WO2022179995A1 - Coussin de siège à multiples couches de fibres - Google Patents

Coussin de siège à multiples couches de fibres Download PDF

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Publication number
WO2022179995A1
WO2022179995A1 PCT/EP2022/054299 EP2022054299W WO2022179995A1 WO 2022179995 A1 WO2022179995 A1 WO 2022179995A1 EP 2022054299 W EP2022054299 W EP 2022054299W WO 2022179995 A1 WO2022179995 A1 WO 2022179995A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
layers
seat cushion
cushion body
fibers
Prior art date
Application number
PCT/EP2022/054299
Other languages
English (en)
Inventor
Arnaud MICHEL
Jérôme GILLMETH
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 EP22706860.8A priority Critical patent/EP4297617A1/fr
Publication of WO2022179995A1 publication Critical patent/WO2022179995A1/fr

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Classifications

    • 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
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/021—Detachable or loose seat 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—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
    • B32B5/12—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 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • B32B5/26—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 also being fibrous or filamentary
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/549—Polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal 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
    • B32B2307/30—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
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
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    • 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
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means

Definitions

  • the present invention relates to a seat cushion body for a transportation vehicle comprising two or three layers, each layer comprising a mix of staple fibers and binding fibers, wherein the layers are connected under the influence of heat, for example a hot gas.
  • the present invention further relates to a method to produce such a cushion body.
  • Seat cushion bodies for transportation vehicles made from fibers are known, for example from EP 2 008549 B1 or from EP 2417 876 B1.
  • EP 2 008549 B1 or from EP 2417 876 B1.
  • a seat cushion body for a transportation vehicle comprising a comfort/resilience-layer and a structure-layer, each layer comprising a mix of staple fibers and binding fibers, wherein the layers are connected under the influence of heat, for example a hot gas and wherein the comfort/resilience-layer has an average density of 15 - 45 kg/m 3 , preferably 20 - 40 kg/m 3 and the structure layer has an average density of 40 - 60 kg/m 3 , preferably 45 - 55 kg/m 3 each determined after the connection.
  • the present invention and this embodiment relate to a seat cushion body, as it 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 cushion is supported by the frame of the seat.
  • a seat cushion according to the present invention can be the seat part that supports the legs of a seat occupant or the back-rest.
  • this cushion body comprises 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.
  • Each of these layers is made from a mix of staple fibers and binding fibers, so that it preferably has an open pore structure.
  • the two layers are 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.
  • the fiber 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 subsequent cooling of the layer increases the binding between the binding- and the staple fibers
  • the prefabricated layers are then 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. No adhesive is needed to connect the layers.
  • the density of at least of the respective layers may be altered, at least locally.
  • the comfort/resilience-layer has an average density of 15 - 45 kg/m 3 , preferably 20 - 40 kg/m 3 and the structure layer has an average density of 40 - 60 kg/m 3 , preferably 45 - 55 kg/m 3 each determined after the connection of the two layers, i.e. the average density is measured after the two layers have been connected, preferably in a mould and more preferably at ambient temperature, between 20 and 30°C.
  • the average density is measured after the two layers have been connected, preferably in a mould and more preferably at ambient temperature, between 20 and 30°C.
  • the average extension of the comfort/resilience-layer in a main load direction is 10 - 40 mm and the average extension of the structure layer in the load direction is 15 - 25 mm, each determined after the connection.
  • the main load direction for the seat part is the direction of gravitation.
  • the main load direction for the back rest is perpendicular to the direction of gravitation.
  • the average extension is an area weighted average, wherein the area of the respective layer perpendicular to the main load direction is taken.
  • a seat cushion body for a transportation vehicle comprising a comfort-layer and a resilience-/structure-layer, each layer comprising a mix of staple fibers and binding fibers, wherein the layers are connected under the influence of heat, for example a hot gas and wherein the comfort-layer has an average density of 20 - 30 kg/m 3 , preferably 22 - 25 kg/m 3 and the resilience-/structure layer has an average density of 30 - 60 kg/m 3 , preferably 40 - 50 kg/m 3 each determined after the connection.
  • this cushion body comprises two layers, a comfort-layer and a resilience-/structure-layer.
  • the comfort-layer provides a comfortable sitting feeling even over a long period of time.
  • the resilience-/structure-layer takes up the load under normal operation conditions and under emergency conditions, for example a crash.
  • Each of these layers is made from a mix of staple fibers and binding fibers, so that it preferably has an open pore structure.
  • the two layers are 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.
  • 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 subsequent cooling of the layer increases the binding between the binding- and the staple fibers
