WO2012038737A1 - A padding layer - Google Patents
A padding layer Download PDFInfo
- Publication number
- WO2012038737A1 WO2012038737A1 PCT/GB2011/051766 GB2011051766W WO2012038737A1 WO 2012038737 A1 WO2012038737 A1 WO 2012038737A1 GB 2011051766 W GB2011051766 W GB 2011051766W WO 2012038737 A1 WO2012038737 A1 WO 2012038737A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- padding layer
- wadding
- fibres
- padding
- layer
- Prior art date
Links
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Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/125—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with projections, depressions or cavities
-
- 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
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/146—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G11/00—Finished upholstery not provided for in other classes
- B68G11/02—Finished upholstery not provided for in other classes mainly composed of fibrous materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G7/00—Making upholstery
- B68G7/02—Making upholstery from waddings, fleeces, mats, or the like
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/02—Cotton wool; Wadding
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4274—Rags; Fabric scraps
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/185—Underlayers in the form of studded or ribbed plates
Definitions
- This invention relates to padding layers, in particular to mattresses and mattress toppers for beds, divans and similar furniture, flooring underlay and upholstery padding (cushioning).
- a mattress is generally defined as a mat or pad, usually placed on top of a bed base or divan (although sometimes placed directly on a floor) on which to sleep or lie.
- mattresses have been filled with a variety of natural materials, including straw and feathers.
- Modern mattresses usually contain either an inner spring core or materials such as latex, viscoelastic, or other polyurethane-type foams.
- Mattresses may also be filled with air or water, or a variety of natural and/or synthetic fibres, such as in futons.
- a typical innerspring mattress consists of three components: the spring core, the foundation, and the upholstery layers.
- the core of the mattress supports the sleeper's body.
- Modern spring mattress cores often called “innersprings,” are made up of steel coil springs, or “coils.”
- connections between the coils help the mattress retain its shape. Most coils are connected by interconnecting wires; encased coils are not connected , but the fabric encasement helps preserve the mattress shape.
- Foam mattresses use shape-conforming latex or viscoelastic memory foam plus polyurethane flexi-foam to provide better support than springs alone, as well as in combinations of springs and foams.
- Latex mattresses generally come in two types of latex, Talalay® and Dunlop®, which are manufactured differently and provide different feels as well as different qualities.
- Box-springs consist of a rigid frame that contains extra-heavy-duty springs. This type of foundation contributes to softer support and a bouncier mattress.
- Grid foundations are a combination of steel and wood.
- upholstery layers cover the mattress and provide cushioning and comfort. Some manufacturers call the mattress core the “support layer” and the upholstery layer the “comfort layer”.
- the upholstery layer consists of three parts: the insulator, the middle upholstery, and the quilt.
- the insulator separates the mattress core from the middle upholstery. It is usually made of fibre or mesh and is intended to keep the middle upholstery in place.
- the middle upholstery comprises all the material between the insulator and the quilt. It is usually made from materials which are intended to provide comfort to the sleeper, including regular foam, viscoelastic foam, felt, polyester fibres, cotton fibres, convoluted (“egg-crate”) foam, and non-woven fibre pads.
- Some prior art mattresses for example as manufactured by the present applicant, comprise a spring core unit surrounded by an insulator pad (usually around 10mm in thickness), then overlaid with a support layer, followed by a comfort layer, and then overlaid with the ticking.
- Mattresses currently on the market are generally made from foam blocks or a central spring unit provided with fibre or foam outer layers. Mattresses made of 100% fibre are occasionally sold as children's mattresses, but are not suitable for the adult market because their performance is poor (they tend to sag or collapse under weight).
- Foam such as polyurethane foam
- foam has a number of advantages, including good resilience and low density.
- polyurethane foams are environmentally unfriendly (both in manufacture, involving the use of organic solvents, and post-manufacture, since foams are not easily recyclable).
- emission of volatile organic compounds (VOCs) from foam mattresses can be a contributor to Sudden I nfant Death Syndrome (cot death), as well as triggering allergic reactions.
- VOCs volatile organic compounds
- foams are often not breathable. This means that sweat and other body fluids tend to collect in foam mattresses leaving them damp to the touch, and in the case of infants, can cause suffocation if a child rolls onto its front during sleep.
- polyester fibre wadding has a number of advantages, including recyclability (the fibres can be made from recycled material, such as polyester drinks bottles; as well as being recycled again at the end of the life of the mattress) and hydrophobicity (polyester fibre wadding does not collect sweat or urine and remains dry to the touch). Furthermore, polyester fibre wadding is odourless and does not emit VOCs, and is generally considered to be a hypoallergenic material. However, in current mattresses, the polyester wadding is typically made from fibres having a linear mass of around 6 to 20 denier, this being necessary to give a reasonable level of support. Even then, additional support in the form of foam blocks or spring units is required to prevent sagging or collapse when bearing the weight of an adult person.
