Cushion comfort member comprising lignocellulosic fibers

Abstract

The present application relates to a cushion comfort member comprising lignocellulosic fibers, comprising an elastic comfort material and a cover fabric. The elastomeric comfort material includes lignocellulosic fibers that provide elastomeric properties to the elastomeric comfort material and a binder at a concentration of from 1 wt% to 30 wt%. And the lignocellulose fibers are bonded together by the binder. The invention also relates to a method for manufacturing such a cushion comfort member.

Description

[0001] This application is a divisional application of the Chinese patent application entitled "Soft and comfortable component containing wood cellulose fibers" and application number 202080065253.0. Patent application 202080065253.0 is a national application that entered the Chinese national stage based on the international application (PCT / SE2020 / 050897) filed on September 24, 2020 under the Patent Cooperation Treaty. Technical Field

[0002] The present invention relates to upholstered furniture components including comfort material, such as a headboard of a bed or the seat or back of a chair.

[0003] Furthermore, the invention relates to the use of the comfort material in upholstered furniture parts, cushions or mattresses. Background Art

[0004] In upholstered furniture, comfort materials are used to provide a comfort layer on the outside of the interior, usually rigid structure of the furniture. A cover layer, usually made of fabric, is then attached to cover the resilient comfort material. The cover layer may form the outside of the furniture that is visible to the user. Alternatively, the cover layer may also be covered with a lining and an outer layer to further protect the cover layer.

[0005] Upholstered furniture often uses a carded nonwoven, often described as a wadding or batting, over the primary comfort material to improve comfort parameters. In most cases, the carded wadding consists of carded bonded thermoplastic polyester fibers. Typically, the wadding comprises a blend of two different kinds of fibers, one of which, a core-sheath binder fiber, has a core-sheath configuration in which the copolymeric sheath has a significantly lower melting point than the core. The binder fiber is used to bond the fibers into the nonwoven.

[0006] Typically, the primary comfort material comprises porous polymer foams, such as polyurethane (PU) foams. PU foams provide comfort and are commercially available. Therefore, they are cheap and abundant.

[0007] However, synthetic comfort materials such as polyurethane foam are often flammable and not environmentally friendly. Furthermore, synthetic primary comfort materials are often used together with additional non-biodegradable materials such as thermoplastics. Furthermore, polyurethane foam produces toxic gases when burned and is often difficult to recycle. Furthermore, several comfort materials involve animal-based products such as goose down, which is less desirable given its source.

[0008] Therefore, there is a need for comfort materials for upholstered furniture, cushions and mattresses that are inexpensive, less flammable and more environmentally friendly. Summary of the invention

[0009] Thus, according to a first aspect, the present invention seeks to mitigate, alleviate, eliminate or circumvent one or more of the above-mentioned deficiencies and disadvantages in the art, either alone or in any combination, by providing a cushioned comfort component comprising an elastic comfort material and a cover fabric. The elastic comfort material comprises lignocellulosic fibers that provide elastic properties to the elastic comfort material and a binder in a concentration of 1 wt % to 30 wt %. The binder binds the lignocellulosic fibers together.

[0010] The elastic comfort material comprising lignocellulose fibers and a binder can be a type of wood fiber-based board that is commonly used as an indoor thermal insulation layer in, for example, a building wall. However, the inventors unexpectedly found that such an insulating board can also be used as an elastic comfort material in a cushion comfort member. The elastic comfort material disclosed herein is commercially available, so it is abundant and cheap and easy to use. In addition, it is more environmentally friendly than other comfort materials available on the market. Since the elastic comfort material is available on the market, the manufacture of the cushion comfort member is promoted, and the process becomes more time-saving and therefore also cheaper.

[0011] The elastic comfort material is light. The density of the elastic comfort material can be 10kg / m 3 Up to 100kg / m 3 Preferably, the density is 30 kg / m 3 Up to 100kg / m 3 , for example 25kg / m 3 Up to 50kg / m 3 , and most preferably, a density of about 40 kg / m 3 . In addition, the elastic comfort material is flexible and soft, so that it can be cut with a simple knife or other cutting tool. The texture of the elastic comfort material is somewhat spongy, and if the applied pressure is released, it springs back to its original shape. The wood cellulose fibers of the elastic comfort material and the binder together form a wool-like material. These properties enable the elastic comfort material to be used in various furniture components, such as headboards or chair seats.

[0012] In a second embodiment, a cushion comfort member is provided wherein the lignocellulosic fibers are wood fibers.

[0013] In another embodiment, a cushion comfort member is provided, wherein a binding agent is present in the elastic comfort material with a concentration of 3 % by weight to 20 % by weight, preferably 4 % by weight to 16 % by weight. Low concentrations of binding agent are advantageous because the cushion comfort material comprises less plastic elements, and therefore become more prone to recycling and more environmentally friendly. By using a binding agent, wood fibers are bonded together, if the applied pressure is removed, the material returns to its initial shape and is not deformed. In addition, the binding agent itself can provide elastic properties for the elastic comfort material. The fiber in the cushion comfort member can be present with a concentration of 70 % by weight to 99 % by weight, preferably 80 % by weight to 97 % by weight, and most preferably 84 % by weight to 96 % by weight. High concentrations of lignocellulose fibers are useful because these fibers are biodegradable and cheap. In addition, it allows the formation of an elastic comfort material with favorable properties such as flexibility, low density and pliability comprising a small amount of binding agent.

[0014] In one embodiment, the binder comprises a thermoplastic material.

[0015] In another embodiment, the binder is a bicomponent binder fiber.

[0016] In yet another embodiment, the elastic comfort material comprises a flame retardant.

