WO2016067062A2 - Foam object laminated with fabric, and the method of manufacturing the foam object laminated with fabric - Google Patents

Foam object laminated with fabric, and the method of manufacturing the foam object laminated with fabric Download PDF

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Publication number
WO2016067062A2
WO2016067062A2 PCT/HU2015/050013 HU2015050013W WO2016067062A2 WO 2016067062 A2 WO2016067062 A2 WO 2016067062A2 HU 2015050013 W HU2015050013 W HU 2015050013W WO 2016067062 A2 WO2016067062 A2 WO 2016067062A2
Authority
WO
WIPO (PCT)
Prior art keywords
load
fabric
hot
melt adhesive
open
Prior art date
Application number
PCT/HU2015/050013
Other languages
French (fr)
Other versions
WO2016067062A3 (en
Inventor
Attila Kovács
Gábor HORVÁTH
Original Assignee
Attila Kovács
Horváth Gábor
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 Attila Kovács, Horváth Gábor filed Critical Attila Kovács
Publication of WO2016067062A2 publication Critical patent/WO2016067062A2/en
Publication of WO2016067062A3 publication Critical patent/WO2016067062A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0092—Producing upholstery articles, e.g. cushions, seats
    • 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 shape; Layered products comprising a layer having particular features of form
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • 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
    • B68G7/00—Making upholstery
    • B68G7/05—Covering or enveloping cores of pads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7371—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable
    • B29C66/73715—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable heat-shrinkable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B29C66/8362—Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/861—Hand-held tools
    • B29C66/8612—Ironing tool type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/751—Mattresses, cushions
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • 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
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/552—Fatigue strength
    • 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
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    • B32B2601/00—Upholstery

