Natural fiber-containing breathable mattress and production process thereof
Through the multi-layer structural design, combining bamboo fiber, coconut fiber and modified bamboo charcoal fiber layer, the problem of reducing moisture absorption and breathability in high humidity environments is solved, achieving high breathability and durability, and providing healthy and comfortable Sleeping environment.
Patent Information
- Application Number
- CN202411444367.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-16
- Publication Date
- 2025-01-07
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
Traditional mattresses are prone to accumulate moisture in high humidity environments, breeding bacteria and mites, affecting sleep quality, and the materials are difficult to degrade, destroying the green environment.
Design of a multi-layer structure of breathable mattress, including a breathable fiber layer, a spring layer and a 3D fabric layer. The breathable fiber layer is pretreated bamboo fiber and coconut fiber foaming, combined with modified bamboo charcoal fiber layer and far-infrared ceramic powder , enhance the effect of hygroscopic, breathable and antibacterial mite removal.
It significantly improves the breathability and hygroscopicity of the mattress, enhances durability and comfort, provides a healthy and green sleeping environment, and improves the user experience.
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Abstract
Description
Technical Field
[0001] The invention relates to the technical field of air-permeable mattresses, in particular to an air-permeable mattress containing natural fibers and a production process thereof. Background Art
[0002] In tropical or high humidity areas, harsh climatic conditions have a significant impact on people's daily lives, especially in terms of sleep. Due to the characteristics of high temperature and high humidity, it is difficult for people to get a comfortable sleeping environment at night. Traditional mattress materials, such as spring mattresses, memory foam mattresses, etc., often perform poorly in humid environments, easily accumulate moisture, and breed bacteria and mites, which not only affects sleep quality, but may also pose a potential threat to people's health. In addition, most mattress materials are difficult to degrade and are easy to damage the green environment.
[0003] In order to meet this challenge, mattress products designed for tropical or high humidity environments have gradually appeared on the market. Among them, natural fiber mattresses have attracted much attention due to their environmental protection and sustainable characteristics. These mattresses use natural fibers, such as jute and bamboo fibers. These materials have good air permeability and moisture absorption. However, in a humid environment for a long time, the moisture inside the natural fibers cannot be discharged and bacteria are easy to breed, resulting in reduced moisture absorption and breathability of the mattress, reduced strength, and the upper layer of the mattress is easy to break.
[0004] In summary, it is of great significance to solve the above problems and prepare a breathable mattress containing natural fibers with good moisture absorption effect and strong durability. Summary of the invention
[0005] The object of the present invention is to provide an air-permeable mattress containing natural fibers and a production process thereof, so as to solve the problems raised in the prior art.
[0006] To achieve the above object, the present invention provides the following technical solutions: A production process of an air-permeable mattress containing natural fibers comprises the following steps: S1: preparing a breathable fiber layer: arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming, and demoulding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0007] Preferably, the method for preparing the air-permeable fiber layer comprises the following steps: (1) Bamboo fiber pretreatment: fresh bamboo was cut into small segments of 3-4 cm, the bamboo nodes were removed, split, steamed at 100-105 °C for 7-8 h, transferred to 7-8 wt% sodium hydroxide solution, soaked at 85-90 °C for 2-3 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 220-230 °C to open the fiber until the fineness reached 100-150 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber pretreatment: The coconut shell fiber is crushed, passed through a 200-400 mesh sieve, added to a 5-6 wt% sodium hydroxide solution, stirred at 70-80 °C for 1-2 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: The preparation of the foaming base material comprises the following steps: adding pretreated coconut shell fiber to deionized water for uniform ultrasonic dispersion, adding pretreated bamboo fiber and composite foaming agent A, pre-foaming in a microwave oven at a power of 600-700 W for 10-12 min, taking out, adding composite latex and composite foaming agent B, stirring evenly, and obtaining a foaming base material; (4) Preparation of modified bamboo charcoal fiber cloth: Add far-infrared ceramic powder to deionized water for uniform ultrasonic dispersion, add aminosilane coupling agent, stir at 60-70°C for 2-3 h, immerse bamboo charcoal fiber cloth in it, add activator, stir at 40-50°C for 3-4 h, filter, wash, and dry to obtain modified bamboo charcoal fiber cloth; (5) Preparation of breathable fiber layer: Arrange the modified bamboo charcoal fiber in a mold, add the foaming base material, and foam for 3-5 hours under the environmental conditions of temperature of 75-80°C, vacuum degree of 100-500Pa, and pressure of 1-1.2Mpa. Demould and obtain a breathable fiber layer.
