Bayer Aktiengesellschaft

Robert Volland

Hans-Albrecht Freitag

Reinhard Samaritter

Johannes Seesing

Herbert Bergmann

Winfried Schoberth

The present invention is directed to an upholstered seat consisting of an in situ foam core based on a cold foam formulation and an air-permeable covering and to a process for integrally producing an upholstered seat with improved standards of comfort by back foaming a covering material in a mold, characterized in that, in a split mold of which the dividing plane preferably extends in the vicinity of the actual seat surface, a sealed foam-impermeable covering material is applied to the internal contour of the mold and that part of the covering material which forms the actual seat surface is clamped in the dividing plane of the mold, the entire mold cavity is filled with foam by metering the foam in correspondingly large quantities, after which the sealing layer around the fully reacted foam core, where it consists of an air-impermeable material, is destroyed by a mechanical treatment, such as needle punching, flexing, compression, knocking, or by solvents to at least such an extent that it becomes permeable to air.

Upholstered seat having an air-permeable covering and a cold foam core

A deformable and durable polyurethane foam molding is made from the reaction product of a polyether polyol component and a polyisocyanate component. The polyether polyol component is a polyether having at least two hydroxyl groups, a molecular weight of from 400 to 10,000 and at least 10 wt. % hydroxyl groups which are primary hydroxyl groups. The polyisocyanate component is a mixture of from 60-90 wt. % 4,4'-diphenyl methane diisocyanate and from 3-30 wt. % 2,4'-diphenyl methane diisocyanate. Such reaction mixture is prepared in each of at least two mixing heads. The index of reaction mixture is different from that in the other mixing head. The mixture is then introduced into associated zones of a mold cavity where the mixture is allowed to foam. The molding is subsequently removed from the mold cavity. These polyurethane foam moldings are particularly useful in making seat cushions.

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Leverkusen, Germany

Robert Volland