Mattress with functional zoned structure and process for its production

Abstract

This invention discloses a mattress with a functional partitioned structure and its manufacturing process, relating to the technical field of mattresses, manufacturing processes, and equipment. The invention includes a heating base, a fixing rod, a support frame, a motor, a lifting screw, a sealing top cover, a support plate, and a demolding mechanism. By setting up a demolding mechanism, the sealing top cover can be stably raised and lowered along the inner wall of the support plate via a motor, lifting screw, and limiting slide plate. The lifting assembly causes the demolding push plate to automatically demold the foamed latex pad. Simultaneously, through the cooperation of a fixed slider, a second guide groove, a first guide groove, a moving rotating plate, rollers, and a fixed pull plate, the demolding push plate can cause the demolded latex pad to flip and unload. Then, the motor is started to reverse the above operations, allowing the demolding push plate to reset. When the demolding push plate detaches from the inner cavity of the heating base, the limiting mechanism can limit and block the demolding push plate, further improving the production efficiency of latex pads of different thicknesses.

Description

Technical Field

[0001] This invention relates to the field of mattress technology and its manufacturing process and equipment, specifically to mattresses with functional partitioning structures and their manufacturing process. Background Technology

[0002] A mattress is an item placed between the human body and the bed to ensure that consumers get healthy and comfortable sleep. There are many types of mattress materials, and mattresses made of different materials can bring different sleep effects. In order to more effectively conform to the human body, existing mattresses have a support component inside. The support component consists of a support sleeve with a return spring inside, so that the surface of the mattress has better elasticity to conform to the curves of the human body. At the same time, to increase the comfort of the mattress, a latex pad made of latex is fixed on the upper surface of the support component. The latex pad has multiple grooves formed on it, so that the latex pad can better breathe and dissipate heat.

[0003] In the current production process of latex mattresses, the latex raw material is foamed and formed inside a mold by heating. However, during this process, the material of the latex increases the friction between the formed latex mattress and the mold, so the latex mattress needs to be removed manually. In addition, the thickness of the latex mattress is difficult to adjust conveniently according to needs. In order to further improve the production efficiency of latex mattresses of different thicknesses, we have proposed a mattress with a functional partition structure and its production process. Summary of the Invention

[0004] The purpose of this invention is to provide a mattress with a functional partition structure and its manufacturing process in order to further improve the production efficiency of latex mattresses of different thicknesses.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a mattress with a functional partition structure, including a mattress cover, wherein a protective cloth is fixedly connected inside the mattress cover and contacts the bottom of the inner wall of the mattress cover, a support sleeve is fixedly connected inside the protective cloth, and a filling layer is fixedly connected to the upper surface of the protective cloth. The filling layer includes: a sponge pad, a latex pad, and memory foam; The memory foam is fixedly connected to the top of the protective fabric and contacts the top of the support sleeve. The latex pad is fixedly connected to the top of the memory foam, and the sponge pad is fixedly connected to the top of the latex pad and contacts the top of the inner wall of the mattress cover.

[0006] As a further aspect of the present invention: the manufacturing process of a mattress with a functional partition structure uses a mattress with a functional partition structure, and the specific steps are as follows: S1. Mixing: The raw materials such as latex (also known as resin juice), foaming agent, stabilizer and filler are thoroughly mixed using a mixer; S2, Foaming Molding: The mixed raw materials are poured into the mold assembly, and the foaming agent is activated and decomposed at a certain temperature by heating. The decomposition of the foaming agent will produce a large amount of gas, which will make the latex form a uniform and delicate bubble structure until a latex pad is formed inside the mold assembly. S3. Cleaning and drying: The latex pads in the conveyor are cleaned by the nozzles and excess water is squeezed out by the pressure rollers. Then the latex pads are placed to dry. S4. Bed Netting Construction: The equipment wraps multiple return springs with non-woven fabric and separates multiple telescopic springs. Then, the fabric is connected and glued together to form a support sleeve. The fabric is then woven to fix the outside of the support sleeve, thus binding the outside of the support sleeve to form a protective fabric. S5. Adhesion: Place the memory foam on the upper surface of the protective cloth, then place the latex pad on the upper surface of the memory foam, and finally place the sponge pad on the upper surface of the latex pad. During this process, the memory foam, latex pad, and sponge pad are bonded and fixed in sequence by adhesive to form a filling layer. S6. Packaging and sewing: The fabric is sewn to the outside of the filling layer, protective cloth, and support cover using equipment to form a mattress cover.

