WO2012140006A1 - Stuffing product for furniture and furniture element comprising such a stuffing product - Google Patents

Stuffing product for furniture and furniture element comprising such a stuffing product Download PDF

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Publication number
WO2012140006A1
WO2012140006A1 PCT/EP2012/056436 EP2012056436W WO2012140006A1 WO 2012140006 A1 WO2012140006 A1 WO 2012140006A1 EP 2012056436 W EP2012056436 W EP 2012056436W WO 2012140006 A1 WO2012140006 A1 WO 2012140006A1
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WO
WIPO (PCT)
Prior art keywords
recycled
materials
family
latex
product
Prior art date
Application number
PCT/EP2012/056436
Other languages
French (fr)
Inventor
Salim Touati
Rémy LANZA
Original Assignee
Ecoval Environnement
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 Ecoval Environnement filed Critical Ecoval Environnement
Publication of WO2012140006A1 publication Critical patent/WO2012140006A1/en

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/22—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with both fibrous and foamed material inlays
    • 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
    • A47C27/122—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 special fibres, such as acrylic thread, coconut, horsehair
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • 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
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/18—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 features of a layer of foamed material
    • B32B5/20—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 features of a layer of foamed material foamed in situ
    • 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
    • B32B5/245—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 being a foam layer
    • 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
    • B68G11/04—Finished upholstery not provided for in other classes mainly composed of resilient materials, e.g. of foam rubber
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/70—Scrap or recycled material
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
    • B32B2307/718—Weight, e.g. weight per square meter
    • 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 relates to a upholstery product for furniture and in particular mattresses, box springs, seats and seat cushions and backrests.
  • the upholstery products hitherto used for this type of use consist essentially of a block or at least one sheet of expanded plastic material, such as, for example, polyurethane foam and / or latex obtained by injection molding. in a mold adapted to the shape of the padding products to be produced.
  • the invention aims to provide a cushioning product that reduces the mass of polyurethane foam and / or latex used in furniture.
  • the subject of the invention is therefore a upholstery product for furniture, in particular mattresses, box springs, seats and cushions, characterized in that it comprises at least one expanded plastic part, such as for example polyurethane foam and / or latex and at least a portion of a nonwoven material comprising a mixture of bi-component fibers and at least one of the following families of recycled materials:
  • the product may have one or more of the following characteristics, considered individually or in any technically feasible combination:
  • said mixture comprises, by weight, between 60 and 90% of expanded plastic material, recycled, between 2 and 15% of recycled textile fibers and between 5 and 20% of two-component fiber mixture,
  • said mixture comprises, by weight, between 45 and 75% of expanded plastic material, recycled, between 5 and 25% of recycled latex, between 1 and 10% of recycled textile fibers, and between 5 and 25% of bi-fiber blend; -composantes,
  • said mixture comprises, by weight, between 35 and 65% of expanded plastic, recycled, between 15 and 35% of recycled latex, between 1 and 8% of recycled textile fibers and between 10 and 30% of bi-fiber blend; components - recycled materials come from mattresses, box springs, seats and used cushions,
  • said at least one portion of expanded plastic material and / or latex is overmolded on said at least a portion of nonwoven materials
  • the product comprises cells for positioning at least one string of coil springs.
  • the invention also relates to a furnishing element comprising at least one upholstery product as previously mentioned.
  • FIG. 1 is a partial cross-sectional view of a first embodiment of a cushioning product according to the invention
  • FIG. 2 is a partial cross-sectional view of a second embodiment of a cushioning product according to the invention.
  • FIG. 3 is a partial cross-sectional view of a third embodiment of a cushioning product according to the invention.
  • the padding product shown in the figures is intended for example for a mattress or box spring.
  • the padding product can also be used for seats, seat or back cushions, sofas, sofa beds, benches, convertible benches, armchairs, relaxation chairs, this list not being exhaustive .
  • the padding product designated by the general reference 10 comprises at least one part 1 1 expanded plastic material, such as for example polyurethane foam and / or at least a part 12 latex and at least one Part 14 of a nonwoven material comprising a mixture of bi-component fibers and recycled materials from, inter alia, mattresses, bedsteads, seats and cushions used.
  • part 1 1 expanded plastic material such as for example polyurethane foam and / or at least a part 12 latex
  • a nonwoven material comprising a mixture of bi-component fibers and recycled materials from, inter alia, mattresses, bedsteads, seats and cushions used.
