CN109881371B - Layered elastomer, manufacturing method thereof and special spinneret plate - Google Patents
Layered elastomer, manufacturing method thereof and special spinneret plate Download PDFInfo
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- CN109881371B CN109881371B CN201910297726.9A CN201910297726A CN109881371B CN 109881371 B CN109881371 B CN 109881371B CN 201910297726 A CN201910297726 A CN 201910297726A CN 109881371 B CN109881371 B CN 109881371B
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Abstract
The invention discloses a layered elastomer, which takes a thermoplastic polyester elastomer as a raw material to extrude long fiber yarns, forms a layered object with a certain thickness after curling and bonding, wherein the front and back surfaces of the layered object are respectively provided with high-hardness fiber yarn layers and low-hardness fiber yarn layers, the middle part in the thickness direction is an interlaced layer formed by mutually interlining and bonding fiber yarns with different hardness, and the support factor tested by the low-hardness surface is more than or equal to 4.0. Compare with the polyester elastomer fibre of high rigidity, low rigidity polyester elastomer fibre has higher resilience, the compliance, durability, and the part that indentation hardness is not enough then relies on the polyester elastomer of high rigidity to improve whole product bulk hardness as the supporting layer, under the condition that low rigidity fibre layer is up, the low rigidity fibre layer of compression initial stage can be for the softer contact experience of user, the soft moderate experience of customer's softness can be given to the stable back staggered floor of compression later stage user seat, high rigidity fibre layer can be harder for the user, the experience that has sufficient holding power, user experience comfort level is good.
Description
Technical Field
The invention relates to an elastic body with a certain thickness formed by curling long-strip fiber yarns, wherein the long-strip fiber yarns are made of thermoplastic polyester elastic bodies which are used as raw materials, the elastic body can be suitable for the fields of office chairs, sofas, beds and the like, and in particular relates to a layered elastic body, a manufacturing method thereof and a special spinneret plate.
Background
Present cushion, sofa pad, mattress etc. often adopt foaming polyurethane, preparation such as latex or spring forms, Support factor (Support factor) is a standard that is used for judging material elasticity and travelling comfort, the pressure value when product compression is to meeting an emergency 65% divides the ratio of the pressure value when product compression is to meeting an emergency 25%, generally speaking, the higher product travelling comfort that is higher is better for the Support factor, the high product of Support factor is experienced in the compression initial stage that the user just sat and is felt softer, the compression later stage after the user sits and experiences and feel harder, can play sufficient supporting effect. The product comfort is poor when the support factor is lower than 2.0. At present, the support factor of the foaming polyurethane product is generally below 3.0, a user experiences hardness in the initial stage of compression in the use process, and the foaming polyurethane product also has the defects of air permeability lack, poor rebound resilience after long-term compression, easy yellowing after long-term use and the like. The supporting factor of the latex product is 3.0-4.0, the latex product is softer, the supporting degree is enough, so that the comfort of the user experience is better, but the latex product has the defect of poor air permeability, and the latex product cannot be made into a high-hardness product due to the fact that the latex product is softer, so that the requirements of more users can be met. The supporting factor of the spring product is 2.0-3.0, although the air permeability of the spring product is good, the soft spring product has insufficient supporting degree, the product with the sufficient supporting degree has insufficient softness, and the spring product is easy to damage and consume quickly after being used for a long time. In order to obtain a better supporting factor, a plurality of mattress products adopt a multi-layer composite structure, for example, the surface layer is sponge, the middle part is latex, and the bottom part is a spring, but the manufacturing process is complex, the cost is higher, the layers are independent from each other, and the user experience is poor.