- Embod iments of the present i nvention seek to provide im provements to mattresses as a whole, and also to component parts of mattresses such as the upholstery or comfort layer, as well as mattress toppers which are mat-like devices for use on mattresses, and which may be configured to fit around the mattress.
- Mattresses or mattress toppers with a profiled surface are well-known, for example from US 2008/0060139, but these mattresses are made of polyurethane or latex foams. Profiled surfaces help to reduce the incidence of pressure sores, especially for immobile persons.
- Upper layers of carpets and laminate flooring are commonly laid onto a cushioning layer of flooring underlay.
- the underlay reduces the rate of wear that the upper layer experiences from foot and other traffic, increases the level of comfort for those walking across the upper layer, and to provide insulation against sound, moisture and/or heat.
- Flooring underlay is typically 6 to 10mm thick beneath carpet and typically about 3mm thick under solid flooring, and is conveniently supplied rolled or folded. Underlay is commonly manufactured from a cushioning layer of foam, sponge rubber, crumb rubber, felt or mixed needled non-woven fibre webs.
- polyester fibre layers are not conventionally used in flooring underlay padding layers, since the high area density of polyester fibres that would be required in order to meet performance criteria would make the cost prohibitive. Further, laid non-woven polyester fibre layers are difficult to cut, wh ich would make them impractical for use as underlay, due to the need of installation contractors to cut the underlay, in situ, to fit the floor plan. Also, profiling of conventional underlay to provide enhanced performance can only be provided by a complex and expensive moulding process.
- padding material used to provide cushioning layers in upholstery are commonly made from foam, in particular high density foam, and in the case of cushions (e.g. in the seat deck of chairs) the padding is commonly composite, having a core of high density foam that has been wrapped in either soft polyester, feather and down or a hypoallergenic down substitute.
- the outer soft polyester provides a soft surface texture, and in combination with the firmer core, it provides a varying degree of firmness with increasing depression of the outer surface.
- Foam such as polyurethane foam
- foam also has a number of advantages, in the manufacture of underlay and cushions for upholstery padding, as discussed above in relation to mattresses and mattress toppers.
- Embodiments of the present invention seek to provide improvements to padding layers as a whole, and also to component parts of padding layers. BRIEF SUMMARY OF THE DISCLOSURE
- a padding layer including fibres as a wadding, the wadding comprising a pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer.
- a mattress comprising a padd ing layer incl ud ing fibres as a wadding, the wadding comprising a pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer.
- a mattress topper comprising a padding layer including fibres as a wadding, the wadding comprising a pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer.
- a flooring underlay comprisi ng a padding layer including fibres as a wadding, the waddi ng comprising a pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer.
- an upholstery padding layer comprising a padding layer including fibres as a wadding, the wadding comprising a pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer.
- an item of furniture comprising an upholstery padding layer comprising a padding layer including fibres as a wadding, the wadding comprising a pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer.
- a method of manufacturing a padding layer comprising forming a wadding of pleated or vertically-lapped non-woven web of fibres, the pleats or laps being oriented substantially perpendicularly to a support surface of the padding layer, .
- At least a portion of the support surface of the padding layer may have a profiled cross-section.
- the profiled cross-section may be cut into at the padding layer.
- the expression "profiled cross-section” includes ridges, corrugations, waves, projections, craters, peaks, troughs and other formations that provide a non-flat profile to the support surface of the padding layer when viewed along the major plane of the padding layer.
- Typical profiles include egg-crate or egg-box profiles, waffle profiles and stippled profiles.
- the profiled section may be formed by a cutting process.
- the wadding is passed through a machine comprising a pair of adjustable rollers, which may themselves be profiled, and a band knife.
- a machine comprising a pair of adjustable rollers, which may themselves be profiled, and a band knife.
- a relatively thick wadding may be cut in two so as to provide two padding layers with complementary profiled surfaces.
- two padding layers can be formed in around the same time that it would otherwise take to form a single padding layer using a thinner wadding.
- Fibre wadding has a number of advantages, including recyclability (the fibres can be made from recycled material, such as waste polyester drinks bottles, or shredded or pulled waste fabric, or fabric from waste carpets; as well as being recycled again at the end of the life of the padding layer).
