"PROCESS FOR OBTAINING BRACKET FOR COVER AND OBTAINEDPRODUCT".

The current invention patent application refers to a "PROCESS FOR OBTAINING BRACKET FOR COVER AND OBTAINED PRODUCT", regarding an obtaining process of a great efficiency cover bracket. That is accomplished by using mixed and interlaced fibers composed of natural and synthetic fibers from different sources and varying the types of fibers and their respective denier titles, producing a set of high resistance cover bracket and resilience such as spring effect with great porosity which allows ventilation and free from odour and of variable density, according to the application need, the materials used can be virgin or eco-reverse.

The professionals who operate in the areas of seat manufacturing for automobiles, matresses, upholstered furnitures, chairs, thin matresses and alikes, know the difficulty to obtain a shawl with porosity whose properties enable a perfect air circulation between the several layers which compose the set seat/seat back, which is confortable and at the same time resistant and anatomic, the brackets used for this purpose are made of injected polyurethane which do not provide the desired comfort in terms of porosity, ventilation and thermo comfort.

Thus, the "PROCESS FOR OBTAINING THE BRACKET FOR COVER AND OBTAINED PRODUCT", is the aim of the current invention and it's based in the obtaining of several densities through a single modeling process, the effect takes place by the use of natural fibers associated to synthetic fibers mixed and arranged in layers; during the moulding process there is the transformation of layers in different densities and larger than the ones initially put into the process. This set of materials

is put into the mould which will shape the product, producing the layers of several densities in the following way: the mould used for the product conformation can be of metal or resin, it's made in order to allow the air passage throught its walls, allowing a flow from one side to another. The air flow can be hot or cold, when hot, the flow makes the synthetic fibers to melt the natural ones connecting the fibers points which will provide the effect of a web which when put into thin layers produces a spring effect.

After melting and when the hot air flow input has been interrupted, the cold air flow starts which causes the fibers cooling and consequently the hardening of thermoplastic synthetic fibers.

According to the characteristics one whishes to obtain, the layer heating system can be used through a process where the effects discribed above are provoked before introducing the shawl into the mould, this process is characterized by heating the fibers through a shawl heating device and only afterwards it is introduced into the mould to be shaped.

In order to obtain the process according to the phases described different production processes can be used, depending on the volume and characteristics, such as: hydraulic, air or mechanic pressing system, these processes can be automated.

The raw material used in the process consists of fibers, such as: cotton, coming from processors or from industrial residues or from natural fibers, is from nenewable source and recyclable material; polyester as fibers coming from PET extrusion, from clothe making residues and industrial residues; and also recycled materials with PET bottles; textile wastes coming from indusrial leftovers; jute, mallow, cizal or coconut (such as bag residues used to transport cereals); and any synthetic fiber

from industrial leftovers. The preparation of these fibers should comprise the definition of the mixture composition, the same ones in pre-defined percentage are open and further on mixed through a mechanical process. The mixture is composed of natural and synthetic fibers, leftovers of the moulding process of the shawl itself and burrs from the shawl finishing processes, thus the leftovers from the product process are incorporated again into the fiber mixture preparation process.

The shawl formation is accomplished through the mixture of natural and synthetic fibers in defined percentages, being of already pre- cured material for further applications in moulding of finished products. This formation is carried out in machines which make a mechanical friction and distribute the fibers through air, forming a thick layer which can have controled and varied volume and weight, afterwards the oven heating with circulating air is carried out, the temperature applied to the shawl in this stage of the process is very important for the final product definition, as well as the low density, since every layer has its physical characteristics pre-defined in this stage.

The process can still be carried out where the natural and synthetic fibers undergo the mechanical opening process and are sent to a storage silo, from where they are forwarded to the fiber polimerization phase where the synthetic fiber, through heat, join the natural fibers, forming shawls which are overlayed in several layers and forwarded to the press where the product is shaped through the mould, and the shawl can also be cut in blanks to be used in matresses, thin matresses, cushions etc., and then it is forwarded to the heat fiber melting, the perfect way of blank preparation is important for the final product performance. The arrangement of layers and the correct placement of amount of natural and

synthetic fibers is important to create in the moulding process the counter- pressure effect on the product external layers, modifying their density.

In order to obtain a perfect compression of what has been developed, illustraing drawings are enclosed to which numeral references are made together with a detailed description as follows, where:

Figure 1 shows a mould schematic view provided with hot and cold air input.