In the prior art, a thermoplastic polyester elastomer is used as a raw material to prepare long fibers, and then the long fibers are curled to form a three-dimensional reticular elastomer with a certain thickness, and the existing three-dimensional reticular elastomer is usually prepared by a single-hardness polyester elastomer. In practice, various methods are used to obtain a larger support factor, for example, by controlling the pore size of a spinneret to produce a product with different diameters of filamentous fibers at the upper and lower sides in the thickness direction, but it is actually found that the method of improving flexibility by using a fine pore size reduces the durability of the three-dimensional reticulated elastomer, and the raw material in the spinneret tends to be discharged to a large pore size, so that the uniformity of discharged filaments cannot be controlled, the density in the thickness direction cannot be controlled, the large-pore size side has a large number of filaments and a large diameter, the small-pore size side has a small number of filaments and a small diameter, so that one side of the product is too soft and the other side of the product is too hard, and the support factor is lower. Further, patent CN105026632A discloses a net-like structure excellent in compression durability, which is made of a polyester-based thermoplastic elastomer, and which is made by providing a heat-retaining region below a nozzle when spinning the polyester-based thermoplastic elastomer, heating the heat-retaining region with a heater, increasing the net surface temperature around the falling position of a continuous linear body of a traction conveyor net, or increasing the cooling water temperature in a cooling tank around the falling position of the continuous linear body, or the like, thereby enhancing the joint strength between the continuous linear bodies constituting the net-like structure and improving the repeated compression durability of the net-like structure. However, in the actual manufacturing process, the arrangement of the heat-insulating area causes thermal degradation of the polyester thermoplastic elastomer in the extrusion process, the yield is low, and the finished product also has the problem of stiffness, particularly when the polyester elastomer with high hardness is singly used for manufacturing, the stiffness problem of the finished product of the three-dimensional reticular elastomer is particularly obvious, although the stiff product can achieve the effect of repeated compression and durability, the rebound resilience of the stiff product is remarkably reduced, the support factor is lower than 3.5, and the use comfort of a user is poor.
Disclosure of Invention
The applicant aims at the defect that the supporting factor of a product manufactured by adopting a single-hardness polyester elastomer in the existing production cannot be obviously improved, and provides a layered elastomer with a reasonable structure, a manufacturing method thereof and a special spinneret plate.
The technical scheme adopted by the invention is as follows:
a laminated elastomer is prepared from thermoplastic polyester elastomer through extruding out long fibres, curling, adhering to form a laminated object with a certain thickness, arranging high-hardness and low-hardness fibre layers on front and back surfaces of said laminated object, arranging staggered layers in the middle of thickness direction, and testing on low-hardness surface to obtain supporting factor greater than or equal to 4.0.
As a further improvement of the above technical solution:
the hardness of the high-hardness material is 92A-97A, and the hardness of the low-hardness material is 80A-91A.
The difference between the melting points of the hardness of the high-hardness material and the hardness of the low-hardness material is more than 15 ℃, preferably more than 20 ℃.
The staggered layer accounts for 15-40% of the whole thickness.
The 40% indentation hardness of the layered elastomer is 120N-300N, and the fatigue-resistant repeated hardness loss is less than 25%.
The low-hardness material accounts for 20-60 wt% of the whole weight.
The density of the layered elastomer is 35-80 KG/m3The thickness is 30 mm-200 mm; the soft segment of the polyester elastomer is polytetrahydrofuran.
Wherein the soft segment content of the high-hardness polyester elastomer is 45-30 wt%, and the soft segment content of the low-hardness polyester elastomer is 46-75 wt%.
The method for manufacturing the layered elastomer comprises the steps of feeding a low-hardness polyester elastomer raw material and a high-hardness polyester elastomer raw material into different extruders, respectively extruding the raw materials into two sides of a spinneret plate through partition plate distribution, and mutually and alternately bonding adjacent high-hardness fiber filaments and low-hardness fiber filaments on two sides of the partition plate in the descending and cooling process of filamentous fibers to obtain the layered elastomer through molding.
The spinneret plate for manufacturing the layered elastomer is characterized in that a partition plate is arranged inside the spinneret plate, or a distribution plate is arranged above the spinneret plate, and the partition plate is arranged inside the distribution plate.
