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WO1992010119A1 - Tissu enduit de mousse, procede d'enduction et article en mousse recouvert par le tissu - Google Patents

Tissu enduit de mousse, procede d'enduction et article en mousse recouvert par le tissu Download PDF

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Publication number
WO1992010119A1
WO1992010119A1 PCT/US1991/009127 US9109127W WO9210119A1 WO 1992010119 A1 WO1992010119 A1 WO 1992010119A1 US 9109127 W US9109127 W US 9109127W WO 9210119 A1 WO9210119 A1 WO 9210119A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam
cloth
coated cloth
coating
making
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/US1991/009127
Other languages
English (en)
Inventor
Christian Thary
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Creme Art Corp
Original Assignee
Creme Art Corp
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 Creme Art Corp filed Critical Creme Art Corp
Publication of WO1992010119A1 publication Critical patent/WO1992010119A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—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 features of a layer of foamed material
    • B32B5/20—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 features of a layer of foamed material foamed in situ
    • 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
    • A47C7/18—Seat parts having foamed material included in cushioning part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/321—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements the preformed part being a lining, e.g. a film or a support lining
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/045—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • D06N3/0045—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers obtained by applying a ready-made foam layer; obtained by compressing, crinkling or crushing a foam layer, e.g. Kaschierverfahren für Schaumschicht
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0065—Permeability to gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0242—Acrylic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/026—Porous