[0008] Preferably, the 3D fabric layer is made of 3D mesh cloth; and the bamboo is Moso bamboo produced in Huzhou, Zhejiang.
[0009] Among them, the composite latex includes modified natural latex and natural latex in a mass ratio of 1:3~4; the foaming base material includes the following raw materials in parts by mass: 4~6 parts of pretreated coconut shell fiber, 15~18 parts of pretreated bamboo fiber, 44~46 parts of deionized water, 2~4 parts of composite foaming agent A, 65~75 parts of composite latex, 2~3 parts of vulcanizing agent, 5.9~8.8 parts of composite foaming agent B; the preparation of the modified bamboo charcoal fiber cloth includes the following steps; the modified bamboo charcoal fiber cloth includes the following raw materials in parts by mass: 7~9 parts of far-infrared ceramic powder, 1~2 parts of aminosilane coupling agent, 20~30 parts of bamboo charcoal fiber cloth, and 4~5 parts of activator.
[0010] Wherein, the aminosilane coupling agent is KH-550; the activator is 1-(3-dimethylaminopropyl)-3-ethylcarbocyanine and N-hydroxysuccinimide in a mass ratio of 1:1-2.
[0011] Preferably, the preparation method of the modified natural latex comprises the following steps: adding natural latex into deionized water, uniformly dispersing by ultrasonication, adding mercaptosilane coupling agent, stirring for 2 to 3 hours under ultraviolet light conditions at 45 to 50°C, centrifuging, and separating to obtain modified natural latex.
[0012] The modified natural latex comprises the following raw materials in parts by weight: 20 to 25 parts of natural latex, 2 to 3 parts of mercaptosilane coupling agent, and 0.5 to 1 part of initiator.
[0013] Among them, the molecular weight of natural latex is 100~500; the mercaptosilane coupling agent is KH-580.
[0014] Preferably, the composite foaming agent A comprises the following raw materials in parts by mass: 8 to 10 parts of azodicarbonamide, 4 to 5 parts of sodium bicarbonate, 7 to 8 parts of modified rosin, 7 to 8 parts of pregelatinized starch, 13 to 15 parts of zinc carbonate, and 13 to 15 parts of citric acid; the composite foaming agent B comprises the following raw materials in parts by mass: 4 to 6 parts of zinc oxide, 0.4 to 0.5 parts of sodium fluorosilicate, 0.1 to 0.2 parts of polyvinyl alcohol, 0.5 to 1 parts of antioxidant D, 0.6 to 0.7 parts of sodium carbonate, and 0.3 to 0.4 parts of dilute hydrochloric acid.
[0015] A more preferred method for preparing the modified rosin comprises the following steps: adding rosin to deionized water, stirring evenly, adding 4-mercaptopyridinedicarboxylic acid and an initiator, stirring for 30 to 40 minutes under ultraviolet light conditions, and freeze-drying to obtain the modified rosin.
[0016] Wherein, the initiator is benzoin dimethyl ether.
[0017] The mass ratio of 4-mercaptopyridine dicarboxylic acid, rosin and initiator in the modified rosin is 1:1.5~2:0.1~0.2.
[0018] More preferably, the breathable mattress comprises a breathable fiber layer, a spring layer and a 3D fabric layer; the spring layer is placed below the natural fiber functional layer, and both are encapsulated in the 3D fabric layer.
[0019] The thickness of the 3D fabric layer is 8~10mm.
[0020] Wherein, in the breathable mattress, the thickness ratio of the breathable fiber layer to the spring layer is 3:7-10.
[0021] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention adopts a multi-layer structure, including a breathable fiber layer, a spring layer and a 3D fabric layer.
