WO2024200032A1 - Procédé de production d'une structure de réseau tridimensionnel - Google Patents

Procédé de production d'une structure de réseau tridimensionnel Download PDF

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Publication number
WO2024200032A1
WO2024200032A1 PCT/EP2024/056841 EP2024056841W WO2024200032A1 WO 2024200032 A1 WO2024200032 A1 WO 2024200032A1 EP 2024056841 W EP2024056841 W EP 2024056841W WO 2024200032 A1 WO2024200032 A1 WO 2024200032A1
Authority
WO
WIPO (PCT)
Prior art keywords
spinnerets
group
melt
thermoplastic elastomer
jets
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/EP2024/056841
Other languages
German (de)
English (en)
Inventor
Michael NEIDHÖFER
Frank Leymann
Heinz BÖHM
Anna Goldhofer
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.)
Indorama Ventures Mobility Obernburg GmbH
Bayerische Motoren Werke AG
Original Assignee
Indorama Ventures Mobility Obernburg GmbH
Bayerische Motoren Werke AG
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 Indorama Ventures Mobility Obernburg GmbH, Bayerische Motoren Werke AG filed Critical Indorama Ventures Mobility Obernburg GmbH
Priority to CN202480020959.3A priority Critical patent/CN121511335A/zh
Publication of WO2024200032A1 publication Critical patent/WO2024200032A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G11/00—Finished upholstery not provided for in other classes
    • B68G11/02—Finished upholstery not provided for in other classes mainly composed of fibrous materials
    • B68G11/03—Finished upholstery not provided for in other classes mainly composed of fibrous materials with stitched or bonded fibre webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G7/00—Making upholstery
    • B68G7/02—Making upholstery from waddings, fleeces, mats, or the like
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments

Definitions

  • the present application relates to a method for producing a three-dimensional network structure, in particular for use in seats.
  • seating furniture has been equipped with upholstery for centuries, which makes the seat, backrest and/or armrests softer and is intended to avoid unpleasant physical reactions, especially when sitting for longer periods. This is particularly the case for seating furniture in all types of transport, which, depending on the occasion, must enable comfortable sitting for hours.
  • seats in motor vehicles and aircraft are particularly worthy of mention.
  • motor vehicles in particular in cars, a crucial role is played by the fact that standing up during the journey is almost completely impossible and the seat can therefore only be left when the vehicle is also left, for example during breaks.
  • the object is achieved by a method for producing a three-dimensional network structure comprising the following steps: providing a thermoplastic elastomer, melting the thermoplastic elastomer to obtain a melt, extruding the melt through a group of spinnerets to obtain melt jets, wherein the group of spinnerets is distributed over a surface so that at least three rows of spinnerets arranged one above the other are formed, deforming and cooling the melt jets to obtain intertwined linear structures, characterized in that the intertwined linear structures form a body whose cross-section has a concave indentation.
  • the network structure is formed by randomly bound loops of continuous, linear structures that are intertwined with each other, wherein the continuous linear structure or structures are arranged in arcs in such a way that they form a three-dimensional structure that is held in shape by spot welding or fusion at intersection points.
  • it is a self-supporting structure that can be compressed by the action of an external force and that develops internal stresses when compressed. These internal stresses ensure that the three-dimensional network structure springs back to its original shape after the force has ceased.
  • the three-dimensional network structure forms an elastic, springy random fiber mat.
  • the continuous linear structure according to the present application contains at least one thermoplastic elastomer.
  • Thermoplastic elastomers are high molecular weight compounds ("polymers") that have elastic properties at a temperature of 298 K, but are thermally deformable like thermoplastics at higher temperatures.
  • polymers high molecular weight compounds
  • thermoplastic elastomers consist of non-covalently cross-linked, chain-like macromolecules and - in contrast to classic elastomers - can be made deformable and melted by the action of heat without chemical decomposition. This makes it possible to recycle thermoplastic elastomers like classic thermoplastics, which is not possible with classic elastomers.
  • thermoplastic elastomers belong to the well-known families of thermoplastic polymers such as polyamides or polyesters.
  • polyamides are polymers that are formed by the formation of amide groups between amino groups and carboxylic acid groups of their monomers.
  • the simplest polyamides are formed either by polymerising a dicarboxylic acid and a diamine such as adipic acid and hexamethylenediamine, which together form polyamide-6,6, or by polymerising an aminocarboxylic acid or a lactam such as s-caprolactam, which polymerises to form polyamide-6.
  • Polyamides which are made from a Dicarboxylic acid and a diamine or of a lactam or an aminocarboxylic acid do not, however, have any elastomeric properties. This requires the involvement of other monomers, which are incorporated into the macromolecules during the construction of the polymer and prevent the formation of overly large, regular and thus crystalline regions of aggregated polymers. Rather, thermoplastic elastomers have smaller crystalline regions in which neighboring macromolecules are cross-linked with one another by non-chemically binding interactions in such a way that the cross-linking can be dissolved by the action of heat and restored when cooled. The formation of such weak cross-links is possible in copolymers whose chains have more different monomers than are absolutely necessary for the formation of the chain.
  • thermoplastic elastomer can, for example, be made up of a dicarboxylic acid and two or more different diamines, or of two or more different dicarboxylic acids and a diamine.
  • a structure made up of two or more different aminocarboxylic acids or two or more different lactams is also possible.
  • polyesters are produced by polymerizing a dicarboxylic acid with a dialcohol.
  • polyethylene terephthalate (PET) is produced from ethylene glycol and terephthalic acid.
  • PET polyethylene terephthalate
  • the polymerization of a hydroxycarboxylic acid or a lactone is also possible.
  • polylactide (PLA) is produced from lactic acid or polycaprolactone is produced from caprolactone.
  • Polyesters that are made up of only a dicarboxylic acid and a dialcohol or a hydroxycarboxylic acid or a lactone do not have elastomeric properties.
  • polyester-based thermoplastic elastomers are typically divided into two classes, polyester-ester block copolymers and polyester-ether block copolymers.
  • thermoplastic elastomers from the group of polyester-ester block copolymers, both the hard and the soft chain segments are formed from polyester units.
  • Suitable dicarboxylic acids for both the hard and soft chain segments are aromatic carboxylic acids such as terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid and diphenyl-4,4'-dicarboxylic acid, as well as alicyclic carboxylic acids such as 1,4-cyclohexyldicarboxylic acid and aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid and fatty acid dimers ("dimer acids").
  • Derivatives of the carboxylic acids mentioned, such as carboxylic acid anhydrides or halides can also be used.
  • aliphatic diols such as 1,4-butanediol, ethylene glycol, trimethylene glycol, pentamethylene glycol, hexamethylene glycol, alicyclic diols such as 1,1-cyclohexanedimethanol and 1,4-cyclohexanedimethanol are used as diol components for the “hard” chain segments.
  • Ester-forming derivatives of these diols such as the corresponding chloro-, bromo- or iodoalkanes can also be used.
  • polyester diols can be used. These are oligomers or polymers which, like polyesters, are made up of dicarboxylic acids and diols, hydroxycarboxylic acids or lactones, but where it is ensured that both chain ends contain hydroxyl groups and which therefore fit into polyester chains like diol units.
  • Polylactones such as polycaprolactone can be used as polyester diols, which are modified by reaction with a diol or a precursor for it such as a halogenalkanol so that both chain ends have hydroxyl groups.
  • Polyester diols typically have an average molar Mass of 300 to 5000 g/mol. Polyester diols are usually based on aliphatic polyesters.
  • polyester-ester block copolymers are triblock copolymers containing terephthalic acid and/or naphthalene-2,6-dicarboxylic acid as dicarboxylic acid, 1,4-butanediol as diol component and polylactone as polyester-diol.
  • Polyester-ether copolymers can be based on the same dicarboxylic acids and diols as polyester-ester copolymers.
  • the base can also be a polymerized hydroxycarboxylic acid or a polymerized lactone.
  • polyester-ether copolymers instead of a polyester-diol component, polyester-ether copolymers contain a polyether-diol component as a "soft" chain segment.
  • the polyether-diol component can be, for example, polyalkylenediols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol as well as ethylene oxide-propylene oxide copolymers.
  • the average molar mass of the polyether-diol component can be between 300 and 5000 g/mol.
  • the three-dimensional network structure consists of a thermoplastic elastomer.
  • thermoplastic elastomer according to the present application is usually in the form of pieces or as granules, which are provided for the process according to the present application.
  • the material can be obtained from fossil raw materials such as crude oil, natural gas or coal as well as from biomass.
  • the provision of recycled material is also possible, for example in the form of shredded, discarded objects consisting of a thermoplastic elastomer according to the present application.
  • shredded three-dimensional network structures made of a thermoplastic elastomer according to the present application are used for the process according to the present application.
