CN114182426B - Foaming and elastic-increasing 3D warp knitting spacer fabric and production method thereof - Google Patents
Foaming and elastic-increasing 3D warp knitting spacer fabric and production method thereof Download PDFInfo
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- CN114182426B CN114182426B CN202111536346.XA CN202111536346A CN114182426B CN 114182426 B CN114182426 B CN 114182426B CN 202111536346 A CN202111536346 A CN 202111536346A CN 114182426 B CN114182426 B CN 114182426B
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
- D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
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- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
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- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/143—Halogen containing compounds
- C08J9/144—Halogen containing compounds containing carbon, halogen and hydrogen only
- C08J9/145—Halogen containing compounds containing carbon, halogen and hydrogen only only chlorine as halogen atoms
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/10—Open-work fabrics
- D04B21/12—Open-work fabrics characterised by thread material
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J2203/142—Halogenated saturated hydrocarbons, e.g. H3C-CF3
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2307/00—Characterised by the use of natural rubber
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/01—Natural vegetable fibres
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/01—Natural vegetable fibres
- D10B2201/02—Cotton
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/06—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated alcohols, e.g. polyvinyl alcohol, or of their acetals or ketals
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Textile Engineering (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
- Knitting Of Fabric (AREA)
Abstract
The foaming and elastic increasing 3D warp knitting spacer fabric and the production method thereof comprise the following steps: firstly, putting a woven and post-set warp-knitted spacer fabric substrate into a mould according to the required size; and filling the foaming core material prefabricated member which is foamed by a foaming machine or is not foamed into a mold provided with the 3D fabric, fully contacting and uniformly mixing the foaming core material prefabricated member and the mold, and then performing treatments such as freezing (gel), vulcanizing, washing, drying and the like to form the required foaming and elastic-increasing 3D warp-knitted spacer fabric. The novel pillow product filling material integrating the advantages of the 3D warp-knitted spacer fabric and the foam material can solve the problems of poor support and elasticity of the existing foam material, unsatisfactory elastic recovery, high noise and cut filament of the existing 3D material.
Description
Technical Field
The invention relates to the field of warp-knitted spacer fabrics, in particular to a foaming elastic-increasing 3D warp-knitted spacer fabric and a production method thereof.
Background
Currently, the filling materials for pillows, mattresses and other cushion-type products are typically 3D warp knit spacer fabrics, latex, sponge, memory cotton, palm, etc. These products each have advantages, but also drawbacks. Taking 3D warp-knitted spacer fabric as an example, the advantages are excellent supporting performance and ventilation and air permeability, the defects are relatively poor elastic recovery, the spacer fabric has slight noise as a pillow filling material, has a certain influence on sleeping of people with sleep disorder, and is easy to break in the cutting process. Foam products such as latex, sponge and memory cotton have excellent elastic recoverability, but the products have insufficient supporting property and poor elasticity, can not completely and effectively support a human body, and easily cause the problems of human vertebra deformation and the like after long-term use.
Disclosure of Invention
The invention aims to solve the problems in the prior art, and provides a foaming and elasticity-increasing 3D warp-knitted spacer fabric which takes a 3D warp-knitted spacer fabric as a supporting base material and a foaming material as a filling core material and a production method thereof, wherein the filling material of cushion products such as a pillow, a mattress, a cushion and the like with high rebound and low deformation is formed by mixing and foaming the 3D material and the foaming material, so that the integral and local foaming and elasticity-increasing 3D warp-knitted spacer fabric can be produced, the advantages of the 3D warp-knitted spacer fabric and the foaming material are complementary, the special-shaped foaming and elasticity-increasing 3D warp-knitted spacer fabric can be produced, and the problem of difficult molding of the 3D warp-knitted spacer fabric is solved.
In order to achieve the above purpose, the invention adopts the following technical scheme:
the production method of the foaming and elastic increasing 3D warp knitting spacer fabric comprises the following steps:
1) Placing the woven and post-shaped warp-knitted spacer fabric substrate into a mold according to the required size;
2) Firstly mixing main materials and auxiliary materials required by a foaming material core material to prepare a foaming core material prefabricated member, foaming the foaming core material prefabricated member by a foaming machine, injecting the foaming core material prefabricated member into a mold provided with a warp-knitted spacer fabric base material, fully contacting and uniformly mixing the warp-knitted spacer fabric base material and the foaming core material prefabricated member foam, and then performing the procedures of gel, vulcanization, flushing and drying to form the finally required foaming and elasticity-increasing 3D warp-knitted spacer fabric;
or, firstly mixing main materials and auxiliary materials required by the foaming material core material to prepare a foaming core material prefabricated part, then injecting the foaming core material prefabricated part into a mould provided with a warp-knitted spacer fabric substrate, vacuumizing the mould to uniformly mix and foam the foaming core material prefabricated part and the warp-knitted spacer fabric substrate in a vacuum state, and performing freezing, vulcanization, flushing and drying procedures to form the finally required foaming and elasticity-increasing 3D warp-knitted spacer fabric.
