Waterproof mattress and preparation process of waterproof breathable layer

Abstract

The waterproof mattress comprises a spring supporting layer, the waterproof breathable layer, a comfortable layer and a surrounding edge, the waterproof breathable layer is arranged on the spring supporting layer, the comfortable layer is arranged on one side of the spring supporting layer of the waterproof breathable layer of the waterproof mattress, and the surrounding edge is arranged around the spring supporting layer. The prepared waterproof mattress can effectively prevent urine, beverages and other liquid from penetrating through the comfortable layer and directly penetrating into the spring supporting layer below the comfortable layer, the service life of the core structure of the mattress is greatly prolonged, in addition, the waterproof breathable layer has a one-way breathable function, and the waterproof breathable layer is not prone to falling off. Sweat gas and hot gas generated during sleeping of a human body can be emitted outwards through the layer, so that the back of a sleeper is prevented from being wet, the problem that a traditional waterproof product is stuffy and airtight is solved, and the sleeping comfort is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile mattress, and further relates to a waterproof mattress and a preparation process of a waterproof and breathable layer. BACKGROUND

[0002] Bed mattress is an indispensable sleep product in daily life, and its quality and function directly affect the health and comfort experience of users. With the continuous improvement of consumer demand, multifunctional mattress gradually becomes the mainstream of the market. However, a serious but often overlooked problem exists in most traditional mattresses during long-term use, that is, the lack of effective waterproof function, which not only affects the service life of the mattress, but also poses multiple threats to the health of users.

[0003] Therefore, it is urgent to develop a waterproof mattress and a preparation process of a waterproof and breathable layer to solve the technical problems in the prior art. SUMMARY

[0004] In view of the above technical problems, the purpose of the present application is to provide a waterproof mattress which can solve the problems proposed in the background art.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme:

[0006] The present application provides a waterproof mattress, comprising:

[0007] a spring support layer;

[0008] a waterproof and breathable layer, which is arranged on the spring support layer;

[0009] a comfort layer, which is arranged on the waterproof and breathable layer away from the spring support layer;

[0010] a surrounding edge, which is arranged around the spring support layer and is detachably connected with the waterproof and breathable layer.

[0011] In some embodiments, the surrounding edge comprises a first high-hardness foam piece and a second high-hardness foam piece, and the first high-hardness foam piece and the second high-hardness foam piece are connected in a head-to-tail occlusion manner.

[0012] In some embodiments, the waterproof and breathable layer comprises a double-layer high-density cloth layer and a nano waterproof and breathable film layer, the double-layer high-density cloth layer is arranged on one side of the waterproof and breathable layer close to the spring support layer, and the nano waterproof and breathable film is arranged on one side of the waterproof and breathable layer close to the comfort layer.

[0013] In some embodiments, a copper ion layer is arranged between the double-layer high-density cloth layer and the nano waterproof and breathable film layer.

[0014] In some embodiments, the double high-density cloth layer is formed by stacking two high-density textile cloths.

[0015] In some embodiments, the waterproof and breathable layer is connected to the surrounding edge through a zipper.

[0016] In some embodiments, the comfort layer is a cotton and linen blended material.

[0017] According to another aspect of the present application, the present application further provides a preparation process of a waterproof and breathable layer, for preparing the waterproof and breathable layer in the waterproof mattress as described in the above embodiments, comprising the following steps:

[0018] S1, first form a point-like fixed connection structure by ultrasonic welding process to obtain a double high-density cloth layer;

[0019] S2, composite a nano waterproof and breathable film layer on one side surface of the double high-density cloth layer through a high-temperature and high-pressure hot pressing process.

[0020] In some embodiments, the temperature of the high-temperature and high-pressure hot pressing process is 110-150℃, the pressure of the high-temperature and high-pressure hot pressing process is 0.3-0.8MPa, and the hot pressing time of the high-temperature and high-pressure hot pressing process is 30-120 seconds.

[0021] In some embodiments, the nano waterproof and breathable film layer is any one of a polytetrafluoroethylene stretched film, a polyurethane nano film, or a hot-pressed composite nanofiber film.

