DE202014011158U1 - Laminated body, designed as a composite body cushion element, and designed as a composite body damping body - Google Patents

Abstract

Laminated body, comprising a first component, which contains foam bodies, and a second component, which contains a fiber material, wherein the laminated body is produced as follows: ■ first, the first and / or the second component of a pre-crushing, ■ by the foam material the first and / or the fiber material of the second component is cut before it is opened, such that the foam particles of the first component have a size of at most 20 mm and / or the fiber material of the second component has a fiber length of at most 50 mm ■ the two components are each opened by passing them through a carding machine together, ■ these two components are mixed together and spread out into a sheet having a first thickness, called web thickness ■ in addition to the two components mentioned, a third, as Glue designated component e is added separately or as part of one of the two mentioned components, ■ several sections of the web material together with adhesive are placed on each other, such that a loose intermediate product with a thickness called intermediate thickness is formed, ■ and the intermediate product is compacted into a final product, and its Thickness called thickness is less than the intermediate thickness.

Description

The innovation concerns a laminated body.

From the DE 38 78 726 T2 For example, there is known a method of producing a foam fiber composite material and a corresponding foam fiber composite material. Hydrophilic, liquid-absorbent foam is mixed with thermoplastic fibers. This is done by the fact that the foam is processed simultaneously with thermoplastic fibers in a card or carding and thereby crushed. Possibly. The foam can be comminuted by pre-grinding, so that not large pieces, but the pre-shredded foam particles desired particle size are placed in the carding or carding.

From the DE OS 1 685 195 A For example, a method for producing a filling or cushioning material is known. The mixed layer produced in a card or carding machine can be laid on one another in the form of several layers so as to create a filling or padding material of the desired material thickness.

Also in practice it is known for the field of production of insulating materials or upholstery fabrics to arrange a first produced nonwoven in several layers or layers.

The innovation is based on the object of specifying a particularly economically producible composite body. Furthermore, the innovation is the object of specifying a cushion element, which has excellent cushioning properties and the lowest possible production costs. Finally, the innovation is the object of specifying a damping element, which has excellent insulation properties and low production costs.

These objects are achieved by a laminated body according to claim 1, a cushioning element according to claim 12 and a damping element according to claim 15. Advantageous embodiments are described in the subclaims.

In other words, the innovation proposes a layered body in which both foam bodies and fiber material form this layered body. In the production of the laminated body, an intimate connection of the individual particles, be it the foam bodies or the fibrous materials, is assisted by the fact that both components are each guided by a card and thereby the respective materials are opened.

In addition, it is provided that these two components are intimately mixed with each other. This can be done, for example, by guiding both components together into the same card and thus not only opening the two components inside the carding machine, but also mixing them together.

According to the proposal as homogeneous as possible material properties, in particular cushioning properties or insulating properties of the composite to be produced supported by the fact that the starting materials, namely the two components mentioned, are not only opened in the carding, but that already have the carding components supplied defined size dimensions. For example, instead of tearing a larger block of foam as part of a pre-shredding or instead of shredding fiber materials such as mattress covers or similar textile elements by tearing, it is proposed that the first and / or the second component is cut in the pre-crushing before these components be led into the clutter.

By pre-shredding in front of the carding possible homogeneous dimensions of the foam bodies or the fibers used are possible. Since this pre-shredding is carried out by cutting according to the proposal, the adherence to certain maximum dimensions is ensured particularly reliably since, unlike cracking, the starting materials are cut into individual sections in a defined manner so that the maximum dimensions in the body which precede the pre-shredding can be defined particularly precisely.

According to the proposal, it is provided that the foam bodies of the first component have a size of at most 20 mm in all directions. The fiber material of the second component has a fiber length of at most 50 mm for the same reasons.

The two open components are spread to a web whose layer thickness is referred to as web thickness.

In order to ensure an intensive cohesion of the processed materials and a dimensional stability of the composite to be produced, it is also intended to glue the material. Apart from the foam bodies and the fibrous material, therefore, a third component in the form of the so-called adhesive is added during the production of the composite body. Depending on the configuration of the adhesive, the addition can be done in different ways: For example, a Resin, for example in the form of a melamine resin granules are sprinkled into the carding, so that already in the carding the mixing of all three components.

