Process for making high strength air cushions

Abstract

This invention relates to the field of air cushions, specifically to a manufacturing process for a high-strength air cushion. The invention uses modified PA6 as the outer layer fabric of the high-strength air cushion. It employs aliphatic hyperbranched epoxy resin as a modifier, which improves the fluid processing properties of the nylon fabric, promotes changes in the crystalline structure of the nylon fabric, and facilitates the formation and refinement of a more stable α-crystalline form. The interaction between PA6 and the aliphatic hyperbranched epoxy resin forms a homogeneous system, and the resulting micro-crosslinked structure significantly improves the mechanical properties of the modified system compared to the matrix resin. The high-strength air cushion prepared by this invention has excellent support strength, does not deform after prolonged use, and allows for easy air circulation, enabling consumers to effectively regulate temperature and humidity, providing breathability and comfort.

Description

Technical Field

[0001] This invention relates to the field of air cushions, and in particular to a manufacturing process for a high-strength air cushion. Background Technology

[0002] Air mattresses are like air-suspended beds, making the user feel as if they are floating in an airflow. This allows for easy repositioning, preventing pressure sores on the back, dampness, and potential infection from eschar formation, and also helps prevent bedsores. Bedsores are primarily caused by continuous pressure on the skin, leading to tissue ischemia and hypoxia, resulting in necrosis and ulceration of the skin. Air mattresses distribute body pressure across the skin of bedridden individuals, reducing localized pressure and preventing cell death. They also keep the skin dry, reducing sweat maceration and preventing localized skin infiltration damage, thus preventing bedsores. Air mattresses are particularly suitable for patients who are bedridden for extended periods, such as those with strokes or brain injuries.

[0003] CN202210349538.8: Belongs to the field of inflatable cushion technology, specifically a multi-layer inflatable cushion material with good sealing and elasticity and its preparation method. The multi-layer inflatable cushion material includes a supporting airbag, the supporting airbag includes a supporting skeleton, and airtight membranes are provided on the upper and lower sides of the supporting skeleton. The supporting airbags are stacked vertically, and shaping layers are provided between two adjacent supporting airbags, above the uppermost supporting airbag, and below the lowermost supporting airbag. A waterproof layer is provided on the upper side of the shaping layer above the uppermost supporting airbag, and a wear-resistant layer is provided on the upper side of the waterproof layer and the lower side of the shaping layer below the lowermost supporting airbag. The supporting skeleton includes a transverse skeleton and a longitudinal skeleton. The supporting skeleton in this invention can support the sealed cavity of the supporting airbag, thereby avoiding large deformation of the inflatable cushion.

[0004] CN202110660566.7 discloses a method for preparing an elastic air cushion material, including the following steps: First, an air bladder membrane is fitted onto the surface of the air cushion body, and a latex pad is placed inside. Multiple through holes are evenly pre-set on the surface of the latex pad, and then a support spring is placed inside the through holes. The two ends of the support spring are fixed to the interior of the air cushion body, thereby providing auxiliary support for the air cushion body through the latex pad and the support spring. The height and hardness of the air cushion body can be adjusted. This application incorporates a latex pad and support spring inside the air cushion body. By controlling the gas delivery volume, the height and hardness of the air cushion body can be adjusted, enhancing its functionality. It can be adjusted according to needs. Furthermore, bamboo charcoal fiber fabric and bamboo fiber fabric are placed inside, giving it certain moisture-wicking, antibacterial, and antistatic properties, and good environmental performance.

[0005] CN201710632316.6: This invention relates to a high-load-bearing environmentally friendly filament-based air cushion material and its preparation method. The air cushion material comprises, from bottom to top, a first PVC film, a first mesh fabric, a filament fabric, a second mesh fabric, and a second PVC film. The first PVC film and the first mesh fabric are bonded together. The filament fabric is connected to the first mesh fabric and the second mesh fabric respectively through weaving. The second mesh fabric and the second PVC film are bonded together. This invention uses a double-layer film structure of "reinforced film + PVC film," which not only improves the product's impact and wear resistance but also protects the filament fabric and maintains the product's inflation pressure even if any layer of the film is damaged and leaks air, ultimately achieving a dual leak-proof effect. In addition, by improving the process conditions and formula, the prepared air cushion material not only has stronger load-bearing capacity, cushioning function, and impact absorption, but also has excellent physical strength, elasticity, anti-aging properties, environmental friendliness, and long service life.

