Functional mattress production method and functional mattress

Abstract

The invention relates to the technical field of textile, and provides a functional mattress production method and a functional mattress, and the functional mattress production method comprises the following steps: S1, 156D moisture-absorption heating and heat-storage viscose polyester blended yarns are used as weft yarns, the moisture-absorption heating filaments account for 8-12%, and a double-needle Raschel bed warp knitting machine is adopted for knitting to obtain a mattress upper-layer fabric; s2, a double-needle-bar warp knitting machine is adopted for weaving a middle-layer fabric, a front needle bar uses L1 and L2 warp satin for combs and variable warp satin to weave upper base cloth, a rear needle bar uses L5 and L6 warp velveteen to weave lower base cloth, a middle comb L3 is used for weaving middle monofilament stand column layers on the front needle bar and the rear needle bar respectively, and the upper base cloth and the lower base cloth are connected to form a three-dimensional fabric; s3, weaving an aluminum-coated polyester warp knitting fabric by adopting a single-needle bar warp knitting machine; s4, bonding together by adopting a compound machine; s5, the functional mattress is obtained through an after-finishing process. According to the technical scheme, the functional mattress is good in softness and has the functions of moisture absorption, heating, heat storage, static resistance and the like.

Description

Technical Field

[0001] The invention relates to the technical field of textiles, and in particular to a production method of a functional mattress and a functional mattress. Background Art

[0002] Most mattress products are made by laminating and quilting plain cloth, woven fabrics and artificial silk floss, and then used as mattresses. Although this kind of mattress looks beautiful, it is hard and has poor softness. However, with the continuous improvement of people's living standards, consumers have an increasing demand for mattress products. As bedding products, the functions and effects of mattress products have attracted more and more attention. Therefore, it is crucial to improve the softness of mattress products and increase their functionality to meet consumers' diverse needs for mattress products. Summary of the invention

[0003] The present invention aims to solve at least one of the technical problems existing in the prior art or related art.

[0004] To this end, the purpose of the present invention is to provide a functional mattress production method and a functional mattress, which has good softness, and has the functions of moisture absorption and heat generation, heat storage, and anti-static. The upper layer of the mattress fabric in contact with the human body contains moisture-absorbing and heating wire, which can absorb human body moisture and quickly generate heat. It has an obvious heating effect, can promote human blood circulation, and improve sleep quality.

[0005] In order to achieve the above-mentioned purpose, the technical scheme of the present invention provides a method for producing a functional mattress, comprising the following steps: S1, using polyester DTY as a surface yarn raw material, using 50D / 36f-75D / 36f polyester FDY as a base yarn raw material, using 156D hygroscopic and heat-generating, heat-storing viscose polyester blended yarn as a weft yarn, wherein the hygroscopic and heat-generating yarn accounts for 8-12% by weight, and knitting using a double-needle Raschel bed warp knitting machine, and obtaining the upper layer fabric of the mattress by means of surface yarn empty threading and 4-needle weft insertion and chain knitting;

[0006] S2, using a double needle bed warp knitting machine to weave the middle layer fabric, wherein the front needle bed of the loom uses two combs L1 and L2 to weave the upper base fabric with warp satin and variable warp satin tissue, and the rear needle bed uses two combs L5 and L6 to weave the lower base fabric with warp flat velvet tissue, and the middle comb L3 weaves the middle monofilament column layer on the front and rear needle beds respectively, connecting the upper and lower base fabrics to form a three-dimensional fabric, the middle monofilament column layer connects and supports the upper and lower base fabrics, the raw material of the upper and lower base fabrics is 75D / 36f polyester FDY, and the raw material of the middle monofilament column layer is 60-100D polyester monofilament;

[0007] S3, using a single needle bed warp knitting machine to weave aluminum coated polyester warp knitted fabric, wherein two combs are used to weave the polyester warp knitted fabric, L1 is a warp plain weave, L2 is a warp pile weave, the raw material is 50-75D polyester yarn FDY, and the fabric weight of the polyester warp knitted fabric is 75-100g / m 2 , the polyester warp knitted fabric is treated with a transition aluminum film to obtain an aluminum-coated polyester warp knitted fabric;

[0008] S4, using a compounding machine to sequentially bond the mattress upper layer fabric, the middle layer fabric and the aluminum-coated polyester warp knitted fabric together;

[0009] S5, after finishing process, a functional mattress is obtained.