  • part 1 1 made of expanded plastic material will be called polyurethane foam.
  • the recycled material comes from at least one of the following families:
  • the predetermined amounts of these different families consist of premixed materials are mixed with each other, these quantities being chosen according to the final product to be obtained.
  • the mixture of bi-component fibers is added to this mixture and these fibers consist of a hot melt component intended, after heating, to consolidate the recycled materials.
  • other materials may be added to the mixture.
  • an additional amount of textile fibers may be added to the blend, depending on the finished product to be produced. It is possible to add additives to the mixture depending on the nature of the finished product.
  • the additives may include an anti-mite product, an anti-fire product.
  • the portion of the nonwoven material has a thickness of between 5 and 20 mm, the weight of this portion is typically between 400 and 1200 gr / m 2 , preferably between 600 and 1000 gr / m 2 , and is worth typically 800gr / m 2 ;
  • a mixture which comprises by weight:
  • the two-component fiber mixture between 5 and 20% of the two-component fiber mixture, preferably between 5 and 15% of the two-component fiber mixture, and typically 10% of the two-component fiber mixture.
  • the portion of the nonwoven material has a thickness of between 20 and 50 mm.
  • the weight of said portion is between 1200 and 2200gr / m 2 , preferably between 1400 and 2000gr / m 2 , and is for example 1700 gr / m 2 .
  • a mixture is selected which comprises, by weight:
  • first family of materials preferably between 40 and 60% of the first family of materials, and typically 50% of the first family of materials, between 5% and 25% of the second family of materials, preferably between 10 and 20% of the second family of materials, and typically 15% of the second family of materials,
  • bicomponent fiber mixture between 5 and 25% of the bicomponent fiber mixture, preferably 10 and 20% of bicomponent fiber mixture, and typically 15% of the bicomponent fiber mixture.
  • the portion of the nonwoven material has a thickness greater than 50mm.
  • This part has for example a density between 2000 and 4000gr / m 2 , preferably between 2500 and 3500gr / m 2 , and typically equal to 3000gr / m 2 .
  • bicomponent fiber mixture between 10 and 30% of the bicomponent fiber mixture, preferably between 15 and 25%, for example 20% of bicomponent fibers.
  • the bi-component fibers consist of two components distributed over the entire length of the fiber. Each component may have different physical or chemical properties.
  • the components can be either variants of the same type of polymer, or two types of polymers totally different.
  • An example of such a fiber is marketed by MAX MODEL SA under the name "Polyester staple fiber, low melt 4/51 mm 1 10 flame retardant reference 4140".
  • the use of other two-component fiber blends is conceivable.
  • the nonwoven material is consolidated by the bi-component fibers through a heat treatment.
  • the nonwoven material is heated in an oven, for example at a temperature of the order of 180 ° C.
  • the heat treatment causes the partial melting of the two-component fiber mixture, which contributes to bonding together the various components of the mixture, that is to say the textile fibers, the latex and the polyurethane.
  • This heat treatment also causes the elimination of certain chemical compounds, for example, VOCs and formaldehyde. These compounds can be thermally decomposed or released in gaseous form.
  • the nonwoven material thus obtained can pass from a calendering step and a cutting step, to form the pieces of dimensions adapted to their end use.
  • the material is not cut but is rolled up and stored as rolls.
  • the portion 14 of the nonwoven material comprising a mixture of bi-component fibers and recycled materials is embedded in a portion 1 1 of polyurethane foam to form the stuffing product 10.
  • the portion 14 of the nonwoven material may be embedded in a latex part.
  • the portion 14 of the nonwoven material is disposed between a portion 1 1 of polyurethane foam and a portion 12 of latex.
  • the portion 14 of the nonwoven material comprises on one side, a portion 1 1 of polyurethane foam or a portion of latex.
  • the portion of polyurethane foam and / or latex is overmolded on said at least a portion of the nonwoven material by injection into a shaped mold adapted to the product to be obtained.
  • the padding product 10 may comprise cells, not shown, for positioning at least one string of coil springs.
  • the padding product according to the invention comprising at least a part obtained from recycled materials from mattresses, sommiers, seats and cushions makes it possible to reduce the mass of the polyurethane foam and / or latex part.
