CN107513149A - 一种涤纶发泡床垫的制备方法 - Google Patents

一种涤纶发泡床垫的制备方法 Download PDF

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CN107513149A
CN107513149A CN201710773771.8A CN201710773771A CN107513149A CN 107513149 A CN107513149 A CN 107513149A CN 201710773771 A CN201710773771 A CN 201710773771A CN 107513149 A CN107513149 A CN 107513149A
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parts
terylene
calcium carbonate
foaming
mattress
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张俊武
姚仟锋
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Suzhou True Mattress Co Ltd
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Abstract

本申请公开了一种涤纶发泡床垫的制备方法，称取涤纶、PAPI、有机锡、一氯三氟甲烷、乙二醇、三乙醇胺、N‑乙基吗啉、高纯水、碳酸钙、AC发泡剂、甲酸、氧化锌、轻质碳酸钙、单脂肪酸甘油酯和丁醇；制备方法简单，回弹率99.5‑99.9%，成本低廉，可操作性强，压缩强度240‑280MPa；伸长率230‑250%，产品柔软，耐用程度高，不易塌陷变形，承托性能高；20%压缩强度16‑20MPa，抗菌防霉，工艺稳定性好，使用寿命长，不易虫蛀，阻燃效果好；相对密度低，拉伸强度160‑240MPa，粘结强度220‑280MPa，原料来源广泛，可以广泛生产并不断代替现有材料。