[0007] As a further embodiment of the present invention: the mold assembly used in S2 includes a heating base. Multiple sets of fixing rods are horizontally and equidistantly fixed to the bottom of the inner wall of the heating base. Each set of fixing rods has multiple members. These multiple fixing rods are longitudinally and equidistantly fixed to the bottom of the inner wall of the heating base. A support frame is provided on one side of the heating base. The support frame is L-shaped. A motor is installed at the top of the support frame. A lifting screw is fixedly connected to the output end of the motor. The lifting screw is rotatably connected to the support frame via a rotating shaft. A sealing top cover is provided on the upper surface of the heating base and sleeved on the outer wall of the lifting screw. The inner wall of the lifting screw has an internal thread that matches the thread on the outer wall of the lifting screw. Two support plates are symmetrically formed on the outer wall of the support frame. The two support plates respectively contact the outer walls of the heating base and the sealing top cover at both ends. A demolding mechanism is provided on the heating base for automatically unloading the latex pad. The demolding mechanism includes: a sealing component and a pushing component; A sealing component installed on the heating base is used to block the latex during the heating process; A pusher assembly mounted on the heating base is used for automatic demolding and unloading of the latex pads; The heating base is provided with a limiting mechanism below the pushing component, and the limiting mechanism is used to limit the height of the pushing component. The sealing assembly includes: A demolding push plate is slidably connected inside the heating base. The demolding push plate is slidably sleeved on the outer wall of multiple fixed rods. Two sets of sealing inserts are symmetrically fixedly connected to the outer wall of the demolding push plate. There are two sealing inserts in one set. The two sealing inserts are symmetrically fixedly connected to the outer wall of one end of the demolding push plate and penetrate into the interior of the sealing top cover.

[0008] As a further embodiment of the present invention: the push component includes: Two movable rotating plates are symmetrically arranged inside the heating base. Two fixed sliders are symmetrically fixed to one end of each of the two movable rotating plates. The two fixed sliders are respectively fixedly connected to two sealing plates. The heating base is provided with a limiting groove for the movable rotating plates to slide up and down. The heating base is fixedly connected inside the limiting groove with a guide frame sleeved on the outer wall of the two fixed sliders. The guide frame passes through the heating base to the top of the sealing top cover.

[0009] As a further embodiment of the present invention: the limiting mechanism includes: A ratchet is mounted on the outer wall of one end of the heating base. A knob is fixedly connected to the end of the ratchet away from the heating base. A positioning block is engaged with the outer wall of the ratchet. A movable slide rod is fixedly connected to the side of the positioning block away from the ratchet. A limit baffle is fixedly connected to the side of the movable slide rod away from the positioning block. A fixing sleeve is provided on the outer wall of one side of the limit baffle. The fixing sleeve is sleeved on the outer wall of the movable slide rod and fixedly connected to the heating base. A return spring is sleeved on the outer wall of the movable slide rod. The two ends of the return spring are in contact with the outer walls of the positioning block and the fixing sleeve, respectively. The end of the ratchet gear furthest from the knob is fixedly connected to a bidirectional lead screw via a connecting shaft. The bidirectional lead screw is rotatably connected to the heating base via a rotating shaft. Two movable slides are symmetrically fitted onto the outer wall of the bidirectional lead screw. The inner walls of the two movable slides are each provided with internal threads that match the threads on the outer wall of the bidirectional lead screw and are slidably connected to the heating base. A lifting push plate is provided above the ends of the two movable slides furthest from each other. The lifting push plate is slidably connected to the heating base and contacts the lower surface of the demolding push plate. Two sliding guide plates are symmetrically formed on the outer wall of the lifting push plate. The two sliding guide plates are slidably connected to the outer walls of two fixed rods respectively. Two sets of rotating brackets are symmetrically rotatably connected to the bottom ends of the two lifting push plates via rotating shafts. The two sets of rotating brackets are rotatably connected to the movable slides via rotating shafts. Multiple rotating brackets are provided in each set. The multiple rotating brackets are laterally equidistantly rotatably connected to the bottom end of the lifting push plate via rotating shafts and are slidably connected to the heating base.

[0010] As a further embodiment of the present invention: the outer wall of the sealing top cover is symmetrically formed with two sets of limiting slide plates that are slidably connected to the support plate. Each set of limiting slide plates has two plates, and the two limiting slide plates are symmetrically formed on one end of the outer wall of the sealing top cover and are slidably connected to the support plate.

[0011] As a further embodiment of the present invention: the outer wall of the sealing insert plate is symmetrically formed with two guide strips, the outer walls of the two guide strips are semi-circular, and the heating base is provided with a docking slot that matches the outer walls of the sealing insert plate and the guide strips.

[0012] As a further embodiment of the present invention: the outer wall of the top of the sealing insert plate is in the shape of a square platform, and the sealing top cover is provided with a lifting groove for the sealing insert plate to slide up and down.

[0013] As a further embodiment of the present invention: two fixed pull plates are symmetrically arranged at the bottom end of the sealing top cover. The two fixed pull plates are respectively in contact with the outer wall of the end of the two movable rotating plates away from the fixed slider, and extend to the outside of the top of the sealing top cover. The top of each of the two fixed pull plates is fixedly connected to a fixed baffle located above the sealing top cover. The lower ends of the two fixed pull plates near the ends of the two movable rotating plates are rotatably connected to rollers through a rotating shaft. The movable rotating plates are provided with linear sliding grooves for the rollers to slide, and the sealing top cover is provided with sliding sleeve grooves for the guide frame to slide.

[0014] As a further embodiment of the present invention: the guide frame is provided with a second guide groove for two fixed sliders to slide, and the guide frame is provided with a first guide groove at the top of a second guide groove, and the inner cavity of the first guide groove and the second guide groove are interconnected.