[0022] Compared with the prior art, the waterproof mattress provided by the present application has the following beneficial effects:

[0023] 1. The waterproof mattress provided by the present application is connected to the surrounding edge through the waterproof and breathable layer, the waterproof and breathable layer completely covers the spring support layer and forms a huge waterproof isolation structure through the sealed connection with the surrounding edge, so that the spring support layer is prevented from being exposed, effectively preventing liquids such as urine and beverages from penetrating through the comfort layer and directly seeping into the spring support layer below, thereby preventing the spring from rusting and internal mold and mite growth, greatly prolonging the service life of the core structure of the mattress, and in addition, the waterproof and breathable layer has a one-way ventilation function, allowing the sweat and heat generated by the human body during sleep to be dissipated outward through the layer, avoiding the accumulation of dampness on the back of the sleeper, solving the problem of stuffiness and poor ventilation of traditional waterproof products, and improving the sleep comfort.

[0024] 2. The waterproof mattress provided by the present application uses a first high-hardness foam piece and a second high-hardness foam piece for the surrounding edge, and connects them through a unique head-tail occlusion connection method, instead of traditional gluing or sewing, effectively enhancing the overall structure, while reducing costs and providing convenience for installation and transportation.

[0025] 3、The waterproof mattress provided by the application greatly improves the mechanical strength, tear resistance and friction resistance of the composite layer by setting a double-layer high-density cloth layer structure, and the copper ion layer added has a significant inhibitory and killing effect on bacteria, fungi and mites in contact, thereby providing strong protection for the health of users.

[0026] 4、The preparation process of the waterproof mattress provided by the application realizes the need for not using any chemical adhesive by specific process parameters, and the material is fused at the molecular layer by high-frequency vibration friction heat generation, the connection point is firm, environmentally friendly and non-toxic, and the spot welding method avoids the hardening and hardening problem caused by overall gluing, greatly retains the original flexibility and air gap of the textile, thereby improving the flexibility of the hooking wire to ensure the bonding strength of the carpet bonding layer, and thereby improving the market competitiveness of the final mattress product. BRIEF DESCRIPTION OF DRAWINGS

[0027] The drawings described herein are used to provide further understanding of the present application, and form a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application, and do not constitute an improper limitation on the present application. In the drawings:

[0028] Figure 1 is a schematic diagram of the overall structure of the present application;

[0029] Figure 2 is an exploded schematic diagram of the overall structure of the present application;

[0030] Figure 3 is a schematic diagram of the waterproof and breathable layer of the present application.

[0031] Explanation of reference numerals:

[0032] 10, comfort layer; 20, waterproof and breathable layer; 21, nano waterproof and breathable film layer; 22, copper ion layer; 23, high-density textile fabric; 30, surrounding edge; 31, first high-hardness foam piece; 32, second high-hardness foam piece; 40, spring support layer. DETAILED DESCRIPTION

[0033] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the specific embodiments of the present application will be described below with reference to the drawings. Obviously, the drawings described below are only some embodiments of the present application, and for those skilled in the art, other drawings can be obtained from these drawings without creative labor, and other embodiments can also be obtained.

[0034] The endpoints and any values ​​of the ranges disclosed in this invention are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this invention.

[0035] This invention provides a waterproof mattress, such as Figures 1-3 As shown, the mattress includes a spring support layer 40, a waterproof and breathable layer 20, a comfort layer 10, and a perimeter 30. The waterproof and breathable layer 20 is disposed on the spring support layer 40, the comfort layer 10 is disposed on one side of the spring support layer 40 of the waterproof and breathable layer 20 of the waterproof mattress, and the perimeter 30 is disposed around the spring support layer 40 and is detachably connected to the waterproof and breathable layer 20.

[0036] Specifically, the spring support layer 40 is made of multiple layers of plate springs to provide sufficient elasticity. Its size is adapted to the internal space of the edge 30 so that it can be stably placed in the edge 30. Preferably, it can be connected to the edge 30 by setting an elastic strap on the inside of the edge 30. The waterproof and breathable layer 20 is laid flat on top of the spring support layer 40. The edge of the waterproof and breathable layer 20 is detachably connected to the edge 30. The comfort layer 10 covers the waterproof and breathable layer 20. The edge 30 is a rectangular frame structure. The height of the edge 30 matches the overall thickness of the mattress so as to limit the deformation of the mattress and enhance the stability of the overall structure of the mattress.

