Cushion core with fully degradable raw materials and preparation method thereof

Abstract

The invention discloses a raw material full-degradable cushion core and a preparation method thereof.The raw material full-degradable cushion core comprises a core layer and surface layers arranged on the upper surface and the lower surface of the core layer, and the core layer is composed of 45-55% of polylactic acid bi-component low-melting-point fibers, 20-30% of biomass fibers and 20-30% of natural fibers; the surface layer is prepared from 45 to 55 percent of polylactic acid bi-component low-melting-point fiber, 20 to 30 percent of biomass fiber and 20 to 30 percent of natural fiber; the core layer and the surface layer are both composed of polylactic acid bi-component low-melting-point fibers, biomass fibers and natural fibers and have the characteristic of full degradation, in addition, in the subsequent composite hot drying process, when hot drying is conducted at the temperature of 180 DEG C, the lower surface layer and the core layer can also be firmly bonded, the production cost is reduced, the humidity of mixed cotton is reduced before hot drying, and therefore the mixed cotton is not prone to falling off. The cotton blending process is faster, and the production speed is further improved.

Description

Technical Field

[0001] The present invention relates to the technical field of daily necessities, and in particular to a cushion core with fully degradable raw materials and a preparation method thereof. Background Art

[0002] As people's living standards improve, their requirements for sleep quality are also increasing. Mattresses, as one of the important daily necessities for sleep, are becoming more and more popular in homes, inns, hotels and other places. Common mattresses on the market include spring mattresses and plant fiber mattresses.

[0003] Most of the existing mattresses are made of mixed materials or single materials during production. The two most common materials are coconut shell fiber and bamboo fiber. Both coconut shell fiber and bamboo fiber are plant fibers, so their own fiber toughness and tensile strength are insufficient, that is, the mattress after production has poor flexibility and is easy to break; moreover, low-melting-point fibers are required when the mattress is produced as a whole. Low-melting-point fibers are fibers with a lower melting point than the main fiber in the non-woven fabric. For example, polyester fiber is mixed with polyethylene fiber to produce non-woven fabrics, and the polyethylene fiber is a low-melting-point fiber; or through copolymerization modification, the melting point is reduced to a level lower than that of the original polymer material, or such as CoPET; in production When carding a nonwoven fabric, 100% composite fibers are used, the fiber cortex is melted with hot air, and then the fibers are bonded to form a nonwoven fabric, or 10-25% low-melting point composite staple fibers are mixed with other thermoplastic fibers in a certain proportion and formed into a nonwoven fabric by hot rolling. Obviously, these fibers and nonwoven fabrics are not biodegradable; 10-25% ordinary low-melting point composite staple fibers can also be used to mix with other biodegradable fibers to produce nonwoven fabrics, such as cotton fibers, viscose fibers, wood pulp fibers and straw fibers. Although the main fibers are biodegradable, the low-melting point composite staple fibers used are not biodegradable fibers, so such nonwoven fabrics cannot be biodegradable. Summary of the invention

[0004] The purpose of the present invention is to provide a mat core with fully degradable raw materials and a preparation method thereof, which has solved the problems raised in the above background technology.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solution: a mat core with fully degradable raw materials, comprising a core layer and a surface layer arranged on the upper and lower surfaces of the core layer, the core layer is composed of 45-55% polylactic acid two-component low-melting point fiber, 20-30% biomass fiber and 20-30% natural fiber, and the surface layer is composed of 45-55% polylactic acid two-component low-melting point fiber, 20-30% biomass fiber and 20-30% natural fiber.

[0006] Preferably, the biomass fiber is one of alpaca wool and wool.

[0007] Preferably, the natural fiber is one of bamboo fiber, bamboo charcoal fiber and coconut shell fiber.

[0008] A method for preparing a fully degradable raw material cushion core, characterized in that it comprises the fully degradable raw material cushion core according to any one of claims 1 to 3, and the preparation method comprises the following steps:

[0009] 1. Weigh, loosen and mix the components according to the required proportions, pre-net, card, air-net and needle punch to prepare the upper and lower surface layers respectively;

[0010] 2. Weigh, loosen, mix, pre-web, card, and air-web the components according to the required proportion to obtain the core layer;

[0011] 3. Then place the two surface layers above and below the core layer respectively, and then send the whole into an oven for heating and melting, cooling and shaping;

[0012] 4. Cut the product into small pieces according to its size to obtain the cushion core.