The warp knitted spacer fabric substrate was produced as follows:
according to the purpose of the foaming and elasticity increasing 3D warp knitting spacer fabric and the local or whole piece foaming and elasticity increasing requirements, the tissue structure design of the warp knitting spacer fabric is designed, and the blank effect of the longitudinal and transverse local areas of monofilaments is caused if necessary, so that the foaming and elasticity increasing threading die production of the local foaming and elasticity increasing 3D warp knitting spacer fabric is facilitated, and the weaving and finishing production of the warp knitting spacer fabric base material is completed by selecting proper weaving and finishing processes.
The size, shape and design and cut of the warp knit spacer fabric substrate are as follows:
when the whole roll of foaming and elasticity-increasing 3D warp-knitted spacer fabric is produced, the warp-knitted spacer fabric base material does not need to be cut, and the fixed-length doffing can be completed according to the length required by the foaming and elasticity-increasing 3D warp-knitted spacer fabric in the weaving process; when the foaming elastic 3D warp-knitted spacer fabric with special shape and special size is produced, the shape and the size of the warp-knitted spacer fabric base material are designed firstly, and then the warp-knitted spacer fabric is cut into sheet-shaped warp-knitted spacer fabric base materials with specified size and shape according to a design draft.
Manufacturing a foam core material prefabricated member:
according to the application and performance requirements of the foaming and elasticity-increasing 3D warp-knitted spacer fabric, proper foaming material core materials and auxiliary materials are selected and uniformly mixed to prepare a required foaming core material prefabricated member.
Foaming production of the foaming and elastic increasing 3D warp knitting spacer fabric:
for the whole-piece type foaming and elasticity-increasing 3D warp-knitted spacer fabric, directly placing the warp-knitted spacer fabric substrate into a mould, then injecting the foaming core material prefabricated member which is or is not subjected to foaming into the mould, uniformly mixing the warp-knitted spacer fabric 3D substrate and the foaming core material prefabricated member, and carrying out freezing (gel), vulcanization, flushing and drying treatment on the warp-knitted spacer fabric to form the required whole-piece type foaming and elasticity-increasing 3D warp-knitted spacer fabric;
the method comprises the steps of firstly penetrating a mandrel into a space of a warp-knitted spacer fabric formed by blank threading and transverse moving of monofilaments, injecting foaming core material prefabricated parts which are or are not foamed into the local positions of the warp-knitted spacer fabric to be foamed, uniformly mixing a warp-knitted spacer fabric 3D base material and the foaming core material prefabricated parts, and performing freezing (gel), vulcanization, flushing and drying treatment on the mixture to form the required local foaming and elastic-increasing 3D warp-knitted spacer fabric.
The thickness of the warp-knitted spacer fabric base material is 1-60 mm, the upper surface and the lower surface are of mesh or plane structures, and the upper surface and the lower surface are of polyester yarns, polyamide yarns, polyvinyl alcohol yarns, polyethylene yarns, polypropylene yarns, cotton yarns or hemp yarns; the middle spacing wire is one or more of polyester monofilament, polyamide monofilament, polyvinyl alcohol monofilament, polyethylene monofilament and polypropylene monofilament, the diameter of the monofilament can be any thickness required, and the arrangement structure of the spacing wire is I-shaped, X-shaped or IXI-shaped.
Main materials in the main and auxiliary materials needed by the foaming material core material comprise at least one of natural latex, polyurethane, polyether, polystyrene, ethylene propylene diene monomer rubber, butyl rubber, polyethylene, polypropylene and EVA.
