DE202005020884U1 - Pillow and cushion production method e.g. for pillows, involves producing pillow and cushion from spacer fabrics, spacer woven fabrics or spacer knitted fabrics which are laid one on top of other in piles - Google Patents

Abstract

The method involves producing pillow and cushion from spacer fabrics, spacer woven fabrics or spacer knitted fabrics. The spacer fabric, spacer woven fabric or spacer knitted fabric are laid one on top of the other in piles. The material layers are warmed and deformed, until a lasting deformation develops in which totally or partly outline of a cushion or pad develops.

Description

Distance tissues are also known as spacer fabrics.

Of the The term "tissue" also includes the following other knits. This includes also knits and crocheted knitwear. In the following, including the other knitted fabrics only by Tissues spoken.

To an older one Proposal should consist mattresses made of spacer fabric. At mattresses is lying comfort is a decisive criterion The feeling of comfort is subject the time change.

It became earlier at least partially to a hard edition or to a corresponding hard suspension value. Then a greater compliance was desired.

The common Mattresses were then spring mattresses. The spring cores in such Mattresses are wire springs, which come in different designs available are. The spring cores can be used with different means hold the intended position.

In more recently, the spring mattresses are at least largely through Mattresses made of plastic foam have been replaced. It is preferable Polyurethane used as a plastic foam.

in the Area of the plastic foam includes the viscoelastic polyurethane foam a significant advancement. This foam has one Glass point, which is in the range of room temperature, preferably slight below room temperature. The consequence is an altered compliance behavior at a slight warming through the lying man. This warming causes another Sinking of the lying human. The concept is the knowledge underlying that the biggest warming there takes place where the body the largest mass Has. That's in the area of the hips and the shoulders of the case. There, the body sinks stronger than without larger, heat-related Indulgence. Through this particular sinking man lies straighter than on conventional Mattresses.

Of the Advantage of greater sinking but is connected with a larger-scale touch of the people with the plastic foam. Already healthy people complain that they stronger by deeper sinking sweat. Sick people are thus sore faster.

It is therefore common to provide the mattresses with a draining coating. In newer Time has been suggested, the drainage layers through a spacer fabric to build. Such spacer fabrics have two spaced ones Tissue layers spaced by filaments or filaments or fibers being held.

The Known spacer fabric are one-piece. That is, out the spaced fabric layers are the filaments, filaments or Fibers led from one layer of fabric to the other and forfeited there.

The However, the invention also comprises multi-part composite knitted fabrics. In the case of a multi-part formation, these form the cover layers separate tissue interconnected by a third tissue.

The Spacer fabrics are made of polyester or polyamide or polypropylene or spandex or glass fibers or polyethylene or cellulose.

At Motor vehicles have already enforced such spacer fabric. By way of example, reference is made to US Pat. No. 6,629,724. The spacer fabrics should the seat ventilate, so that sweat accumulating moisture by sweating and the Steam can be deducted. The distances can be up to 15 mm. Spacer fabrics are also known in textiles. There they should ventilate waterproof layers. By way of example, reference is made to US Pat. No. 6,716,778. The spacer fabrics be synonymous for Mattresses have been known for some time.

The U.S. Patent Numbers 6687937, U.S. Patent Numbers 6687935, U.S. Patent Numbers 6668408, U.S. Patent Numbers 6499157; U.S. Patent No. 6460209, US Pat. No. 4,447,874 and US Pat. No. 6,115,861 describe such mattresses. The spacer fabrics form part of channels through which the water vapor be removed, which is caused by sweating of the person lying. In part, spacer fabrics are provided as continuous layers.

The older proposal has realized that the coating of plastic foam with a Spacer tissue, although a ventilation causes. But the positive effect of viscoelasticity is lost because Insulation is created with the intermediate spacer fabric. The body heat can no longer significantly affect the foam.

The older proposal has set itself the task of creating a mattress, which takes advantage of the spacer fabric and, moreover, a comparable quality as viscoelastic foam be sitting.

• a) mindestens 20 mm dick ist, vorzugsweise mindestens 30 mm dick ist und noch weiter bevorzugt mindestens 40 mm dick ist
• b) eine gestufte Nachgiebigkeit besitzt.