  • the shredded three-dimensional network structures are remains of seat cushions.
  • the three-dimensional network structure was produced according to the process of the present application.
  • thermoplastic elastomer is heated above its melting point and thus melted into a melt.
  • This melt is fed to an extruder and extruded through spinnerets.
  • a spinneret in the sense of the present application is understood to be a single opening through which melt can, for example, escape into a surrounding liquid or gaseous medium.
  • the spinnerets in the sense of the present application can have all shapes known to the person skilled in the art. In particular, a circular shape is just as possible as an oval, a polygon such as a triangle, square, pentagon or hexagon or even a star shape.
  • the spinnerets can be holes that have the shape mentioned, or they can be closed, slit-shaped figures with the shapes mentioned.
  • solid linear structures are formed by exiting holes with the shapes mentioned
  • hollow linear structures of the shapes mentioned are formed by exiting closed, slit-shaped figures.
  • the spinnerets in the sense of the present application can be arranged as openings in a flat plate, a concave surface or a convex surface.
  • groups of spinnerets are required.
  • the number of spinnerets used is not limited, but in one embodiment it is at least 20, at least 30, at least 40 or at least 50. In particular, there is no upper limit to the number. In one embodiment, however, it is at most 150, at most 200, at most 300 or at most 400 spinnerets.
  • the spinnerets can be arranged on a flat plate, a concave surface or a convex surface in any way known to the person skilled in the art so that they form rows in any spatial direction and that at least three rows of spinnerets arranged one above the other are formed, wherein the term "over” is to be understood such that the group of spinnerets can be rotated in any direction and by any angle before assessing whether they are arranged one above the other.
  • the spinnerets form a grid on the flat plate, the convex surface or the concave surface. In one embodiment, they are arranged in concentric circles.
  • the gaseous medium can be air or an inert gas such as nitrogen, carbon dioxide or argon.
  • the liquid medium can be water.
  • the temperature of the liquid or gaseous medium is below the melting or softening temperature of the thermoplastic elastomer. In this case, the liquid or gaseous medium acts as a coolant, causing the thermoplastic elastomer to solidify.
  • jets of melt When passing through the spinnerets, jets of melt are formed which, depending on the temperature of the gaseous or liquid medium, solidify immediately or only after a certain time, such as a few minutes or a few seconds. Solidification does not have to take place suddenly, but can take place in a solidification process lasting minutes or seconds, during which the melt contained in the jets initially becomes viscous and then solid. In one embodiment, its surface has a sticky surface texture temporarily or during the entire solidification process.
  • the melt jets are deformed in such a way that intertwined, linear structures are formed. In one embodiment, this occurs when the melt jets pass from a gaseous medium into a liquid medium and are slowed down and intertwined as they pass through the interface. At the same time as they are intertwined, the melt jets come into contact with each other. In one embodiment, this occurs at a point in the solidification process when the melt jets still have a sticky surface texture, so that the solidifying melt jets stick together and thus the linear structures of the three-dimensional network structure are not only intertwined, but also are connected to one another by gluing. In this way, the three-dimensional network structure is kept in shape in a particularly stable manner.
  • the linear structures form the three-dimensional network structure in the form of a body during the solidification process, the cross-sectional area of which transverse to the direction of production corresponds to or is at least similar to the area on which the group of spinnerets is arranged. If the group of spinnerets forms a rectangle, for example, the three-dimensional network structure has the shape of a cuboid; if it forms a circle, the three-dimensional network structure has the shape of a cylinder.
  • this also means that in processes according to the prior art, the shape of the three-dimensional network structure is largely determined by the shape of the group of spinnerets, which massively impairs the flexibility of the product and the manufacturing process.
  • thermoforming for example, which leads to compaction of the material that is sometimes difficult or even uncontrollable, or by abrasive processes, which result in large amounts of waste and thus a waste of resources that is contrary to sustainability.
  • the intertwined linear structures form a body whose cross-section has a concave indentation and which can therefore be regarded as a concave surface.
  • a concave surface is understood to be a surface that includes at least two points whose connecting line lies entirely or partially outside the surface.
  • concave surfaces are surfaces that have an inward-facing indentation or, more commonly, a dent.
  • Concave cross-sections in three-dimensional network structures represent a clear approximation to the use of a three-dimensional network structure as a cushioning material, so that the effort for shaping after production and, if necessary, cutting to a desired Size is significantly reduced, simply because the amount of deformation required is reduced.
  • This problem of the prior art is solved by maintaining a standardized group of spinnerets, the group being of a size that is sufficient to produce all the required cross-sections.
  • the group can have a standard shape such as rectangular, square, circular, polygonal or oval.
  • the group is then covered with a precisely fitting plate that seals it tightly, the plate having an opening whose area corresponds to the desired cross-sectional area and which acts as a type of aperture during the extrusion of the melt, ensuring that linear structures in the desired geometry emerge from the group of spinnerets. Any number of different apertures for different cross-sectional geometries can be maintained for one and the same group of spinnerets.
  • the group of spinnerets may include spinnerets having different diameters.
  • the group of spinnerets may include both spinnerets that produce melt jets with a solid shape and spinnerets that produce melt jets with a tubular shape. Accordingly, solid and hollow melt jets may be produced with one and the same group of spinnerets.
  • all spinnerets that produce melt jets that are the same in terms of thickness and shape are located in a common region of the group of spinnerets.
  • all spinnerets that produce hollow melt jets of a diameter a can be located in a region of the group of spinnerets, while all spinnerets that generate massive melt jets with a diameter b are arranged in another area of the group.
  • This makes it possible to generate three-dimensional network structures that have areas that contain different linear structures or consist of different linear structures. In this way - together with a cross-section of the three-dimensional network structure that has a concave indentation - the properties of the three-dimensional network structure can be set much more precisely than is the case in the prior art.
  • the concave indentation does not have to be a completely or partially rounded indentation; rather, a completely angular shape is also possible.
  • the cross-sectional area can be a polygonal area with a concave bulge.
  • the cross-sectional area can be a concave kite. Concave pentagons, hexagons, heptagons or octagons or concave polygons with a larger number of corners are also possible.
  • Fig. 1 shows an arrangement of spinnerets 3 which contains a large number of individual spinnerets 1, whereby for reasons of clarity only individual spinnerets have been provided with a reference number.
  • the arrangement 3 is partially covered with a cover 2, the opening of which has a concave bulge 4.
  • Fig. 2 shows the products obtained with a combination of an arrangement of spinnerets 3 with an orifice 2 as in Fig. 1.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