[0022] 3D fabric layer: It has a unique three-dimensional grid structure, good air permeability, and a large number of independent support points, which can initially disperse body pressure, isolate the breathable fiber layer, improve softness, and alleviate possible discomfort for users with high body sensitivity; Breathable fiber layer: natural plant fiber is pre-foamed, with a loose and porous structure and good air permeability. The present invention uses bamboo fiber as the skeleton of the natural fiber layer, which has high strength and air permeability, is not easy to collapse, can improve comfort, and has good antibacterial and mite removal effects. At the same time, a part of the natural latex is modified for co-foaming, which increases the softness of the mattress and the toughness of the mattress, thereby improving the user experience. However, if only bamboo fiber is used, there may be a problem of large pores and easy collapse. Therefore, the present invention additionally adds coconut shell fiber for foaming and filling in the bamboo fiber skeleton, which not only ensures the original strength, but also increases the toughness and improves the user experience. The air permeability of coconut shell fiber is better than that of bamboo fiber, and the combination can significantly improve the air permeability of the original material. In order to improve the air permeability and water absorption of the mattress, the present invention introduces an additional modified bamboo charcoal fiber layer under the foaming material: bamboo charcoal fiber is known as a breathing fiber, and its structure has good air permeability, can quickly absorb sweat and moisture discharged by the human body, provide a dry effect, and can also absorb harmful gases such as formaldehyde in the mattress, providing customers with a healthy and green use environment; The present invention further adds far-infrared ceramic powder to the bamboo charcoal fiber cloth, which can absorb external heat energy and release far-infrared rays, penetrate the skin and subcutaneous tissue, promote human cell activity, improve sleep quality, and work synergistically with the bamboo charcoal fiber to jointly improve sleep comfort. However, directly adding the bamboo charcoal fiber has poor binding properties, so the bamboo charcoal fiber and the far-infrared ceramic powder are modified in advance to improve the use effect. At the same time, its structure also helps to improve the stability of the connection between the modified bamboo charcoal fiber layer and the foaming material.
[0023] (2) The composite foaming agent A used in the present invention contains rosin as an adhesive for preparing natural fiber foaming materials. Rosin is a light yellow or brown transparent solid substance with excellent adhesion strength. In the composite foaming agent, it has a good binding effect on polar materials, can better combine plant fibers together, and can also provide support for plant fibers. By grafting pyridine dicarboxylic acid, the polycarboxylic acid structure can make the latex and plant fibers connect more closely, improving the overall material structure strength; in addition, pyridine dicarboxylic acid is a compound with high thermal stability. After grafting, it can significantly improve the heat resistance of rosin, has a certain flame retardant effect, and can assist rosin in forming a layer of organic film on the surface of plant fibers, thereby improving the waterproof and moisture-proof effect, and helping sweat and moisture to pass through the porous structure and be absorbed by the modified bamboo charcoal fiber layer below, thereby improving the air permeability and hygroscopicity of the mattress. DETAILED DESCRIPTION Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in the field without making any creative work shall fall within the scope of protection of the present invention.
[0024] It should be noted that there are no special restrictions on the purchase manufacturers of all the raw materials involved in the present invention, which exemplarily include: 3D mesh, purity 99%, provided by Hebei Huanji Wire Mesh Products Co., Ltd.; bamboo, moso bamboo, produced in Huzhou, Zhejiang; coconut shell fiber, purity 99%, provided by Qingdao Kairuihang International Trade Co., Ltd.; far-infrared ceramic powder, purity 99%, provided by Hefei Xiangzheng Chemical Technology Co., Ltd.; bamboo charcoal fiber cloth, purity 99%, provided by Anhui Tianfu Environmental Protection Technology Materials Co., Ltd.; natural latex, purity 99%, provided by natural latex; azodicarbonamide, purity 99%, provided by Hubei Tosoh Chemical Technology Co., Ltd.; rosin, purity 99%, provided by Changzhou Provided by Jiaye Chemical Co., Ltd.; pregelatinized starch, purity 99%, provided by Hebei Yaxin Biotechnology Co., Ltd.; polyvinyl alcohol, molecular weight 1000~2000, provided by Sichuan Lai Te Ju Xin Pharmaceutical Excipients Co., Ltd.; vulcanizing agent, purity 99%, provided by Ningbo Aikemu New Materials Co., Ltd.; sodium fluorosilicate, purity 99%, provided by Jinan Guocheng Chemical Co., Ltd.; antioxidant D, purity 99%, provided by Kangdisi Chemical (Hubei) Co., Ltd.; 4-mercaptopyridine dicarboxylic acid, purity 99%, provided by JACS-Zhengzhou Jacks Chemical Products Co., Ltd.; benzoin dimethyl ether, purity 99%, provided by Chongqing Ruiya Biotechnology Co., Ltd.; In the following examples, parts are by mass and all raw materials are commercially available.
[0025] The modified rosin is prepared in advance, comprising the following steps: adding 16 parts of rosin to 60 parts of deionized water, stirring evenly, adding 10 parts of 4-mercaptopyridine dicarboxylic acid and 2 parts of benzoin dimethyl ether in a mass ratio, stirring for 35 minutes under ultraviolet light conditions, and freeze-drying to obtain the modified rosin.
