Production method of special-shaped air fiber cushion

Abstract

The invention belongs to the technical field of air fiber product production, and particularly relates to a production method of a special-shaped air fiber cushion, which comprises the following process steps: core material pretreatment, core material pressurization, hot water shaping unit, cold water shaping unit and post-treatment. By means of the innovative production method and the unique mold design, accurate control over shaping and shaping links of the air fiber mat is achieved, the stability and consistency of the product quality are effectively improved, and the ever-increasing requirements of the market for the high-quality air fiber mat are met. According to the production method, the shaping and shaping process can be accurately controlled, and efficient and high-quality production of the air fiber cushion is achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of air fiber product production, and particularly relates to a production method for a special-shaped air fiber mat. Background Art

[0002] In current fields such as household items and industrial cushioning materials, air fiber mats are increasingly favored by consumers due to their excellent breathability, outstanding resilience, and good comfort, and the market demand shows a continuous growth trend. However, there are many bottlenecks in the existing air fiber mat production technology: the market demand for products is becoming more diverse and personalized, and consumers are no longer satisfied with standard products and are eager for unique products that can demonstrate personal taste. However, the existing production process is limited by equipment, technology, and processes, with poor flexibility, making it difficult to quickly iterate and customize products. The development cycle of new functions is long and the cost is high, and it is difficult, costly, and inefficient to switch production between different products. This not only limits the ability of enterprises to meet market demand but also hinders the innovative development of the industry, and the variety of market products is difficult to meet consumer needs, urgently requiring new solutions. Summary of the Invention

[0003] To solve the problems existing in the above-mentioned prior art, the present invention aims to overcome the difficulties in the existing air fiber mat production technology. Through innovative production methods and unique mold designs, precise control in the shaping and setting processes of air fiber mats is achieved, effectively improving the stability and consistency of product quality to meet the increasing market demand for high-quality air fiber mats. The production method described in the present invention can precisely control the shaping and setting processes and achieve efficient and high-quality production of air fiber mats.

[0004] To achieve the above object, the present invention adopts the following technical solutions:

[0005] A production method for a special-shaped air fiber mat, comprising the following technological steps:

[0006] (1) Core material pretreatment: Using a straight knife cutting device, cut the produced air fiber core material according to the pre-designed sample shape; place the cut air fiber core material stably in a dedicated mold that matches it.

[0007] Preferably, during the cutting process, precisely control the cutting path and parameters to ensure that the cutting edge is neat and the size is accurate.

[0008] Preferably, the mold is made of an alloy material with high strength, high temperature resistance, and corrosion resistance; the mold is divided into a movable upper mold and a fixed lower mold, and the lower mold is firmly installed on the workbench of the production equipment through a screw fixing device.

[0009] (2) Core material pressing: Lay the pre-treated air fiber core material evenly in the lower mold, ensuring uniform distribution of the core material without obvious voids or extrusion deformation; click the start button to start the high-precision air pressure control system. Under the drive of air pressure, the upper mold slowly descends at a set speed, applying uniform and stable pressure to the core material, enabling the core material to be initially formed and closely conform to the shape of the mold.

[0010] Preferably, the air pressure control system can precisely adjust the air pressure magnitude and the pressing speed.

[0011] Preferably, the upper mold slowly descends at a speed of 2 m / s - 5 m / s under the drive of air pressure.

[0012] (3) Hot water shaping unit: After the core material is pressed, the mold enters the hot water unit position smoothly through the slide rail; the mold slowly descends until the hot water completely covers the mold; in the hot water, the sample is shaped according to the preset shaping time.

[0013] Preferably, multiple small holes are distributed on the upper mold, which can ensure that the water forms a uniform water flow when entering the mold, enabling the sample to be heated more evenly in all directions.

[0014] Preferably, the diameter of the small holes on the upper mold is 1 cm.

[0015] Preferably, the shaping time is controlled within 60 s - 300 s;

[0016] Preferably, the shaping time can be flexibly adjusted according to the characteristics of the air fiber material to ensure sufficient shaping without damaging the material properties due to overheating.

[0017] Preferably, the water temperature of the hot water is controlled at 65 - 85 °C.

[0018] Preferably, the hot water unit is equipped with an intelligent temperature control device, which can precisely control the water temperature within the set temperature range, and the temperature fluctuation does not exceed ±1 °C.