  • This padding product has the same characteristics for example of comfort, a padding product consisting of polyurethane foam and / or latex.

Abstract

The invention relates to a stuffing product (10) for furniture, in particular mattresses, pillows, seats and cushions, characterized in that it includes at least one portion (11) made of an expanded plastic material, e.g. such as polyurethane and/or latex foam and at least one portion (14) made of a non-woven material comprising a mixture of bicomponent fibers and at least one of the following families of recycled materials: a first family of materials predominantly containing an expanded plastic material, a second family of materials containing predominantly latex, a third family of materials containing textile fibers.

Description

Produit de rembourrage pour l'ameublement et élément d'ameublement comportant un tel produit de rembourrage  Upholstery product for upholstery and upholstery comprising such upholstery product
La présente invention concerne un produit de rembourrage pour l'ameublement et en particulier de matelas, de sommiers, de sièges et de coussins d'assises et de dossiers.  The present invention relates to a upholstery product for furniture and in particular mattresses, box springs, seats and seat cushions and backrests.
Les produits de rembourrage employés jusqu'à présent pour ce type d'utilisation sont composés essentiellement d'un bloc ou d'au moins une nappe en matière plastique expansée, comme par exemple de la mousse de polyuréthane et/ou en latex obtenu par injection dans un moule adapté à la forme des produits de rembourrage à réaliser.  The upholstery products hitherto used for this type of use consist essentially of a block or at least one sheet of expanded plastic material, such as, for example, polyurethane foam and / or latex obtained by injection molding. in a mold adapted to the shape of the padding products to be produced.
Or, il s'avère que le polyuréthane ainsi que le latex sont des matériaux qui deviennent de plus en plus onéreux augmentant de ce fait le prix de revient des meubles utilisant ces produits.  However, it turns out that polyurethane and latex are materials that are becoming increasingly expensive thereby increasing the cost of furniture using these products.
L'invention a pour but de proposer un produit de rembourrage qui permet de réduire la masse de mousse de polyuréthane et/ou de latex employée dans l'ameublement.  The invention aims to provide a cushioning product that reduces the mass of polyurethane foam and / or latex used in furniture.
L'invention a donc pour objet un produit de rembourrage pour l'ameublement, notamment de matelas, de sommiers, de sièges et de coussins, caractérisé en ce qu'il comprend au moins une partie en matière plastique expansée, comme par exemple de la mousse de polyuréthane et/ou en latex et au moins une partie d'un matériau non tissé comportant un mélange de fibres bi-composantes et d'au moins l'une des familles de matériaux recyclés suivants :  The subject of the invention is therefore a upholstery product for furniture, in particular mattresses, box springs, seats and cushions, characterized in that it comprises at least one expanded plastic part, such as for example polyurethane foam and / or latex and at least a portion of a nonwoven material comprising a mixture of bi-component fibers and at least one of the following families of recycled materials:
- une première famille de matériaux contenant majoritairement une matière plastique expansée,  a first family of materials mainly containing an expanded plastic material,
- une seconde famille de matériaux contenant majoritairement du latex,  a second family of materials containing predominantly latex,
- une troisième famille contenant des fibres textiles.  a third family containing textile fibers.
Le produit peut présenter une ou plusieurs des caractéristiques ci-dessous, considérées individuellement ou selon toutes les combinaisons techniquement possibles :  The product may have one or more of the following characteristics, considered individually or in any technically feasible combination:
- ledit mélange comprend, en poids, entre 60 et 90% de matière plastique expansée, recyclée, entre 2 et 15% de fibres textiles recyclées et entre 5 et 20% de mélange de fibres bi-composantes,  said mixture comprises, by weight, between 60 and 90% of expanded plastic material, recycled, between 2 and 15% of recycled textile fibers and between 5 and 20% of two-component fiber mixture,
- ledit mélange comprend, en poids, entre 45 et 75% de matière plastique expansée, recyclée , entre 5 et 25% de latex recyclé, entre 1 et 10% de fibres textiles recyclées, et entre 5 et 25% de mélange de fibres bi-composantes,  said mixture comprises, by weight, between 45 and 75% of expanded plastic material, recycled, between 5 and 25% of recycled latex, between 1 and 10% of recycled textile fibers, and between 5 and 25% of bi-fiber blend; -composantes,
- ledit mélange comprend, en poids, entre 35 et 65% de matière plastique expansée, recyclée, entre 15 et 35% de latex recyclé, entre 1 et 8% de fibres textiles recyclées et entre 10 et 30% de mélange de fibres bi-composantes, - les matériaux recyclés proviennent de matelas, de sommiers, de sièges et de coussins usagés, said mixture comprises, by weight, between 35 and 65% of expanded plastic, recycled, between 15 and 35% of recycled latex, between 1 and 8% of recycled textile fibers and between 10 and 30% of bi-fiber blend; components - recycled materials come from mattresses, box springs, seats and used cushions,
- ladite au moins une partie de matière plastique expansée, et/ou de latex est surmoulée sur ladite au moins une partie de matériaux non tissés, et  said at least one portion of expanded plastic material and / or latex is overmolded on said at least a portion of nonwoven materials, and
- le produit comporte des alvéoles pour le positionnement d'au moins un chapelet de ressorts hélicoïdaux ensachés.  the product comprises cells for positioning at least one string of coil springs.