[0010] Preferably, in step S2, the spacing between the front and rear needle beds is 2-5 mm, and the weight of the middle layer fabric is 60-120 g / m 2 .

[0011] Preferably, in step S1, when a double-needle Raschel bed warp knitting machine is used for knitting, the machine gauge is 18 needles / inch and the gauge is 14-16 mm.

[0012] Preferably, in step S1, a double-needle Raschel bed warp knitting machine is used to weave the grey cloth, the grey cloth is slit and then subjected to shaping treatment, then brushed and ironed before treatment, and then dyed or printed, the fixing temperature is 130-145°C, and the heat preservation is carried out for 10 minutes. The printed and dyed grey cloth is then washed and dried for shaping, the shaping temperature is 130°C to 145°C, the speed is 18-25m / min, and the shaped grey cloth is then brushed, ironed, and sheared to obtain the upper fabric of the mattress.

[0013] Preferably, in step S3, the thickness of the aluminum coating is 0.5-0.8 mm.

[0014] Preferably, in step S4, water-based composite adhesives A and B of Shanghai Chengshang Industrial Co., Ltd. are used as adhesives, adhesive A is CS716A, adhesive B is CS716B, the ratio of adhesive A to adhesive B is 1:0.05, the temperature of the heating roller of the composite machine is set to 150-200°C, the speed is 13-18m / min, and the amount of adhesive between the bottom of the upper fabric and the top of the middle fabric is 80-120g / m 2 The glue amount between the bottom of the middle layer fabric and the top of the aluminum-coated polyester warp knitted fabric is 60-70g / m 2 .

[0015] The technical solution of the present invention further provides a functional mattress, which is obtained by using any of the functional mattress production methods in the above technical solutions.

[0016] Preferably, the functional mattress comprises an upper layer fabric of the mattress, an intermediate layer fabric and an aluminum-coated polyester warp knitted fabric which are compositely bonded in sequence, wherein the upper base fabric of the intermediate layer fabric is a mesh structure, the lower base fabric is a flat cloth structure, the middle monofilament column layer is an "X"-shaped cross column structure, and the upper layer fabric of the mattress is a cloud blanket fabric with moisture absorption, heat generation and heat storage functions.

[0017] Preferably, the thickness of the middle layer fabric is 2-5 mm.

[0018] The functional mattress production method and the functional mattress proposed by the present invention have the following beneficial technical effects:

[0019] (1) The present invention proposes a method for producing a functional mattress and a functional mattress. By using a viscose-polyester blended yarn that absorbs moisture and generates heat and stores heat as the weft yarn, on the one hand, it is easy to weave without affecting the surface softness of the upper fabric of the mattress. On the other hand, the surface of the functional mattress product has the functions of absorbing moisture, generating heat and storing heat.

[0020] (2) In the functional mattress production method and the functional mattress proposed by the present invention, a double-needle bed warp knitting machine is used to weave the middle layer of fabric and the warp knitting is specially designed so that the middle monofilament column layer connects the upper and lower base fabrics to form a three-dimensional fabric. The middle monofilament column layer connects and supports the upper and lower base fabrics to present a three-dimensional hollow structure. It is relatively light and thin and has the function of locking in still air and preventing heat loss.

[0021] (3) In the functional mattress production method and the functional mattress proposed by the present invention, the aluminum-coated polyester warp knitted fabric is obtained by treating the polyester warp knitted fabric with an aluminum film, so that the functional mattress has good electrical conductivity and good thermal insulation performance. On the one hand, it can effectively conduct static electricity away, and on the other hand, it can further prevent air circulation in the middle layer of fabric, reduce heat exchange between the middle air and the outside air, and further improve the thermal insulation effect. On the other hand, it can provide fire protection and prevent the spread of fire.

[0022] (4) The present invention proposes a method for producing a functional mattress and a functional mattress, which are soft and have functions such as moisture absorption and heating, heat storage, and anti-static. The upper layer of the mattress fabric in contact with the human body contains moisture-absorbing and heating fibers, which can absorb moisture from the human body and the environment and quickly generate heat by utilizing their strong physical vaporization heat effect. They have obvious heating effects, can promote blood circulation in the human body, and improve sleep quality.

