WO2022179994A1 - Seat cushion with a protective layer - Google Patents

Seat cushion with a protective layer Download PDF

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Publication number
WO2022179994A1
WO2022179994A1 PCT/EP2022/054298 EP2022054298W WO2022179994A1 WO 2022179994 A1 WO2022179994 A1 WO 2022179994A1 EP 2022054298 W EP2022054298 W EP 2022054298W WO 2022179994 A1 WO2022179994 A1 WO 2022179994A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
protective layer
seat cushion
cushion body
seat
Prior art date
Application number
PCT/EP2022/054298
Other languages
French (fr)
Inventor
Christophe Chaut
Marc Engel
Original Assignee
Zephyros, Inc.
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 Zephyros, Inc. filed Critical Zephyros, Inc.
Priority to EP22706632.1A priority Critical patent/EP4297616A1/en
Publication of WO2022179994A1 publication Critical patent/WO2022179994A1/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
    • 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
    • B32B5/026—Knitted fabric
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/006—Pressing and sintering powders, granules or fibres
    • 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
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • 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
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/542—Placing or positioning the reinforcement in a covering or packaging element before or during moulding, e.g. drawing in a sleeve
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/70—Completely encapsulating inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B2037/0092—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding in which absence of adhesives is explicitly presented as an advantage
    • 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
    • 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
    • B32B2262/0261—Polyamide 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
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • B32B2262/132—Knitted 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
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • B32B2307/581—Resistant to cut
    • 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
    • B32B2307/584—Scratch resistance
    • 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
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • 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
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/64—Back-rests or cushions

