WO2013126972A2 - Matériau et procédé de fabrication d'un tel matériau - Google Patents

Matériau et procédé de fabrication d'un tel matériau Download PDF

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Publication number
WO2013126972A2
WO2013126972A2 PCT/BE2013/000010 BE2013000010W WO2013126972A2 WO 2013126972 A2 WO2013126972 A2 WO 2013126972A2 BE 2013000010 W BE2013000010 W BE 2013000010W WO 2013126972 A2 WO2013126972 A2 WO 2013126972A2
Authority
WO
WIPO (PCT)
Prior art keywords
layer
foam
layers
air
oriented
Prior art date
Application number
PCT/BE2013/000010
Other languages
English (en)
Other versions
WO2013126972A3 (fr
Inventor
Willy Poppe
Original Assignee
Imhold, Naamloze Vennootschap
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 Imhold, Naamloze Vennootschap filed Critical Imhold, Naamloze Vennootschap
Publication of WO2013126972A2 publication Critical patent/WO2013126972A2/fr
Publication of WO2013126972A3 publication Critical patent/WO2013126972A3/fr

Links

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
    • A47C27/14—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
    • A47C27/144—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
    • 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
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
    • B26D3/28—Splitting layers from work; Mutually separating layers by cutting
    • B26D3/281—Splitting layers from work; Mutually separating layers by cutting the work being simultaneously deformed by the application of pressure to obtain profiled workpieces