- recyclability the fibres can be made from recycled material, such as waste polyester drinks bottles, or shredded or pulled waste fabric, or fabric from waste carpets; as well as being recycled again at the end of the life of the padding layer.
- a further advantage is hydrophobicity (polyester fibre wadding does not collect sweat or urine and remains dry to the touch).
- polyester fibre wadding is odourless and does not emit VOCs, and is generally considered to be a hypoallergenic material.
- a pleated or vertically lapped non-woven web of fibres (particularly polyester fibres) h as a low a rea d en sity, wh i ch m ay m a ke prod u cts l ig ht a n d correspondingly less expensive to manufacture and transport.
- the padding layer may easily be cut (e.g. in the manufacture of upholstery or when fitting underlay), as a result of the vertically lapped arrangement of the fibres.
- the padding layer may be an underlay.
- the padding layer may be an upholstery padding layer.
- the fibres have a linear mass of not more than 25 denier.
- the fibres have a linear mass of less than 15 denier, preferably less than 10 denier, preferably less than 5 denier, preferably less than 3 denier, and in particularly preferred embodiments no more than 1 .5 denier.
- microfibres i.e. fibres of 1 denier or below
- Fibres of 0.8 denier or below can give a particularly good softness, while still maintaining good support due to the vertically-lapped wadding construction.
- fine fibres for example, less than 5 denier
- fine fibres can produce a known wadding with a very soft surface texture, such waddings do not provide sufficient support, and tend to collapse or sag very quickly.
- the vertical lapping of the wadding makes it extremely breathable in a direction from top to bottom. This means that moisture (e.g. sweat or urine) is not retained by the padding layer, especially since fibres are hydrophobic.
- the vertical lapping of the wadding gives excellent localised support for loads without deforming unduly in regions where no load is present. This is because each vertical lap of the wadding can provide relatively independent vertical resilience from other vertical laps, especially those some distance away. This is in stark contrast to a more traditional air-laid or cross-laid fibre wadding construction, where a load placed on top of the padding layer will tend to cause overall sag. In this way, the problem or roll-together on a double padding layer (e.g. a mattress or cushion where two people will tend to roll towards each other when asleep or seated, because of the central sag) is reduced or avoided. This is in some ways similar to the functionality of known pocket-sprung mattresses or seat decks, but can be achieved by embodiments of the present invention without the need for springs.
- Padding layer waddings of embodiments of the present invention preferably have a thickness (from a first major surface to an opposite second major surface) of at least 20mm, often in the range 20mm to 35mm, an in some embodiments at least 50mm, or at least 60mm, and in some embodiments at least 100mm or 150mm.
- the thickness in this context, is to be understood as the thickness provided by a single layer of wadding - in other words, each lap or pleat has a height of at least 20mm etc. in these embodiments.
- Some embodiments of the present invention use only a single layer of wadding, rather than multiple layers of wadding layered on top of each other to achieve a desired thickness.
- Other embodiments comprise two, three or more layers of wadding; in this way, a thicker wadding can be constructed from multiple layers of thinner wadding.
- the vertical laps or pleats of the wadding are cross-needled to provide additional structural strength. This helps to reduce or prevent damage to the padding layer when it is rolled or cut in half between its major surfaces.
- a special advantage of the present invention is that it is environmentally friendly.
- the fibres for the wadding can be obtained from drinks bottles, or carpets, and other waste by chipping, melting and spinning. Moreover, at the end of its life, the wadding can also be easily recycled without having to go through a time consuming manual process of removing polyurethane foam blocks that are traditionally used to provide necessary support in known padding layers.
- the padding layer of the present invention may include springs or spring units as a padding layer core, in which case it will generally not be reliable, may not be cut in half, although parts of its support surface may still be profiled.
- a sprung padding layer core may be omitted entirely so as to provide an easily reliable padding layer.
- the padding layer wadding may be adhered onto a reliable or bendable layer of backing material, such as a thin, densely-needled backing layer or sheet.
- a suitable backing layer or sheet may comprise a felt, for example 2mm to 4mm needlefelt. Polyester may be used as a material for the backing layer or sheet.
- a further example of a backing layer may be a damp-proof membrane.
- the padding layer wadding of embodiments of the present invention may be provided with a ticking or cover.