[0013] Preferably, the cotton is humidified and mixed during the loosening and mixing in step 1 and step 2, the humidity of the mixed material is 60-70%, and the mixing time is 120 seconds for each 60 kg mixing.

[0014] Preferably, a carding machine is required to perform carding work in step 1 and step 2, and the carding machine includes a cylinder, a doffer and a plurality of groups of working rollers, wherein the angle of the card cloth tooth tip of the cylinder is 10°, the angle of the card cloth tooth tip of the doffer is 35°, the angle of the card cloth tooth tip of the plurality of working rollers is 25°, and the direction of the card cloth tooth tip of the cylinder is opposite to the direction of the card cloth tooth tip of the doffer and the direction of the card cloth tooth tip of the plurality of working rollers.

[0015] Preferably, the working linear speed of the cylinder is 1130 m / min, the linear speed of the doffer is 33 m / min, the speed ratio of the cylinder to the doffer is 1:34, the working rolls are arranged in 5 groups and spaced apart along the circumference of the cylinder, and the linear speeds of the 5 groups of working rolls are 32 m / min for the first group, 32 m / min for the second group, 31 m / min for the second group, 28 m / min for the third group, 25 m / min for the fourth group, and 20 m / min for the fifth group in the order of combing the working rolls.

[0016] Preferably, the gauges between each set of working rollers and the cylinder are 90 inches, 69 inches, 15 inches, 35 inches, and 28 inches respectively.

[0017] Preferably, the oven in step 3 is a stepped circulating hot air heating device, with a first section temperature of 152-160 degrees Celsius, a second section temperature of 168-174 degrees Celsius, and a third section temperature of 172-178 degrees Celsius.

[0018] Preferably, the conveying speed of the oven in step 3 is 2.2 m / min-4.5 m / min.

[0019] Compared with the prior art, the beneficial effects of the present invention include: the core layer and the surface layer of the present invention are both composed of polylactic acid two-component low-melting point fiber, biomass fiber and natural fiber, and are both fully degradable. In addition, in the subsequent composite heat drying process, the surface layer and the core layer can be firmly bonded when the heat drying is below 180 degrees Celsius, thereby reducing production costs. The humidity of the mixed cotton is reduced before heat drying, and the mixing process is faster, thereby further improving the production speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the production process of the present invention. DETAILED DESCRIPTION

[0021] Embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although certain embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as being limited to the embodiments described herein, which are instead provided for a more thorough and complete understanding of the present invention. It should be understood that the drawings and embodiments of the present invention are only for exemplary purposes and are not intended to limit the scope of protection of the present invention.

[0022] It should be understood that the various steps described in the method embodiments of the present invention may be performed in different orders and / or in parallel. In addition, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this respect.

[0023] The term "including" and its variations used herein are open inclusions, i.e., "including but not limited to". The term "connected" may be directly connected or indirectly connected through intermediate components (elements). The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one other embodiment"; the term "some embodiments" means "at least some embodiments". The relevant definitions of other terms will be given in the following description.

[0024] It should be noted that the concepts such as "first" and "second" mentioned in the present invention are only used to distinguish between devices, modules or units, and are not used to limit these devices, modules or units to be different devices, modules or units, nor are they used to limit the order or interdependence of the functions performed by these devices, modules or units.

[0025] Example 1

[0026] A raw material fully degradable cushion core, comprising a core layer and surface layers arranged on the upper and lower surfaces of the core layer,

[0027] The core layer is composed of 45% polylactic acid bicomponent low-melting point fiber, 30% biomass fiber and 25% natural fiber, and the surface layer is composed of 45% polylactic acid bicomponent low-melting point fiber, 25% biomass fiber and 30% natural fiber.

[0028] In this embodiment, the biomass fiber is alpaca wool, and the natural fiber is bamboo fiber.

[0029] like Figure 1 The method for preparing a raw material fully degradable cushion core shown includes the above raw material fully degradable cushion core, and the preparation method includes the following steps:

[0030] 1. Weigh, loosen and mix the components according to the required proportions, pre-net, card, air-net and needle punch to prepare the upper and lower surface layers respectively;

[0031] 2. Weigh, loosen, mix, pre-web, card, and air-web the components according to the required proportion to obtain the core layer;

[0032] 3. Then place the two surface layers above and below the core layer respectively, and then send the whole into an oven for heating and melting, cooling and shaping;

[0033] 4. Cut the product into small pieces according to its size to obtain the cushion core.

[0034] Wherein, the cotton is humidified and mixed during the loosening and mixing in step 1 and step 2, the mixed material humidity is 60%, and the mixing time is 120 seconds for each 60 kg mixing.