[0017] In another embodiment, the flame retardant is selected from organic or inorganic compounds containing sulfur, bromine, chlorine, phosphorus, nitrogen, aluminum and / or magnesium; metal compounds; minerals; and / or bromine and / or ammonium salts or carboxylates; or combinations thereof. Preferably, the flame retardant is ammonium sulfate.

[0018] In another embodiment, there is provided a cushioned comfort member according to any one of the preceding claims, wherein the thickness T of the elastic comfort material is about 5 mm to 100 mm. Preferably, the thickness T is about 20 mm to 60 mm.

[0019] In another embodiment, a cushioned comfort component is provided, wherein the cushioned comfort component is an upholstered furniture component. The upholstered furniture component also includes a base component. Preferably, the upholstered furniture component is a headboard, a back seat, an armrest or an upholstered seat. The base component can be composed of solid wood board, plywood, oriented strand board (OSB), particle board (also known as low density board), HDF (high density board) or MDF (medium density board).

[0020] In one embodiment, the cushioned comfort member is a mattress or a seat cushion.

[0021] In another embodiment, the covering material is a fabric. The fabric can be a woven fabric or a nonwoven fabric. The fabric can contain fibers of cotton, hemp, linen and / or polyester.

[0022] In one embodiment, the cushioned comfort member further comprises a lining, said lining being arranged at least partially over the covering material.Preferably, the lining is arranged between the covering material and the outer fabric.

[0023] According to a second aspect, a use of an elastic comfort material in an upholstered comfort component is provided. The elastic comfort material comprises lignocellulose fibers that provide elastic properties to the elastic comfort material and a binder in a concentration of 1 wt % to 30 wt %. The binder binds the lignocellulose fibers together. The upholstered comfort component can be, for example, a headboard, a back seat, an upholstered seat, an armrest, a mattress or a cushion.

[0024] In one embodiment, the elastic comfort material has a density of 10 kg / m 3 Up to 100kg / m 3 , preferably 30kg / m 3 Up to 100kg / m 3 , for example 25kg / m 3 Up to 50kg / m 3 , and most preferably about 40 kg / m 3 .

[0025] In another embodiment, the lignocellulosic fibers are wood fibers.

[0026] In another embodiment, the binder is present in the elastic comfort material at a concentration of 2 to 20 wt%.Preferably, the binder is present in the elastic comfort material at a concentration of 3 to 7 wt%.

[0027] In yet another embodiment, the elastic comfort material comprises a flame retardant, for example is impregnated with a flame retardant. Preferably, the flame retardant is selected from organic or inorganic compounds containing sulfur, bromine, chlorine, phosphorus, nitrogen, aluminum and / or magnesium; metal compounds; minerals; and / or bromine and / or ammonium salts or carboxylates; or combinations thereof. Preferably, the flame retardant is ammonium sulfate.

[0028] According to a third aspect, a method for manufacturing a cushioned comfort component as disclosed above is provided. The method comprises the steps of providing an elastic comfort material, optionally cutting the elastic comfort material into elastic comfort material pieces having a desired shape and size, and at least partially covering the elastic comfort material pieces with a covering material.

[0029] In one embodiment, the method further comprises the step of arranging the optionally cut piece of elastic comfort material on the base member prior to the arranging step.

[0030] In another embodiment, the method further comprises the step of applying a liner over the cover material.

[0031] In yet another embodiment, the method further comprises the step of applying an outer fabric over the cover material or liner, if present.

[0032] According to a fourth aspect, there is provided an elastic comfort material comprising lignocellulosic fibers providing elastic properties to the elastic comfort material and a binder at a concentration of 1 wt % to 30 wt %. The binder binds the lignocellulosic fibers together and the binder is a bicomponent binder fiber.

[0033] According to a fifth aspect, a method for making an elastic comfort material is provided, the elastic comfort material comprising lignocellulosic fibers providing elastic properties to the elastic comfort material and a binder at a concentration of 1 wt % to 30 wt %. The binder binds the lignocellulosic fibers together, and the binder is a bicomponent binder fiber. The method comprises the following steps: determining the concentration of the binder relative to the lignocellulosic fibers; mixing the desired amount of lignocellulosic fibers and the binder, thereby obtaining a mixture of the lignocellulosic fibers and the binder; placing the mixture on a conveying device; conveying the mixture to an oven via a roller; subjecting the mixture to heat in the oven so that the binder partially melts and binds the lignocellulosic fibers together; and removing the formed elastic comfort material from the oven.

[0034] In one embodiment, the step of mixing the desired amounts of lignocellulosic fibers and the binder is performed in a plurality of passes in an aerated drum.

[0035] In another embodiment, the step of subjecting the mixture to heat further comprises adjusting the height of the soon-to-be elastic conformable material in the mixture with rollers in the oven.

[0036] In yet another embodiment, the method further comprises the step of cutting the formed elastic comfort material into predetermined shapes, lengths and / or pieces.

[0037] The method may further include winding the elastic comfort material onto a roll.

[0038] Further advantageous features of the invention are described in detail in the embodiments disclosed herein.Furthermore, advantageous features of the invention are defined in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] These and other aspects, features and advantages that can be achieved by the present invention will become apparent and elucidated from the following description of embodiments of the present invention with reference to the accompanying drawings, in which:

[0040] Figure 1aA cross section of an upholstered comfort member is depicted;

[0041] Figure 1b depicts a cross-section of a cushioned comfort member according to a second embodiment;

[0042] Figure 2 An exemplary embodiment of a padded comfort member is shown;

[0043] Figure 3 Another exemplary embodiment of a cushioned comfort member is shown;

[0044] Figure 4 A flow chart showing a method for manufacturing an upholstered comfort component;

[0045] Figure 5a depicts a cross-section of a cushioned comfort member according to a third embodiment; and

[0046] Figure 5b A cross-section of a cushioned comfort member according to a fourth embodiment is depicted. DETAILED DESCRIPTION

[0047] The term "upholstered comfort component" as used in this application relates to any comfort component having a furniture covering. Thus, various components of seating furniture such as sofas, armchairs, dining chairs, office chairs, etc., such as armrests, seating areas, backrests and frames are included in this term. In addition, "upholstered comfort components" also include other comfort components having a furniture covering, such as bed frames, headboards, mattresses and cushions.