- Figure 2 is a schematic view of a known air-laid fibre wadding for a padding layer
- Figure 3 is a schematic view of vertically-lapped fibre wadding for a padding layer of the present invention
- Figure 4 is a schematic view of the wadding of Figure 1 bearing a load
- Figure 5 is a schematic view of the wadding of Figure 2 bearing a load
- Figure 7 is a schematic view of the wadding of Figure 4 after the load is removed;
- Figure 8 is a schematic view of the wadding of Figure 5 after the load is removed;
- Figure 9 is a schematic view of the wadding of Figure 6 after the load is removed;
- Figure 10 is a schematic view of the wadding of Figure 1 in a rolled configuration
- Figure 12 is a schematic view of the wadding of Figure 3 in a rolled configuration
- Figure 14 shows a wadding of embodiments of the present invention provided with a cut profiled cross-section on its support surface
- Figure 15 is a schematic view of a wadding for a padding layer of the present invention passing between a pair of profiling rollers and being split in two by a band knife or splitting blade;
- Figure 16 is a schematic cross-sectional view of a pair of padding layers with complementary profiled surfaces that have been cut from a single wadding.
- Figure 1 shows a known padding layer (wadding) 1 , such as a mattress wadding, wadding of a mattress topper, underlay layer or upholstery layer, made of cross-laid fibres having a general orientation 2 that is generally in the plane of the wadding 1 (although exaggerated in the drawing for clarity).
- a padding layer such as a mattress wadding, wadding of a mattress topper, underlay layer or upholstery layer, made of cross-laid fibres having a general orientation 2 that is generally in the plane of the wadding 1 (although exaggerated in the drawing for clarity).
- Figure 2 shows an alternative known padding layer (wadding) 3 is made of air-laid fibres having a general orientation 4 that is generally perpendicular to the plane of the wadding 3, but it can be seen that there is little side-to-side support between the fibres.
- Figure 3 shows a padding layer (wadding) 5 of the present invention comprising a vertically-lapped or pleated web 6 of polyester fibres of linear mass not greater than 5 denier.
- the laps or pleats 7 have a generally vertical orientation 8.
- the laps or pleats 7 are formed from a non-woven web of fibres that is less than 3mm thick, and preferably about 1 mm thick (e.g. a mattress approximately 2000mm long has about 2000 pleats). Greater than 75%, and preferably 90% of the fibres of the non-woven web are aligned such that they are substantially perpendicular to the 8 in the surface of the pleated padding layer 5.
- FIG. 4 shows the vertically-lapped or pleated wadding 5 of Figure 3 (the present invention) supporting the load 9 in a spring-like manner, compressing vertically to accommodate the shape of the load 9 without flattening in neighbouring regions 10.
- each lap or pleat 7 acts as a vertical spring, cross-needling providing limited horizontal attachment between neighbouring pleats but without causing the wadding 5 to flatten except under the load 9.
- Figure 7 shows how the known cross-laid wadding 1 struggles to recover after the load 9 is removed, since the fibres are matted with each other.
- the known air-laid wadding 3 in Figure 8 recovers somewhat better after removal of the load 9, but still remains flattened due to fibre matting. It is only the vertically-lapped or pleated wadding 5 (the present invention) shown in Figure 9 that readily recovers its shape due to the independently springy nature of the laps or pleats 7.
- Figure 10 shows the known cross-laid wadding 1 of Figures 1 , 4 and 7 in a rolled configuration. It can be seen that the inner surface 1 1 of the wadding 1 becomes puckered, while the outer surface 12 becomes stretched. The stretching and puckering remains evident after unrolling, as shown in Figure 1 1 , leading to permanent deformation into a banana-like shape.
- the vertically-lapped or pleated wadding 5 (the present invention) of Figures 3, 6 and 9 can be rolled ( Figure 12) and unrolled ( Figure 13) without permanent deformation.
- the cross-needling (not shown) allows the laps or pleats 7 to move apart on the outer surface 14 of the wadding 5 while moving closer together on the inner surface 13.
- the surface of the wadding layer may be provided with profiling.
- profiling can be used to modify the depression performance of the wadding layer, being the extent by which the surface is depressed as a function of applied pressure.
- the provision of a more easily compressible surface wadding region on a firmer wadding region can provide an initially soft feeling when pressure is applied, which may be perceived as being more luxurious. Such a luxurious feel can be desirable in upholstery cushioning and underlays.
- the wadding layer may be provided with a uniform profile pattern across the wadding layer.
- a uniform profiling on the surface of the underlay will provide a uniform compression performance (i.e. extent of depression of the surface as a function of applied pressure) across an entire floor fitted with the underlay.
- a different compression performance may be provided in different regions by use of different profiling patterns in the different regions, or by selective profiling in different regions.
- a single layer of wadding covering the seat deck and back regions with different levels of support (i.e. different compression performances) in those regions.
- a non-uniform level of support i.e. non-uniform compression performance
- a seat e.g. a softer feel in a central region of the wadding, and a firmer feel at edge regions.
