of different melting points or open times in the foam web current manufacturing processes were not able to sufficiently heat bond the materials together through heat lamination.
  • the face material 30 may be any commonly used class A surface material that includes polyester or has a backing including polyester to which the fiber web pad 20 may be heat punched.
  • the heat may be applied by heat rollers 100 that allow heat to saturate through the material, specifically the fiber web pad 20 and face material 30.
  • the bonding force is then provided when the combined layers 20, 30 are pressed together by the forming rollers 102.
  • FIG. 4 illustrates an additional pair of heat rollers 100 on each of the materials to create pressure and heat soaking to both sides of the individual portions of the material 10.
  • only one of the rollers could be heated or one set of rollers while the opposing rollers are not heated.
  • the forming rollers 102 then press and form the combined layers 20, 30 together in the material 10. This process speed, temperature of the heat rollers and amount of pressure by the forming rollers 102 may vary.
  • the final material includes a face material 30 having a bond area 35 with the fiber web pad 20 where the two materials are heat bonded. While the present invention allows recycled polyester fibers to be used, the heat lamination could also be done with virgin materials. Significant benefits include the easy allowance in the manufacturing process of recycled materials and the elimination of the need for adhesive, thereby creating environmentally friendly materials from a content standpoint as well as the end of life cycle standpoint. While the drawings and the application discuss the surface material 10 being directed to seats and other vehicle materials such as headliners, door panels, arm rests, dash panels and more, the materials may also have applicability to houses and offices such as the materials on the facing of cubicles.
  • a flame lamination such as an open flame may be applied to the foam transforming a thin layer of the polyester to a tacky or adhesive state.
  • the scrim fabric 40 may also be bonded through heat to form the surface material 10. While FIGS. 3 and 4 show bonding through heat rollers without a scrim, additional heat rollers may be used to include the scrim fabric 40 being bonded to the fiber web pad 20, similar to that as shown in FIG. 7.
  • the scrim layer 40 also will need to be polyester to provide a sufficient bond such that the materials are generally similar in nature to allow for a complete bond to each other.

Landscapes

  • Laminated Bodies (AREA)

Abstract

La présente invention porte sur un matériau de mobilier, et, plus particulièrement, sur un matériau de siège et sur un procédé pour sa formation. Le matériau de mobilier est formé à l'aide de matériaux écologiques, et un procédé de formation réduit ou élimine l'utilisation d'adhésif, tout en augmentant l'utilisation de matériaux de déchets après utilisation et post-industriels.
PCT/US2010/043624 2009-07-31 2010-07-29 Matériau de siège et procédé de formation WO2011014603A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US23022009P 2009-07-31 2009-07-31
US61/230,220 2009-07-31

Publications (1)

Publication Number Publication Date
WO2011014603A1 true WO2011014603A1 (fr) 2011-02-03

Family

ID=43529691

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2010/043624 WO2011014603A1 (fr) 2009-07-31 2010-07-29 Matériau de siège et procédé de formation

Country Status (1)

Country Link
WO (1) WO2011014603A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5536341A (en) * 1994-09-01 1996-07-16 Davidson Textron Inc. Soft panel with thermoplastic fiber cluster layer
US5888616A (en) * 1996-08-30 1999-03-30 Chrysler Corporation Vehicle interior component formed from recyclable plastics material
US20030106741A1 (en) * 2001-12-07 2003-06-12 Graham Tompson Multi-density sound attenuating laminates and methods of making same
US20060182947A1 (en) * 2005-02-16 2006-08-17 Azdel, Inc. Fiber reinforced thermoplastic composite including mineral fillers

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5536341A (en) * 1994-09-01 1996-07-16 Davidson Textron Inc. Soft panel with thermoplastic fiber cluster layer
US5888616A (en) * 1996-08-30 1999-03-30 Chrysler Corporation Vehicle interior component formed from recyclable plastics material
US20030106741A1 (en) * 2001-12-07 2003-06-12 Graham Tompson Multi-density sound attenuating laminates and methods of making same
US20060182947A1 (en) * 2005-02-16 2006-08-17 Azdel, Inc. Fiber reinforced thermoplastic composite including mineral fillers

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