[0015] Compared with the prior art, the beneficial effects of the present invention are: By setting up a demolding mechanism, the sealing top cover can be stably raised and lowered along the inner wall of the support plate via a motor, lifting screw, and limiting slide plate. During this process, the demolding push plate is separated from the inner wall of the heating base by the lifting assembly, so as to facilitate automatic demolding of the foamed latex pad. At the same time, through the cooperation of the fixed slider, the second guide groove, the first guide groove, the moving rotating plate, the roller, and the fixed pull plate, the demolding push plate can drive the demolded latex pad to flip and unload. Then, the motor is started to drive the lifting screw to rotate in the opposite direction, so as to reverse the above operation and make the demolding push plate automatically flip and reset. When producing latex pads of different thicknesses according to the needs of use, the limiting mechanism can limit and block the demolding push plate when it leaves the inner cavity of the heating base, which can further improve the production efficiency of latex pads of different thicknesses. Attached Figure Description

[0016] Figure 1This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the heating base of the present invention; Figure 3 This is a schematic diagram of the limiting mechanism structure of the present invention; Figure 4 This is a schematic cross-sectional view of the sealing top cover of the present invention; Figure 5 This is a schematic cross-sectional view of the guide frame structure of the present invention; Figure 6 This is a schematic diagram of the connection structure between the fixed pull plate and the roller of the present invention; Figure 7 This is a schematic diagram of the internal structure of the heating base of the present invention; Figure 8 For the present invention Figure 1 A magnified schematic diagram of the structure at point A in the diagram; Figure 9 This is a schematic diagram of the cross-sectional structure of the mattress cover of the present invention.

[0017] In the diagram: 1. Heating base; 2. Demolding mechanism; 201. Docking slot; 202. Limiting slide groove; 203. First guide groove; 204. Fixed pull plate; 205. Moving rotating plate; 206. Demolding push plate; 207. Guide strip; 208. Sealing plate; 209. Second guide groove; 2010. Sliding sleeve groove; 2011. Guide frame; 2012. Fixed slider; 2013. Roller; 2014. Fixed baffle; 3. Limiting mechanism; 301. Sliding guide plate; 302. Lifting push plate; 303. Rotating bracket; 304. Moving slide; 305. Two-way lead screw; 306. Knob; 307. Ratchet; 308. Positioning block; 309. Return spring; 3010. Moving slide rod; 3011. Fixed sleeve block; 3012. Limiting baffle; 4. Support plate; 5. Limiting slide plate; 6. Support frame; 7. Sealing top cover; 8. Motor; 9. Fixed rod; 10. Lifting lead screw; 11. Mattress cover; 12. Filling layer; 1201. Sponge pad; 1202. Latex pad; 1203. Memory foam; 13. Protective cloth; 14. Support sleeve. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this invention, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," and "set up" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The following describes embodiments of the invention based on its overall structure.

[0020] Please see Figures 1-9 In this embodiment of the invention, a mattress with a functional partition structure and its manufacturing process include a mattress cover 11, a protective cloth 13 that is fixedly connected inside the mattress cover 11 and contacts the bottom of the inner wall of the mattress cover 11, a support sleeve 14 that is fixedly connected inside the protective cloth 13, and a filling layer 12 that is fixedly connected to the upper surface of the protective cloth 13.

[0021] The filling layer 12 includes: a sponge pad 1201, a latex pad 1202, and a memory foam 1203; the memory foam 1203 is fixedly connected to the top of the protective fabric 13 and contacts the top of the support sleeve 14; the latex pad 1202 is fixedly connected to the top of the memory foam 1203; and the sponge pad 1201 is fixedly connected to the top of the latex pad 1202 and contacts the top of the inner wall of the mattress cover 11.

[0022] The manufacturing process for mattresses with functional zoned structures involves the following steps: S1. Mixing: The raw materials such as latex (also known as resin juice), foaming agent, stabilizer and filler are thoroughly mixed using a mixer; S2, Foaming Molding: The mixed raw materials are poured into the mold assembly, and the foaming agent is activated and decomposed at a certain temperature by heating. The decomposition of the foaming agent will produce a large amount of gas, which will make the latex form a uniform and delicate bubble structure until a latex pad 1202 is formed inside the mold assembly. S3. Cleaning and drying: The latex pad 1202 in the conveyor is cleaned by the nozzle, and the excess water on the latex pad 1202 is squeezed out by the pressure roller. Then the latex pad 1202 is placed to dry. S4. Bed netting manufacturing: The non-woven fabric is used to wrap multiple return springs and separate multiple extension springs. Then, the support sleeve 14 is formed by adhesive bonding in a connected arrangement. The fabric is then fixed to the outside of the support sleeve 14 by weaving, thereby binding the outside of the support sleeve 14 to form a protective fabric 13. S5. Adhesion: Place memory foam 1203 on the upper surface of protective cloth 13, then place latex pad 1202 on the upper surface of memory foam 1203, and finally place sponge pad 1201 on the upper surface of latex pad 1202. During this process, memory foam 1203, latex pad 1202 and sponge pad 1201 are sequentially bonded and fixed by adhesive to form filling layer 12. S6. Packaging and sewing: The fabric is sewn and fixed to the outside of the filling layer 12, protective cloth 13 and support sleeve 14 by the equipment to form the mattress cover 11.

