A compression and rolling method for sponge sofa

Abstract

The present invention discloses a compression and rolling method for a sponge sofa, belonging to the field of sofa packaging technology. The method comprises the following steps: testing the loss rate of the sponge after rebound at different compression rates; presetting the loss rate and determining the required compression rate of the sofa through testing; obtaining a preset compression rate based on the set loss rate target and calculating the diameter and volume of a tubular bag; packing the sofa in a PE vacuum bag, compressing the sofa with a compressor at a compression rate exceeding the preset compression rate, and then rolling the sofa up; rolling the sofa up by machine or manually, inserting the rolled-up sofa into a tubular bag of a certain diameter, breaking the PE vacuum bag, releasing air into the PE vacuum bag, causing the sponge sofa to expand in the tubular bag until it reaches the volume of the tubular bag and is restrained by the tubular bag, achieving the set loss rate target, and completing the packaging. The compression and rolling method for a sponge sofa solves the problems of existing compression technologies that easily lead to excessive deformation of the sofa and the inability to control the sponge loss rate.

Description

Technical Field

[0001] The invention relates to the technical field of sofa packaging, in particular to a compression and rolling method for a sponge sofa. Background Art

[0002] There are two compression technologies for compression sofas on the existing market. One is vertical downward compression, which applies force downward. When expanding, it expands upward. Because the height of the sofa backrest, armrest height, and cushion height are not consistent, when the sofa is compressed downward, the loss rate of each part will be different, resulting in the sofa cover becoming loose after the sofa is opened. The roll-up cannot control the compression volume, that is, the compression rate cannot be controlled, resulting in different sofa loss rates in each position. After opening, the sofa height in each position is different, uneven, and the sofa is excessively deformed. The other is vacuum compression, which applies force to the middle of the sofa. When expanding, it expands 360 degrees outward. The vacuum compression method is also difficult to control the compression rate, resulting in excessive deformation of the sofa. Summary of the Invention

[0003] In order to overcome the defects of the prior art, the present invention provides a compression and rolling method for a sponge sofa to solve the above problems.

[0004] The technical solution adopted by the present invention to solve the technical problem is: a compression and rolling method for a sponge sofa, comprising the following steps:

[0005] S1: First test the loss rate of the sofa after the sponge rebounds under different compression rates;

[0006] S2: Preset a loss rate target, and determine the required compression rate of the sofa through the test in step S1 as the preset compression rate B;

[0007] S3: Calculate the volume of the sofa sponge after compression using the preset compression rate B and the volume of the sofa sponge before compression; use the volume of the sponge after compression as the volume of the tubular bag, and the width of the sponge sofa as the height of the tubular bag, thereby calculating the diameter D and volume of the tubular bag;

[0008] S4: Pack the sofa with a PE vacuum bag, compress the sofa with a compressor at a compression rate exceeding the preset compression rate B, and then roll up the sofa;

[0009] S5: Put the rolled-up sofa into a tubular bag with a diameter of D, break the PE vacuum bag, and release air into the PE vacuum bag to make the sponge sofa expand in the tubular bag. After expanding to the volume of the tubular bag, it is restricted by the tubular bag to achieve the set loss rate target and complete the packaging.

[0010] Preferably, the step S1 includes:

[0011] S11: assigning different compression rates to different sponges and performing compression;

[0012] S12: After the sponge rebounds, the compression loss rate of the sponge at different compression rates is calculated.

[0013] Optionally, step S2 includes:

[0014] S21: preset loss rate after the sponge sofa rebounds;

[0015] S22: Screen out sponges with a compression loss rate less than or equal to a preset loss rate, and record the compression rate of the sponge used in step S1 as the preset compression rate B of the sponge sofa.