[0023] (5) The present invention proposes a method for producing a functional mattress and a functional mattress, wherein the upper surface of the middle layer fabric is a mesh structure, which is conducive to the upward and downward flow of heat. The middle part is a polyester monofilament "X"-shaped cross column, and the space between the columns is filled with still air, which can reduce heat loss.

[0024] (6) The present invention provides a method for producing a functional mattress and a functional mattress, wherein the mattress upper fabric layer, the middle fabric layer and the aluminum-coated polyester warp-knitted fabric are effectively composited and bonded together, are not easily dislocated, and have strong firmness.

[0025] (7) The present invention proposes a method for producing a functional mattress and a functional mattress. When a human body contacts the mattress, the moisture-absorbing, heat-generating and heat-storing fibers in the mattress absorb the moisture released by the human body to generate heat and conduct the moisture away at the same time. A part of the heat generated by the fibers is used to warm the human body, and another part is transferred to the still air in the middle layer through the mesh holes of the bottom fabric on the middle layer for storage. The fibers themselves also have the function of storing heat, which greatly improves the thermal insulation effect. At the same time, the composite aluminum-coated polyester warp knitted fabric makes the mattress have good thermal insulation, electrical conductivity and fireproof functions. While improving the softness of the mattress product, its functionality is increased, which not only improves the comfort of the mattress, but also meets the diverse needs of consumers for mattress products.

[0026] (8) The present invention proposes a method for producing a functional mattress and a functional mattress, which use 156D moisture-absorbing and heat-generating viscose-polyester blended yarn as the weft yarn, without affecting the appearance design of the upper fabric of the mattress. Different designs can be made according to needs to form functional mattresses of different styles, enriching product diversity. The velvet surface of the functional mattress is neat and elastic, soft and smooth to the touch, bright in color, and highly practical and comfortable.

[0027] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0029] Figure 1 A schematic structural diagram of a functional mattress according to an embodiment of the present invention is shown;

[0030] Figure 2 A schematic structural diagram of an intermediate layer fabric of a functional mattress according to an embodiment of the present invention is shown;

[0031] Figure 3 A side cross-sectional view of a functional mattress according to Embodiment 1 of the present invention is shown;

[0032] Figure 4 A front view of a functional mattress according to Embodiment 1 of the present invention is shown;

[0033] Figure 5 It shows a reverse side view of a functional mattress according to Embodiment 1 of the present invention.

[0034] in, Figure 1 and Figure 2 The corresponding relationship between the reference numerals and the components is as follows:

[0035] 102 mattress upper fabric, 1022 moisture-absorbing heating wire, 104 middle layer fabric, 1042 upper base fabric, 1044 lower base fabric, 1046 middle monofilament column layer, 1048 mesh structure, 106 aluminum-coated polyester warp knitted fabric. DETAILED DESCRIPTION

[0036] The present invention discloses a method for producing a functional mattress and a functional mattress. Those skilled in the art can refer to the content of this article and appropriately improve the process parameters to achieve the desired effect. It should be particularly noted that all similar substitutions and modifications are obvious to those skilled in the art and are considered to be included in the present invention. The method and application of the present invention have been described through preferred embodiments, and relevant personnel can obviously modify or appropriately change and combine the method and application described herein without departing from the content, spirit and scope of the present invention to achieve and apply the technology of the present invention.

[0037] The present invention will be further described below in conjunction with embodiments:

[0038] Example 1

[0039] A method for producing a plain color functional cloud blanket mattress comprises the following steps:

[0040] The surface yarn material is 150D / 144F polyester DTY with a linear density of 1.04D; the base yarn material is 75D / 36f polyester FDY filament, and the weft yarn is 156D hygroscopic and heat-generating, heat-storing viscose polyester blended yarn, of which the hygroscopic and heat-generating yarn accounts for 10% by weight. It is woven using a double-needle Raschel bed warp knitting machine with a machine gauge of 18 needles / inch and a gauge of 16mm. The surface yarn threading method of the grey fabric is the surface yarn empty threading, and the base fabric of the grey fabric adopts a 4-needle weft lining and chain knitting method. The hygroscopic and heat-generating yarn and the heat-storing viscose polyester yarn are purchased from Shanghai Qiuhui Company.

