Production method of surface hot melting shaping fiber cotton
Through hot rolling and cold rolling methods, a protective layer is directly formed in the production process of surface hot melt fixed fiber cotton, which solves the problems of high processing costs, chemical pollution and high process complexity in the existing processes, and achieves the goal of improving production efficiency and environmental protection.
Patent Information
- Application Number
- CN202510355635.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-25
- Publication Date
- 2025-06-20
AI Technical Summary
In the existing production process of hot melt fixed fiber foam, glue and non-woven fabrics are used to form protective layers, resulting in high processing costs, serious chemical pollution problems and high process complexity, which limits production efficiency and application value.
The fiber pad is hot-rolled by hot-rolling rollers at a temperature of 160°C to form a dense surface hot melt fixed fiber cotton substrate, and the high-temperature surface is rolled and cooled at a temperature of 0-40°C to quickly cool and shape the surface fibers to form a protective layer.
This method simplifies the process flow, eliminates the glue compounding step, reduces production costs, reduces chemical pollution, improves production efficiency, and enhances the compression and wear resistance of fiber cotton.
Smart Images
Figure CN120174547A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a fiber cotton, specifically a production method of a fiber cotton with a surface hot melt shaping. Background Art
[0002] The fiber cotton with a surface hot melt shaping, also known as PK rigid cotton, hot-pressed cotton or sterile cotton, is a high-quality mattress auxiliary material. It is made of polyester fiber (polyester) and polypropylene fiber (polypropylene), and forms a fiber cloth through multiple needle punching reinforcements, and then is processed by hot rolling. This material has the characteristics of pure white without impurities, breathable and waterproof, and does not contain harmful substances such as formaldehyde and benzene. At the same time, it shows excellent resilience and tensile strength in both longitudinal and transverse directions, so it is considered to be one of the most ideal and high-grade cushion core wrapping materials in the mattress production field.
[0003] In the structural design of a mattress, the fiber cotton with a surface hot melt shaping is placed between the spring layer and the filling layer, playing a key isolation role. The spring layer provides the basic support for the mattress, while the filling layer is responsible for ensuring comfort and fitting. The presence of the fiber cotton with a surface hot melt shaping effectively prevents direct contact between the spring layer and the filling layer, reduces the extrusion and deformation of the spring on the filling layer, and thus significantly extends the service life of the mattress. In addition, the softness and resilience of the fiber cotton with a surface hot melt shaping further improve the overall comfort of the mattress, bringing a more gentle sleep experience to users. At the same time, the fiber cotton with a surface hot melt shaping has good antibacterial and anti-mite properties, which helps to keep the mattress clean and hygienic, and provides a healthier sleep environment for users. Its light weight also makes the mattress more convenient to handle and clean.
[0004] In the prior art, after the fiber cotton with a surface hot melt shaping is produced, a layer of non-woven fabric is usually adhered to the surface of the fiber cotton with a surface hot melt shaping through a thermal compounding process. The specific method is to thermally bond the non-woven fabric to the surface of the fiber cotton with a surface hot melt shaping using glue to form a protective layer. The main purpose of this protective layer is to enhance the tensile strength of the fiber cotton with a surface hot melt shaping, prevent it from being damaged due to stretching or friction during use, and thus improve the durability and stability of the material.
[0005] Although the traditional technology can improve the tensile ability of the fiber cotton with a surface hot melt shaping to a certain extent, it has the following significant disadvantages, which limit the production efficiency and application value: 1: The processing cost is high. Using glue and non-woven fabric increases the additional material cost. At the same time, the thermal compounding process requires independent processing steps, including glue coating, compounding and curing, etc. These steps not only extend the production cycle, but also require additional equipment and manual operations, resulting in a significant increase in the overall processing cost.
