Manufacturing process of high-strength mattress cushion layer

Abstract

The invention discloses a manufacturing process of a high-strength mattress cushion layer. The preparation method comprises the following steps: S1, opening and carding 4080 hot melting point fibers, 3D fibers, a bio-based material and 25-35% of colored chemical fibers in proportion, and lapping to form a uniform fiber web to prepare a surface layer; s2, opening, carding and lapping 4080 hot melting point fibers, 3D fibers, a bio-based material and colored chemical fibers in proportion to form a uniform fiber web, and preparing a core layer; s3, carrying out primary needling insertion on the surface layer and carrying out secondary needling insertion on the core layer by adopting a needling machine; s4, paving a surface layer subjected to the puncture procedure on each of the two side surfaces of the core layer subjected to the puncture procedure, then feeding the core layer subjected to the puncture procedure into a drying oven for drying, and cutting according to the size of a product after cooling and shaping to obtain a mattress cushion layer; according to the invention, not only is the problem of product layering solved, but also the air permeability is increased, meanwhile, the supporting force is relatively strong, and the surface hand feeling problem is solved through the plane material, so that the comfort is better.

Description

Technical Field

[0001] This invention relates to the field of daily necessities technology, and in particular to a manufacturing process for a high-strength mattress padding layer. Background Art

[0002] A mattress, as a tool placed on a bed to provide sleep, is an item used between the human body and the bed to ensure consumers get a healthy and comfortable sleep. It comes in a variety of materials. Different materials provide different sleep-aiding functions and achieve different sleep effects. Mattresses can be divided into: spring mattresses, latex mattresses, 3D material mattresses, memory foam mattresses, palm fiber mattresses, and other sub-types.

[0003] The mattress padding layer, placed on top of the mattress core springs, should not only provide the necessary firmness for support but also offer excellent resilience—a balance of firmness and softness—while also maintaining good breathability. Current padding layers are made by directly shaping cotton layers produced by a web-laying machine in an oven. The fiber structure of this type of padding layer is simply a multi-layered, cross-laminated structure, resulting in poor toughness and breathability, making it prone to folding and delamination. Summary of the Invention

[0004] The purpose of this invention is to provide a manufacturing process for a high-strength mattress padding layer, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a manufacturing process for a high-strength mattress padding layer, comprising the following steps;

[0006] S1: To make the surface material, 30-50% of 4080 hot melting point fiber, 10-30% of 3D fiber, 5-15% of bio-based material and 25-35% of colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the surface layer.

[0007] S2: To make the core material, 20-40% of 4080 hot melting point fiber, 10-30% of 3D fiber, 5-15% of bio-based material and 35-45% of colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the core layer.

[0008] S3: Insertion molding, using a needle punching machine to perform one needle punching insertion on the surface layer and a second needle punching insertion on the core layer;

[0009] S4: Product forming. A layer of surface material with the piercing process is laid flat on both sides of the core layer that has completed the piercing process. Then it is sent into an oven to dry. After cooling and shaping, it is cut according to the size of the product to obtain the mattress padding.

[0010] Preferably, the 3D fiber is a 3D polyester filament fiber cotton web.

[0011] Preferably, the bio-based material is one or a mixture of bamboo fiber, wool, or both.

[0012] Preferably, the oven in S4 is a stepped circulating hot air heating device, with the temperature of the first section being 120-150 degrees Celsius, the temperature of the second section being 160-180 degrees Celsius, and the temperature of the third section being 170-190 degrees Celsius.

[0013] Preferably, the oven in S4 uses internally circulated hot air, and the air volume in the first section is 6500-7000 m³ / h. 3 / min, the air volume in the first section is 7200-8500m³ / min. 3 / min, the air volume in the first section is 8200-9500m³ / min. 3 / min.

[0014] Preferably, the conveying speed of the oven in S4 is 8.2 m / min per 1 kg / m².

[0015] Compared with the prior art, the beneficial effects of the present invention include: before the combination of the upper and lower surface materials and the middle core material, the surface material and core material produced by the web laying machine are first passed through the needle punching machine to make their own fibers form columnar shapes, and then combined for drying and cooling shaping. This not only solves the product layering problem, but also increases breathability and has strong support. In addition, the surface material solves the surface feel problem, resulting in better comfort. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the framework of the present invention. Detailed Implementation

[0017] Embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. While some embodiments of the invention are shown in the drawings, it should be understood that the invention can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the invention. It should be understood that the accompanying drawings and embodiments are for illustrative purposes only and are not intended to limit the scope of protection of the invention.