[0041] After the grey fabric is slit, it is shaped at a temperature of 140°C. After shaping, the grey fabric is brushed and ironed before processing. The brushing speed is 10m / min, the needle roller speed is 530 rpm; the ironing temperature is 190°C, and the fabric speed is 14m / min.

[0042] The pre-treated grey fabric is dyed, and the dyeing process is as follows: pad dyeing → pre-drying → steaming → washing → shaping and drying. Padding: Dyeing is performed according to conventional processes. During dyeing, the grey fabric fluff is passed upward through the dye tank and then through the penetration roller. Pre-drying: The grey fabric after rolling liquid is pre-dried in an oven at a temperature of 130 degrees and a speed of 12m / min. High-temperature and high-pressure steaming and color fixing: The dried dyed grey fabric is placed in a high-pressure tank for high-pressure and high-temperature color fixing. The conditions for high-pressure steaming and color fixing are as follows: the high-pressure color fixing temperature is 135°C, the time is 10min, and the pressure is 0.25MPa. Washing: The grey fabric after gas steaming and color fixing is washed by a 10-slot open-width washing machine, washed once, the washing temperature is 55°C, and the cloth speed is controlled at 16m / min. Washing is performed according to conventional processes. Detergents and antistatic agents are added during the washing process and softening treatment is performed during the washing process. The detergent is used to wash away excess sizing and floating color on the fabric. Setting and drying: The printed grey fabric after soft water washing is passed through a high-temperature setting machine for tenter drying. The setting temperature is 142°C and the cloth feeding speed is 12m / min.

[0043] After shaping, the blank towel is brushed, ironed, and cut. The ironing temperature for the front and back sides is 125℃, and the cloth speed is 13m / min; the ironing temperature is 110℃, and the cloth speed is 13m / min.

[0044] The raw materials of the upper and lower base fabrics of the middle layer fabric are 75D / 36f polyester FDY. The raw material of the middle layer is 75D polyester monofilament. The front needle bed of the loom uses two combs L1 and L2 to weave the upper base fabric with warp satin and variable warp satin organization. The rear needle bed uses two combs L5 and L6 to weave the lower base fabric with warp velvet organization. The middle comb L3 weaves the middle monofilament column layer on the front and rear needle beds respectively to connect the upper and lower base fabrics to form a three-dimensional fabric. The middle monofilament column layer connects and supports the upper and lower base fabrics. The spacing between the front and rear needle beds is 3mm. The thickness of the middle layer fabric is 3mm and the weight is 80g / m 2 , the structure is as follows Figure 2 As shown, the upper base fabric 1042 and the lower base fabric 1044 are connected and supported by an intermediate monofilament column layer 1046. The intermediate monofilament column layer 1046 is an "X"-shaped cross column structure, the upper base fabric 1042 is a mesh structure 1048, and the lower base fabric 1044 is a flat cloth structure.

[0045] A single needle bed warp knitting machine is used to weave aluminum-coated polyester warp knitted fabric. Two comb bars are used to weave the polyester warp knitted fabric. L1 is a warp plain weave, L2 is a warp pile weave, the raw material is 75D polyester yarn, and the fabric weight is 80g / m 2 The polyester warp knitted fabric is treated with a transition aluminum film to obtain an aluminum-coated polyester warp knitted fabric, and the thickness of the aluminum film is 0.7 mm.

[0046] The three layers of fabrics that make up the mattress (the upper fabric of the mattress, the middle fabric and the aluminum-coated polyester warp knitted fabric) use water-based composite glue A and B as adhesives. The ratio of A and B is 1:0.05. A is CS716A and B is CS716B, which are purchased from Shanghai Chengshang Industrial Co., Ltd. The three fabrics that make up the mattress are bonded together by a composite machine. The temperature of the heating roller of the composite machine is set at 180°C. The upper fabric is a cloud blanket product that is relatively thick. The amount of glue applied between the bottom of the upper fabric and the top of the middle fabric is 90g / m 2 The glue amount between the bottom of the middle layer fabric and the top of the aluminum-coated polyester warp knitted fabric is 65g / m 2 The speed of the compound locomotive is 14m / min, and the structure is as follows Figure 1 As shown, the mattress upper layer fabric 102, the middle layer fabric 104, and the aluminum-coated polyester warp knitted fabric 106 are compositely bonded in sequence, and the moisture-absorbing heating wire 1022 is in the base fabric of the mattress upper layer fabric 102, and the upper surface is fluff, which is softer and more comfortable.

