Novel monofilament high-gauge mattress material and preparation method thereof

Abstract

The invention provides a novel monofilament high-gauge mattress material and a preparation method thereof, and belongs to the technical field of textile, high-quality composite fiber is selected as a core material, a middle spacer layer is composed of thousands of superfine and super-tough fiber filaments, the toughness is good, the supporting force is high, and the problem that in the production process of existing high-gauge fabric, the high-gauge mattress material is not prone to deformation is solved. Only the middle separation wire is simply inserted into the upper surface and the lower surface, and nodules are not fixed and are easy to slide. The product disclosed by the invention can show extraordinary rebound resilience when being pressed, has excellent air permeability, is completely non-toxic and harmless, does not release formaldehyde, does not contain heavy metals, does not release any other harmful substances, and realizes perfect fusion of safety and environmental protection.

Description

Technical Field

[0001] The invention belongs to the field of textile technology, in particular to a novel monofilament high-gauge mattress material and a preparation method thereof. Background Art

[0002] Mattress is one of the most important household items in people's lives. With the continuous emergence of new materials and new technologies, the structure of mattress is also constantly innovating and developing. Common mattress materials include springs, memory foam, mountain palm, latex and polyurethane. Mattress is directly related to people's sleep quality and physical health. A suitable mattress can provide proper support so that all parts of the body are evenly stressed, thereby reducing physical fatigue. The air permeability of the mattress is crucial for regulating body temperature during sleep. A mattress with good air permeability can dissipate the heat generated by the human body in time, keep the mattress cool and comfortable, and help improve sleep quality.

[0003] A mattress that is too hard or too soft may make it impossible for the spine to maintain its normal physiological curvature, leading to problems such as spinal twisting and back pain. A harder mattress will cause the shoulders, back, buttocks and other parts of the body to press against the surface of the mattress, putting the spine in an uncomfortable position. In addition, harder materials are usually not breathable, and the constantly multiplying dust mites cause the accumulation of allergens, which in turn produces various odors. If the mattress is too soft, it lacks support, and people cannot maintain the normal physiological curvature of the spine when lying on it. Sleeping on it for a long time can easily cause lumbar muscle strain, back pain, and may also cause serious health problems such as lumbar spondylosis.

[0004] In view of the above problems, the present invention proposes a new type of single-filament high-gauge mattress material and a preparation method thereof, which uses modified polyester fibers that have undergone special fiber treatment as raw materials, and produces a mattress after weaving. The mattress has good supporting force and good ventilation and air permeability, and can make various parts of the body fit better into the mattress during sleep, and can obtain greater elasticity and comfort. Summary of the invention

[0005] The purpose of the present invention is to solve the above problems in the prior art and to provide a new type of single-filament high-gauge mattress material and a preparation method thereof.

[0006] The purpose of the present invention can be achieved by the following technical scheme: A new type of monofilament high-gauge mattress material, characterized in that it includes the following raw materials: PTA slices, ethylene glycol (MEG), auxiliary raw materials, wherein:

[0007] The PTA slices account for 40-50%;

[0008] PTA (purified terephthalic acid) chips are one of the main raw materials for polyester fiber production, with excellent physical and chemical properties, such as high melting point, high strength, good wear resistance and corrosion resistance;

[0009] The ethylene glycol (MEG) accounts for 40-50%;

[0010] The auxiliary raw materials account for 5-8%.

[0011] Preferably, the auxiliary raw materials include a catalyst, a stabilizer, a dispersant, a toner and a lubricant.

[0012] Preferably, the catalyst includes antimony trioxide and titanium dioxide, which are used to accelerate the esterification reaction and subsequent polycondensation reaction between the PTA chips and ethylene glycol, thereby improving production efficiency.

[0013] Preferably, the stabilizer includes an antioxidant, a light stabilizer and a hydrolysis resistance agent, which are used to improve the thermal stability, light stability and hydrolysis resistance of the composite fiber and prevent the product from being degraded or discolored during processing and use.

