EP1443071B1 - Verfahren zur Herstellung eines geschäumten Verbundkörpers, der dadurch enthaltene Schaumkörper und seine Verwendung. - Google Patents

Verfahren zur Herstellung eines geschäumten Verbundkörpers, der dadurch enthaltene Schaumkörper und seine Verwendung. Download PDF

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Publication number
EP1443071B1
EP1443071B1 EP04075149A EP04075149A EP1443071B1 EP 1443071 B1 EP1443071 B1 EP 1443071B1 EP 04075149 A EP04075149 A EP 04075149A EP 04075149 A EP04075149 A EP 04075149A EP 1443071 B1 EP1443071 B1 EP 1443071B1
Authority
EP
European Patent Office
Prior art keywords
foam article
layer
thermoplastic film
laminated foam
foam
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.)
Revoked
Application number
EP04075149A
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English (en)
French (fr)
Other versions
EP1443071A1 (de
EP1443071B8 (de
Inventor
Leonardus Petrus Maria Schraven
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.)
Schraven Holding BV
Original Assignee
Schraven Holding BV
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
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Application filed by Schraven Holding BV filed Critical Schraven Holding BV
Publication of EP1443071A1 publication Critical patent/EP1443071A1/de
Application granted granted Critical
Publication of EP1443071B1 publication Critical patent/EP1443071B1/de
Publication of EP1443071B8 publication Critical patent/EP1443071B8/de
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • 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
    • 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