[0026] The modified natural latex is prepared in advance, comprising the following steps: adding 25 parts of natural latex to 75 parts of deionized water, uniformly dispersing by ultrasonication, adding 2.5 parts of mercaptosilane coupling agent and 1 part of benzoin dimethyl ether, stirring for 2.5 hours under ultraviolet light conditions at 45°C, centrifuging, and separating to obtain the modified natural latex.
[0027] Example 1: S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7 h, transferred to 7.5 wt% sodium hydroxide solution, soaked at 85 °C for 2.5 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 225 °C to open the fiber until the fineness reached 125 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber treatment: The coconut shell fiber was crushed, passed through a 200-mesh sieve, added into a 5.5 wt% sodium hydroxide solution, stirred at 75 °C for 1.5 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: 5 parts of pretreated coconut shell fiber were added to 45 parts of deionized water and ultrasonically dispersed uniformly, 16 parts of pretreated bamboo fiber and 3 parts of composite foaming agent A were added, and pre-foamed in a microwave oven at a power of 650 W for 11 min. After taking out, 70 parts of composite latex (the mass ratio of modified natural latex to natural latex is 1:3.5) and 7.3 parts of composite foaming agent B (5 parts of zinc oxide, 0.45 parts of sodium fluorosilicate, 0.15 parts of polyvinyl alcohol, 0.7 parts of antioxidant D, 0.65 parts of sodium carbonate, and 0.35 parts of dilute hydrochloric acid) were added, and stirred evenly to obtain a foaming base material.
[0028] (4) Preparation of modified bamboo charcoal fiber cloth: 8 parts of far-infrared ceramic powder were added to 85 parts of deionized water by mass, and ultrasonically dispersed uniformly; 1.5 parts of aminosilane coupling agent were added, and stirred at 65°C for 2.5 hours; 25 parts of bamboo charcoal fiber cloth were immersed therein; 4.5 parts of activator were added, and stirred at 45°C for 3.5 hours; filtered, washed, and dried to obtain modified bamboo charcoal fiber cloth; (5) Arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming for 4 hours under the environmental conditions of a temperature of 75°C, a vacuum degree of 300Pa, and a pressure of 1Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0029] In the technical solution, the compound foaming agent A includes the following components: by mass, 9 parts of azodicarbonamide, 4.5 parts of sodium bicarbonate, 7.5 parts of modified rosin, 7.5 parts of pregelatinized starch, 14 parts of zinc carbonate, and 14 parts of citric acid.
[0030] Example 2: S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7 h, transferred to 7 wt % sodium hydroxide solution, soaked at 85 °C for 2 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 220 °C to open the fiber until the fineness reached 100 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber treatment: The coconut shell fiber was crushed, passed through a 200-mesh sieve, added into a 5 wt % sodium hydroxide solution, stirred at 70 ° C for 1 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: 4 parts of pretreated coconut shell fiber were added to 44 parts of deionized water and ultrasonically dispersed uniformly. 15 parts of pretreated bamboo fiber and 2 parts of composite foaming agent A were added and pre-foamed in a microwave oven at 600 W for 10 min. After taking out, 65 parts of composite latex (the mass ratio of modified natural latex to natural latex was 1:3) and 5.9 parts of composite foaming agent B (4 parts of zinc oxide, 0.4 parts of sodium fluorosilicate, 0.1 parts of polyvinyl alcohol, 0.5 parts of antioxidant D, 0.6 parts of sodium carbonate and 0.3 parts of dilute hydrochloric acid) were added and stirred uniformly to obtain a foaming base material.
[0031] (4) Preparation of modified bamboo charcoal fiber cloth: 7 parts of far-infrared ceramic powder were added to 80 parts of deionized water by mass, and ultrasonically dispersed uniformly; 1 part of aminosilane coupling agent was added, and stirred at 60°C for 2 hours; 20 parts of bamboo charcoal fiber cloth were immersed therein; 4 parts of activator were added, and stirred at 40°C for 3 hours; filtered, washed, and dried to obtain modified bamboo charcoal fiber cloth; (5) Arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming for 3 hours under the environmental conditions of a temperature of 75°C, a vacuum degree of 100Pa, and a pressure of 1Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0032] In the technical solution, the compound foaming agent A includes the following components: by mass, 8 parts of azodicarbonamide, 4 parts of sodium bicarbonate, 7 parts of modified rosin, 7 parts of pregelatinized starch, 13 parts of zinc carbonate, and 13 parts of citric acid.