Definitions

  • a material and a method for manufacturing such a material are provided.
  • the present invention relates to a multi-layered material and a method for manufacturing such a multi-layered material.
  • More specifically it is a multi-layered material that is both soft and flexible, but which also provides support, so that it can be used in mattresses, pillows, cushions and similar articles, for example.
  • the mattress or pillow absorbs moisture from perspiration. This moisture must be quickly removed from the contact surface with the body of the user in order to prevent a clammy or damp, and thus uncomfortable, feeling .
  • This moisture also has to be emitted back to the environment, in order to prevent saturation of the mattress or the pillow. In particular this could for example result in the moisture absorption by the mattress and the pillow stopping, and mould and bacterial growth in the pillow or mattress being fostered.
  • the extent to which moisture can be removed from the surface, and the extent to which the moisture can be emitted back to the environment, are highly related to the permeability to air of the material, which in turn is highly related to the extent to which the pores in the material are open, the size of these pores and the total porosity.
  • a known material for the said applications is polyurethane foam, i.e.
  • PU foam whereby specific elastic properties of the PU foam can be obtained through variations during production, such that it is suitable as a material for the said applications, and is thereby acceptable, both with regard to compressibility and with regard to permeability to air, but does no excel in either of the two areas.
  • Another known foam is reticulated foam. This means that it is rather a net-like foam, whereby there are few, if any, thin membranes in the foam, such that the material has very good permeability to air, and thus also very good moisture exchange characteristics.
  • Such a reticulated foam can be made for example by filling the cells of a traditional PU foam with an explosive gas and allowing it to explode, such that the walls of the cells in the foam are burned, broken and/or removed by the heat and/or force.
  • reticulated foams in other ways.
  • reticulated foams generally have poor compressibility properties. In practice they are too soft, and are thus already fully compressed under a low load, to be widely used in the said applications.
  • the purpose of the present invention is to provide a solution to at least one of the aforementioned and other disadvantages, by providing a multi-layered material that at least comprises a first layer and a second layer bonded thereto, whereby both layers are made from flexible foam and the first layer is made from a foam with a greater permeability to air than the foam of the second layer, and whereby the second layer has openings that run across the entire thickness of the second layer in order to enable air exchange between the first layer and the second layer.
  • the permeability to air is hereby a measure of the ease with which air can flow through the foam. This can be considered as a permeability value, or a value derived from it, for the foam as used in the known Darcy equation.
  • the permeability to air as a general concept can also be expressed as a pressure drop, i.e. a resistance to the flow of air that is measured on a foam in standardised conditions, for example according to ISO standard 9237:1995.
  • a high pressure drop indicates that the material has a low permeability to air and a low pressure drop that the material has a high permeability to air.
  • a permeability value can also be approximately determined on the basis of a number of parameters of the foam, whereby the most important are: the size and fraction of pores and the total porosity.
  • the foam of the first layer has a pressure drop, measured according to ISO 9237:1995, that is less than 1 kPa, more preferably less than 0.5 kPa, and even more preferably less than 0.1 kPa .
  • the foam of the second layer has a pressure drop, measured according to ISO 9237:1995, that is greater than 1 kPa, preferably greater than 2 kPa, and even more preferably greater than 3 kPa.
  • the advantage of a favourable elastic-mechanical behaviour of a foam for example a viscoelastic foam, can be combined with a good air permeability of a different type of foam, in order to give both good properties to a piece of the multi-layered material .
  • the first layer is made of reticulated foam. This gives outstandingly good results relating to moisture absorption and moisture emission. This result is even better if the reticulated foam is hydrophilic.
  • the first layer is provided with cutaways that connect to the openings in the second layer.
  • This material has the advantage that it is easy to make using a standard profiling machine, and that it has an improved permeability to air and moisture due to the cutaways, which together with the openings define preferred air displacement channels.
  • the cutaways in the first layer do not continue to the surface of the first layer turned away from the second layer, such that this prevents the cutaways from forming starting points for tearing on this surface.
  • the openings in the second layer are wider in the direction away from the first layer .
  • the openings in the second layer constitute between 67% and 150% of the volume of the foam of the second layer, and preferably close to 100%.
  • the invention also comprises a mattress, a mattress topper, a pillow or a cushion that comprises at least one layer of the said material according to the invention, whereby the layer of material is oriented such that the second layer is oriented inwards, in other words in which the second layer is oriented in the direction of the core of such an article, in other words in which the first layer is intended to be the closest to the body of the user during use.
  • the material according to the invention acquires a good combination of comfort and support for the user, and also good moisture management. Furthermore the invention concerns a method for manufacturing such a multi-layered material that comprises the following steps: the composition of a multi-layered composite flexible layer of at least three layers of flexible foam bonded together; the cutting of the middle layer of the three layers to form two separate layers of the material, whereby the applied cut essentially runs through the middle layer of the three layers and also continues locally up to each of the outermost layers of the three layers.
  • the cutting of the middle layer of the three layers is done in a profiling machine with simultaneous deformation of the composite layer, whereby the position and form of the cut is controlled by the thicknesses of the layers and the settings of the profiling machine .
  • Such a profiling machine is a known machine in the field of foam processing and is also known as a 'convoluting machine' .
  • This is a machine that variably impresses a foam layer locally by means of profiled rollers, after which this layer is cut in the impressed state to form two profiled foam layers.
  • a profiling with a complementary pattern is obtained on the foam layers.
  • Such a machine is described in US 4603445 for example.
  • the three layers are chosen such that the two outer layers of the three layers have a permeability to air that is greater than the permeability to air of the middle layer of these three layers, such that a material is obtained that satisfies the requirements for a material according to the invention as described above.
