WO2021093156A1

WO2021093156A1 - Comfortable elastic pad product and manufacturing method therefor

Info

Publication number: WO2021093156A1
Application number: PCT/CN2020/071132
Authority: WO
Inventors: 欧阳丹晴; 郑扎贤
Original assignee: 上海海凯生物材料有限公司
Priority date: 2019-11-13
Filing date: 2020-01-09
Publication date: 2021-05-20
Also published as: CN110804804A

Abstract

A comfortable elastic pad product, comprising an outer sleeve layer and a cushion core. The cushion core is made of a composite fiber material; the composite fiber material consists of composite elastic fibers having a three-dimensional spiral structure and a binder; the composite fibers are arranged in a pad in a crossed mode to form an "X" structure, and the composite fibers are constructed to form a plurality of triangle structures. The composite fibers are arranged in the pad in a crossed mode to form the 'X' structure, a single spiral fiber tends to be vertical to achieve good compression resilience, and the fibers are constructed to form the plurality of triangle structures, thereby realizing good stability and resilience and having a fluffy structure, solving the problem of poor elastic utilization rates of fibers of conventional flat laying structures "=", and also solving the problem that structures in a vertical process "‖" are easy to collapse.

Description

Comfortable elastic cushion product and manufacturing method thereof

Technical field

The invention relates to the technical field of daily-use cushion products, in particular to a comfortable elastic cushion product and a manufacturing method thereof.

Background technique

With the continuous improvement of people's living standards, people's requirements for mats are also increasing day by day. Humans spend one third of their time in sleep, so they have a critical eye on mattress products that affect sleep quality. At present, there are two main types of mattresses in the market: one is latex pads, which have the characteristics of good elasticity and fatigue resistance, but they do not have breathable and moisture-permeable properties and are relatively expensive, which limits their application scope; The second type is Zongdian. Zongdian has a natural and environmental protection effect, but it is harder, easy to be moth-eaten and costly, which limits the application of this kind of product. If on the basis of cost control, the development of mattress products with breathable and moisture permeability, elasticity and comfort has become an urgent need in the market.

The elastic yarn is a kind of composite short fiber with permanent three-dimensional results. It has good elasticity and resilience, and the cost is not high. The corresponding product can be developed by using the elastic yarn in combination with a special process. Therefore, by using the special structure and the raw material of the elastic silk, the good elasticity of the elastic silk and the good gap between the fibers, it is possible to develop mattress products with excellent comfort.

Summary of the invention

In view of this, the purpose of the present invention is to provide a comfortable elastic cushion product and a manufacturing method thereof.

The specific technical scheme adopted by the present invention is:

A comfortable elastic cushion product, comprising an outer layer and a cushion core, the cushion core is made of a composite fiber material, the composite fiber material is composed of a composite elastic fiber with a three-dimensional spiral structure and a binder, the composite fiber In the mat, they are arranged in an "X" structure, and a plurality of composite fibers are structured into a number of triangular "△" structures.

In order to better realize the present invention, the composite elastic fibers with a three-dimensional spiral structure are PTT/PET/PBT, PTT/PET and PBT/PET.

In order to better realize the present invention, the binder is low-melting polyester fiber.

In order to better realize the present invention, the mass ratio of composite elastic fibers in the composite fiber material is 50-90%, and the mass ratio of the binder is 10-50%.

In order to better realize the present invention, the grammage of the pad products is between 50g and 20,000g/m2.

In order to better realize the present invention, the cushion products include soft cushion products and hard cushion products. The soft cushion products use composite elastic fibers with a fineness of 1D-5D*51-88MM, and the hard cushion products use fine Composite elastic fiber with a degree of 5D-25D*51-88MM.

Correspondingly, the present invention also provides a method for manufacturing the above-mentioned comfortable elastic cushion product, which includes the following steps:

A. Unpacking and mixing: Put the composite elastic fiber and low-melting fiber on the unpacking machine respectively, unpack and weigh according to the set ratio, and mix and flow out;

B. Opening: pre-open the mixed two fibers and feed them into the cotton storage box at the same time;

C. Cotton feeding: the opened fiber is fed from the cotton storage box to the vibrating cotton feeder, and the output of cotton is controlled by photoelectric;

D. Carding: According to the gram weight of the product, it will be carded into a net;

E. Laying: The thin layer of mesh is laid back and forth through the laminator;

F. Acupuncture: The cotton net enters the acupuncture machine through the escort device for pre-needling and main-needling;

G. Shaping: low-temperature and slow-speed shaping;

H. Hot noodles: roller hot noodles;

I. Roll or piece packaging.

In order to better realize the present invention, in step B, the speed of the opener during pre-opening is 950 rpm.

