NOWO: Mold system for fiber seats and cushions

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NOWO: Mold system for fiber seats and cushions

Schmidt, J.A. / Vivanco, S.

A system for molding and thermalbonding polyester fiber into three-dimensional shapes in a one-step process has been developed and patented by Nowo Development Oy of Turku, Finland. The fiber molding process uses the same successful vacuum filling technique as found in Nowo Development's high-capacity NOWO VAC pillow filling machines. Instead of filling a pillow or cushion, it is also possible to fill an air-permeable mold with the vacuum filling principle. The mold is filled with the exact amount of fiber. There is no cutting of the block nor any raw material waste (waste from cut blocks can be as high as 25 %). The filling and bonding occur in the same mold. The intermediate step of first producing a fiber block is completely eliminated. Different portions of the mold can be filled with different amounts of fiber thus achieving different densities in the same pad. Nowo Development has conducted trials using polyester fiber in the form of both staple and clusters, polyester fiber made from reclaimed PET bottle waste, and blends of chopped foam and polyester fiber. The actual selection of the raw material, of course, depends on the requirements of the end product. Fiber densities have been achieved ranging from 1.5 lbs/ft(exp3) to over 5 lbs/ft(exp3). It has been found that the performance of the molded seat pads is primarily a function of the fiber characteristics, particularly the binder fiber, and not so much a function of the forming technique.