[0006] The air cushions produced by the above patents and existing technologies provide a good user experience in the short term, but the experience declines significantly with long-term use. In addition, most air cushions have a long strip assembly structure, and the part in contact with the skin is not breathable, making the skin prone to sweating and dampness under pressure. Summary of the Invention

[0007] To address the aforementioned technical problems, this invention provides a manufacturing process for a high-strength air cushion, the steps of which are as follows:

[0008] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0009] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0010] S3: One of the fabrics has a logo printed on it using screen printing.

[0011] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0012] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0013] S6: Trim and trim the edges of the air cushion;

[0014] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0015] Furthermore, the welding temperature is 140-160℃ and the welding time is 5-15s.

[0016] Furthermore, in the process of leak detection, the pressure inside the air cushion is controlled at 5000-8000 Pa.

[0017] Furthermore, the present invention provides a method for preparing a nylon fabric:

[0018] S1: By weight, dry 85-100 parts of PA6 new material at 80-90℃ for 18-24 hours;

[0019] S2: Weigh 0.5-3 parts of modifier, 3-7 parts of silsesquioxane alkyl amide compound, and add 100-150 parts of tetrahydrofuran to the reaction vessel containing PA6 while stirring.

[0020] S3: After drying the mixture in a 50-70℃ forced-air drying oven for 3-6 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0021] Furthermore, the temperature of the twin-screw extruder is 220-240℃.

[0022] Furthermore, the modifier of this invention is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0023] S1: Weigh 0.2-1 parts diethylenetriamine and 0.2-1 parts acrylonitrile by weight, heat to 75-100℃, react for 2-5 hours to obtain the curing agent;

[0024] S2: Mix 0.2-1 parts of curing agent, 12-20 parts of bisphenol A type epoxy resin E-51, and 16-22 parts of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool and demold it, and leave it at room temperature for 8-12 hours to obtain aliphatic hyperbranched epoxy resin.

[0025] Furthermore, the curing step of the present invention is as follows: first, cure at room temperature for 5-8 hours, then raise the temperature to 70-90℃ and continue curing for 1-3 hours.

[0026] Furthermore, the method for preparing the silsesquioxane alkylamide compound is as follows:

[0027] 30-48 parts of a mercaptoamide compound, 100-150 parts of N,N-dimethylformamide, 0.5-4 parts of acrylic polyurethane, and 2-4 parts of triethylamine were slowly heated to 70-80°C and stirred for 100-200 min under nitrogen protection. Then, 0.03-0.22 parts of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) were added, and the mixture was stirred for 50-100 min at 70-80°C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0028] Furthermore, the method for preparing the thioamide compound is as follows:

[0029] Weigh 25-32 parts of p-mercaptoterephthalic acid and 450-650 parts of water according to the mass fraction. Start stirring, heat to 45-60℃, purge with nitrogen for protection, and then slowly add 40-50 parts of 1,5-pentanediamine. Adjust the pH of the solution, stir for 0.5-2 hours, and evaporate to remove water to obtain the mercaptoamide compound.

[0030] Furthermore, the method for preparing the acrylic-based polyurethane is as follows:

[0031] According to the mass fractions, 20-28 parts of isophorone diisocyanate, 0.1-0.5 parts of organotin, 0.01-0.05 parts of di-tert-butyl-p-cresol and 17-25 parts of hydroxypropyl acrylate (HPA) are added to a reaction vessel and heated to 100-115℃ for 3-5 hours to obtain acrylic polyurethane.