[0037] In some embodiments, such as Figure 2 As shown, the edging 30 includes a first high-hardness foam component 31 and a second high-hardness foam component 32, which are connected end-to-end with each other.

[0038] Specifically, both the first high-hardness foam component 31 and the second high-hardness foam component 32 are cuboid structures with lengths matching the side lengths of the circumference 30. The two end faces of the first high-hardness foam component 31 are provided with stepped grooves, and the two end faces of the second foam component are provided with corresponding protruding tenons. The protruding tenons are inserted into the stepped grooves so that the first high-hardness foam component 31 and the second high-hardness foam component 32 are connected by a corresponding interlocking mechanism. In addition, the density of the foam components is usually 40-60D to balance support and comfort.

[0039] It should be noted that the first high-hardness foam component 31 and the second high-hardness foam component 32 can also be connected by mortise and tenon joints or by snap hooks. No limitation is made here; it depends on the actual needs.

[0040] In some embodiments, such as Figures 1-3 As shown, the waterproof and breathable layer 20 includes a double-layer high-density fabric layer and a nano waterproof and breathable membrane layer 21. The double-layer high-density fabric layer is disposed on the side of the waterproof and breathable layer 20 near the spring support layer 40, and the nano waterproof and breathable membrane is disposed on the side of the waterproof and breathable layer 20 near the comfort layer 10.

[0041] Specifically, the double-layer high-density fabric layer consists of two layers of fabric stacked on top of each other. The double-layer high-density fabric layer and the nano waterproof and breathable membrane layer 21 are bonded to the double-layer high-density fabric layer with an adhesive. The double-layer high-density fabric layer significantly improves the tear resistance and durability of the waterproof and breathable layer 20. In addition, the microporous structure of the nano membrane has both waterproof and breathable functions. It can block rainwater and sweat from penetrating into the spring support layer 40, while allowing water vapor exhaled by the human body to be quickly discharged, keeping the inside of the mattress dry, inhibiting the growth of mold, and greatly enhancing the overall performance of the mattress.

[0042] In some embodiments, such as Figure 3 As shown, a copper ion layer 22 is provided between the double-layer high-density fabric layer and the nano waterproof and breathable membrane layer 21.

[0043] Specifically, the copper ion layer 22 is loaded onto the surface of the double-layer high-density fabric layer near the nano-waterproof and breathable membrane through an impregnation process. After impregnation, it is dried and cured to make the copper ion layer 22 evenly dispersed in the gaps between the fabric fibers. Copper ions have antibacterial properties against common bacteria such as Escherichia coli and Staphylococcus aureus, which can inhibit the growth of microorganisms inside the mattress due to sweat and skin residue, thereby improving the hygiene and safety performance of the mattress.

[0044] In some embodiments, the double high-density fabric layer is composed of two layers of high-density textile fabric 23 stacked together.

[0045] Specifically, each layer of the double-layer high-density fabric is woven from warp and weft yarns, both of which are high-count polyester fibers, greatly improving the tear resistance of the double-layer high-density fabric and thus extending the service life of the waterproof and breathable layer 20. The two layers of fabric are bonded together by a hot-pressing process, which avoids sewing to eliminate seam holes, thereby further enhancing the overall waterproofness while maintaining the softness of the fabric.

[0046] In some embodiments, such as Figures 1-3 As shown, the waterproof and breathable layer 20 is connected to the edge 30 by a zipper.

[0047] Specifically, the zipper is preferably an invisible waterproof zipper, with one zipper tape set along the inner edge of the edging 30 and its length matching the perimeter of the edging 30. Another zipper tape is sewn onto the edge of the waterproof and breathable layer 20, and the zipper tape on the waterproof and breathable layer 20 is aligned and engaged with the zipper tape on the edging 30. The zipper setting enables quick disassembly and removal, thereby facilitating the individual replacement or cleaning of the waterproof and breathable layer 20.

[0048] In some embodiments, the comfort layer 10 is made of a cotton-linen blend.