L'invention a aussi pour objet un élément d'ameublement comprenant au moins un produit de rembourrage tel que précédemment mentionné.  The invention also relates to a furnishing element comprising at least one upholstery product as previously mentioned.
D'autres caractéristiques et avantages de l'invention ressortiront de la description détaillée qui va suivre, à titre indicatif et nullement limitatif, en référence aux dessins annexés, parmi lesquels :  Other features and advantages of the invention will emerge from the detailed description which follows, by way of indication and in no way limitative, with reference to the appended drawings, among which:
- la Fig. 1 est une vue partielle en coupe transversale d'un premier mode de réalisation d'un produit de rembourrage, conforme à l'invention,  FIG. 1 is a partial cross-sectional view of a first embodiment of a cushioning product according to the invention,
- la Fig. 2 est une vue partielle en coupe transversale d'un deuxième mode de réalisation d'un produit de rembourrage, conforme à l'invention, et  FIG. 2 is a partial cross-sectional view of a second embodiment of a cushioning product according to the invention, and
- la Fig. 3 est une vue partielle en coupe transversale d'un troisième mode de réalisation d'un produit de rembourrage, conforme à l'invention.  FIG. 3 is a partial cross-sectional view of a third embodiment of a cushioning product according to the invention.
Le produit de rembourrage représenté sur les figures est destiné par exemple à un matelas ou un sommier. Le produit de rembourrage peut être également destiné aux sièges, aux coussins d'assises ou de dossiers, aux canapés, aux canapés-lits, aux banquettes, aux banquettes convertibles, aux fauteuils, aux fauteuils de relaxation, cette liste n'étant pas limitative.  The padding product shown in the figures is intended for example for a mattress or box spring. The padding product can also be used for seats, seat or back cushions, sofas, sofa beds, benches, convertible benches, armchairs, relaxation chairs, this list not being exhaustive .
Dans le cas des matelas ou des sommiers, le produit de rembourrage est couramment désigné par les spécialistes par le terme suspension.  In the case of mattresses or bed bases, the upholstery product is commonly designated by the specialists by the term suspension.
Ainsi que représenté sur les figures, le produit de rembourrage désigné par la référence générale 10 comprend au moins une partie 1 1 matière plastique expansée, comme par exemple de la mousse de polyuréthane et/ou au moins une partie 12 en latex et au moins une partie 14 d'un matériau non tissé comportant un mélange de fibres bi- composantes et de matériaux recyclés provenant, entre autres, de matelas, de sommiers, de sièges et de coussins usagés.  As shown in the figures, the padding product designated by the general reference 10 comprises at least one part 1 1 expanded plastic material, such as for example polyurethane foam and / or at least a part 12 latex and at least one Part 14 of a nonwoven material comprising a mixture of bi-component fibers and recycled materials from, inter alia, mattresses, bedsteads, seats and cushions used.
Dans ce qui suit, la partie 1 1 en matière plastique expansée sera dénommée, en mousse polyuréthane.  In what follows, the part 1 1 made of expanded plastic material will be called polyurethane foam.