[0023] According to the manufacturing process of a mattress with a functional partition structure, the mold assembly used in S2 includes a heating base 1. Multiple sets of fixing rods 9 are horizontally and equidistantly fixed to the bottom of the inner wall of the heating base 1. Each set of fixing rods 9 has multiple members, and these members are longitudinally and equidistantly fixed to the bottom of the inner wall of the heating base 1. A support frame 6 is provided on one side of the heating base 1. The support frame 6 is L-shaped, and a motor 8 is installed at the top of the support frame 6. A lifting screw 10 is fixedly connected to the output end of the motor 8. The lifting screw 10 is rotatably connected to the support frame 6 via a rotating shaft. A sealing top cover 7 is provided on the upper surface of the heating base 1, which is fitted onto the outer wall of the lifting screw 10. The inner wall of the lifting screw 10 has internal threads that match the threads on the outer wall of the lifting screw 10. Two support plates 4 are symmetrically formed on the outer wall of the support frame 6. The two support plates 4 contact the outer walls of the heating base 1 and the sealing top cover 7 at both ends, respectively. A demolding mechanism 2 is provided on the heating base 1 for automatically unloading the latex pad.

[0024] The demolding mechanism 2 includes: a sealing component and a pushing component; the sealing component is disposed on the heating base 1 to block the latex during the heating process; the pushing component is disposed on the heating base 1 for automatic demolding and unloading of the latex pad; a limiting mechanism 3 is disposed below the pushing component on the heating base 1, and the limiting mechanism 3 is used to limit the height of the pushing component.

[0025] The sealing assembly includes: a demolding push plate 206 that is slidably connected to the inside of the heating base 1, the demolding push plate 206 being slidably sleeved on the outer wall of multiple fixing rods 9, and two sets of sealing inserts 208 being symmetrically fixedly connected to the outer wall of the demolding push plate 206. Each set of sealing inserts 208 has two members, and the two sealing inserts 208 are symmetrically fixedly connected to one end of the outer wall of the demolding push plate 206 and extend through to the inside of the sealing top cover 7.

[0026] The pushing component includes: two movable rotating plates 205 symmetrically arranged inside the heating base 1; two fixed sliders 2012 are symmetrically fixedly connected to one end of each of the two movable rotating plates 205; the two fixed sliders 2012 are respectively fixedly connected to two sealing inserts 208; the heating base 1 has a limiting groove 202 for the movable rotating plates 205 to slide up and down; a guide frame 2011 is fixedly connected inside the limiting groove 202 of the heating base 1 and sleeved on the outer wall of the two fixed sliders 2012; the guide frame 2011 passes through the heating base 1 to the top of the sealing top cover 7; two fixed pull plates 204 are symmetrically arranged at the bottom end of the sealing top cover 7; the two fixed pull plates 204 are respectively connected to the outer wall of the end of the two movable rotating plates 205 away from the fixed sliders 2012. The two fixed pull plates 204 are in contact with each other and extend to the top of the sealing top cover 7. The top of each fixed pull plate 204 is fixedly connected to a fixed baffle 2014 located above the sealing top cover 7. The lower ends of the two fixed pull plates 204, which are close to one end of the two movable rotating plates 205, are rotatably connected to rollers 2013 through a rotating shaft. The movable rotating plate 205 has a straight sliding groove for the rollers 2013 to slide. The sealing top cover 7 has a sliding sleeve groove 2010 for the guide frame 2011 to slide. The guide frame 2011 has a second guide groove 209 for the two fixed sliders 2012 to slide. The guide frame 2011 has a first guide groove 203 at the top of one of the second guide grooves 209. The first guide groove 203 and the inner cavity of one of the second guide grooves 209 are interconnected.

[0027] In this embodiment: When using this device, the starting motor 8 drives the lifting screw 10 to rotate. Simultaneously, the sealing top cover 7, driven by the threads on the outer wall of the lifting screw 10, slides along the inner wall of the support plate 4 and the outer wall of the guide frame 2011 via the limiting slide plate 5 and the sliding sleeve groove 2010. At this time, the fixed pull plate 204, blocked by the moving rotating plate 205 via the roller 2013, does not move synchronously with the sealing top cover 7. When the sealing top cover 7 contacts the outer wall of the fixed baffle 2014, the fixed baffle 2014, driven by the sealing top cover 7, drives the fixed pull plate 204 to move synchronously. Simultaneously, the roller 2013... 13. Driven by the fixed pull plate 204, the rotating shaft drives the moving rotating plate 205 to rise synchronously along the inner wall of the heating base 1. At this time, the fixed slider 2012 slides along the inner wall of the second guide groove 209 under the drive of the moving rotating plate 205. At the same time, the sealing insert plate 208 drives the guide insert 207 to slide along the inner wall of the docking slot 201 under the drive of the fixed slider 2012, and drives the demolding push plate 206 to slide synchronously along the outer wall of multiple fixed rods 9. This allows the demolding push plate 206 to separate from the inner wall of the heating base 1, so as to facilitate the automatic demolding of the foamed latex pad 1202.