  • the middle layer is made of viscoelastic foam and the outermost layers of reticulated foam.
  • Figure 1 schematically shows a perspective view of a piece of material according to the invention
  • figure 2 shows a cross-section of the piece of material of figure 1 according to the line II-II;
  • figure.3 shows a method for manufacturing the material of figures 1 and 2;
  • figure 4 shows a cross-section of a variant of a material according to the invention
  • figure 5 shows a perspective view of another variant of a material according to the method
  • figure 6 shows a mattress in which the material of figure 4 is used.
  • figures 7 and 8 show variants of a mattress in which the material of figure 4 is used.
  • the material 1 shown in figures 1 and 2 in this example consists of three layers, i.e. a first layer 2, a second layer 3, and a third layer 4, whereby the second layer 3 is between the other two layers .
  • the first layer 2 is a continuous layer with cutaways 5 that do not continue to the surface 6 of this first layer 2 that is turned away from the second layer 3.
  • the first layer is made from a reticulated polyurethane foam with a high permeability to air. This is clear from the low pressure drop of ⁇ 0.1 kPa, measured on this material according to ISO 9237:1995.
  • the second layer 3 is a continuous layer that is formed by foam parts 7 and openings 8 between these foam parts 7 that run through the entire thickness D of the second layer 3.
  • the foam parts 7 are thinner in the direction of the first layer 2 towards the third layer 4, and the openings 8 are correspondingly larger in this direction.
  • the second layer 3 is made of a viscoelastic polyurethane foam. This viscoelastic foam has a low permeability to air. This is clear from the high pressure drop of 5.3 kPa, measured on this material according to ISO 9237:1995.
  • the third layer 4 is a discontinuous layer consisting of foam caps 9 that are made from the same foam as the first layer 1 and which are on the foam parts 7.
  • the foam of the . first layer 2 has a much higher permeability to air than the foam of the second layer 3.
  • the material 1 can be manufactured in the following way:
  • a three-layered flexible composite layer 10 is manufactured by bonding a flexible middle layer 11 of viscoelastic foam between two flexible outer layers 12 of reticulated foam.
  • this composite layer 10 is guided by a profiling machine, i.e. a convoluting machine'.
  • a profiling machine i.e. a convoluting machine'.
  • Such a machine comprises two rollers 13 with regularly positioned projections 14 between which the composite layer 10 is guided.
  • the composite layer 10 is compressed locally by the projections 14 and also moved forward in the direction of the arrow P. While the composite layer 10 is still in a compressed state, it is cut with a blade 15.
  • the settings of the profiling machine such as for example the geometry of the projections 14, the distance between the rollers 13 mutually and between the rollers 13 and the blade 15 are chosen such that the cut that the blade 15 makes is transverse through the middle layer 11, and also locally, where the deformation of the composite layer 10 by the projections 14 is the greatest, continuing up to the outer layers 12. These settings of course depend on the thickness of the middle layer 11 and the outer layers 12.
  • the composite layer 10 is symmetrical and the blade 15 is at an equal distance from each roller 13, so that a symmetrical cut is made, and as a result of this two identical pieces of material 1 are obtained .
  • Other settings and other composite layers 10 are of course also possible and will lead to variants.
  • the alternative embodiment of the material 1 as shown in figure 4 differs from the embodiment of figures 1 and 2 described above because it only consists of two layers, i.e. a first layer 2 and a second layer 3.
  • This alternative embodiment can be manufactured by, in the method described above, successively removing the foam caps 9 and possibly a part of the foam parts 7, for example by cutting them off.
  • the alternative embodiment of the material 1 shown in figure 5 differs from the embodiment of figures 1 and 2 described above, because in this case the openings 8 are channel-shaped openings 16.
  • This embodiment can be made by guiding the composite layer 10 through a contour cutting machine, whereby the settings of the contour cutting machine are such that a cut goes back and forth through the middle layer 11, and hereby also by through sections of the outer layers 12.
  • Such a contour cutting machine is known in the field of foam processing, and comprises a band knife whose orientation can be varied, in order to cut the correct contours in this way.
  • the material 1 of figure 5 can, with or without the complementary material 1 that is formed during such a cutting operation, and which is not shown in figure 5, be guided again through the contour cutting machine in a direction perpendicular to the direction in which it is worked the first time, so that channels perpendicular to the channel shaped openings 16 also occur, which can only be in the middle layer 11, or also in the outer layers 12.
  • the mattress 17 shown as a cross-section in figure 6 essentially consists of two layers of material 1 according to the invention, whereby the second layer 3 is oriented inwards .
  • the first layer 2 will be easily compressed and a gives a soft feeling, while the second layer will present its viscoelastic behaviour and the person will be given a support that is adjusted to the pressure that is exerted locally.
  • the mattress 17 can absorb moisture produced by the user while using the mattress 17, and can also emit that moisture through openings 8 other than on which the person is lying, or when the mattress 17 is not used. As a result problems with moisture accumulation in the mattress 17. and insufficient absorption of moisture can be prevented.
  • a sound-producing device such as a telephone, MP3 player or an alarm, can be placed in it, whereby thanks to the openings 8 in the layers of material, the sound produced is hardly damped, if at all, but conveyed and spread over the pillow, so that the user of the pillow can hear the sound optimally .
  • a supporting layer 18 of reticulated foam is placed between the two layers of material 1 according to the invention. This is primarily used in order to have some flexibility relating to the precise positioning of the foam parts 7 on one another, so that the manufacture of such a mattress 17 becomes easier.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention se rapporte à un matériau multicouche (1) qui comprend au moins une première couche (2) et une seconde couche (3) liée à cette dernière, les deux couches (2, 3) étant composées d'une mousse flexible, la première couche (2) étant composée d'une mousse qui présente une perméabilité à l'air plus importante que celle de la mousse de la seconde couche (3), et la seconde couche (3) présentant des ouvertures (8) qui traversent toute l'épaisseur de la seconde couche (3) afin de permettre un échange d'air entre la première couche et la seconde couche.
PCT/BE2013/000010 2012-02-29 2013-02-26 Matériau et procédé de fabrication d'un tel matériau WO2013126972A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BE2012/0126 2012-02-29
BE2012/0126A BE1020548A3 (nl) 2012-02-29 2012-02-29 Een materiaal en een werkwijze om een materiaal te vervaardigen.