According to the older proposal, this is achieved using a mattress layer of spacer fabric which

• a) is at least 20 mm thick, preferably at least 30 mm thick and even more preferably at least 40 mm thick
• b) has a graded compliance.

The Stufigkeit arises from the fact that when squeezing the Spacer fabric with reaching each additional stage additional Parts of the spacer fabric are involved in the load bearing, until then were uninvolved in the load.

• c) dass zwischen den äußeren Abstandsgeweben weitere Gewebe vorgesehen sind, deren Dicke geringer als der Abstand zwischen den Abstandsgeweben ist. Die weiteren Abstandsgewebe zwischen den äußeren Gewebeschichten werden im folgenden als dünnere Gewebeschichten bezeichnet. Eine dünnere Gewebeschicht beteiligt sich erst dann an der Lastaufnahme, wenn das Abstandsgewebe auf ein Maß zusammengedrückt ist, das gleich der Dicke dieser dünneren Gewebeschicht ist.
• d) dass die äußeren Gewebeschichten die Matratze nur teilflächig überdecken und zwischen diesen Teilen weitere Gewebeschichten angeordnet sind, welche eine geringere Dicke besitzen. Die weiteren Gewebeschichten werden im folgenden als dünnere Gewebeschichten bezeichnet. Eine dünnere Gewebeschicht beteiligt sich erst dann an der Lastaufnahme, wenn das Abstandsgewebe auf ein Maß zusammengedrückt ist, das gleich der Dicke dieser dünneren Gewebeschicht ist.

According to the older proposal, this is optionally achieved by

• c) that between the outer spacer fabrics further fabrics are provided whose thickness is less than the distance between the spacer fabrics. The further spacer fabrics between the outer fabric layers are referred to below as thinner fabric layers. A thinner layer of fabric does not participate in the load bearing until the spacer fabric is compressed to a dimension equal to the thickness of that thinner layer of fabric.
• d) that the outer fabric layers cover the mattress only part of the surface and between these parts more fabric layers are arranged, which have a smaller thickness. The further tissue layers are referred to below as thinner tissue layers. A thinner layer of fabric does not participate in the load bearing until the spacer fabric is compressed to a dimension equal to the thickness of that thinner layer of fabric.

The thinner Tissue layer according to c) can by straight fibers or threads or Filaments are formed, which are held in one of the outer layers and buckle if the spacer fabric is compressed accordingly.

The thinner Tissue layer according to c) can also be formed by grinding or slinging placed in the space between the outer fabric layers are and by appropriate compression of the spacer fabric a Experience deformation. Optionally, the loops or loops also formed by the filaments, fibers or filaments forming the outer fabric layers connect with each other.

The thinner Tissue layer according to c) can also by a similar spacer fabric like the original one Spacer fabrics are formed in the space between the outer layers of the original one Spacer fabric is arranged.

The thinner Tissue layer according to c) can also be formed by webs, the in the space between the outer fabric layers arranged and with one of the outer fabric layers connected or integral with this fabric layer.

The Partial outer fabric layers after d) are preferably formed by webs which are rectilinear and / or curved longitudinal the mattress or across or at an angle to go to. Between the outer tissue layers forming Webs are provided more webs, which are the thinner layer of tissue form. Optionally behaves it is also the other way around, i. Optionally, the thinner layers of fabric become also by the straight and / or curved longitudinally of the mattress or transverse or oblique formed to extending webs. Then there are between these bars provided further webs, which form the outer fabric layers. Optional The above-described webs according to d) are also annular. It can various rings can be arranged inside each other. It can also be one each single ring may be provided as a web which surrounds a knob. The Rings can exactly circular or square or arbitrary. In that sense, the Rings also have the shape of honeycombs.

It can in the execution according to d) also a plurality of rings evenly or unevenly distributed be arranged. The rings can be the same or have different shape.

Preferably is in the execution according to d) one of the outer fabric layers trained throughout, while on the opposite side of the spacer fabric, the webs are provided. It is an advantage to arrange this spacer fabric so that the continuous layer facing the person lying down. As a result, the bearing surface is increased.

Optional can arranged according to d) rings spaced from each other be or touch each other or even make up the part of another ring. In the sense of the older proposal such a case exists in a honeycomb structure. Preferably Nubs correspond to the honeycomb structure, which in the of the Honeycomb enclosed interior are provided.