Definitions

  • the present invention relates to a seat part for a transportation vehicle comprising a seat cushion body and a protective layer.
  • the present invention further relates to a method to produce the inventive seat part.
  • a seat part for a transportation vehicle comprising a seat cushion body and a protective layer, wherein the protective layer comprises a substance which sealingly connects the protective layer and the seat cushion body.
  • the present invention relates to a seat part, that is part of a transportation vehicle seat.
  • a transportation vehicle is for example an aero plane, a train, a boat or an automotive vehicle, such as a car, a bus or a truck, a bicycle, a motorbike and/or support articles for disabled humans, such as wheelchairs.
  • the seat part is supported by the frame of the seat.
  • a seat part according to the present invention can be the seat part that supports the legs of a seat occupant or the back-rest.
  • the seat part comprises a seat cushion body that provides the structure to absorb loads and that provides comfort for the seat occupant.
  • the seat cushion body may be single- or multi-layered.
  • the seat cushion body may comprise two layers, a comfort/resilience-layer and a structure- layer.
  • the comfort/resilience-layer takes up the load under normal operation conditions and provides a comfortable sitting feeling even over a long period of time.
  • the structure-layer takes up the load, particularly under emergency conditions, for example a crash.
  • this cushion body comprises three layers, a comfort-layer, a resilience-layer and a structure-layer.
  • the comfort-layer provides a comfortable sitting feeling even over a long period of time.
  • the resilience-layer takes up the load under normal operation conditions.
  • the structure-layer takes up the load under emergency conditions, for example a crash.
  • the seat cushion body comprises one, two, three or more layer(s)
  • at least one, preferably all layers is/are preferably made from fibers, more preferably made from a mix of staple fibers and binding fibers, so that the seat cushion body preferably has an open pore structure.
  • the layers may be produced separately by inserting the fiber mix into a mould, in which the fiber mix gets the desired shape and the desired density of the respective layer.
  • the density of the fiber mix in the mould may be altered by compressing the fibers.
  • the fiber mix is preferably provided as a loose material which is filled, for example blown into the mould.
  • the fiber mix is preferably not provided as a prefabricated layer, which is for example stapled into the mould, but as loose material.
  • the fiber mix is heated, so that the staple fibers and the binding fibers are at least partially connect.
  • the binding fibers comprise a core and a surrounding sheath material.
  • the fiber mix in the mould is heated to an extent, that the melting point of the sheath material is reached, preferably exceeded, so that the sheath material gets tacky and binds with the staple fibers.
  • the subsequent cooling of the layer increases the binding between the binding- and the staple fibers
  • the prefabricated layers may then be inserted, preferably stapled into a second mould in which they are connected under the influence of heat, for example a hot gas, that is forced through and/or around the respective layer.
  • the layers may also be pressed together. No adhesive is preferably needed to connect the layers.
  • the density of at least one the respective layers may be altered, at least locally. More preferably the density of all layers inserted into the second mould is altered during their connection.
  • the seat part comprises a protective layer, that protects the seat part, particularly the seat cushion body against abrasion, fire/flash and/or vandalism.
  • this protective layer comprises a substance, that sealingly connects the protective layer to the seat cushion body.
  • the sealing connection of the substance at the seat cushion is established under the influence of heat and more preferably by pressing the protective layer against the seat cushion body.
  • a material bond between the protective layer and the seat cushion body is established and/or improved. No separate adhesive, which has to applied between the surface of the protective layer and the surface of the seat cushion body is needed.
  • the substance that establishes the sealing connection between the protective layer and the seat cushion body is heated to an extent, that its melting point temperature is reached or exceeded.
  • the substance is preferably provided as a separate layer which is more preferably laminated to the other layers of the protective layer and which is even more preferably directly adjacent to the seat cushion body.
  • the sealing substance may be provided as a yarn and knitted into the protective layer.
  • the sealing layer may be provided only locally or preferably along the entire surface of the protective layer which faces towards the seat cushion body.
  • the protective layer is heat shrinkable.
  • the protective layer shrinks for example under the influence of an elevated temperature. Due to the shrinkage, a gap or an air layer between the protective layer and the seat cushion body is at least partially, more preferably totally eliminated, so that more preferably, the protective layer is in tight-fitting contact with the surface of the seat cushion body.
  • the shrinkage of the protective layer is preferably achieved by a shrinkable substance in the protective layer, preferably a polymeric substance more preferably a thermoplastic substance.
  • the shrink-temperature at which the protective layer starts to shrink is lower than the melting point temperature of the substance which sealingly connects the protective layer to the seat cushion body.
  • This preferred embodiment of the present invention has the advantage, that when the protective layer is heated, it first starts to shrink and then, in case its temperature is further elevated, the already shrunk protective layer is sealingly connected to the seat cushion body. A material bond is established due to the sealing connection by first melting the sealing layer and then cool it down below the melting temperature again.
  • the sealing layer is preferably a thermoplastic layer.
  • the melting point temperature of the sealing layer is ⁇ 110°C, more preferably ⁇ 100°C.
  • the seat cushion body comprises a polymeric substance, more preferably a polyamide.
  • the protective layer particularly the sealing layer, comprises a polymeric substance, more preferably a polyamide.
  • the polymeric substance of the protective layer has a melting point temperature £ the melting point temperature of the polymeric substance in the seat cushion body.
  • a melting point temperature of the seat cushion body equal to the melting point temperature of the protective layer has the advantage that the seat cushion body can be formed, for example in a mould prior to the adhesion of the protective cover at the seat cushion body.
  • a melting point temperature of the protective layer being lower than the melting point temperature of the seat cushion body allows a sealing connection between seat cushion body and protective layer without deformation of seat cushion body.
  • the seat cushion body comprises fibers, more preferably, the fibers are a fiber mix, preferably a mix of staple- and binding-fibers.
  • the fibers in one, two, three or all layers of the seat cushion body are oriented parallel to a main-load direction, particularly after the layers have been connected.
  • the main load direction is preferably the direction of gravity for the seat part that supports the legs of a seat occupant and an essentially horizontal direction for the back rest.
  • more than 60%, more preferably more than 70% and even more preferred more than 85% based on the total number of fibers in one layer are oriented parallel to the main load direction. Parallelism is still given as long as the angel between the respective fiber and the main load direction preferably does not exceed ⁇ 20°.
  • the fibers for the layer(s) are preferably polymer fibers, more preferably thermoplastic polymers.
  • the fiber may at least partially be recycled.
  • Each layer preferably comprises a mix of staple fibers and binding fibers.
  • the binding fibers provide a material bond between the staple fibers.
  • the mixing ratio is preferably between 40/60 staple fiber/binding and 60/40 staple fibers/binding fibers.
  • the staple fibers preferably have an average length of 10 - 200 mm, more preferably 50 - 120 mm.
  • the average is a number-average, i.e. the length of all staple fibers in one sample is summed up and then divided by the number of assessed fibers.
  • the staple fibers preferably have an average diameter of 1 -50 deci-tex, more preferably 8 - 44 deci-tex.
  • the average is a number-average, i.e. the diameter of all fibers in one sample is summed up and then divided by the number of assessed fibers.
  • the staple fibers are preferably Polyamid fibers.
  • the binding fibers preferably have an average length of 10 - 200 mm, more preferably 50 - 120 mm.
  • the average is a number-average, i.e. the length of all binding fibers in one sample is summed up and then divided by the number of assessed fibers.
  • the binding fibers preferably have an average diameter of 1 -50 deci-tex, more preferably 8 -44 deci-tex.
  • the average is a number-average, i.e. the diameter of all fibers in one sample is summed up and then divided by the number of assessed fibers.