D'une manière générale, le matériau recyclé provient d'au moins l'une des familles suivantes :  In general, the recycled material comes from at least one of the following families:
- une première famille de matériaux contenant majoritairement une mousse de polyuréthane, - une seconde famille de matériaux contenant majoritairement du latex, a first family of materials predominantly containing a polyurethane foam, a second family of materials containing predominantly latex,
- une troisième famille de matériaux contenant des fibres textiles.  a third family of materials containing textile fibers.
Les quantités prédéterminées de ces différentes familles constituées de matériaux préalablement broyés sont mélangées les unes aux autres, ces quantités étant choisies en fonction du produit final à obtenir.  The predetermined amounts of these different families consist of premixed materials are mixed with each other, these quantities being chosen according to the final product to be obtained.
Le mélange de fibres bi-composantes est ajouté à ce mélange et ces fibres sont constituées d'un composant thermofusible destiné, après chauffage, à consolider les matériaux recyclés. En variante, d'autres matériaux peuvent êtres ajoutés au mélange. Par exemple, une quantité supplémentaire de fibres textiles peut être ajoutée au mélange, en fonction du produit fini à produire. Il est possible d'ajouter au mélange des additifs en fonction de la nature du produit fini.  The mixture of bi-component fibers is added to this mixture and these fibers consist of a hot melt component intended, after heating, to consolidate the recycled materials. Alternatively, other materials may be added to the mixture. For example, an additional amount of textile fibers may be added to the blend, depending on the finished product to be produced. It is possible to add additives to the mixture depending on the nature of the finished product.
Par exemple, les additifs peuvent comporter un produit anti-acariens, un produit anti-feu....  For example, the additives may include an anti-mite product, an anti-fire product.
Dans un premier exemple de réalisation, la partie du matériau non tissé présente une épaisseur comprise entre 5 et 20mm, le poids de cette partie est typiquement compris entre 400 et 1200gr/m2, de préférence entre 600 et 1000gr/m2, et vaut typiquement 800gr/m2 ; In a first exemplary embodiment, the portion of the nonwoven material has a thickness of between 5 and 20 mm, the weight of this portion is typically between 400 and 1200 gr / m 2 , preferably between 600 and 1000 gr / m 2 , and is worth typically 800gr / m 2 ;
Pour produire un tel matériau non tissé, on choisit un mélange qui comprend en poids :  To produce such a nonwoven material, a mixture is selected which comprises by weight:
- entre 40 et 80% de la première famille de matériaux, de préférence entre 50 et between 40 and 80% of the first family of materials, preferably between 50 and
70% de la première famille de matériaux, et par exemple 60% de la première famille de matériaux, 70% of the first family of materials, and for example 60% of the first family of materials,
- entre 15 et 45% de la troisième famille de matériaux, de préférence entre 25 et 35% de la troisième famille de matériaux, et typiquement 30% de la troisième famille de matériaux,  between 15 and 45% of the third family of materials, preferably between 25 and 35% of the third family of materials, and typically 30% of the third family of materials,
- entre 5 et 20% du mélange de fibres bi-composantes, de préférence entre 5 et 15% du mélange de fibres bi-composantes, et typiquement 10% du mélange de fibres bi- composantes.  between 5 and 20% of the two-component fiber mixture, preferably between 5 and 15% of the two-component fiber mixture, and typically 10% of the two-component fiber mixture.
Dans un second exemple de réalisation, la partie du matériau non tissé, présente une épaisseur comprise entre 20 et 50 mm. Le poids de ladite partie est compris entre 1200 et 2200gr/m2, de préférence entre 1400 et 2000gr/m2, et vaut par exemple 1700 gr/m2. Pour produire un tel matériau non tissé, on choisit un mélange qui comprend, en poids : In a second embodiment, the portion of the nonwoven material has a thickness of between 20 and 50 mm. The weight of said portion is between 1200 and 2200gr / m 2 , preferably between 1400 and 2000gr / m 2 , and is for example 1700 gr / m 2 . To produce such a nonwoven material, a mixture is selected which comprises, by weight:
- entre 30 et 70% de la première famille de matériaux, de préférence entre 40 et 60% de la première famille de matériaux, et typiquement 50% de la première famille de matériaux, - entre 5% et 25% de la seconde famille de matériaux, de préférence entre 10 et 20% de la seconde famille de matériaux, et typiquement 15% de la seconde famille de matériaux, between 30 and 70% of the first family of materials, preferably between 40 and 60% of the first family of materials, and typically 50% of the first family of materials, between 5% and 25% of the second family of materials, preferably between 10 and 20% of the second family of materials, and typically 15% of the second family of materials,
- entre 10 et 30% de la troisième famille de matériaux, de préférence entre 15 et 25% de la troisième famille de matériaux, et typiquement 20% de la troisième famille de matériaux,  between 10 and 30% of the third family of materials, preferably between 15 and 25% of the third family of materials, and typically 20% of the third family of materials,
- entre 5 et 25% du mélange de fibres bi-composantes, de préférence 10 et 20% de mélange de fibres bi-composantes, et typiquement 15% du mélange de fibres bi- composantes.  between 5 and 25% of the bicomponent fiber mixture, preferably 10 and 20% of bicomponent fiber mixture, and typically 15% of the bicomponent fiber mixture.