Auxiliary materials in main and auxiliary materials needed by the foaming material core material comprise a catalyst, a foaming stabilizer and a foaming agent; the catalyst comprises at least one of stannous octoate, potassium carboxylate, dibutyl tin dilaurate, 2,4, 6-tris (dimethylaminomethyl) phenol, 1,3, 5-tris (dimethylaminopropyl) hexa-aminotriazine, dimethylaminoethoxyethanol, AS-33 modified triethylene diamine, a mixture of 97% stannous octoate and 3% 2-ethylhexanoic acid, and a dipropylene glycol solution of 33% triethylene diamine; the foaming stabilizer comprises at least one of a light foam stabilizer BP-1002, an antioxidant dimethylethanolamine, a sponge hardening agent HME-810, high-resilience silicone oil Y1036, slow-resilience silicone oil B8002 and low-density silicone oil 8183; the foaming agent comprises at least one of HFC foaming agent, alkane foaming agent, methylene dichloride, dinitroso pentamethylene tetramine and sodium oleate.
The auxiliary materials in the main auxiliary materials required by the foaming material core material also comprise additives, wherein the additives comprise vulcanizing agents, anti-aging agents, oxidizing agents and thickening agents.
The main and auxiliary materials required by the foam material core material are as follows: 80 to 100 parts of natural latex, 5 to 25 parts of methylene dichloride, 1.6 to 3.5 parts of sulfur, 0.3 to 0.8 part of sodium dodecyl benzene sulfonate, 0.6 to 3.5 parts of zinc dimethyl dithiocarbamate, 0.8 to 2.3 parts of anti-aging agent RD, 15 to 35 parts of aluminum hydroxide, 1.5 to 5 parts of zinc oxide, 2.0 to 2.5 parts of sodium fluosilicate and 1 to 8 parts of dimethylaminoethoxy ethanol.
The foaming elastic 3D warp-knitted spacer fabric comprises a warp-knitted spacer fabric substrate and a foaming material core material filled in the warp-knitted spacer fabric substrate; the foaming and elastic increasing 3D warp knitting spacer fabric can be a whole-piece foaming and elastic increasing 3D warp knitting spacer fabric which is produced by foaming in the whole area, and can also be a local foaming and elastic increasing 3D warp knitting spacer fabric which is formed by foaming in a local shape.
The foaming and elastic increasing 3D warp-knitted spacer fabric can be formed by putting a piece of warp-knitted spacer fabric substrate into a mold separately to foam with a foam material prefabricated member, or can be formed by stacking a plurality of pieces of warp-knitted spacer fabric substrates together to foam with the foam material prefabricated member at one time.
The warp-knitted spacer fabric base material can be a coiled continuous warp-knitted spacer fabric or a sheet-shaped special-shaped warp-knitted spacer fabric with any special size and special shape which is cut according to design requirements.
Compared with the prior art, the technical scheme of the invention has the beneficial effects that:
1. the foaming and elasticity increasing 3D warp-knitted spacer fabric combines the advantages of the 3D warp-knitted spacer fabric and foam materials such as sponge and latex, has the performance characteristics of high support and high rebound of the 3D warp-knitted spacer fabric, has the advantage of low collapse rate of the foam materials, is a novel pillow product filling material integrating support, rebound resilience and excellent elastic recovery, and can greatly solve the problems of poor support and elasticity of the existing foam materials and unsatisfactory elastic recovery of the existing 3D materials.
2. The foam elastic 3D warp knitting spacer fabric can thoroughly solve the noise generated when the 3D material is used as a filling material of a pillow and a cushion due to the fact that foam materials such as latex, sponge and the like are filled in the gaps of the 3D fabric spacer wires, and the foam elastic 3D warp knitting spacer fabric has soft touch feeling and supports.
3. The foaming increases bullet 3D warp knitting spacer fabric because of combining with foam materials such as latex, sponge, has solved that there is some broken silk to drop after the 3D material itself cuts, and is difficult to clear up, perhaps unable clean up, therefore stink the problem of human skin.
4. The production method of the foaming and elastic-increasing 3D warp-knitted spacer fabric is the combination of the foaming process of the 3D warp-knitted spacer fabric and the foaming process of the foam material, has simple production flow, can produce the special-shaped foaming and elastic-increasing 3D warp-knitted spacer fabric, meets the requirements of pillow products on different shapes of filling materials, and the like, and can be molded in one step.