[0018] 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. Furthermore, 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.

[0019] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to". The term "connection" can refer to a direct connection or an indirect connection via intermediate components (elements). The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments". Definitions of other terms will be given in the following description.

[0020] It should be noted that the concepts of "first" and "second" mentioned in this invention are only used to distinguish between devices, modules or units, and are not intended to limit these devices, modules or units to necessarily be different devices, modules or units, nor are they intended to limit the order or interdependence of the functions performed by these devices, modules or units.

[0021] Example 1

[0022] A manufacturing process for a high-strength mattress padding layer, such as Figure 1 As shown, it includes the following steps;

[0023] S1: To make the surface material, 37% 4080 hot melting point fiber, 22% 3D polyester filament fiber cotton web, 12% bamboo fiber and 29% colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the surface layer.

[0024] S2: To make the core material, 32% 4080 hot melting point fiber, 17% 3D fiber, 13% bamboo fiber and 38% colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the core layer.

[0025] S3: Insertion molding, using a needle punching machine to perform one needle punching insertion on the surface layer and a second needle punching insertion on the core layer;

[0026] S4: Product forming. A layer of the pierced surface layer is laid flat on both sides of the core layer after the piercing process, and then sent to an oven for drying. After cooling and shaping, it is cut according to the product size to obtain the mattress padding layer. The oven is a stepped circulating hot air heating device; the temperature of the first section is 132 degrees Celsius, and the air volume is 6700 m³ / h. 3 / min, the temperature in the second section is 164 degrees Celsius, and the air volume is 7300m³ / min. 3 / min, the temperature in the third section is 186 degrees Celsius, and the air volume is 9200 m³ / min. 3 The conveying speed is 8.2 m / min.

[0027] Example 2

[0028] A manufacturing process for a high-strength mattress padding layer, such as Figure 1 As shown, it includes the following steps;

[0029] S1: To make the surface material, 43% 4080 hot melting point fiber, 21% 3D fiber, 10% bio-based material and 26% colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the surface layer.

[0030] S2: To make the core material, 29% 4080 hot melting point fiber, 16% 3D fiber, 11% bio-based material and 44% colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the core layer.

[0031] S3: Insertion molding, using a needle punching machine to perform one needle punching insertion on the surface layer and a second needle punching insertion on the core layer;

[0032] S4: Product forming. A layer of the pierced surface layer is laid flat on both sides of the core layer after the piercing process, and then sent to an oven for drying. After cooling and shaping, it is cut according to the product size to obtain the mattress padding layer. The oven is a stepped circulating hot air heating device; the temperature of the first section is 145 degrees Celsius, and the air volume is 6800 m³ / h. 3 / min, the temperature in the second section is 167 degrees Celsius, and the air volume is 8200 m³ / min. 3 / min, the temperature in the third section is 179 degrees Celsius, and the air volume is 9100 m³ / min. 3 The conveying speed is 8.2 m / min.

[0033] Example 3

[0034] A manufacturing process for a high-strength mattress padding layer, such as Figure 1 As shown, it includes the following steps;

[0035] S1: To make the surface material, 46% 4080 hot melting point fiber, 17% 3D fiber, 7% bio-based material and 30% colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the surface layer.

[0036] S2: To make the core material, 31% 4080 hot melting point fiber, 24% 3D fiber, 8% bio-based material and 37% colored chemical fiber are opened and combed in proportion, and laid into a uniform fiber web to obtain the core layer.

[0037] S3: Insertion molding, using a needle punching machine to perform one needle punching insertion on the surface layer and a second needle punching insertion on the core layer;

[0038] S4: Product forming. A layer of the pierced surface layer is laid flat on both sides of the core layer after the piercing process, and then sent to an oven for drying. After cooling and shaping, it is cut according to the product size to obtain the mattress padding layer. The oven is a stepped circulating hot air heating device; the temperature of the first section is 120-150 degrees Celsius, and the air volume is 6900 m³ / h.3 / min, the temperature in the second section is 160-180 degrees Celsius, and the air volume is 8000m³ / min. 3 / min, the temperature in the third section is 170-190 degrees Celsius, and the air volume is 8800m³ / min. 3 The conveying speed is 8.2 m / min.