  • the binding fibers preferably comprise a Polyamid-core and a sheath made from a polymer with a melting point between 110 and 160 °C, more preferably 135 - 145 °C.
  • the sheath is preferably a CoPA.
  • the core of the binding material preferably has an average diameter of 0.5 - 25 deci-tex, more preferably 4 - 22 deci- tex.
  • All layers of one seat cushion body are preferably made of the same fibers; i.e. the same fiber material and/or the same fiber length and/or the same fiber diameter and even more preferably of the same ratio between staple- and binding fibers. More preferably, the layers only differ in density and/or thickness and/or shape all measured/determined at the final seat cushion body.
  • At least one of the layers which forms the seat cushion body has at least locally a skin layer at its circumference.
  • This skin layer is preferably formed during the heating, baking of the individual layer.
  • this skin layer is provided between two layers of one seat cushion body.
  • This skin layer preferably provides the binding between two layers in one seat cushion body.
  • the porosity of the fiber material is preferably reduced in comparison to the fiber material in this layer. However, the porosity is preferably still large enough so that a gas can be forced through the skin layer.
  • the staple fibers and binding fibers are distributed homogeneously within one layer.
  • Homogenously according to present invention means that the standard deviation of 10 samples taken in one layer is less than 5 %. The samples are taken from the final seat cushion body after the individual layers of one seat cushion body have been connected.
  • the layers of the seat cushion body are surrounded by a fire/flash resistance layer and/or anti-vandalism layer and/or anti-abrasion-layer.
  • a fire/flash resistance layer and/or anti-vandalism layer and/or anti-abrasion-layer Preferably at least two, more preferably all of these protective layers are provided as one integral piece.
  • the individual layers of the protective layer are preferably produced at least partially separately and are more preferably then laminated.
  • the polymeric substance of the sealing layer has a melting point temperature £ a melting point temperature of one component of the staple- and/or binding-fibers of the seat cushion body.
  • a melting point temperature of the staple and/or binding-fibers equal to the melting point temperature of the protective layer has the advantage that the seat cushion body can be formed, for example in a mould, prior to the adhesion of the protective layer at the seat cushion body.
  • a melting point temperature of the protective layer being lower than the melting point temperature of staple and/or binding-fibers allows a sealing connection between seat cushion body and protective layer without deformation of seat cushion body.
  • the protective layer comprises a sealing layer, an abrasion resistance layer and/or a fire/flash-blocker layer and/or an anti-vandalism layer.
  • the anti-vandalism layer makes the seat cushion part more resistant against mechanical abuse for example with a knife, a screw-driver or the like.
  • the entire protective layer for example the fire/flash resistance layer and/or anti-vandalism layer and/or anti-abrasion-layer, and/or the sealing layer, are preferably provided as one integral piece.
  • the individual layers of the protective layer are preferably laminated and/or provided by a coating process such as spraying, painting or the like.
  • the seat cushion body is enveloped by the protective layer; i.e. the seat cushion body is surrounded by the protective layer at all surfaces.
  • the protective layer is preferably provided as an envelope and/or cover into which the seat cushion body can be inserted.
  • the protective layer envelope can be produced by forming a protective layer blank and connecting the edges of the formed blank, for example by sealing the edges.
  • the protective layer envelope/cover has an overlapping portion, for example a flap, which is connected to the protective layer envelope/cover after the seat cushion bod has been inserted into the envelope/cover.
  • the protective layer comprises a knitted abrasion resistance layer.
  • this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
  • a yarn with abrasion resistance properties is provided, which is knitted into an abrasion resistance layer.
  • a knitted layer is at least partially coated with an abrasion resistance substance.
  • Another subject matte of the present invention is a protective layer, particularly for a seat cushion body preferably for a transportation, wherein the protective layer comprises a substance which sealingly connects the protective layer and the seat cushion body.
  • This embodiment of the present invention is directed to a protective layer, which can be, for example, wrapped seat cushion body, which is for example part of transportation vehicle or a conventional chair, a sofa, a bed or the like.
  • this protective layer comprises a substance, that sealingly connects the protective layer to the seat cushion body.
  • the sealing connection of the substance at the seat cushion is established under the influence of heat and more preferably by pressing the protective layer against the seat cushion body.
  • a material bond between the protective layer and the seat cushion body is established and/or improved. No separate adhesive, which has to applied between the surface of the protective layer and the surface of the seat cushion body is needed.
  • the substance that establishes the sealing connection between the protective layer and the seat cushion body is heated to an extent, that its melting point temperature is reached or exceeded.
  • the substance is preferably provided as a separate layer which is more preferably laminated to the other layers of the protective layer and which is even more preferably directly adjacent to the seat cushion body.
  • the sealing substance may be provided as a yarn and knitted into the protective layer.
  • the sealing layer may be provided only locally or preferably along the entire surface of the protective layer which faces towards the seat cushion body.
  • the melting point temperature of the sealing layer is ⁇ 110°C, more preferably ⁇ 100°C.
  • the protective layer is heat shrinkable.
  • the protective layer shrinks for example under the influence of an elevated temperature. Due to the shrinkage, a gap or an air layer between the protective layer and the seat cushion body is at least partially, more preferably totally eliminated, so that more preferably, the protective layer is in tight-fitting contact with the surface of the seat cushion body.
  • the shrinkage of the protective layer is preferably achieved by a shrinkable substance in the protective layer, preferably a polymeric substance more preferably a thermoplastic substance.
  • the shrink-temperature at which the protective layer starts to shrink is lower than the melting point temperature of the substance which sealingly connects the protective layer to the seat cushion body.
  • This preferred embodiment of the present invention has the advantage, that when the protective layer is heated, it first starts to shrink and then, in case its temperature is further elevated, the already shrunk protective layer is sealingly connected to the seat cushion body. A material bond is established due to the sealing connection by first melting the sealing layer and then cool it down below the melting temperature again.
  • the sealing layer is preferably a thermoplastic layer.
  • the protective layer comprises a knitted abrasion resistance layer.
  • the protective layer comprises a sealing layer, an abrasion resistance layer and/or a fire blocker layer and/or an anti-vandalism layer.
  • Another subject matter of the present invention is a method to produce the inventive seat cushion part the protective layer is laminated at the seat cushion body.
  • This embodiment of the present invention is a method to produce the inventive seat cushion part.
  • the protective layer is laminated to the seat cushion body, preferably on its entire surface.
  • the lamination takes place by heating the protective layer and/or the seat cushion body so that the glass transition temperature of at least one polymeric component of the protective layer and/or the seat cushion body is reached or exceeded and preferably pressing the protective layer and the seat cushion body together.
  • the sealing connection between the protective layer and the seat cushion body preferably takes place in a mould. No glue is applied for the lamination.
  • the protective layer comprises a sealing layer which comprises a polymeric component whose glass transition temperature is exceeded. During heating and/or after cooling down at least at ambient temperature, a material bond between the protective layer and the seat cushion body is established.
  • the seat cushion body preferably comprises at least two layers, wherein the layers preferably differ in average density and in thickness.
  • Each of these layers is preferably made from a mix of staple fibers and binding fibers, so that it preferably has an open pore structure.
  • the two layers can be produced separately by inserting the fiber mix into a mould, in which the fiber mix gets the desired shape and the desired density of the respective layer.
  • the density of the fiber mix in the mould may be altered by compressing the fibers.
  • the fiber mix is preferably provided as a loose material which is filled, for example blown into the mould.