[0019] (4) Cold water setting unit: After shaping is completed, the mold rises smoothly out of the water under the action of air pressure and enters the cold water unit through the slide rail; the mold descends until it is completely immersed in the cold water tank. The cold water quickly enters the mold through the small holes on the mold, enabling the sample to be evenly cooled and completed setting in a short time, improving production efficiency.

[0020] Preferably, the cold water unit is equipped with a temperature control device and a cooling circulation device, which can stably control the cold water temperature at 15 - 25 °C.

[0021] (5) Post - processing: After the shaping is completed, the mold rises and leaves the cold water unit; then, under the action of air pressure, the upper mold rises quickly and smoothly; then the sample is taken out of the mold and placed on a plastic tray to drain the excess moisture on the surface and inside of the sample; subsequently, the sample is sent to a drying equipment for drying, and finally a finished air fiber sample is obtained.

[0022] The drying temperature is 40°C - 45°C and the drying time is 10 - 15 minutes. The drying equipment adopts hot air circulation technology to ensure that the sample is thoroughly dried.

[0023] Compared with the prior art, the process of the present invention has the following improvements:

[0024] The water molding process involved in this patent has achieved a significant breakthrough compared with the traditional hot oil molding:

[0025] (1) During the operation process, the water molding process significantly reduces the processing temperature, avoids potential safety hazards caused by high temperature, greatly improves the safety during the production process, and provides a more reliable working environment for the operators.

[0026] (2) At the same time, the lower working temperature means a significant reduction in energy consumption, reduces the long - term operation cost for enterprises, and improves the economic benefits.

[0027] (3) In the product forming stage, the water molding process adopts cold water shaping method, which can more precisely control the product forming process, make the internal structure of the product more uniform and stable, and effectively improve the product quality. In sharp contrast, the traditional hot oil shaping only relies on heat shaping. When the molded sample is taken out at too high a temperature, it is extremely easy to have deformation problems, seriously affecting the product quality and qualification rate.

[0028] The present invention also realizes a major transformation of the production mode from traditional intermittent production to continuous production by improving the equipment, greatly improving the production efficiency. The equipment has a precise temperature control system. The operator can randomly input the required temperature parameters on the equipment operation interface according to the characteristics of different materials, and the equipment can quickly and precisely adjust the temperature to the target value, so as to meet the strict requirements of various materials for different temperatures during the production process, effectively improving the stability and consistency of product quality. At the same time, the equipment innovatively introduces a rapid cooling technology after the shaping stage, enabling the product to quickly cool down after shaping. Compared with the traditional cooling method, it greatly shortens the production cycle, significantly improves the production efficiency, saves production costs, and enhances the competitiveness of the enterprise in the market.

[0029] Beneficial effects

[0030] The present invention discloses a production method of a special - shaped air fiber mat. Compared with the prior art, the present invention has the following beneficial effects:

[0031] Strong adaptability: The production method and mold design have good versatility and flexibility. They can quickly switch production of products according to different product shapes, sizes, and material requirements by adjusting equipment parameters and mold structures, meeting diverse market demands.

[0032] Quality improvement: The carefully designed small hole structure on the mold, combined with the intelligent temperature-controlled hot water and cold water systems, realizes uniform transfer of heat and cold during the shaping and setting processes, effectively solving the problems of uneven shaping and poor setting effect in the traditional production process, greatly improving the stability and consistency of product quality, reducing the defective rate, and effectively enhancing production efficiency. Specific implementation manners

[0033] Hereinafter, the present invention will be described in detail. Before the description, it should be understood that the terms used in this specification and the appended claims should not be construed as limited to the general meaning and dictionary meaning, but should be interpreted based on the principle that allows the inventor to appropriately define the terms for the best interpretation, according to the meanings and concepts corresponding to the technical aspects of the present invention. Therefore, the description presented here is only a preferred example for illustrative purposes and is not intended to limit the scope of the present invention. Thus, it should be understood that other equivalent ways or improved ways can be obtained without departing from the spirit and scope of the present invention.

[0034] The following examples are only listed as examples of the implementation schemes of the present invention and do not constitute any limitation to the present invention. Those skilled in the art can understand that modifications within the scope not deviating from the essence and concept of the present invention fall within the protection scope of the present invention. Unless otherwise specified, the reagents and instruments used in the following examples are all commercially available products.