[0006] 2: Chemical pollution problem. The glue used in traditional methods usually contains volatile organic compounds (VOCs), which may release harmful chemicals during production and use. This not only pollutes the environment but also poses a potential threat to human health. Especially in products like mattresses that come into long-term contact with the human body, the chemical pollution problem is particularly prominent.
[0007] 3: Process complexity: The glue hot compounding process increases the complexity of the production process. Specialized equipment is required to apply the glue, precisely align the non-woven fabric, and complete the hot pressing. This process not only reduces production efficiency but may also lead to inconsistent product quality due to improper operation, such as poor adhesion or peeling of the protective layer. Therefore, it is necessary to make further improvements. Summary of the Invention
[0008] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide a production method for surface hot-melt shaped fiber cotton that is simple in structure, convenient to use, can form an effective protective layer for the surface hot-melt shaped fiber cotton without using glue and non-woven fabric, while reducing production costs, reducing chemical pollution, and simplifying the process flow to meet the requirements of modern mattress manufacturing for efficient, environmentally friendly, and high-performance materials.
[0009] The purpose of the present invention is achieved in the following way: A production method for surface hot-melt shaped fiber cotton, comprising the following steps: S1: Provide a fiber mat; S2: The fiber mat enters a hot rolling roll, and the hot rolling roll hot-rolls the fiber mat at a temperature of 160°C - 240°C to form a dense surface hot-melt shaped fiber cotton substrate; S3: The surface hot-melt shaped fiber cotton substrate enters a cold roll for cooling. When the surface temperature of the surface hot-melt shaped fiber cotton substrate is 100 - 150°C, a cold roll with a temperature of 0 - 40°C is used to roll one surface of the surface hot-melt shaped fiber cotton substrate to quickly cool and shape the surface fibers, thereby forming a protective layer; S4: The surface hot-melt shaped fiber cotton is cooled and rolled into a rolled product.
[0010] Further: The pressure of the cold roll is 10 - 50 kN / m, and the rolling speed of the cold roll is 5 - 20 m / min.
[0011] Further: The temperature of the cold roll is 10°C.
[0012] Further: The rolling pressure of the cold roll is 30 kN / m.
[0013] Further: The rolling speed of the cold roll is 10 m / min.
[0014] The fiber mat described above is a needle-punched fiber mat composed of polyester and polypropylene fibers.
[0015] Furthermore: The hot rolling rolls include a first hot rolling roll and a second hot rolling roll which are relatively installed. After the fiber mat to be hot rolled bypasses the first hot rolling roll, it enters the second hot rolling roll. The first hot rolling roll heats the first surface of the fiber mat, and the second hot rolling roll heats the second surface of the fiber mat; The cold roll is installed on one side of the second hot rolling roll, and the cold roll cools the first surface of the fiber mat substrate with hot melt shaping on the surface. The beneficial effects of the present invention are: 1. The structure is simple, the production cost is low, and the market competitiveness is improved.
[0016] 2. After the hot rolling of the fiber mat with hot melt shaping on the surface is completed, the cold roll is used to roll the high-temperature surface, so that the surface fibers are quickly cooled and shaped, forming a dense protective layer. This process is carried out synchronously with the production of the fiber mat with hot melt shaping on the surface, and no additional composite process is required. Compared with the traditional technology of forming a protective layer by thermally compounding non-woven fabric with glue, this technology simplifies the process flow, eliminates the independent bonding step, shortens the production time, and improves the production efficiency.
[0017] 3. The traditional technology relies on glue to bond non-woven fabric, and the volatile organic compounds (VOCs) contained in the glue will be released during production and use, causing chemical pollution. This technology completely eliminates the use of glue and non-woven fabric, avoids VOC emissions, and meets the requirements of green manufacturing and environmental protection.
[0018] 4. There is no need to purchase glue and non-woven fabric, which significantly reduces the material cost. Estimated at market prices, the traditional technology requires an additional cost of about ¥0.6 per square meter of fiber mat with hot melt shaping on the surface for glue and non-woven fabric, while this technology only increases a small amount of energy consumption (about ¥0.1 / m²) through the cold roll process, and the comprehensive cost is reduced by about ¥0.5 / m².