[0014] Antioxidants are a class of chemical substances that, when present in small amounts in a polymer system, can delay or inhibit the oxidation process of the polymer, thereby increasing the service life of the polymer. Light stabilizers, also known as UV stabilizers, are a class of stabilizing agents used to inhibit the photo-oxidative degradation of polymer resins and improve the weather resistance of plastic products.

[0015] Preferably, the dispersant includes one or two of triethylhexyl phosphate, sodium dodecyl sulfate, methyl amyl alcohol, cellulose derivatives, and polyacrylamide, which are used to improve the dispersion effect of pigments and fillers in monofilaments, improve the uniformity of the product, and enhance the appearance quality of the product.

[0016] Dispersant is a surfactant that has two opposite properties, lipophilicity and hydrophilicity, in its molecule. It can evenly disperse the solid and liquid particles of inorganic and organic pigments that are difficult to dissolve in liquids. It can also prevent the sedimentation and agglomeration of particles, forming the amphiphilic reagent required for a stable suspension.

[0017] Preferably, the color powder is used to change the color of the material to make it more beautiful and increase the appearance and market competitiveness of the product.

[0018] Preferably, the lubricant comprises calcium stearate or zinc stearate.

[0019] A method for preparing the novel monofilament high-gauge mattress material according to claim 1, comprising the following steps:

[0020] S1 Preparation of composite fiber: PTA slices, ethylene glycol (MEG) and auxiliary raw materials are mixed evenly according to the proportion, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using a special drawing and pulling equipment, and the processed composite fiber is neatly wound, and the diameter of the composite fiber is 100~500μm;

[0021] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0022] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so that the three-layer fabric is firmly fastened together;

[0023] In the prior art, the loom used is a traditional double-needle bed light mechanical cam loom, which has low output, low quality stability, high energy consumption, and large floor space. Its huge mechanical gearbox structure leads to large oil and gas pollution. Its disadvantages are very prominent and cannot meet the weaving needs of existing high-end monofilament fabrics. The new servo electronic gear cam shaft double needle bed warp knitting machine is used because it has the function of real-time horizontal movement of the double needle bed and arbitrary setting and adjustment of the spacing. The needle bed is pre-embedded with a high-frequency heating rod, which has the function of rapid heating and cooling within 0.5 seconds. At the same time, the needle tip UV dispensing system and the 365 / 395LED ultraviolet light source are used for instant glue curing. Based on the major transformation and upgrade of the equipment, while the middle monofilament spacer is inserted into the upper and lower surfaces, the upper and lower ends of the fiber filament are bonded and fixed to the upper and lower surfaces respectively under the joint action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together, which can greatly improve the stability of the mattress material.

[0024] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting;

[0025] S5 inspection: After passing the inspection, the goods are packaged and put into storage.

[0026] The quality inspector checks whether the mattress looks smooth and neat after sewing, whether the stitches are even, whether the corners are smooth and symmetrical, and whether the mattress fabric has defects such as color difference and broken yarn.

[0027] Preferably, in step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and when the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0028] For monofilament mattresses, the needle bed of the existing warp knitting machine is further modified, and a high-temperature bonding process is added during weaving to fix the position of each monofilament to prevent it from shifting when compressed and destroying the overall shape of the mattress, thereby improving the stability of the mattress material.

[0029] Preferably, in step S5, vacuum adsorption traction and hook-and-loop Velcro rollers are used to rub, stretch and pull the mattress to unify the consistency of the material and maintain dimensional stability.

[0030] Because the middle spacer layer has good toughness and elasticity, it cannot be rolled up like ordinary high-gauge fabrics. Vacuum adsorption traction and friction stretching traction of hook-surface Velcro rollers are required. In order to ensure the consistency and dimensional stability of the material, the warp knitting machine needs to be lifted to a certain height as a whole to facilitate cutting. After the produced fabric reaches the required specifications, it needs to be cut and removed immediately before production can continue.