Drawings
FIG. 1 is a schematic illustration of the production flow of a foamed elasticized 3D warp knit spacer fabric of the present invention;
FIG. 2 is a schematic representation of a monolithic integrally foamed elasticized 3D warp knit spacer fabric of example 1;
FIG. 3 is a schematic representation of a monolithic partially foamed elasticized 3D warp knit spacer fabric of example 2;
FIG. 4 is a schematic representation of example 3 multi-piece partially foamed elasticized 3D warp knit spacer fabric;
fig. 5 is a schematic representation of a profiled foamed elasticized 3D warp knit spacer fabric of example 4.
Detailed Description
In order to make the technical problems, technical schemes and beneficial effects to be solved more clear and obvious, the invention is further described in detail below with reference to the accompanying drawings and embodiments.
Example 1
As shown in fig. 1 to 2, a foamed elasticized 3D warp knit spacer fabric (monolithic integral) according to this embodiment comprises a warp knit spacer fabric substrate 1 and a foamed material core material 2.
Firstly, designing a weave structure of a warp-knitted spacer fabric substrate 1 according to the purpose of a foaming and texturing 3D warp-knitted spacer fabric and the local or whole foaming and texturing requirements, selecting a proper yarn and monofilament to weave an upper layer 3, a lower layer 4 and a spacer layer 5 of the warp-knitted spacer fabric substrate, and performing post-setting on the woven warp-knitted spacer fabric to form the warp-knitted spacer fabric substrate 1; and directly placing the warp-knitted spacer fabric substrate 1 into a mould, then injecting the foaming core material prefabricated member which is or is not foamed into the mould, uniformly mixing the warp-knitted spacer fabric substrate and the foaming core material prefabricated member, and performing treatments such as freezing (gel), vulcanizing, flushing, drying and the like on the warp-knitted spacer fabric substrate to form the required monolithic foaming elastic-increasing 3D warp-knitted spacer fabric.
The monolithic foaming elastic-increasing 3D warp knitting spacer fabric can be cut according to the requirement and then used as a filling material of pillow products such as pillows, mattresses, cushions, sofa cushions and the like.
In this embodiment, the main and auxiliary materials required by the foam material core material are as follows: 94 parts of natural latex, 15 parts of dichloromethane, 2.8 parts of sulfur, 0.5 part of sodium dodecyl benzene sulfonate, 2.4 parts of zinc dimethyl dithiocarbamate, 2.0 parts of anti-aging agent RD, 20 parts of aluminum hydroxide, 3.2 parts of zinc oxide, 2.2 parts of sodium fluosilicate and 5 parts of dimethylaminoethoxy ethanol.
The foaming and elasticity-increasing 3D warp-knitted spacer fabric takes the 3D warp-knitted spacer fabric as a base material and takes the foaming material as a core material, has the performance characteristics of high support, high resilience and the like of the 3D warp-knitted spacer fabric, has the performance advantages of excellent elastic recoverability of the foaming material, can solve the problems of noise and cut silk of the 3D warp-knitted spacer fabric material, is a novel pillow product filling material integrating the advantages of the 3D warp-knitted spacer fabric and the foaming material, and can greatly solve the problems of poor support and elasticity of the existing foaming material, unsatisfactory elastic recoverability, high noise and cut silk of the existing 3D material.
Example 2
As shown in fig. 1 and 3, the foamed and elasticized 3D warp knitted spacer fabric (single piece part) according to the present embodiment comprises a warp knitted spacer fabric substrate 1 and a foamed material core 2, and the functional areas thereof comprise a foamed and elasticized 3D fabric foamed and elasticized area 6 and a foamed and elasticized 3D fabric non-elasticized area 7.
Firstly, the weave structure of the warp-knitted spacer fabric is designed according to the application of the foaming and elastic-increasing 3D warp-knitted spacer fabric, and the blank effect of the longitudinal and transverse partial areas of the monofilaments is caused by the processes of monofilament blank threading, monofilament bar electronic traversing and the like, so that the foaming and elastic-increasing threading mould production of the partial foaming and elastic-increasing 3D warp-knitted spacer fabric is facilitated, and the weaving, post finishing and the like of the warp-knitted spacer fabric base material are finished by selecting proper weaving and post finishing processes, so that the required 3D warp-knitted spacer fabric base material 1 is formed. Then, penetrating a mandrel into a space of a warp-knitted spacer fabric formed by blank penetration and transverse movement of a monofilament, putting the warp-knitted spacer fabric prefabricated member penetrating the mandrel into a mold, injecting the foaming core material prefabricated member which is or is not foamed into the mold, uniformly mixing the warp-knitted spacer fabric base material 1 and the foaming core material prefabricated member, and finally, performing treatments such as freezing (gel), vulcanizing, flushing, drying and the like on the warp-knitted spacer fabric to form the required single-piece local foaming and elastic-increasing 3D warp-knitted spacer fabric.