[0048] As will be described hereinafter, improved upholstered furniture components and methods for providing such furniture components will be described.

[0049] Reference Figure 1a , a cushion comfort member 100 is shown. The cushion comfort member 100 includes several layers, which are a base component 110, an elastic comfort material 120 and a cover material 130. Figure 1a The proportions of the different layers in are not accurate.

[0050] Figure 1b Another embodiment of a cushioned comfort member 100 is shown. Figure 1b The cushion comfort member 100 in the embodiment also includes a base part 110, an elastic comfort material 120 and a covering material 130. In addition, Figure 1b The cushioned comfort member 100 in FIG. 1 includes a lining 140 and an outer fabric 150 . Figure 1b The proportions of the different layers in FIG. 1 are not accurate. An enlarged portion of the elastic comfort material 120 is shown in circle 160. The elastic comfort material 120 includes fibers 170 and binder fibers 180.

[0051] The base member 110 may be a board. The base member 110 is preferably made of a rigid material such as particle board, fiberboard, plywood or wood.

[0052] The elastic and comfortable material 120 is elastic and flexible so that its shape can be adapted to various sizes. In addition, the elastic and comfortable material 120 can be cut into any desired shape. Cutting can be carried out using, for example, a knife, a saw, a pair of scissors or any other suitable cutting device.

[0053] Typically, the elastic comfort material 120 is applied to the structural body of the furniture piece, i.e., the base component 110. The thickness T of the elastic comfort material 120 is in the range of 5 mm to 100 mm, preferably 10 mm to 80 mm, and most preferably about 20 mm to 60 mm. The thickness T can vary within a specific range as the elastic comfort material extends. Optionally, the elastic comfort material 120 is derived from a thicker elastic comfort material blank (not shown) having a thickness of, for example, 45 mm or 200 mm to form an elastic comfort material 120 blank of thickness T.

[0054] The elastic comfort material 120 comprises cellulose fibers, such as lignocellulosic fibers 170, which are preferably wood fibers (e.g., spruce, pine, poplar, or birch fibers). Alternatively, the lignocellulosic fibers 170 are plant fibers, such as bast fibers such as hemp, jute, or flax, or fruit fibers such as coconut fibers; pulp fibers, such as paper fibers; or fibers from recycled particle boards.

[0055] Wood fiber, hemp fiber or coconut fiber are preferred because they are easy to recycle and therefore environmentally friendly. Wood fiber can be harvested from young trees that have different characteristics compared to the wood of older trees. Since there is a large part of young forests that are not utilized, this is also beneficial to the environment. On the contrary, after the young forest area is cleaned up, the materials of the young forest are simply burned.

[0056] Furthermore, hemp and coconut fibers are abundant and reasonably priced, making the production of the elastic comfort material 120 cost effective.

[0057] The length L of the wood fiber can be in the range of about 1 mm to 50 mm, preferably 6 mm to 25 mm. The length may have an impact on how soft or rigid the fiber is and how durable the fiber is. A wire cloth screen of a specific width (i.e., 1 mm to 50 mm) can be used to determine the size of the lignocellulosic fibers 170 so that, for example, 95% of the lignocellulosic fibers 170 pass through the width of the screen and therefore have a size smaller than the width of the screen. Applicable standards are ISO 3310-1:2016 and ISO 2591-1:1988.

[0058] According to one embodiment, at least 95% of the wood fibers pass through a wire cloth screen width of 25 mm according to ISO 3310-1:2016 and ISO 2591-1:1988. Furthermore, according to ISO 3310-1:2016 and ISO 2591-1:1988, no more than 5% by weight, such as no more than 10% by weight, of the wood fibers pass through a wire cloth screen width of 6 mm.

[0059] In addition, the elastic comfort material 120 includes a binder 180. The binder 180 is used to bind the wood fibers together and provide flexibility in the material. By binding the wood fibers together, if the applied pressure is removed, the material returns to its original shape instead of being deformed. Preferably, the binder is a binder fiber. According to a less preferred embodiment, the binder is a resin or a granular thermoplastic. Although resin can be used to provide the elastic comfort material 120, it provides a less flexible and less elastic comfort material. Similar disadvantages apply to granular thermoplastics.

[0060] Binder fibers are preferred because less binder is needed to provide the elastic comfort material 120. A single binder fiber can be bonded to several lignocellulosic fibers 170 of the elastic comfort material 120. In addition, the effective surface area per volume unit of the fiber is much higher than that of particles. In addition, the binder fiber itself can provide elastic properties.

[0061] The binder 180 may be a thermoplastic binder selected from the group consisting of granular polypropylene (PP), granular polyethylene (PE), bicomponent binder fibers (dual binder fibers), or combinations thereof. Dual binder fibers represent a preferred binder.