[0031] Compared with the prior art, the preparation method of the novel monofilament high-gauge mattress material has the following beneficial effects:

[0032] 1. The present invention provides a new type of monofilament high-gauge mattress material and a preparation method thereof. The raw material is 100% modified polyester fiber. It is a pure fabric product that does not release formaldehyde, heavy metals, or any other harmful substances. It is safe and environmentally friendly. The final product has a relatively simple composition, is more convenient for secondary recycling, and helps to achieve a circular economy.

[0033] 2. The present invention provides a new type of single-filament high-gauge mattress material and a preparation method thereof, which is produced using warp knitting textile technology and has a unique three-dimensional structure. The middle is composed of countless filaments, and there is nothing to block the airflow, so the air permeability is excellent.

[0034] 3. The present invention provides a new type of single-filament high-gauge mattress material and a preparation method thereof. The middle spacer layer is composed of tens of thousands of ultra-fine and ultra-tough fiber filaments with good toughness and strong supporting force. While the middle single filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber filament are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, thereby ensuring that the three layers of fabric are firmly fastened together, can exhibit excellent resilience when compressed, and can better fit the human body during sleep without sinking.

[0035] 4. The present invention provides a new type of single-filament high-gauge mattress material and a preparation method thereof. Due to the excellent physical properties of the modified polyester fiber, compared with traditional warp-knitted mattress gauge fabrics, the adjustment range of the fabric gauge in the present invention is larger and more flexible. On the premise of ensuring that various physical properties meet customer usage requirements, the maximum gauge can be adjusted to 80cm.

[0036] 5. The present invention provides a new type of single-filament high-gauge mattress material and a preparation method thereof. In the preparation method, the upper and lower ends of the middle layer of polyester yarn are bonded and fixed together with the upper and lower surfaces, so that the entire mattress material becomes very stable, which can effectively avoid the collapse and tilting of the mattress during use.

[0037] In summary, the present invention provides a new type of single-filament high-gauge mattress material and a preparation method thereof, wherein high-quality composite fibers are selected as the core material, and the middle spacer layer is composed of tens of thousands of ultra-fine and ultra-tough fiber filaments, which have good toughness and strong support, and improve the existing high-gauge fabric in the production process, in which the middle spacer is simply inserted into the upper and lower surfaces, and the knots are not fixed, which is prone to sliding. The product of the present invention can show extraordinary resilience when under pressure, and at the same time has excellent air permeability, and is completely non-toxic and harmless, does not release formaldehyde, does not contain heavy metals, and does not release any other harmful substances, achieving a perfect fusion of safety and environmental protection. DETAILED DESCRIPTION Specific embodiment one:

[0040] Mechanical properties determine the reaction and performance of a mattress when subjected to stress. Breaking strength, breaking elongation and elastic modulus are three important indicators of mechanical properties of materials. Specific Example 1 is a test of the mechanical properties of a new type of single-filament high-gauge mattress material. Specific Example 1 is as follows:

[0041] 1) A novel monofilament high-gauge mattress material and a preparation method thereof, comprising the following steps:

[0042] S1 Preparation of composite fiber: PTA slices, ethylene glycol (MEG) and auxiliary raw materials are mixed evenly in the required proportion, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using a special drawing and pulling equipment, and the processed composite fiber is neatly wound, and the diameter of the composite fiber is 100~500μm;

[0043] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0044] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0045] In the prior art, the loom used is a traditional double-needle bed light mechanical cam loom, which has low output, low quality stability, high energy consumption, and large floor space. Its huge mechanical gearbox structure leads to large oil and gas pollution. Its disadvantages are very prominent and cannot meet the weaving needs of existing high-end monofilament fabrics. The new servo electronic gear cam shaft double needle bed warp knitting machine is used because it has the function of real-time lateral movement of the double needle bed and arbitrary setting and adjustment of the spacing. The needle bed is pre-embedded with a high-frequency heating rod, which has the function of rapid heating and cooling within 0.5s. At the same time, the needle tip UV dispensing system and the 365 / 395LED ultraviolet light source are used for instant glue curing. Based on the major transformation and upgrade of the equipment, while the middle monofilament spacer is inserted into the upper and lower surfaces, the upper and lower ends of the fiber filament are bonded and fixed to the upper and lower surfaces respectively under the joint action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together, which can greatly improve the stability of the mattress material.