[0047] Post-finishing process: ironing → cutting → sewing → inspection → packaging.

[0048] Plain color functional cloud blanket mattress product Figures 3 to 5 As shown, the mattress upper fabric, middle fabric and aluminum-coated polyester warp knitted fabric are effectively bonded together, not easy to dislocate and strong in firmness. The upper surface of the middle fabric is a mesh structure, which is conducive to the upward and downward flow of heat. The middle part is a polyester monofilament "X"-shaped cross column, and the columns are filled with still air to reduce heat loss.

[0049] Example 2

[0050] A printed functional cloud blanket mattress comprises the following steps:

[0051] The surface yarn material is 120D / 192F polyester DTY with a linear density of 0.62D; the base yarn material is 50D / 36f polyester FDY filament, and the weft yarn is 156D hygroscopic and heat-generating, heat-storing viscose polyester blended yarn, of which the hygroscopic and heat-generating yarn accounts for 8% by weight. It is woven using a double-needle Raschel bed warp knitting machine; the machine number is 18 needles / inch, the gauge is 14mm, the surface yarn of the grey cloth is threaded in the form of empty threading of the surface yarn, and the base fabric of the grey cloth is 4-needle weft-inserted and chain-knitted, wherein the hygroscopic and heat-generating yarn and the heat-storing viscose polyester yarn are purchased from Shanghai Qiuhui Company.

[0052] After the grey fabric is cut, it needs to be shaped at a temperature of 138°C. After shaping, the grey fabric is pre-treated by brushing and ironing. The brushing speed is 12m / min, the needle roller speed is 520 rpm; the ironing temperature is 193°C, and the fabric speed is 16m / min.

[0053] The pre-treated grey fabric is printed, and the printing process is as follows: printing → pre-drying → steaming → washing → shaping and drying. Process parameters: printing color paste concentration 2.5wt%, magnetic speed of the printing machine magnetic rod: 0.5m / s, drying temperature: 110℃, grey fabric color paste carrying rate 90%. Fabric speed 12m / min. High temperature and high pressure steaming and color fixing: the dried dyed grey fabric is placed in a high pressure tank for high pressure and high temperature color fixing. The conditions for high pressure steaming and color fixing are as follows: the high pressure color fixing temperature is 130℃, the time is 10min, and the pressure is 0.2MPa. Washing: the grey fabric after gas steaming and color fixing is washed by a 10-slot open-width washing machine, washed once, the washing temperature is 58℃, and the fabric speed is controlled at 17m / min. Washing is carried out according to conventional processes. Detergents and antistatic agents are added during the washing process and softening treatment is performed during the washing process. The detergent is used to wash away excess slurry and floating color on the fabric. Setting and drying: The printed grey fabric after soft water washing is passed through a high-temperature setting machine for tenter drying. The setting temperature is 140°C and the cloth feeding speed is 13m / min.

[0054] After shaping, the blank towel is brushed, ironed, and cut. The ironing temperature for the front and back sides is 120℃, and the cloth speed is 14m / min; the ironing temperature is 115℃, and the cloth speed is 14m / min.

[0055] The raw materials of the upper and lower base fabrics of the middle layer fabric are 75D / 36f polyester FDY. The raw material of the middle layer is 60D polyester monofilament. The front needle bed of the loom uses two combs L1 and L2 to weave the upper base fabric with warp satin and variable warp satin organization. The rear needle bed uses two combs L5 and L6 to weave the lower base fabric with warp flat velvet organization. The middle comb L3 weaves the middle monofilament column layer on the front and rear needle beds respectively to connect the upper and lower base fabrics to form a three-dimensional fabric. The middle monofilament column layer connects and supports the upper and lower base fabrics. The distance between the front and rear needle beds is 2mm, the thickness of the middle fabric is 2mm, and the weight is 70g / m 2 ,, structure such as Figure 2 As shown, the upper base fabric 1042 and the lower base fabric 1044 are connected and supported by an intermediate monofilament column layer 1046. The intermediate monofilament column layer 1046 is an "X"-shaped cross column structure, the upper base fabric 1042 is a mesh structure 1048, and the lower base fabric 1044 is a flat cloth structure.