[0016] Specifically, step S11 includes: obtaining multiple groups of sponges of consistent sizes, sorting these sponge groups, and setting compression rates with increasing values ​​for these sponge groups according to the sorting, wherein the compression rates of the sponges in each sponge group are consistent, calculating the compressed thickness H of the sponges in each sponge group based on these compression rates, and compressing the sponges in each sponge group based on the compressed thickness H of each sponge group.

[0017] It is worth noting that step S12 includes: releasing the compression of the sponge in the sponge group after standing for a preset compression time and allowing it to rebound naturally, and measuring the thickness of the sponge in each sponge group after standing for a preset rebound time, and calculating the compression loss rate of the sponge by the thickness of the sponge sofa before compression and the thickness of the sponge after compression and rebound.

[0018] Preferably, in step S11, the thickness H of the sponge in each sponge group after compression is obtained by the compression ratio, H=E*(1-compression ratio), where E is the thickness of the sponge sofa before compression.

[0019] Optionally, in step S11, the preset compression time is greater than or equal to 72 hours.

[0020] Preferably, in step S12, the preset rebound time is greater than or equal to 48 hours.

[0021] Specifically, in step S11, the ambient temperature during compression is between 70°C and 80°C.

[0022] The beneficial effect of the present invention is that, in the compression and wrapping method of the sponge sofa, after the loss rate is set to a certain value, the compression rate is determined based on the loss rate, and the upper limit of the compression rate of the sponge sofa is controlled by the diameter of the tubular bag to achieve the goal of controlling the loss rate, so that the sponge sofa will not be excessively deformed after compression. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 The present invention is a flowchart of a method for compressing and wrapping a sponge sofa in one embodiment of the present invention. DETAILED DESCRIPTION

[0024] The following is a further description of specific embodiments of the present invention in conjunction with the accompanying drawings. It should be noted that the description of these embodiments is intended to facilitate understanding of the present invention and does not constitute a limitation of the present invention. In addition, the technical features involved in the various embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

[0025] like Figure 1 As shown, a compression and rolling method for a sponge sofa comprises the following steps:

[0026] S1: First test the loss rate of the sofa after the sponge rebounds under different compression rates;

[0027] S2: Preset a loss rate target based on the required recovery effect, and determine the required compression rate of the sofa through the test in step S1 as the preset compression rate B;

[0028] S3: The volume of the sofa sponge after compression is calculated using the preset compression rate B and the volume of the sofa sponge before compression; the volume of the sponge after compression is used as the volume of the tube bag, and the width of the sponge sofa is used as the height of the tube bag, thereby calculating the diameter D and volume of the tube bag; in this embodiment, the diameter and volume of the tube bag can be calculated by the preset compression rate B of the sofa sponge volume: for example, the actual size of the sofa is 2 meters long, 0.9 meters wide, and 0.7 meters high, the volume V0 of the sofa sponge before compression is 1 cubic meter, and the preset compression rate B is 80% , then the volume V1 of the sofa's sponge after compression is 1*(1-80%)=0.2 cubic meters, and the volume V2 of the tubular bag is 0.2 cubic meters; after compression, the sofa curls in the direction of its width. In this embodiment, the width of the sofa is 0.9 meters, so the height h of the tubular bag needs to be 0.9 meters to match the width of the sofa. In this way, the radius r of the tubular bag can be calculated by the formula of cylindrical volume V=π*r²*h, and then the diameter d of the tubular bag can be obtained based on the radius r; in this embodiment, the diameter d of the tubular bag can be obtained to be 0.47 meters. Because the length of the sponge compression time and the temperature in the container will affect the loss rate, the optimal control range of the tubular bag's diameter d is to increase by about 4 cm, that is, the tubular bag is best between 47 cm and 51 cm. A larger diameter d will affect the transportation cost, and a smaller diameter d will affect the sofa's recovery effect;

[0029] S4: Pack the sofa with a PE vacuum bag, compress the sofa with a compressor at a compression rate exceeding the preset compression rate B, and then roll up the sofa;

[0030] S5: Place the rolled-up sofa in a tubular bag with a diameter of D. The PE vacuum bag is broken and air is released into the bag, allowing the foam sofa to expand within the bag. Once it expands to the bag's full volume, it is restrained by the bag to achieve the desired loss rate, completing the roll-up. Since the foam sofa is restrained by the bag, it reaches the preset compression rate B, thus achieving the desired loss rate.