[0062] The dual binder fiber can be a core / sheath fiber or a parallel fiber. Typically, the binder fiber is a core / sheath fiber. In addition, the dual binder fiber can be hollow. The dual binder fiber can, for example, be a core / sheath fiber that includes a core formed of PP and includes a PE sheath that embeds the PP core. The core of the dual binder fiber has a higher melting point than the melting point of the outer covering layer. The advantage of the dual binder fiber is that when the dual binder fiber is heated to achieve bonding, only the outer sheath will melt, while the core will remain solid. In this way, since the core of the dual binder fiber is intact, the flexibility of the elastic comfort material 120 is improved.

[0063] According to one embodiment, the linear density of the twin fibers is in the range of 0.5 dtex to 5 dtex, for example in the range of 1 dtex to 3 dtex. The linear density may be about 1.3 dtex. In addition, the twin fibers may be short fibers. Such short fibers may be 3 mm to 10 mm long, for example 5 mm to 8 mm long. The twin fibers may be about 6 mm long.

[0064] In addition, the binder fiber can be a curled fiber that provides additional elasticity. Therefore, the binder fiber can be an eccentric double fiber. Combinations of different binder fibers can also be used to affect the elastic properties of the elastic comfort material. In addition to the double binder fiber, short fibers such as double short fibers can also be added to adjust the properties of the elastic comfort material 120 obtained.

[0065] When a dual binder is used as the binder 180, the dual fibers will bind the lignocellulosic fibers 170 together during the thermoforming process. If the elastic comfort material 120 is further processed with heat, the inner core may also melt and help maintain the desired shape obtained. Depending on the materials used, if the elastic comfort material 120 is not further heat treated, the inner core can provide additional flexibility and / or integrity.

[0066] The concentration of the binder 180 in the comfort material 120 is in the range of 1 wt % to 30 wt %, preferably 2 wt % to 24 wt %, for example 3 wt % to 20 wt %. The concentration of the binder 180 in the comfort material 120 may further be 4 wt % to 16 wt %. By using dual binder fibers, a smaller amount of binder may be used.

[0067] Elasticity and density are properties that may be affected by the concentration of the binder 180. How much of an effect the binder 180 will have on the elasticity of the elastic comfort material 120 depends on the type of binder and / or binder fiber used. For example, tests conducted by the inventors have shown that a combination of dual binder fibers and hollow conjugate binder fibers produces a higher elasticity of the elastic comfort material 120 than when a combination of dual binder fibers and eccentric dual binder fibers are used.

[0068] Different concentrations of binder 180 may be preferred for different applications of the elastic comfort material 120. If the application of the comfort material 120 requires less elasticity, a lower concentration of binder fiber is generally suitable than if the application requires a highly elastic material.

[0069] The size of the binder fiber is preferably within the size range of the wood cellulose fiber 170 and close to the size of the wood cellulose fiber 170 to achieve a satisfactory elastic comfort material 120. The advantage of the binder fiber 180 having a small particle size is that a larger number of binder fibers 180 can be used, which creates more bonding sites between the cellulose fibers in the elastic comfort material 120.

[0070] The resilient comfort material 120 may be a type of "wood fiber insulation fleece" such as provided by Hunton, Steico, Gutex or Pavatex, such as Hunton Nativo, Steico flex, Gutex Thermoflex or Pavatex Pavatherm.

[0071] Table 1 shows the test results of the static and dynamic setting values ​​of polyethylene (PE) foam, polyester VLAP, and elastic comfort material 120 having conjugate binder fiber or eccentric binder fiber as binder 180, respectively. PE foam and polyester VLAP are comfort materials known in the art. However, since polyester VLAP and PE foam are synthetic materials made from materials of non-renewable sources, these materials are less environmentally friendly than the elastic comfort material 120 disclosed herein.

[0072] A low set value is preferred because it indicates that the elastic comfort material 120 will recover when the static load is removed. If the set value is ideally equal to zero, there will be no visible deformation in the comfort material. The set values ​​shown in Table 1 were measured using ISO 3358:2014 to test the permanent deformation after 80,000 cycles.

[0073] As shown in Table 1, the elastic comfort material 120 has a set value of 38% to 41%, which is lower (and therefore better) than, for example, polyester VLAP. The test results show that the elastic comfort material 120 has favorable properties for its intended use as a comfort material.

[0074] Table 1

[0075]

[0076] According to one embodiment, about 76% to 92% by weight of the resilient comfort material 120 is composed of wood fibers, which are sustainable and recyclable materials. Therefore, the resilient comfort material 120 is much more environmentally friendly than, for example, other synthetic polymer foams used as comfort materials in the art. In addition, the resilient comfort material 120 can utilize and be formed from leftover materials from, for example, sawmills.

[0077] In addition, the wood fibers in the comfort material 120 are bio-based and have hygroscopic properties, which can provide advantages for comfort experience because natural fibers that feel more comfortable when close to the human body have sufficient water vapor permeability. Therefore, wood fibers with sufficient air permeability, i.e., water vapor permeability, cause moisture (e.g., evaporation) to be lost.

[0078] The low concentration of binder 180 allows the elastic comfort material 120 to contain less plastic elements, thus making it more environmentally friendly and easier to recycle.

[0079] The density of the elastic comfort material 120 may be 10 kg / m 3 Up to 300kg / m 3 , for example 10kg / m 3 Up to 100kg / m 3 , preferably 30kg / m 3 Up to 100kg / m 3 , for example 25kg / m 3 Up to 50kg / m 3 , and most preferably about 40 kg / m 3 .