Description

一种涤纶发泡床垫的制备方法
技术领域
本申请属于床垫材料领域，尤其涉及一种涤纶发泡床垫的制备方法。
背景技术
床垫是为了保证消费者获得健康而又舒适的睡眠而使用的一种介于人体和床之间的物品，床垫材质繁多，不同材料制作的床垫能给人带来不同的睡眠效果。
1881年，美国德克萨斯州休斯敦郊外一个小镇，一位名叫Daniel Haynes的扎棉机工匠开始了一种棉塞床垫的生产。
1900年，美.西蒙斯，袋装弹簧床垫，二十世纪初，丹洛甫，橡胶发泡软垫，1932年，意大利，马里奥·贝里纪，以聚氨基甲酸泡沫用于垫子，第二次世界大战时，德国，路易斯·考拉尼，还设计了一种椭圆形床垫，并按人体躺在床垫上不同部位的体压，分成软、中、硬的三个部分，使人体骨骼保持最佳状态，国外还出现了一种“主动回应弹簧系统”，改变了以往惯用的弹簧构造形式，使人更加舒适，弹性持久不变；有些弹簧床垫还与聚酯发泡结合，软硬度可随人选择。
一张好床垫不但能使人拥有舒适的睡眠，而且对身体也大有好处。一般而言，长期性错误的睡姿，尤其是使用不良的床垫，会使脊椎骨节产生位移，因而刺激脊椎内部神经，导致神经所控制的器官逐渐失去正常功能。床垫太硬不但会压迫人体背部神经，也会影响血液正常循环，时间长了还会造成腰酸背痛及坐骨神经酸痛。
3D床垫由双面网布和中间连接丝组成，双面网布决定了传统材料无可比拟的透气性，中间连接丝为0.18mm粗的涤纶单丝，保证了3D网布的回弹性。
用8-10层的3D材料叠加至厚度16cm.然后外套用三明治网布和3D材料绗缝加拉链或用棉天鹅绒绗缝套
3D床垫的主材就是由一个个3D材料叠加起来，所以3D床垫的分类基本上是由3D材料的分类来决定的。
除了工作、生活、身体、心理等方面的原因外，拥有“卫生、舒适、美观、耐用”的健康寝具是获得高质量睡眠的关键所在。
随着物质文明和技术工艺的不断进步，现代人们使用的床垫种类逐渐趋向多元化，主要有：弹簧床垫、棕榈床垫、乳胶床垫、水床垫、气床垫、磁床垫等，在这些床垫中，弹簧床垫占较大的比重。
发明内容
解决的技术问题：
本申请针对上述技术问题，提供一种涤纶发泡床垫的制备方法，解决现有涤纶发泡床垫质地硬、耐用程度差、易塌陷变形、承托性能差、保养不好易虫蛀或发霉等技术问题。
技术方案：
一种涤纶发泡床垫的制备方法，包括如下步骤：
第一步：按照重量份数配比称取涤纶100份、PAPI15-35份、有机锡1-5份、一氯三氟甲烷7.5-9.5份、乙二醇3-7份、三乙醇胺1.5-5.5份、N-乙基吗啉0.4-0.8份、高纯水5-25份、碳酸钙13-17份、AC发泡剂0.5-4.5份、甲酸0.05-0.45份、氧化锌3-7份、轻质碳酸钙10-30份、单脂肪酸甘油酯0.3-0.7份和丁醇1-5份；
第二步：将涤纶、PAPI、有机锡和一氯三氟甲烷投入球磨机中球磨10-30min粉碎，再加入乙二醇、三乙醇胺、N-乙基吗啉和高纯水，在反应釜中升温至30-50℃，转速为3000-3200r/min速度下，搅拌3-7s，再加入碳酸钙、AC发泡剂和甲酸，升温至60-100℃，混合10-20s；
第三步：加入剩余原料，调节搅拌速度至4500-5500 r/min，混合1-5min，最后将混合均匀的产物装入模具中，升温至190-240℃，压力控制到0.6-0.9MPa，加热8-12min即得。
作为本发明的一种优选技术方案：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI15份、有机锡1份、一氯三氟甲烷7.5份、乙二醇3份、三乙醇胺1.5份、N-乙基吗啉0.4份、高纯水5份、碳酸钙13份、AC发泡剂0.5份、甲酸0.05份、氧化锌3份、轻质碳酸钙10份、单脂肪酸甘油酯0.3份和丁醇1份。
作为本发明的一种优选技术方案：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI35份、有机锡5份、一氯三氟甲烷9.5份、乙二醇7份、三乙醇胺5.5份、N-乙基吗啉0.8份、高纯水25份、碳酸钙17份、AC发泡剂4.5份、甲酸0.45份、氧化锌7份、轻质碳酸钙30份、单脂肪酸甘油酯0.7份和丁醇5份。
作为本发明的一种优选技术方案：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI15份、有机锡5份、一氯三氟甲烷9.5份、乙二醇3份、三乙醇胺1.5份、N-乙基吗啉0.4份、高纯水25份、碳酸钙13份、AC发泡剂4.5份、甲酸0.45份、氧化锌7份、轻质碳酸钙10份、单脂肪酸甘油酯0.7份和丁醇5份。
作为本发明的一种优选技术方案：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI25份、有机锡3份、一氯三氟甲烷8.5份、乙二醇5份、三乙醇胺3.5份、N-乙基吗啉0.6份、高纯水15份、碳酸钙15份、AC发泡剂2.5份、甲酸0.25份、氧化锌5份、轻质碳酸钙20份、单脂肪酸甘油酯0.5份和丁醇3份。
有益效果：
本发明所述一种涤纶发泡床垫的制备方法采用以上技术方案与现有技术相比，具有以下技术效果：1、制备方法简单，回弹率99.5-99.9%，成本低廉，可操作性强，压缩强度240-280MPa；2、伸长率230-250%，产品柔软，耐用程度高，不易塌陷变形，承托性能高；3、20%压缩强度16-20MPa，抗菌防霉，工艺稳定性好，使用寿命长，不易虫蛀，阻燃效果好；4、相对密度低，拉伸强度160-240MPa，粘结强度220-280MPa，原料来源广泛，可以广泛生产并不断代替现有材料。