[0056] A single needle bed warp knitting machine is used to weave aluminum-coated polyester warp knitted fabric. Two comb bars are used to weave the polyester warp knitted fabric. L1 is a warp plain weave, L2 is a warp pile weave, the raw material is 50D polyester yarn, and the fabric weight is 75g / m 2 The polyester warp knitted fabric is treated with a transition aluminum film to obtain an aluminum-coated polyester warp knitted fabric, and the thickness of the aluminum film is 0.6 mm.

[0057] The three layers of fabrics constituting the mattress (the upper fabric of the mattress, the middle fabric and the aluminum-coated polyester warp knitted fabric) use water-based composite glue A and glue B as adhesives. The ratio of A glue and B glue is 1:0.05. Glue A is CS716A and glue B is CS716B. They are purchased from Shanghai Chengshang Industrial Co., Ltd. The three fabrics constituting the mattress are bonded together by a composite machine. The temperature of the heating roller of the composite machine is set at 190°C. The upper fabric is a cloud blanket product that is relatively thick. The amount of glue applied between the bottom of the upper fabric and the top of the middle fabric is 100g / ㎡, and the amount of glue applied between the bottom of the middle fabric and the top of the aluminum-coated polyester warp knitted fabric is 60g / ㎡; the speed of the composite machine is 16m / min, and the structure is as follows Figure 1 As shown, the mattress upper layer fabric 102, the middle layer fabric 104, and the aluminum-coated polyester warp knitted fabric 106 are compositely bonded in sequence, and the moisture-absorbing heating wire 1022 is in the base fabric of the mattress upper layer fabric 102, and the upper surface is fluff, which is softer and more comfortable.

[0058] Post-finishing process: ironing → cutting → sewing → inspection → packaging. The physical structure of the printed functional cloud blanket mattress product is not significantly different from that of Example 1.

[0059] The plain color functional cloud blanket mattress obtained in Example 1 of the present invention and the conventional plain color mattress were tested and compared in performance, and the test results are shown in Tables 1 and 2 below.

[0060] The performance of the printed functional cloud blanket mattress obtained in Example 2 of the present invention and the conventional printed mattress were tested and compared, and the test results are shown in Tables 3 and 4 below.

[0061] Table 1 Test results of moisture absorption and heat generation performance of the plain color functional cloud blanket mattress of Example 1 of the present invention and the conventional plain color mattress

[0062]

[0063] Note: Test environment (room temperature 20.±2°C, initial humidity 40.±3%RH, humidified to 90.±5%RH) Table 2 Test results of heat storage and heat preservation performance of plain color functional cloud blanket mattress of Example 1 of the present invention and conventional plain color mattress

[0064]

[0065]

[0066] Note: Test environment (room temperature 20.±2℃, humidity 65.±4%RH)

[0067] Table 3 Hygroscopic and heat-generating test results of the printed functional cloud blanket mattress of Example 2 of the present invention and the conventional printed mattress

[0068]

[0069] Note: Test environment (room temperature 20.±2°C, initial humidity 40.±3%RH, humidified to 90.±5%RH) Table 4 Test results of heat storage and heat preservation performance of printed functional cloud blanket mattress of Example 2 of the present invention and conventional printed mattress

[0070]

[0071]

[0072] Note: Test environment (room temperature 20.±2℃, humidity 65.±4%RH)

[0073] In summary, the functional mattress proposed in the present invention adopts moisture-absorbing, heat-generating and heat-storing viscose-polyester blended yarn as weft yarn, which is not only easy to weave and does not affect the surface softness of the upper fabric of the mattress, but also has the functions of moisture-absorbing, heat-generating and heat-storing. It cooperates with the middle layer fabric and the special warp knitting design of the present invention to present a three-dimensional hollow structure, and is relatively light and thin, which can lock in still air and prevent heat loss. It cooperates with the aluminum-coated polyester warp knitted fabric to prevent air circulation in the middle layer fabric and reduce the heat exchange between the middle air and the outside air, so that the functional mattress has moisture-absorbing, heat-generating and heat-storing effects that are significantly better than conventional mattresses.