[0080] Preferably, the elastic comfort material 120 contains a flame retardant. The flame retardant can be a commercially available flame retardant, such as an organic or inorganic compound containing sulfur, bromine, chlorine, phosphorus, nitrogen, aluminum and / or magnesium; a metal compound; a mineral; and / or bromine and / or ammonium salts or carboxylates; or a combination thereof. The flame retardant can be, for example, ammonium sulfate. For example, the elastic comfort material 120 can be treated with a flame retardant by spraying, soaking or impregnating the elastic comfort material 120 with a flame retardant dissolved or dispersed in a liquid. The elastic comfort material 120 can also contain flame retardant fibers. Flame retardant fibers are known in the art (see, for example, WO 2017 / 084721A1).

[0081] Optionally, the elastic comfort material 120 is slightly compacted to provide a comfort material 120 with enhanced thermal insulation properties. The initially less dense elastic comfort material can be compacted by slightly compressing it under heat to provide a permanently denser material, i.e., a compacted material. However, according to such an embodiment, the compacted elastic comfort material 120 is still soft and flexible, but its density is less than 300 kg / m 3 , for example, at 100kg / m 3 Up to 200kg / m 3 within the range.

[0082] The covering material 130 may be a fabric. The fabric may be a woven fabric or a nonwoven fabric. The fabric may include fibers of cotton, hemp, linen and / or polyester. The lining 140 may be a lining 140 as disclosed in WO 2015 / 177267A1. The purpose of the lining 140 is to provide protection against wear and tear, and the lining 140 may also facilitate convenient assembly of the furniture cover and prevent deformation of the comfort material 120 during assembly of the outer fabric 150.

[0083] Outer fabric 150 facing Figure 1b The exterior of the cushioned comfort member 100 is shown in FIG.

[0084] Figure 2 An exemplary embodiment of a chair 200 having an upholstered seat is shown. The seat includes an upholstered comfort member 100 as disclosed herein.

[0085] Reference Figure 3 , showing yet another exemplary embodiment. Figure 3 A bed 300 is shown having a mattress including a cushioned comfort member 100 according to one embodiment shown. Figure 4 , a schematic diagram of a method 400 for manufacturing a cushion comfort component 100 is shown. The method 400 comprises a first step 410 of providing an elastic comfort material 120. In an optional second step 420 of cutting the elastic comfort material 120, a workpiece of the comfort material 120 is obtained. Depending on the cushion comfort component 100 to be manufactured, the elastic cuttable comfort material 120 can be cut and formed into any desired size and / or shape, if necessary.

[0086] In the next step, the piece of elastic comfort material 120 is preferably arranged 430 on the provided base member 110 and then padded 440 within the cover material 130. The elastic comfort material 120 is placed on the outside of the base member 110.

[0087] Alternatively, method 400 further includes: Figure 1b The step of applying 450 the lining 140 on the covering material 130 is shown. In addition, the method may also include the following steps: Figure 1b The step of applying 460 the outer fabric 150 on the cover material 130 or on the liner 140 is shown.

[0088] The elastic comfort material 120 is manufactured by first determining the concentration of the binder 180 relative to the lignocellulosic fibers 170. The concentration determination is based on weight. After the determination, the desired amount of lignocellulosic fibers 170 and the binder 180 are mixed in a plurality of processes in an air-filled drum, thereby obtaining a mixture of lignocellulosic fibers and the binder.

[0089] The mixture is placed on a conveyor with a forming head, such as a conveyor belt. The mixture can fall onto the conveyor belt or be blown onto the conveyor belt. The conveyor transports the mixture to the oven via rollers. The rollers will determine the height of the final elastic comfort material 120.

[0090] The oven subjects the mixture to heat, causing the binder in the mixture to partially melt and bind the lignocellulosic fibers together. Optionally, the oven blows heat through the mixture from one or more directions, causing the binder 180 to at least partially melt and form a matrix with the lignocellulosic fibers 170. The heat blown from one or more directions provides efficient heating and uniform heat distribution throughout the material to be formed. Optionally, this step may also include a roller that adjusts the height of the mixture that will become the elastic comfort material 120.

[0091] The bonded elastic comfort material 120 is taken out of the oven in the shape of a large cushion or mattress, which can be cut into predetermined shapes, lengths and / or sheets. Optionally, the elastic comfort material 120 can be wound onto a roll.

[0092] In this method, the binder 180 used is preferably a dry binder 180, thereby reducing the number of steps for the molding process compared to when a liquid binder is used.

[0093] Therefore, the elastic comfort material 120 disclosed herein comprises lignocellulose fiber 170 providing elastic properties for the elastic comfort material 120, and a binder 180 having a concentration of 1 wt % to 30 wt %, for example 8 wt % to 24 wt %. The binder 180 bonds the lignocellulose fiber 170 together and is preferably a double binder fiber. In addition, the binder 180 can also contribute to the elasticity of the elastic comfort material 120. The double binder fiber can be an eccentric or concentric core-sheath binder fiber or an eccentric parallel binder fiber. Optionally, the double binder fiber is curled. The lignocellulose fiber 170 can be a wood fiber, for example, a wood fiber from spruce, pine, poplar or birch, and the length L of the fiber can be in the range of about 1 mm to 50 mm, preferably 6 mm to 25 mm.

[0094] Optionally, the elastic comfort material 120 is combined with a metal spring or spring coil, such as a bonnell spring or pocket spring 190, such as Figure 5a The elastic comfort material 120 is arranged on the layer of metal spring / spring coil 190, and also as shown. Figure 1b An optional cover fabric 130 , an optional lining 140 , and an optional outer fabric 150 are shown provided over the elastic comfort material 120 .

[0095] Further optionally, if Figure 5b As shown, a cloth 135 that is harder and less elastic than the elastic comfort material 120 is arranged under the spring 190. Such a cloth 135 can be jute cloth. Figure 5b The embodiment shown in also includes an additional layer 120b of elastic comfort material 120 and a second outer fabric 150b.

