Recyclable mattress structure and method

Abstract

The invention relates to the technical field of mattresses, in particular to a recoverable mattress structure and method, the recoverable mattress structure comprises a support layer, the upper and lower sides of the support layer are provided with fabric layers, and a buffer layer is arranged between the upper fabric layer and the support layer; the mattress has the beneficial effects that the whole mattress can be pressed into a composite board with a certain thickness and certain mechanical property through a reasonably designed mattress layered structure, and the board can be widely used as a house building material, a packaging board and the like, so that a complete new solution is provided for efficient recycling of the mattress.

Description

Technical Field

[0001] The invention relates to the technical field of mattresses, in particular to a recyclable mattress structure and a method. Background Art

[0002] Traditional mattresses are mainly composed of latex layer (or sponge layer), hard cotton layer (or spray-bonded cotton, or non-bonded cotton), brown silk cotton layer (hemp fiber layer) and metal spring layer. After being discarded, these mattresses can only be treated as domestic waste, or incinerated, or landfilled. Because it is very difficult to recycle and reuse these mattresses, it brings a heavy burden to the environment. First, the workload of disassembling mattresses is huge; second, materials such as latex or sponge are difficult to degrade naturally, and they are thermosetting materials, which are difficult to recycle and reuse; third, the disassembled springs are loose and disordered, difficult to transport, and have extremely high impurity content, which significantly increases the cost of re-smelting steel.

[0003] With the development of material civilization and the enhancement of environmental awareness, developing a mattress that not only meets ergonomic requirements but can also be efficiently recycled and reused after the end of its service life has become a technical problem that needs to be urgently solved in the current mattress manufacturing field. Summary of the invention

[0004] The purpose of the present invention is to provide a recyclable mattress structure and method. When the mattress is produced, the structure of the mattress and the selection of materials are reasonably arranged. When the mattress is discarded, the conditions for quickly pressing it into a composite board with certain mechanical properties are met, which provides a prerequisite for the recycling of the product to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solution: a recyclable mattress structure, comprising a support layer, wherein fabric layers are provided on the upper and lower sides of the support layer, a buffer layer is provided between the upper fabric layer and the support layer, and a buffer layer is provided between the lower fabric layer and the support layer.

[0006] Preferably, the support layer includes a metal spring layer, the metal spring layer includes a plurality of springs, the outer side of the springs is coated with a wrapping layer made of low-melting-point fiber, and the amount of the low-melting-point fiber is not less than 35%.

[0007] Preferably, the metal spring layer has two elastic self-locking hooks. When recycled, under the action of a press, the self-locking hooks hook the upper and lower circles of the spring to reduce the possibility of spring rebound.

[0008] Preferably, the buffer layer includes a chemical fiber flake layer 1, the chemical fiber flake layer 1 is made of a polyester hard cotton layer, and the polyester hard cotton layer contains 15% of low-melting point adhesive fiber.

[0009] Preferably, the fabric layer includes fabric layer one and fabric layer two, the metal spring layer and chemical fiber flake layer one are arranged between fabric layer one and fabric layer two, fabric layer one and fabric layer two are both made of polyester / cotton (65 / 35) blended knitted fabric with a gram weight of 150-350 grams per square meter, and 30-50% of the polyester is low-melting point polyester.

[0010] Preferably, buffer layers are provided on both the upper and lower sides of the support layer, and both buffer layers are connected to the fabric layer.

[0011] Preferably, the fabric layer comprises a fabric layer 1 and a fabric layer 2, and both the fabric layer 1 and the fabric layer 2 are made of polyester / cotton (65 / 35) blended woven fabrics with a gram weight of about 220-350 g / m2, and 30-50% of the polyester is low-melting-point polyester; The buffer layer includes a chemical fiber flake layer 1, a natural fiber flake layer 1 and a chemical fiber flake layer 3, the chemical fiber flake layer 1 and the chemical fiber flake layer 3 are made of polyester hard cotton layer, the natural fiber flake layer 1 is made of brown silk cotton layer, and both the polyester hard cotton layer and the brown silk cotton layer contain 25% low melting point adhesive fiber; The supporting layer comprises a metal spring layer, the metal spring layer comprises a plurality of springs, each spring is covered with a cloth cover, the cloth cover material is a knitted cloth made of low melting point fiber, and the gram weight is about 120-180 grams per square meter.

