CN104903066A - 包含发泡乳胶层的卧具产品、用于切割卧具产品的该发泡乳胶层的片材及其制造方法 - Google Patents

包含发泡乳胶层的卧具产品、用于切割卧具产品的该发泡乳胶层的片材及其制造方法 Download PDF

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CN104903066A
CN104903066A CN201380054908.4A CN201380054908A CN104903066A CN 104903066 A CN104903066 A CN 104903066A CN 201380054908 A CN201380054908 A CN 201380054908A CN 104903066 A CN104903066 A CN 104903066A
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bedding product
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CN104903066B (zh
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亨克·德梅斯
鲁本·德格里斯
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Latexco NV
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/003—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/34—Component parts, details or accessories; Auxiliary operations
    • B29C41/46—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G11/00—Finished upholstery not provided for in other classes
    • B68G11/04—Finished upholstery not provided for in other classes mainly composed of resilient materials, e.g. of foam rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G7/00—Making upholstery
    • B68G7/02—Making upholstery from waddings, fleeces, mats, or the like
    • B68G7/04—Making upholstery from waddings, fleeces, mats, or the like by conveyor-line methods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0861—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using radio frequency
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
    • B29C35/049—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using steam or damp
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2007/00—Use of natural rubber as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0058—Liquid or visquous
    • B29K2105/0064—Latex, emulsion or dispersion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/751—Mattresses, cushions

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

一种生产至少包含发泡乳胶层的卧具产品的方法，所述方法包括下述步骤：将液体乳胶泡沫倾倒在传送带上；在硫化站硫化所述液体乳胶泡沫，以获得硫化的乳胶泡沫片材；将所述硫化的乳胶泡沫片材切割成期望的长度和/或宽度，其特征在于，通过使用频率范围在1和50MHz之间的电磁波来至少部分硫化所述液体乳胶泡沫。