[0031] In the compression and wrapping method of the sponge sofa, after the loss rate is set to a certain value, the compression rate is determined based on the loss rate, and the upper limit of the compression rate of the sponge sofa is controlled by the diameter of the tubular bag to achieve the goal of controlling the loss rate and prevent the sponge sofa from excessive deformation after compression.

[0032] In this embodiment, the material of the tubular bag is one of Oxford cloth, composite woven kraft paper and thickened non-woven fabric to ensure toughness and prevent the force during the expansion of the cotton from being too great, which may cause the tubular bag to burst and create logistics and transportation risks.

[0033] Preferably, the step S1 includes:

[0034] S11: assigning different compression rates to different sponges and performing compression;

[0035] S12: After the sponge rebounds, the compression loss rate of the sponge at different compression rates is calculated.

[0036] Preferably, the step S2 includes:

[0037] S21: Presetting a preset loss rate of the sponge sofa after rebounding. In this embodiment, the loss rate of the sofa after opening is set to be controlled at 2%, so the preset loss rate is set to 2%, and the rebound recovery rate is 98%;

[0038] S22: Filter out sponges with a compression loss rate less than or equal to a preset loss rate, and record the compression rate used by the sponge in step S1 as the preset compression rate B of the sponge sofa. Therefore, the compression rate with a loss rate of less than 2% from the compression rate of 84% to 90% is the target indicator to be controlled in step S1.

[0039] Optionally, step S11 includes: obtaining multiple groups of sponges of consistent size (5 sponge samples per group, 6 groups in total, 30 sponge samples in total, and the size of these 30 sponge samples is 30 cm × 30 cm × 30 cm), sorting these sponge groups, and setting compression rates with increasing values ​​for these sponge groups according to the sorting (the compression rate ranges from 84% to 90%, and the corresponding loss rate is tested using different compression rates. It can be evaluated how much range the volume of the tubular bag should be controlled to be optimal. When the customer requires different packaging solutions, the recovery effect of the sponge sofa can be estimated), wherein the compression rate of the sponges in each sponge group is consistent, and the compressed thickness H of the sponges of each sponge group is calculated according to these compression rates (the thickness of the first group of sponge samples compressed according to the compression rate is 30*(1-84%)=4.8 cm, and so on), and compressing the sponges of each sponge group according to the compressed thickness H of each sponge group;

[0040] Specifically, step S12 includes: releasing the compression of the sponges in the sponge group after standing for a preset compression time and allowing them to rebound naturally; measuring the thickness of the sponges in each sponge group after standing for a preset rebound time (wherein the thickness of the sponges in each sponge group is the average thickness of the five sponge samples in the group after natural rebound); and calculating the compression loss rate of the sponge based on the thickness of the sponge sofa before compression and the thickness of the sponge after compression and rebound. The sponge loss rate is 1-(thickness of the sponge after compression and rebound / thickness of the sponge sofa before compression). For example, if the average thickness of the five sponge samples in a group with a compression rate of 84% after natural rebound is 29.5, the loss rate is 1-(29.5 / 30) = 1.66%.

[0041] It is worth noting that, in step S11, the thickness H of the sponge in each sponge group after compression is obtained by the compression ratio, H=E*(1-compression ratio), where E is the thickness of the sponge sofa before compression.

[0042] Specifically, in step S11, the preset compression time is greater than or equal to 72 hours. The compression time is set to be greater than or equal to 72 hours in order to ensure that the sponge is completely compressed to the target compression ratio.