[0012] Preferably, the fabric layer comprises a fabric layer 1 and a fabric layer 2, both the fabric layer 1 and the fabric layer 2 are made of polyester woven fabric, with a gram weight of about 250-400 g / m2, and 30-50% of the polyester is low-melting-point polyester, with a melting point of 130-150 degrees Celsius; The buffer layer includes a chemical fiber flake layer 1, a natural fiber flake layer 1, a chemical fiber flake layer 2, a chemical fiber flake layer 3, a natural fiber flake layer 2 and a chemical fiber flake layer 4. The chemical fiber flake layer 1, the chemical fiber flake layer 2, the chemical fiber flake layer 3 and the chemical fiber flake layer 4 all use a polyester hard cotton layer. The natural fiber flake layer 1 and the natural fiber flake layer 2 all use a brown silk cotton layer. The polyester hard cotton layer and the brown silk cotton layer both contain 25% low melting point adhesive fiber, have a gram weight of 320-850 grams per square meter, and a thickness of 3-8 cm. The support layer includes a metal spring layer, the metal spring layer includes a plurality of springs, each spring is covered with a cloth cover, the cloth cover material is a woven fabric made of low melting point fiber, and the gram weight is 120-180 grams per square meter; The fabric layer one, the chemical fiber flake layer one, the natural fiber flake layer one, the chemical fiber flake layer two, the metal spring layer, the chemical fiber flake layer three, the natural fiber flake layer two, the chemical fiber flake layer four and the fabric layer two are stacked from top to bottom.

[0013] A mattress recycling method, for a recyclable mattress structure, comprising the following steps: Recyclable mattress structures are pressed into composite boards for use in housing construction and packaging.

[0014] Compared with the prior art, the present invention has the following beneficial effects: By designing a reasonable mattress layered structure, the entire mattress can be pressed into a composite board with a certain thickness and certain mechanical properties. The board can be widely used as housing building materials, packaging boards, etc., thus proposing a completely new solution for the efficient recycling of mattresses. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the spring structure in Embodiment 9 of the present invention; Figure 3 This is a schematic diagram of the spring structure in Embodiment 10 of the present invention; Figure 4 This is a schematic diagram of the spring structure in the eleventh embodiment of the present invention.

[0016] In the figure: fabric layer 1, chemical fiber flake layer 2, natural fiber flake layer 1, chemical fiber flake layer 3, chemical fiber flake layer 2, metal spring layer 5, chemical fiber flake layer 3, 6, natural fiber flake layer 2, 7, chemical fiber flake layer 4, fabric layer 2, 9. DETAILED DESCRIPTION

[0017] In order to make the purpose and technical solution of the present invention clearly and completely described, and the advantages more clearly understood, the embodiments of the present invention are further described in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are part of the embodiments of the present invention, rather than all of the embodiments, and are only used to explain the embodiments of the present invention, and are not used to limit the embodiments of the present invention. All other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] Embodiment 1, the present invention provides a technical solution: a recyclable mattress structure, comprising a support layer, wherein fabric layers are provided on the upper and lower sides of the support layer, a buffer layer is provided between the upper fabric layer and the support layer, the support layer comprises a metal spring layer 5, the metal spring layer 5 comprises a plurality of springs, the outer side of the spring is coated with a wrapping layer made of low-melting point fiber, the amount of low-melting point fiber used is not less than 35%, the buffer layer comprises a chemical fiber flake layer 2, the chemical fiber flake layer 2 adopts a polyester hard cotton layer, the polyester hard cotton layer contains 15% low-melting point adhesive fiber, the fabric layer comprises a fabric layer 1 and a fabric layer 2 9, the metal spring layer 5 and the chemical fiber flake layer 2 are provided between the fabric layer 1 and the fabric layer 2 9, the fabric layer 1 and the fabric layer 2 9 are both made of polyester / cotton (65 / 35) blended knitted fabrics with a gram weight of 150-350 grams per square meter, and 30-50% of the polyester is low-melting point polyester.