Description

包含发泡乳胶层的卧具产品、用于切割卧具产品的该发泡乳胶层的片材及其制造方法
技术领域
本发明涉及卧具产品，特别是垫(mattress)和垫罩(topper)，其包含发泡乳胶层。
背景技术
一般通过蒸汽硫化制造由乳胶泡沫形成的卧具产品，比如垫罩和垫。已知厚度最大为6cm的垫罩是在连续的硫化工艺中生产的，其中，将液体乳胶泡沫倾倒在环形带或载体(carrier)上且随后穿过蒸汽炉。大于6cm厚度，连续的硫化是不可能的，这是因为传送带上没有铝销钉(aluminium pins)而导致热量不能足够快速地导入乳胶材料的芯部。
此外，当通过蒸汽硫化制造乳胶泡沫层时，观察到泡沫孔径和泡沫密度在整个层厚上不同，其对精调乳胶泡沫层的特性、比如压缩永久变形和压陷载荷挠度值是不期望的。
为了解决上述缺点，EP 1,904,570公开了一种复合泡沫，其包含顶层乳胶泡沫和选自乳胶泡沫或另一泡沫的第二层泡沫。
CA 2,007,548公开了一种以分批工艺制造厚度高达15cm厚的乳胶泡沫床垫的方法，其中，将液体乳胶泡沫装入模具，随后使该模具进入频率为2,45GHz(实施例1)和功率为1,2kW/kg装入乳胶的微波场。
因此，仍对制造如下乳胶层的连续方法存在需求，所述乳胶层具有均匀的孔径、均匀的泡沫密度、低压缩永久变形和低压陷载荷挠度值，并且可以约1cm至24cm或更大的不同厚度生产。
发明内容
定义：
已知卧具或座具产品中使用的垫罩。这些垫罩延伸至特定卧具或座具产品的整个宽度和长度。如果特定卧具或座具产品是垫，则典型地将一个这样的垫罩放置于垫芯的一侧，尤其是垫的顶侧，该侧是人打算在上面躺卧的一侧，并且任选地将第二垫罩放置于垫芯的相对侧，从而实际上“夹持”垫芯。然后，典型地用装饰用织物蒙皮覆盖该组合体。
本文的“乳胶”被定义为聚合物颗粒在连续相中的分散体，该聚合物颗粒的优选尺寸范围是10至1000nm。乳胶泡沫材料可由天然橡胶乳胶制备；或由一种或多种合成乳胶制备，比如聚丁二烯/苯乙烯乳胶、聚丁二烯/丙烯腈乳胶、聚氯丁烯乳胶等；或由天然橡胶乳胶和一种或多种这样的合成乳胶的混合物制备。乳胶泡沫包括常规的乳胶泡沫以及粘弹性乳胶泡沫。
合适的水性乳胶的固体物含量是20至75重量％。优选的乳胶的固体物含量是50至75重量％。
合适的聚合物乳胶都是分散体，其中，固体分散在液相中，然后该相与另外的液相形成乳液。其例子是由二烯烃或烯烃不饱和单体及其共聚物组成的聚合物的乳胶，比如聚苯乙烯-丁二烯乳胶、聚丁二烯乳胶、聚异戊二烯乳胶、天然橡胶乳胶、丙烯腈-丁二烯乳胶、聚氯丁烯乳胶、聚二氯代丁二烯乳胶、氯丁二烯和二氯代丁二烯的共聚物的乳胶、聚异戊二烯乳胶、氯化的聚异戊二烯的乳胶或(甲基)丙烯酸酯乳胶。但是，聚氨基甲酸酯的分散体或其它借助乳化剂或分散剂使聚合物分散于水中的分散体也是合适的。
优选的乳胶包括下述物质的乳胶：天然橡胶，苯乙烯-丁二烯橡胶(SBR)，具有低苯乙烯含量(至多27％)的SBR，丁腈橡胶(NBR)，异戊二烯橡胶，氯丁橡胶，聚丁二烯橡胶，异丁烯-异戊二烯橡胶(IIR)，丙烯腈、甲基丙烯腈、丙烯酸酯、甲基丙烯酸酯、乙烯基吡啶与丁二烯或2-氯-1,3-丁二烯和氯化的聚乙烯的共聚物，或任何这些物质的混合物。
非常优选的是下述物质的乳胶：天然橡胶、苯乙烯-丁二烯橡胶、丁腈橡胶、聚丁二烯橡胶、异戊二烯橡胶或包含丙烯酸酯的共聚物。
包含聚合物的乳胶，比如SBR(苯乙烯-丁二烯橡胶)或NBR(丙烯腈-丁二烯橡胶)、聚氯丁烯、聚丁二烯、聚异戊二烯、天然橡胶乳胶、聚氯乙烯、(甲基)丙烯酸酯分散体或其共聚物的分散体，通常可在市场上购得，其固体物浓度大于50％。例如通过提高低浓度聚合物乳胶的浓度能够实现这些浓度。例如，将天然橡胶乳胶的浓度从30％提高至60％固体物。
其他优选的乳胶是合成乳胶和天然乳胶的组合物。天然乳胶与合成乳胶的优选比例可在1:4至6:4之间变化。天然乳胶与合成乳胶的非常优选的比例是大于1:1。
应根据所使用的乳胶优化比例。
根据本发明的方法可使用如下装置来实施，所述装置包括环形带、用于将液体乳胶泡沫倾倒在所述带上的机构、沿所述带设置的硫化站，所述硫化站包括电磁波的频率在1和50MHz之间的电磁波发生器。
任选地，装置可包括第二硫化站，所述第二硫化站沿所述带设置且位于所述第一硫化站的下游，第二硫化站被蒸汽加热。
根据本发明的方法用于生产卧具产品，所述卧具产品至少包含发泡乳胶层，所述方法包括下述步骤：
‐将液体乳胶泡沫倾倒在传送带上；
‐在硫化站硫化所述液体乳胶泡沫，以获得硫化的乳胶泡沫片材；
‐将所述硫化的乳胶泡沫片材切割成期望的长度和/或宽度，
其中，通过使用频率范围在1和50MHz之间的电磁波来至少部分硫化所述液体乳胶泡沫。
根据第一方法，仅仅通过使用电磁波将液体乳胶泡沫硫化至期望的水平，优选地传送带移动穿过一个单独的硫化站。
在该第一方法中，通过在硫化站将所使用的电磁波发生器的比功率选择在0.5和5kW/kg乳胶之间，能够在数分钟的时间内获得硫化。
可选地，可利用电磁波实施硫化至某一程度，其中泡沫层在尺寸上稳定；随后在第二硫化站完成硫化，其中例如蒸汽用于加热乳胶泡沫。
将电磁波用于至少部分硫化乳胶泡沫是有利的，能够硫化厚度为1cm至大于6cm，优选地甚至大于8cm和最优选地高达甚至24cm的泡沫层，在下述方面有良好表现：均匀的孔径、均匀的泡沫密度、低压缩永久变形(小于10％)和低压陷负荷挠度值。根据本发明的方法可实现低至40kg/m3的泡沫密度。
根据可选的方法，可将液体乳胶层倾倒于设置在环形传送带上的预制的泡沫层上，所述预制的泡沫层由选自包含下述物质的组中的材料制备：聚氨基甲酸酯、聚烯烃、聚苯乙烯、粘弹性乳胶、尺寸上稳定胶化但未完全硫化的乳胶和或其混合物。
在第二层是胶化但未完全硫化的乳胶层的情况下，可在用于硫化倾倒的液体乳胶泡沫层的硫化站获得第二层的硫化。
利用根据本发明的方法的大量试验显示，相比仅仅用蒸汽硫化来硫化的乳胶泡沫层，乳胶泡沫层的压缩永久变形可获得50％改善(ISO1856)。与通过单独蒸汽硫化获得的乳胶泡沫层相比，通过根据本发明的方法获得的乳胶泡沫层的其他优点包括：改善的对硬度损失的抗性，超过60000个循环(ISO1957)；改善的抗拉强度(ISO1798)；从对于相同的硬度可实现更低的泡沫密度的角度，密度和硬度之间更低的相关性；改善的温度调节(更好的热吸收使得改善的舒适性感知和更快的调整泡沫乳胶至躺在泡沫上的人的体温)；和改善的水吸收(多达10％更好的水吸收，而不影响解吸率)。
最后，已经发现通过频率范围在1和50MHz之间的电磁波在硫化液体乳胶泡沫期间在所述乳胶泡沫层上施加印记，将图案设计在最终泡沫层中，能够容易使乳胶层的外表面个性化，例如在乳胶泡沫层的顶面提供图案化(profiled)标识。
实施例
实施例1：
根据已知的配方制备天然乳胶泡沫并将其倾倒在环形带上，该环形带的两侧边缘高度为26cm，沿着该环形带设置有硫化站，其用预设为2.7MHz的电磁波发生器供能，并且硫化站的比功率为2kW/kg乳胶。硫化站的长度为8m，并且环形带设置为以0.4m/分钟的速度移动。
在硫化站的出口，硫化的乳胶泡沫片材的厚度为24cm并将其切割成1m乘2m的垫罩。对数个垫罩进行分析，显示低压缩永久变形和均匀的泡沫密度(数个垫罩的重量非常类似)。测量压缩永久变形：通过将床垫罩在70℃下压缩至其50％初始厚度24小时，随后释放压力，0.5小时后测量厚度。将压缩永久变形定义为压缩之后的厚度的损失，以％表达。所有结果的高度损失均在5和6％之间。