Or it can be provided to add the so-called adhesive as thermoplastic fibers, which are either also already introduced into the carding or even present as part of the so-called second component, namely as part of the fiber material. For example, fibers may be provided of thermoplastic material or it may be provided to use fibers which are provided with an outer shell layer or with outer thermoplastic or designed as a hot melt adhesive particles. Alternatively, to introduce the so-called adhesive already in the carding, can be provided to give up the adhesive on the two open and mixed components when they have left the card, so that, for example, the adhesive can be applied to the mentioned web, for example in the form of a granulate which is scattered on the web or in the form of the mentioned, a bonding permitting fibers or melt adhesive threads that can be placed in this area on the web.

Subsequently, the web material provided with the adhesive or the adhesive is processed to a greater layer thickness, as can be done in a conventional manner, for example by means of a cross-lapping or an aerodynamic web forming by individual sections of the web goods are superimposed. In this way, a loose so-called intermediate product is created whose layer thickness depends on the number of superimposed sections of the web and which is referred to as the so-called intermediate thickness. The several superimposed layers do not yet form the layered body in this process step, since they are not yet connected to each other and are therefore not referred to as a body.

Only then is the intermediate product compacted into a final product, so that the layered body is created, namely having the mentioned several layers of the web. By compacting the loose intermediate, the layer thickness of this final product, referred to as the final thickness, is less than the intermediate thickness of the loose intermediate.

Aside from the types of adhesives already mentioned above, any other materials can be used if, in the sense of the present proposal, they serve as an adhesive to ensure a dimensionally stable bond of the material. However, as already mentioned, particularly advantageous materials can be used as adhesives which can be thermally activated and which comprise, for example, monofilaments or multi-filament yarns as fusible filaments or in which the adhesive contains fused fibers which do not internally melting component as the core and on the outside thereof have a melting component, or the adhesive can, as explained, be present as granules of resin or plastic. In this case, during the compression of the intermediate product to the final layered body advantageously a heated press can be used, so that in addition to the mechanical pressing process also a thermal activation of the adhesive takes place, so that after opening the press, the final product its final thickness or a him possibly permanently retained during pressing mediated shaping.

An economically advantageous production of the composite can be supported by the fact that although high quality if not virgin, unused material is used, which is in the form of production residues, so that not only disposal costs can be saved in this case, but also the excellent product properties of virgin material determine the excellent quality of the composite. The fact that the materials supplied are opened in the carding, largely homogeneous material properties of the fiber materials or the foam bodies are effected because the influences resulting from different shapes of the foam bodies used or from different shapes of the fiber materials used, by opening in the Carding as far as possible neutralized and homogenized.

In a particularly surprising and economically particularly advantageous manner, however, it has been shown in tests that for the first component of the foam bodies or for the second component of the fiber material, and in a particularly surprising way even if recycling material is used for both components, the material properties of the produced Obviously, due to the combination of foam on the one hand and fiber material on the other, the laminated body essentially corresponds to the material properties of a laminate produced from virgin materials. In this way, the use of material is not only economically advantageous, which otherwise would have to be disposed of as waste and thereby possibly cause costs, but it is particularly possible in an environmentally beneficial way to reduce the amount of waste and the first time in a product used materials a second life cycle, the Due to its excellent material properties is not a "downcycling" represents, but where a veritable virgin material properties of a product is possible, which can be referred to as virgin material in contrast to a recycled product. For example, old foam mattresses may be used which are comminuted to provide the foam bodies and old mattress covers or other textile materials may be used to provide the fiber material to be used according to the proposal.

When using recycled material this is preferably sanitized before the two open components are mixed together and in particular the sanitation can take place before the respective components are fed into the carding, so that designed with its surface roughness carding is operated hygienically flawless and so that The clutter does not allow the formation of undesirable seed nests, for example, by their surface roughness. The sanitation can be carried out, for example, thermally by heating the recycled material to a temperature of at least 130 ° C. This represents a reliable sanitation of the material and on the other hand does not burden the foams to be used nor the fibrous material to be used, so that with regard to the desired cushioning properties, this type of sanitization exerts no adverse effects on the starting material to be used.

Advantageously, the first component may comprise foam bodies of a PU foam. In the first experiments, it has been found that PU foams enable the production of laminates by means of the proposed method, which have excellent cushioning properties or also insulating properties.

The produced laminate consists of a plurality of layers of the web, namely by creating an intermediate product which has the corresponding number of layers of the web. Without having to change the production of the layered body in this area and to change the production facility, laminates of different thicknesses can be produced, namely by stacking the final product produced from the intermediate product and other, similar end products and joining them together, for example by pressing them together and likewise be joined together by means of thermally activated adhesives, so that ultimately a product can be created, which has a multiple or many times greater thickness than the so-called final thickness of the compressed intermediate product.