[0046] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting is completed;

[0047] S5 inspection: After passing the inspection, the goods are packaged and put into storage.

[0048] In step S1, the materials required for preparing the composite fiber are used in the following amounts:

[0049] PTA chips (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%).

[0050] PTA (purified terephthalic acid) chips are one of the main raw materials for polyester fiber production, with excellent physical and chemical properties such as high melting point, high strength, good wear resistance and corrosion resistance.

[0051] In step S1, the auxiliary raw materials include a catalyst, a stabilizer, a dispersant, a toner and a lubricant.

[0052] In step S1, the catalyst includes antimony trioxide and titanium dioxide, which is used to accelerate the esterification reaction and subsequent polycondensation reaction between PTA chips and ethylene glycol, thereby improving production efficiency.

[0053] In step S1, the stabilizer includes an antioxidant, a light stabilizer and a hydrolysis resistance agent, which are used to improve the thermal stability, light stability and hydrolysis resistance of the composite fiber and prevent the product from being degraded or discolored during processing and use.

[0054] Antioxidants are a class of chemical substances that, when present in small amounts in a polymer system, can delay or inhibit the oxidation process of the polymer, thereby increasing the service life of the polymer. Light stabilizers, also known as UV stabilizers, are a class of stabilizing agents used to inhibit the photo-oxidative degradation of polymer resins and improve the weather resistance of plastic products.

[0055] In step S1, the dispersant includes one or two of triethylhexyl phosphate, sodium dodecyl sulfate, methyl amyl alcohol, cellulose derivatives, and polyacrylamide, which are used to improve the dispersion effect of pigments, fillers or other additives in the monofilaments and improve the uniformity and appearance quality of the products.

[0056] Dispersant is a surfactant that has two opposite properties, lipophilicity and hydrophilicity, in its molecule. It can evenly disperse the solid and liquid particles of inorganic and organic pigments that are difficult to dissolve in liquids. It can also prevent the sedimentation and agglomeration of particles, forming the amphiphilic reagent required for a stable suspension.

[0057] In step S1, the color powder is used to change the color of the material to make it more beautiful and increase the appearance and market competitiveness of the product.

[0058] In step S1, the lubricant includes calcium stearate or zinc stearate.

[0059] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0060] For monofilament mattresses, the needle bed of the existing warp knitting machine is further modified, and a high-temperature bonding process is added during weaving to fix the position of each monofilament to prevent it from shifting when compressed and destroying the overall shape of the mattress, thereby improving the stability of the mattress material.

[0061] In step S5, vacuum adsorption traction and hook-surface Velcro rollers are used for friction, stretching and traction to ensure the consistency and dimensional stability of the material. To facilitate cutting, the warp knitting machine needs to be lifted to a certain height as a whole.

[0062] Because the middle spacer layer has good toughness and elasticity, it cannot be rolled up like ordinary high-gauge fabrics. Vacuum adsorption traction and friction stretching traction of hook-surface Velcro rollers are required. In order to ensure the consistency and dimensional stability of the material, the warp knitting machine needs to be lifted to a certain height as a whole to facilitate cutting. After the produced fabric reaches the required specifications, it needs to be cut and removed immediately before production can continue.

[0063] 2) Mechanical properties test: Refer to the standard ASTMD3822-07 and related literature to test the single fiber strength of each composite fiber. Use the YG028PC electronic multifunctional strength machine to test the mechanical properties of the composite fiber. Set the machine clamping distance to 20mm, the room temperature to 25±2℃, the humidity to 55±5%, the stretching speed to 5mm / min, and the pre-tension to 5cN. The number of experiments is 30 times. After completing the above settings, you can start the tensile test.

[0064] 3) Results: The specific parameters of the mechanical properties of the composite fibers are shown in the following table.