As outlined above the knobbed top is deeper than the top of the honeycomb or vice versa.

The Spacer fabric can form all or part of the mattress.

at one complete made of spacer fabric mattress comes to the extreme ventilation yet an extremely good washability and dryness added.

at a combination of the spacer fabric with other material layers to a mattress can any other material layers occur. That includes the same or other spacer fabrics.

The Different material layers can be made by welding or Gluing or mechanically joined together. A cheap connection created with a Velcro connection. In this case, the spacer fabric form part of the Velcro connection.

The Invention has recognized that the Making up the spacer fabric causes some effort. After the older one Proposal is therefore intended that the spacer fabric in the Final form to be created. That leaves by change reach the weaving or knitting process. In principle, that may be due to a change the programming of the associated Making machines run out. Includes for large amounts of tissue the optimal solution, also an economical solution. For smaller ones Tissues can be the change programming uneconomical. This is especially true when the dimensions change.

The Invention has therefore set itself the task of programming independent Processing opportunity especially for Find upholstery and pillows.

To The invention is characterized by the use of spacer knitted fabrics, in particular fabrics of a thermoplastic and by hot working reached. The necessary warming The knitwear can be done in different ways. Preferably finds radiant heat and / or contact heat of a gaseous or liquid Heat transfer application. Among the advantageous gaseous Heat carriers can also include steam. The steam has a very favorable heat transfer. With the steam you can Even temperatures of more than 100 degrees Celsius can be achieved. In the case are found steam application, which under increased pressure stands. At higher Pressure, the steam can easily be heated well over 100 degrees Celsius. Furthermore can Hot gases as Used heat transfer medium become. With the hot gases can all temperatures are reached, which for the thermoforming of eligible plastics are required. This is also true for thermoforming polyester which has a high melting point. In the form of Polyethylene terephthalate (PET) is the melting point at 250 degrees Celsius and more.

advantageously, can the gaseous or liquid Heat transfer medium Well knit fabrics or knitted fabrics and ensure uniform contact everywhere. This is synonymous with a uniform warming.

Optional can also take place uneven heating, for example, to leave the tissues unchanged, the none or should experience only a slight permanent deformation.

To the hot deformation, it may be appropriate to the parts first Annealing to preserve the achieved shape. For tempering is suitable an oven, both an intermittently operated oven and a continuously operated oven. Continuous furnaces are e.g. Tunnel ovens, in which is a continuous flow of products. In the ovens can the temperature can be kept arbitrarily or lowered or controlled become. The length a continuous furnace results from the desired duration of the heat treatment and the conveying speed of the oven.

To the heat treatment and so far no heat treatment is provided, after deformation, is a rapid cooling of Advantage. The cooling can with a suitable coolant be accelerated. The coolant came gaseous or liquid be. As a coolant is also cooling air suitable. The cooling air can easily penetrate the knitted fabrics, woven or knitted fabrics. there Ambient air can be used, but also air with lower Temperature, which arises by appropriate cooling.

The Knitted fabrics, woven or knitted fabrics can also be used with ease liquid Coolant, in particular cooled with water because the water easily flows out of the spacer fabric and because The knit then dries very quickly afterwards. The drying can be conveyed with drying air or drying gas. As a drying gas For example, the exhaust gas is suitable for heating the knitted fabric or knitted fabric with gas as heat carrier. The is called, It may be advantageous to first knit the knitted fabrics, woven or knitted fabrics a gaseous one Heat transfer medium for hot deformation to warm, to cool after deformation with water and then with the Exhaust gas from the first heating to bring about a drying.

Optionally, it is expedient, the exhaust gas by mixing with ambient air to a lower temperature for drying the fabric, knitted or knitted fabric.

advantageously, can the warming be controlled very precisely. This applies both to the duration of the warming as also for the course of warming and also for the height the outside at the filaments, fibers, etc. temperature applied. By the warming are those of a subsequent deformation Affected fabric parts or fabric parts on the outside of the filaments, fibers etc. transferred from the purely elastic region in an area in which at subsequent Deformation after appropriate cooling in the deformed state a permanent deformation arises. Preferably, a temperature set at the parts to be deformed, the at least 5, preferably at least 10 and more preferably 20% below the temperature of the melting point.