Definitions

  • Foam object laminated with fabric and the method of manufacturing the foam object laminated with fabric
  • the subject of the invention is a fabric laminated foam object, with synthetic fabric laminated on the surface of the open-cell flexible foam, in order to tension the surface of the flexible foam, thus improving the mechanical properties of the fabric laminated foam; and also the method of manufacturing the foam object laminated with this kind of fabric.
  • the typical field of application of open-cell flexible foam materials is the manufacturing of mattresses and pillows of chair and bed furniture.
  • Such solutions include the popular method of producing the comfort surface of sitting and sleeping surfaces using flexible foam, if requested.
  • the option of producing the surfaces using foams with different properties provides the required level of comfort to the users, as it allows them to select the hardness of the foam used as the sitting or sleeping surface.
  • Comfort foaming is used to produce open-cell polyurethane comfort foams for use in the upholstery industry, in normal, soft and flexible versions. Comfort foams are also categorised according to their density (kg/m 3 ) and flexibility, their “laden surface resistance” (kPa).
  • the price of foams increases proportionately with the higher values of kg/m 3 density and kPa flexibility.
  • the materials of open-cell foams largely comprise of petroleum products.
  • the disadvantageous rise of the world market price of oil has an unfavourable impact on specific market processes, including the price of the foam produced from petroleum products, thus also affecting this branch of furniture manufacturing.
  • Foams operate through the compression of the upper open foam cells in case of surface mechanical load, and the absorption and distribution of point load on the lower laden surface of the foam.
  • the load-bearing of the material is disproportionate and uneven, because while the upper (directly laden) foam layer is completely compressed when it is loaded (and it gets damaged and broken with time), the underlying layers are only minimally compressed (or not compressed at all).
  • the compression rate depends on the weight and duration of the load, the size (area) of the loading surface, the thickness of the laden surface, the kg/m 3 quality of the foam, i.e. the flexibility mechanical properties of the laden surface.
  • the solution according to the invention is based on the recognition that by laminating a load-bearing fabric layer onto the surface open-cell flexible foam, which shrinks during laminating, and then mechanical tension is created in the surface layer of the open-cell flexible foam in contact with it, the significant improvement of the technical characteristics of the open-cell flexible foam can be achieved.
  • a laminating process executed with a specific temperature and surface pressure, applying hot-melt adhesive coating is suitable for producing the subject of the invention.
  • Figure 1 denotes a normal open-cell flexible foam with the size of a pillow, as the basis for manual laminating
  • Figure 2 displays the manual laminating of the load-bearing fabric onto the upper side of the open-cell flexible foam with the size of a pillow
  • Figure 3 displays the manual laminating of the load-bearing fabric onto the upper side and the four vertical sides of the open-cell flexible foam with the size of a pillow
  • Figure 4 and 5 represent the process of laminating on all sides
  • Figure 6 represents the pillow made of flexible open-cell foam, manually laminated on all sides
  • Figure 7 displays the process of manual laminating
  • Figure 8 displays the process of mechanical laminating
  • Figure 9 denotes a normal open-cell flexible foam with the size of a pillow, as the basis for mechanical laminating
  • Figure 10 displays the mechanical laminating of the load-bearing fabric onto the upper side of the open-cell flexible foam with the size of a pillow
  • Figure 1 1 displays the mechanical laminating of the load-bearing fabric onto the upper side and the four vertical sides of the open-cell flexible foam with the size of a pillow
  • Figure 12 represents the pillow made of flexible open-cell foam, mechanically laminated on all sides.
  • the point flexibility of the open-cell flexible foam 1 object does reduce, but this does not affect the sense of comfort (or only to a minimal extent).
  • the horizontal co-suspension of the laden surface increases, and therefore the compressive stress properties of the foam significantly improve.
  • the mechanical properties of the open-cell flexible foam 1 object can be further improved, by not only laminating the upper load-bearing surface with the load- bearing fabric 2, but the entire geometrical surface (furniture pad, bed mattress, other laden foam parts).
  • the complete coating consisting of load-bearing fabric 2 prevents the significant flexible deformation caused by the properties of the foam and decreases undesirable environmental impacts (effects of direct contact with air, temperature fluctuations, UV light radiation).
  • the laminated strained load-bearing fabric 2 increases the surface resistance of the open-cell flexible foam 1 object and more evenly spreads/distributes surface load, thus the load and destruction and also the point fatigue of foam cells decrease in the open-cell flexible foam 1 object.
  • the first component to implementing the product is the already known open-cell flexible foam 1 object, but in an alternate quality, different from its typical field of application.
  • the second (and last) component is the load-bearing fabric 2 fixed to the open-cell flexible foam 1 object through laminating, which is suitable for carrying the single- sided hot-melt adhesive coating 5.
  • the synthetic load-bearing fabric 2 considering its surface, can be air permeable, semi-airtight or completely airtight.
  • typically synthetic load-bearing fabric 2 (or fabric mixed with synthetic fibre) is used, with the shrinking requirement of 0.5-2%.
  • the hot-melt adhesive coating 5 applied onto the fabric can be applied using foil or pasting technology.
  • the fixing of the load-bearing fabric 2 to the open-cell flexible foam 1 object is performed.
  • the manual laminating tool 3 or mechanical laminating tool 4 at 120-220 degrees Celsius, heated from the side opposite to the hot-melt adhesive coating 5, due to the hot-melt adhesive coating 5 a cohesion-quality mechanical bond is formed.
  • the technological action applied to the working surface requires the minimum and maximum surface pressure of 0.025-0.25 N/cm 2 .
  • the fabric is therefore fixed to the open-cell flexible foam 1 object. Simultaneously, on the treated surface, due to the tension caused by the shrinking of load-bearing fabric 2, the mechanical properties of the surface change.
  • the synthetic load-bearing fabric 2 shrinks, strains (the ideal volume of shrinking is 0.5-2%), thus tightening the load-bearing surface of the open-cell flexible foam 1 object and creating the desired mechanical change of the material.
  • the open-cell flexible foam 1 object used for the process can be of 2-4 categories lesser quality than the one previously applied in the specific field of application.
  • Technical openings 6 shall be made on the surface of the open-cell flexible foam 1 object laminated with the semi-airtight or airtight load-bearing fabric 2, in order to ensure free air-flow for the purpose of the necessary open type dynamic operation.
  • the mechanical quality change affecting (even) all sides of the open-cell flexible foam 1 object - which is achieved through the solution of the invention - has a measurable positive impact.
  • the vertical load is distributed more evenly horizontally and perpendicularly to the laden surface.
  • the surface load of the cheaper open-cell flexible foam 1 object is more even, and with the solution of the invention, the mechanical properties of the foam are improved by the average of 2-4 quality levels on the specific foam quality scale.
  • foam with smaller density and compressive stress resistance can be used in more demanding application fields, with a longer life cycle.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