[0039] Example 4

[0040] A manufacturing process for a high-strength mattress padding layer differs from that in Example 1 in that, in this example, the bio-based material uses an equal amount of wool to replace bamboo fiber.

[0041] Example 5

[0042] The manufacturing process of a high-strength mattress padding layer differs from that of Example 2 in that, in this example, the bio-based material uses an equal amount of wool to replace bamboo fiber.

[0043] Example 6

[0044] The manufacturing process of a high-strength mattress padding layer differs from that of Example 3 in that, in this example, the bio-based material uses an equal amount of wool to replace bamboo fiber.

[0045] Comparative Example 1

[0046] The manufacturing process of a high-strength mattress padding layer differs from that of Example 1 in that step S3 is reduced in this example.

[0047] Comparative Example 2

[0048] The manufacturing process of a high-strength mattress padding layer differs from that of Example 2 in that step S3 is omitted in this example.

[0049] Comparative Example 3

[0050] The manufacturing process of a high-strength mattress padding layer differs from that of Example 3 in that step S3 is reduced in this example.

[0051] Comparative Example 4

[0052] The manufacturing process of a high-strength mattress padding layer differs from that of Example 4 in that step S3 is omitted in this example.

[0053] Comparative Example 5

[0054] The manufacturing process of a high-strength mattress padding layer differs from that of Example 5 in that step S3 is reduced in this example.

[0055] Comparative Example 6

[0056] The manufacturing process of a high-strength mattress padding layer differs from that of Example 6 in that step S3 is omitted in this example.

[0057] Performance testing

[0058] Test (1) Support strength: Take a mattress padding sample with a thickness of 25cm, and compress it at a constant speed along the thickness direction of the sample for 50mm and then stop the compression. Record the pressure corresponding to the specified deformation point to evaluate the support strength of the mattress padding. The greater the pressure, the greater the support strength of the mattress padding.

[0059] Test (2) Air permeability: Tested according to JIS L 1096-2019:

[0060]

[0061]

[0062] Based on Examples 1-6 and Comparative Examples 1-6, and combined with the data in Table 1, it can be seen that mattress padding with a double needle-punching process for both the surface layer and the core material is more conducive to greater support strength and breathability.

[0063] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for manufacturing a high-strength mattress cushion layer, characterized in that: The steps include: S1: Making the surface material, opening and combing 30-50% 4080 thermal melting point fiber, 10-30% 3D fiber, 5-15% bio-based material and 25-35% colored chemical fiber in proportion, laying a web to form a uniform fiber web, and making the surface layer; S2: making the core material, opening and combing 20-40% 4080 thermal melting point fiber, 10-30% 3D fiber, 5-15% bio-based material and 35-45% colored chemical fiber in proportion, laying a web to form a uniform fiber web, and making a core layer; S3: Insertion molding, using a needle punching machine to perform a first needle insertion on the surface layer and a second needle insertion on the core layer; S4: Product forming: a layer of surface layer that has completed the puncture process is laid on both sides of the core layer that has completed the puncture process, and then sent into an oven for drying. After cooling and shaping, the mattress cushion layer is obtained after cutting according to the size of the product.

2. The manufacturing process of a high-strength mattress cushion layer according to claim 1 is characterized in that: The 3D fiber adopts a 3D polyester filament fiber cotton mesh.

3. The manufacturing process of a high-strength mattress cushion layer according to claim 1 is characterized in that: The bio-based material is bamboo fiber, wool or a mixture of the two.

4. The manufacturing process of a high-strength mattress cushion layer according to claim 1 is characterized in that: The oven in S4 is a stepped circulating hot air heating device, the temperature of the first section is 120-150 degrees Celsius, the temperature of the second section is 160-180 degrees Celsius, and the temperature of the third section is 170-190 degrees Celsius.

5. The manufacturing process of a high-strength mattress cushion layer according to claim 1 is characterized in that: The oven in S4 adopts internal circulation hot air, and the air volume in the first section is 6500-7000m 3 / min, the air volume in the first section is 7200-8500m 3 / min, the air volume in the first section is 8200-9500m 3 / min.

6. The method for manufacturing a high-strength mattress cushion layer according to claim 1, characterized in that: The conveying speed of the oven in S4 is 8.2 m / min per 1 kg / ㎡.

Images