The invention has the following beneficial effects:
the invention uses two kinds of high and low different hardness thermoplastic polyester elastomers with melting points different by more than 15 ℃ as raw materials, long fiber yarns are extruded and then curled and bonded to form a layered object with a certain thickness, the front and back surfaces of the layered object are respectively provided with high hardness fiber yarn layers and low hardness fiber yarn layers, the middle part in the thickness direction is an interlaced layer formed by mutually interlining and bonding the high hardness fiber yarns and the low hardness fiber yarns, and the support factor is 4.0 or more. Compare with the polyester elastomer fibre of high rigidity, low rigidity polyester elastomer fibre has higher resilience, the compliance, durability, and the part that indentation hardness is not enough then relies on the polyester elastomer of high rigidity to improve whole product bulk hardness as the supporting layer, consequently under the circumstances that low rigidity fibre layer is up, from last low rigidity fibre layer down in proper order, staggered floor and high rigidity fibre layer, the low rigidity fibre layer of compression initial stage can be given the softer contact experience of user, the user sits steady back staggered floor and can give the soft moderate experience of customer, high rigidity fibre layer can be given the user harder, the experience that has sufficient holding power, user experience comfort level is good. According to the invention, the polyester elastomer fibers with high hardness and low hardness are matched with each other, wherein the hardness of the high-hardness material is 92A-97A, and the hardness of the low-hardness material is 80A-91A, so that the optimal hardness effect and softening effect are realized, and the support factor is obviously improved.
According to the invention, the distribution plate is arranged above the spinneret plate, the partition plate is arranged in the distribution plate, the high-hardness polyester elastomer and the low-hardness polyester elastomer are distributed through the distribution plate and respectively enter two sides of the spinneret plate, high-hardness fiber filaments and low-hardness fiber filaments are formed when the high-hardness fiber filaments and the low-hardness fiber filaments are sprayed out of the spinneret plate, the adjacent high-hardness fiber filaments and low-hardness fiber filaments on two sides of the partition plate are mutually staggered and bonded in the spraying and descending process, and the low-hardness polyester elastomer can be fully melted due to the lower melting point of the low-hardness polyester elastomer and the higher temperature of the die head part affected by the high-hardness fiber filaments, so that the low-hardness polyester elastomer can be prominently used as an adhesive during cooling, the bonding force of the junction of the staggered area of the high.
The invention has another advantage that two sides of the product have different indentation hardness, so that a consumer can select the optimal indentation hardness and touch feeling which are preferred by the consumer to determine the suitable side as the using side according to the preference of the consumer. The invention can change the hardness of two sides by changing two materials, thereby controlling the support factor, rebound resilience, comfort and hand feeling of the product, producing more optional products by matching and combining different high and low hardness, and having wide selection range of consumers.
Compared with a three-dimensional reticular elastomer product made of a single-hardness material, the low-hardness polyester elastomer has 40% indentation hardness of one surface of the low-hardness polyester elastomer between 120N and 300N, and is moderate in hardness; the fatigue-resistant repeated hardness loss is less than 25%, the support factor of one surface of the low-hardness polyester elastomer can reach more than 4.0, the comfort is greatly improved, the surface rebound rate of the product can be greatly improved, and the possibility of collapse or deformation is reduced; the compression sound deadening property was evaluated as acceptable or excellent, and the noise at the time of compression was reduced, and the touch was excellent, and the mattress was particularly suitable for use as a mattress.
The manufacturing process of the invention only needs to add one path of extruder, can realize simultaneous extrusion of the polyester elastomers with different hardness values by slightly improving the spinneret plate, has simple and convenient process, is easy to realize quality control, can directly obtain higher support factors for products, is simple and convenient to manufacture, and has obvious economic value.
Drawings
FIG. 1 is a schematic diagram showing the distribution of two different hardness polyester elastomers according to the present invention.
FIG. 2 shows a manufacturing process of the present invention.
FIG. 3 is a schematic view of a distribution plate according to the present invention.
Fig. 4 is a schematic view of a spinneret plate according to the present invention.
Fig. 5 is a schematic view of a distribution plate and spinneret assembly of the present invention.
In the figure: 1. a low hardness layer; 2. a staggered layer; 3. a high hardness layer; 4. a distribution plate; 5. a spinneret plate; 6. a separator.
Detailed Description
The following describes embodiments of the present invention with reference to the drawings.