Furthermore, the laminate produced according to the proposal may contain further layers beyond the so-called end product, for example by providing an additional surface layer on one or both surfaces of the end product, which is accordingly applied to one or both surfaces of the final product, for example glued. This may be a decorative layer or a heat reflection layer or a moisture barrier layer in the form of a film or the like.

According to a first advantageous use, it may be provided to provide a cushioning element, for example a cushion of a sitting or lying furniture or a mattress, with the aid of the laminated body proposed according to the proposal.

If such a proposed prepared padding element is designed as a mattress, this can advantageously have sections with differently configured layer elements, so that the mattress sections having different properties, namely, in these sections, the layer elements have different cushioning properties. These different cushioning properties can be determined by the geometry of the respective layer elements or, for example, by their hardness, for example, by the end products are produced by different levels of compression of the intermediate product.

The proposed design according to the upholstery element may advantageously have inserted elements of foreign materials, such as metallic spring elements, as they are known in a spring mattress or the laminate of the cushion element may be provided with a textile layer, which for example affects the extensibility of the composite body and thus influences the cushioning properties of the cushion element ,

According to a second advantageous application, it can be provided to create a damping element as a semi-finished, for example in the form of plates, roll-up sheets o. The like .. Such a damping element, for example, allow a mechanical damping, as known in upholstery materials is. However, the damping element can also be used for acoustic damping or acoustic insulation or for thermal damping or thermal insulation. As a layer element according to the present proposal, such a damping element is particularly economical to produce.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 3878726 T2 [0002]
• DE 1685195 A [0003]

Claims (15)

Layer body, with a first component containing foam bodies, and a second component containing a fibrous material, wherein the laminated body is made as follows: ■ first the first and / or the second component are subjected to pre-shredding, By cutting the foam material of the first and / or the fiber material of the second component before it is opened, In such a way that the foam particles of the first component have a size of at most 20 mm and / or the fiber material of the second component has a fiber length of at most 50 mm, ■ the two components are each opened by passing them together through a clutter, ■ these two components are mixed together and spread to a web having a first thickness, called web thickness, ■ in addition to the two components mentioned above, a third component called adhesive is added separately or as part of one of the two components mentioned, ■ several sections of the web material together with adhesive are placed on top of each other in such a way that a loose intermediate product with a thickness called intermediate thickness is produced, ■ and the intermediate is compressed to a final product, which has several layers of the web as a layered body, and whose thickness, referred to as the final thickness, is less than the intermediate thickness. Layered body after Claim 1 characterized by an adhesive which is thermally activatable and which comprises fusible threads in the form of monofilaments or multi-filament yarns and / or contains fused fibers internally having a non-melting component as the core and outside of which a fusing component, and / or as granules of resin or plastic. Layered body after Claim 1 or 2 , characterized in that in its manufacture the web has been folded in a cross-stacker to the desired intermediate thickness. Layered body after Claim 1 or 2 , characterized in that in its production the web material has been combined in an aerodynamic web forming to the desired intermediate thickness. Laminate according to one of the preceding claims, characterized in that virgin, unused material in the form of production residues has been used in its production for the first and second components. Laminated body according to one of Claims 1 to 4 , characterized in that used in its preparation for the first and / or second component material used in the form of recycled material. Layered body after Claim 6 , characterized in that in its manufacture the recycled material has been sanitized before the two opened components have been mixed together. Layered body after Claim 7 , characterized in that in its manufacture the recycled material has been thermally sanitized by being heated to a temperature of at least 130 ° C. Laminate according to one of the preceding claims, characterized in that the first component contains foam particles of a PU foam. Laminate according to one of the preceding claims, characterized in that in its manufacture a plurality of end products have been joined together, such that the layer body thus created has a thickness which is several times the final thickness. Laminate according to one of the preceding claims, characterized in that a surface layer has been applied to one or both surfaces of the final product during its production. Upholstery element, which has a laminated body according to one of the preceding claims. Upholstery element Claim 12 , characterized in that it is designed as a mattress having sections with differently configured layer elements having different cushioning properties. Upholstery element Claim 12 or 13 , characterized in that it has inserted elements of foreign materials. Damping element as a semi-finished product, characterized in that it is produced as a layer element according to one of the preceding claims.