[0096] The comfort material 120 acts as a soft cushioning material on the coil spring or springs 190 and will hide the feel of the metal and provide additional surface comfort.

[0097] Table 2 shows the test results from the height loss performance test. For two pillows containing a combination of elastic comfort material 120 and pocket springs or a combination with Bonnier metal springs, the total height loss after 50,000 cycles was measured in percentage. The total height loss was 19% for the pillow containing a combination of elastic comfort material 120 and pocket springs, and 15% for the pillow containing a combination of elastic comfort material 120 and Bonnier metal springs. These results are within the threshold of acceptable results and therefore meet the height loss requirements over time. The test results are also in the same range as the total height loss of conventional materials in the art (e.g., polyester VLAP).

[0098] Table 2

[0099]

[0100] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent.Therefore, the foregoing preferred specific embodiments should be construed as merely illustrative and not limiting of the present disclosure in any way whatsoever.

[0101] Although the present invention has been described above with reference to specific embodiments, the present invention is not intended to be limited to the specific forms set forth herein. On the contrary, the present invention is limited only by the appended claims, and within the scope of these appended claims, other embodiments other than the above specific embodiments are equally possible, such as different embodiments other than those described above.

[0102] In the claims, the term "comprises / comprising" does not exclude the presence of other elements or steps. Additionally, although individual features may be included in different claims, these may possibly be advantageously combined, and the inclusion in different claims does not imply that a combination of features is not feasible and / or advantageous.

[0103] In addition, singular references do not exclude a plurality. Terms without a specific quantifier, the terms "first", "second" etc. do not exclude a plurality.

[0104] The present invention provides the following technical solutions:

[0105] Solution 1. A cushioned comfort component, comprising an elastic comfort material (120) and a covering fabric (130), wherein the elastic comfort material (120) contains wood cellulose fibers (170) that provide elastic properties to the elastic comfort material and a binder (180) with a concentration of 1 weight % to 30 weight %, wherein the binder (180) bonds the wood cellulose fibers (170) together.

[0106] Option 2. The cushion comfort member according to Option 1, wherein the lignocellulosic fibers (170) are wood fibers.

[0107] Option 3. The cushion comfort member according to any of the preceding options, wherein the adhesive (180) comprises a thermoplastic material.

[0108] Option 4. The cushion comfort component according to Option 3, wherein the binder (180) is a bicomponent binder fiber.

[0109] Option 5. The cushion comfort component according to any of the preceding options, wherein the binder (180) is present in the elastic comfort material at a concentration of 3% to 20% by weight, preferably 4% to 16% by weight.

[0110] Option 6. A cushion comfort component according to any of the preceding options, wherein the wood cellulosic fibers (170) are present in a concentration of 70% to 99% by weight, preferably 80% to 97% by weight, and most preferably 84% to 96% by weight.

[0111] Solution 7. The cushion comfort component according to any one of the preceding solutions, wherein the density of the elastic comfort material (120) is 10 kg / m 3 Up to 100kg / m 3 , preferably 30kg / m 3 Up to 100kg / m 3 , for example 25kg / m 3 Up to 50kg / m 3 .

[0112] Option 8. The cushioned comfort component according to any one of the preceding options, wherein the elastic comfort material (120) contains a flame retardant.

[0113] Option 9. A cushioned comfort component according to any one of the preceding options, wherein the thickness T of the elastic comfort material (120) is approximately 5 mm to 100 mm, preferably 20 mm to 60 mm.

[0114] Option 10. A cushioned comfort component according to any one of the preceding options, wherein the cushioned comfort component is an upholstered furniture component, and the upholstered furniture component also includes a base component (110); preferably, the upholstered furniture component is a headboard, a back seat, an armrest or an upholstered seat.

[0115] Option 11. A cushioned comfort member according to Option 11, wherein the base component (110) includes solid wood board, plywood, oriented strand board (OSB), particle board (also known as low-density board), HDF (high-density board) or MDF (medium-density board).

[0116] Aspect 12. The cushioned comfort member according to any one of Aspects 1 to 10, wherein the cushioned comfort member is a mattress or a seat cushion.

[0117] Option 13. The cushioned comfort member according to any of the preceding options, wherein the covering material (130) is fabric.

[0118] Option 14. The cushioned comfort component according to any of the preceding options further comprises a lining (140), which is at least partially arranged above the covering material (130); preferably, the lining is arranged between the covering material (130) and the outer fabric (150).

[0119] Option 15. The cushioned comfort component according to any one of options 1 to 10 or 13 to 15, further comprising a layer of coil springs or pocket springs (190) arranged adjacent to the elastic comfort material (120).

[0120] Scheme 16. Use of an elastic comfort material in a cushion comfort component, wherein the elastic comfort material (120) comprises wood cellulose fibers (170) that provide elastic properties to the elastic comfort material and a binder (180) in a concentration of 1 weight % to 30 weight %, wherein the binder (180) bonds the wood cellulose fibers (170) together, wherein the cushion comfort component can be, for example, a headboard, a back seat, a cushioned seat, an armrest, a mattress or a cushion.

[0121] Solution 17. Use of the elastic comfort material according to Solution 17 in a cushion comfort component, wherein the density of the elastic comfort material (120) is 10 kg / m 3 Up to 100kg / m 3 , preferably 30kg / m 3 Up to 100kg / m 3 , for example 25kg / m 3 Up to 50kg / m 3 .

[0122] Option 18. Use of the elastic comfort material according to Option 17 or 18 in a cushion comfort component, wherein the wood cellulose fiber (170) is wood fiber.