[0019] 5. The rapid cooling of the cold roll makes the surface fibers more dense, enhances the physical bonding force between the fibers, and effectively improves the compressive and wear-resistant properties.
[0020] 6. The protective layer and the cotton layer are made of the same material, and compared with non-woven fabric, it has a longer service life. Description of the Drawings
[0021] Figure 1 This is the distribution diagram of the hot rolling rolls in the present invention.
[0022] Figure 2 This is the cross-sectional view of the finished product structure of the fiber mat with hot melt shaping on the surface in the present invention. Detailed Embodiments
[0023] The following further describes the present invention in detail with reference to the drawings. A production method of a fiber mat with hot melt shaping on the surface includes the following steps: This method produces surface hot-melt shaped fiber cotton through the following steps: S1: Provide fiber mat 1 as the raw material basis for subsequent processing. The fiber mat is usually made of polyester and polypropylene fibers through a needling process, with a uniform structure and preliminary strength, laying the foundation for hot rolling and cold roll treatment.
[0024] S2: Fiber mat 1 enters the hot rolling roll and is hot rolled at a temperature of 160°C - 240°C. The high temperature and pressure soften the fibers and make them closely combine to form a dense surface hot-melt shaped fiber cotton substrate 2. This step ensures that the fibers inside the material are fully bonded and have a uniform density.
[0025] S3: Immediately after hot rolling, when the surface temperature of the surface hot-melt shaped fiber cotton substrate 2 is 100 - 150°C, use a cold roll 3 with a temperature of 0 - 40°C to roll one surface of it. The rapid contact between the low temperature of the cold roll and the high temperature surface causes the surface fibers to cool and solidify rapidly, forming a dense protective layer 4. This process utilizes the temperature difference (up to 150°C) to achieve rapid freezing and compaction of the fiber molecular chains.
[0026] S4: After the surface hot-melt shaped fiber cotton cools to room temperature, it is rolled into a finished coil, completing the production process.
[0027] In this process, the hot rolling temperature is 160°C - 240°C.
[0028] The surface temperature of the surface hot-melt shaped fiber cotton is 100 - 150°C.
[0029] The temperature of the cold roll is 0 - 40°C.
[0030] Compared with traditional technologies, the protective layer in this case is formed synchronously by cold roll rolling during the production process, eliminating the need for additional glue or non-woven fabric lamination processes, simplifying the process flow, and reducing production time.
[0031] Performance improvement: Experimental data shows that this protective layer enables the surface hot-melt shaped fiber cotton to have a longitudinal tensile strength of 160 N / cm (150 N / cm for traditional technologies), and the surface hardness is increased to 70 Shore A (60 Shore A for traditional ones).
[0032] Cost and environmental protection advantages: Eliminating glue and non-woven fabrics saves about ¥0.5 in material cost per square meter, and at the same time avoids the emission of volatile organic compounds (VOCs), meeting the green manufacturing standards.
[0033] In one embodiment, the cold roller 3 applies a pressure of 10 - 50 kN / m during the rolling process, and the rolling speed is controlled at 5 - 20 m / min. The pressure ensures that the surface fibers are fully compacted, and the speed matches the continuity of the production line. Their combined action makes the protective layer uniform and dense. The appropriate pressure and speed avoid the phenomena of excessive fiber extrusion or uneven cooling.
[0034] During this process, the required cold roller pressure is: 10 - 50 kN / m.
[0035] Rolling speed: 5 - 20 m / min.
[0036] Compared with the traditional technology, optimized performance parameters are used in this case. Specifically: when the pressure is 30 kN / m, the thickness of the protective layer is uniform, and the internal stress is controlled below 180 MPa (the safety threshold < 200 MPa), avoiding microcracks. When the speed is 10 m / min, the cooling efficiency is optimal, and the production efficiency is increased by about 10%.
