Padding element for seats and method of manufacturing the same

Abstract

Padding element for seats such as sofas, armchairs, chairs and armrests, wherein such seats have a support structure, or similar support structure for the human body or parts thereof, such as rest or anti-fatigue mats, anti-decubitus mattresses, shower mats, anti-impact mats, wherein the padding element is provided with a support surface for a user, wherein the padding element includes one film or covering, one gel layer adhering to part of the film or covering and one compact elastomeric layer having a surface for contact with the gel layer and with part of the film or covering and one surface for contact with the seat and/or with the support structure of the seat, wherein the compact elastomeric layer adheres to the gel layer and the film or covering; method for obtaining such padding element.

What is claimed is: 
     
         1 . A method for making a padding element for seats such as sofas, armchairs, seats, armrests, wherein said seats have a support structure, and similar support structures for the human body or parts thereof, such as rest or anti-fatigue mats, anti-decubitus mattresses, shower mats, anti-impact mats, wherein said padding element is equipped with a support surface for a user, comprising the following steps of:
 providing a mould having a surface,   providing a film or covering, wherein said providing step comprises inserting or spraying said film or covering in said mould,   pouring a gel on at least part of said film or covering,   waiting a time interval to make said gel cross link, in order to obtain a gel layer and to make said gel layer adhere to at least part of said film or covering,   pouring an elastomer,   waiting a time interval to make said elastomer set in order to obtain a compact elastomeric layer and to make said compact elastomeric layer adhere to said gel layer and to at least part of said film or covering.   
     
     
         2 . The method according to  claim 1 , wherein said step of providing a film or covering comprises:
 a step of vacuum thermoforming said film or covering and/or   a step of providing a film of polyurethane or a fabric, or a waterproofed fabric, or a high-elasticity fabric, or a waterproofed high-elasticity fabric, or a polyester-elastane fabric, or a waterproofed polyester-elastane fabric, or a fabric spread-coated with a waterproof material, or a fabric spread-coated with a polyurethane material, or a polyurethane paint, etc., wherein said film or covering corresponds to said support surface for a user and to said surface of said mould, and/or wherein said film or covering is at least partially transparent or covering or it has a “watermark” transparency, or other suitable finishes, and/or   a step of providing a surface finishing or surface grain, an ornamental finishing, or a shiny or glossy or opaque finishing, and/or colouring said film or covering.   
     
     
         3 . The method according to  claim 1 , wherein said step of pouring a gel comprises:
 a step of pouring a polyurethane gel, and/or   a step of pouring a gel having a Shore 00 hardness D′ equal to zero or a Shore 000 hardness D′ lower than 60.   
     
     
         4 . The method according to  claim 1 , wherein said step of pouring an elastomer comprises:
 a step of pouring a polyurethane elastomer, and/or   a step of pouring an elastomer having a hardness D″ that is greater than the hardness D′ of the gel, and/or   a step of pouring an elastomer having a Shore 00 hardness D″ of more than 10.   
     
     
         5 . The method according to  claim 1 , comprising a step of coating or spraying or painting said compact elastomeric layer, so as to obtain a coating layer for closing the padding element, wherein said coating layer comprises a polyurethane coating or a polyurethane paint. 
     
     
         6 . The method according to  claim 1 , comprising the following steps:
 trimming said padding element or said film or covering or said coating layer, and/or   inserting and/or positioning at least one ornamental element, an ornamental insert, a logo, a label, a writing, a colour, an advertising element or other, of the two and/or three-dimensional type, between said gel layer and said film or covering and/or between said gel layer and said compact elastomeric layer, and/or   positioning, or inserting, or spraying or applying an adhesion primer between said film or covering and said compact elastomeric layer or between said film or covering and said gel layer or between said gel layer and said compact elastomeric layer, and/or   applying glues, instant glues, bi-adhesives, or releasable adhesion means, or locking means, of the foxed or releasable type, or combinations thereof, onto said compact elastomeric layer and/or onto the coating layer and/or onto the support structure and applying said padding element onto said support structure.   
     
     
         7 . The method according  claim 1 , wherein said step of providing a mould having a surface comprises providing at least one distribution of projections or ridges and a distribution of valleys on said surface, wherein said valleys are located between said projections or ridges, and/or a distribution of crests on said valleys.