The invention is characterized in that a distribution plate is arranged above a spinneret plate, a partition plate is arranged in the distribution plate, thermoplastic polyester is used as a hard section, tetrahydrofuran is used as a soft section to prepare polyester elastomers with high hardness and low hardness as raw materials, the polyester elastomers with the high hardness and the low hardness are respectively sent into different extruders and respectively extruded into two sides of the spinneret plate through the partition plate distribution of the distribution plate, high-hardness fiber filaments and low-hardness fiber filaments which are adjacent to two sides of the partition plate are mutually staggered and bonded in the filament discharging process of the spinneret plate, strip fibers are curled in water, and finally, a layered elastomer is formed in a mold, wherein the high-hardness fiber filaments and the low-hardness fiber filaments are mutually staggered in the middle of the thickness direction of a product, and the staggered layer accounts for 15. As shown in fig. 3, the vertical partition plate may be located in the middle of the distribution plate, and may be arranged perpendicular to the distribution plate and the spinneret plate, or may be adjusted in position on the distribution plate according to the actual usage of the polyester elastomer raw material with different hardness.
The thread-shaped fiber of the layered elastomer can be hollow fiber or other irregular solid fiber.
TABLE 1
The specific test method is as follows:
1. thickness: the thickness of the product was measured using a thickness gauge, and 5 samples were randomly selected and averaged.
2. Density: and putting the product into an oven, setting the temperature of the oven to 80 ℃ for 3h, measuring the length, the width and the height of the product after ensuring that the moisture is removed, calculating the volume, weighing the product by a three-position precision balance accurate to decimal point, and then calculating the density.
3. 40% indentation hardness test: the test surface is a low-hardness polyester elastomer surface, the test thickness is 50mm, the product is placed between an upper pressure plate and a lower pressure plate at a constant temperature of 23 ℃, the product is compressed to strain 40% at a test speed of 100mm/min, the upper pressure plate compresses the product downwards, a pressure sensor at the upper end senses pressure, the pressure is converted into a voltage signal and is transmitted to a display for analysis, meanwhile, the pressure value is displayed on a screen, and the average value is obtained after three tests.
4. And (3) testing a support factor: the test surface is a low-hardness polyester elastomer surface, the product is placed between an upper pressure plate and a lower pressure plate at a constant temperature of 23 ℃, the product is compressed to the strain of 25 percent and 65 percent respectively at the test speed of 100mm/min, the upper pressure plate compresses the product downwards, a pressure sensor at the upper end senses the pressure, the pressure is converted into a voltage signal and is transmitted to a display for analysis, the pressure value is displayed on a screen at the same time, and the average value is obtained after three tests. The support factor was obtained by dividing the 65% pressure value by the 25% pressure value.
5. Fatigue-resistant repeated compression hardness loss rate: and (3) putting the product on a lower platform of a repeated compression tester at a constant temperature of 23 ℃, setting a compression force 750N, repeatedly compressing the product at a frequency of 70 times per minute, and evaluating the performance of the product after compressing for 8 ten thousand times. Fatigue-resistant repeated compression hardness loss rate = (difference between hardness force before and after product test)/hardness force before product test 100%, and the average value is taken for three tests.
6. And (3) evaluating the compression silencing property, namely continuously compressing the layered elastomer, and evaluating the silencing property of the sound by three different testers, wherein the sound is classified into a good grade, a good grade and a poor grade.
Example 1
Feeding a raw material of a low-hardness polyester elastomer B-1 accounting for 40 mass percent of the total amount into a first component extruder, heating to a 220 ℃ molten state, and heating a raw material of a high-hardness polyester elastomer A-2 accounting for 60 mass percent of the total amount into a 230 ℃ molten state in a second component extruder; respectively extruding the measured raw materials into a die head, distributing the raw materials by a partition plate of a distribution plate, respectively locating A-2 raw materials and B-1 raw materials at two sides of a spinneret plate, drawing at a speed of 0.4 m/min, alternately bonding adjacent high-hardness fiber filaments and low-hardness fiber filaments at two sides of the partition plate in the process that filamentous fibers fall down and fall into cold water for cooling and curling at 30 ℃, finally forming the layered elastomer in a die, testing the layered elastomer by the method to obtain the layered elastomer with physical property parameters shown in table 2 and a density of 60Kg/cm3The thickness is 50mmm, the surface hardness of the low-hardness polyester elastomer material is 221N, and the fatigue repeated compression resistant hardness loss rate is 25%.