Definitions

  • This invention relates to a latex foam coated cloth, to a method for coating the cloth and to a soft foam article covered by the cloth.
  • One object of the present invention is to provide a foam coated cloth that is breathable so as to permit the passage of gas but whose coating nevertheless prevents the passage of viscous foamable liquid polyurethane mixtures so as to permit open cell soft polyurethane foam molding directly against the cloth coating without permeating the cloth.
  • the coated cloth includes a porous cloth that is breathable and a latex foam coating on the cloth.
  • the latex foam coating has a thickness in the range of about .025 to 3.0 millimeters and an open cell structure with about 400 to 600 openings per square millimeter so as to permit the passage of gas such that the coated cloth is breathable while nevertheless preventing the passage of viscous foamable liquid polyurethane mixtures so as to permit open cell soft polyurethane foam molding directly against the cloth coating without permeating the cloth.
  • Both the lower and upper extremes of the range of openings per unit area as well as the thickness of the foam coating are important in providing a coated cloth that is breathable while nevertheless preventing the passage of viscous foamable liquid polyurethane mixtures. More specifically, if the foam coating has large enough openings so that there are less than about 400 openings per square millimeter, the coated cloth will not prevent the passage of viscous foamable liquid polyurethane mixtures such that open cell soft polyurethane foam cannot be molded directly against the cloth. Furthermore, if the foam coating has small enough openings so that there are more than about 600 openings per square millimeter, the coated cloth will not permit the passage of gas so as to be breathable.
  • the foam coating must have a thickness that is at least about .025 millimeters to prevent the passage of viscous foamable liquid polyurethane mixtures and must have a thickness no greater than about 3.0 millimeters to permit the passage of gas so as to be breathable.
  • the latex foam coating is an acrylic copolymer.
  • Another object of the invention is to provide a method for making the foam coated cloth which is breathable while nevertheless preventing the passage of viscous foamable liquid polyurethane mixtures so as to permit open cell soft polyurethane foam molding directly against the cloth coating without permeating the cloth.
  • the method for making a foam coated cloth is performed by mixing an acrylic copolymer, a pH neutralizer, a stiffener, water and a latex premix with a frothing agent and an aerosol with the ratio by weight of the frothing agent over the aerosol in the range of about 2.3 to 2.85.
  • This mixture is deposited on a porous cloth for foaming as a foam coating having an open cellular structure with about 400 to 600 cells per square millimeter and a thickness in the range of about .025 to 3.0 millimeters such that the coated cloth is breathable while nevertheless preventing the passage of viscous, foamable liquid polyurethane mixtures.
  • the foam coating is deposited with different thicknesses in the .025 to 3.0 millimeter range depending upon the particular application for which the foam coated cloth is to be utilized. More specifically, the foam coating is deposited with a thickness in the range of about .025 to .25 millimeter for use with free rise foamable liquid polyurethane mixtures and is deposited with a thickness of about .25 to 3.0 millimeters for use in providing overpacking with foamable liquid polyurethane mixtures.
  • a thickness of about .25 to 1.0 millimeter is sufficient to prevent penetration of the cloth by the liquid polyurethane mixture during the overpacking, while a thickness of about 1.0 to 3.0 millimeters also provides strength to the cloth as well as preventing the liquid polyurethane mixture from penetrating the cloth during the overpacking.
  • the method is most economically performed on a commercial basis by heating of the deposited foam layer to dry the foam coating.
  • the foam coating is disclosed in one practice as being crushed such as between rotating rolls to increase the density of the foam coating. This crushed foam coating is then preferably heated to accelerate the curing of the foam. Such processing permits the coated cloth to be manufactured as a generally continuous strip during movement along deposition, drying, crushing, and curing stations. It is also possible for the foam to be deposited, dried and cured without crushing.
  • the stiffener is preferably an acrylic acid copolymer that is most preferably provided as a gel.
  • the frothing agent is preferably ammonium stearate and the preferred aerosol is disodium n-octadecylsulfosuccinamate.
  • Another object of the invention is to provide an improved soft foam article with a breathable cover.
  • the improved soft foam article includes a cover having a porous cloth that is breathable and that has an interior including a latex foam coating having a thickness in the range of about .025 to 3.0 millimeters.
  • the latex foam coating has an open cell structure with about 400 to 600 openings per square millimeter so as to permit the passage of gas such that the coated cloth cover is breathable while nevertheless being impermeable to viscous foamable liquid polyurethane mixtures.
  • An open cell soft polyurethane foam core of the article is molded in situ within the cover in direct engagement with the latex foam coating which prevents the foam core from permeating the porous cloth.
  • the covered soft foam article of the invention has particular utility for use as a seating component such as a seat cushion, a seat back, a headrest and an armrest and, in such applications, overpacking of the foam core is preferably utilized such that the foam layer is preferably in the .25 to 3.0 millimeter thickness range that functions best with overpacking.
  • FIGURE 1 is a: sectional view taken through a coated cloth constructed in accordance with the present invention and made according to the method thereof so as to be breathable while nevertheless preventing the passage of viscous liquid polyurethane foam mixtures;
  • FIGURE 2 is a plan view of the cloth taken along the direction of line 2-2 in Figure 1;
  • FIGURE 3 is view that illustrates one practice of the method for making the foam coated cloth in accordance with the invention.
  • FIGURE 4 is a sectional view similar to Figure 5 showing the cloth prior to a crushing step that increases the density of the foam;