[0123] Option 19. Use of the elastic comfort material according to Options 17 to 19 in a cushioned comfort component, wherein the binder (180) is present in the elastic comfort material in a concentration of 3% to 20% by weight, preferably 4% to 16% by weight.

[0124] Scheme 20. Use of the elastic comfort material according to Schemes 17 to 20 in a cushioned comfort component, wherein the elastic comfort material (120) is impregnated with a flame retardant; preferably, the flame retardant is selected from organic or inorganic compounds containing sulfur, bromine, chlorine, phosphorus, nitrogen, aluminum and / or magnesium; metal compounds; minerals; and / or bromine and / or ammonium salts or carboxylates; or a combination thereof, preferably, the flame retardant is ammonium sulfate.

[0125] Solution 21. A method for manufacturing a cushion comfort component, wherein the method (400) comprises the following steps:

[0126] - providing (410) an elastic comfort material (120) according to any one of schemes 1 to 15;

[0127] - optionally cutting (420) the elastic comfort material (120) into pieces of elastic comfort material (120) having desired shapes and sizes; and

[0128] - At least partially covering (440) the workpiece of elastic comfort material (120) with a covering material (130).

[0129] Option 22. A method according to Option 22, wherein the method further comprises the step of arranging (430) the optionally cut elastic comfort material (120) workpiece on the base member (110) before the padding (440) step.

[0130] Option 23. A method according to Option 22 or 23, wherein the method further comprises the step of applying (450) a lining (140) on the covering material (130).

[0131] Option 24. A method according to any one of Option 22 to Option 24, wherein the method further comprises the step of applying (460) an outer fabric (150) onto the covering material (130) or the lining (140), if present.

[0132] Option 25. An elastic, comfortable material (120) comprising cellulose fibers (170) providing elastic properties to the elastic, comfortable material and a binder (180) having a concentration of 1 wt % to 30 wt %, wherein the binder (180) bonds the cellulose fibers (170) together, and wherein the binder (180) is a bicomponent binder fiber.

[0133] Embodiment 26. A method for manufacturing an elastic comfort material (120), the elastic comfort material (120) comprising lignocellulosic fibers (170) providing elastic properties to the elastic comfort material and a binder (180) at a concentration of 1 wt % to 30 wt %, the binder (180) binding the lignocellulosic fibers (170) together, and wherein the binder (180) is a bicomponent binder fiber, wherein the method comprises the following steps:

[0134] - determining the concentration of the binder (180) relative to the lignocellulosic fibers (170);

[0135] - mixing a desired amount of lignocellulosic fibers (170) and said binder (180), thereby obtaining a mixture of lignocellulosic fibers (170) and binder (180);

[0136] - placing the mixture on a conveying device;

[0137] - conveying the mixture via rollers into an oven;

[0138] - subjecting the mixture to heat in the oven so that the binder (180) partially melts and binds the lignocellulosic fibers (170) together; and

[0139] - Removing the formed elastic comfort material from the oven (120).

[0140] Embodiment 27. The method according to Embodiment 26, wherein the step of mixing the desired amount of lignocellulosic fibers (170) and the binder (180) is performed in a plurality of processes in an air-filled drum.

[0141] Option 28. A method according to Option 26 or 27, wherein the step of subjecting the mixture to heat further comprises adjusting the height of the mixture that is to become the elastic comfort material (120) in the oven using a roller.

[0142] Option 29. The method according to any one of Options 26 to 28, further comprising the step of cutting the formed elastic comfort material (120) into predetermined shapes, lengths and / or pieces.

[0143] Option 30. The method according to any one of Option 26 to Option 29, further comprising winding the elastic comfort material (120) onto a roller.

Claims

1. A cushion comfort component, comprising an elastic comfort material (120) and a covering fabric (130), wherein the elastic comfort material (120) contains wood cellulose fibers (170) that provide elastic properties to the elastic comfort material and a binder (180) with a concentration of 1 weight % to 30 weight %, wherein the binder is a bicomponent binder fiber containing a thermoplastic material, and the binder (180) bonds the wood cellulose fibers (170) together, wherein the wood cellulose fibers (170) have a length (L) of about 1-50 mm.

2. The cushion comfort member according to claim 1, wherein the lignocellulosic fibers (170) are wood fibers.

3. The cushion comfort member of claim 1, wherein the binder (180) is present in the elastic comfort material at a concentration of 3% to 20% by weight.

4. The cushion comfort member of claim 3, wherein the binder (180) is present in the elastic comfort material at a concentration of 4% to 16% by weight.

5. The cushion comfort member of claim 1, wherein the lignocellulosic fibers (170) are present in a concentration of 70% to 99% by weight.

6. The cushion comfort element of claim 5, wherein the lignocellulosic fibers (170) are present in a concentration of 80% to 97% by weight.

7. The cushion comfort element of claim 6, wherein the lignocellulosic fibers (170) are present in a concentration of 84 to 96 wt. %.

8. The cushion comfort member according to claim 1, wherein the density of the elastic comfort material (120) is 10 kg / m 3 Up to 100kg / m 3 .

9. The cushion comfort member according to claim 8, wherein the density of the elastic comfort material (120) is 30 kg / m 3 Up to 100kg / m 3 .

10. The cushion comfort member according to claim 9, wherein the density of the elastic comfort material (120) is 25 kg / m 3 Up to 50kg / m 3 .

11. The cushioned comfort member of claim 1, wherein the resilient comfort material (120) comprises a flame retardant.

12. The cushioned comfort member according to claim 1, wherein the thickness T of the elastic comfort material (120) is 5 mm to 100 mm.

13. The cushioned comfort member according to claim 12, wherein the thickness T of the elastic comfort material (120) is 20 mm to 60 mm.