[0035] Among them, in step 1 and step 2, a carding machine is required to perform carding work, and the carding machine includes a cylinder, a doffer and a plurality of groups of working rollers in which the tooth tips of the card clothing are set, wherein the angle of the tooth tip of the card clothing of the cylinder is 10°, the angle of the tooth tip of the card clothing of the doffer is 35°, the angle of the tooth tip of the card clothing of the plurality of working rollers is 25°, and the direction of the tooth tip of the card clothing of the cylinder is opposite to the direction of the tooth tip of the card clothing of the doffer and the direction of the tooth tip of the card clothing of the plurality of working rollers.

[0036] Among them, the working linear speed of the cylinder is 1130 m / min, the linear speed of the doffer is 33 m / min, the speed ratio of the cylinder to the doffer is 1:34, the working rolls are adopted in 5 groups, and are arranged at intervals along the circumference of the cylinder, and the linear speeds of the 5 groups of working rolls are 32 m / min for the first group, 32 m / min for the second group, 31 m / min for the second group, 28 m / min for the third group, 25 m / min for the fourth group, and 20 m / min for the fifth group in the order of combing the working rolls.

[0037] Among them, there are 5 groups of working rollers, and the gauges between each group of working rollers and the cylinder are 90 inches, 69 inches, 15 inches, 35 inches, and 28 inches respectively.

[0038] Among them, the oven in step 3 is a stepped circulating hot air heating device, with a first section temperature of 152 degrees Celsius, a second section temperature of 168 degrees Celsius, and a third section temperature of 172 degrees Celsius.

[0039] Wherein, the conveying speed of the oven in step 3 is 2.2m / min-4.5m / min.

[0040] Example 2

[0041] A mat core with fully degradable raw materials, comprising a core layer and surface layers arranged on the upper and lower surfaces of the core layer, the core layer is composed of 50% polylactic acid two-component low-melting point fiber, 30% biomass fiber and 20% natural fiber, and the surface layer is composed of 50% polylactic acid two-component low-melting point fiber, 20% biomass fiber and 30% natural fiber.

[0042] In this embodiment, the biomass fiber is alpaca wool, and the natural fiber is bamboo fiber.

[0043] like Figure 1 The method for preparing a raw material fully degradable cushion core shown includes the above raw material fully degradable cushion core, and the preparation method includes the following steps:

[0044] 1. Weigh, loosen and mix the components according to the required proportions, pre-net, card, air-net and needle punch to prepare the upper and lower surface layers respectively;

[0045] 2. Weigh, loosen, mix, pre-web, card, and air-web the components according to the required proportion to obtain the core layer;

[0046] 3. Then place the two surface layers above and below the core layer respectively, and then send the whole into an oven for heating and melting, cooling and shaping;

[0047] 4. Cut the product into small pieces according to its size to obtain the cushion core.

[0048] Wherein, the cotton is humidified and mixed during the loosening and mixing in step 1 and step 2, the mixed material humidity is 60-70%, and the mixing time is 120 seconds for each 60 kg mixing.

[0049] Among them, in step 1 and step 2, a carding machine is required to perform carding work, and the carding machine includes a cylinder, a doffer and a plurality of groups of working rollers in which the tooth tips of the card clothing are set, wherein the angle of the tooth tip of the card clothing of the cylinder is 10°, the angle of the tooth tip of the card clothing of the doffer is 35°, the angle of the tooth tip of the card clothing of the plurality of working rollers is 25°, and the direction of the tooth tip of the card clothing of the cylinder is opposite to the direction of the tooth tip of the card clothing of the doffer and the direction of the tooth tip of the card clothing of the plurality of working rollers.

[0050] Among them, the working linear speed of the cylinder is 1130 m / min, the linear speed of the doffer is 33 m / min, the speed ratio of the cylinder to the doffer is 1:34, the working rolls are adopted in 5 groups, and are arranged at intervals along the circumference of the cylinder, and the linear speeds of the 5 groups of working rolls are 32 m / min for the first group, 32 m / min for the second group, 31 m / min for the second group, 28 m / min for the third group, 25 m / min for the fourth group, and 20 m / min for the fifth group in the order of combing the working rolls.

[0051] Among them, there are 5 groups of working rollers, and the gauges between each group of working rollers and the cylinder are 90 inches, 69 inches, 15 inches, 35 inches, and 28 inches respectively.