[0032] Reaction mechanism:

[0033] The acrylic polyurethane and mercaptoamide compounds undergo an addition reaction, followed by an addition reaction with γ-methacryloyloxypropyl cage-like silsesquioxane, thereby improving the aging resistance of the nylon fabric.

[0034] Technical effects:

[0035] The manufacturing process of a high-strength air cushion according to the present invention has the following significant advantages compared with the prior art:

[0036] 1. This invention uses aliphatic hyperbranched epoxy resin as a modifier to prepare nylon fabric; the addition of aliphatic hyperbranched epoxy resin improves the fluid processing performance of nylon fabric, promotes the change of crystalline structure of nylon fabric, and is conducive to the generation and perfection of more stable α crystal form; the interaction between PA6 and aliphatic hyperbranched epoxy resin forms a homogeneous system, and the generated micro-crosslinked structure makes the mechanical properties of the modified system significantly improved compared with the matrix resin.

[0037] 2. This invention adds aliphatic hyperbranched epoxy resin as a modifier, which maximizes the tensile strength and impact strength of the nylon fabric, and gradually increases the bending strength and bending modulus of the nylon fabric as well.

[0038] 3. The nylon fabric prepared by this invention has a homogeneous fracture morphology, exhibits in-situ toughening and reinforcement characteristics, and has good overall performance;

[0039] 4. The high-strength air cushion prepared by this invention has excellent support strength, does not deform after long-term use, and allows for easy air circulation. Consumers can effectively regulate temperature and humidity, and it is breathable and comfortable. Attached image description:

[0040] Figure 1 This is a picture of an air cushion product manufactured using the process of this invention. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0042] The specific embodiments of the present invention are tested according to the following method:

[0043] 1. Melt index test: Take an appropriate amount of dried modified nylon fabric and test the melt index of the corresponding blend under the conditions of 2.5 kg load and 230℃ using a melt indexer.

[0044] 2. Mechanical property testing: The modified nylon fabric was prepared into strips, and its mechanical properties were tested on a universal mechanical testing machine in accordance with national testing standards; the tensile strength test rate was set to 50 mm / min, and the bending strength test rate was set to 2 mm / min.

[0045] 3. The test method for resistance to aging and cracking is as follows: Take a sample (5cm x 1cm x 2mm) and age it in a high-temperature aging chamber. After aging, place the sample at room temperature for more than 2 hours, then attach it to a cylinder of the same diameter and bend it into the same arc. Observe and compare the number and size of cracks on the sample surface.

[0046] Example 1

[0047] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0048] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0049] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0050] S3: One of the fabrics has a logo printed on it using screen printing.

[0051] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0052] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0053] S6: Trim and trim the edges of the air cushion;

[0054] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0055] The welding temperature is 140℃ and the time is 5 seconds.

[0056] During the leak detection process, the pressure inside the air cushion is controlled at 5000 Pa.

[0057] The method for preparing a nylon fabric as described above:

[0058] S1: Dry 85kg of new PA6 material at 80℃ for 18h;

[0059] S2: Weigh 0.5 kg of modifier and 3 kg of silsesquioxane alkyl amide compound, and add 100 kg of tetrahydrofuran dropwise into the reactor containing PA6 while stirring.

[0060] S3: After drying the mixture in a 50℃ forced-air drying oven for 3 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0061] The temperature of the twin-screw extruder is 220℃.

[0062] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0063] S1: Weigh 0.2 kg of diethylenetriamine and 0.2 kg of acrylonitrile, heat to 75°C, react for 2 h to obtain the curing agent;

[0064] S2: Mix 0.2 kg of curing agent, 12 kg of bisphenol A type epoxy resin E-51, and 16 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool it, demold it, and leave it at room temperature for 8 hours to obtain aliphatic hyperbranched epoxy resin.

[0065] The curing steps are as follows: first cure at room temperature for 5 hours, then raise the temperature to 70°C and continue curing for 1 hour.