Example 2
Feeding a raw material B-2 of the low-hardness polyester elastomer accounting for 40 mass percent of the total amount into a first component extruder, heating the raw material to a 220 ℃ molten state, and heating a raw material A-1 of the high-hardness polyester elastomer accounting for 60 mass percent of the total amount into a 240 ℃ molten state in a second component extruder; respectively extruding the measured raw materials into a die head, distributing the raw materials by a partition plate of a distribution plate, respectively locating A-1 raw materials and B-2 raw materials at two sides of a spinneret plate, drawing at a speed of 0.4 m/min, alternately bonding adjacent high-hardness fiber filaments and low-hardness fiber filaments at two sides of the partition plate in the process that filamentous fibers fall down and fall into cold water for cooling and curling at 30 ℃, finally forming the layered elastomer in a die, testing the layered elastomer by the method to obtain the layered elastomer with physical property parameters shown in table 2 and a density of 60Kg/cm3A thickness of 50mmm, a surface hardness of the low-hardness polyester elastomer material of 245N, and a fatigue repeated compression resistant hardness loss rate of 21%。
Example 3
Feeding a raw material B-2 of the low-hardness polyester elastomer accounting for 40 mass percent of the total amount into a first component extruder, heating the raw material to a 220 ℃ molten state, and heating a raw material A-2 of the high-hardness polyester elastomer accounting for 60 mass percent of the total amount into a 230 ℃ molten state in a second component extruder; respectively extruding the measured raw materials into a die head, distributing the raw materials by a partition plate of a distribution plate, respectively positioning an A-2 raw material and a B-2 raw material at two sides of a spinneret plate, drawing at a speed of 0.4 m/min, alternately bonding adjacent high-hardness fiber filaments and low-hardness fiber filaments at two sides of the partition plate in the process that filamentous fibers fall down and fall into a cold water cooling and curling process at 30 ℃, finally forming the layered elastomer in a die, testing the layered elastomer by the method to obtain the layered elastomer with physical property parameters shown in table 2 and a density of 60Kg/cm3The thickness is 50mmm, the surface hardness of the low-hardness polyester elastomer material is 177N, and the fatigue repeated compression resistant hardness loss rate is 18%.
Comparative example 1
Heating a raw material of a low-hardness polyester elastomer B-2 accounting for 100 mass percent of the total amount to a 220 ℃ molten state in an extruder; extruding into a die head, discharging filaments after passing through a spinneret plate, drawing at a speed of 0.4 m/min, allowing the filaments to fall into 30 ℃ cold water, and finally forming in a die to obtain a layered elastomer with a density of 60Kg/cm3The thickness was 50mmm, the layered elastomer had a hardness of 107N, and the fatigue repeated compression resistant hardness loss rate was 27%. The hardness of the layered elastic body of the embodiment is only 107N, and the mattress feels soft and has obviously insufficient supporting hardness.
Comparative example 2
Heating a high-hardness polyester elastomer A-1 raw material accounting for 100 mass percent of the total amount to a molten state at 240 ℃ in an extruder; extruding into a die head, discharging filaments after passing through a spinneret plate, drawing at a speed of 0.4 m/min, allowing the filaments to fall into 30 ℃ cold water, and finally forming in a die to obtain a layered elastomer with a density of 60Kg/cm3The thickness was 50mmm, the layered elastomer had a hardness of 351N, and the fatigue repeated compression resistant hardness loss rate was 35%. The layered elastomer of the embodiment has extremely high hardness and is used for making a mattressIs too hard and has insufficient durability by repeated compression.