[0019] The structure is as follows: Fabric layer Buffer layer → polyester hard cotton layer Support layer Fabric layer.

[0020] Recyclable mattress structures are pressed into composite boards for use in housing construction and packaging.

[0021] Embodiment 2, on the basis of embodiment 1, proposes: buffer layers are provided on the upper and lower sides of the support layer, and the two buffer layers are connected to the fabric layer; the fabric layer includes fabric layer 1 and fabric layer 2 9, fabric layer 1 and fabric layer 2 9 are both made of polyester / cotton (65 / 35) blended woven fabrics with a gram weight of about 220-350 g / m2, and 30-50% of the polyester is low-melting point polyester; the buffer layer includes chemical fiber flake layer 2, natural fiber flake layer 3 and chemical fiber flake layer 3 6, chemical fiber flake layer 2 and chemical fiber flake layer 3 6 are made of polyester hard cotton layer, and natural fiber flake layer 1 3 is made of brown silk cotton layer, and the polyester hard cotton layer and the brown silk cotton layer contain 25% low-melting point adhesive fiber; the support layer includes a metal spring layer 5, the metal spring layer 5 includes a plurality of springs, each spring is covered with a cloth cover, and the cloth cover material is a knitted cloth made of low-melting point fiber with a gram weight of about 120-180 g / m2.

[0022] The structure is as follows: Fabric layer Buffer layer → brown silk cotton layer Polyester hard cotton layer Support layer Buffer layer → polyester hard cotton layer Fabric layer Recyclable mattress structures are pressed into composite boards for use in housing construction and packaging.

[0023] Embodiment 3, on the basis of embodiment 1, proposes: buffer layers are provided on the upper and lower sides of the support layer, and the two buffer layers are connected with fabric layers; the fabric layer comprises fabric layer 1 and fabric layer 2 9, fabric layer 1 and fabric layer 2 9 are both made of polyester woven fabrics with a gram weight of about 250-400 grams per square meter, 30-50% of the polyester is low-melting point polyester with a melting point of 130-150 degrees Celsius; the buffer layer comprises chemical fiber flake layer 1 2, natural fiber flake layer 1 3, chemical fiber flake layer 2 4, chemical fiber flake layer 3 6, natural fiber flake layer 2 7 and chemical fiber flake layer 4 8, chemical fiber flake layer 1 2, chemical fiber flake layer 2 4, chemical fiber flake layer 3 6, chemical fiber flake layer 4 8 are all made of polyester hard cotton layers, natural fiber flake layer 1 3 and natural fiber flake layer 2 7 are all made of brown silk cotton layers, polyester Both the hard cotton layer and the brown silk cotton layer contain 25% low melting point adhesive fiber, with a gram weight of 320-850 g / m2 and a thickness of 3-8 cm; the supporting layer includes a metal spring layer 5, which includes a plurality of springs, and the springs are of an hourglass-shaped structure, that is, the diameter of the springs decreases from both ends to the middle, so that the buffering performance is better, and the design of the variable diameter spring eliminates the compression restriction caused by the overlap between the spring wires, so that the height of the spring after compression does not exceed twice the diameter of the spring wire; each spring is covered with a cloth cover, and the cloth cover material is a woven cloth made of low melting point fiber, with a gram weight of 120-180 g / m2; fabric layer 1, chemical fiber flake layer 2, natural fiber flake layer 1 3, chemical fiber flake layer 2 4, metal spring layer 5, chemical fiber flake layer 3 6, natural fiber flake layer 2 7, chemical fiber flake layer 4 8 and fabric layer 2 9 are stacked from top to bottom.

[0024] The structure is as follows: Fabric layer Buffer layer → brown silk cotton layer Polyester hard cotton layer Support layer Buffer layer → polyester hard cotton layer Brown silk cotton layer Fabric layer Recyclable mattress structures are pressed into composite boards for use in housing construction and packaging.