Definitions

  • the present invention relates to a method of manufacturing a laminated foam article, as well as to a laminated foam article obtained by using such a method.
  • the present invention furthermore relates to the use of such a foam article.
  • a method of manufacturing a laminated foam article is furthermore known from European patent application No. 0 305 219 , wherein an adhesive is applied to one surface of a compressible foam layer, after which the adhesive-coated surface is contacted with a layer of a cover material for forming a so-called bilayer. Subsequently the layer of cover material is contacted with a heated die, with regions of the foam layer being compressed under the influence of pressure and heat, which compressed regions will melt and contract, as a result of which a relief pattern is formed in the bilayer.
  • Such a laminated foam article can subsequently be cut to the desired length and be used for a number of purposes, such as seat cushions, back cushions and the like.
  • Materials suitable for use as a cover material include both synthetic and natural fabrics, blown or cast films, or animal skins and the like, with the special selection of the cover material being determined by the intended end use of the laminate product.
  • the relief pattern is formed for decorative reasons.
  • One drawback of such a method is the fact that an adhesive is required for durably bonding the cover material to the foam substrate.
  • the use of an adhesive requires that the substrate be coated with a thin layer of adhesive over the entire surface area thereof, so that no regions are formed in which an inadequate bond to the supporting surface is obtained.
  • An additional drawback of the use of an adhesive is the fact is that there is a risk of the adhesive on the foam article becoming visible through the cover material in time if cover materials in light colours are used, which is undesirable, in particular when the material is used for seat cushions.
  • a sound-absorbing material comprising a flexible polyurethane foam having adhered to its surface a microporous film of an elastomer, preferably a polyurethane.
  • a sound-absorbing material thus obtained may be used in buildings and in automobiles, for example.
  • European patent application No. 0 047 086 relates to a resilient foam material which has been rendered flame retardant by coating the foam material with a special vinylidene chloride polymer.
  • One aspect of the present invention is to provide a method of manufacturing a laminated foam article, which foam article does not have the aforesaid drawbacks.
  • Another aspect of the present invention is to provide a method of manufacturing a laminated foam article, which foam article is composed of at least two durably bonded-together layers, the outer layer of which can be provided in any desired colour.
  • Yet another aspect of the present invention is to provide a method of manufacturing a laminated foam article, which foam article is ready for use as a piece of furniture without the stitching of separate materials and the subsequent covering of the foam article therewith by an upholsterer being required.
  • Another aspect of the present invention is to provide a laminated foam article having the appearance of a foam material enveloped in an upholstery material, which can furthermore be cleaned by means of a moist cloth.
  • One aspect of the present invention is furthermore to provide a laminated foam article wherein the construction and the structure of layers is such that frequent compression and springing back of the laminated foam article will not result in the formation of cracks in the laminated foam article.
  • the method comprises the following steps:
  • the laminated foam article will comprise three layers, viz. a first thermoplastic film, a second layer of a plastic dispersion and a third elastomeric coating.
  • the second layer of a plastic dispersion in particular functions to give the final foam article a full sensation and a rich aura.
  • thermoplastic film in a thickness of 2-8 ⁇ m, with a thickness of about 4 ⁇ m being especially preferred.
  • the elastomeric coating in a thickness of 10-50 ⁇ m, with a thickness of 30 ⁇ m being especially preferred.
  • the layer of a plastic dispersion in a thickness of 20-100 ⁇ m, with a thickness of 60 ⁇ m being especially preferred.
  • An advantageous effect of the use of the aforesaid layer thicknesses is that the physical characteristics of the foam substrate, in particular the flexibility thereof, are retained, which is very important, e.g. when the substrate is used to form a piece of furniture.
  • the layers that are separately applied in the present method exhibit an elasticity and mutual compatibility such that no cracks will form therein upon compression and springing back, not even after prolonged intensive use.
  • the foam substrate as used in step i) of the present method is preferably a polyurethane-based foam.
  • Polyurethane is a polymer which is obtained through condensation of a polyisocyanate and a hydroxyl-containing material, generally a polyol.
  • a bubble formation reaction is induced through the use of a blowing agent.
  • the blowing agent may comprise one or more substances which evaporate during the reaction between polyisocyanate and polyol, such as a fluorocarbon compound, or the blowing agent may chemically react with the isocyanate to form a gas, such as the reaction of water with isocyanate, as a result of which carbon dioxide is released, which carbon dioxide functions as a blowing agent. It is in particular desirable for the polyurethane foam to have a density in the 15-75 kg/m 3 range.
  • the thermoplastic film applied in step ii) of the present invention is preferably a polyurethane-based thermoplastic film.
  • the thermoplastic film in particular functions to seal the pores and openings that are present in the foam substrate. After the thermoplastic film has been applied to the foam substrate, the pores and openings that are present in the foam substrate are completely sealed, so that the layer to be subsequently applied to the thermoplastic film cannot enter the substrate foam.
  • the thermoplastic film must be considered to be an intermediate layer or support layer for each layer to be additionally applied.
  • Such a thermoplastic layer is in particular desirable in order to retain the springing characteristics of the substrate.
  • the thermoplastic layer will be capable of maintaining a durable bond with the substrate, because of the plastic nature of such a layer.
  • thermoplastic film Furthermore it is desirable in specific embodiments to add one or more components selected from the group consisting of liquefiers, pigments, solvents and crosslinking enhancers to the composition for forming the thermoplastic film. In addition it is desirable in specific embodiments to add one or more components selected from the group consisting of liquefiers, pigments, solvents, crosslinking enhancers, UV light-absorbing agents and flame retardants to the composition for forming the elastomeric coating.
  • steps ii) ,iv) and v) are preferably carried out by spraying. Since each layer is separately applied by means of a spray gun, it is possible to provide all the places on the substrate that are difficult of access with a layer.
  • the present invention furthermore relates to a laminated foam article built up of, successively, a foam substrate, a thermoplastic film and an elastomeric coating, wherein a layer of a plastic dispersion is present between said thermoplastic film and said elastomeric coating.
  • the laminated foam article obtained by using the present method is in particular used in a situation in which an element of a slightly resilient nature is required, in particular in the field of pieces of furniture, in which connection couches, footstools, chairs, headrests and footrests, bean-bag seats, as well as playground equipment and cushions for chairs are to be considered.
  • the chairs based on the present laminated foam article are suitable for use as desk chairs or conference chairs, but also as chairs for handicapped people.
  • the present laminated foam article is also suitable for use in wet spaces, for example as a toilet mat, a bathroom mat or shower mat, a shower stool, a bathtub, a water bed rim or a head support in a bathtub.
  • the laminated foam article obtained by using the present method may also be mounted on a rigid support, which, after being fitted with associated legs and possibly with a backrest and armrests, can be used as a chair. It is also possible, however, to form a construction, especially a piece of furniture, in particular a chair, substantially entirely from the laminated foam article.