Preferably becomes the gaseous or liquid Heat transfer between the spaced outer layers entered. The heat transfer enter the Heat here to the filaments, fibers and threads from which the outer layers connect with each other. The warming may take place before deformation or during deformation or after preforming. Cheap is a warming before deformation, because the feeder of the gaseous or liquid Heat carrier thereby is simplified and because the resistance to deformation then very is low. Cheap is also a feeder of the gaseous or liquid After the heat carrier the deformation, because the energy consumption is then particularly low. By the warming relax filaments, fibers and threads and stay these parts after subsequent cooling in the deformed state. That is, the knitted, woven and knitted fabrics reserves the desired Form after the discharge.

Preferably become the gaseous or liquid Heat transfer abandoned in bursts. Then the heating process extended and lets himself go the heating process good on the basis of the number of impacts of the heat carrier check.

Cheap, the gaseous or liquid heat transfer medium with overpressure across from the environment against the knitted fabric, fabrics and knits to wear. The overpressure is preferably at least 1 bar, more preferably at least 2 bar, and most preferably at least 3 bar. The desired Pressure can be built up with a pump. There are heat resistant ones Pump. But it can also be first the pressure is built up and then heating the gaseous or liquid Heat carrier take place, so that it to no significant heat load the pump is coming.

The Fabrics, knitted fabrics and knitted fabrics can be applied any place with the gaseous or liquid Heat carrier acted upon become. This is true both at the spaced layers and at the faces between the spaced layers possible. The gaseous or liquid heat transfer then flows through the fabric or knitted fabric to exit at a predetermined location. With the outlet or the outlet openings can the flow be steered. additionally let yourself the flow influence, by at the outlet opening or the outlet openings a negative pressure is applied.

surprisingly Way it turns out that an admission the spaced layers from the outside not to damage the Layers leads, if it is ensured in the above manner, that the heat carrier, the tissue, knitted fabric and Knitted fabric penetrates without stopping and an uncontrolled warming to cause.

Independently of may be the gaseous or liquid Heat transfer medium immediately be carried into the gap.

To the Entering the heat carrier between the spaced outer layers is a lateral entry between the spaced layers of knitted or woven or knitted fabric possible. These are suitable for the side arranged nozzles. Cheap are several juxtaposed leads, in particular Nozzles. Cheap are also perforated windows. The hole windows include a wall with a plurality of openings disposed therein. The openings can be free of a nozzle effect or develop a nozzle effect to a lesser extent or to a great extent. The openings can be evenly distributed be. Then a grid structure is created. The openings can also be distributed unevenly be to the heat transfer medium in the deformation areas with high concentration of fibers and Filaments in necessary large Scope available to deliver.

Optional can also lances used to enter the heat carrier become. The lances can targeted the heat transfer lead to the needs.

The Lances can small diameter and have a tip, so that the lances the Do not damage the knitted fabric when they enter the knitted fabric. The lances can with one or more openings be provided. With small diameter and appropriate length have the lances the form of nails.

Optionally, the nail-shaped lances are also out through the spaced layers pushed through into the space between the spaced layers. On the way, all areas of the knit can be reached with short lances. At the same time it is possible to isolate the lances on the outside to prevent heating of the spacer fabric at an undesirable point. Sufficient insulation can already arise because the lances are surrounded by a protective tube at a short distance.

The Deformation of the knitted fabric can take place in a mold. The shape can be completely or partially closed. As far as the form partially is open and with a gaseous Heat transfer medium is being worked Nevertheless, a burden on the environment by means of a deduction device be prevented.

surprisingly Way you can not only small deformations but also large deformations on the knitted fabric be made. It can be large deformations in particular Support the way by mechanically bringing and securing the spaced layers become. This is easier in those areas where a pressure is applied becomes, as in other areas. Therefore, according to the invention wholly or partially applied to the spaced layers a train, which are opposite to the printing area. The train can be mechanically applied by the fact that on the outer layers is attacked. An attack with hooks and / or comes into consideration Pliers. The hooks or pliers can be arranged slidably in the form and if necessary from the Form to be extended to in the knitted fabric and knitted fabrics too to grab. Cheap are movable hooks that can open to the deformed knitted fabric, Free tissue and knits.