Abstract

La présente invention concerne un procédé de production d'une structure de réseau tridimensionnel, comprenant les étapes suivantes : fournir un élastomère thermoplastique, faire fondre l'élastomère thermoplastique afin d'obtenir une masse fondue, extruder la masse fondue à travers un groupe de filières afin d'obtenir des jets de matière fondue, le groupe de filières étant distribué sur une zone de façon à former au moins trois rangées de filières disposées les unes sur les autres, et former et refroidir les jets de matière fondue afin d'obtenir des structures linéaires entrelacées. Les structures linéaires entrelacées forment un corps dont la section transversale forme un évidement concave.
PCT/EP2024/056841 2023-03-24 2024-03-14 Procédé de production d'une structure de réseau tridimensionnel Ceased WO2024200032A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202480020959.3A CN121511335A (zh) 2023-03-24 2024-03-14 制备三维网络结构的方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023107446.6 2023-03-24
DE102023107446.6A DE102023107446A1 (de) 2023-03-24 2023-03-24 Sitz III

Publications (1)

Publication Number Publication Date
WO2024200032A1 true WO2024200032A1 (fr) 2024-10-03

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Family Applications (1)

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PCT/EP2024/056841 Ceased WO2024200032A1 (fr) 2023-03-24 2024-03-14 Procédé de production d'une structure de réseau tridimensionnel

Country Status (3)

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CN (1) CN121511335A (fr)
DE (1) DE102023107446A1 (fr)
WO (1) WO2024200032A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6378150B1 (en) * 1999-02-25 2002-04-30 Nhk Spring Co., Ltd. Cushion member, method and apparatus for manufacturing the same
JP2013234419A (ja) * 2013-08-29 2013-11-21 Shiienji:Kk 立体網状構造体製造方法及び立体網状構造体製造装置
EP3064628A1 (fr) * 2013-10-29 2016-09-07 Toyobo Co., Ltd. Structure en réseau ayant une excellente durabilité contre une compression
EP3290557A1 (fr) * 2015-04-28 2018-03-07 Toyobo Co., Ltd. Structure de type filet

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6378150B1 (en) * 1999-02-25 2002-04-30 Nhk Spring Co., Ltd. Cushion member, method and apparatus for manufacturing the same
JP2013234419A (ja) * 2013-08-29 2013-11-21 Shiienji:Kk 立体網状構造体製造方法及び立体網状構造体製造装置
EP3064628A1 (fr) * 2013-10-29 2016-09-07 Toyobo Co., Ltd. Structure en réseau ayant une excellente durabilité contre une compression
EP3290557A1 (fr) * 2015-04-28 2018-03-07 Toyobo Co., Ltd. Structure de type filet

Also Published As

Publication number Publication date
DE102023107446A1 (de) 2024-09-26
CN121511335A (zh) 2026-02-10

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