  • the prefabricated layers are then 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. No adhesive is needed to connect the layers.
  • the density of at least of the respective layers may be altered, at least locally.
  • the comfort-layer has an average density of 15 - 30 kg/m 3 , preferably 20 - 25 kg/m 3 and the resilience-/structure-layer has an average density of 30 - 60 kg/m 3 , preferably 40 - 50 kg/m 3 each determined after the connection of the two layers, i.e. the average density is measured after the two layers have been connected, preferably in a mould and more preferably at ambient temperature, between 20 and 30°C.
  • the average density is measured after the two layers have been connected, preferably in a mould and more preferably at ambient temperature, between 20 and 30°C.
  • the average extension of the comfort-layer in a main load direction is 5 - 15 mm and the average extension of the structure layer in the load direction is 10 - 45 mm, each determined after the connection.
  • the main load direction for the seat part is the direction of gravitation.
  • the main load direction for the back rest is perpendicular to the direction of gravitation.
  • the average extension is an area weighted average, wherein the area of the respective layer perpendicular to the main load direction is taken.
  • a seat cushion body for a transportation vehicle comprising a comfort-layer, a resilience-layer and a structure-layer, each layer comprising a mix of staple fibers and binding fibers, wherein the layers are each connected under the influence of heat, for example a hot gas and wherein the comfort-layer has an average density of 20 - 30 kg/m 3 and the resilience-layer has an average density of 30 - 40 kg/m 3 and the structure layer has an average density of 45 - 55 kg/m 3 each determined after the connection.
  • 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.
  • Each of these layers is made from a mix of staple fibers and binding fibers, so that it preferably has an open pore structure.
  • the three layers are 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.
  • 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 subsequent cooling of the layer increases the binding between the binding- and the staple fibers
  • the prefabricated layers are then 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. No adhesive is needed to connect the layers.
  • the density of at least of the respective layers may be altered, at least locally.
  • the comfort-layer has an average density of 15 - 30 kg/m 3 , preferably 20 - 25 kg/m 3
  • the resilience-layer has an average density of 30 - 45 kg/m 3 , preferably 35 - 40 kg/m 3
  • the structure layer has an average density of 40 - 60 kg/m 3 , preferably 45 - 55 kg/m 3 each determined after the connection of the three layers, i.e. the average density is measured after the two layers have been connected, preferably in a mould and more preferably at ambient temperature, between 20 and 30°C.
  • the average density is measured after the two layers have been connected, preferably in a mould and more preferably at ambient temperature, between 20 and 30°C.
  • the average extension of the comfort-layer in a load direction is 5 - 15 mm
  • the average extension of the resilience-layer in a load direction is 15 - 25 mm
  • the average extension of the structure layer in the load direction is 15 - 25 mm, each determined after the connection.
  • the main load direction for the seat part is the direction of gravitation.
  • the main load direction for the back rest is perpendicular to the direction of gravitation.
  • the average extension is an area weighted average, wherein the area of the respective layer perpendicular to the main load direction is taken.
  • the fibers in one, two, or all layers of the seat cushion body are oriented parallel to the main-load direction, particularly after the layers have been connected.
  • 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 layers 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 120 and 160 °C, more preferably 135 - 145 °C.
  • the sheath is preferably 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 all measured at the final seat cushion body.
  • At least one of the layers which form 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 the layer. However, the porosity is still large enough 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 layer of one seat cushion body have been connected.
  • the layers of the seat cushion body are surrounded by a fire resistance layer and/or anti-vandalism layer and/or anti- abrasion-layer.
  • a fire resistance layer and/or anti-vandalism layer and/or anti- abrasion-layer Preferably at least two, more preferably all of these protection layers are provided as one integral piece.
  • the layers are preferably laminated.
  • Another subject matter of the present invention is a method to produce a seat cushion body according to the present invention, wherein the layers of the seat cushion are prebaked and then connected under the influence of heat, preferably a hot gas, which is forced around and/or through the layers.
  • heat preferably a hot gas
  • This embodiment of the present invention is a method to produce the inventive seat body.
  • the inventive seat cushion body comprises at least two layers, wherein the layers differ in average density and in thickness.
  • Each of these layers is made from a mix of staple fibers and binding fibers, so that it preferably has an open pore structure.
  • the two layers are 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 are then 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 layers of the seat cushion body are stacked into a protection cover.
  • This protection cover surrounds the staked layers preferably on all sides.
  • the protection layer may protect the layers made from fibers against abrasion, fire, flash and/or vandalism.
  • the cover comprises closure means to close the cover after the layers have been inserted.
  • the cover is a laminate of at least two different layers.