Compared with the monolithic integrated foaming and elastic-increasing 3D warp-knitted spacer fabric in the embodiment 1, the monolithic integrated foaming and elastic-increasing 3D warp-knitted spacer fabric is more suitable for mattress production, and has the advantages that in areas with larger weight distribution of a human body, such as buttocks and the like, the elastic recovery of the mattress can be increased through local foaming and elastic-increasing, the sinking deformation of the mattress is reduced, the service life of the mattress is prolonged, and meanwhile, the original excellent performances of ventilation and the like of the 3D warp-knitted spacer fabric are maintained in the areas with smaller weight distribution of the human body.
In this embodiment, the main and auxiliary materials required by the foam material core material are as follows: 94 parts of natural latex, 15 parts of dichloromethane, 2.8 parts of sulfur, 0.5 part of sodium dodecyl benzene sulfonate, 2.4 parts of zinc dimethyl dithiocarbamate, 2.0 parts of anti-aging agent RD, 20 parts of aluminum hydroxide, 3.2 parts of zinc oxide, 2.2 parts of sodium fluosilicate and 5 parts of dimethylaminoethoxy ethanol.
Example 3
As shown in fig. 1 and 4, the foamed and elasticized 3D warp knitted spacer fabric (multi-piece part type) according to the present embodiment comprises a warp knitted spacer fabric substrate 1 and a foamed material core 2, and the functional areas thereof comprise a foamed and elasticized 3D fabric foamed elasticized area 6 and a foamed and elasticized 3D fabric non-elasticized area 7.
Firstly, the weave structure of the warp-knitted spacer fabric is designed according to the application of the foaming and elastic-increasing 3D warp-knitted spacer fabric, and the blank effect of the longitudinal and transverse partial areas of the monofilaments is caused by the processes of monofilament blank threading, monofilament bar electronic traversing and the like, so that the foaming and elastic-increasing threading mould production of the partial foaming and elastic-increasing 3D warp-knitted spacer fabric is facilitated, and the weaving, post finishing and the like of the warp-knitted spacer fabric base material are finished by selecting proper weaving and post finishing processes, so that the required 3D warp-knitted spacer fabric base material 1 is formed. Then, penetrating the core mould into the space of the warp-knitted spacer fabric formed by the blank penetration and the transverse movement of the monofilament, placing the warp-knitted spacer fabric prefabricated member with the core mould in a mould according to the required number of layers, injecting the foaming core material prefabricated member which is or is not foamed into the mould to uniformly mix the warp-knitted spacer fabric base material 1 and the foaming core material prefabricated member, and finally, carrying out treatments such as freezing (gel), vulcanizing, flushing, drying and the like on the warp-knitted spacer fabric to form a plurality of required local foaming and elastic increasing 3D warp-knitted spacer fabrics.
The multi-piece local foaming and elastic increasing 3D warp knitting spacer fabric is suitable for mattress forming production, the multi-piece overlapped foaming forming can directly reach the use thickness of a mattress without additional viscose, and has the advantages of being applicable to non-gelling integrated forming production of mattress products, carrying out local foaming and elastic increasing on the edge area of the mattress where consumers often sit, increasing the elastic restorability of the edge part of the mattress, reducing the sinking deformation of the edge of the mattress, reducing the edge slipping phenomenon of the mattress, prolonging the service life of the mattress, and simultaneously, keeping the original excellent performances of ventilation and air permeability of the 3D warp knitting spacer fabric in a sleeping area.
In this embodiment, the main and auxiliary materials required by the foam material core material are as follows: 92 parts of natural latex, 10 parts of dichloromethane, 2.8 parts of sulfur, 0.7 part of sodium dodecyl benzene sulfonate, 2.8 parts of zinc dimethyl dithiocarbamate, 2.0 parts of anti-aging agent RD, 26 parts of aluminum hydroxide, 4.1 parts of zinc oxide, 2.2 parts of sodium fluosilicate and 5 parts of dimethylaminoethoxy ethanol.
Example 4
As shown in fig. 1 and 5, the foamed and elasticized 3D warp-knitted spacer fabric (profiled) according to the present embodiment comprises a warp-knitted spacer fabric substrate 1 and a foamed core material 2.