[0028] When one fixed slider 2012 contacts the top of the inner wall of a second guide groove 209, the other fixed slider 2012 separates from the inner wall of the other second guide groove 209 and contacts the inner wall of the first guide groove 203. At the same time, the movable rotating plate 205 rotates around one fixed slider 2012 as the axis. At this time, the roller 2013 slides along the inner wall of the movable rotating plate 205 under the drive of the fixed pull plate 204 until the roller 2013 contacts the inner wall of one side of the movable rotating plate 205. At this time, the other roller 2013 contacts the inner wall of one side of the first guide groove 203 under the drive of the movable rotating plate 205. At the same time, the demolding push plate 206 flips under the drive of the two fixed sliders 2012 through the sealing insert plate 208, so as to facilitate the flipping and unloading of the demolded latex pad 1202.

[0029] Then, the motor 8 is started to drive the lifting screw 10 to rotate in the opposite direction, thereby reversing the above operation and causing the demolding push plate 206 to automatically flip and reset. When the demolding push plate 206 contacts the bottom of the inner wall of the heating base 1, the motor 8 is stopped and lubricating oil is sprayed onto the inside of the heating base 1 and the upper surface of the demolding push plate 206. Then, the raw material of the latex pad 1202 is poured into the inside of the heating base 1 and covers the upper surface of the demolding push plate 206. During this process, the raw material is blocked by the mutual contact of the guide strip 207, the sealing plate 208 and the inner wall of the docking slot 201. When the raw material is evenly covered on the demolding push plate 206, the material is pushed back into place. When the upper surface of plate 206 is reached, motor 8 is started to make the sealing top cover 7 continue to descend until the sealing top cover 7 contacts the upper surface of the heating base 1 and fits the outer wall of the sealing insert plate 208. Then, the latex pad 1202 is foamed and formed by heating. The above operation is repeated to realize the automatic unloading of the latex pad 1202, thereby further improving the production efficiency of the latex pad 1202. When producing latex pads 1202 of different thicknesses according to the usage requirements, when the demolding push plate 206 is separated from the inner cavity of the heating base 1, the limiting mechanism 3 can limit and block the demolding push plate 206, thus realizing the production of latex pads 1202 of different thicknesses.

[0030] In a preferred embodiment of the present invention, the limiting mechanism 3 includes: a ratchet 307 disposed on the outer wall of one end of the heating base 1; a knob 306 fixedly connected to the end of the ratchet 307 away from the heating base 1; a positioning block 308 meshing with the outer wall of the ratchet 307; a movable slide rod 3010 fixedly connected to the side of the positioning block 308 away from the ratchet 307; a limiting baffle 3012 fixedly connected to the side of the movable slide rod 3010 away from the positioning block 308; a fixing sleeve 3011 disposed on the outer wall of one side of the limiting baffle 3012; the fixing sleeve 3011 sleeved on the outer wall of the movable slide rod 3010 and fixedly connected to the heating base 1; a return spring 309 sleeved on the outer wall of the movable slide rod 3010; and the two ends of the return spring 309 respectively contact the outer walls of the positioning block 308 and the fixing sleeve 3011.

[0031] The end of the ratchet 307 furthest from the knob 306 is fixedly connected to a bidirectional lead screw 305 via a connecting shaft. The bidirectional lead screw 305 is rotatably connected to the heating base 1 via a rotating shaft. Two movable slides 304 are symmetrically sleeved on the outer wall of the bidirectional lead screw 305. The inner walls of both movable slides 304 are provided with internal threads that match the threads on the outer wall of the bidirectional lead screw 305, and are slidably connected to the heating base 1. A lifting push plate 302 is provided above the ends of the two movable slides 304 that are furthest from each other. The lifting push plate 302 is slidably connected to the heating base 1 and to the demolding push plate. The lower surfaces of the plates 206 are in contact with each other. The outer wall of the lifting push plate 302 is symmetrically formed with two sliding guide plates 301. The two sliding guide plates 301 are slidably connected to the outer walls of the two fixed rods 9 respectively. The bottom ends of the two lifting push plates 302 are symmetrically connected to two sets of rotating brackets 303 through rotating shafts. The two sets of rotating brackets 303 are slidably connected to the movable slide block 304 through rotating shafts. Multiple sets of rotating brackets 303 are provided in one set. Multiple rotating brackets 303 are laterally equidistantly rotatably connected to the bottom end of the lifting push plate 302 through rotating shafts and are slidably connected to the heating base 1.

[0032] In this embodiment: latex pads 1202 of different thicknesses are produced according to usage requirements. When the demolding push plate 206 detaches from the inner cavity of the heating base 1, the ratchet 307 is rotated by rotating the knob 306. At this time, the positioning block 308, under the pressure of the ratchet 307, pushes the limiting baffle 3012 to slide along the outer wall of the heating base 1 through the moving slide rod 3010. At the same time, the moving slide rod 3010 slides along the inner wall of the fixed sleeve 3011. At this time, the positioning block 308 retracts through the moving compression return spring 309. When the ratchet 307 drives the next tooth groove to move to the end of the positioning block 308, the return spring 309 pushes the positioning block 308 to engage with the ratchet 307 by rebounding, which can limit the rotation of the ratchet 307. At the same time, the bidirectional screw... Driven by the ratchet 307, the 305 rotates inside the heating base 1 via the connecting shaft. At this time, the two movable slides 304 slide along the inner wall of the heating base 1 via the threaded connection of the two-way lead screw 305. Simultaneously, the rotating bracket 303, driven by the movable slides 304, pushes the lifting push plate 302 to move along the inner wall of the heating base 1. The lifting push plate 302 slides along the outer wall of the two fixed rods 9 via the two sliding guide plates 301, thereby allowing for convenient adjustment of the height of the lifting push plate 302. When the lifting push plate 302 is adjusted to the appropriate height as required, the demolding push plate 206 slides back to its original position. At this time, the demolding push plate 206 stops moving under the obstruction of the sliding guide plate 301, thus enabling the production of latex pads 1202 of different thicknesses.