[0033] Example 3: S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7.5 h, transferred to 8 wt % sodium hydroxide solution, soaked at 90 °C for 3 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 230 °C to open the fiber until the fineness reached 150 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber treatment: The coconut shell fiber was crushed, passed through a 200-mesh sieve, added into a 6 wt % sodium hydroxide solution, stirred at 80 ° C for 2 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: 6 parts of pretreated coconut shell fiber were added to 46 parts of deionized water and ultrasonically dispersed uniformly. 18 parts of pretreated bamboo fiber and 4 parts of composite foaming agent A were added and pre-foamed in a microwave oven at 700 W for 12 min. After taking out, 75 parts of composite latex (the mass ratio of modified natural latex to natural latex was 1:4) and 8.8 parts of composite foaming agent B (6 parts of zinc oxide, 0.5 parts of sodium fluorosilicate, 0.2 parts of polyvinyl alcohol, 1 part of antioxidant D, 0.7 parts of sodium carbonate and 0.4 parts of dilute hydrochloric acid) were added and stirred uniformly to obtain a foaming base material.
[0034] (4) Preparation of modified bamboo charcoal fiber cloth: 9 parts of far-infrared ceramic powder were added to 90 parts of deionized water by mass ratio, and ultrasonically dispersed uniformly; 2 parts of aminosilane coupling agent were added, and stirred at 70°C for 3 hours; 30 parts of bamboo charcoal fiber cloth were immersed therein; 5 parts of activator were added, and stirred at 50°C for 4 hours; filtered, washed, and dried to obtain modified bamboo charcoal fiber cloth; (5) Arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming for 5 hours under the environmental conditions of a temperature of 80°C, a vacuum degree of 500Pa, and a pressure of 1.2Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0035] In the technical scheme, the ratio of the composite foaming agent A includes the following components: by mass, 10 parts of azodicarbonamide, 5 parts of sodium bicarbonate, 8 parts of modified rosin, 8 parts of pregelatinized starch, 15 parts of zinc carbonate, and 15 parts of citric acid.
[0036] Comparative Example 1: Based on Example 1, coconut shell fiber is not introduced, and the other processes remain unchanged.
[0037] S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7 h, transferred to 7.5 wt% sodium hydroxide solution, soaked at 85 °C for 2.5 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 225 °C to open the fiber until the fineness reached 125 μm, and pretreated bamboo fiber was obtained; (2) Preparation of foaming base material: 16 parts of pretreated bamboo fibers were added to 45 parts of deionized water and ultrasonically dispersed uniformly. 3 parts of composite foaming agent A were added and pre-foamed in a microwave oven at 650 W for 11 min. After taking out, 70 parts of composite latex (the mass ratio of modified natural latex to natural latex was 1:3.5) and 7.3 parts of composite foaming agent B (5 parts of zinc oxide, 0.45 parts of sodium fluorosilicate, 0.15 parts of polyvinyl alcohol, 0.7 parts of antioxidant D, 0.65 parts of sodium carbonate, and 0.35 parts of dilute hydrochloric acid) were added and stirred uniformly to obtain a foaming base material.
[0038] (4) Preparation of modified bamboo charcoal fiber cloth: 8 parts of far-infrared ceramic powder were added to 85 parts of deionized water by mass, and ultrasonically dispersed uniformly; 1.5 parts of aminosilane coupling agent were added, and stirred at 65°C for 2.5 hours; 25 parts of bamboo charcoal fiber cloth were immersed therein; 4.5 parts of activator were added, and stirred at 45°C for 3.5 hours; filtered, washed, and dried to obtain modified bamboo charcoal fiber cloth; (5) Arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming for 4 hours under the environmental conditions of a temperature of 75°C, a vacuum degree of 300Pa, and a pressure of 1Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0039] In the technical solution, the compound foaming agent A includes the following components: by mass, 9 parts of azodicarbonamide, 4.5 parts of sodium bicarbonate, 7.5 parts of modified rosin, 7.5 parts of pregelatinized starch, 14 parts of zinc carbonate, and 14 parts of citric acid.
[0040] Comparative Example 2: Based on Example 1, the rosin was not modified and the other processes remained unchanged.