  • FIGURE 5 is a cross-sectional view taken through a mold in which coated cloth of this invention is located to receive a foamable liquid polyurethane mixture for in situ molding in order to provide the covered soft foam article of this invention;
  • FIGURE 6 is a partially broken away view illustrating the manner in which the covered soft foam article can be utilized as a seat cushion, a seat back, or a headrest
  • FIGURE 7 is a partially broken away view illustrating the manner in which the covered soft foam article can be utilized as an armrest;
  • FIGURE 8 is an enlarged sectional view illustrating the interface between the molded open cell soft polyurethane foam and the foam coated cloth cover.
  • FIGURE 9 is a view similar to Figure 3 but illustrating the processing without any crushing of the foam coating on the cloth.
  • a coated cloth 10 constructed in accordance with the present invention is disclosed as including a porous cloth 12 that is breathable and a latex foam coating 14 on the cloth.
  • the porous cloth 12 includes warp yarn 16 and woof yarn 18 such that there are pores or openings 20 through which the cloth breathes.
  • the latex foam coating 14 on the porous cloth 12 has an average thickness t in the range of about .025 to 3.0 millimeters.
  • the latex foam coating as shown in Figure 2 has an open cell structure with about 400 to 600 cells or openings 22 per square millimeter.
  • the latex foam coating 14 permit the passage of gas through the foam openings 22 while nevertheless preventing the passage of viscous foamable liquid polyurethane mixtures which have a viscosity of about 600 to 800 centipoises. More specifically, it is important for the foam coating to have a thickness of at least about .025 millimeters and openings 22 that are small enough so that there are at least about 400 openings per square millimeter in order to prevent the passage of viscous foamable liquid polyurethane foam mixtures such that open cell soft polyurethane foam can be formed directly against the latex foam coating without permeating the cloth.
  • the thickness t of the foam coating is not greater than about 3.0 millimeters and that the openings 22 are large enough so that there are no more than about 600 openings per square millimeter so the coated cloth will permit the passage of gas and thus be breathable.
  • apparatus 24 is utilized to perform a method for making the foam coated cloth 10 as described above in connection with Figures 1 and 2. More specifically, this apparatus 24 shown in Figure 3 includes a supply roll 26 from which the cloth 12 is unrolled upon rotation in the clockwise direction of arrow 27, a deposition station 28, a drying station 30, a crushing station 32, a curing station 33 and a delivery roll 34 onto which the coated cloth is wound upon rotation in the clockwise direction of arrow 35 after movement as shown in the direction of arrow 36 from the left toward the right through the four stations.
  • the deposition station 28 includes an applicator 37 having a mixing chamber 38 in which a suitable mixer 40 provides mixing of components as a mixture 42 that provides the latex foam coating 14. More specifically, this mixture includes an acrylic copolymer, a pH neutralizer, a stiffener, water and a latex premix as well as a frothing agent and an aerosol. Furthermore, the ratio by weight of the frothing agent over the aerosol is in the range of about 2.3 to 2.85 and most preferably about 2.58.
  • the frothing agent is a surfactant that reduces the surface tension so that air is more easily entrained in the mixture by the mixing action.
  • the aerosol is a weaker surfactant that causes the larger air cells to break into smaller ones and thereby provides air cells of more uniform size as well as providing greater stability so that the mixture can be spread as shown or pumped if necessary. It is important for the ratio of the frothing agent and the aerosol to be in the range described above so as to ensure sufficient frothing without having so much aerosol that the mixture collapses upon the eventual foaming.
  • Applicator 37 has a lower end 44 with an opening for depositing the latex foam mixture 42 on the porous cloth 12 as the cloth is moved from the supply roll 26 at the left toward the right.
  • the deposited mixture 42 of the coated cloth 10' foams to an open cellular structure 14' shown in Figure 4 with about 400 to 600 cells or openings 22 per square millimeter.
  • the thickness to which the foam coating 12 is deposited in the .025 to 3.0 millimeter range depends upon the application for which the foam coated cloth is to be used. More specifically, the foam coating is normally deposited with a thickness of about .025 to .25 millimeter for use with free rise foamable liquid polyurethane mixtures, while the foam coating is deposited with a thickness of about .25 to 3 millimeters for use in providing overpacking with foamable liquid polyurethane mixtures. When overpacking is to be utilized, deposition of the foam coating with a thickness of about .25 to 1.0 millimeter is sufficient to prevent penetration of the cloth by the liquid polyurethane mixture during the overpacking.
  • Deposition of the foam coating on the cloth with a thickness of about 1.0 to 3.0 millimeters provides strength to the cloth as well as preventing the liquid polyurethane mixture from penetrating the cloth during overpacking.
  • the foam coated cloth moves through the drying station 30 where a suitable heater 46 is located to heat and provide rapid drying of the foam coating. While the foam coating could be air dried, this heating to provide the drying makes the processing much faster and thus more economical and effective.
  • the crushing station 32 shown in Figure 3 Downstream from the drying station 30, the crushing station 32 shown in Figure 3 includes lower and upper crushing rolls 48 and 50 that are respectively rotated clockwise and counterclockwise as shown by arrows 52 and 54. These crushing rolls crush the foam coated cloth to decrease the average foam coating thickness from the initial thickness t' to the final thickness t and thereby increase the density and thus the strength of the foam. The resultant coated cloth is thus strengthened by this crushing. It is possible for the crushing to reduce the foam thickness to as little as about 10% of its original thickness. For some foam compositions which are somewhat elastic, the foam coating thickness may rebound to a certain extent after the crushing step. For other foam compositions which are less elastic, there will be little or no rebound in the thickness.
  • the final thickness t of the foam coating 14 is selected depending upon the application for which the foam coated cloth is to be used as discussed above.