[0052] Among them, the oven in step 3 is a stepped circulating hot air heating device, with a temperature of 156 degrees Celsius in the first section, 171 degrees Celsius in the second section, and 175 degrees Celsius in the third section.

[0053] Wherein, the conveying speed of the oven in step 3 is 2.2m / min-4.5m / min.

[0054] Example 3

[0055] A mat core with fully degradable raw materials, comprising a core layer and surface layers arranged on the upper and lower surfaces of the core layer, the core layer is composed of 55% polylactic acid two-component low-melting point fiber, 25% biomass fiber and 20% natural fiber, and the surface layer is composed of 55% polylactic acid two-component low-melting point fiber, 20% biomass fiber and 25% natural fiber.

[0056] In this embodiment, the biomass fiber is alpaca wool, and the natural fiber is bamboo fiber.

[0057] like Figure 1 The method for preparing a raw material fully degradable cushion core shown includes the above raw material fully degradable cushion core, and the preparation method includes the following steps:

[0058] 1. Weigh, loosen and mix the components according to the required proportions, pre-net, card, air-net and needle punch to prepare the upper and lower surface layers respectively;

[0059] 2. Weigh, loosen, mix, pre-web, card, and air-web the components according to the required proportion to obtain the core layer;

[0060] 3. Then place the two surface layers above and below the core layer respectively, and then send the whole into an oven for heating and melting, cooling and shaping;

[0061] 4. Cut the product into small pieces according to its size to obtain the cushion core.

[0062] Wherein, the cotton is humidified and mixed during the loosening and mixing in step 1 and step 2, the mixed material humidity is 60-70%, and the mixing time is 120 seconds for each 60 kg mixing.

[0063] Among them, in step 1 and step 2, a carding machine is required to perform carding work, and the carding machine includes a cylinder, a doffer and a plurality of groups of working rollers in which the tooth tips of the card clothing are set, wherein the angle of the tooth tip of the card clothing of the cylinder is 10°, the angle of the tooth tip of the card clothing of the doffer is 35°, the angle of the tooth tip of the card clothing of the plurality of working rollers is 25°, and the direction of the tooth tip of the card clothing of the cylinder is opposite to the direction of the tooth tip of the card clothing of the doffer and the direction of the tooth tip of the card clothing of the plurality of working rollers.

[0064] Among them, the working linear speed of the cylinder is 1130 m / min, the linear speed of the doffer is 33 m / min, the speed ratio of the cylinder to the doffer is 1:34, the working rolls are adopted in 5 groups, and are arranged at intervals along the circumference of the cylinder, and the linear speeds of the 5 groups of working rolls are 32 m / min for the first group, 32 m / min for the second group, 31 m / min for the second group, 28 m / min for the third group, 25 m / min for the fourth group, and 20 m / min for the fifth group in the order of combing the working rolls.

[0065] Among them, there are 5 groups of working rollers, and the gauges between each group of working rollers and the cylinder are 90 inches, 69 inches, 15 inches, 35 inches, and 28 inches respectively.

[0066] Among them, the oven in step 3 is a stepped circulating hot air heating device, with a temperature of 160 degrees Celsius in the first section, 174 degrees Celsius in the second section, and 178 degrees Celsius in the third section.

[0067] Wherein, the conveying speed of the oven in step 3 is 2.2m / min-4.5m / min.

[0068] Test 1: According to the national standard: "GB / T26706-2011 Soft Furniture Cotton Fiber Elastic Mattress", the plant fiber bed cores prepared in Examples 1 to 3 were tested, and the test results are as follows:

[0069] Durability requirements: Test times: 30,000 times. After the test, the core material should not be torn or dislocated; the inner core palm fiber should not be obviously broken or debris produced; the outer fabric should be intact, with no palm fiber sticking out.

[0070] The compression rebound rate of the plant fiber bed cores prepared in Examples 1 to 3 is ≥90%, indicating that the prepared bed cores have good rebound ability. The compression permanent deformation rate of the palm fiber mattress in GB / T 26706-2011 Soft Furniture Palm Fiber Elastic Mattress is required to be ≤12%. The compression permanent deformation rate of the plant fiber bed cores prepared in Examples 1 to 3 is ≤9%, which is lower than the requirement for the compression permanent deformation rate of the palm fiber mattress, indicating that the bed core has good stability and strong deformation resistance; and the elastic coefficient is ≥537N / mm, indicating that the bed core has good supporting capacity.