Firstly, designing a weave structure of a warp-knitted spacer fabric substrate 1 according to the purpose of a foaming and texturing 3D warp-knitted spacer fabric and the local or whole foaming and texturing requirements, selecting a proper yarn and monofilament to weave an upper layer 3, a lower layer 4 and a spacer layer 5 of the warp-knitted spacer fabric substrate, and performing post-setting on the woven warp-knitted spacer fabric to form the warp-knitted spacer fabric substrate 1; the shape and the size of the warp-knitted spacer fabric base material 1 are designed and cut according to the end product application, then the cut warp-knitted spacer fabric base material 1 is put into a mould (one layer or a plurality of layers), foaming core material prefabricated parts which are or are not foamed are injected into the mould, the warp-knitted spacer fabric base material and the foaming core material prefabricated parts are uniformly mixed, and the warp-knitted spacer fabric base material and the foaming core material prefabricated parts are subjected to treatments such as freezing (gel), vulcanizing, washing, drying and the like, so that the required special-shaped foaming elastic-increasing 3D warp-knitted spacer fabric is formed.
The special-shaped foaming and elasticity-increasing 3D warp knitting spacer fabric is suitable for one-step molding of pillow and cushion products, multiple stacked foaming molding and combining with a special-shaped mold, and can be used for one-step molding to produce products with different shapes. The method has the advantages that the method can be used for the non-gelling integrated molding production of special-shaped products such as pillows and cushions, and the defect that the 3D material is difficult to mold when being independently used and the radian of part of products cannot meet the design requirement is overcome.
In this embodiment, the main and auxiliary materials required by the foam material core material are as follows: 94 parts of natural latex, 20 parts of dichloromethane, 2.8 parts of sulfur, 0.5 part of sodium dodecyl benzene sulfonate, 2.4 parts of zinc dimethyl dithiocarbamate, 2.0 parts of anti-aging agent RD, 25 parts of aluminum hydroxide, 2.5 parts of zinc oxide, 2.2 parts of sodium fluosilicate and 5 parts of dimethylaminoethoxy ethanol.
The foregoing is merely illustrative of specific embodiments of the present invention, but the design concept of the present invention is not limited thereto, and any insubstantial modification of the present invention by using the design concept shall fall within the scope of the present invention.
Claims (6)
1. The production method of the foaming and elastic increasing 3D warp knitting spacer fabric is characterized by comprising the following steps of:
1) Placing the woven and post-shaped warp-knitted spacer fabric substrate into a mold according to the required size;
2) Firstly mixing main materials and auxiliary materials required by a foaming material core material to prepare a foaming core material prefabricated member, foaming the foaming core material prefabricated member by a foaming machine, injecting the foaming core material prefabricated member into a mold provided with a warp-knitted spacer fabric base material, fully contacting and uniformly mixing the warp-knitted spacer fabric base material and the foaming core material prefabricated member foam, and then performing the procedures of gel, vulcanization, flushing and drying to form the finally required foaming and elasticity-increasing 3D warp-knitted spacer fabric;
or, firstly mixing main materials and auxiliary materials required by the foaming material core material to prepare a foaming core material prefabricated part, then injecting the foaming core material prefabricated part into a mould provided with a warp-knitted spacer fabric substrate, vacuumizing the mould to uniformly mix and foam the foaming core material prefabricated part and the warp-knitted spacer fabric substrate in a vacuum state, and performing freezing, vulcanization, flushing and drying procedures to form the finally required foaming and elasticity-increasing 3D warp-knitted spacer fabric;
the main and auxiliary materials required by the foam material core material are as follows: 80-100 parts of natural latex, 5-25 parts of dichloromethane, 1.6-3.5 parts of sulfur, 0.3-0.8 part of sodium dodecyl benzene sulfonate, 0.6-3.5 parts of zinc dimethyl dithiocarbamate, 0.8-2.3 parts of antioxidant RD, 15-35 parts of aluminum hydroxide, 1.5-5 parts of zinc oxide, 2.0-2.5 parts of sodium fluosilicate and 1-8 parts of dimethylaminoethoxy ethanol;
for the local foaming and elasticity increasing 3D warp knitting spacer fabric which is formed by foaming the local shape, firstly, a mandrel is penetrated into a space of the warp knitting spacer fabric which is formed by blank threading and transverse moving of a monofilament, and a foaming core material prefabricated member which is or is not foamed is injected into the local position which is required to be foamed and elasticity increasing.