[0025] In the fourth embodiment, the metal spring in the supporting layer is provided with two elastic self-locking hooks, so that when recycled, under the action of a press, the self-locking hooks can hook the upper and lower circles of the spring, thereby reducing the possibility of spring rebound. The spring self-locking buckle can instantly restrain the rebound of the spring, so that the compression process of the recycled plate takes less than 20 seconds;.

[0026] In the fifth embodiment, the metal spring in the support layer is a variable helical diameter spring, so that when it is recycled, the space occupied by the spring can be reduced as much as possible under the action of a press.

[0027] In the sixth embodiment, the buffer layer is a hard cotton layer made of chemical fiber, such as polyester fiber, which contains no less than 15% low-melting point adhesive fiber, the melting point of the low-melting point is 130-150 degrees Celsius, the gram weight is 280-850 grams per square meter, and the thickness is 3-8 cm.

[0028] In the seventh embodiment, the buffer layer may be a natural fiber flake layer, such as a silk flake layer. The brown silk flake layer contains no less than 20% of low melting point adhesive fiber, has a gram weight of 320-850 g / m2, and a thickness of 3-8 cm.

[0029] In the eighth embodiment, the fabric layer can be a blended fabric of chemical fiber and natural fiber, such as polyester / cotton (65 / 35) blended knitted fabric with a gram weight of 150-350 g / m2. The low melting point in the fabric is generally not less than 20%, and the melting point of the low melting point is 130-180 degrees Celsius.

[0030] Embodiment 9: A self-locking bracket is provided on the spring in the metal spring layer 5, as shown in the attached Figure 2 shown.

[0031] Embodiment 10: The spring in the metal spring layer 5 adopts a hook compression separation structure, see the attached Figure 3 shown.

[0032] Embodiment 11: The spring in the metal spring layer 5 adopts a hook compression integrated structure, see the attached Figure 4 shown.

[0033] The recyclable mattress structures prepared in Examples 1 to 11 have the following advantages: 1. Reasonable design of mattress layer structure: The mattress is composed of multiple layers from top to bottom, which are flame retardant fabric layer, hard cotton layer, brown silk cotton layer, spring layer, brown silk cotton layer, hard cotton layer, flame retardant fabric layer (or ordinary fabric). The hard cotton layer and brown silk cotton layer can be repeated multiple times according to needs, and can also be composed of hard cotton of various specifications, or composed of brown silk cotton layers of various specifications.

[0034] 2. Reasonable material selection. Each layer contains a certain proportion of low-melting-point fibers (melting point is generally below 150 degrees Celsius), usually not less than 15%. In addition to low-melting-point fibers, other fibers used in each layer can be various common natural fibers, or chemical fibers, or recycled fibers, or a mixture of multiple fibers.

[0035] 3. The spring layer is a structure with uniformly distributed springs, and each spring is wrapped with a wrapping layer containing low-melting-point fibers.

[0036] 4. Since each layer contains low-melting-point fibers, after the mattress is recycled, based on the bonding properties of the low-melting-point fibers, under the action of temperature and pressure, the entire mattress can be pressed into a composite board with a certain thickness and certain mechanical properties. The board can be widely used as building materials, packaging boards, etc., thus proposing a new solution for the efficient recycling of mattresses.

[0037] 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 recyclable mattress structure, comprising a support layer, characterized in that: Fabric layers are arranged on both the upper and lower sides of the support layer.

2. The recyclable mattress structure according to claim 1, characterized in that: A buffer layer is arranged between the upper fabric layer and the supporting layer, and a buffer layer is arranged between the lower fabric layer and the supporting layer.

3. The recyclable mattress structure according to claim 1, characterized in that: The support layer comprises a metal spring layer (5), the metal spring layer (5) comprises a plurality of springs, the outer sides of the springs are coated with a wrapping layer made of low-melting-point fibers, and the amount of the low-melting-point fibers used is not less than 35%.

4. The recyclable mattress structure according to claim 3, characterized in that: The metal spring layer (5) has two elastic self-locking hooks. When recycled, under the action of a press, the self-locking hooks hook the upper and lower circles of the spring, thereby reducing the possibility of spring rebound.