[0066] The preparation method of the silsesquioxane alkylamide compound is as follows:

[0067] 30 kg of a mercaptoamide compound, 100 kg of N,N-dimethylformamide, 0.5 kg of acrylic polyurethane, and 2 kg of triethylamine were slowly heated to 70 °C and stirred for 100 min under nitrogen protection. Then, 0.03 kg of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) was added, and the mixture was stirred for 50 min at 70 °C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0068] The method for preparing the mercaptoamide compound is as follows:

[0069] Weigh 25 kg of mercaptoterephthalic acid and 450 kg of water, start stirring, heat to 45 °C, purge with nitrogen for protection, then slowly add 40 kg of 1,5-pentanediamine, adjust the pH of the solution, stir for 0.5 h, evaporate to remove water, and obtain mercaptoamide compound.

[0070] The preparation method of the acrylic polyurethane is as follows:

[0071] 20 kg of isophorone diisocyanate, 0.1 kg of organotin, 0.01 kg of di-tert-butyl-p-cresol and 17 kg of hydroxypropyl acrylate (HPA) were added to a reaction vessel and heated to 100 °C for 3 h to obtain acrylic polyurethane.

[0072] Example 2

[0073] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0074] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0075] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0076] S3: One of the fabrics has a logo printed on it using screen printing.

[0077] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0078] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0079] S6: Trim and trim the edges of the air cushion;

[0080] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0081] The welding temperature is 145℃ and the time is 9s.

[0082] During the leak detection process, the pressure inside the air cushion is controlled at 6000 Pa.

[0083] The method for preparing a nylon fabric as described above:

[0084] S1: Dry 90kg of new PA6 material at 85℃ for 20h;

[0085] S2: Weigh 1 kg of modifier, 4 kg of silsesquioxane alkyl amide compound, and add 110 kg of tetrahydrofuran dropwise into the reaction vessel containing PA6 while stirring.

[0086] S3: After drying the mixture in a 55℃ forced-air drying oven for 4 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0087] The temperature of the twin-screw extruder is 225°C.

[0088] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0089] S1: Weigh 0.5 kg of diethylenetriamine and 0.5 kg of acrylonitrile, heat to 80°C, react for 3 hours to obtain the curing agent;

[0090] S2: Mix 0.5 kg of curing agent, 15 kg of bisphenol A type epoxy resin E-51, and 18 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool and demold it, and leave it at room temperature for 9 hours to obtain aliphatic hyperbranched epoxy resin.

[0091] The curing steps are as follows: first cure at room temperature for 6 hours, then raise the temperature to 75°C and continue curing for 2 hours.

[0092] The preparation method of the silsesquioxane alkylamide compound is as follows:

[0093] 36 kg of a mercaptoamide compound, 110 kg of N,N-dimethylformamide, 1 kg of acrylic polyurethane, and 3 kg of triethylamine were slowly heated to 75 °C and stirred for 140 min under nitrogen protection. Then, 0.1 kg of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) was added, and the mixture was stirred for 60 min at 75 °C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0094] The method for preparing the mercaptoamide compound is as follows:

[0095] Weigh 27 kg of p-mercaptoterephthalic acid and 500 kg of water, start stirring, heat to 50 °C, purge with nitrogen for protection, then slowly add 44 kg of 1,5-pentanediamine, adjust the pH of the solution, stir for 1 h, evaporate to remove water, and obtain the mercaptoamide compound.

[0096] The preparation method of the acrylic polyurethane is as follows:

[0097] 23 kg of isoflurane diisocyanate, 0.2 kg of organotin, 0.02 kg of di-tert-butyl-p-cresol and 19 kg of hydroxypropyl acrylate (HPA) were added to a reaction vessel and heated to 105 °C for 4 h to obtain acrylic polyurethane.

[0098] Example 3

[0099] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0100] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0101] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0102] S3: One of the fabrics has a logo printed on it using screen printing.

[0103] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0104] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0105] S6: Trim and trim the edges of the air cushion;

[0106] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0107] The welding temperature is 155℃ and the time is 13s.

[0108] During the leak detection process, the pressure inside the air cushion is controlled at 7000 Pa.