[0033] As a preferred embodiment of the present invention, the outer wall of the sealing top cover 7 is symmetrically formed with two sets of limiting slide plates 5 that are slidably connected to the support plate 4. There are two limiting slide plates 5 in one set, and the two limiting slide plates 5 are symmetrically formed on one end of the outer wall of the sealing top cover 7 and are slidably connected to the support plate 4.

[0034] In this embodiment, the sealing top cover 7 can be stably raised and lowered along the inner wall of the support plate 4 by means of the limiting slide plate 5 and the support plate 4 during the lifting and lowering process.

[0035] In a preferred embodiment of the present invention, the outer wall of the sealing insert 208 is symmetrically formed with two guide strips 207, the outer walls of the two guide strips 207 are semi-circular, and the heating base 1 is provided with a docking slot 201 that matches the outer walls of the sealing insert 208 and the guide strips 207.

[0036] In this embodiment, the guide strip 207 and the docking slot 201 cooperate with each other, so that the sealing plate 208 can block the port of the docking slot 201.

[0037] In a preferred embodiment of the present invention, the outer wall of the top of the sealing insert 208 is in the shape of a square platform, and the sealing top cover 7 is provided with a lifting groove for the sealing insert 208 to slide up and down.

[0038] In this embodiment, the sealing plate 208 can be precisely inserted into the interior of the sealing top cover 7 and slide along the inner wall of the sealing top cover 7 by the cooperation between the square-shaped outer wall and the lifting slide groove.

[0039] The working principle of this invention is as follows: When using this device, the starting motor 8 drives the lifting screw 10 to rotate. At the same time, the sealing top cover 7, driven by the thread on the outer wall of the lifting screw 10, slides along the inner wall of the support plate 4 and the outer wall of the guide frame 2011 through the limiting slide plate 5 and the sliding sleeve groove 2010. At this time, the fixed pull plate 204 does not move synchronously with the sealing top cover 7 due to the obstruction of the moving rotating plate 205 by the roller 2013. When the sealing top cover 7 contacts the outer wall of the fixed baffle 2014, the fixed baffle 2014 drives the fixed pull plate 204 to move synchronously under the drive of the sealing top cover 7. At the same time, the roller... Driven by the fixed pull plate 204, the rotating shaft drives the moving rotating plate 205 to rise synchronously along the inner wall of the heating base 1. At this time, the fixed slider 2012 slides along the inner wall of the second guide groove 209 under the drive of the moving rotating plate 205. Meanwhile, the sealing insert plate 208 drives the guide insert 207 to slide along the inner wall of the docking slot 201 under the drive of the fixed slider 2012, and drives the demolding push plate 206 to slide synchronously along the outer wall of multiple fixed rods 9. This allows the demolding push plate 206 to separate from the inner wall of the heating base 1, so as to facilitate the automatic demolding of the foamed latex pad 1202.

[0040] When one fixed slider 2012 contacts the top of the inner wall of a second guide groove 209, the other fixed slider 2012 separates from the inner wall of the other second guide groove 209 and contacts the inner wall of the first guide groove 203. At the same time, the movable rotating plate 205 rotates around one fixed slider 2012 as the axis. At this time, the roller 2013 slides along the inner wall of the movable rotating plate 205 under the drive of the fixed pull plate 204 until the roller 2013 contacts the inner wall of one side of the movable rotating plate 205. At this time, the other roller 2013 contacts the inner wall of one side of the first guide groove 203 under the drive of the movable rotating plate 205. At the same time, the demolding push plate 206 flips under the drive of the two fixed sliders 2012 through the sealing insert plate 208, so as to facilitate the flipping and unloading of the demolded latex pad 1202.

[0041] Then, the motor 8 is started to drive the lifting screw 10 to rotate in the opposite direction, thereby reversing the above operation. This allows the demolding push plate 206 to automatically flip and reset. When the demolding push plate 206 contacts the bottom of the inner wall of the heating base 1, the motor 8 is stopped, and lubricating oil is sprayed onto the inside of the heating base 1 and the upper surface of the demolding push plate 206. Then, the raw material of the latex pad 1202 is poured into the inside of the heating base 1, covering the upper surface of the demolding push plate 206. During this process, the guide strip 207 and the seal... The mutual contact between the insert plate 208 and the inner wall of the docking slot 201 can block the raw material. When the raw material is evenly covered on the upper surface of the demolding push plate 206, the motor 8 is started to make the sealing top cover 7 continue to descend until the sealing top cover 7 contacts the upper surface of the heating base 1 and fits the outer wall of the sealing insert plate 208. Then, the latex pad 1202 is foamed and formed by heating. The above operation is repeated to achieve automatic unloading of the latex pad 1202, thereby further improving the production efficiency of the latex pad 1202.