Fabric laminated foam object, on whose open-cell flexible foam surface synthetic load- bearing fabric - or fabric mixed with synthetic fibre - (2) is laminated so, that on one side of the surface of the load-bearing fabric (2) hot-melt adhesive coating (5) is applied, and the hot-melt adhesive coating (5) is arranged between the surface of the open-cell flexible foam object (1 ) and the load-bearing fabric (2), the layered material composition comprising of the load-bearing fabric (2) and the hot-melt adhesive coating (5) has the property of shrinking 0.5-2% of its size during the 120-220 degrees Celsius temperature range of the laminating; and method of manufacturing thereof.

Description

Foam object laminated with fabric, and the method of manufacturing the foam object laminated with fabric
The subject of the invention is a fabric laminated foam object, with synthetic fabric laminated on the surface of the open-cell flexible foam, in order to tension the surface of the flexible foam, thus improving the mechanical properties of the fabric laminated foam; and also the method of manufacturing the foam object laminated with this kind of fabric.
The typical field of application of open-cell flexible foam materials is the manufacturing of mattresses and pillows of chair and bed furniture.
In order to develop increasingly comfortable designs of sitting and sleeping surfaces, the industry aims to provide newer and newer solutions. Such solutions include the popular method of producing the comfort surface of sitting and sleeping surfaces using flexible foam, if requested. The option of producing the surfaces using foams with different properties provides the required level of comfort to the users, as it allows them to select the hardness of the foam used as the sitting or sleeping surface.
Foaming is used to produce open-cell polyurethane comfort foams for use in the upholstery industry, in normal, soft and flexible versions. Comfort foams are also categorised according to their density (kg/m3) and flexibility, their "laden surface resistance" (kPa).
The price of foams increases proportionately with the higher values of kg/m3 density and kPa flexibility.
The materials of open-cell foams largely comprise of petroleum products. The disadvantageous rise of the world market price of oil has an unfavourable impact on specific market processes, including the price of the foam produced from petroleum products, thus also affecting this branch of furniture manufacturing.
Unfortunately the manufacturers of comfort furniture and mattresses tend to use cheaper foams instead of better quality ones in order to optimise costs, thus risking the quality and life cycle of finished products (upholstered furniture, bed mattresses).
Based on market classification: the higher the density of the open-cell flexible foam and the resistance of the laden surface (flexibility), the better its quality classification. These characteristics have a significant impact on the life cycle and purchase price of the foam.
Appropriate loading capacity is currently achieved in furniture manufacturing through the changing of foam quality depending on the field of application, by applying foams with density and flexibility selected according to demand.
Foams operate through the compression of the upper open foam cells in case of surface mechanical load, and the absorption and distribution of point load on the lower laden surface of the foam.
With regard to the entire cross-section of the foam, the load-bearing of the material is disproportionate and uneven, because while the upper (directly laden) foam layer is completely compressed when it is loaded (and it gets damaged and broken with time), the underlying layers are only minimally compressed (or not compressed at all).
As a consequence of such uneven load, in case of lesser quality foams, fatigue is highly disproportionate, and with time, through the influence of undesirable environmental impacts (effects of direct contact with air, temperature fluctuations, UV light radiation), because of fatigue the load-bearing layer gets to a lower position and this can even cause the rapid pitting of the foam.
The compression rate depends on the weight and duration of the load, the size (area) of the loading surface, the thickness of the laden surface, the kg/m3 quality of the foam, i.e. the flexibility mechanical properties of the laden surface.
State of the art solutions include examples of influencing the surface quality, i.e. the - sight (e.g. according to document no. US 3774250),