[0043] Optionally, in step S12, the preset rebound time is greater than or equal to 48 hours. Setting the rebound time to greater than or equal to 48 hours is to ensure that the sponge rebounds completely naturally.

[0044] Preferably, in step S11, the ambient temperature during compression is between 70° C. and 80° C. The purpose of the ambient temperature during compression is to simulate the temperature of the goods when placed in the container during transportation. Both sponge and glue will undergo chemical changes due to temperature, so it is necessary to simulate the environmental conditions of the goods during transportation.

[0045] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments. It is apparent to those skilled in the art that various changes, modifications, substitutions, and variations to these embodiments may be made without departing from the principles and spirit of the present invention, and these changes and modifications still fall within the scope of protection of the present invention.

Claims

1. A compression and rolling method for a sponge sofa, characterized in that: The following steps are involved: S1: First test the loss rate of the sofa after the sponge rebounds under different compression rates; S2: Preset a loss rate target, and determine the required compression rate of the sofa through the test in step S1 as the preset compression rate B; S3: Calculate the volume of the sofa sponge after compression using the preset compression rate B and the volume of the sofa sponge before compression; use the volume of the sponge after compression as the volume of the tubular bag, and the width of the sponge sofa as the height of the tubular bag, thereby calculating the diameter D and volume of the tubular bag; S4: Pack the sofa with a PE vacuum bag, compress the sofa with a compressor at a compression rate exceeding the preset compression rate B, and then roll up the sofa; S5: Put the rolled-up sofa into a tubular bag with a diameter of D, break the PE vacuum bag, and release air into the PE vacuum bag to make the sponge sofa expand in the tubular bag. After expanding to the volume of the tubular bag, it is restricted by the tubular bag to achieve the set loss rate target and complete the packaging.

2. The compression and rolling method for a sponge sofa according to claim 1, characterized in that: The step S1 comprises: S11: assigning different compression rates to different sponges and performing compression; S12: After the sponge rebounds, the compression loss rate of the sponge at different compression rates is calculated.

3. The compression and rolling method for a sponge sofa according to claim 2, characterized in that: The step S2 comprises: S21: preset loss rate after the sponge sofa rebounds; S22: Screen out sponges with a compression loss rate less than or equal to a preset loss rate, and record the compression rate of the sponge used in step S1 as the preset compression rate B of the sponge sofa.

4. The compression and rolling method for a sponge sofa according to claim 3, characterized in that: The step S11 includes: obtaining multiple groups of sponges of the same size, sorting these sponge groups, and setting compression rates with increasing values ​​for these sponge groups according to the sorting, wherein the compression rates of the sponges in each sponge group are the same, calculating the compressed thickness H of the sponges in each sponge group based on these compression rates, and compressing the sponges in each sponge group based on the compressed thickness H of each sponge group.

5. The compression and rolling method for a sponge sofa according to claim 4, characterized in that: The step S12 includes: releasing the compression of the sponge in the sponge group after standing for a preset compression time and allowing it to rebound naturally, and measuring the thickness of the sponge in each sponge group after standing for a preset rebound time, and calculating the compression loss rate of the sponge based on the thickness of the sponge sofa before compression and the thickness of the sponge after compression and rebound.

6. The compression and rolling method for a sponge sofa according to claim 5, characterized in that: In the step S11 , the thickness H of the sponge in each sponge group after compression is obtained by the compression ratio, H=E*(1-compression ratio), where E is the thickness of the sponge sofa before compression.

7. The compression and rolling method for a sponge sofa according to claim 6, characterized in that: In step S11, the preset compression time is greater than or equal to 72 hours.

8. The compression and rolling method for a sponge sofa according to claim 7, characterized in that: In step S12, the preset rebound time is greater than or equal to 48 hours.

9. The compression and rolling method for a sponge sofa according to claim 8, characterized in that: In step S11 , the ambient temperature during compression is between 70° C. and 80° C.

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