Especially favorable conditions arise when the attack on the fabric, knitted or crocheted done by suction.

To is it economical, suction surfaces on the knitted fabric to be formed, woven or knitted fabric. This is optionally achieved in that a bibulous film on the knitted fabric is attached to the relevant. Preferably the film after the deformation of the knitted fabric, woven or knitted fabric solved again, to the patency fabric, knits or knits. The release can be omitted where the patency of the knitted fabric in the concrete application is not required. For example, the film can be peeled off again when it is on the Removal of the film arrives. If necessary, this happens under warming the slide, the release facilitated. In this case, films come into consideration, which at the contact surface with The microfluidized microfilaments are knitted so that using microwaves a damage of the knitted fabric is prevented.

Instead of A single, suckable film can also be laminated on various pieces of film become. As far as the foil pieces have sufficiently small dimensions and sufficient distance from each other have, goes from the foil pieces no significant impairment the continuity of the knitted fabric. As a result, such pieces of film can always remain on the knitted fabric.

The foil pieces are yielding. The compliance is in different applications not mandatory. Then can instead of the foil pieces too less flexible tiles or pieces be used by plates. These parts come with additional Functions occupy, e.g. with the attachment to the chair structure or the sofa construction. So far, such constructions exist almost exclusively wooden. That has reasons for price, but also mounting reasons, because the padding then attaches to the construction by nailing or stapling can be attached. The knitted fabrics according to the invention can be with the parts described above on the construction nail or staples. At least with the brackets can the knitted fabric even without the padding described above.

In The drawing are various embodiments of the invention shown.

The 1 shows a thermoplastic material consisting of two layers 26 and 27 of which the upper layer 26 a spacer fabric. The materials used are the same as the materials in the known mattresses with spacer fabric described above. The shape is different.

The lower layer 27 is a polyurethane foam layer is. The layer 26 has a thickness of 60 mm. The layer 27 also a thickness of 60 mm. The material is with a washable textile 25 envelops.

To 1 owns the spacer fabric of the layer 26 an upper fabric layer 2 and a lower fabric layer 1a , The 1 shows the spacer fabric lying on his head. Both layers 1 and 2 are through filaments 3 connected with each other. In addition, starting from the layer 2 , even more filaments 4 provided, whose length is less than the distance between the layers 1 and 2 is. In case of compression take the filaments 3 immediately load up. The filaments 4 but participate only in the load, if they are the shift 1 touch.

The embodiment according to 2 differs from the embodiment according to 1a in that instead of the filaments 4 wound filaments 5 are provided. The wound filaments 5 better support the shift 1 from.

The embodiment according to 3 differs from the embodiment according to 1a in that instead of the filaments 4 other filaments 6 are provided, which with an intermediate layer 7 are connected. Through the intermediate layer 7 a better support is achieved.

The embodiment according to 4 and 5 is in 4 also shown lying on his head. The embodiment has an upper fabric layer 10 , from the filaments 13 and 14 out. The filaments 13 hold fabric strips 11 , the filaments 14 hold fabric strips 12 , The filaments 14 are shorter than the filaments 13 so that the distance of the strips 12 from the shift 10 less than the distance of the strips 11 from the shift 10 is.

The Stripes 11 form together with the filaments 13 Footbridges, as well as the stripes 12 with the filaments 14 ,

In case of compression of the spacer fabric take first the webs with the strips 11 put the load on until your distance from the layer 10 equal to the distance between the strips 12 and the layer 10 is. Then the bridges take part with the stripes 12 at the load suspension.

In the embodiment according to 6 is a modification of the in 4 and 5 shown system represented by webs. The bridges 21 run so that a honeycomb structure is created. Every honeycomb 20 encloses a pimple 22 , The bridges 21 have in the embodiment, the function of the webs 11 , the nubs the function of the webs 12 , Accordingly, the webs exist 11 at the illustrated end of fabric strips which are connected by filaments to an opposite layer of fabric of the spacer fabric. Also the pimples 22 have a fabric layer that is connected by filaments to the opposing fabric layer of the spacer fabric.