- air permeability (e.g. according to document no. US 4025686),
- surface evenness (e.g. according to document no. JP 2004338188) of the product made of flexible foam, through the application of a laminated external layer, however these do not include the improvement of the technical characteristics of the flexible foam material of the comfort surfaces, not in their objectives, nor in their solutions.
Considering the discovered deficiencies, it is our objective to improve the technical properties of the comfort surfaces in an economic way, using simple technical methods, and also to thus improve their life cycles.
The solution according to the invention is based on the recognition that by laminating a load-bearing fabric layer onto the surface open-cell flexible foam, which shrinks during laminating, and then mechanical tension is created in the surface layer of the open-cell flexible foam in contact with it, the significant improvement of the technical characteristics of the open-cell flexible foam can be achieved. We recognised that a laminating process executed with a specific temperature and surface pressure, applying hot-melt adhesive coating is suitable for producing the subject of the invention.
The solution according to the invention is described by the main claim, and its favourable implementation versions are described by the subclaims.
Hereinafter, the invention is presented based on drawings, on which
Figure 1 denotes a normal open-cell flexible foam with the size of a pillow, as the basis for manual laminating,
Figure 2 displays the manual laminating of the load-bearing fabric onto the upper side of the open-cell flexible foam with the size of a pillow,
Figure 3 displays the manual laminating of the load-bearing fabric onto the upper side and the four vertical sides of the open-cell flexible foam with the size of a pillow, Figure 4 and 5 represent the process of laminating on all sides, Figure 6 represents the pillow made of flexible open-cell foam, manually laminated on all sides,
Figure 7 displays the process of manual laminating,
Figure 8 displays the process of mechanical laminating,
Figure 9 denotes a normal open-cell flexible foam with the size of a pillow, as the basis for mechanical laminating,
Figure 10 displays the mechanical laminating of the load-bearing fabric onto the upper side of the open-cell flexible foam with the size of a pillow,
Figure 1 1 displays the mechanical laminating of the load-bearing fabric onto the upper side and the four vertical sides of the open-cell flexible foam with the size of a pillow,
Figure 12 represents the pillow made of flexible open-cell foam, mechanically laminated on all sides.
Due to the laminated load-bearing fabric 2, the point flexibility of the open-cell flexible foam 1 object does reduce, but this does not affect the sense of comfort (or only to a minimal extent). However, the horizontal co-suspension of the laden surface increases, and therefore the compressive stress properties of the foam significantly improve.
The mechanical properties of the open-cell flexible foam 1 object can be further improved, by not only laminating the upper load-bearing surface with the load- bearing fabric 2, but the entire geometrical surface (furniture pad, bed mattress, other laden foam parts).
In case of laminating the entire surface (all sides) of the open-cell flexible foam 1 object, due to the tension of the synthetic load-bearing fabric 2, the load perpendicular to the surface is also distributed more evenly in the vertical direction.
The complete coating consisting of load-bearing fabric 2 prevents the significant flexible deformation caused by the properties of the foam and decreases undesirable environmental impacts (effects of direct contact with air, temperature fluctuations, UV light radiation). The laminated strained load-bearing fabric 2 increases the surface resistance of the open-cell flexible foam 1 object and more evenly spreads/distributes surface load, thus the load and destruction and also the point fatigue of foam cells decrease in the open-cell flexible foam 1 object.
The first component to implementing the product is the already known open-cell flexible foam 1 object, but in an alternate quality, different from its typical field of application.
The second (and last) component is the load-bearing fabric 2 fixed to the open-cell flexible foam 1 object through laminating, which is suitable for carrying the single- sided hot-melt adhesive coating 5. In order to achieve the set objective, the synthetic load-bearing fabric 2, considering its surface, can be air permeable, semi-airtight or completely airtight.