  • the fiber mix is preferably not provided as a prefabricated layer, which is for example stapled into the mould. In the mould the fixer mix is heated, so that the staple fibers and the binding fibers at least partially connect.
  • the binding fibers comprise a core and a surrounding sheath material.
  • the fiber mix in the mould is heated to an extent, that the melting point of the sheath material is reached, preferably exceeded, so that the sheath material gets tacky and binds with the staple fibers.
  • the heat in preferably executed with a hot gas, that is forced through and/or around the fiber mix in the respective mould. The subsequent cooling of the layer increases the binding between the binding- and the staple fibers.
  • the prefabricated layers may then be inserted, for example stapled or stacked, into a second mould in which they are connected under the influence of heat, for example a hot gas, that is forced through around the respective layer and/or around the layer stack. No adhesive is needed to connect the layers that form the seat body cushion.
  • the density of at least of the respective layers may be altered, at least locally, so that the desired density in the respective mould is reached.
  • a skin layer is developed at at least one layer.
  • This skin layer is preferably utilized to provide a material bond between the layers of the seat cushion body.
  • At least two, more preferably all layers are made from the same fiber mix. However, the average density of the layers differs.
  • the seat cushion body is inserted into an envelope-formed protective cover, which surrounds the seat cushion body at its entire surface.
  • the seat cushion body may comprise one, two, three or more layers.
  • the layer(s) of the seat cushion body is/are inserted individually into the protective cover, for example stacked into a protective cover.
  • This protective cover surrounds the layer or the staked layers preferably on the entire surface.
  • the protective cover may protect the layers which are preferably made from fibers against abrasion, fire, flash and/or vandalism.
  • the seat cushion body can be inserted as an integral piece in the protective cover. This piece may comprise one, two, three or more layer(s).
  • the protective cover comprises closure means to close the cover after the layers have been inserted.
  • This closure means may be a flap which is after insertion of the seat cushion body connected to the protective cover, for example sealed.
  • the protection cover protective cover is a laminate of at least two different layers.
  • the cover comprises a sealing layer, preferably a layer with a melting point temperature between 110 - 160 °C, more preferably between 135 and 145°C.
  • the sealing layer comprises or is made of Polyamid.
  • the protective layer or the protective cover is gas-permeable.
  • the layers and the protective cover are heated.
  • This heating preferably takes place in a mould.
  • the mould may form and/or compress the protective cover and/or at least one of the fiber layers.
  • a material bond between the layers themselves and between the protective cover and one, two or three fiber layers takes place.
  • all material bonds are established without a separate adhesive, like a glue or the like.
  • the protective layer or the protective cover may shrink to fit tightly around the seat cushion body, which is preferably made from fibers more preferably staple or stacked fiber layers.
  • Figure 1 shows a seat cushion body with three layers.
  • Figure 2 shows the insertion of a seat cushion body into a protective cover/envelope.
  • Figure 3 depicts the inventive seat cushion part.
  • Figure 4 depicts an example of the protective cover 9
  • Figure 1 shows a seat cushion body 1 with three layers, here a comfort-layer layer 2, resilience-layer 4 and a structure-layer 5.
  • the seat cushion body is part of seat in a transportation vehicle, like an aero plane, a train, a bus, a ruck an automotive or the like.
  • the seat cushion body may be a seating part or the back rest of a seat.
  • the main load provided by a seat occupant is indicated by the arrow L.
  • the skilled person understands that there may be other load directions, which are however smaller, preferably significantly smaller, than the main load direction.
  • the comfort layer 3 which is adjacent to the seat occupant or adjacent to the main load direction, provides the comfort and the resilience-layer 4 provides the support for a seat occupant needed under normal operation conditions.
  • the structure layer 5 provides the structure needed in an emergency situation, like a crash- or a near- crash-situation.
  • All layers 3 - 5 are preferably made from a fiber mix of staple- and binding fibers, wherein, in the present case, the fibers of all layers are made or may comprise Polyamide.
  • the fibers and/or the fiber-mix in all layers 3 - 5 is identical or nearly identical.
  • the three layers 3 - 5 differ in their average density, wherein the comfort-layer 3 preferably has a lower average density than the average density of the resilience-layer and the resilience-layer preferably has a lower average density than the average density of the structure-layer 5.
  • Two adjacent layers are preferably connected by a material bond at their interface 15.
  • This material bond is preferably established by heating the fibers at least at the interface 15 or a sheath around the binding fibers temporarily above their melting point temperature.
  • the layers 3 - 5 are preferably heated by a hot gas which is forced through and/or around the layers 3 - 5.
  • the comfort layer has an average density of 20 kg/m 3 and the resilience layer an average density of 35 kg/m 3 and the structure layer a density 50 kg/m 3 all densities measured at the final seat cushion body, i.e. after the three layers have been connected, preferably in a mould.
  • All layers 3 - 5 of the seat cushion body are preferably produced separately, for example by inserting the fiber mix into a mould.
  • the fiber mix for one layer is distributed and/or compressed such that the layer preferably has a homogeneous density and/or such that the fibers are preferably oriented with their length-extension at least essentially parallel to the expected main load direction L.
  • the fiber mix gets its desired shape and preferably its desired density.
  • the fiber mix is heated to an extent that the surface of the binding fibers softens or melts and establishes a tacky binding between the staple- and the binding fibers.
  • the fiber mix is preferably heated by a hot gas which is forced through and/or around the fiber mix.
  • a skin layer 8 establishes at the entire surface of preferably each layer 3 - 5.
  • This skin layer can be utilized to connect the two adjacent layers 3 - 5 at their interface 15, by softening and/or melting the skin layer at least locally. Even though not depicted, the skilled person understands that the layers 3 - 5 may differ in size and/or shape.
  • Figure 2 shows schematically an embodiment in which a plane protective layer has been formed into a protective cover, here a protective envelope 9, which is closed here at three sides, here by a seal 15.
  • a protective cover here a protective envelope 9, which is closed here at three sides, here by a seal 15.
  • One side is open, so that the seat cushion body 1 can be inserted into the protective envelope. After the insertion of the seat cushion body 1 , the open side is closed as well.
  • the layers are preferably inserted into the protective cover unconnectedly. The connection between these layers preferably takes place prior and/or simultaneously and/or after the connection between the seat cushion body and the protective cover.
  • Figure 3 discloses schematically the embodiment according to the present invention, after the seat cushion body 1 has been inserted into the protective envelope and the protective cover has been closed.
  • the protective envelope 9 comprises a flap 10, which is connected, preferably sealed, to the protective cover after the seat cushion body has been inserted,
  • the flap 10 is preferably integral with the rest of the protective cover and more preferably the same material or material composition.
  • the protective cover 9 according to Figure 3 is preferably shrinkable, preferably under the influence of heat, so that the protective cover fits tightly around the seat cushion body, which is here a cuboid. After and/or during the shrinkage, the proactive cover is connected, preferably sealed with the surface of the seat cushion body 1.
  • FIG. 4 depicts an example of a protective cover 9, from which the protective cover/envelope 9 can be made.
  • the protective cover 9 comprises three layers 12 - 14, which are preferably laminated together.
  • the abrasion layer 12 is preferably the outer layer of the seat cushion part, i.e. the part that is in contact with the seat occupant.
  • the abrasion layer reduces the ware of the seat cushion part.
  • the fire blocker layer assures the required fire- and/or flash-resistance.
  • the sealing layer 14 is adjacent to the seat cushion body 1 and sealingly connects the protective cover 9 and the seat cushion body under the influence of heat and preferably pressure. Preferably, no adhesive is needed for the connection of the protective cover 9 and the seat cushion body.
  • the layers 12 - 14 are preferably laminated. Alternatively, the layers 12 and 13 are laminated and the sealing layer is applied for example by spraying. List of reference signs:

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Abstract

The present invention relates to a seat part for a transportation vehicle comprising a seat cushion body and a protective layer. The present invention further relates to a method to produce the inventive seat part.

Description

Seat cushion with a protective Layer
The present invention relates to a seat part for a transportation vehicle comprising a seat cushion body and a protective layer. The present invention further relates to a method to produce the inventive seat part.
Seat parts, for example for aircrafts, trains, cars or the like need to have a protective layer to protect it against ware, fire/flash and/or vandalism. In the past, the application of a protective layer was difficult and time consuming.
It was therefore the objective of the present invention to provide a seat part and a method to produce this seat part that overcomes the deficiencies of the state in the art.
The problem is solved with a seat part for a transportation vehicle comprising a seat cushion body and a protective layer, wherein the protective layer comprises a substance which sealingly connects the protective layer and the seat cushion body.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
The present invention relates to a seat part, that is part of a transportation vehicle seat. A transportation vehicle is for example an aero plane, a train, a boat or an automotive vehicle, such as a car, a bus or a truck, a bicycle, a motorbike and/or support articles for disabled humans, such as wheelchairs. The seat part is supported by the frame of the seat. A seat part according to the present invention can be the seat part that supports the legs of a seat occupant or the back-rest.
According to this embodiment of the present invention, the seat part comprises a seat cushion body that provides the structure to absorb loads and that provides comfort for the seat occupant. The seat cushion body may be single- or multi-layered.
The seat cushion body may comprise two layers, a comfort/resilience-layer and a structure- layer. The comfort/resilience-layer takes up the load under normal operation conditions and provides a comfortable sitting feeling even over a long period of time. The structure-layer takes up the load, particularly under emergency conditions, for example a crash. According to another embodiment of the present invention, this cushion body comprises three layers, a comfort-layer, a resilience-layer and a structure-layer. The comfort-layer provides a comfortable sitting feeling even over a long period of time. The resilience-layer takes up the load under normal operation conditions. The structure-layer takes up the load under emergency conditions, for example a crash.
Regardless whether the seat cushion body comprises one, two, three or more layer(s), at least one, preferably all layers is/are preferably made from fibers, more preferably made from a mix of staple fibers and binding fibers, so that the seat cushion body preferably has an open pore structure.
The layers may be produced separately by inserting the fiber mix into a mould, in which the fiber mix gets the desired shape and the desired density of the respective layer. The density of the fiber mix in the mould may be altered by compressing the fibers. The fiber mix is preferably provided as a loose material which is filled, for example blown into the mould. The fiber mix is preferably not provided as a prefabricated layer, which is for example stapled into the mould, but as loose material. In the mould the fiber mix is heated, so that the staple fibers and the binding fibers are at least partially connect. As described later, the binding fibers comprise a core and a surrounding sheath material. The fiber mix in the mould is heated to an extent, that the melting point of the sheath material is reached, preferably exceeded, so that the sheath material gets tacky and binds with the staple fibers. The subsequent cooling of the layer increases the binding between the binding- and the staple fibers
The prefabricated layers may then be inserted, preferably stapled into a second mould in which they are connected under the influence of heat, for example a hot gas, that is forced through and/or around the respective layer. The layers may also be pressed together. No adhesive is preferably needed to connect the layers. In the second mould, the density of at least one the respective layers may be altered, at least locally. More preferably the density of all layers inserted into the second mould is altered during their connection.
Further according to the present invention, the seat part comprises a protective layer, that protects the seat part, particularly the seat cushion body against abrasion, fire/flash and/or vandalism.
According to the present invention, this protective layer comprises a substance, that sealingly connects the protective layer to the seat cushion body. The sealing connection of the substance at the seat cushion is established under the influence of heat and more preferably by pressing the protective layer against the seat cushion body. As soon as the protective layer cools down, a material bond between the protective layer and the seat cushion body is established and/or improved. No separate adhesive, which has to applied between the surface of the protective layer and the surface of the seat cushion body is needed.
Preferably, the substance that establishes the sealing connection between the protective layer and the seat cushion body is heated to an extent, that its melting point temperature is reached or exceeded. The substance is preferably provided as a separate layer which is more preferably laminated to the other layers of the protective layer and which is even more preferably directly adjacent to the seat cushion body. Alternatively or additionally, the sealing substance may be provided as a yarn and knitted into the protective layer. The sealing layer may be provided only locally or preferably along the entire surface of the protective layer which faces towards the seat cushion body.
According to another inventive or preferred embodiment of the present invention, the protective layer is heat shrinkable.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
According to this embodiment of the present invention, the protective layer shrinks for example under the influence of an elevated temperature. Due to the shrinkage, a gap or an air layer between the protective layer and the seat cushion body is at least partially, more preferably totally eliminated, so that more preferably, the protective layer is in tight-fitting contact with the surface of the seat cushion body. The shrinkage of the protective layer is preferably achieved by a shrinkable substance in the protective layer, preferably a polymeric substance more preferably a thermoplastic substance.
Preferably, the shrink-temperature at which the protective layer starts to shrink is lower than the melting point temperature of the substance which sealingly connects the protective layer to the seat cushion body. This preferred embodiment of the present invention has the advantage, that when the protective layer is heated, it first starts to shrink and then, in case its temperature is further elevated, the already shrunk protective layer is sealingly connected to the seat cushion body. A material bond is established due to the sealing connection by first melting the sealing layer and then cool it down below the melting temperature again. The sealing layer is preferably a thermoplastic layer. Preferably, the melting point temperature of the sealing layer is <110°C, more preferably < 100°C.
Preferably, the seat cushion body comprises a polymeric substance, more preferably a polyamide. According to another preferred embodiment of the present invention, the protective layer, particularly the sealing layer, comprises a polymeric substance, more preferably a polyamide. Preferably, the polymeric substance of the protective layer has a melting point temperature £ the melting point temperature of the polymeric substance in the seat cushion body. A melting point temperature of the seat cushion body equal to the melting point temperature of the protective layer has the advantage that the seat cushion body can be formed, for example in a mould prior to the adhesion of the protective cover at the seat cushion body. A melting point temperature of the protective layer being lower than the melting point temperature of the seat cushion body allows a sealing connection between seat cushion body and protective layer without deformation of seat cushion body.
Preferably, the seat cushion body comprises fibers, more preferably, the fibers are a fiber mix, preferably a mix of staple- and binding-fibers.
Preferably, the fibers in one, two, three or all layers of the seat cushion body are oriented parallel to a main-load direction, particularly after the layers have been connected. The main load direction is preferably the direction of gravity for the seat part that supports the legs of a seat occupant and an essentially horizontal direction for the back rest. Preferably, more than 60%, more preferably more than 70% and even more preferred more than 85% based on the total number of fibers in one layer are oriented parallel to the main load direction. Parallelism is still given as long as the angel between the respective fiber and the main load direction preferably does not exceed ± 20°.
The fibers for the layer(s) are preferably polymer fibers, more preferably thermoplastic polymers. The fiber may at least partially be recycled. Each layer preferably comprises a mix of staple fibers and binding fibers. The binding fibers provide a material bond between the staple fibers. The mixing ratio is preferably between 40/60 staple fiber/binding and 60/40 staple fibers/binding fibers.
The staple fibers preferably have an average length of 10 - 200 mm, more preferably 50 - 120 mm. The average is a number-average, i.e. the length of all staple fibers in one sample is summed up and then divided by the number of assessed fibers. The staple fibers preferably have an average diameter of 1 -50 deci-tex, more preferably 8 - 44 deci-tex. The average is a number-average, i.e. the diameter of all fibers in one sample is summed up and then divided by the number of assessed fibers. The staple fibers are preferably Polyamid fibers.