- Figure 14 shows a wadding layer (e.g. a mattress wadding, mattress topper, or upholstery layer, such as a cushion) 20 having a support surface (e.g. major plane) 21 with a profiled cross-section 22.
- the support surface 21 is provided with a variety of different profiled features selected to give different support in different regions 21 A, 21 B and 21 C of the support surface 21 . This can provide a wadding layer 20 with enhanced support and comfort.
- a mattress it is able to provide different support characteristics for different parts of the body, for example, providing high and low pressure areas, such that the regions corresponding to the locations of the hips, buttocks and shoulders of a person sleeping on the mattress receive greater support than other regions, since these projecting parts of the body depress the support surface more than other parts of the body, such as the head, feet, legs and the small of the back.
- a uniformly recessed region may also be provided (now shown).
- a three zoned mattress may be provided with an egg-box-like pattern at each end and two recessed regions, each interspersed by zones with a ribbed pattern.
- the wadding layer is advantageously provided with the same profile on both sides, so that the wadding layer can be turned so that use of each side can be alternated.
- Figure 15 shows a relatively thick wadding 23 passing between a pair of profiling rollers 24, 25.
- a band knife or splitting blade 26 is provided generally between the rollers 24, 25.
- this manufacturing process can provide a very accurate and consistent thickness to the finished product, which is particularly advantageous in the case of flooring underlay.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Architecture (AREA)
- Mechanical Engineering (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Laminated Bodies (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1306737.6A GB2498302B (en) | 2010-09-20 | 2011-09-20 | A padding layer |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1015696.6 | 2010-09-20 | ||
GBGB1015696.6A GB201015696D0 (en) | 2010-09-20 | 2010-09-20 | Mattress |
GBGB1016789.8A GB201016789D0 (en) | 2010-09-20 | 2010-10-06 | Profiled mattress |
GB1016789.8 | 2010-10-06 | ||
GBGB1019939.6A GB201019939D0 (en) | 2010-11-24 | 2010-11-24 | A padding layer |
GB1019939.6 | 2010-11-24 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2012038737A1 true WO2012038737A1 (en) | 2012-03-29 |
Family
ID=45873491
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB2011/051766 WO2012038737A1 (en) | 2010-09-20 | 2011-09-20 | A padding layer |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB2498302B (en) |
WO (1) | WO2012038737A1 (en) |
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US20110311758A1 (en) * | 2010-05-24 | 2011-12-22 | Jim Burns | Fiber-based carpet cushion with added resilience from vertically oriented fiber construction |
EP2739775A1 (en) * | 2011-05-24 | 2014-06-11 | Brebey S.r.l. | Component made of non-woven natural textile fibres, and method and machine for the production thereof |
WO2016094395A1 (en) * | 2014-12-08 | 2016-06-16 | Zephyros, Inc. | Vertically lapped fibrous flooring |
USD834838S1 (en) | 2017-04-07 | 2018-12-04 | Kimberly-Clark Worldwide, Inc. | Non-woven material |
US10460715B2 (en) | 2015-01-12 | 2019-10-29 | Zephyros, Inc. | Acoustic floor underlay system |
CN110740662A (en) * | 2017-05-15 | 2020-01-31 | 斯塔斯普林斯公司 | Base mat arrangement such as a bed with adjustable firmness |
US10755686B2 (en) | 2015-01-20 | 2020-08-25 | Zephyros, Inc. | Aluminized faced nonwoven materials |
CN113279136A (en) * | 2020-02-19 | 2021-08-20 | 立肯诺(上海)新材料科技有限公司 | Pearl fiber composite thermal insulation flocculus and preparation method thereof |
US11541626B2 (en) | 2015-05-20 | 2023-01-03 | Zephyros, Inc. | Multi-impedance composite |
WO2023059475A1 (en) * | 2021-10-05 | 2023-04-13 | Piana Nonwovens, Llc | Consumer goods made with pieces of vertically lapped nonwoven |
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CN110740662A (en) * | 2017-05-15 | 2020-01-31 | 斯塔斯普林斯公司 | Base mat arrangement such as a bed with adjustable firmness |
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CN113279136B (en) * | 2020-02-19 | 2022-09-23 | 立肯诺(上海)新材料科技有限公司 | Pearl fiber composite thermal insulating flocculus and preparation method thereof |
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Also Published As
Publication number | Publication date |
---|---|
GB2498302A (en) | 2013-07-10 |
GB2498302B (en) | 2015-05-06 |
GB201306737D0 (en) | 2013-05-29 |
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