In order to better realize the present invention, in step D, when combing, the speed of the cylinder is 300 rpm, and the speed of the single doffer is 30 rpm;

In order to better realize the present invention, the shaping equipment used in step G is a natural gas heating oven, the shaping temperature is 140 degrees, and it is divided into four zones, namely upper air blowing, lower air blowing, upper air blowing, and lower air blowing. The wind speed gradually increases, 20HZ, 25HZ, 30HZ, 40HZ; step H, the roller surface temperature is 160 degrees, and the speed matches the oven speed.

Compared with the prior art, the present invention has the following beneficial effects:

1. Comfortable elasticity is the rigid demand of market consumers. At present, the elastic cushion products include chemical foam cushion products and spring cushion products. Spring cushion products only use springs to achieve elasticity, but the touch is not good; sponge, memory Chemical foamed products such as cotton, latex, etc. increase flexibility in touch and achieve flexibility in performance. However, because chemical foamed products have insufficient safety, especially they are smelly, easy to age, and cannot be washed in the sun, etc. ; Fibrous hard cotton technology, including polyester, palm and other cushion products, has no elasticity, especially the elastic recovery is very poor, and it is very easy to deform. The invention combines the elastic principle of the spring, uses natural permanent three-dimensional spiral structure fibers, and adopts special fiber arrangement technology to form the honeycomb structure of foamed products, and realizes cushion products with excellent softness, fluffy, elasticity and elastic recovery, and The density can be adjusted to achieve different thicknesses and different hardnesses to meet more needs.

2. In the present invention, the composite fibers are arranged in an "X" structure in the mat. A single spiral fiber tends to be vertical to achieve good compression and rebound. Multiple fibers are structured into several triangular "△" structures. Very good stability, resilience and fluffy structure, make up for the conventional flat "=" structure, the problem of poor elastic utilization rate of the fiber, and at the same time make up for the problem of easy collapse of the vertical process "‖".

3. The cushion product provided by the present invention has zero heavy metal formaldehyde, and has a convenient processing flow, and at the same time, there is no sewage and waste gas discharge, and the production is environmentally friendly.

4. The cost of the cushion product provided by the present invention is close to that of the current foam product, but it is more durable, can be cleaned, and is more hygienic.

Description of the drawings

Figure 1 is a cross-sectional view of the comfortable elastic cushion product described in Example 1.

Detailed ways

The present invention will be further described in detail below with reference to the examples, but the implementation of the present invention is not limited to this. Without departing from the above technical ideas of the present invention, various substitutions and changes can be made based on common technical knowledge and conventional means in the field. , Should be included in the scope of the present invention.

Example 1

A comfortable elastic cushion product, comprising an outer layer and a cushion core, the cushion core is made of a composite fiber material, the composite fiber material is composed of a composite elastic fiber with a three-dimensional spiral structure and a binder, as shown in Figure 1 It shows that the composite fiber has the state parallel, vertical, and oblique, and the oblique has left and right oblique. The oblique angle shown in the figure is only an example. There are actually many different inclination angles. The composite fibers are arranged in an "X" structure in a cross arrangement in the mat, and a plurality of composite fibers are structured into a number of triangular "△" structures.

The preparation method of the cushion core in the above-mentioned cushion products is as follows:

1. Ingredients: 80% composite elastic fiber 5.5 Uniqueness*88mm

Low melting point polyester fiber 20% 4.0dtex*51mm

2. Target product: 1200g/square, 3cm thickness, 80,000 times compression and rebound 95% or more

3. The processing steps are as follows:

A. Unpacking and mixing: Put the composite elastic fiber and low-melting fiber on the unpacking machine respectively, unpack and weigh according to the set ratio, and mix them together to flow out

B. Opening: pre-open the two mixed fibers and feed them into the cotton storage box at the same time. The speed of the opener is 950 rpm.

C. Cotton feeding: the opened fiber is fed from the cotton storage box to the vibrating cotton feeder, and the output of cotton is controlled by photoelectric

D. Carding: According to the designed ration of 30 g/square, the net is carded. The speed of the cylinder is 300 rpm, and the speed of the single doffer is 30 rpm.