[0065] Table 1 Mechanical properties of composite fibers

[0066] Fracture strength refers to the maximum ability of a material to resist fracture when subjected to external force. For mattress materials, the greater the fracture strength, the less likely the material is to break when subjected to force, thus ensuring the durability and stability of the mattress. Elongation at break refers to the maximum elongation of a material before it breaks when subjected to external force. It reflects the plastic deformation capacity of the material. For mattress materials, appropriate elongation at break can enable the mattress to better fit the curve of the human body when under pressure and provide a comfortable sleeping experience. Elastic modulus is a physical quantity that describes the relationship between stress and strain of a material in the elastic deformation stage. It reflects the ability of a material to resist elastic deformation. For mattress materials, the size of the elastic modulus directly affects the support performance and comfort of the mattress. As can be seen from the table, the composite fiber produced by this method has excellent mechanical properties.

[0067] Specific example 2:

[0068] Specific embodiment 2 is a process optimization of a new type of single-filament high-gauge mattress mentioned in specific embodiment 1. The material properties under different process conditions are compared to obtain the best process, and a mattress is prepared based on the optimized process. The difference in compression performance of mattress materials with the same thickness and different densities is analyzed, and the relationship between density and compression performance is established, providing a theoretical basis for the development of new mattress materials. The content of specific embodiment 2 is as follows:

[0069] 1) Sample preparation

[0070] S1 Preparation of composite fiber: PTA slices (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%) (catalyst, stabilizer, dispersant, color powder and lubricant) are mixed evenly in the required proportions, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using special drawing equipment. The diameter of the composite fiber is 100~500μm, and the processed composite fiber is neatly wound.

[0071] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0072] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0073] The weaving densities are 90, 100, 110, 120, 130, 140, 150 kg / m 3 , the serial numbers are A, B, C, D, E, F, and G respectively.

[0074] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting is completed;

[0075] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0076] 2) Test instruments and equipment

[0077] Microcomputer controlled electronic universal testing machine

[0078] 3) Compression performance test method

[0079] According to GB / T 26706-2011, the compression performance of the mattress sample was tested using a microcomputer-controlled electronic universal testing machine. The sample was placed on a compression platform, a round pad was placed in the center of the sample, and a 4N pressure was applied vertically downward at a speed of 20mm / min. The distance between the lower surface of the pad and the platform was recorded and calculated as the mattress material height H. o The sample to be measured is placed between the two plates of the compressor, compressed to 30% of its height, and kept in a compressed state at room temperature for 22 hours. The force is then released, and after 3 hours, a force of 4N is applied again. At this time, the distance between the lower surface and the plate is measured as height H1. The experimental results are statistically analyzed, and the sample compression rebound rate R is calculated according to formula (1), the compression permanent deformation rate CS is calculated according to formula (2), and the elastic coefficient k is calculated according to formula (3):

[0080] R=H1 / H o ×100% (1)

[0081] CS = (H o -H1) / H o ×100% (2)

[0082] K=P / 30%H o (3)

[0083] Where: R is the compression rebound rate of the mattress material, %;

[0084] CS: compression permanent deformation rate of mattress material, %;

[0085] K is the elastic coefficient of the mattress material, N / mm;

[0086] P--The compression force of the mattress material when it is compressed by 30%, N;

[0087] H o ——Initial height of mattress material, mm;

[0088] H1: Height of the mattress material after compression, mm.

[0089] 4) Results: The compression performance data of composite fiber materials with different weaving densities are shown in the table below.

[0090] Table 2 Compression performance of mattresses with different weaving densities

[0091] As can be seen from the table, the compression rebound rate is basically linearly related to the density, and as the density continues to increase, the compression rebound rate also continues to increase. This is because as the density increases, the gap between the fibers inside the mattress is significantly reduced, the fibers are closely connected, and the material as a whole is more inclined to be an elastomeric material, and its linear elastic stage increases, which is manifested as an increase in the compression rebound rate in this experimental test; the compression permanent deformation rate is basically negatively linearly related to the density of the mattress material. The higher the density, the lower the compression permanent deformation rate, that is, the stronger the deformation resistance of the mattress material. This is because as the density of the mattress increases, the number of fibers per unit volume increases significantly; the elastic coefficient is positively correlated with its density, and the elastic coefficient value of the mattress increases significantly with the increase of its density. Specific embodiment three:

[0093] Specific embodiment 3 is a parameter detection of a new type of single-filament high-gauge mattress mentioned in specific embodiment 2. The content of specific embodiment 3 is as follows:

[0094] 1) Sample preparation

[0095] S1 Preparation of composite fiber: PTA chips (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%) (catalyst, stabilizer, dispersant, color powder and lubricant) are mixed evenly in the required proportions, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using special drawing equipment, and the processed composite fiber is neatly wound.

[0096] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0097] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0098] S4 Cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material exceeding the edge, and weigh it after cutting.

[0099] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0100] 2) Vertical and horizontal density detection of fabric surface

[0101] The transverse density of the surface of warp knitted spacer fabric is also called "transverse density", which is the number of longitudinal rows of coils within 1 cm along the horizontal row direction of the warp knitted spacer fabric surface. The longitudinal density is also called "longitudinal density", which is the number of longitudinal rows of coils within 1 cm along the longitudinal length of the warp knitted spacer fabric surface. The transverse and longitudinal densities of warp knitted spacer fabric not only affect the air permeability of the fabric, but also affect the comfort and compression performance of the fabric. Generally, the greater the transverse and longitudinal density, the worse the air permeability of the fabric and the stronger the compression resistance of the fabric. To ensure the accuracy of the measurement, take 5 areas in the middle part of the fabric for measurement and take the average value of the measurement results. Specific embodiment four:

[0103] Specific embodiment 4 is a parameter detection of a new type of single-filament high-gauge mattress mentioned in specific embodiment 1. The content of specific embodiment 4 is as follows:

[0104] 1) Sample preparation

[0105] S1 Preparation of composite fiber: PTA chips (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%) (catalyst, stabilizer, dispersant, color powder and lubricant) are mixed evenly in the required proportions, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using special drawing equipment, and the processed composite fiber is neatly wound.

[0106] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0107] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0108] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting is completed;

[0109] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0110] 2) Single-layer fabric size and thickness detection

[0111] The thickness of warp knitted spacer fabric is one of the important factors affecting the compression performance of warp knitted spacer fabric. Generally, the greater the thickness, the more unstable the compression of the fabric, so in processing and production, appropriately adjusting the thickness of the fabric can improve the compression performance of the spacer fabric. The thickness of the fabric was measured with a ruler. Before the experiment, the spacer fabric was cut into square samples with a size of 135mm×135mm. Five pieces of fabric were selected for measurement, and the average value of the measurement results was taken. Specific embodiment five:

[0113] Specific embodiment 5 is a parameter detection of a new type of single-filament high-gauge mattress mentioned in specific embodiment 1. The content of specific embodiment 5 is as follows:

[0114] 1) Sample preparation

[0115] S1 Preparation of composite fiber: PTA chips (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%) (catalyst, stabilizer, dispersant, color powder and lubricant) are mixed evenly in the required proportions, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using special drawing equipment, and the processed composite fiber is neatly wound.

[0116] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0117] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0118] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting is completed;

[0119] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0120] 2) Spacer wire diameter detection

[0121] The thickness of the spacer wire is one of the important indicators that affect the compression performance of warp knitted spacer fabrics. Under the same other conditions, the thicker the spacer wire, the greater the compression stiffness of the spacer fabric and the stronger the compression resistance. Take 5 pieces of spacer wires of warp knitted spacer fabrics, measure their diameters with a CU6 fiber fineness tester, and take the average value to represent the diameter of the sample spacer wire. Specific embodiment six:

[0123] Specific embodiment 6 is a parameter detection of a new type of single-filament high-gauge mattress mentioned in specific embodiment 1. The content of specific embodiment 6 is as follows:

[0124] 1) Sample preparation

[0125] S1 Preparation of composite fiber: PTA chips (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%) (catalyst, stabilizer, dispersant, color powder and lubricant) are mixed evenly in the required proportions, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using special drawing equipment, and the processed composite fiber is neatly wound.