[0042] When latex pads 1202 of different thicknesses are produced according to usage requirements, when the demolding push plate 206 disengages from the inner cavity of the heating base 1, the ratchet 307 is rotated by turning the knob 306. At this time, the positioning block 308, under the pressure of the ratchet 307, pushes the limiting baffle 3012 along the outer wall of the heating base 1 through the moving slide rod 3010. At the same time, the moving slide rod 3010 slides along the inner wall of the fixed sleeve block 3011. At this time, the positioning block 308 retracts through the moving compression return spring 309. When the ratchet 307 drives the next tooth groove to move to the end of the positioning block 308, the return spring 309 pushes the positioning block 308 to engage with the ratchet 307 by rebounding, which can limit the rotation of the ratchet 307. At the same time, the bidirectional lead screw 305... Driven by the ratchet 307, the connecting shaft rotates inside the heating base 1. At this time, the two movable slides 304 are connected by threads to the double-acting screw 305 and slide along the inner wall of the heating base 1. Simultaneously, the rotating bracket 303, driven by the movable slides 304, pushes the lifting push plate 302 to move along the inner wall of the heating base 1. The lifting push plate 302 slides along the outer wall of the two fixed rods 9 through the two sliding guide plates 301, so that the height of the lifting push plate 302 can be easily adjusted. When the lifting push plate 302 is adjusted to a suitable height as required, the demolding push plate 206 slides back to its original position. At this time, the demolding push plate 206 stops moving under the obstruction of the sliding guide plate 301, which can realize the production of latex pads 1202 of different thicknesses.

[0043] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A manufacturing process for a mattress with a functional zoned structure, characterized in that, The specific steps are as follows: S1. Mixing: The raw materials such as latex, foaming agent, stabilizer and filler are thoroughly mixed using a mixer; S2, Foaming Molding: The mixed raw materials are poured into the mold assembly, and the foaming agent is activated and decomposed at a certain temperature by heating. The decomposition of the foaming agent will generate a large amount of gas, which will make the latex form a uniform and delicate bubble structure until a latex pad (1202) is formed inside the mold assembly. S3. Cleaning and drying: The latex pad (1202) in the conveyor is cleaned by the nozzle, and the excess water on the latex pad (1202) is squeezed out by the pressure roller. Then the latex pad (1202) is placed to dry. S4. Bed netting: The non-woven fabric is wrapped around multiple return springs and separated into multiple extension springs by the equipment. Then, the support sleeve (14) is formed by adhesive bonding in a connected arrangement. The fabric is then fixed to the outside of the support sleeve (14) by weaving, thereby binding the outside of the support sleeve (14) to form a protective cloth (13). S5. Adhesion: Place memory foam (1203) on the upper surface of protective cloth (13), then place latex pad (1202) on the upper surface of memory foam (1203), and finally place sponge pad (1201) on the upper surface of latex pad (1202). During this process, memory foam (1203), latex pad (1202) and sponge pad (1201) are bonded and fixed in sequence by adhesive to form a filling layer (12). S6. Packaging and sewing: The fabric is sewn to the outside of the filling layer (12), protective cloth (13), and support sleeve (14) using equipment to form a mattress cover (11). The mold assembly used in S2 includes a heating base (1). Multiple sets of fixing rods (9) are horizontally and equidistantly fixed to the bottom of the inner wall of the heating base (1). Each set of fixing rods (9) has multiple members. These multiple fixing rods (9) are longitudinally and equidistantly fixed to the bottom of the inner wall of the heating base (1). A support frame (6) is provided on one side of the heating base (1). The support frame (6) is L-shaped. A motor (8) is installed at the top of the support frame (6). A lifting screw (10) is fixedly connected to the output end of the motor (8). The lifting screw (10)... The heating base (1) is rotatably connected to the support frame (6) via a rotating shaft. The upper surface of the heating base (1) is provided with a sealing top cover (7) sleeved on the outer wall of the lifting screw (10). The inner wall of the lifting screw (10) is provided with an internal thread that matches the thread of the outer wall of the lifting screw (10). The outer wall of the support frame (6) is symmetrically formed with two support plates (4). The two support plates (4) are in contact with the outer walls of the heating base (1) and the sealing top cover (7) at both ends, respectively. The heating base (1) is provided with a demolding mechanism (2). The demolding mechanism (2) is used to automatically unload the latex pad. The demolding mechanism (2) includes: a sealing component and a pushing component; A sealing assembly is provided on the heating base (1) to block the latex during the heating process; A push assembly is provided on the heating base (1) for automatic demolding and unloading of the latex pad; The heating base (1) is provided with a limiting mechanism (3) below the pushing component. The limiting mechanism (3) is used to limit the height of the pushing component. The sealing assembly includes: A demolding push plate (206) is slidably connected inside the heating base (1). The demolding push plate (206) is slidably sleeved on the outer wall of multiple fixing rods (9). Two sets of sealing inserts (208) are symmetrically fixedly connected to the outer wall of the demolding push plate (206). Two sets of sealing inserts (208) are provided in one set. The two sealing inserts (208) are symmetrically fixedly connected to the outer wall of one end of the demolding push plate (206) and penetrate into the interior of the sealing top cover (7). The limiting mechanism (3) includes: A ratchet (307) is mounted on the outer wall of one end of the heating base (1). A knob (306) is fixedly connected to the end of the ratchet (307) away from the heating base (1). A positioning block (308) is meshed with the outer wall of the ratchet (307). A movable slide rod (3010) is fixedly connected to the side of the positioning block (308) away from the ratchet (307). A [missing information - likely a device or mechanism] is fixedly connected to the side of the movable slide rod (3010) away from the positioning block (308). A limiting baffle (3012) is provided with a fixing sleeve (3011) on one side of its outer wall. The fixing sleeve (3011) is sleeved on the outer wall of the movable slide rod (3010) and fixedly connected to the heating base (1). A return spring (309) is sleeved on the outer wall of the movable slide rod (3010). The two ends of the return spring (309) are in contact with the positioning insert (308) and the outer wall of the fixing sleeve (3011) respectively. The ratchet (307) is fixedly connected to a bidirectional lead screw (305) at the end away from the knob (306) via a connecting shaft. The bidirectional lead screw (305) is rotatably connected to the heating base (1) via a rotating shaft. Two movable slides (304) are symmetrically sleeved on the outer wall of the bidirectional lead screw (305). The inner walls of the two movable slides (304) are provided with internal threads that match the threads on the outer wall of the bidirectional lead screw (305) and are slidably connected to the heating base (1). A lifting push plate (302) is provided above the ends of the two movable slides (304) that are far apart from each other. The lifting push plate (302) is slidably connected to the heating base (1) and is also connected to the demolding plate. The lower surfaces of the push plate (206) are in contact with each other. The outer wall of the lifting push plate (302) is symmetrically formed with two sliding guide plates (301). The two sliding guide plates (301) are slidably connected to the outer walls of the two fixed rods (9). The bottom ends of the two lifting push plates (302) are symmetrically connected to two sets of rotating brackets (303) through a rotating shaft. The two sets of rotating brackets (303) are slidably connected to the movable slide (304) through a rotating shaft. A set of rotating brackets (303) is provided with multiple units. The multiple rotating brackets (303) are laterally equidistantly connected to the bottom end of the lifting push plate (302) through a rotating shaft and are slidably connected to the heating base (1).