Dans un troisième exemple de réalisation, la partie du matériau non tissé a une épaisseur supérieure à 50mm. Cette partie présente par exemple une densité comprise entre 2000 et 4000gr/m2 de préférence comprise entre 2500 et 3500gr/m2, et valant typiquement 3000gr/m2. In a third embodiment, the portion of the nonwoven material has a thickness greater than 50mm. This part has for example a density between 2000 and 4000gr / m 2 , preferably between 2500 and 3500gr / m 2 , and typically equal to 3000gr / m 2 .
Pour produire ce matériau, on choisit un mélange qui contient, en poids :  To produce this material, a mixture is chosen which contains, by weight:
- entre 20 et 60% de la première famille de matériaux, de préférence entre 30 et between 20 and 60% of the first family of materials, preferably between 30 and
50%, par exemple 40% de la première famille de matériaux, 50%, for example 40% of the first family of materials,
- entre 15 et 35% de la seconde famille de matériaux, de préférence entre 20 et 30%, par exemple de 25% de la seconde famille de matériaux,  between 15 and 35% of the second family of materials, preferably between 20 and 30%, for example 25% of the second family of materials,
- entre 5 et 25% de la troisième famille de matériaux, de préférence entre 10 et 20%, par exemple 15% de la troisième famille de matériaux,  between 5 and 25% of the third family of materials, preferably between 10 and 20%, for example 15% of the third family of materials,
- entre 10 et 30% du mélange de fibres bi-composantes, de préférence entre 15 et 25%, par exemple 20% de fibres bi-composantes.  between 10 and 30% of the bicomponent fiber mixture, preferably between 15 and 25%, for example 20% of bicomponent fibers.
Les fibres bi-composantes sont constituées de deux composants répartis sur toute la longueur de la fibre. Chaque composant peut présenter différentes propriétés physiques ou chimiques. Les composants peuvent être soit des variantes d'un même type de polymère, soit deux types de polymères totalement différents. Un exemple d'une telle fibre est commercialisé par la société MAX MODEL SA sous le nom « Polyester staple fiber, low melt 4/51 mm 1 10 ^ flame retardant référence 4140 >>. L'utilisation d'autres mélanges de fibres bi-composantes est envisageable.  The bi-component fibers consist of two components distributed over the entire length of the fiber. Each component may have different physical or chemical properties. The components can be either variants of the same type of polymer, or two types of polymers totally different. An example of such a fiber is marketed by MAX MODEL SA under the name "Polyester staple fiber, low melt 4/51 mm 1 10 flame retardant reference 4140". The use of other two-component fiber blends is conceivable.
Le matériau non tissé est consolidé par les fibres bi-composantes par l'intermédiaire d'un traitement thermique. Pour cela, le matériau non tissé est chauffé dans un four, par exemple à une température de l'ordre de 180°C. Le traitement thermique provoque la fusion partielle du mélange de fibres bi-composantes, ce qui contribue à lier entre eux les différents composants du mélange, c'est-à-dire les fibres textiles, le latex et le polyuréthane. Ce traitement thermique provoque aussi l'élimination de certains composés chimiques, par exemple, les COV et le formaldéhyde. Ces composés peuvent être décomposés thermiquement ou être libérés sous forme gazeuse. The nonwoven material is consolidated by the bi-component fibers through a heat treatment. For this, the nonwoven material is heated in an oven, for example at a temperature of the order of 180 ° C. The heat treatment causes the partial melting of the two-component fiber mixture, which contributes to bonding together the various components of the mixture, that is to say the textile fibers, the latex and the polyurethane. This heat treatment also causes the elimination of certain chemical compounds, for example, VOCs and formaldehyde. These compounds can be thermally decomposed or released in gaseous form.