[0074] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for producing a functional mattress, characterized in that: The following steps are involved: S1, using polyester DTY as the surface yarn raw material, 50D / 36f-75D / 36f polyester FDY as the base yarn raw material, and 156D hygroscopic and heat-generating, heat-storing viscose polyester blended yarn as the weft yarn, wherein the hygroscopic and heat-generating yarn accounts for 8-12% by weight, and knitting is carried out on a double-needle Raschel bed warp knitting machine, and the upper layer fabric of the mattress is obtained by the method of surface yarn empty threading and 4-needle weft insertion and chain knitting; S2, using a double needle bed warp knitting machine to weave the middle layer fabric, wherein the front needle bed of the loom uses two combs L1 and L2 to weave the upper base fabric with warp satin and variable warp satin tissue, and the rear needle bed uses two combs L5 and L6 to weave the lower base fabric with warp flat velvet tissue, and the middle comb L3 weaves the middle monofilament column layer on the front and rear needle beds respectively, connecting the upper and lower base fabrics to form a three-dimensional fabric, the middle monofilament column layer connects and supports the upper and lower base fabrics, the raw material of the upper and lower base fabrics is 75D / 36f polyester FDY, and the raw material of the middle monofilament column layer is 60-100D polyester monofilament; S3, using a single needle bed warp knitting machine to weave aluminum coated polyester warp knitted fabric, wherein two combs are used to weave the polyester warp knitted fabric, L1 is a warp plain weave, L2 is a warp pile weave, the raw material is 50-75D polyester yarn FDY, and the fabric weight of the polyester warp knitted fabric is 75-100g / m 2 , the polyester warp knitted fabric is treated with a transition aluminum film to obtain an aluminum-coated polyester warp knitted fabric; S4, using a compounding machine to sequentially bond the mattress upper layer fabric, the middle layer fabric and the aluminum-coated polyester warp knitted fabric together; S5, after finishing process, a functional mattress is obtained.

2. The method for producing a functional mattress according to claim 1, characterized in that: In step S2, the distance between the front and rear needle beds is 2-5 mm, and the weight of the middle layer fabric is 60-120 g / m 2 .

3. The method for producing a functional mattress according to claim 1, characterized in that: In step S1, when a double-needle Raschel bed warp knitting machine is used for knitting, the machine gauge is 18 needles / inch and the gauge is 14-16 mm.

4. The method for producing a functional mattress according to claim 3, characterized in that: In step S1, a double-needle Raschel bed warp knitting machine is used to weave a grey cloth, the grey cloth is slit and then subjected to shaping treatment, then brushed and ironed before treatment, and then dyed or printed, the fixing temperature is 130-145°C, and the heat preservation is carried out for 10 minutes. The printed and dyed grey cloth is then washed and dried for shaping, the shaping temperature is 130-145°C, the machine speed is 18-25m / min, and the shaped grey cloth is then brushed, ironed, and sheared to obtain the upper fabric of the mattress.

5. The method for producing a functional mattress according to claim 1, characterized in that: In step S3, the thickness of the aluminum coating is 0.5-0.8 mm.

6. The method for producing a functional mattress according to claim 1, characterized in that: In step S4, water-based composite glues A and B produced by Shanghai Chengshang Industrial Co., Ltd. are used as adhesives, wherein glue A is CS716A, and glue B is CS716B, and the ratio of glue A to glue B is 1: 0.05, the temperature of the heating roller of the laminating machine is set to 150-200℃, the speed is 13-18m / min, and the glue amount between the bottom of the upper fabric and the top of the middle fabric is 80-120g / m 2 The glue amount between the bottom of the middle layer fabric and the top of the aluminum-coated polyester warp knitted fabric is 60-70g / m 2 .

7. A functional mattress, characterized in that: The functional mattress is obtained by the production method of any one of claims 1 to 6.

8. The functional mattress according to claim 7, characterized in that: It includes a mattress upper layer fabric, a middle layer fabric and an aluminum-coated polyester warp knitted fabric that are compositely bonded in sequence, wherein the upper base fabric of the middle layer fabric is a mesh structure, the lower base fabric is a flat cloth structure, the middle monofilament column layer is an "X"-shaped cross column structure, and the mattress upper layer fabric is a cloud blanket fabric with moisture absorption, heat generation and heat storage functions.

9. The functional mattress according to claim 8, characterized in that: The thickness of the middle layer fabric is 2-5 mm.

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