[0035] Example 1

[0036] A production method of a special-shaped air fiber mat, comprising the following technological steps:

[0037] Preparation work:

[0038] According to the product design requirements, select a mold with appropriate specifications and shapes, and conduct a comprehensive inspection of the mold to ensure no damage, deformation, etc. Use high-precision measuring tools to check the dimensional accuracy of the mold to ensure that the mold meets the production requirements. Clean and lubricate the slide rails, and check the straightness and parallelism of the slide rails to ensure that the mold can move smoothly and smoothly on the slide rails.

[0039] Check whether the water level, water temperature control system, heating and refrigeration devices of the hot water unit and cold water unit are working properly. Add appropriate amounts of water and corresponding additives to ensure that the water temperature can reach the set value quickly and accurately. Calibrate the pressure of the pneumatic equipment and detect leaks to ensure that the pneumatic control system can stably and accurately control the air pressure and the pressurization speed.

[0040] Cutting and placing steps:

[0041] Place the raw material of the air fiber mat on the workbench of the laser cutting equipment. Import the cutting drawing of the sample through the CAD system and set the cutting parameters. Start the cutting equipment for trial cutting and check the cutting effect, such as the flatness of the cutting edge and the dimensional accuracy. Fine-tune the cutting parameters according to the trial cutting results to ensure the cutting quality. Carefully place the cut mat in the lower mold, ensuring that the mat is evenly distributed in the mold.

[0042] Core material placement and pressurization steps:

[0043] Evenly spread the cut air fiber core material on the mat in the lower mold. Start the pneumatic control system and set parameters such as the pressurization pressure of 0.15 mpa, the pressurization speed of 5 m / min, and the holding pressure time of 30 s. Click the start button and the upper mold slowly descends to pressurize the core material.

[0044] Hot water shaping steps:

[0045] After the core material is pressurized, the mold enters the hot water unit through the slide rail. During the descent of the mold, ensure that the mold completely enters the hot water tank and that the hot water can smoothly enter the inside of the mold through the small holes on the mold. Set the hot water temperature to 85 °C and the shaping time to 2 min according to the characteristics of the air fiber material and the product requirements.

[0046] Cold water setting steps:

[0047] After shaping, the mold rises and leaves the hot water unit and enters the cold water unit. Similarly, during the descent of the mold, ensure that the cold water can evenly enter the mold. Set the cold water temperature to 20 °C and the setting time to 2 min according to the characteristics of the product.

[0048] Removal and post-treatment steps:

[0049] After setting, the mold rises and leaves the cold water unit. The upper mold rises, and the sample is taken out of the mold and placed on a plastic tray for water control. The water-controlled sample is sent to the drying equipment, and the drying temperature is set to 42 °C and the time to 12 min. During the drying process, regularly check the dryness of the sample to ensure that the sample is completely dry to obtain the finished air fiber shaped sample.

[0050] This production method and mold design have good versatility and flexibility. According to different product shapes, sizes, and material requirements, by adjusting equipment parameters and mold structures, product switching production can be quickly achieved to meet diverse market demands. The carefully designed small hole structure on the mold, combined with an intelligent temperature-controlled hot water and cold water system, realizes the uniform transfer of heat and cold during the shaping and setting processes, effectively solving the problems of uneven shaping and poor setting effect in traditional production processes, greatly improving the stability and consistency of product quality, reducing the defective rate, and effectively enhancing production efficiency. Compared with the original process in the prior art, the defective rate of the process described in this application is greatly reduced, and the production rate is greatly increased. The specific comparison data is shown in Table 1 below.

[0051] Table 1. Comparison data of the process described in this application and the original process in the prior art

[0052] Name Original process Process of this application Defective rate % 11％ 3％ Production rate (pieces / hour) 55 97

[0053] Example 2

[0054] A production method for a special-shaped air fiber mat, including the following technological steps:

[0055] Preparation work:

[0056] According to the product design requirements, select a mold with appropriate specifications and shapes, and conduct a comprehensive inspection of the mold to ensure there are no problems such as damage and deformation. Use high-precision measuring tools to check the dimensional accuracy of the mold to ensure that the mold meets the production requirements. Clean and lubricate the slide rails, and check the straightness and parallelism of the slide rails to ensure that the mold can move smoothly and smoothly on the slide rails.