The binding fibers preferably have an average length of 10 - 200 mm, more preferably 50 - 120 mm. The average is a number-average, i.e. the length of all binding fibers in one sample is summed up and then divided by the number of assessed fibers. The binding fibers preferably have an average diameter of 1 -50 deci-tex, more preferably 8 -44 deci-tex. The average is a number-average, i.e. the diameter of all fibers in one sample is summed up and then divided by the number of assessed fibers. The binding fibers preferably comprise a Polyamid-core and a sheath made from a polymer with a melting point between 110 and 160 °C, more preferably 135 - 145 °C. The sheath is preferably a CoPA. The core of the binding material preferably has an average diameter of 0.5 - 25 deci-tex, more preferably 4 - 22 deci- tex.
All layers of one seat cushion body are preferably made of the same fibers; i.e. the same fiber material and/or the same fiber length and/or the same fiber diameter and even more preferably of the same ratio between staple- and binding fibers. More preferably, the layers only differ in density and/or thickness and/or shape all measured/determined at the final seat cushion body.
According to a preferred embodiment of the present invention at least one of the layers which forms the seat cushion body has at least locally a skin layer at its circumference. This skin layer is preferably formed during the heating, baking of the individual layer. Preferably, this skin layer is provided between two layers of one seat cushion body. This skin layer preferably provides the binding between two layers in one seat cushion body. In the skin layer, the porosity of the fiber material is preferably reduced in comparison to the fiber material in this layer. However, the porosity is preferably still large enough so that a gas can be forced through the skin layer.
Preferably, the staple fibers and binding fibers are distributed homogeneously within one layer. Homogenously according to present invention means that the standard deviation of 10 samples taken in one layer is less than 5 %. The samples are taken from the final seat cushion body after the individual layers of one seat cushion body have been connected.
According to the present invention, the layers of the seat cushion body are surrounded by a fire/flash resistance layer and/or anti-vandalism layer and/or anti-abrasion-layer. Preferably at least two, more preferably all of these protective layers are provided as one integral piece. The individual layers of the protective layer are preferably produced at least partially separately and are more preferably then laminated.
Preferably, the polymeric substance of the sealing layer has a melting point temperature £ a melting point temperature of one component of the staple- and/or binding-fibers of the seat cushion body. A melting point temperature of the staple and/or binding-fibers equal to the melting point temperature of the protective layer has the advantage that the seat cushion body can be formed, for example in a mould, prior to the adhesion of the protective layer at the seat cushion body. A melting point temperature of the protective layer being lower than the melting point temperature of staple and/or binding-fibers allows a sealing connection between seat cushion body and protective layer without deformation of seat cushion body.
Preferably, the protective layer comprises a sealing layer, an abrasion resistance layer and/or a fire/flash-blocker layer and/or an anti-vandalism layer. The anti-vandalism layer makes the seat cushion part more resistant against mechanical abuse for example with a knife, a screw-driver or the like.
The entire protective layer, for example the fire/flash resistance layer and/or anti-vandalism layer and/or anti-abrasion-layer, and/or the sealing layer, are preferably provided as one integral piece. The individual layers of the protective layer are preferably laminated and/or provided by a coating process such as spraying, painting or the like.
Preferably, the seat cushion body is enveloped by the protective layer; i.e. the seat cushion body is surrounded by the protective layer at all surfaces.
The protective layer is preferably provided as an envelope and/or cover into which the seat cushion body can be inserted. The protective layer envelope can be produced by forming a protective layer blank and connecting the edges of the formed blank, for example by sealing the edges. Preferably, the protective layer envelope/cover has an overlapping portion, for example a flap, which is connected to the protective layer envelope/cover after the seat cushion bod has been inserted into the envelope/cover.
According to another preferred or inventive embodiment of the present invention, the protective layer comprises a knitted abrasion resistance layer. The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
According to this preferred or inventive embodiment of the present invention, a yarn with abrasion resistance properties is provided, which is knitted into an abrasion resistance layer. Alternatively, a knitted layer is at least partially coated with an abrasion resistance substance.
Another subject matte of the present invention is a protective layer, particularly for a seat cushion body preferably for a transportation, wherein the protective layer comprises a substance which sealingly connects the protective layer and the seat cushion body.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
This embodiment of the present invention is directed to a protective layer, which can be, for example, wrapped seat cushion body, which is for example part of transportation vehicle or a conventional chair, a sofa, a bed or the like.
According to the present invention, this protective layer comprises a substance, that sealingly connects the protective layer to the seat cushion body. The sealing connection of the substance at the seat cushion is established under the influence of heat and more preferably by pressing the protective layer against the seat cushion body. As soon as the protective layer cools down, a material bond between the protective layer and the seat cushion body is established and/or improved. No separate adhesive, which has to applied between the surface of the protective layer and the surface of the seat cushion body is needed.
Preferably, the substance that establishes the sealing connection between the protective layer and the seat cushion body is heated to an extent, that its melting point temperature is reached or exceeded. The substance is preferably provided as a separate layer which is more preferably laminated to the other layers of the protective layer and which is even more preferably directly adjacent to the seat cushion body. Alternatively or additionally, the sealing substance may be provided as a yarn and knitted into the protective layer. The sealing layer may be provided only locally or preferably along the entire surface of the protective layer which faces towards the seat cushion body.
Preferably, the melting point temperature of the sealing layer is <110°C, more preferably < 100°C.
According to a preferred or another inventive embodiment of the present application, the protective layer is heat shrinkable.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
According to this embodiment of the present invention, the protective layer shrinks for example under the influence of an elevated temperature. Due to the shrinkage, a gap or an air layer between the protective layer and the seat cushion body is at least partially, more preferably totally eliminated, so that more preferably, the protective layer is in tight-fitting contact with the surface of the seat cushion body. The shrinkage of the protective layer is preferably achieved by a shrinkable substance in the protective layer, preferably a polymeric substance more preferably a thermoplastic substance.
Preferably, the shrink-temperature at which the protective layer starts to shrink is lower than the melting point temperature of the substance which sealingly connects the protective layer to the seat cushion body. This preferred embodiment of the present invention has the advantage, that when the protective layer is heated, it first starts to shrink and then, in case its temperature is further elevated, the already shrunk protective layer is sealingly connected to the seat cushion body. A material bond is established due to the sealing connection by first melting the sealing layer and then cool it down below the melting temperature again. The sealing layer is preferably a thermoplastic layer.
According to yet another preferred or another inventive embodiment of the present application, the protective layer comprises a knitted abrasion resistance layer.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
Preferably, the protective layer comprises a sealing layer, an abrasion resistance layer and/or a fire blocker layer and/or an anti-vandalism layer.
Another subject matter of the present invention is a method to produce the inventive seat cushion part the protective layer is laminated at the seat cushion body.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
This embodiment of the present invention is a method to produce the inventive seat cushion part. According to the present invention, the protective layer is laminated to the seat cushion body, preferably on its entire surface. The lamination takes place by heating the protective layer and/or the seat cushion body so that the glass transition temperature of at least one polymeric component of the protective layer and/or the seat cushion body is reached or exceeded and preferably pressing the protective layer and the seat cushion body together. The sealing connection between the protective layer and the seat cushion body preferably takes place in a mould. No glue is applied for the lamination. Preferably, the protective layer comprises a sealing layer which comprises a polymeric component whose glass transition temperature is exceeded. During heating and/or after cooling down at least at ambient temperature, a material bond between the protective layer and the seat cushion body is established.
The seat cushion body preferably comprises at least two layers, wherein the layers preferably differ in average density and in thickness. Each of these layers is preferably made from a mix of staple fibers and binding fibers, so that it preferably has an open pore structure. The two layers can be produced separately by inserting the fiber mix into a mould, in which the fiber mix gets the desired shape and the desired density of the respective layer. The density of the fiber mix in the mould may be altered by compressing the fibers. The fiber mix is preferably provided as a loose material which is filled, for example blown into the mould. The fiber mix is preferably not provided as a prefabricated layer, which is for example stapled into the mould. In the mould the fixer mix is heated, so that the staple fibers and the binding fibers at least partially connect. The binding fibers comprise a core and a surrounding sheath material. The fiber mix in the mould is heated to an extent, that the melting point of the sheath material is reached, preferably exceeded, so that the sheath material gets tacky and binds with the staple fibers. The heat in preferably executed with a hot gas, that is forced through and/or around the fiber mix in the respective mould. The subsequent cooling of the layer increases the binding between the binding- and the staple fibers.