[0037] In addition, it also helps to improve the performance: the porosity of its protective layer is reduced to 5% (8% in the traditional technology), significantly enhancing the waterproof property, and the hydrostatic pressure resistance is increased from 10 kPa to 15 kPa. The uniform pressure and speed ensure the consistency of product quality and are suitable for large-scale production.
[0038] In one embodiment, the temperature of the cold roller is set at 10 °C, forming a large temperature difference (90 - 140 °C) with the surface temperature of the hot-melt shaped fiber cotton (100 - 150 °C). This temperature difference ensures the rapid cooling and solidification of the surface fibers, and the fiber crystallinity is controlled at 40 - 45%, forming a hard protective layer while retaining a certain degree of flexibility.
[0039] In this embodiment, the cold roller temperature of 10 °C is preferably used to quickly shape the surface fibers. After calculation by the applicant, the surface hardness is increased to 70 Shore A, and the tensile strength is increased by 6.7%. At the same time, the rebound rate only slightly decreases from 85% to 83% (a decrease of 2.4%), maintaining the softness of the hot-melt shaped fiber cotton as a mattress auxiliary material while significantly enhancing the surface protection ability. Therefore, 10 °C is the optimized value, avoiding problems such as frosting that may be caused by too low a temperature (such as 0 °C) or insufficient cooling due to too high a temperature (such as 40 °C).
[0040] In one embodiment: the rolling pressure of the cold roller is set at 30 kN / m. This pressure moderately compacts the surface fibers during the cooling process, forming a dense structure while avoiding the accumulation of internal stress or fiber damage caused by excessive extrusion.
[0041] In this embodiment, when the internal stress is controlled to 30 kN / m, the internal stress remains below 180 MPa (far lower than the safety threshold of 200 MPa), ensuring no cracking risk during long-term use. At the same time, the surface roughness Ra after rolling is reduced to 5.2 μm (8.6 μm in the traditional technology), the contact angle is increased to 110°, and the waterproof performance is significantly improved. In this implementation, moderate pressure does not require high-energy-consuming equipment, reducing the production cost.
[0042] In one of the embodiments, the cold roll rolling speed is 10 m / min, which matches the speed of the hot rolling production line, ensuring the continuity of the production process. The appropriate speed makes the cooling and compaction effects uniform, avoiding quality inconsistencies caused by being too fast or too slow.
[0043] In one of the embodiments, the fiber mat 1 is made of polyester and polypropylene fibers through a needling process. The polyester fibers provide strength and durability, the polypropylene fibers enhance flexibility, and the needling reinforcement makes the fiber distribution uniform, providing a stable substrate for subsequent hot rolling and cold roll treatment.
[0044] For example, the needling density of the fiber mat 1 is about 200 punches / cm².
[0045] The substrate density is 0.25 g / cm³.
[0046] In this embodiment, through the applicant's calculation, the combination of polyester and polypropylene endows the surface hot-melt shaped fiber felt with excellent resilience (up to 85%) and strength. The needling process ensures the uniformity of the fiber mat, and the uniform fiber mat facilitates the formation of a consistent protective layer and substrate structure during hot rolling and cold roll treatment.
[0047] As Figure 1 shown, in one of the embodiments, the hot rolling roll includes a first hot rolling roll 5 and a second hot rolling roll 6, which heat the first side and the second side of the fiber mat 1 respectively, ensuring uniform heating on both sides and forming the surface hot-melt shaped fiber felt substrate 2.
[0048] It should be noted that: The cold roll is installed on one side of the second hot rolling roll 6, and the first side of the surface hot-melt shaped fiber felt substrate 2 is rolled and cooled to form the protective layer 4. This configuration utilizes the high-temperature state after hot rolling to immediately cool one side and retain the softness of the other side. Thus, when the surface hot-melt shaped fiber felt substrate 2 is used, the side with the protective layer 4 is used as the connection surface, and the side without the protective layer 4 is used as the contact surface for users, ensuring the use texture.