[0109] The method for preparing a nylon fabric as described above:

[0110] S1: Dry 95kg of new PA6 material at 85℃ for 22h;

[0111] S2: Weigh 2 kg of modifier, 6 kg of silsesquioxane alkyl amide compound, and add 140 kg of tetrahydrofuran dropwise into the reaction vessel containing PA6 while stirring.

[0112] S3: After drying the mixture in a 65℃ forced-air drying oven for 5 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0113] The temperature of the twin-screw extruder is 235°C.

[0114] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0115] S1: Weigh 0.8 kg of diethylenetriamine and 0.8 kg of acrylonitrile, heat to 95°C, and react for 4 hours to obtain the curing agent;

[0116] S2: Mix 0.8 kg of curing agent, 18 kg of bisphenol A type epoxy resin E-51, and 20 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool and demold it, and leave it at room temperature for 11 hours to obtain aliphatic hyperbranched epoxy resin.

[0117] The curing steps are as follows: first cure at room temperature for 7 hours, then raise the temperature to 85°C and continue curing for 2 hours.

[0118] The preparation method of the silsesquioxane alkylamide compound is as follows:

[0119] 42 kg of a mercaptoamide compound, 140 kg of N,N-dimethylformamide, 3 kg of acrylic polyurethane, and 3 kg of triethylamine were slowly heated to 75 °C and stirred for 180 min under nitrogen protection. Then, 0.2 kg of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) was added, and the mixture was stirred for 90 min at 75 °C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0120] The method for preparing the mercaptoamide compound is as follows:

[0121] Weigh 30 kg of mercaptoterephthalic acid and 600 kg of water, start stirring, heat to 55°C, purge with nitrogen for protection, then slowly add 48 kg of 1,5-pentanediamine, adjust the pH of the solution, stir for 1.5 h, evaporate to remove water, and obtain mercaptoamide compound.

[0122] The preparation method of the acrylic polyurethane is as follows:

[0123] 26 kg of isoflurane diisocyanate, 0.4 kg of organotin, 0.04 kg of di-tert-butyl-p-cresol and 22 kg of hydroxypropyl acrylate (HPA) were added to a reaction vessel and heated to 110 °C for 4 h to obtain acrylic polyurethane.

[0124] Example 4

[0125] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0126] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0127] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0128] S3: One of the fabrics has a logo printed on it using screen printing.

[0129] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0130] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0131] S6: Trim and trim the edges of the air cushion;

[0132] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time, and control the pressure at 8000pa.

[0133] The welding temperature is 160℃ and the time is 15s.

[0134] During the leak detection process, the pressure inside the air cushion is controlled at 8000 Pa.

[0135] The method for preparing a nylon fabric as described above:

[0136] S1: Dry 100 kg of new PA6 material at 90℃ for 24 hours;

[0137] S2: Weigh 3 kg of modifier, 7 kg of silsesquioxane alkyl amide compound, and add 150 kg of tetrahydrofuran dropwise into the reaction vessel containing PA6 while stirring.

[0138] S3: After drying the mixture in a 70℃ forced-air drying oven for 6 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0139] The temperature of the twin-screw extruder is 240℃.

[0140] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0141] S1: Weigh 1 kg of diethylenetriamine and 1 kg of acrylonitrile, heat to 100℃, react for 5 h to obtain the curing agent;

[0142] S2: Mix 1 kg of curing agent, 20 kg of bisphenol A type epoxy resin E-51, and 22 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool it, demold it, and leave it at room temperature for 12 hours to obtain aliphatic hyperbranched epoxy resin.

[0143] The curing steps are as follows: first cure at room temperature for 8 hours, then raise the temperature to 90°C and continue curing for 3 hours.