The prefabricated layers may then be inserted, for example stapled or stacked, into a second mould in which they are connected under the influence of heat, for example a hot gas, that is forced through around the respective layer and/or around the layer stack. No adhesive is needed to connect the layers that form the seat body cushion. In the second mould, the density of at least of the respective layers may be altered, at least locally, so that the desired density in the respective mould is reached.
Preferably, during prebaking of the individual layers a skin layer is developed at at least one layer. This skin layer is preferably utilized to provide a material bond between the layers of the seat cushion body.
Preferably at least two, more preferably all layers are made from the same fiber mix. However, the average density of the layers differs.
According to another preferred or inventive embodiment of the present invention, the seat cushion body is inserted into an envelope-formed protective cover, which surrounds the seat cushion body at its entire surface.
The disclosure made regarding this embodiment of the present invention also applies for the other embodiments of the present application and vice versa. Subject matters disclosed in connection with this embodiment of the present can be incorporated in other embodiments and vice versa.
The seat cushion body may comprise one, two, three or more layers. Preferably, the layer(s) of the seat cushion body is/are inserted individually into the protective cover, for example stacked into a protective cover. This protective cover surrounds the layer or the staked layers preferably on the entire surface. The protective cover may protect the layers which are preferably made from fibers against abrasion, fire, flash and/or vandalism. Alternatively, the seat cushion body can be inserted as an integral piece in the protective cover. This piece may comprise one, two, three or more layer(s).
Preferably, the protective cover comprises closure means to close the cover after the layers have been inserted. This closure means may be a flap which is after insertion of the seat cushion body connected to the protective cover, for example sealed.
Preferably, the protection cover protective cover is a laminate of at least two different layers. Preferably at the surface, that faces towards the fiber layers, the cover comprises a sealing layer, preferably a layer with a melting point temperature between 110 - 160 °C, more preferably between 135 and 145°C. Preferably, the sealing layer comprises or is made of Polyamid.
Preferably, the protective layer or the protective cover is gas-permeable.
Preferably, after the fiber layers have been inserted into the protective cover, the layers and the protective cover are heated. This heating preferably takes place in a mould. The mould may form and/or compress the protective cover and/or at least one of the fiber layers. During the heating, a material bond between the layers themselves and between the protective cover and one, two or three fiber layers takes place. Preferably all material bonds are established without a separate adhesive, like a glue or the like.
During the heating, for example prior to and/or during lamination of the protective layer and the seat cushion body, the protective layer or the protective cover may shrink to fit tightly around the seat cushion body, which is preferably made from fibers more preferably staple or stacked fiber layers.
The inventions are now explained according to the Figures. These explanations do not limit the scope of protection. The explanations apply to all embodiments of the present invention likewise.
Figure 1 shows a seat cushion body with three layers.
Figure 2 shows the insertion of a seat cushion body into a protective cover/envelope.
Figure 3 depicts the inventive seat cushion part.
Figure 4 depicts an example of the protective cover 9
Figure 1 shows a seat cushion body 1 with three layers, here a comfort-layer layer 2, resilience-layer 4 and a structure-layer 5. The seat cushion body is part of seat in a transportation vehicle, like an aero plane, a train, a bus, a ruck an automotive or the like. The seat cushion body may be a seating part or the back rest of a seat. The main load provided by a seat occupant is indicated by the arrow L. The skilled person understands that there may be other load directions, which are however smaller, preferably significantly smaller, than the main load direction. The comfort layer 3 which is adjacent to the seat occupant or adjacent to the main load direction, provides the comfort and the resilience-layer 4 provides the support for a seat occupant needed under normal operation conditions. The structure layer 5 provides the structure needed in an emergency situation, like a crash- or a near- crash-situation. All layers 3 - 5 are preferably made from a fiber mix of staple- and binding fibers, wherein, in the present case, the fibers of all layers are made or may comprise Polyamide. Preferably, the fibers and/or the fiber-mix in all layers 3 - 5 is identical or nearly identical. The three layers 3 - 5 differ in their average density, wherein the comfort-layer 3 preferably has a lower average density than the average density of the resilience-layer and the resilience-layer preferably has a lower average density than the average density of the structure-layer 5. Two adjacent layers are preferably connected by a material bond at their interface 15. This material bond is preferably established by heating the fibers at least at the interface 15 or a sheath around the binding fibers temporarily above their melting point temperature. The layers 3 - 5 are preferably heated by a hot gas which is forced through and/or around the layers 3 - 5. In the present case, the comfort layer has an average density of 20 kg/m3 and the resilience layer an average density of 35 kg/m3 and the structure layer a density 50 kg/m3 all densities measured at the final seat cushion body, i.e. after the three layers have been connected, preferably in a mould.
All layers 3 - 5 of the seat cushion body are preferably produced separately, for example by inserting the fiber mix into a mould. In the mould the fiber mix for one layer is distributed and/or compressed such that the layer preferably has a homogeneous density and/or such that the fibers are preferably oriented with their length-extension at least essentially parallel to the expected main load direction L. In the mould, the fiber mix gets its desired shape and preferably its desired density. After insertion into the mould the fiber mix is heated to an extent that the surface of the binding fibers softens or melts and establishes a tacky binding between the staple- and the binding fibers. The fiber mix is preferably heated by a hot gas which is forced through and/or around the fiber mix. As soon as the fiber mix is cooled down, preferably to ambient temperature, this tack binding solidifies and proved a solid binding between the staple- and the binding fibers. During this heating, or backing, preferably a skin layer 8 establishes at the entire surface of preferably each layer 3 - 5. This skin layer can be utilized to connect the two adjacent layers 3 - 5 at their interface 15, by softening and/or melting the skin layer at least locally. Even though not depicted, the skilled person understands that the layers 3 - 5 may differ in size and/or shape.
Figure 2 shows schematically an embodiment in which a plane protective layer has been formed into a protective cover, here a protective envelope 9, which is closed here at three sides, here by a seal 15. One side is open, so that the seat cushion body 1 can be inserted into the protective envelope. After the insertion of the seat cushion body 1 , the open side is closed as well. In case the seat cushion body comprises more than one layer, the layers are preferably inserted into the protective cover unconnectedly. The connection between these layers preferably takes place prior and/or simultaneously and/or after the connection between the seat cushion body and the protective cover.
Figure 3 discloses schematically the embodiment according to the present invention, after the seat cushion body 1 has been inserted into the protective envelope and the protective cover has been closed. In the present case, the protective envelope 9 comprises a flap 10, which is connected, preferably sealed, to the protective cover after the seat cushion body has been inserted, The flap 10 is preferably integral with the rest of the protective cover and more preferably the same material or material composition.
The protective cover 9 according to Figure 3 is preferably shrinkable, preferably under the influence of heat, so that the protective cover fits tightly around the seat cushion body, which is here a cuboid. After and/or during the shrinkage, the proactive cover is connected, preferably sealed with the surface of the seat cushion body 1.
Figure 4 depicts an example of a protective cover 9, from which the protective cover/envelope 9 can be made. In the present case, the protective cover 9 comprises three layers 12 - 14, which are preferably laminated together. The abrasion layer 12 is preferably the outer layer of the seat cushion part, i.e. the part that is in contact with the seat occupant. The abrasion layer reduces the ware of the seat cushion part. The fire blocker layer assures the required fire- and/or flash-resistance. The sealing layer 14 is adjacent to the seat cushion body 1 and sealingly connects the protective cover 9 and the seat cushion body under the influence of heat and preferably pressure. Preferably, no adhesive is needed for the connection of the protective cover 9 and the seat cushion body. The layers 12 - 14 are preferably laminated. Alternatively, the layers 12 and 13 are laminated and the sealing layer is applied for example by spraying. List of reference signs:
1 seat cushion body
2 seat cushion part
3 comfort-layer
4 resilience-layer
5 structure-layer
6 seating area
7 bottom
8 skin layer
9 protective layer, protective cover, protective envelope
10 flap
11 seat part
12 abrasion resistance layer
13 fire blocker
14 substance, sealing layer
15 interface
16 connection, seal
L main-load direction, z-direction