Après ce traitement thermique, le matériau non tissé ainsi obtenu peut passer d'une étape de calandrage et à une étape de découpe, pour former les pièces de dimensions adaptées à leur utilisation finale. Alternativement, le matériau n'est pas découpé mais être enroulé et stocké sous forme de rouleaux.  After this heat treatment, the nonwoven material thus obtained can pass from a calendering step and a cutting step, to form the pieces of dimensions adapted to their end use. Alternatively, the material is not cut but is rolled up and stored as rolls.
Selon un premier exemple de réalisation montré à la Fig. 1 , la partie 14 du matériau non tissé comportant un mélange de fibres bi-composantes et de matériaux recyclés est noyée dans une partie 1 1 en mousse de polyuréthane pour former le produit de rembourrage 10.  According to a first exemplary embodiment shown in FIG. 1, the portion 14 of the nonwoven material comprising a mixture of bi-component fibers and recycled materials is embedded in a portion 1 1 of polyurethane foam to form the stuffing product 10.
Selon une variante non représentée, la partie 14 du matériau non tissé peut être noyée dans une partie en latex.  According to a variant not shown, the portion 14 of the nonwoven material may be embedded in a latex part.
Selon un deuxième mode de réalisation montré à la Fig. 2, la partie 14 du matériau non tissé est disposée entre une partie 1 1 en mousse de polyuréthane et une partie 12 en latex.  According to a second embodiment shown in FIG. 2, the portion 14 of the nonwoven material is disposed between a portion 1 1 of polyurethane foam and a portion 12 of latex.
Selon un troisième exemple de réalisation représenté à la Fig. 3, la partie 14 du matériau non tissé comporte d'un côté, une partie 1 1 en mousse de polyuréthane ou une partie en latex.  According to a third exemplary embodiment shown in FIG. 3, the portion 14 of the nonwoven material comprises on one side, a portion 1 1 of polyurethane foam or a portion of latex.
D'une manière générale et selon un procédé connu, la partie en mousse de polyuréthane et/ou de latex est surmoulée sur ladite au moins une partie du matériau non tissé par injection dans un moule de forme adaptée au produit à obtenir.  In a general manner and according to a known method, the portion of polyurethane foam and / or latex is overmolded on said at least a portion of the nonwoven material by injection into a shaped mold adapted to the product to be obtained.
Le produit de rembourrage 10 peut comporter des alvéoles, non représentées, pour le positionnement d'au moins un chapelet de ressorts hélicoïdaux ensachés.  The padding product 10 may comprise cells, not shown, for positioning at least one string of coil springs.
Le produit de rembourrage selon l'invention comportant au moins une partie obtenue à partir de matériaux recyclés provenant notamment de matelas, de sommiers, de sièges et de coussins permet de diminuer la masse de la partie en mousse de polyuréthane et/ou de latex.  The padding product according to the invention comprising at least a part obtained from recycled materials from mattresses, sommiers, seats and cushions makes it possible to reduce the mass of the polyurethane foam and / or latex part.
Ce produit de rembourrage présente les mêmes caractéristiques par exemple de confort, qu'un produit de rembourrage constitué de mousse de polyuréthane et/ou de latex.  This padding product has the same characteristics for example of comfort, a padding product consisting of polyurethane foam and / or latex.

Claims

REVENDICATIONS
1 .- Produit de rembourrage (10) pour l'ameublement, notamment de matelas, de sommiers, de sièges et de coussins, caractérisé en ce qu'il comprend au moins une partie (1 1 , 12) matière plastique expansée, comme par exemple de la mousse de polyuréthane et/ou en latex et au moins une partie (14) d'un matériau non tissé comportant un mélange de fibres bi-composantes et d'au moins l'une des familles de matériaux recyclés suivants : une première famille de matériaux contenant majoritairement de la matière plastique expansée, une seconde famille de matériaux contentant majoritairement du latex, une troisième famille de matériaux contenant des fibres textiles.  1 .- Upholstery product (10) for furniture, in particular mattresses, box springs, seats and cushions, characterized in that it comprises at least one part (1 1, 12) expanded plastic material, such as by example of the polyurethane foam and / or latex and at least a portion (14) of a nonwoven material comprising a mixture of bi-component fibers and at least one of the following families of recycled materials: a first family of materials containing predominantly expanded plastic material, a second family of materials mainly containing latex, a third family of materials containing textile fibers.