5. The recyclable mattress structure according to claim 3, characterized in that: The buffer layer comprises a chemical fiber flake layer (2), wherein the chemical fiber flake layer (2) is a polyester hard cotton layer, and the polyester hard cotton layer contains 15% of low melting point adhesive fiber.

6. The recyclable mattress structure according to claim 5, characterized in that: The fabric layer comprises a fabric layer 1 (1) and a fabric layer 2 (9), the metal spring layer (5) and the chemical fiber flake layer 1 (2) are arranged between the fabric layer 1 (1) and the fabric layer 2 (9), the fabric layer 1 (1) and the fabric layer 2 (9) are both made of polyester / cotton (65 / 35) blended knitted fabric with a gram weight of 150-350 g / m2, and 30-50% of the polyester is low-melting point polyester.

7. The recyclable mattress structure according to claim 2, characterized in that: Buffer layers are provided on both the upper and lower sides of the support layer, and both buffer layers are connected to the fabric layer.

8. The recyclable mattress structure according to claim 7, characterized in that: The fabric layer comprises a fabric layer 1 (1) and a fabric layer 2 (9), and the fabric layer 1 (1) and the fabric layer 2 (9) are both made of polyester / cotton (65 / 35) blended woven fabric with a gram weight of about 220-350 g / m2, and 30-50% of the polyester is low-melting-point polyester; The buffer layer comprises a chemical fiber flake layer one (2), a natural fiber flake layer one (3) and a chemical fiber flake layer three (6), the chemical fiber flake layer one (2) and the chemical fiber flake layer three (6) are made of a polyester hard cotton layer, and the natural fiber flake layer one (3) is made of a brown silk cotton layer, and both the polyester hard cotton layer and the brown silk cotton layer contain 25% low melting point adhesive fiber; The support layer comprises a metal spring layer (5), the metal spring layer (5) comprises a plurality of springs, each spring is covered with a cloth cover, the cloth cover material is a knitted cloth made of low melting point fiber, and the gram weight is about 120-180 grams per square meter.

9. The recyclable mattress structure according to claim 7, characterized in that: The fabric layer comprises a fabric layer 1 (1) and a fabric layer 2 (9), the fabric layer 1 (1) and the fabric layer 2 (9) are both made of polyester woven fabric with a gram weight of about 250-400 g / m2, 30-50% of the polyester is low melting point polyester with a melting point of 130-150 degrees Celsius; The buffer layer comprises a chemical fiber flake layer 1 (2), a natural fiber flake layer 1 (3), a chemical fiber flake layer 2 (4), a chemical fiber flake layer 3 (6), a natural fiber flake layer 2 (7) and a chemical fiber flake layer 4 (8); the chemical fiber flake layer 1 (2), the chemical fiber flake layer 2 (4), the chemical fiber flake layer 3 (6) and the chemical fiber flake layer 4 (8) are all made of polyester hard cotton layer, the natural fiber flake layer 1 (3) and the natural fiber flake layer 2 (7) are all made of brown silk cotton layer, the polyester hard cotton layer and the brown silk cotton layer both contain 25% low melting point adhesive fiber, have a gram weight of 320-850 g / m2 and a thickness of 3-8 cm; The support layer comprises a metal spring layer (5), the metal spring layer (5) comprises a plurality of springs, each spring is covered with a cloth cover, the cloth cover material is a woven cloth made of low melting point fiber, and the gram weight is 120-180 grams per square meter; The fabric layer one (1), the chemical fiber flake layer one (2), the natural fiber flake layer one (3), the chemical fiber flake layer two (4), the metal spring layer (5), the chemical fiber flake layer three (6), the natural fiber flake layer two (7), the chemical fiber flake layer four (8) and the fabric layer two (9) are stacked from top to bottom.

10. A mattress recycling method for recycling the recyclable mattress structure according to any one of claims 1 to 9, characterized in that: The method comprises the following steps: Recyclable mattress structures are pressed into composite boards for use in house building materials and packaging boards.

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