Publications (2)

Publication Number Publication Date
WO2013126972A2 true WO2013126972A2 (fr) 2013-09-06
WO2013126972A3 WO2013126972A3 (fr) 2014-01-16

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/BE2013/000010 WO2013126972A2 (fr) 2012-02-29 2013-02-26 Matériau et procédé de fabrication d'un tel matériau

Country Status (2)

Country Link
BE (1) BE1020548A3 (fr)
WO (1) WO2013126972A2 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015067974A1 (fr) 2013-11-05 2015-05-14 Dóczi András Péter Insert de matelas
JP2015161034A (ja) * 2014-02-26 2015-09-07 株式会社イノアックコーポレーション 衣料用パットとその製造方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4603445A (en) 1983-09-09 1986-08-05 Span-America Medical Systems, Inc. Support pad and method of manufacture
DE20017581U1 (de) 1999-11-10 2000-12-21 Kabelwerk Eupen Ag Eupen Matratze

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5031261A (en) * 1990-03-15 1991-07-16 E. R. Carpenter Company, Inc. Mattress overlay for avoidance of decubitus ulcers
US5163194A (en) * 1992-01-31 1992-11-17 Imperial Feather Corporation (Toronto) Ltd. Adjustable cervical pillow
US5604021A (en) * 1994-12-23 1997-02-18 Ohio Mattress Company Licensing And Components Group Multi-layer support pad having regions of differing firmness
JP3564598B2 (ja) * 1998-09-18 2004-09-15 西川リビング株式会社 マットレス
TW577803B (en) * 2002-10-25 2004-03-01 Nam Liong Entpr Co Ltd Multilayered elastic material with stereoscopic pattern and method for forming the same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4603445A (en) 1983-09-09 1986-08-05 Span-America Medical Systems, Inc. Support pad and method of manufacture
DE20017581U1 (de) 1999-11-10 2000-12-21 Kabelwerk Eupen Ag Eupen Matratze

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015067974A1 (fr) 2013-11-05 2015-05-14 Dóczi András Péter Insert de matelas
US9930971B2 (en) 2013-11-05 2018-04-03 András Péter Dóczi Mattress insert
JP2015161034A (ja) * 2014-02-26 2015-09-07 株式会社イノアックコーポレーション 衣料用パットとその製造方法

Also Published As

Publication number Publication date
BE1020548A3 (nl) 2013-12-03
WO2013126972A3 (fr) 2014-01-16

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