[0144] The preparation method of the silsesquioxane alkylamide compound is as follows:

[0145] 48 kg of a mercaptoamide compound, 150 kg of N,N-dimethylformamide, 4 kg of acrylic polyurethane, and 4 kg of triethylamine were slowly heated to 80 °C and stirred for 200 min under nitrogen protection. Then, 0.22 kg of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) was added, and the mixture was stirred for 100 min at 80 °C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0146] The method for preparing the mercaptoamide compound is as follows:

[0147] Weigh 32 kg of p-mercaptoterephthalic acid and 650 kg of water, start stirring, heat to 60 °C, purge with nitrogen for protection, then slowly add 50 kg of 1,5-pentanediamine, adjust the pH of the solution, stir for 2 h, evaporate to remove water, and obtain the mercaptoamide compound.

[0148] The preparation method of the acrylic polyurethane is as follows:

[0149] 28 kg of isoflurane diisocyanate, 0.5 kg of organotin, 0.05 kg of di-tert-butyl-p-cresol and 25 kg of hydroxypropyl acrylate (HPA) were added to a reaction vessel and heated to 115 °C for 5 h to obtain acrylic polyurethane.

[0150] Comparative Example 1

[0151] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0152] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0153] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0154] S3: One of the fabrics has a logo printed on it using screen printing.

[0155] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0156] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0157] S6: Trim and trim the edges of the air cushion;

[0158] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0159] The welding temperature is 140℃ and the time is 5 seconds.

[0160] During the leak detection process, the pressure inside the air cushion is controlled at 5000 Pa.

[0161] The method for preparing a nylon fabric as described above:

[0162] S1: Dry 85kg of new PA6 material at 80℃ for 18h;

[0163] S2: Weigh 0.5 kg of modifier and 100 kg of tetrahydrofuran, and add them dropwise into the reactor containing PA6 while stirring.

[0164] S3: After drying the mixture in a 50℃ forced-air drying oven for 3 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0165] The temperature of the twin-screw extruder is 220℃.

[0166] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0167] S1: Weigh 0.2 kg of diethylenetriamine and 0.2 kg of acrylonitrile, heat to 75°C, react for 2 h to obtain the curing agent;

[0168] S2: Mix 0.2 kg of curing agent, 12 kg of bisphenol A type epoxy resin E-51, and 16 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool it, demold it, and leave it at room temperature for 8 hours to obtain aliphatic hyperbranched epoxy resin.

[0169] The curing steps are as follows: first cure at room temperature for 5 hours, then raise the temperature to 70°C and continue curing for 1 hour.

[0170] Comparative Example 2

[0171] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0172] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0173] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0174] S3: One of the fabrics has a logo printed on it using screen printing.

[0175] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0176] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0177] S6: Trim and trim the edges of the air cushion;

[0178] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0179] The welding temperature is 140℃ and the time is 5 seconds.

[0180] During the leak detection process, the pressure inside the air cushion is controlled at 5000 Pa.

[0181] The method for preparing a nylon fabric as described above:

[0182] S1: Dry 85kg of new PA6 material at 80℃ for 18h;

[0183] S2: Weigh 0.5 kg of modifier and 3 kg of silsesquioxane alkyl amide compound, and add 100 kg of tetrahydrofuran dropwise into the reactor containing PA6 while stirring.

[0184] S3: After drying the mixture in a 50℃ forced-air drying oven for 3 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0185] The temperature of the twin-screw extruder is 220℃.

[0186] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0187] S1: Weigh 0.2 kg of diethylenetriamine and 0.2 kg of acrylonitrile, heat to 75°C, react for 2 h to obtain the curing agent;

[0188] S2: Mix 0.2 kg of curing agent, 12 kg of bisphenol A type epoxy resin E-51, and 16 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool it, demold it, and leave it at room temperature for 8 hours to obtain aliphatic hyperbranched epoxy resin.

[0189] The curing steps are as follows: first cure at room temperature for 5 hours, then raise the temperature to 70°C and continue curing for 1 hour.