For this purpose, typically synthetic load-bearing fabric 2 (or fabric mixed with synthetic fibre) is used, with the shrinking requirement of 0.5-2%. The hot-melt adhesive coating 5 applied onto the fabric can be applied using foil or pasting technology.
The manual or mechanical execution of laminating as technology is an unmissable part of the production process during the implementation of the product.
On the surface of the quality-improving synthetic load-bearing fabric 2, using the 5 hot-melt adhesive coating, the fixing of the load-bearing fabric 2 to the open-cell flexible foam 1 object is performed. During laminating, on load-bearing fabric 2, between the hot-melt adhesive coating 5 and the open-cell flexible foam 1 object, using the manual laminating tool 3 or mechanical laminating tool 4, at 120-220 degrees Celsius, heated from the side opposite to the hot-melt adhesive coating 5, due to the hot-melt adhesive coating 5 a cohesion-quality mechanical bond is formed. During the manual or mechanical laminating process, the technological action applied to the working surface requires the minimum and maximum surface pressure of 0.025-0.25 N/cm2.
Using the hot-melt adhesive coating 5 on the surface of the quality-improving synthetic load-bearing fabric 2, the fabric is therefore fixed to the open-cell flexible foam 1 object. Simultaneously, on the treated surface, due to the tension caused by the shrinking of load-bearing fabric 2, the mechanical properties of the surface change.
During the laminating action, due to the thermal effect, the synthetic load-bearing fabric 2 (or fabric mixed with synthetic fibre) shrinks, strains (the ideal volume of shrinking is 0.5-2%), thus tightening the load-bearing surface of the open-cell flexible foam 1 object and creating the desired mechanical change of the material.
The open-cell flexible foam 1 object used for the process can be of 2-4 categories lesser quality than the one previously applied in the specific field of application.
Technical openings 6 shall be made on the surface of the open-cell flexible foam 1 object laminated with the semi-airtight or airtight load-bearing fabric 2, in order to ensure free air-flow for the purpose of the necessary open type dynamic operation.
Keeping the technical opening(s) 6 on the laden surface of the open-cell flexible foam 1 object is undesirable, only on the lower or side surfaces, because in case of specific fields of application, the "great volume" of air flowing from the surface due to the load can cause disturbing sound effects because of the narrowing cross-section.
The mechanical quality change affecting (even) all sides of the open-cell flexible foam 1 object - which is achieved through the solution of the invention - has a measurable positive impact.
Due to laminating as specified in the invention, the vertical load is distributed more evenly horizontally and perpendicularly to the laden surface.
With this applied technology, the surface load of the cheaper open-cell flexible foam 1 object is more even, and with the solution of the invention, the mechanical properties of the foam are improved by the average of 2-4 quality levels on the specific foam quality scale.
Through the improvement of the surface material quality according to the invention, the sense of appropriate dynamic suspension can be ensured, and in addition to this, a simple solution enables the applicability of an "industrial-like" technology.
Our solution reduces the weight of the used foam material, significantly increases the life cycle of the foam applied and makes the production of semi-finished pillows/mattresses or finished products more economic.
Due to the multi-cycle fatigue test performed in the testing laboratory of Eurofoam Hungary Sajobabony, and based on the test results made available to us, in case of laden use (test with 40 000 compressions), the foam certified for the life cycle of 5 years shows 60-70% less fatigue, and compared to traditional foams, in case of identical load, life cycle is at least doubled.
Therefore foam with smaller density and compressive stress resistance can be used in more demanding application fields, with a longer life cycle.
List of referenced designations:
1 open-cell flexible foam
2 load-bearing fabric
3 manual laminating tool
4 mechanical laminating tool
5 hot-melt adhesive coating
6 technical opening