10 shows a schematic drawing of the hot deformation according to the invention. The resulting spacer fabric is placed in a heating station. There it is brought to an outside temperature with hot air, which is 5 to 10% below the temperature of the melting point. The heating is carried out in the manner described below at a hot gas temperature which is 10 to 30% higher than the temperature of the melting point. At this outside temperature, a temperature gradient results at the middle of the filaments or fibers of the fabric. In the middle, the filaments and fibers still have a temperature that is characteristic of the elastic region of the plastic. In the state, the fabrics become a deformation station 46 fed. There the fabrics experience a desired deformation. Matrices can be used as tools. The deformed tissues are still cooled in the mold until there is also a temperature at the outside of the filaments and fibers, eg room temperature, at which the tissue has permanently assumed the acquired shape.

The 7 to 9 show examples of shaping the tissues.

To 7 It is provided that the tissues are a mattress 30 with molded joints 31 form. At the impressions a compression of the filaments, fibers, etc. is shown schematically. To mold in the hinge point, the blanks of spacer fabric delivered with a uniform cross section are heated with hot air at the intended joints. Subsequently, a board or the like is pressed with the narrow side in the heated area of the molding. After reaching the desired penetration depth of the molding with cooling air is applied until the filaments, fibers, etc. have reached room temperature again. After that, the board is removed.

The 8th shows a seat cushion 35 with a vault 36 at the top. The seat cushion is made of a molded piece of spacer fabric supplied with a uniform cross-section. As after 7 the molding is subjected to hot air. Unlike the procedure according to 7 however, the hot air is injected between the spaced tissues. The thus heated molding is compressed between a die and a male until the in 8th shown form is reached.

9 shows a U-shaped upholstery 40 for an armrest with thighs 41 , which should include the armrests of a chair on both sides. The heating, shaping and cooling takes place as in the exemplary embodiment 8th ,

In another, not shown embodiment is a pillow instead of the pad made in the same way as the pad.

In another embodiment, not shown, the molding is immediately inserted into a mold and also takes place in the heating of the mold. The mold then has nozzle surfaces at the respective locations, through which heating means and coolant can penetrate into the mold cavity. So that a sufficient heating means and coolant supply takes place, openings are provided at opposite location, where discharged heating medium and spent coolant escape again can. For the application of water vapor, the openings are selectively closable in order to set a desired pressure level in the mold can.

11 shows a molding 52 a spacer fabric with two spaced layers 53 and 54 passing through filaments 55 be connected to each other. The molding 52 lies between two shaping plates 50 and 51 , At the side, which is the plate 50 is facing, the molding is with a foil 57 Mistake. The foil is laminated.

In the plate 50 are suction with intake ports 56 , Through the suction and suction channels is a negative pressure to the film 57 applied, so that the film 57 closing to the contour of the plate 50 invests. Then the molding will be 52 with hot gas from the direction 58 flows through, so that the filaments 55 soften. The hot gas occurs 59 out of the molding again. After sufficient softening, cooling takes place. The cooling is done abruptly in the embodiment with cooling water. Thereafter, the molding remains in the new form.

The embodiment according to 12 is different from that 11 through another feeder of the Heißgaes. To 12 is a plate 60 with hot gas supply 61 provided in the embodiment of the plate 60 protrude into the shape of a nail and into the molding 52 penetration. With this hot gas supply, a targeted hot gas supply takes place in the area of deformation. A small amount of hot gas is required. The molding is less affected by the hot gas.

The embodiment according to 13 differs from the embodiments according to 11 and 12 in that instead of a foil 57 on the molding 52 a variety of evenly distributed film spots 65 are provided. The stains are placed so that they lie exactly on the intake in the upcoming deformation of the molding. The spots 65 and cause the suction as in the embodiments 11 and 12 a concern to the contour of the plate 50 ,

Claims (5)

Mattress, all or part of one or a plurality of spacer fabrics, spacer fabrics or spacer fabrics or the like, with two spaced layers each are made by elements such as filaments, fibers or threads with each other are connected, characterized by layers and filaments, fibers or threads, which consist of thermoplastic material. Mattress according to claim 1, characterized by knitted fabrics, Knitted fabrics or fabrics that are at least one-sided, in whole or in part with a suction surface are provided. Mattress according to claim 2, characterized by films as suction surface. Mattress according to claim 3, characterized by laminated Films. Mattress according to claim 27 or 28, characterized through film stains or film parts.