  • the curing station 33 preferably includes a heater 56 that heats the crushed open cell foam to accelerate the curing.
  • a modified embodiment of the apparatus utilized to perform the method for making the foam coated cloth 10 is identified by reference numeral 24' and has the same components as the embodiment of Figure 3 except for the fact that there is no crushing station 32 as with the previously described embodiment.
  • the initial thickness to which the foam layer 14 is deposited will be substantially the same as the final thickness. Otherwise, the processing is the same as the previously described processing and thus need not be repeated.
  • the stiffener of the latex foam increases the viscosity and is most preferably an acrylic acid copolymer that is a gel, such as sold by the Rohm and Haas Company of Philadelphia, Pennsylvania, United States of America, under the trademark Acrysol ASE-95, which is supplied as an aqueous solution that is acid neutralized to provide the gel before mixing with the other components.
  • the frothing agent utilized is preferably ammonium stearate such as sold by Standard Adhesive & Chemical Company of Dalton, Georgia, United States of America, under the trademark Stanfax 318.
  • One aerosol utilized is disodium n- octadecylsulfosuccinamate.
  • the calcium carbonate filler is merely utilized to provide more volume and thus cost reduction.
  • This filler is a clay powder that is dispersed in the mixture during mixing and can also be provided as a premixed aqueous dispersion which is sold by the previous mentioned ECC American, Inc. of Sandersville, Georgia under the trademark Eccatex 90 and is 68% solids.
  • the latex foam mixture of this example has a viscosity of about 940 centipoises when measured by Brookfield Viscosity, Low Viscosity Formula, Mixer Paddle #3, at 30 revolutions per minute.
  • the density of the resultant latex foam is on the order of about .15 grams per cubic centimeter when air is introduced by the mixing from the atmosphere. Introduction of pressurized air into a closed chamber where the mixing is performed provides a greater porosity and hence a lower density such as about .12 grams per cubic centimeter.
  • a pour-in-place mold 58 is illustrated as having a mold member 60 that defines a mold cavity 62 and as also having a cover 64 illustrated as being supported by a pivotal connection 66 for movement between the open position shown by solid line representation and a closed position where the top of the mold cavity 62 is closed at the phantom line location 67.
  • Mold member 60 is illustrated as including a vacuum housing 68 defining a vacuum chamber 70 that is communicated by passages 72 with the mold cavity 62.
  • the cover 64 is illustrated as having vents 74 that permit the escape of gas generated by the foam reaction during foam molding within the cavity 62 as is hereinafter more fully described.
  • the coated cloth 10 illustrated in Figures 1 and 2 is placed within the cavity 62 of mold 58 as shown in Figure 5 to make a covered soft foam article in accordance with the present invention. More specifically, the coated cloth 10 is positioned within the mold cavity 62 where it is maintained by a vacuum supplied from the vacuum chamber 70 through the passages 72. It should be noted that, while the coated cloth is breathable as described above, a vacuum drawn to a sufficient extent within the vacuum chamber 70 will maintain the cloth against the surface of the mold cavity 62 since the latex foam coating 14 on the porous cloth 12 does limit the gas flow therethrough to a certain extent. After proper positioning of the coated cloth 10, the vacuum is terminated so the foam molding can proceed.
  • a viscous foamable liquid polyurethane mixture 76 is supplied into the mold cavity 62 as shown in Figure 5 for foaming by the pour-in-place process.
  • the latex foam coating 14 of the coated cover 10 prevents the viscous foamable liquid polyurethane mixture 76 from permeating the porous cloth 12 and destroying its utility by permeating the cloth yarns and providing stiffening thereof and by preventing passage through the porous cloth so as to damage its outer exposed surface.
  • Closing of the cover 64 permits the foaming to take place to fill the mold cavity as gas generated during the foaming reaction escapes through the cover vents 74.
  • a seat 78 is illustrated as including covered soft foam components that embody the article of the present invention as made by the foam molding described above. More specifically, the seat 78 includes a frame 80 and seating components 82 which embody covered soft foam articles constructed in accordance with the present invention. These seating components 82 include a vehicle seat cushion 84, a vehicle seat back 86, and a vehicle headrest 88. Furthermore, as illustrated in Figure 7, another seating component 82 is illustrated as a vehicle armrest 90 that embodies a covered soft foam article of the present invention. These seating components 82 can function for furniture as well as for vehicle seating.
  • each of the seating components 82 embodying the covered soft foam article of the present invention includes the coated cover 10 which, as previously described, includes the porous cloth 12 that is breathable and has an interior including the latex foam coating 14. More specifically, the latex foam coating as previously described is preferably an acrylic copolymer and has a thickness in the range of about .025 to 3.0 millimeters as well as having the open cell structure previously described with about 400 to 600 openings per square millimeter so as to permit the passage of gas such that the cloth cover is breathable while nevertheless being impermeable to viscous foamable liquid polyurethane mixtures such as the mixture 76 previously described in connection with Figure 5.
  • Each component 82 also has an open cell soft polyurethane foam core 92 molded in situ within the cover. This in situ molding as best illustrated in Figure 8 is with the foam core 92 in direct engagement with the latex foam coating 14 which prevents the foam core from permeating the porous cloth 12. Furthermore, as illustrated, the porous cloth 12 has short tufts 94 secured in pairs by connector yarns 96 that extend around the warp yarn 16.
  • Overpacking is normally utilized with seating components by introducing more liquid polyurethane mixture than is required to fill the mold by free rise.
  • the overpacking thus provides a greater density of the foam core.
  • the thickness of the foam layer 14 on the coated cloth is preferably about .25 to 3.0 millimeters when utilized with seating components such as the seat cushion 54, seat back 86, headrest 88 and armrest 90 shown in Figures 6 and 7.