[0057] Check whether the water levels, water temperature control systems, heating and refrigeration devices of the hot water unit and cold water unit are working properly, add appropriate amounts of water and corresponding additives to ensure that the water temperature can reach the set value quickly and accurately. Conduct pressure calibration and leakage detection on the pneumatic equipment to ensure that the pneumatic control system can stably and accurately control the air pressure magnitude and pressurization speed.

[0058] Cutting and placing steps:

[0059] Place the air fiber mat raw material on the workbench of the laser cutting equipment, import the cutting drawing of the sample through the CAD system, and set the cutting parameters. Start the cutting equipment for trial cutting, check the cutting effect, such as the flatness of the cutting edge and dimensional accuracy. According to the trial cutting results, fine-tune the cutting parameters to ensure the cutting quality. Carefully place the cut mat in the lower mold to ensure that the position of the mat in the mold is evenly distributed.

[0060] Core material placement and pressurization steps:

[0061] Place the cut air fiber core material evenly on the mat in the lower mold. Start the pneumatic control system and set parameters such as the pressurization pressure of 0.1 mpa, the pressurization speed of 2 m / min, and the pressure holding time of 300 s. Click the start button, and the upper mold slowly descends to pressurize the core material.

[0062] Hot water shaping step:

[0063] After the core material is pressurized, the mold enters the hot water unit through the slide rail. During the descent of the mold, ensure that the mold completely enters the hot water tank and that hot water can smoothly enter the interior of the mold through the small holes on the mold. Set the hot water temperature to 65 °C and the shaping time to 5 min according to the characteristics of the air fiber material and the product requirements.

[0064] Cold water setting step:

[0065] After shaping is completed, the mold rises and leaves the hot water unit and enters the cold water unit. Similarly, during the descent of the mold, ensure that cold water can enter the mold evenly. Set the cold water temperature to 25 °C and the setting time to 4 min according to the characteristics of the product.

[0066] Taking out and post-treatment steps:

[0067] After setting is completed, the mold rises and leaves the cold water unit. The upper mold rises, takes out the sample from the mold, and places it on a plastic tray for water control. Send the water-controlled sample to the drying equipment, set the drying temperature to 45 °C and the time to 10 min. During the drying process, regularly check the dryness of the sample to ensure that the sample is completely dry to obtain a finished air fiber shaped sample.

[0068] Example 3

[0069] A production method of a shaped air fiber mat, including the following process steps:

[0070] Preparation work:

[0071] According to the product design requirements, select a mold with appropriate specifications and shapes, and conduct a comprehensive inspection of the mold to ensure that there are no problems such as damage and deformation. Use high-precision measuring tools to check the dimensional accuracy of the mold to ensure that the mold meets the production requirements. Clean and lubricate the slide rail, and check the straightness and parallelism of the slide rail to ensure that the mold can move smoothly and smoothly on the slide rail.

[0072] Check whether the water level, water temperature control system, heating and refrigeration devices of the hot water unit and the cold water unit are working properly, add appropriate amounts of water and corresponding additives to ensure that the water temperature can reach the set value quickly and accurately. Conduct pressure calibration and leak detection on the pneumatic equipment to ensure that the pneumatic control system can stably and accurately control the air pressure and pressurization speed.

[0073] Cutting and placing steps:

[0074] Place the raw material of the air fiber mat on the workbench of the laser cutting equipment, import the cutting drawing of the sample through the CAD system, and set the cutting parameters. Start the cutting equipment, conduct a trial cut, and check the cutting effect, such as the flatness of the cutting edge and dimensional accuracy. According to the trial cut results, fine-tune the cutting parameters to ensure the cutting quality. Carefully place the cut mat in the lower mold, ensuring that the position of the mat in the mold is evenly distributed.

[0075] Core material placement and pressing steps:

[0076] Evenly spread the cut air fiber core material on the mat in the lower mold. Start the pneumatic control system, set parameters such as the pressing pressure of 0.3 mpa, the pressing speed of 10 m / min, and the holding pressure time of 10 s. Click the start button, and the upper mold slowly descends to press the core material.