2.- Produit selon la revendication 1 , caractérisé en ce que ledit mélange comprend, en poids, entre 60 et 90% de matière plastique expansée, recyclée, entre 2 et 15% de fibres textiles recyclées, et entre 5 et 20% de mélange de fibres bi-composantes.  2. Product according to claim 1, characterized in that said mixture comprises, by weight, between 60 and 90% of expanded plastic material, recycled, between 2 and 15% of recycled textile fibers, and between 5 and 20% of mixture of bi-component fibers.
3. - Produit selon la revendication 1 , caractérisé en ce que ledit mélange comprend, en poids, entre 45 et 75% de matière plastique expansée recyclée, entre 5 et 25% de latex recyclé, entre 1 et 10% de fibres textiles recyclées, et entre 5 et 25% de mélange de fibres bi-composantes.  3. - Product according to claim 1, characterized in that said mixture comprises, by weight, between 45 and 75% of recycled plastics material, between 5 and 25% recycled latex, between 1 and 10% recycled textile fibers, and between 5 and 25% of two-component fiber blend.
4. - Produit selon la revendication 1 , caractérisé en ce que ledit mélange comprend, en poids, entre 35 et 65% de matière plastique expansée recyclée, entre 15 et 35% de latex recyclé, entre 1 et 8% de fibres textiles recyclées, et entre 10 et 30% de mélange de fibres bi-composantes.  4. - Product according to claim 1, characterized in that said mixture comprises, by weight, between 35 and 65% of recycled plastics material, between 15 and 35% recycled latex, between 1 and 8% recycled textile fibers, and between 10 and 30% of two-component fiber blend.
5. - Produit selon l'une quelconque des revendications 1 à 4, caractérisé en ce que les matériaux recyclés proviennent de matelas, de sommiers, de sièges et de coussins usagés.  5. - Product according to any one of claims 1 to 4, characterized in that the recycled materials come from mattresses, sommiers, seats and used cushions.
6. - Produit selon l'une quelconque des revendications 1 à 5, caractérisé en ce que ladite au moins une partie (1 1 , 12) en matière plastique expansée et/ou en latex est surmoulée sur ladite au moins une partie (14) du matériau non tissé.  6. - Product according to any one of claims 1 to 5, characterized in that said at least a portion (1 1, 12) of expanded plastic material and / or latex is overmolded on said at least a portion (14) nonwoven material.
7. - Produit selon l'une quelconque des revendications 1 à 6, caractérisé en ce qu'il comporte des alvéoles pour le positionnement d'au moins un chapelet de ressorts hélicoïdaux ensachés.  7. - Product according to any one of claims 1 to 6, characterized in that it comprises cells for positioning at least one string of coil springs bagged.
8.- Elément d'ameublement, caractérisé en ce qu'il comprend au moins un produit de rembourrage (10) selon l'une quelconque des revendications 1 à 7.  8.- item of furniture, characterized in that it comprises at least one padding product (10) according to any one of claims 1 to 7.
PCT/EP2012/056436 2011-04-11 2012-04-10 Stuffing product for furniture and furniture element comprising such a stuffing product WO2012140006A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1153131A FR2973792B1 (en) 2011-04-11 2011-04-11 UPHOLSTERY FOR FURNITURE AND FURNISHING ELEMENT COMPRISING SUCH A PADDING PRODUCT
FR1153131 2011-04-11

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US20230092909A1 (en) * 2020-03-25 2023-03-23 L&P Property Management Company Pocketed Spring Assembly

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IT201900021312A1 (en) * 2019-11-15 2021-05-15 Materassificio Montalese S P A SYSTEM FOR THE REALIZATION OF A PADDED BAND FOR MATTRESSES
US20230092909A1 (en) * 2020-03-25 2023-03-23 L&P Property Management Company Pocketed Spring Assembly

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FR2987615B1 (en) 2015-01-30
FR2973792A1 (en) 2012-10-12
FR2987615A1 (en) 2013-09-06
FR2973792B1 (en) 2013-05-17

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