Landscapes

  • Laminated Bodies (AREA)

Claims (20)

  1. Verfahren zur Herstellung eines laminierten Schaumartikels, umfassend:
    i) die Bereitstellung eines Schaumsubstrats;
    ii) das Aufbringen eines thermoplastischen Films auf dem Schaumsubstrat;
    dadurch gekennzeichnet, dass Schritt iv) und Schritt v) ausgeführt werden, die Folgendes umfassen:
    iv) das Auftragen einer Schicht aus einer Kunststoffdispersion auf den thermoplastischen Film, der in Schritt ii) erhalten wurde, und
    v) das Auftragen der elastomeren Beschichtung auf die Schicht aus einer Kunststoffdispersion, die in Schritt iv) erhalten wurde.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der thermoplastische Film in einer Dicke von 2 bis 8 µm aufgetragen wird.
  3. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass die elastomere Beschichtung in einer Dicke von 10 bis 50 µm aufgetragen wird.
  4. Verfahren nach einem oder mehr der vorangehenden Ansprüche, dadurch gekennzeichnet, dass die Schicht aus einer Kunststoffdispersion in einer Dicke von 20 bis 100 µm aufgetragen wird.
  5. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass ein Schaum auf Polyurethanbasis als Schaumsubstrat verwendet wird.
  6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass der Polyurethanschaum eine Dichte im Bereich von 15 bis 75 kg/m3 aufweist.
  7. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der thermoplastische Film ein thermoplastischer Film auf Polyurethanbasis ist.
  8. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass eine Zweikomponenten-Elastomer-Zusammensetzung auf Polyurethanbasis als elastomere Beschichtung verwendet wird.
  9. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass eine oder mehr Komponenten, ausgewählt aus der Gruppe bestehend aus Verflüssigern, Pigmenten, Lösemitteln und Vernetzungsverstärkern, der Zusammensetzung hinzugefügt werden, um den thermoplastischen Film zu bilden.
  10. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass eine oder mehr Komponenten, ausgewählt aus der Gruppe bestehend aus Verflüssigern, Pigmenten, Lösemitteln, Vernetzungsverstärkern, UV-Licht absorbierenden Mitteln und Flammhemmstoffen, der Zusammensetzung zur Bildung der elastomeren Beschichtung hinzugefügt werden.
  11. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass einer oder mehrere der Schritte ii), iv) und v) durch Sprühen ausgeführt werden.
  12. Laminierter Schaumartikel, der der Reihe nach aus einem Schaumsubstrat, einem thermoplastischen Film und einer elastomeren Schicht aufgebaut ist, dadurch gekennzeichnet, dass eine Schicht aus einer Kunststoffdispersion zwischen dem thermoplastischen Film und der elastomeren Beschichtung vorhanden ist.
  13. Laminierter Schaumartikel nach Anspruch 12, dadurch gekennzeichnet, dass der thermoplastische Film eine Schichtdicke von 2 bis 8 µm aufweist.
  14. Laminierter Schaumartikel nach Anspruch 12 oder 13, dadurch gekennzeichnet, dass die elastomere Beschichtung eine Schichtdicke von 10 bis 50 µm aufweist.
  15. Laminierter Schaumartikel nach einem der Ansprüche 12 bis 14, dadurch gekennzeichnet, dass die Schicht aus einer Kunststoffdispersion eine Schichtdicke von 20 bis 100 µm aufweist.
  16. Verwendung eines laminierten Schaumartikels nach einem oder mehreren der Ansprüche 12 bis 15 als Möbelstück.
  17. Verwendung eines laminierten Schaumartikels nach einem oder mehreren der Ansprüche 12 bis 15 als Polster.
  18. Verwendung eines laminierten Schaumartikels nach einem oder mehreren der Ansprüche 12 bis 15 als Spielgerät.
  19. Verwendung eines laminierten Schaumartikels nach einem oder mehreren der Ansprüche 12 bis 15 als Matte in einem Nassraum.
  20. Verwendung eines laminierten Schaumartikels nach einem oder mehreren der Ansprüche 12 bis 15 als Badewanne.
EP04075149A 2003-01-30 2004-01-23 Verfahren zur Herstellung eines geschäumten Verbundkörpers, der dadurch enthaltene Schaumkörper und seine Verwendung. Revoked EP1443071B8 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1022527A NL1022527C2 (nl) 2003-01-30 2003-01-30 Werkwijze ter vervaardiging van een gelamineerd schuimdeel, aldus verkregen schuimdeel en toepassing daarvan.
NL1022527 2003-01-30