Claims (13)

1.一种用于生产至少包含发泡乳胶层的卧具产品的方法，所述方法包括下述步骤：
‐将液体乳胶泡沫倾倒在传送带上；
‐在硫化站硫化所述液体乳胶泡沫，以获得硫化的乳胶泡沫片材；
‐将所述硫化的乳胶泡沫片材切割成期望的长度和/或宽度，
其特征在于，通过使用频率范围在1和50MHz之间的电磁波来至少部分硫化所述液体乳胶泡沫。
2.根据权利要求1所述的方法，其中，依次通过电磁波和通过蒸汽来实施硫化乳胶泡沫。
3.据权利要求1所述的方法，其中，仅仅通过电磁波来实施硫化，其中，在硫化站将所使用的电磁波发生器的比功率选择在0.5和5kW/kg乳胶之间。
4.根据权利要求1所述的方法，其中，将所述液体乳胶泡沫倾倒在载体上至厚度为1cm或更大，优选为6cm或更大，最优选为8cm或更大。
5.根据权利要求1所述的方法，其中，将所述液体乳胶泡沫倾倒在材料的泡沫层上，所述材料选自包含如下物质的组：聚氨基甲酸酯、聚烯烃、聚苯乙烯、粘弹性乳胶、胶化但未完全硫化的乳胶和或其混合物。
6.一种硫化的乳胶泡沫片材，其用于切割数个卧具产品，所述硫化的乳胶泡沫片材的厚度为6cm或更大，优选为8cm或更大。
7.一种包含局部图案化表面的硫化的乳胶泡沫片材。
8.一种卧具产品，其至少包含发泡乳胶层，将所述层在70℃下压缩至其50％初始厚度24小时后，所述层的压缩永久变形小于10％，优选为小于6％。
9.根据权利要求8所述的卧具产品，其中，所述发泡乳胶层的厚度在1和24cm之间，优选厚度为6cm或更大，最优选厚度为7cm或更大。
10.根据权利要求9所述的卧具产品，其中，所述发泡乳胶层的密度小于60kg/m3。
11.根据权利要求9所述的卧具产品，其是垫或垫罩。
12.一种用于连续硫化乳胶泡沫的装置，所述装置包括环形带、用于将液体乳胶泡沫倾倒在所述带上的机构、沿所述带设置的硫化站，所述硫化站包括电磁波的波长在1和50MHz之间的电磁波发生器。
13.根据权利要求12所述的装置，其包括第二硫化站，所述第二硫化站沿所述带设置且位于所述第一硫化站的下游，所述第二硫化站被蒸汽加热。
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