[0049] In this embodiment, the first and second hot rolling rollers ensure that the fibers inside the base material are fully bonded, with uniform density, thereby enhancing the overall strength. The cold roller only cools the first surface, forming an asymmetric protective layer and retaining the softness of the second surface, meeting the dual requirements of the mattress for support and comfort. At the same time, the compact configuration of the hot rolling and the cold roller reduces intermediate links, and the production efficiency is increased by about 10%.
[0050] In summary, in this case, the production working principle of the surface hot melt shaped fiber cotton is based on physical processing and temperature control. Through three core steps of needle punching reinforcement, hot rolling densification, and cold roller rolling for rapid cooling, a protective layer is formed synchronously during the production process. The key lies in utilizing the temperature difference between the high temperature after hot rolling and the low temperature of the cold roller, combined with appropriate pressure, to optimize the surface fiber structure and replace the traditional glue composite non-woven fabric process. This method not only enhances the tensile strength, hardness, wear resistance, and waterproofness of the surface hot melt shaped fiber cotton, but also reduces costs and realizes environmentally friendly production, having significant technical advantages and industrial application value.
[0051] Obviously, the above embodiments are merely examples given for clear illustration and are not limitations on the implementation manners. For those of ordinary skill in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to enumerate all implementation manners here. And the obvious changes or modifications derived therefrom still fall within the protection scope of the claims of the present invention.
Claims
1. A method for producing surface hot-melt-set fiber cotton, characterized in that: The following steps are involved: S1: Provide fiber mat (1); S2: the fiber mat (1) enters a hot rolling roller, and the hot rolling roller hot-rolls the fiber mat (1) at a temperature of 160° C. to 240° C. to form a dense surface heat-melt-shaped fiber cotton substrate (2); S3: the surface heat-melt-set fiber cotton substrate (2) enters a cold roller (3) for cooling. When the surface temperature of the surface heat-melt-set fiber cotton substrate (2) is 100-150° C., a cold roller (3) with a temperature of 0-40° C. is used to roll a surface of the surface heat-melt-set fiber cotton substrate (2) to quickly cool and set the surface fibers, thereby forming a protective layer (4); S4: The surface heat-melted fiber sponge is cooled and rolled into a finished coil.
2. The method for producing a surface heat-melt-set fiber sponge according to claim 1, characterized in that: The pressure of the cold roller (3) is 10-50 kN / m, and the rolling speed of the cold roller (3) is 5-20 m / min.
3. The method for producing a surface heat-melt-set fiber sponge according to claim 1, characterized in that: The temperature of the cold roller (3) is 10°C.
4. The method for producing a surface heat-melt-set fiber sponge according to claim 1, characterized in that: The rolling pressure of the cold roller (3) is 30 kN / m.
5. The method for producing a surface heat-melt-set fiber sponge according to claim 1, characterized in that: The rolling speed of the cold roller (3) is 10 m / min.
6. The method for producing a surface heat-melt-set fiber sponge according to claim 1, characterized in that: The fiber mat (1) is a needle-punched fiber mat composed of polyester and polypropylene fibers.
7. The method for producing a surface heat-melt-set fiber sponge according to claim 1, characterized in that: The hot calendering rollers include a first hot calendering roller (5) and a second hot calendering roller (6) which are relatively mounted. The fiber mat (1) to be hot calendered passes around the first hot calendering roller (5) and enters the second hot calendering roller (6). The first hot calendering roller (5) heats the first side of the fiber mat (1), and the second hot calendering roller (6) heats the second side of the fiber mat (1). The cold roller (3) is mounted on one side of the second hot calendering roller (6), and the cold roller (3) cools the first side of the surface heat-melted fiber cotton substrate (2).