[0126] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0127] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0128] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting is completed;

[0129] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0130] 2) Inspection of the weaving angle and arrangement of spacer yarns

[0131] The weaving angle of the spacer yarn is the angle between the spacer yarn and the surface layer of the fabric, which is determined by the production process and shaping process of the spacer fabric. The tilt angle of the warp knitted spacer fabric is determined by taking a side photo of the fabric. The arrangement of the spacer yarn is divided into V-type, X-type, and IXI-type. The V-type and X-type warp knitted spacer fabrics have good compression stability, while the V-type is prone to tilting under greater compression force. This experiment uses the third arrangement type IXI, which makes the fabric not only have good compressive resistance in the vertical direction, but also relatively stable under compression. Specific embodiment seven:

[0133] Specific embodiment 7 is a parameter detection of a new type of single-filament high-gauge mattress mentioned in specific embodiment 1. The content of specific embodiment 7 is as follows:

[0134] 1) Sample preparation

[0135] S1 Preparation of composite fiber: PTA chips (40-50%), ethylene glycol (MEG) (40-50%), auxiliary raw materials (5-8%) (catalyst, stabilizer, dispersant, color powder and lubricant) are mixed evenly in the required proportions, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using special drawing equipment, and the processed composite fiber is neatly wound.

[0136] S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively;

[0137] S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so as to ensure that the three layers of fabric are firmly fastened together;

[0138] S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting is completed;

[0139] In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function, and while the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are respectively bonded and fixed to the upper and lower surfaces under high temperature conditions.

[0140] 2) Surface density test of spacer fabrics

[0141] The surface density of spacer fabric is the weight of the fabric per unit area of ​​the spacer fabric. The greater the surface density, the tighter the spacer wires, the better the compression performance of the fabric, and the greater the weight. In this experiment, the samples were cut into 135mm×135mm squares, and five samples were randomly selected and weighed using an electronic balance. The weight was then converted into weight per square meter to represent the surface density of the experimental spacer fabric.

[0142] 3) Results

[0143] Table 3 Basic parameters of warp knitted spacer fabrics Specific embodiment eight:

[0145] Specific embodiment 8 is a performance test of a new type of single-filament high-gauge mattress mentioned in specific embodiment 1. The performance test index and method are as follows:

[0146] 1) Color fastness to rubbing: According to GB / T 3920-2008 "Textiles - Tests for color fastness - Color fastness to rubbing", the color fastness to rubbing of mattress fabrics is tested.

[0147] 2) Moisture permeability: Test the moisture permeability of mattress fabrics according to GB / T 12704.2-2009 "Test method for moisture permeability of textile fabrics Part 2: Evaporation method".

[0148] 3) Formaldehyde content: Test the formaldehyde content of mattress fabrics according to GB / T 2912.1-2009 "Determination of formaldehyde in textiles - Part 1: Free and hydrolyzed formaldehyde (water extraction method)".

[0149] 4) Durability: Test the durability of mattress fabrics according to FZ / T 62020-2012 “Household Textile Warp Knitted Spacer Mattresses”.

[0150] 5) Flame retardancy: Test the flame retardancy of mattress fabrics in accordance with GB 17927.1-2011 “Assessment of anti-ignition properties of soft furniture mattresses and sofas Part 1: Smoldering cigarettes”.

[0151] 6) Antibacterial property: According to GB / T 20944.3-2008 “Evaluation of antibacterial properties of textiles Part 3: Oscillation method”, the antibacterial property of mattress fabrics against Staphylococcus aureus (AACC 6538) was tested.

[0152] 7) Air permeability: The YG461G fully automatic air permeability meter was used to conduct an air permeability test on a mattress woven from composite fibers. The air permeability meter is suitable for measuring the air permeability of various fabrics such as woven fabrics, knitted fabrics, and non-woven fabrics. The thickness of warp knitted spacer fabrics is relatively large. The instrument measures the fabric thickness in the range of 0 to 50 mm and the measurement range is 0.2 to 11838 mm / s. The experimental test data was collected according to the current national standard GB / T5453-1997 for measuring textiles and fabrics. The air permeability test was performed using the method of measuring flow at a constant pressure. The test pressure difference unit was Pa. The air permeability of the spacer fabric was tested when the pressure difference between the two sides of the fabric was 100 Pa. Each sample was tested 3 times.