Figure 2 shows a schematic view of the shawl heating device.

Figure 3 shows a cold mould schematic view. Figure 4 shows a schematic view of the alternate process.

"PROCESS FOR OBTAINING BRACKET FOR COVER AND OBTAINED PRODUCT", is constituted of the obtaining of several densities through a single moulding process, the effect is obtained with the use of natural fibers associated to synthetic fibers mixed and arranged in layers (1), during the moulding process there is the transformation of layers in different densities and larger than the ones initially put into the process. This set of materiais is put into the mould (2) which will shape the product, producing the layers of several densities in the following way: the mould is used for the product conformation and can be of metal or resin, it is constituted so as to allow the air passage through its walls, allowing a flow from one side to another.

The air flow can be hot (3) or cold (4), when hot the flow makes the synthetic fibers to melt the natural ones connecting fiber points which will give a web effect which when put into a thick layer produces a spring effect.

After melting and when the hot air flow has been interrupted, the cold air flow input starts which causes the cooling of fibers and

consequently the hardening of thermoplastic synthetic fibers.

According to the characteristics one wishes to obtain, the shawl layer heating system can be used through a process where the effects described above are provoked before introducing the shawl into the mould, this process is characterized by heating the fibers through a shawl heating device (5) and only afterwards it is introduced into the cold mould (6) to be shaped.

In order to obtain the process according to the phases described different production processes can be used, depending on the volume and characteristics, such as: hydraulic, air or mechanical pressing system, these processos can be automated.

The raw material used in the process consists of fibers, such as: cotton, from processors or from industrial residues or from natural fibers, is from a renewable source and recyclable material; the polyester as fibers from PET extrusion, from residues from clothe making, industrial residues and also recycled materials such as PET bottles; textile wastes from industrial leftovers; jute, mallow, cizal or coconut (such as bag residues used to transport cereals); and any synthetic fiber from industrial leftovers. The preparation of these fibers should comprise the definition of mixture composition, the same ones in pre-defined percentage are opened and further mixed through a mechanical process. The mixture is composed of natural and synthetic fibers, leftovers from moulding process of the shawl itself and burrs from the shawl finishing processes, thus the leftovers from the product process are incorporated again into the fiber mixture preparation process.

The formation of shawl is carried out through the mixture of natural and synthetic fibers in defined percentages, being of already pre-

cured material for further applications in finished products moulding. This formation is carried out in machines which make a mechanical friction and distribute the fibers through air, forming a thick layer which can have controlled and variable volume and weight, and further on the heating is carried out in an oven with cirdulating air, the temperature applied to the shawl in this stage of the process is very important for the final product definition, as well as the low density, since each layer has its physical characteristics pre-defined in this phase.

The process can still be carried out where the natural and synthetic fibers undergo the mechanical opening process (7) and sent to a storage silo (8), from where they are forwarded to a fiber polimerization phase (9), where the synthetic fiber, through heat, join the natural fibers, forming shawls which are overlayed in several layers and forwarded to the press (10) where the product is shaped through the mould, and the shawl can also be cut in blanks to be used in matresses, thin matresses, cushions etc., and then it is forwarded to the heat for fiber melting (11), the perfect way to prepare the blank is important for the final product performance. The arrangement of layers and the correct placement of the amount of natural and synthetic fibers is important to create in the moulding process, the counter-pressure effect on the product's external layers modifying their density.

Based on what has been described and illustrated, we can see that the "PROCESS FOR OBTAINING BRACKET FOR COVER AND OBTAINED PRODUCT" has great advantages in relation to processes and products existing in the market, since the process now claimed provides a better mechanical resistance against the deformation, allows the passage of air between its pores consequently avoiding the accumulation of moisture

mainly the one coming from perspiration, holds a better mechanical structure, has a spring effect which makes it anatomic, comfortable and relaxing, being the product even ecologically correct, since recycled material are used in its manufacturing, and it can be recyclable, be in the leftovers of materials after the cut or even after being used, thus, becoming one of the few products which after being used can give rise to the same product, what allows a reduction to the final cost.

It should be pointed out yet that the hot air can be produced through the device inserted into the mould itself with the exchange of heat by thermo oil heating system circulating through tube and coil or yet it can be heated through air displacing through electrical resistances. Since it's innovating and until then not understood in the technical state it's perfect fit into the criteria which defines the invention patent. Its claims are the following ones.