[0041] S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7 h, transferred to 7.5 wt% sodium hydroxide solution, soaked at 85 °C for 2.5 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 225 °C to open the fiber until the fineness reached 125 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber treatment: The coconut shell fiber was crushed, passed through a 200-mesh sieve, added into a 5.5 wt% sodium hydroxide solution, stirred at 75 °C for 1.5 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: 5 parts of pretreated coconut shell fiber were added to 45 parts of deionized water and ultrasonically dispersed uniformly, 16 parts of pretreated bamboo fiber and 3 parts of composite foaming agent A were added, and pre-foamed in a microwave oven at a power of 650 W for 11 min. After taking out, 70 parts of composite latex (the mass ratio of modified natural latex to natural latex is 1:3.5) and 7.3 parts of composite foaming agent B (5 parts of zinc oxide, 0.45 parts of sodium fluorosilicate, 0.15 parts of polyvinyl alcohol, 0.7 parts of antioxidant D, 0.65 parts of sodium carbonate, and 0.35 parts of dilute hydrochloric acid) were added, and stirred evenly to obtain a foaming base material.
[0042] (4) Preparation of modified bamboo charcoal fiber cloth: 8 parts of far-infrared ceramic powder were added to 85 parts of deionized water by mass, and ultrasonically dispersed uniformly; 1.5 parts of aminosilane coupling agent were added, and stirred at 65°C for 2.5 hours; 25 parts of bamboo charcoal fiber cloth were immersed therein; 4.5 parts of activator were added, and stirred at 45°C for 3.5 hours; filtered, washed, and dried to obtain modified bamboo charcoal fiber cloth; (5) Arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming for 4 hours under the environmental conditions of a temperature of 75°C, a vacuum degree of 300Pa, and a pressure of 1Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0043] In the technical solution, the compound foaming agent A includes the following components: by mass, 9 parts of azodicarbonamide, 4.5 parts of sodium bicarbonate, 7.5 parts of rosin, 7.5 parts of pregelatinized starch, 14 parts of zinc carbonate, and 14 parts of citric acid.
[0044] Comparative Example 3: Based on Example 1, the modified bamboo charcoal fiber cloth was replaced with cotton cloth, and the other processes remained unchanged.
[0045] S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7 h, transferred to 7.5 wt% sodium hydroxide solution, soaked at 85 °C for 2.5 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 225 °C to open the fiber until the fineness reached 125 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber treatment: The coconut shell fiber was crushed, passed through a 200-mesh sieve, added into a 5.5 wt% sodium hydroxide solution, stirred at 75 °C for 1.5 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: 5 parts of pretreated coconut shell fiber were added to 45 parts of deionized water and ultrasonically dispersed uniformly, 16 parts of pretreated bamboo fiber and 3 parts of composite foaming agent A were added, and pre-foamed in a microwave oven at a power of 650 W for 11 min. After taking out, 70 parts of composite latex (the mass ratio of modified natural latex to natural latex is 1:3.5) and 7.3 parts of composite foaming agent B (5 parts of zinc oxide, 0.45 parts of sodium fluorosilicate, 0.15 parts of polyvinyl alcohol, 0.7 parts of antioxidant D, 0.65 parts of sodium carbonate, and 0.35 parts of dilute hydrochloric acid) were added, and stirred evenly to obtain a foaming base material.
[0046] (4) placing the cotton in a mold, adding a foaming base material, foaming for 4 hours under the environmental conditions of a temperature of 75°C, a vacuum degree of 300Pa, and a pressure of 1Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0047] In the technical solution, the compound foaming agent A includes the following components: by mass, 9 parts of azodicarbonamide, 4.5 parts of sodium bicarbonate, 7.5 parts of modified rosin, 7.5 parts of pregelatinized starch, 14 parts of zinc carbonate, and 14 parts of citric acid.
[0048] Comparative Example 4: Based on Example 1, the latex was not modified and the other processes remained unchanged.
[0049] S1: Preparation of air-permeable fiber layer: (1) Bamboo fiber pretreatment: Fresh bamboo was cut into 3.5 cm segments, the bamboo nodes were removed, split, steamed at 100 °C for 7 h, transferred to 7.5 wt% sodium hydroxide solution, soaked at 85 °C for 2.5 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 225 °C to open the fiber until the fineness reached 125 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber treatment: The coconut shell fiber was crushed, passed through a 200-mesh sieve, added into a 5.5 wt% sodium hydroxide solution, stirred at 75 °C for 1.5 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: 5 parts of pretreated coconut shell fiber were added to 45 parts of deionized water and ultrasonically dispersed uniformly, 16 parts of pretreated bamboo fiber and 3 parts of composite foaming agent A were added, and pre-foamed in a microwave oven at a power of 650 W for 11 min. After taking out, 70 parts of natural latex and 7.3 parts of composite foaming agent B (5 parts of zinc oxide, 0.45 parts of sodium fluorosilicate, 0.15 parts of polyvinyl alcohol, 0.7 parts of antioxidant D, 0.65 parts of sodium carbonate, and 0.35 parts of dilute hydrochloric acid) were added, and stirred uniformly to obtain a foaming base material.