[0153] Table 4 Basic parameters of warp knitted spacer fabrics

[0154] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A new type of monofilament high-gauge mattress material, characterized in that: Including the following raw materials: PTA chips, ethylene glycol (MEG), auxiliary raw materials, including: The PTA slices account for 40-50%; The ethylene glycol (MEG) accounts for 40-50%; The auxiliary raw materials account for 5-8%.

2. A novel monofilament high-gauge mattress material as claimed in claim 1, characterized in that: The auxiliary raw materials include catalyst, stabilizer, dispersant, color powder and lubricant.

3. A novel monofilament high-gauge mattress material as claimed in claim 1, characterized in that: The catalyst comprises antimony trioxide and titanium dioxide, and is used to accelerate the esterification reaction and the subsequent polycondensation reaction between the PTA chips and ethylene glycol, thereby improving the production efficiency.

4. A novel monofilament high-gauge mattress material as claimed in claim 1, characterized in that: The stabilizer includes an antioxidant, a light stabilizer and a hydrolysis resistance agent, which is used to improve the thermal stability, light stability and hydrolysis resistance of the composite fiber and prevent the product from being degraded or discolored during processing and use.

5. A novel monofilament high-gauge mattress material as claimed in claim 1, characterized in that: The dispersant includes one or two of triethylhexyl phosphoric acid, sodium dodecyl sulfate, methyl amyl alcohol, cellulose derivatives, and polyacrylamide, and is used to improve the dispersion effect of pigments and fillers in monofilaments, improve the uniformity of products, and enhance the appearance quality of products.

6. A novel monofilament high-gauge mattress material as claimed in claim 1, characterized in that: The color powder is used to change the color of the material, making it more beautiful and increasing the appearance and market competitiveness of the product.

7. A novel monofilament high-gauge mattress material as claimed in claim 1, characterized in that: The lubricant includes calcium stearate or zinc stearate.

8. A method for preparing the novel monofilament high-gauge mattress material according to claim 1, characterized in that: The steps include: S1 Preparation of composite fiber: PTA slices, ethylene glycol (MEG) and auxiliary raw materials are mixed evenly according to the proportion, heated and melted into liquid in a vacuum tank, and the molten mixed slurry is drawn into composite fiber using a special drawing and pulling equipment, and the processed composite fiber is neatly wound; S2 finishing: the composite fiber and the veil are sent to the warping machine for finishing respectively; S3 weaving: After finishing, the composite fiber and the veil are sent to the warp knitting machine for weaving. After weaving, a single-filament high-gauge fabric is generated. While the middle single-filament is inserted into the upper and lower surfaces, the upper and lower ends of the fiber are respectively bonded and fixed to the upper and lower surfaces under the combined action of high temperature and UV glue, so that the three-layer fabric is firmly fastened together; S4 cutting: Cut the woven monofilament high-gauge fabric according to the specified specifications, cut off the material beyond the edge, and weigh it after cutting; S5 inspection: After passing the inspection, the goods are packaged and put into storage.

9. A method for preparing a novel monofilament high-gauge mattress material as claimed in claim 8, characterized in that: In step S3, after the warp knitting machine is modified, the groove needles of the warp knitting machine have a heating function. When the middle spacer wire is inserted into the upper and lower surfaces, the upper and lower ends of the fiber wire are bonded and fixed to the upper and lower surfaces respectively under high temperature conditions.

10. A method for preparing a novel monofilament high-gauge mattress material as claimed in claim 8, characterized in that: In step S5, vacuum adsorption traction and hook-and-loop Velcro rollers are used to rub, stretch and pull the mattress to unify the consistency of the material and maintain dimensional stability.

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