E. Laying the netting: the net-like thin layer is laid back and forth by the netting machine for 8-9 layers, and the thickness of the cotton net is 50-60 cm

F. Acupuncture: The cotton web enters the acupuncture machine through the escort device, and the two parts of the pre-needling and the main needling reach a thickness of 5 cm. The frequency of the pre-needling machine is 500 punctures/min, the needle row density is 4000 pieces/m, and the needle holes The diameter is 4.0mm, this time the stroke is 30 cm, the frequency of the main punching machine is 650 punches/min, the pin density is 6000 per meter, and the diameter of the pinhole is 3.0mm. This time the stroke is 20 cm. The weight reaches 300 g/square, the thickness is 4 cm

G setting: The setting equipment is a natural gas heating oven, the length is 12 meters, the low temperature and slow speed setting, the temperature is 140 degrees, and it is divided into four areas, which are upper blow, lower blow, upper blow, and lower blow. The wind speed is gradually increasing, 20HZ, 25HZ, 30HZ, 40HZ, and then enter the natural wind cooling zone with a length of 2 meters, the cotton thickness is 3 cm, the weight is 400 g/square * cm thick, and 1200 g/square

H hot surface: In order to make both sides smooth and clean, the surface is ironed by a roller, the temperature is 160 degrees, and the speed is matched with the oven.

I roll or cut piece packing

4. Perform performance tests on the finished products processed in the embodiment, and the results are as follows:

A. Weight: within the range of plus or minus 5%

B. Elastic recovery: more than 95%

C. Air permeability: 6000ml or more

D. Moisture permeability: more than 3000 ml

F. Aging resistance: excellent

G. Skin-friendly: excellent

H. Safety: zero formaldehyde, zero heavy metal, zero peculiar smell.

Although the foregoing embodiments have been described, those skilled in the art can make additional changes and modifications to these embodiments once they learn the basic creative concept. Therefore, the foregoing is only the implementation of the present invention. For example, this does not limit the scope of patent protection of the present invention. Any equivalent structure or equivalent process transformation made using the content of the description and drawings of the present invention, or directly or indirectly applied to other related technical fields, are included in this same principle. The invention is within the scope of patent protection.

Claims

A comfortable elastic cushion product, which is characterized by comprising an outer jacket layer and a cushion core, the cushion core is made of composite fiber material, and the composite fiber material is composed of composite elastic fibers with a three-dimensional spiral structure and a binder, The composite fibers are arranged in an intersecting arrangement in the mat, in an "X" structure, and a plurality of composite fibers are structured into a plurality of triangular "△" structures.
The comfortable elastic cushion product according to claim 1, wherein the composite elastic fibers with a three-dimensional spiral structure are PTT/PET/PBT, PTT/PET and PBT/PET.
The comfortable elastic cushion product according to claim 1 or 2, wherein the adhesive is a low-melting polyester fiber.
The comfortable elastic cushion product according to claim 3, wherein the composite elastic fiber in the composite fiber material accounts for 50-90% by mass, and the binder accounts for 10-50% by mass.
The comfortable elastic cushion product according to claim 3, wherein the cushion product has a weight of 50 g to 20,000 g/m2.
The comfortable elastic cushion product according to claim 3, characterized in that the cushion products include soft cushion products and hard cushion products, and the soft cushion products are made of 1D-5D*51-88MM. Composite elastic fiber, hard mat products use composite elastic fiber with a fineness of 5D-25D*51-88MM.
The method for manufacturing the comfortable elastic cushion product according to any one of claims 4-6, characterized in that it comprises the following steps:

A. Unpacking and mixing: Put the composite elastic fiber and low-melting fiber on the unpacking machine respectively, unpack and weigh according to the set ratio, and mix and flow out;

B. Opening: pre-open the mixed two fibers and feed them into the cotton storage box at the same time;

C. Cotton feeding: the opened fiber is fed from the cotton storage box to the vibrating cotton feeder, and the output of cotton is controlled by photoelectric;

D. Carding: According to the gram weight of the product, it will be carded into a net;

E. Laying: The thin layer of mesh is laid back and forth through the laminator;

F. Acupuncture: The cotton net enters the acupuncture machine through the escort device for pre-needling and main-needling;

G. Shaping: low temperature and slow shaping;

H. Hot noodles: roller hot noodles;

I. Roll or piece packaging.
The manufacturing method according to claim 7, characterized in that, in step B, the speed of the opener during the pre-opening is 950 rpm.
The manufacturing method according to claim 7, characterized in that, in step D, when combing, the speed of the cylinder is 300 rpm, and the speed of the single doffer is 30 rpm;
The manufacturing method according to claim 7, characterized in that the shaping equipment used in step G is a natural gas heating oven, the shaping temperature is 140 degrees, and it is divided into four areas, which are upper blowing, lower blowing, upper blowing, and lower blowing. The wind speed gradually increases, 20HZ, 25HZ, 30HZ, 40HZ; step H, the roller surface temperature is 160 degrees, and the speed matches the oven speed.