[0190] The preparation method of the silsesquioxane alkylamide compound is as follows:

[0191] 100 kg of N,N-dimethylformamide, 0.5 kg of acrylic polyurethane, and 2 kg of triethylamine were slowly heated to 70 °C and stirred for 100 min under nitrogen protection. Then, 0.03 kg of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) was added, and the mixture was stirred for 50 min at 70 °C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0192] The preparation method of the acrylic polyurethane is as follows:

[0193] 20 kg of isophorone diisocyanate, 0.1 kg of organotin, 0.01 kg of di-tert-butyl-p-cresol and 17 kg of hydroxypropyl acrylate (HPA) were added to a reaction vessel and heated to 100 °C for 3 h to obtain acrylic polyurethane.

[0194] Comparative Example 3

[0195] A manufacturing process for a high-strength air cushion, comprising the following steps:

[0196] S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers.

[0197] S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine;

[0198] S3: One of the fabrics has a logo printed on it using screen printing.

[0199] S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A;

[0200] S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer.

[0201] S6: Trim and trim the edges of the air cushion;

[0202] S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time.

[0203] The welding temperature is 140℃ and the time is 5 seconds.

[0204] During the leak detection process, the pressure inside the air cushion is controlled at 5000 Pa.

[0205] The method for preparing a nylon fabric as described above:

[0206] S1: Dry 85kg of new PA6 material at 80℃ for 18h;

[0207] S2: Weigh 0.5 kg of modifier and 3 kg of silsesquioxane alkyl amide compound, and add 100 kg of tetrahydrofuran dropwise into the reactor containing PA6 while stirring.

[0208] S3: After drying the mixture in a 50℃ forced-air drying oven for 3 hours, it is then extruded in a twin-screw extruder to obtain nylon fabric.

[0209] The temperature of the twin-screw extruder is 220℃.

[0210] The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows:

[0211] S1: Weigh 0.2 kg of diethylenetriamine and 0.2 kg of acrylonitrile, heat to 75°C, react for 2 h to obtain the curing agent;

[0212] S2: Mix 0.2 kg of curing agent, 12 kg of bisphenol A type epoxy resin E-51, and 16 kg of hyperbranched epoxy resin, then place the mixture in a vacuum glass bottle and remove air bubbles at room temperature. Pour the mixture into a mold, cure it, cool it, demold it, and leave it at room temperature for 8 hours to obtain aliphatic hyperbranched epoxy resin.

[0213] The curing steps are as follows: first cure at room temperature for 5 hours, then raise the temperature to 70°C and continue curing for 1 hour.

[0214] The preparation method of the silsesquioxane alkylamide compound is as follows:

[0215] 30 kg of a mercaptoamide compound, 100 kg of N,N-dimethylformamide, and 2 kg of triethylamine were slowly heated to 70 °C and stirred for 100 min under nitrogen protection. Then, 0.03 kg of γ-methacryloyloxypropyl cage-like silsesquioxane (CAS No.: 160185-24-0) was added, and the mixture was stirred for 50 min at 70 °C under nitrogen protection. The N,N-dimethylformamide was then evaporated to obtain a silsesquioxane-containing alkylamide compound.

[0216] The method for preparing the mercaptoamide compound is as follows:

[0217] Weigh 25 kg of mercaptoterephthalic acid and 450 kg of water, start stirring, heat to 45 °C, purge with nitrogen for protection, then slowly add 40 kg of 1,5-pentanediamine, adjust the pH of the solution, stir for 0.5 h, evaporate to remove water, and obtain mercaptoamide compound.

[0218]

[0219]