[0077] Hot water shaping steps:

[0078] After the core material is pressed, the mold enters the hot water unit through the slide rail. During the descent of the mold, ensure that the mold completely enters the hot water tank and the hot water can smoothly enter the interior of the mold through the small holes on the mold. According to the characteristics of the air fiber material and product requirements, set the hot water temperature at 65 °C and the shaping time at 300 s.

[0079] Cold water setting steps:

[0080] After shaping is completed, the mold rises and leaves the hot water unit and enters the cold water unit. Similarly, during the descent of the mold, ensure that the cold water can evenly enter the mold. According to the characteristics of the product, set the cold water temperature at 15 °C and the setting time at 1 min.

[0081] Removal and post-treatment steps:

[0082] After setting is completed, the mold rises and leaves the cold water unit. The upper mold rises, takes out the sample from the mold, and places it on a plastic tray for water control. Send the water-controlled sample to the drying equipment, set the drying temperature at 40 °C and the time at 15 min. During the drying process, regularly check the dryness of the sample to ensure that the sample is completely dry, and obtain the finished air fiber shaped sample.

[0083] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions required to be protected by the present invention.

Claims

1. A method for producing a special-shaped air fiber mat, characterized in that: The process steps include: (1) Core material pretreatment: Use straight knife cutting equipment to cut the produced air fiber core material according to the pre-designed sample shape; place the cut air fiber core material stably in a matching special mold; (2) Pressurizing the core material: evenly lay the pre-treated air fiber core material in the lower mold to ensure that the core material is evenly distributed without obvious gaps or extrusion deformation; click the start button to start the high-precision air pressure control system, and the upper mold is driven by the air pressure to slowly descend at a set speed, applying uniform and stable pressure to the core material, so that the core material is initially formed and closely fits the shape of the mold; (3) Hot water shaping unit: After the core material is pressurized, the mold passes through the slide rail and smoothly enters the hot water unit position; the mold slowly descends until the hot water completely covers the mold; in the hot water, the sample is shaped according to the preset shaping time; (4) Cold water shaping unit: After shaping is completed, the mold rises steadily out of the water under the action of air pressure and enters the cold water unit through the slide rail; the mold descends until it is completely immersed in the cold water tank, and cold water quickly enters the mold through the small holes on the mold, so that the sample is evenly cooled and shaping is completed in a short time; (5) Post-processing: After the shaping is completed, the mold rises and leaves the cold water unit; then the upper mold rises quickly and smoothly under the action of air pressure; then the sample is taken out of the mold and placed on a plastic tray to drain excess moisture on the surface and inside of the sample; then, the sample is sent to a drying equipment for drying, and finally a finished air fiber sample is obtained.

2. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (1), during the cutting process, the cutting path and parameters are precisely controlled to ensure that the cutting edges are neat and the dimensions are accurate.

3. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (1), the mold is made of a high-strength, high-temperature-resistant, and corrosion-resistant alloy material; the mold is divided into a movable upper mold and a fixed lower mold, and the lower mold is firmly mounted on the workbench of the production equipment by a screw fixing device.

4. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (2), the air pressure control system can accurately adjust the air pressure and the pressurization speed; the upper mold slowly descends at a speed of 2m / s-5m / s under the drive of the air pressure.

5. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (3), a plurality of small holes are distributed on the upper mold, which can ensure that water forms a uniform water flow when entering the mold, so that the sample is heated in an all-round and more uniform manner; preferably, the diameter of the small holes on the upper mold is 1 cm.

6. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (3), the shaping time is controlled within a range of 60s-300s; the shaping time can be flexibly adjusted according to the characteristics of the air fiber material to ensure that the shaping is sufficient and that the material properties are not damaged due to excessive heating; the water temperature of the hot water is controlled within a range of 65-85°C; the hot water unit is equipped with an intelligent temperature control device that can accurately control the water temperature within a set temperature range, with a temperature fluctuation of no more than ±1°C.

7. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (4), the cold water unit is equipped with a temperature control device and a cooling circulation device, which can stably control the cold water temperature at 15-25°C.

8. The method for producing a special-shaped air fiber mat according to claim 1, characterized in that: In step (5), the drying temperature is 40° C.-45° C., the drying time is 10-15 min, and the drying equipment adopts hot air circulation technology to ensure that the sample is thoroughly dried.