[0050] (4) Preparation of modified bamboo charcoal fiber cloth: 8 parts of far-infrared ceramic powder were added to 85 parts of deionized water by mass, and ultrasonically dispersed uniformly; 1.5 parts of aminosilane coupling agent were added, and stirred at 65°C for 2.5 hours; 25 parts of bamboo charcoal fiber cloth were immersed therein; 4.5 parts of activator were added, and stirred at 45°C for 3.5 hours; filtered, washed, and dried to obtain modified bamboo charcoal fiber cloth; (5) Arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming for 4 hours under the environmental conditions of a temperature of 75°C, a vacuum degree of 300Pa, and a pressure of 1Mpa, and demolding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
[0051] In the technical solution, the compound foaming agent A includes the following components: by mass, 9 parts of azodicarbonamide, 4.5 parts of sodium bicarbonate, 7.5 parts of modified rosin, 7.5 parts of pregelatinized starch, 14 parts of zinc carbonate, and 14 parts of citric acid.
[0052] Performance test: (1) A sample with a thickness of 8 mm was prepared from the bottom up using the breathable fiber layer of each embodiment. According to GB / T12704.2-2009 "Test method for moisture permeability of textile fabrics - Part 2: Evaporation method", a positive cup method test (the foaming material surface is in contact with the cup mouth) was performed at 38°C and a relative humidity of 50%. The moisture permeability was measured. The experimental data are shown in Table 1. (2) A sample with a thickness of 2 mm was prepared from the top down using the breathable fiber layer of each embodiment. A tensile strength test was performed using a fabric strength testing machine. The tensile strength was measured. The experimental data are shown in Table 2.
[0053] Table 1
[0054] Table 2
[0055] Conclusion: It can be seen from the table that in Comparative Example 1, coconut shell fiber is not introduced, resulting in larger pores in the material, reduced tensile strength, and slightly decreased moisture permeability; in Comparative Example 2, the rosin is not modified, the rosin stability is reduced, the fiber cannot be well bonded and wrapped, and the tensile strength and moisture permeability are reduced; in Comparative Example 3, the modified bamboo charcoal fiber cloth is replaced with cotton cloth, which cannot absorb the discharged moisture in time, the moisture absorption effect is reduced, and the moisture permeability is reduced; in Comparative Example 4, the latex is not modified, the interfacial bonding with the plant fiber is reduced, and the tensile strength is reduced.
[0056] In summary, the present invention successfully prepares a breathable mattress with good breathability and moisture absorption effect and high strength by providing a method for preparing a natural fiber breathable layer.
[0057] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.
Claims
1. A production process for an air-permeable mattress containing natural fibers, characterized in that: The following steps are involved: S1: preparing a breathable fiber layer: arranging the modified bamboo charcoal fiber in a mold, adding a foaming base material, foaming, and demoulding to obtain a breathable fiber layer; S2: a spring layer is arranged under the breathable fiber layer, and a 3D fabric layer is used for sewing and encapsulation, and then tested to obtain a breathable mattress.
2. The production process of a breathable mattress containing natural fibers according to claim 1, characterized in that: The method for preparing the air-permeable fiber layer comprises the following steps: (1) Bamboo fiber pretreatment: fresh bamboo was cut into small segments of 3-4 cm, the bamboo nodes were removed, split, steamed at 100-105 °C for 7-8 h, transferred to 7-8 wt% sodium hydroxide solution, soaked at 85-90 °C for 2-3 h, rinsed with deionized water, dried, transferred to a mechanical fiber opener at 220-230 °C to open the fiber until the fineness reached 100-150 μm, and pretreated bamboo fiber was obtained; (2) Coconut shell fiber pretreatment: The coconut shell fiber is crushed, passed through a 200-400 mesh sieve, added to a 5-6 wt% sodium hydroxide solution, stirred at 70-80 °C for 1-2 h, filtered, washed, and dried to obtain pretreated coconut shell fiber; (3) Preparation of foaming base material: The preparation of the foaming base material comprises the following steps: adding pretreated coconut shell fiber to deionized water for uniform ultrasonic dispersion, adding pretreated bamboo fiber and composite foaming agent A, pre-foaming in a microwave oven at a power of 600-700 W for 10-12 min, taking out, adding composite latex, vulcanizing agent and composite foaming agent B, stirring evenly, and obtaining a foaming base material; (4) Preparation of modified bamboo charcoal fiber cloth: Add far-infrared ceramic powder to deionized water for uniform ultrasonic dispersion, add aminosilane coupling agent, stir at 60-70°C for 2-3 h, immerse bamboo charcoal fiber cloth in it, add activator, stir at 40-50°C for 3-4 h, filter, wash, and dry to obtain modified bamboo charcoal fiber cloth; (5) Preparation of breathable fiber layer: Arrange the modified bamboo charcoal fiber in a mold, add the foaming base material, and foam for 3-5 hours under the environmental conditions of temperature of 75-80°C, vacuum degree of 100-500Pa, and pressure of 1-1.2Mpa. Demould and obtain a breathable fiber layer.