  • the cover comprises a binding layer, preferably a layer with a melting point between 120 - 160 °C, more preferably between 135 and 145°C.
  • the binding layer comprises or is made of Polyamid.
  • the protection cover is gas-permeable.
  • the layers and the protection cover are heated.
  • This heating preferably takes place in a mould.
  • the mould may form and/or compress the protection layer and/or at least one of the fiber layers.
  • a material bond between the layers themselves and between the protection 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 protection cover may shrink to fit tightly around the fiber layers.
  • Figure 1 shows a seat cushion body with two layers.
  • Figure 2 shows a seat cushion body with three layers.
  • Figure 3a, 3b show a top view and a side view of a seat cushion body with three layers.
  • Figure 4 shows another side view of a seat cushion body with three layers.
  • Figure 5 shows a single layer of a seat cushion body
  • Figure 6 shows a seat cushion body with two layers.
  • FIG. 1 shows a seat cushion body 1 according to the present invention with two layers, here a comfort/resilience layer 2 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/resilience layer which is adjacent to the seat occupant or adjacent to the main load direction, provides the comfort and the support for a seat occupant needed under normal operation conditions.
  • the structure layer provides the structure needed in an emergency situation, like a crash- or a near-crash-situation.
  • Both layers 2, 5 are made from a fiber mix of staple- and binding fibers, which, in the present case both are made or comprise Polyamid. Preferably, the fibers and/or the fiber-mix in both layers is identical or nearly identical.
  • the two layers 2, 5 differ in their average density, wherein the comfort/resilience layer has a lower density than the average density of the structure layer.
  • the two layers are connected by a material bond at their interface 10. This material bond is established by heating the fibers at least at the interface 10 or a sheath around the binding fibers temporarily above their melting point.
  • the layers 2, 5 are preferably heated by a hot gas which is forced through and/or around the layers 2, 5.
  • the comfort/resilience layer has an average density of 30 kg/m 3 and the structure layer an average density of 50 kg/m 3 both densities measured at the final seat cushion body, i.e. after the two layers have been connected, preferably in a mold.
  • Both layers 2, 5 of the seat cushion body are produced separately, for example by inserting the fiber mix into a mould.
  • the fiber mix In the mould the fiber mix is distributed and/or compressed such that the layer preferably has a homogeneous density and/or such that the fibers are oriented with their length-extension at least essentially parallel to the expected main load direction.
  • the fiber mix gets its desired shape and preferably its desired density.
  • the fiber mix After insertion into the mould the fiber mix, 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.
  • this tack binding solidifies and proved a solid binding between the staple- and the binding fibers.
  • a skin layer establishes at the surface of preferably both layers. This skin layer can be utilized to connect the two layers together at their interface 10, by softening and/or melting the skin layer at least locally.
  • the layer 3which is adjacent to the seat occupant or next to the main load direction L is a comfort layer and the layer connected to the comfort layer 3 is a resilient/structure layer 9.
  • the comfort layer has an average density of 20 kg/m 3 and the resilience/structure layer an average density of 45 kg/m 3 both densities measured at the final seat cushion body, i.e. after the two layers have been connected, preferably in a mold.
  • FIG. 2 shows another embodiment of the inventive seat cushion body, so that reference can be made to the disclosure regarding Figures 1 and 2.
  • the seat cushion body 1 has three layers, i.e. a comfort layer 3 adjacent to the seat occupant or adjacent to the main load direction L. Adjacent to the comfort layer 3 is a resilience layer 4 and adjacent to the resilience layer 4 is a structure layer 5.
  • the comfort layer 3 provides a comfortable sitting feeling for the seat occupant.
  • the resilience layer 4 takes up the load under normal operation conditions.
  • the structure layer 5 takes the load under emergency conditions.
  • 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 mold.
  • Figure 3a is a top view of an inventive seat cushion body and Figure 3b is a side view of the seat cushion body according to Figure 3a.
  • the individual fiber layers 3 - 5 may have different extensions in the x- and y-direction, which are perpendicular to the main load direction, which is in the present case parallel to the z-direction.
  • the individual fiber layers may overlap. In the present case all three fiber layers locally overlap.
  • Form Figure 3b it can be seen, that the layers have different extensions in the z-direction, here the main load direction.
  • layer 4 is inserted into an opening in layer 3, which is an alternative embodiment of the inventive seat cushion body.
  • Figure 4 shows an alternative to the embodiment according to Figures 3a and 3b. However, reference is made to the disclosure regarding these Figures.
  • one layer here the structure layer 5 is provided in several, here two parts. More than one layer can be provided in two or more parts.
  • Figure 5 shows a single fiber layer 2 - 5, 9.
  • the thickness, here in the z- direction of the fiber layer may vary in the x- and/or in the y-direction.
  • the average thickness is calculated by integrating the extension in the z-direction over the extension in x- and y- direction and divide it by the area. In case a fiber layer comprises several parts, the thickness is averaged over all parts of this layer.
  • the skin layer preferably extends over all surfaces of a fiber-layer.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