TABLE 2
Compared with a layered elastomer product made of a single material (a first comparative example and a second comparative example), under the condition that a low-hardness fiber layer faces upwards, as shown in fig. 1, a low-hardness fiber layer, a staggered layer and a high-hardness fiber layer are sequentially arranged from top to bottom, the low-hardness fiber layer can provide softer contact experience for a user at the initial stage of compression, the staggered layer can provide moderate soft experience for the user after the user sits stably at the later stage of compression, the high-hardness fiber layer can provide hard and enough supporting force experience for the user, the supporting factor of the low-hardness polyester elastomer surface can reach more than 4.0, the 40% indentation hardness is 177N-245N, the fatigue-resistant repeated hardness loss is only 18% -25%, the surface rebound rate of the product can be greatly improved, and the possibility of collapse or deformation is reduced; the compression noise reduction property is evaluated to be excellent or good, the noise at the time of compression can be reduced, the comfort is greatly improved, and the mattress is particularly suitable for being used as a mattress.
The foregoing description is illustrative of the present invention and is not to be construed as limiting thereof, as the invention may be modified in any manner without departing from the spirit thereof. For example, a distribution plate may not be provided above the spinneret plate, and a partition plate may be directly provided inside the spinneret plate, as long as the polyester elastomer raw materials with two hardnesses can be fed into the two sides of the spinneret plate, respectively.
Claims (7)
1. A lamellar elastomer, which takes thermoplastic polyester elastomer as raw material to extrude long-strip fiber yarn, and forms a lamellar object with certain thickness after curling and bonding, and is characterized in that: the front and back surfaces of the layered object are respectively high-hardness and low-hardness fiber yarn layers, the middle part in the thickness direction is an interlaced layer formed by mutually interlining and bonding fiber yarns with different hardness, and the support factor tested by the low-hardness surface is more than or equal to 4.0; the hardness of the high-hardness material is 92A-97A, and the hardness of the low-hardness material is 80A-91A; the difference between the melting points of the hardness of the high-hardness material and the hardness of the low-hardness material is more than 15 ℃; the staggered layer accounts for 15-40% of the whole thickness.
2. The layered elastomer of claim 1, wherein: the difference between the melting points of the hardness of the high-hardness material and the hardness of the low-hardness material is more than 20 ℃.
3. The layered elastomer of claim 1, wherein: the 40% indentation hardness of the layered elastomer is 120N-300N, and the fatigue-resistant repeated hardness loss is less than 25%.
4. The layered elastomer of claim 1, wherein: the low-hardness material accounts for 20-60 wt% of the whole weight.
5. The layered elastomer of claim 1, wherein: the density of the layered elastomer is 35-80 KG/m3The thickness is 30 mm-200 mm; the soft segment of the polyester elastomer is polytetrahydrofuran.
6. The layered elastomer of claim 1, wherein: wherein the soft segment content of the high-hardness polyester elastomer is 45-30 wt%, and the soft segment content of the low-hardness polyester elastomer is 46-75 wt%.
7. A method of making the layered elastomer of claim 1, wherein: feeding the raw material of the low-hardness polyester elastomer and the raw material of the high-hardness polyester elastomer into different extruders, respectively extruding the raw materials into two sides of a spinneret plate through partition plate distribution, and mutually and alternately bonding adjacent high-hardness fiber yarns and low-hardness fiber yarns on two sides of the partition plate in the descending and cooling process of the filamentous fibers to obtain the layered elastomer through molding.
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| CN111020723A (en) * | 2019-11-19 | 2020-04-17 | 安徽东锦资源再生科技有限公司 | Spinneret plate for producing large bright flat fibers |
| CN111690991A (en) * | 2020-07-23 | 2020-09-22 | 昆山无双金属科技有限公司 | Novel mask mould spinneret plate |
| CN113463217B (en) * | 2021-07-12 | 2023-05-26 | 无锡科逸新材料有限公司 | Dimensionally stable layered elastomer |
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| US4816494A (en) * | 1988-02-22 | 1989-03-28 | E. R. Carpenter Company, Inc. | Enhanced homogeneous polyurethane foam comfort cushioning and process for making same |
| JPH08244162A (en) * | 1995-03-13 | 1996-09-24 | Sekisui House Ltd | Gypsum particle board and its manufacture |
| CN101946033A (en) * | 2007-12-28 | 2011-01-12 | 3M创新有限公司 | Composite nonwoven fibrous webs and methods of making and using the same |
| CN106637677A (en) * | 2017-02-08 | 2017-05-10 | 佛山市南海必得福无纺布有限公司 | Dual-channel spun-laying system |
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