2. A method of producing a foamed ballistic 3D warp knitted spacer fabric according to claim 1 wherein said warp knitted spacer fabric substrate is produced by: according to the purpose of the foaming and elasticity increasing 3D warp knitting spacer fabric and the local or whole piece foaming and elasticity increasing requirements, the tissue structure design of the warp knitting spacer fabric is designed, so that the blank effect of the longitudinal and transverse local area of the monofilaments is caused, the foaming and elasticity increasing threading die production of the local foaming and elasticity increasing 3D warp knitting spacer fabric is facilitated, and the weaving and finishing production of the warp knitting spacer fabric base material is completed by selecting a proper weaving and finishing process.
3. The method of producing a foamed ballistic 3D warp knitted spacer fabric according to claim 1 wherein: for the monolithic foaming and elastic increasing 3D warp-knitted spacer fabric, the warp-knitted spacer fabric substrate is directly put into a mold, and then the foaming core material prefabricated member which is or is not foamed is injected into the mold.
4. The method of producing a foamed ballistic 3D warp knitted spacer fabric according to claim 1 wherein: the thickness of the warp-knitted spacer fabric base material is 1-60 mm, the upper surface and the lower surface are of mesh or plane structures, and the upper surface and the lower surface are of polyester yarns, polyamide yarns, polyvinyl alcohol yarns, polyethylene yarns, polypropylene yarns, cotton yarns or hemp yarns; the intermediate spacing wire is one or more of polyester monofilament, polyamide monofilament, polyvinyl alcohol monofilament, polyethylene monofilament and polypropylene monofilament, and the arrangement structure of the spacing wire is I-shaped, X-shaped or IXI-shaped.
5. The foaming and elasticizing 3D warp-knitted spacer fabric prepared by the production method according to any one of claims 1-4, which is characterized in that: the foaming elastic 3D warp-knitted spacer fabric comprises a warp-knitted spacer fabric substrate and a foaming material core material filled in the warp-knitted spacer fabric substrate; the foaming and elastic increasing 3D warp knitting spacer fabric can be a whole-piece foaming and elastic increasing 3D warp knitting spacer fabric which is produced by foaming in the whole area, and can also be a local foaming and elastic increasing 3D warp knitting spacer fabric which is formed by foaming in a local shape.
6. A foamed ballistic 3D warp knitted spacer fabric according to claim 5 wherein: the foaming and elastic increasing 3D warp-knitted spacer fabric can be formed by putting a piece of warp-knitted spacer fabric substrate into a mold separately to foam with a foam material prefabricated member, or can be formed by stacking a plurality of pieces of warp-knitted spacer fabric substrates together to foam with the foam material prefabricated member at one time.
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|---|---|---|---|---|
| CN103867879A (en) * | 2012-12-13 | 2014-06-18 | 江南大学 | Light board with warp knitting three-dimensional grid fabrics as frame and production method thereof |
| CN105946250A (en) * | 2016-07-05 | 2016-09-21 | 胡润屏 | Manufacturing method of pad 3D monofilament structure non-fabric composite elastic material |
| CN108017901A (en) * | 2017-12-05 | 2018-05-11 | 福建福联精编有限公司 | A kind of Three-dimensional warp knitting space fabric enhancing special-shaped foam material and preparation method thereof |
| CN108569014A (en) * | 2018-06-27 | 2018-09-25 | 海盐荣华经编有限公司 | A kind of expansion type warp knit composite material and its preparation process with purification function |
| CN110922626A (en) * | 2019-12-13 | 2020-03-27 | 绿野乳胶科技(深圳)有限公司 | Method for preparing safe latex product added with fragrant and medicinal plants |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103867879A (en) * | 2012-12-13 | 2014-06-18 | 江南大学 | Light board with warp knitting three-dimensional grid fabrics as frame and production method thereof |
| CN105946250A (en) * | 2016-07-05 | 2016-09-21 | 胡润屏 | Manufacturing method of pad 3D monofilament structure non-fabric composite elastic material |
| CN108017901A (en) * | 2017-12-05 | 2018-05-11 | 福建福联精编有限公司 | A kind of Three-dimensional warp knitting space fabric enhancing special-shaped foam material and preparation method thereof |
| CN108569014A (en) * | 2018-06-27 | 2018-09-25 | 海盐荣华经编有限公司 | A kind of expansion type warp knit composite material and its preparation process with purification function |
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