Publications (3)

Publication Number Publication Date
EP1443071A1 EP1443071A1 (de) 2004-08-04
EP1443071B1 true EP1443071B1 (de) 2008-10-08
EP1443071B8 EP1443071B8 (de) 2009-02-18

Family

ID=32653378

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04075149A Revoked EP1443071B8 (de) 2003-01-30 2004-01-23 Verfahren zur Herstellung eines geschäumten Verbundkörpers, der dadurch enthaltene Schaumkörper und seine Verwendung.

Country Status (6)

Country Link
EP (1) EP1443071B8 (de)
AT (2) ATE410470T1 (de)
DE (2) DE202004021552U1 (de)
DK (1) DK1443071T3 (de)
ES (1) ES2315610T3 (de)
NL (1) NL1022527C2 (de)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1025922C2 (nl) * 2004-04-09 2005-10-11 Zuid Nl Clubmeubelfabriek B V Werkwijze ter vervaardiging van een gelamineerd schuimdeel, aldus verkregen schuimdeel en toepassing daarvan.
DE202011050991U1 (de) 2011-08-16 2012-11-23 Kunststofftechnik Schedel Gmbh Wannenkörper
DE202011050990U1 (de) 2011-08-16 2012-11-23 Kunststofftechnik Schedel Gmbh Bademöbel für eine Dampfdusche sowie Set aus einer Dampfvorrichtung und einem Bademöbel
CH706686B1 (de) * 2012-06-28 2016-07-15 Schwarzwyss Gmbh Beschichteter Schaumstoffkörper.
DE102013009725A1 (de) 2013-06-10 2014-12-11 Maria Bessinger Sanitäre Installationseinheit

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH431048A (de) * 1965-01-29 1967-02-28 Semperit Ag Verfahren zur Herstellung von Schichtstoffen
GB1250479A (de) * 1968-02-29 1971-10-20
EP0047086A1 (de) * 1980-09-03 1982-03-10 Imperial Chemical Industries Plc Kombination aus elastischem Polyurethanschaum und Polsterungsmaterial mit verbesserter Feuerbeständigkeit
DE3512400A1 (de) 1985-04-04 1989-07-13 Wolfgang Gubalke Polster-formstueck
US4867826A (en) * 1987-08-28 1989-09-19 Actex, Inc. Method for making laminated foam articles
NL9300960A (nl) 1993-06-04 1995-01-02 Leolux Meubelfab Bv Zitmeubel met verschuifbare rugkussens.
DE19517702C1 (de) * 1995-05-13 1996-12-05 Goldschmidt Ag Th Verwendung einer wäßrigen Dispersion als Gleitmittel für das Beziehen geschäumter Formkörper aus Polyurethanschaum
DE19915314A1 (de) * 1999-04-03 2000-10-05 Alkor Gmbh Verbundwerkstoff und Verfahren zu dessen Herstellung

Also Published As

Publication number Publication date
EP1443071A1 (de) 2004-08-04
DE602004016896D1 (de) 2008-11-20
DK1443071T3 (da) 2009-02-16
DE202004021552U1 (de) 2008-12-24
NL1022527C2 (nl) 2004-08-03
ES2315610T3 (es) 2009-04-01
AT10985U1 (de) 2010-02-15
ATE410470T1 (de) 2008-10-15
EP1443071B8 (de) 2009-02-18

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