Claims

Claims:
1 . Seat part (11 ) for a transportation vehicle comprising a seat cushion body (1 ) and a protective layer (9), characterized in, that the protective layer comprises a substance (14) which sealingly connects the protective layer and the seat cushion body (1 ).
2. Seat part (11 ) according to claim 1 or the preamble of claim 1 , characterized in, that the protective layer is heat shrinkable.
3. Seat part (11 ) according to claim 2, characterized in, that a shrink-temperature of the protective layer is lower than a melting temperature of the substance (14) which sealingly connects the protective layer (9) to the seat cushion body (1).
4. Seat part (11) according to claims 1 - 3, characterized in, that the seat cushion body (1 ) comprises a polymeric substance.
5. Seat part (11 ) according to claims 1 - 4, characterized in, that the protective layer (9) comprises a polymeric substance.
6. Seat part according to claim 5, characterized in, that the polymeric substance of the protective layer (9) has a melting temperature < the melting temperature of the polymeric substance in the seat cushion body (1).
7. Seat part (11 ) according to claims 1 - 5, characterized in, that seat cushion body (1 ) comprises fibers.
8. Seat part (11 ) according to claim 7, characterized in, that the fibers are a fiber mix, preferably a mix of staple- and binding-fibers.
9. Seat part (11 ) according to claims 7 or 8, characterized in, that the staple fibers are Polyamide-fibers.
10. Seat part (11) according to claims 7 -9, characterized in, that binding fibers comprise a Polyamide-core and a sheath made from a polymer with a melting point between 110 and 160 °C.
11. Seat part (11) according to claims 7 - 10, characterized in the polymeric substance (14) has a melting point < a melting point of one component of the staple- and/or binding-fibers.
12. Seat part (11) according to one of the preceding claims or the preamble of claim 1 , characterized in, that the protective layer comprises a knitted abrasion resistance layer (12).
13. Seat part (11 ) according to one of the preceding claims, characterized in, that the protective layer comprises a sealing layer (14), an abrasion resistance layer and/or a fire blocker layer (13) and/or an anti-vandalism layer.
14. Seat part (11) according to claim 13, characterized in, that the fire resistance layer and/or anti-vandalism layer and/or anti-abrasion-layer, and/or the sealing layer are provided as one integral piece.
15. Seat part (11 ) according to one of the preceding claims, characterized in, that the seat cushion body (1) is enveloped by the protective layer (9).
16. Seat part (11) according to claim 15, characterized in, that the protective layer has an overlapping portion.
17. Protective layer, particularly for a seat cushion body preferably for a transportation, characterized in, that the protective layer comprises a substance (14) which sealingly connects the protective layer and the seat cushion body (1).
18. Protective layer according to claim 17 or the preamble of claim 17, characterized in, that the protective layer is heat shrinkable.
19. Protective layer according to claims 17 or 18 or the preamble of claim 17, characterized in, that it comprises a knitted abrasion resistance layer (12).
20. Protective layer, particularly according to claims 17 - 19, characterized in, that the protective layer comprises a sealing layer (14), an abrasion resistance layer and/or a fire blocker layer (13) and/or an anti-vandalism layer.
21. Method to produce a seat cushion part according to one of the preceding claims, characterized in, that the protective layer (9) is laminated at the seat cushion body (1)-
22. Method according to claim 21 or the preamble of claim 21 , characterized in that the seat cushion body (1) is inserted into an envelope-formed protective layer (9).
23. Method according to claims 21 or 22, characterized in, that the seat cushion body (1) and the protective layer are formed in a mould.
24. Method according to claim 22, characterized in, that the seat cushion body (1) comprises a plurality of layers, which are connected in the mould.
25. Method according to claims 21 - 24, characterized in, that the protective layer is heated by convection and/or conduction and/or radiation and/or induction.
26. Method according to claims 24 - 25, characterized in, that the layers are prebaked and then connected under the influence of heat, preferably a hot gas.
27. Method according to claim 26, characterized in, that during prebaking of the individual layers a skin layer (8) is developed around at least one layer (2 - 5, 9).
28. Method according to claims 24 - 27, characterized in, that the layers are stacked into a protective cover.
29. Method according to claim 28, characterized in, that the layers and the protective cover are subsequently heated.
30. Method according to claims 20 - 29, characterized in that the protective layer shrinks prior to and/or during lamination with the seat cushion body.
PCT/EP2022/054298 2021-02-23 2022-02-22 Seat cushion with a protective layer WO2022179994A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP22706632.1A EP4297616A1 (en) 2021-02-23 2022-02-22 Seat cushion with a protective layer

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP21158601 2021-02-23
EP21158601.1 2021-02-23
EP21178766.8 2021-06-10
EP21178766 2021-06-10

Publications (1)

Publication Number Publication Date
WO2022179994A1 true WO2022179994A1 (en) 2022-09-01

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Family Applications (1)

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EP (1) EP4297616A1 (en)
WO (1) WO2022179994A1 (en)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000039201A2 (en) * 1998-12-28 2000-07-06 Kimberly-Clark Worldwide, Inc. Breathable composite elastic material having a cellular elastomeric film layer and method of making same
WO2000078578A1 (en) * 1999-06-17 2000-12-28 Milliken & Company Low permeability airbag cushions having film coatings of extremely low thickness
WO2007114232A1 (en) * 2006-03-31 2007-10-11 Ts Tech Co., Ltd. Sitting seat
WO2018159729A1 (en) * 2017-03-03 2018-09-07 帝人フロンティア株式会社 Fiber structure and method for producing same
WO2020065560A1 (en) * 2018-09-25 2020-04-02 Proprietect L.P. Composite foam article

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000039201A2 (en) * 1998-12-28 2000-07-06 Kimberly-Clark Worldwide, Inc. Breathable composite elastic material having a cellular elastomeric film layer and method of making same
WO2000078578A1 (en) * 1999-06-17 2000-12-28 Milliken & Company Low permeability airbag cushions having film coatings of extremely low thickness
WO2007114232A1 (en) * 2006-03-31 2007-10-11 Ts Tech Co., Ltd. Sitting seat
WO2018159729A1 (en) * 2017-03-03 2018-09-07 帝人フロンティア株式会社 Fiber structure and method for producing same
WO2020065560A1 (en) * 2018-09-25 2020-04-02 Proprietect L.P. Composite foam article

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