Claims

PATENT CLAIMS
1 . Fabric laminated foam object, on whose open-cell flexible foam surface synthetic load-bearing fabric - or fabric mixed with synthetic fibre - (2) is laminated so, that on one side of the surface of the load-bearing fabric (2) hot- melt adhesive coating (5) is applied, and the hot-melt adhesive coating (5) is arranged between the surface of the open-cell flexible foam object (1 ) and the load-bearing fabric (2),
characterized in that the layered material composition comprising of the load- bearing fabric (2) and the hot-melt adhesive coating (5) has the property of shrinking 0.5-2% of its size during the 120-220 degrees Celsius temperature range of the laminating.
2. The fabric laminated foam object pursuant to claim 1 ,
characterized in that the layered material composition comprising of the load- bearing fabric (2) and the hot-melt adhesive coating (5) is created from hot- shrink load-bearing fabric (2) and/or hot-shrink hot-melt adhesive coating (5).
3. The fabric laminated foam object pursuant to claim 1 or claim 2,
characterized in that the load-bearing fabric (2) is air-permeable.
4. The fabric laminated foam object pursuant to claim 1 or claim 2,
characterized in that the load-bearing fabric (2) is airtight or semi-airtight and at least one air-permeable technical opening (6) is made on the surface of the open-cell flexible foam object (1 ) covered with load-bearing fabric (2).
5. Method to manufacture the fabric laminated foam object according to any of the previous claims, according to which hot-melt adhesive coating (5) and load- bearing fabric (2) are placed on at least some part of the surface of an open-cell flexible foam object (1 ), and by heating the hot-melt adhesive coating (5) in contact with the surface of the flexible foam body (1 ) we perform a laminating action,
characterized in that on the surface of the flexible foam body (1 ) an appropriately flexible sheet - with the property of shrinking 0.5-2% of its size in the temperature range of 120-220 degrees Celsius during laminating - consisting of the load- bearing fabric (2) and the hot-melt adhesive coating (5) is placed.
6. The method pursuant to claim 5,
wherein during laminating, the hot-melt adhesive coating (5) is heated to a temperature between 120-220 degrees Celsius, from the direction of the load- bearing fabric (2).
7. The method pursuant to claim 6,
wherein during laminating, the surface of the open-cell flexible foam object (1 ) and the load-bearing fabric (2) are pressed against each other with pressure between 0.025-0.25 N/cm2 .
8. The method pursuant to either of claims 5-7,
wherein laminating is performed on an open-cell flexible foam object (1 ) with the thickness between 3-30 cm.
9. The method pursuant to either of claims 5-7,
wherein laminating is performed with hot-shrink, synthetic load-bearing fabric or load-bearing fabric mixed with synthetic fibre (2).
PCT/HU2015/050013 2014-10-30 2015-10-30 Foam object laminated with fabric, and the method of manufacturing the foam object laminated with fabric WO2016067062A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
HU1400515A HUP1400515A2 (en) 2014-10-30 2014-10-30 Textile reinforced foam body and method for making the same
HUP1400515 2014-10-30

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WO2016067062A3 WO2016067062A3 (en) 2016-08-25

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220241979A1 (en) * 2019-06-25 2022-08-04 Anji Bata Robot Co., Ltd. Carrying and deflection correction system for elastic material, and method thereof

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1260632B (en) * 1993-03-29 1996-04-22 Sepi Spa PROCESS AND EQUIPMENT FOR THE MANUFACTURE OF A PADDED ELEMENT, IN PARTICULAR FOR A VEHICLE SEAT.
US20070131347A1 (en) * 2005-12-13 2007-06-14 Lear Corporation Method of forming a fabric covered article
US20080057814A1 (en) * 2006-08-29 2008-03-06 Worthen Industries Adhesive film and method for bonding foams and fabrics

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220241979A1 (en) * 2019-06-25 2022-08-04 Anji Bata Robot Co., Ltd. Carrying and deflection correction system for elastic material, and method thereof

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