[0220] The embodiments described above are merely illustrative of implementation methods of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A manufacturing process for a high-strength air cushion, comprising the following steps: S1: Fabric cutting, which involves cutting all rolls of fabric into shape using a cutting machine. The fabric includes upper and lower nylon outer layers and an aluminum foil insulation layer located between the upper and lower nylon outer layers. S2: Multiple through holes are punched into the aluminum foil insulation layer using a punching machine; S3: One of the fabrics has a logo printed on it using screen printing. S4: Another piece of fabric is connected to the air nozzle via high-frequency welding, with a current of 0.4A; S5: Stack the upper nylon fabric layer, the aluminum film insulation layer and the lower nylon fabric layer in sequence, and use a hot melt machine to weld the edges of the upper nylon fabric layer and the lower nylon fabric layer together, and weld the upper nylon fabric layer and the lower nylon fabric layer together at the positions corresponding to the through holes in the aluminum film insulation layer. S6: Trim and trim the edges of the air cushion; S7: Leakage detection. Connect the air nozzle of the air cushion to the detection device and ventilate it. Detect the internal pressure of the air cushion over a period of time. The method for preparing the nylon fabric is as follows: A1: By weight, dry 85-100 parts of PA6 new material at 80-90℃ for 18-24 hours; A2: Weigh 0.5-3 parts of modifier, 3-7 parts of silsesquioxane alkyl amide compound, and add 100-150 parts of tetrahydrofuran dropwise into the reaction vessel containing PA6 while stirring. A3: After drying the mixture in a 50-70℃ forced-air drying oven for 3-6 hours, it is extruded in a twin-screw extruder to obtain nylon fabric; The modifier is an aliphatic hyperbranched epoxy resin, and its preparation method is as follows: B1: Weigh 0.2-1 parts by weight of diethylenetriamine and 0.2-1 parts by weight of acrylonitrile, heat to 75-100℃, react for 2-5 hours to obtain the curing agent; B2: Mix 0.2-1 parts of curing agent, 12-20 parts of bisphenol A type epoxy resin E-51, and 16-22 parts of hyperbranched epoxy resin, place the mixture in a vacuum glass bottle, remove air bubbles at room temperature, pour it into a mold, cure, cool and demold, and leave at room temperature for 8-12 hours to obtain aliphatic hyperbranched epoxy resin.

2. The manufacturing process of a high-strength air cushion according to claim 1, characterized in that: The welding temperature is 140-160℃ and the time is 5-15s.

3. The manufacturing process of a high-strength air cushion according to claim 1, characterized in that: During the leak detection process, the pressure inside the air cushion is controlled at 5000-8000 Pa.

4. The manufacturing process of a high-strength air cushion according to claim 1, characterized in that: The temperature of the twin-screw extruder is 220-240℃.

5. The manufacturing process of a high-strength air cushion according to claim 1, characterized in that: The curing steps are as follows: first cure at room temperature for 5-8 hours, then raise the temperature to 70-90℃ and continue curing for 1-3 hours.

6. The manufacturing process of a high-strength air cushion according to claim 1, characterized in that: The preparation method of the silsesquioxane alkylamide compound is as follows: 30-48 parts of a mercaptoamide compound, 100-150 parts of N,N-dimethylformamide, 0.5-4 parts of acrylic polyurethane, and 2-4 parts of triethylamine are slowly heated to 70-80°C and stirred for 100-200 min under nitrogen protection. Then, 0.03-0.22 parts of γ-methacryloyloxypropyl cage-like silsesquioxane are added, and the mixture is stirred for 50-100 min at 70-80°C under nitrogen protection. The N,N-dimethylformamide is then evaporated to obtain a silsesquioxane-containing alkylamide compound.

7. The manufacturing process of a high-strength air cushion according to claim 6, characterized in that: The method for preparing the mercaptoamide compound is as follows: Weigh 25-32 parts of p-mercaptoterephthalic acid and 450-650 parts of water according to the mass fraction. Start stirring, heat to 45-60℃, purge with nitrogen for protection, and then slowly add 40-50 parts of 1,5-pentanediamine. Adjust the pH of the solution, stir for 0.5-2 hours, and evaporate to remove water to obtain the mercaptoamide compound.

8. The manufacturing process of a high-strength air cushion according to claim 6, characterized in that: The preparation method of the acrylic polyurethane is as follows: According to the mass fractions, 20-28 parts of isophorone diisocyanate, 0.1-0.5 parts of organotin, 0.01-0.05 parts of di-tert-butyl-p-cresol and 17-25 parts of hydroxypropyl acrylate (HPA) are added to a reaction vessel and heated to 100-115℃ for 3-5 hours to obtain acrylic polyurethane.

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