具体实施方式
实施例1:
按照重量份数配比称取涤纶100份、PAPI15份、有机锡1份、一氯三氟甲烷7.5份、乙二醇3份、三乙醇胺1.5份、N-乙基吗啉0.4份、高纯水5份、碳酸钙13份、AC发泡剂0.5份、甲酸0.05份、氧化锌3份、轻质碳酸钙10份、单脂肪酸甘油酯0.3份和丁醇1份。
将涤纶、PAPI、有机锡和一氯三氟甲烷投入球磨机中球磨10min粉碎，再加入乙二醇、三乙醇胺、N-乙基吗啉和高纯水，在反应釜中升温至30℃，转速为3000/min速度下，搅拌3s，再加入碳酸钙、AC发泡剂和甲酸，升温至60℃，混合10s。
加入剩余原料，调节搅拌速度至4500 r/min，混合1min，最后将混合均匀的产物装入模具中，升温至190℃，压力控制到0.6MPa，加热8min即得。
制备方法简单，回弹率99.5%，成本低廉，可操作性强，压缩强度240MPa；伸长率230%，产品柔软，耐用程度高，不易塌陷变形，承托性能高； 20%压缩强度16MPa，抗菌防霉，工艺稳定性好，使用寿命长，不易虫蛀，阻燃效果好；相对密度低，拉伸强度160MPa，粘结强度220MPa，原料来源广泛，可以广泛生产并不断代替现有材料。
实施例2:
按照重量份数配比称取涤纶100份、PAPI35份、有机锡5份、一氯三氟甲烷9.5份、乙二醇7份、三乙醇胺5.5份、N-乙基吗啉0.8份、高纯水25份、碳酸钙17份、AC发泡剂4.5份、甲酸0.45份、氧化锌7份、轻质碳酸钙30份、单脂肪酸甘油酯0.7份和丁醇5份。
将涤纶、PAPI、有机锡和一氯三氟甲烷投入球磨机中球磨10-30min粉碎，再加入乙二醇、三乙醇胺、N-乙基吗啉和高纯水，在反应釜中升温至30-50℃，转速为3000-3200r/min速度下，搅拌3-7s，再加入碳酸钙、AC发泡剂和甲酸，升温至60-100℃，混合10-20s。
加入剩余原料，调节搅拌速度至4500-5500 r/min，混合1-5min，最后将混合均匀的产物装入模具中，升温至190-240℃，压力控制到0.6-0.9MPa，加热8-12min即得。
制备方法简单，回弹率99.5-99.9%，成本低廉，可操作性强，压缩强度240-280MPa；伸长率230-250%，产品柔软，耐用程度高，不易塌陷变形，承托性能高； 20%压缩强度16-20MPa，抗菌防霉，工艺稳定性好，使用寿命长，不易虫蛀，阻燃效果好；相对密度低，拉伸强度160-240MPa，粘结强度220-280MPa，原料来源广泛，可以广泛生产并不断代替现有材料。
实施例3:
按照重量份数配比称取涤纶100份、PAPI15份、有机锡5份、一氯三氟甲烷9.5份、乙二醇3份、三乙醇胺1.5份、N-乙基吗啉0.4份、高纯水25份、碳酸钙13份、AC发泡剂4.5份、甲酸0.45份、氧化锌7份、轻质碳酸钙10份、单脂肪酸甘油酯0.7份和丁醇5份。
将涤纶、PAPI、有机锡和一氯三氟甲烷投入球磨机中球磨10-30min粉碎，再加入乙二醇、三乙醇胺、N-乙基吗啉和高纯水，在反应釜中升温至30-50℃，转速为3000-3200r/min速度下，搅拌3-7s，再加入碳酸钙、AC发泡剂和甲酸，升温至60-100℃，混合10-20s。
加入剩余原料，调节搅拌速度至4500-5500 r/min，混合1-5min，最后将混合均匀的产物装入模具中，升温至190-240℃，压力控制到0.6-0.9MPa，加热8-12min即得。
制备方法简单，回弹率99.5-99.9%，成本低廉，可操作性强，压缩强度240-280MPa；伸长率230-250%，产品柔软，耐用程度高，不易塌陷变形，承托性能高； 20%压缩强度16-20MPa，抗菌防霉，工艺稳定性好，使用寿命长，不易虫蛀，阻燃效果好；相对密度低，拉伸强度160-240MPa，粘结强度220-280MPa，原料来源广泛，可以广泛生产并不断代替现有材料。
实施例4:
按照重量份数配比称取涤纶100份、PAPI25份、有机锡3份、一氯三氟甲烷8.5份、乙二醇5份、三乙醇胺3.5份、N-乙基吗啉0.6份、高纯水15份、碳酸钙15份、AC发泡剂2.5份、甲酸0.25份、氧化锌5份、轻质碳酸钙20份、单脂肪酸甘油酯0.5份和丁醇3份。
将涤纶、PAPI、有机锡和一氯三氟甲烷投入球磨机中球磨20min粉碎，再加入乙二醇、三乙醇胺、N-乙基吗啉和高纯水，在反应釜中升温至40℃，转速为3200r/min速度下，搅拌7s，再加入碳酸钙、AC发泡剂和甲酸，升温至100℃，混合20s。
加入剩余原料，调节搅拌速度至5500 r/min，混合5min，最后将混合均匀的产物装入模具中，升温至240℃，压力控制到0.9MPa，加热12min即得。
制备方法简单，回弹率99.9%，成本低廉，可操作性强，压缩强度280MPa；伸长率250%，产品柔软，耐用程度高，不易塌陷变形，承托性能高； 20%压缩强度20MPa，抗菌防霉，工艺稳定性好，使用寿命长，不易虫蛀，阻燃效果好；相对密度低，拉伸强度240MPa，粘结强度280MPa，原料来源广泛，可以广泛生产并不断代替现有材料。
以上实施例中的组合物所有组分均可以商业购买。
上述实施例只是用于对本发明的内容进行阐述，而不是限制，因此在与本发明的权利要求书相当的含义和范围内的任何改变，都应该认为是包括在权利要求书的范围内。