[0071] Test 2: According to "GB 18587-2001 Limits of Hazardous Substances Release from Carpets, Carpet Pads and Carpet Adhesives for Indoor Decoration and Renovation Materials", "GB / T 18204.26-2000 Determination of Formaldehyde in the Air of Public Places" and "GB / T 26706-2011 Soft Furniture Cotton Fiber Elastic Mattresses", UV-Vis analysis was used to detect the content of free formaldehyde. The limit requirement was 0.050 mg / ㎡h. The detection values ​​(MDL) of Examples 1 to 3 were 0.011 mg / ㎡h, 0.013 mg / ㎡h, and 0.015 mg / ㎡h, respectively, which were all lower than the limit. The result was ND (not detected, <MDL).

[0072] Test 3: The mattresses prepared in Examples 1 to 3 were placed in a sealed box. After 24 hours, the negative ion concentration was measured at a distance of 1 cm from the mattress sample. The average value of the test result was 1.03×10 3 , indicating that the mattress does not release formaldehyde, and can release negative ions and purify the air.

[0073] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A fully degradable raw material cushion core, comprising a core layer and surface layers arranged on the upper and lower surfaces of the core layer, characterized in that: The core layer is composed of 45-55% polylactic acid bicomponent low melting point fiber, 20-30% biomass fiber and 20-30% natural fiber, and the surface layer is composed of 45-55% polylactic acid bicomponent low melting point fiber, 20-30% biomass fiber and 20-30% natural fiber.

2. The fully degradable raw material cushion core according to claim 1, characterized in that: The biomass fiber is one of alpaca wool and wool.

3. The fully degradable raw material cushion core according to claim 1, characterized in that: The natural fiber is one of bamboo fiber, bamboo charcoal fiber and coconut shell fiber.

4. A method for preparing a fully degradable cushion core made of raw materials, characterized in that: The raw material fully degradable cushion core according to any one of claims 1 to 3 is prepared by the following steps:

1. Weigh, loosen and mix the components according to the required proportions, pre-net, card, air-net and needle punch to prepare the upper and lower surface layers respectively; 2. Weigh, loosen, mix, pre-web, card, and air-web the components according to the required proportion to obtain the core layer; 3. Then place the two surface layers above and below the core layer respectively, and then send the whole into an oven for heating and melting, cooling and shaping; 4. Cut the product into small pieces according to its size to obtain the cushion core.

5. The method for preparing a fully degradable raw material cushion core according to claim 4, characterized in that: During the loosening and mixing in step 1 and step 2, the cotton is humidified and mixed, the humidity of the mixed material is 60-70%, and the mixing time is 120 seconds for each 60 kg mixing.

6. The method for preparing a fully degradable raw material cushion core according to claim 5, characterized in that: In step 1 and step 2, a carding machine is required to perform the carding work, and the carding machine includes a cylinder, a doffer, and a plurality of sets of working rollers. The tooth tip angle of the card cloth of the cylinder is 10°, the tooth tip angle of the card cloth of the doffer is 35°, and the tooth tip angle of the card cloth of the plurality of working rollers is 25°. The direction of the tooth tip of the card cloth of the cylinder is opposite to the direction of the tooth tip of the card cloth of the doffer and the direction of the tooth tip of the card cloth of the plurality of working rollers.

7. The method for preparing a fully degradable raw material cushion core according to claim 6, characterized in that: The working linear speed of the cylinder is 1130 m / min, the linear speed of the doffer is 33 m / min, the speed ratio of the cylinder to the doffer is 1:34, the working rolls are in 5 groups and are arranged at intervals along the circumference of the cylinder, and the linear speeds of the 5 groups of working rolls are 32 m / min for the first group, 32 m / min for the second group, 31 m / min for the second group, 28 m / min for the third group, 25 m / min for the fourth group, and 20 m / min for the fifth group in the order of combing the working rolls.

8. The method for preparing a fully degradable raw material cushion core according to claim 7, characterized in that: The gauges between each set of working rollers and the cylinder are 90 inches, 69 inches, 15 inches, 35 inches, and 28 inches respectively.

9. The method for preparing a fully degradable raw material cushion core according to claim 4, characterized in that: The oven in step 3 is a stepped circulating hot air heating device, with a first section temperature of 152-160 degrees Celsius, a second section temperature of 168-174 degrees Celsius, and a third section temperature of 172-178 degrees Celsius.

10. The method for preparing a fully degradable raw material cushion core according to claim 9, characterized in that: The conveying speed of the oven in step 3 is 2.2 m / min-4.5 m / min.

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