La présente invention concerne un corps de coussin de siège pour un véhicule de transport comprenant deux ou trois couches, chaque couche comprenant un mélange de fibres discontinues et de fibres de liaison, les couches étant reliées sous l'influence de la chaleur, par exemple d'un gaz chaud. La présente invention concerne en outre un procédé de production d'un tel corps de coussin.
PCT/EP2022/054299 2021-02-23 2022-02-22 Coussin de siège à multiples couches de fibres WO2022179995A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP22706860.8A EP4297617A1 (fr) 2021-02-23 2022-02-22 Coussin de siège à multiples couches de fibres

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21158601 2021-02-23
EP21158601.1 2021-02-23

Publications (1)

Publication Number Publication Date
WO2022179995A1 true WO2022179995A1 (fr) 2022-09-01

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EP (1) EP4297617A1 (fr)
WO (1) WO2022179995A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5079074A (en) * 1990-08-31 1992-01-07 Cumulus Fibres, Inc. Dual density non-woven batt
GB2405646A (en) * 2003-09-08 2005-03-09 John Cotton Group Ltd Two layer filling for bed mattresses and upholstery
WO2007114232A1 (fr) * 2006-03-31 2007-10-11 Ts Tech Co., Ltd. Siège
EP2008549B1 (fr) 2006-03-31 2012-05-16 TS Tech Co., Ltd. Élément coussin, siège et procédé de fabrication associé
EP2417876B1 (fr) 2010-08-10 2013-04-24 Schukra Gerätebau GmbH Corps de coussin de siège et procédé de production d'un corps de coussin de siège

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5079074A (en) * 1990-08-31 1992-01-07 Cumulus Fibres, Inc. Dual density non-woven batt
GB2405646A (en) * 2003-09-08 2005-03-09 John Cotton Group Ltd Two layer filling for bed mattresses and upholstery
WO2007114232A1 (fr) * 2006-03-31 2007-10-11 Ts Tech Co., Ltd. Siège
EP2008549B1 (fr) 2006-03-31 2012-05-16 TS Tech Co., Ltd. Élément coussin, siège et procédé de fabrication associé
EP2417876B1 (fr) 2010-08-10 2013-04-24 Schukra Gerätebau GmbH Corps de coussin de siège et procédé de production d'un corps de coussin de siège

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