Claims (5)

1.一种涤纶发泡床垫的制备方法，其特征在于，包括如下步骤：
第一步：按照重量份数配比称取涤纶100份、PAPI15-35份、有机锡1-5份、一氯三氟甲烷7.5-9.5份、乙二醇3-7份、三乙醇胺1.5-5.5份、N-乙基吗啉0.4-0.8份、高纯水5-25份、碳酸钙13-17份、AC发泡剂0.5-4.5份、甲酸0.05-0.45份、氧化锌3-7份、轻质碳酸钙10-30份、单脂肪酸甘油酯0.3-0.7份和丁醇1-5份；
第二步：将涤纶、PAPI、有机锡和一氯三氟甲烷投入球磨机中球磨10-30min粉碎，再加入乙二醇、三乙醇胺、N-乙基吗啉和高纯水，在反应釜中升温至30-50℃，转速为3000-3200r/min速度下，搅拌3-7s，再加入碳酸钙、AC发泡剂和甲酸，升温至60-100℃，混合10-20s；
第三步：加入剩余原料，调节搅拌速度至4500-5500 r/min，混合1-5min，最后将混合均匀的产物装入模具中，升温至190-240℃，压力控制到0.6-0.9MPa，加热8-12min即得。
2.根据权利要求1所述的一种涤纶发泡床垫的制备方法，其特征在于：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI15份、有机锡1份、一氯三氟甲烷7.5份、乙二醇3份、三乙醇胺1.5份、N-乙基吗啉0.4份、高纯水5份、碳酸钙13份、AC发泡剂0.5份、甲酸0.05份、氧化锌3份、轻质碳酸钙10份、单脂肪酸甘油酯0.3份和丁醇1份。
3.根据权利要求1所述的一种涤纶发泡床垫的制备方法，其特征在于：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI35份、有机锡5份、一氯三氟甲烷9.5份、乙二醇7份、三乙醇胺5.5份、N-乙基吗啉0.8份、高纯水25份、碳酸钙17份、AC发泡剂4.5份、甲酸0.45份、氧化锌7份、轻质碳酸钙30份、单脂肪酸甘油酯0.7份和丁醇5份。
4.根据权利要求1所述的一种涤纶发泡床垫的制备方法，其特征在于：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI15份、有机锡5份、一氯三氟甲烷9.5份、乙二醇3份、三乙醇胺1.5份、N-乙基吗啉0.4份、高纯水25份、碳酸钙13份、AC发泡剂4.5份、甲酸0.45份、氧化锌7份、轻质碳酸钙10份、单脂肪酸甘油酯0.7份和丁醇5份。
5.根据权利要求1所述的一种涤纶发泡床垫的制备方法，其特征在于：所述第一步中涤纶发泡床垫的原料按重量份数配比如下：涤纶100份、PAPI25份、有机锡3份、一氯三氟甲烷8.5份、乙二醇5份、三乙醇胺3.5份、N-乙基吗啉0.6份、高纯水15份、碳酸钙15份、AC发泡剂2.5份、甲酸0.25份、氧化锌5份、轻质碳酸钙20份、单脂肪酸甘油酯0.5份和丁醇3份。
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