14. The upholstered comfort component according to any one of the preceding claims, wherein the upholstered comfort component is an upholstered furniture component, the upholstered furniture component further comprising a base part (110).

15. The upholstered comfort component of claim 14, wherein the upholstered furniture component is a headboard, back seat, armrest or upholstered seat.

16. The cushioned comfort member according to claim 14, wherein the base component (110) comprises solid wood board, plywood, oriented strand board (OSB), particle board (also known as low-density board), HDF (high-density board) or MDF (medium-density board).

17. The upholstered comfort component according to any one of claims 1 to 13, wherein the upholstered comfort component is a mattress or a seat cushion.

18. The cushioned comfort member of claim 1, wherein the covering material (130) is fabric.

19. The cushioned comfort member of claim 1, wherein the cushioned comfort member further comprises a liner (140) disposed at least partially over the cover material (130).

20. The cushioned comfort member of claim 19, wherein the lining is arranged between the covering material (130) and the outer fabric (150).

21. The cushioned comfort member of claim 1, wherein the cushioned comfort member further comprises a layer of coil springs or pocket springs (190) disposed adjacent the resilient comfort material (120).

22. Use of an elastic comfort material in a cushion comfort component, wherein the elastic comfort material (120) comprises wood cellulose fibers (170) that provide elastic properties to the elastic comfort material and a binder (180) with a concentration of 1 wt % to 30 wt %, wherein the binder (180) bonds the wood cellulose fibers (170) together, wherein the wood cellulose fibers (170) have a length (L) of about 1-50 mm.

23. Use of a resilient comfort material according to claim 22 in an upholstered comfort component, wherein the upholstered comfort component is a headboard, a back seat, an upholstered seat, an armrest, a mattress or a seat cushion.

24. Use of the elastic comfort material in a cushion comfort component according to claim 22, wherein the density of the elastic comfort material (120) is 10 kg / m 3 Up to 100kg / m 3 .

25. Use of the elastic comfort material in a cushion comfort component according to claim 24, wherein the density of the elastic comfort material (120) is 30 kg / m 3 Up to 100kg / m 3 .

26. Use of the elastic comfort material according to claim 25 in a cushion comfort component, wherein the density of the elastic comfort material (120) is 25 kg / m 3 Up to 50kg / m 3 .

27. Use of the elastic comfort material in a cushion comfort element according to claim 22, wherein the lignocellulosic fibers (170) are wood fibers.

28. Use of the elastic comfort material according to claim 22 in a cushion comfort component, wherein the binder (180) is present in the elastic comfort material in a concentration of 3% to 20% by weight.

29. Use of an elastic comfort material according to claim 28 in a cushion comfort element, wherein the binder (180) is present in the elastic comfort material in a concentration of 4% to 16% by weight.

30. Use of the elastic comfort material according to claim 22 in a cushion comfort element, wherein the elastic comfort material (120) is impregnated with a flame retardant.

31. Use of the elastic comfort material according to claim 30 in a cushion comfort component, wherein the flame retardant is selected from inorganic or organic compounds containing sulfur, bromine, chlorine, phosphorus, nitrogen, aluminum and / or magnesium; metal compounds; minerals; and / or bromine and / or ammonium salts or carboxylates; or combinations thereof.

32. Use of a resilient comfort material in a cushion comfort component according to claim 31, wherein the flame retardant is ammonium sulfate.

33. A method for manufacturing a cushioned comfort component, wherein the method (400) comprises the following steps: - providing (410) an elastic comfort material (120) according to any one of claims 1 to 13; - optionally cutting (420) the elastic comfort material (120) into pieces of elastic comfort material (120) having a desired shape and size; as well as - At least partially covering (440) the workpiece of elastic comfort material (120) with a covering material (130).

34. A method according to claim 33, wherein the method further comprises the step of arranging (430) the optionally cut elastic comfort material (120) workpiece on the base member (110) before the step of at least partially covering (440) the elastic comfort material (120) workpiece.

35. The method of claim 33, wherein the method further comprises the step of applying (450) a liner (140) over the cover material (130).

36. Method according to any one of claims 33 to 35, wherein the method further comprises the step of applying (460) an outer fabric (150) over the cover material (130) or the lining (140), if present.

37. A method for making an elastic comfort material (120), the elastic comfort material (120) comprising lignocellulosic fibers (170) providing elastic properties to the elastic comfort material and a binder (180) in a concentration of 1 wt% to 30 wt%, the binder (180) binding the lignocellulosic fibers (170) together, and wherein the binder (180) is a bicomponent binder fiber, wherein the lignocellulosic fibers (170) have a length (L) of about 1-50 mm, wherein the method comprises the steps of: - mixing lignocellulosic fibers (170) and bicomponent binder fibers, thereby obtaining a mixture of lignocellulosic fibers (170) and bicomponent binder fibers; - placing the mixture on a conveying device; - conveying the mixture via rollers into an oven; - subjecting the mixture to heat in the oven so that the bicomponent binder fibers partially melt and bind the lignocellulosic fibers (170) together; as well as - Removing the formed elastic comfort material from the oven (120).

38. The method of claim 37, wherein the step of mixing the desired amount of lignocellulosic fibers (170) and the bicomponent binder fibers is performed in a plurality of passes in an aerated drum.

39. The method of claim 37 or 38, wherein the step of subjecting the mixture to heat further comprises adjusting the height of the mixture that will become the elastic comfort material (120) in the oven using rollers.

40. The method of claim 37, further comprising the step of cutting the formed elastic comfort material (120) into predetermined shapes, lengths and / or pieces.

41. The method of claim 37, further comprising winding the elastic comfort material (120) onto a roll.

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