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Laminated Bodies (AREA)

Abstract

Un tissu enduit (10) comporte un tissu poreux qui respire (12) pourvu d'un revêtement de mousse de latex qui respire (14) mais qui néanmoins empêche le passage de mélanges polyuréthane liquides visqueux susceptibles de moussage, de telle sorte qu'une mousse polyuréthane souple à alvéoles ouvertes (92) peut être formée en contact direct avec le revêtement sans passer à travers le tissu poreux (12). Le revêtement en mousse de latex (14) présente une épaisseur d'environ 0,025 à 3,0 millimètres et une structure à alvéoles ouvertes avec environ 400 à 600 ouvertures par millimètre carré. Le tissu enduit (10) est fabriqué par dépôt sur le tissu (12) d'un revêtement en mousse de latex acrylique (14) qui est ensuite séché, éventuellement broyé pour accroître la densité de mousse, et finalement durci. Un article en mousse souple recouvert par le tissu enduit trouve une application particulière comme constituant de siège (82), par exemple un coussin de siège (84), un dossier de siège (86) ou un repose-tête (88).
PCT/US1991/009127 1990-12-07 1991-12-05 Tissu enduit de mousse, procede d'enduction et article en mousse recouvert par le tissu Ceased WO1992010119A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US62353890A 1990-12-07 1990-12-07
US623,538 1990-12-07

Publications (1)

Publication Number Publication Date
WO1992010119A1 true WO1992010119A1 (fr) 1992-06-25

Family

ID=24498466

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1991/009127 Ceased WO1992010119A1 (fr) 1990-12-07 1991-12-05 Tissu enduit de mousse, procede d'enduction et article en mousse recouvert par le tissu

Country Status (3)

Country Link
AU (1) AU1152392A (fr)
CA (1) CA2095020A1 (fr)
WO (1) WO1992010119A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0555476A4 (en) * 1991-08-27 1993-10-06 Namba Press Works Co., Ltd. Skin material back-coated with thin-film latex foam and integrated foamed product utilizing the skin material
US7354424B2 (en) 1998-08-07 2008-04-08 Tamicare Ltd. Protective garment
US7767133B2 (en) 2004-11-05 2010-08-03 TamiCare, Ltd. Method and apparatus to produce stretchable products
US7901740B2 (en) 2004-11-05 2011-03-08 Tamicare Ltd. Methods to produce stretchable products
US9731319B2 (en) 2004-11-05 2017-08-15 Tamicare Ltd. Stretchable sheets comprising a variety of layers and zones and methods to produce such products
KR101927930B1 (ko) * 2016-10-27 2018-12-11 코오롱글로텍주식회사 다수의 수지층을 포함하는 통기성 시트
CN111535046A (zh) * 2020-03-23 2020-08-14 郑崇素 一种乳胶发泡层和pu贴面合成方法
US11633937B2 (en) * 2016-02-17 2023-04-25 Inoac Corporation Skin foam-in-place foamed article and production method thereof

Citations (6)

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US4439473A (en) * 1982-09-30 1984-03-27 Jerry Lippman Hydrophobic foam fabric coating
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EP0555476A4 (en) * 1991-08-27 1993-10-06 Namba Press Works Co., Ltd. Skin material back-coated with thin-film latex foam and integrated foamed product utilizing the skin material
US5460873A (en) * 1991-08-27 1995-10-24 Ogawa; Taro Cover fabric with latex foam backing and integrally foamed article using the same
US7354424B2 (en) 1998-08-07 2008-04-08 Tamicare Ltd. Protective garment
US7767133B2 (en) 2004-11-05 2010-08-03 TamiCare, Ltd. Method and apparatus to produce stretchable products
US7901740B2 (en) 2004-11-05 2011-03-08 Tamicare Ltd. Methods to produce stretchable products
US8323764B2 (en) 2004-11-05 2012-12-04 Tamicare Ltd. Methods to produce stretchable products
US9731319B2 (en) 2004-11-05 2017-08-15 Tamicare Ltd. Stretchable sheets comprising a variety of layers and zones and methods to produce such products
US11633937B2 (en) * 2016-02-17 2023-04-25 Inoac Corporation Skin foam-in-place foamed article and production method thereof
KR101927930B1 (ko) * 2016-10-27 2018-12-11 코오롱글로텍주식회사 다수의 수지층을 포함하는 통기성 시트
CN111535046A (zh) * 2020-03-23 2020-08-14 郑崇素 一种乳胶发泡层和pu贴面合成方法

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