Patent ID: 6033501
Filing Date: 2000-03-07
Classification: B29C,B29K,B68G,D04H

Abstract:
A process for preparing a cushion structure using fiber aggregate, comprising(a) preparing a fiber aggregate by mixing and dispersing synthetic binder fibers into synthetic matrix fibers, wherein the binder fibers are conjugated fibers composed of a binder component and a non-binder component, wherein the binder component has a melting point lower than that of the non-binder component and the matrix fibers;(b) loosening an amount of the fiber aggregate with a loosening device;(c) forming a mold cavity having a larger shape than that of a molded cushion structure, wherein the mold cavity is defined by a gas-permeable top mold movable upward and downward, a gas-permeable bottom mold movable upward and downward, and a fixed mold frame;(d) filling the mold cavity with the fiber aggregate by directly transporting the loosened fiber from the loosening device to the mold cavity with a flow of air;(e) compressing the fiber aggregate filled in the mold cavity by the gas-permeable top and/or bottom mold until the compressed fiber aggregate attains a desired bulk density;(f) passing heated air through the compressed fiber aggregate via the gas-permeable top and bottom mold to fuse the binder component of the binder fibers so that the matrix fibers are bound with the molten binder fibers at their crossing points to form a heated fiber aggregate;(g) cooling the heated fiber aggregate by passing a cooling air so as to unite the matrix fibers with solidified binder fibers;(h) removing a molded cushion structure from the mold cavity by a downward movement of the bottom mold.