3. The production process of a breathable mattress containing natural fibers according to claim 2, characterized in that: The composite latex comprises modified natural latex and natural latex in a mass ratio of 1:3-4; The foaming base material comprises the following raw materials in parts by weight: 4-6 parts of pretreated coconut shell fiber, 15-18 parts of pretreated bamboo fiber, 44-46 parts of deionized water, 2-4 parts of composite foaming agent A, 65-75 parts of composite latex, 2-3 parts of vulcanizing agent, and 5.9-8.8 parts of composite foaming agent B; The preparation of the modified bamboo charcoal fiber cloth comprises the following steps: The modified bamboo charcoal fiber cloth comprises the following raw materials in parts by weight: 7 to 9 parts of far-infrared ceramic powder, 1 to 2 parts of aminosilane coupling agent, 20 to 30 parts of bamboo charcoal fiber cloth, and 4 to 5 parts of activator.
4. The production process of a breathable mattress containing natural fibers according to claim 3, characterized in that: The preparation method of the modified natural latex comprises the following steps: adding natural latex into deionized water, uniformly dispersing by ultrasonication, adding mercaptosilane coupling agent and initiator, stirring for 2-3 hours under ultraviolet light conditions at 45-50° C., centrifuging, and separating to obtain the modified natural latex.
5. The production process of a breathable mattress containing natural fibers according to claim 4, characterized in that: The modified natural latex comprises the following raw materials in parts by weight: 20-25 parts of natural latex, 2-3 parts of mercaptosilane coupling agent, and 0.5-1 part of initiator.
6. The production process of a breathable mattress containing natural fibers according to claim 2, characterized in that: The composite foaming agent A comprises the following raw materials in parts by weight: 8 to 10 parts of azodicarbonamide, 4 to 5 parts of sodium bicarbonate, 7 to 8 parts of modified rosin, 7 to 8 parts of pregelatinized starch, 13 to 15 parts of zinc carbonate, and 13 to 15 parts of citric acid; the composite foaming agent B comprises the following raw materials in parts by weight: 4 to 6 parts of zinc oxide, 0.4 to 0.5 parts of sodium fluorosilicate, 0.1 to 0.2 parts of polyvinyl alcohol, 0.5 to 1 parts of antioxidant D, 0.6 to 0.7 parts of sodium carbonate, and 0.3 to 0.4 parts of dilute hydrochloric acid.
7. The production process of a breathable mattress containing natural fibers according to claim 6, characterized in that: The preparation method of the modified rosin comprises the following steps: adding rosin into deionized water, stirring evenly, adding 4-thiopyridine dicarboxylic acid and an initiator, stirring for 30 to 40 minutes under ultraviolet light conditions, and freeze-drying to obtain the modified rosin.
8. The production process of a breathable mattress containing natural fibers according to claim 6, characterized in that: The mass ratio of 4-mercaptopyridinedicarboxylic acid, rosin and initiator in the modified rosin is 1:1.5-2:0.1-0.
2.
9. The air-permeable mattress prepared by the production process of an air-permeable mattress containing natural fibers according to any one of claims 1 to 8, characterized in that: The air-permeable mattress comprises an air-permeable fiber layer, a spring layer and a 3D fabric layer; the spring layer is placed below the natural fiber functional layer, and the two are encapsulated in the 3D fabric layer.
10. The air-permeable mattress containing natural fibers according to claim 9, characterized in that: The thickness ratio of the air-permeable fiber layer to the spring layer in the air-permeable mattress is 3:7-10.