2. The manufacturing process of the mattress with functional zoned structure according to claim 1, characterized in that, The push component includes: Two movable rotating plates (205) are symmetrically arranged inside the heating base (1). Two fixed sliders (2012) are symmetrically fixed to one end of each of the two movable rotating plates (205). The two fixed sliders (2012) are respectively fixedly connected to two sealing plates (208). The heating base (1) is provided with a limiting groove (202) for the movable rotating plates (205) to slide up and down. The heating base (1) is fixedly connected inside the limiting groove (202) with a guide frame (2011) sleeved on the outer wall of the two fixed sliders (2012). The guide frame (2011) passes through the heating base (1) to the outside of the top of the sealing top cover (7).

3. The manufacturing process of the mattress with functional zoned structure according to claim 1, characterized in that, The outer wall of the sealing top cover (7) is symmetrically formed with two sets of limiting slide plates (5) that are slidably connected to the support plate (4) in the upper and lower directions. There are two sets of limiting slide plates (5), which are symmetrically formed on one end of the outer wall of the sealing top cover (7) and slidably connected to the support plate (4).

4. The manufacturing process of the mattress with functional zoned structure according to claim 1, characterized in that, The outer wall of the sealing plate (208) is symmetrically formed with two guide strips (207). The outer walls of the two guide strips (207) are semi-circular. The heating base (1) is provided with a docking slot (201) that matches the outer walls of the sealing plate (208) and the guide strips (207).

5. The manufacturing process of the mattress with functional zoned structure according to claim 1, characterized in that, The outer wall of the top of the sealing insert (208) is in the shape of a square platform, and the sealing top cover (7) has a lifting groove for the sealing insert (208) to slide up and down.

6. The manufacturing process of the mattress with a functional zoned structure according to claim 2, characterized in that, Two fixed pull plates (204) are symmetrically arranged at the bottom end of the sealing top cover (7). The two fixed pull plates (204) are in contact with the outer wall of the end of the two movable rotating plates (205) away from the fixed slider (2012) and extend to the outside of the top of the sealing top cover (7). The top of the two fixed pull plates (204) is fixedly connected to a fixed baffle (2014) located above the sealing top cover (7). The lower ends of the two fixed pull plates (204) near the two movable rotating plates (205) are rotatably connected to rollers (2013) through a rotating shaft. The movable rotating plate (205) is provided with a straight groove for the rollers (2013) to slide. The sealing top cover (7) is provided with a sliding sleeve groove (2010) for the guide frame (2011) to slide.

7. The manufacturing process of the mattress with functional zoned structure according to claim 2, characterized in that, The guide frame (2011) is provided with a second guide groove (209) for two fixed sliders (2012) to slide. The guide frame (2011) is provided with a first guide groove (203) at the top of a second guide groove (209). The first guide groove (203) and the inner cavity of a second guide groove (209) are interconnected.

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