[0049] Specifically, the comfort layer 10 is made of a cotton-linen blend fabric, wherein the ratio of cotton fiber to linen fiber in the cotton-linen blend fabric is preferably 6:4, so as to balance the softness of cotton fiber and the high breathability of linen fiber, effectively improving the comfort of the body during sleep. In addition, the comfort layer 10 can be treated with anti-mite treatment to further improve the hygiene of the mattress, making the mattress suitable for sensitive people, thereby enhancing the market competitiveness of the mattress product.

[0050] The present application will be further described in detail below with reference to embodiments and comparative examples.

[0051] Examples 1-4 and Comparative Examples 1-2 provide waterproof mattresses and methods for their preparation.

[0052] Example 1 provides a waterproof mattress and its preparation method, including the following steps:

[0053] Step 1: First, the two high-density fabric layers are formed into a point-fixed connection structure through ultrasonic welding to obtain a double-layer high-density fabric layer.

[0054] Step 2: The nano waterproof and breathable membrane layer is subjected to high-temperature and high-pressure hot pressing treatment at a temperature of 130℃ and a pressure of 0.5MPa for 60 seconds, so that the nano waterproof and breathable membrane layer is composited on one side of the double-layer high-density fabric layer.

[0055] Example 2

[0056] Example 2 provides a waterproof mattress and its preparation method, including the following steps:

[0057] Step 1: First, the two high-density fabric layers are formed into a point-fixed connection structure through ultrasonic welding to obtain a double-layer high-density fabric layer.

[0058] Step 2: The nano waterproof and breathable membrane layer is subjected to high-temperature and high-pressure hot pressing treatment at a temperature of 150℃ and a pressure of 0.8MPa for 120 seconds, so that the nano waterproof and breathable membrane layer is composited on one side of the double-layer high-density fabric layer.

[0059] Comparative Example 1

[0060] Comparative Example 1 provides a waterproof mattress and its preparation method, comprising the following steps:

[0061] Step 1: First, the two high-density fabric layers are welded together to form a fixed connection structure to obtain a double-layer high-density fabric layer;

[0062] Step 2: The nano waterproof and breathable membrane layer is subjected to high-temperature and high-pressure hot pressing treatment at a temperature of 130℃ and a pressure of 0.5MPa for 60 seconds, so that the nano waterproof and breathable membrane layer is composited on one side of the double-layer high-density fabric layer.

[0063] Comparative Example 2

[0064] Comparative Example 2 provides a waterproof mattress and its preparation method, comprising the following steps:

[0065] Step 1: First, the two high-density fabric layers are formed into a point-fixed connection structure through ultrasonic welding to obtain a double-layer high-density fabric layer.

[0066] Step 2: The nano waterproof and breathable membrane layer is subjected to high-temperature and high-pressure hot pressing treatment at a temperature of 200℃ and a pressure of 0.8MPa for 120 seconds, so that the nano waterproof and breathable membrane layer is composited on one side of the double-layer high-density fabric layer.

[0067] Comparative Example 3

[0068] Comparative Example 3 provides a waterproof mattress and its preparation method, comprising the following steps:

[0069] Step 1: First, the two high-density fabric layers are formed into a fixed connection structure through ultrasonic welding to obtain a double-layer high-density fabric layer.

[0070] Step 2: The nano waterproof and breathable membrane layer is subjected to high-temperature and high-pressure hot pressing treatment at a temperature of 130℃ and a pressure of 2MPa for 60 seconds, so that the nano waterproof and breathable membrane layer is composited on one side of the double-layer high-density fabric layer.

[0071] Comparative Example 4

[0072] Comparative Example 4 provides a waterproof mattress and its preparation method, comprising the following steps:

[0073] Step 1: First, the two high-density fabric layers are formed into a fixed connection structure through ultrasonic welding to obtain a double-layer high-density fabric layer.

[0074] Step 2: The nano waterproof and breathable membrane layer is subjected to high-temperature and high-pressure hot pressing treatment at a temperature of 130℃ and a pressure of 0.5MPa for 200 seconds, so that the nano waterproof and breathable membrane layer is composited on one side of the double-layer high-density fabric layer.

[0075] Performance testing

[0076] The waterproof mattresses prepared in Examples 1-2 and Comparative Examples 1-4 were tested for waterproof performance, breathability, and structural strength. The waterproof performance was tested according to GB / T18944.1-2003 "Polymer Porous Elastic Materials - Sponge and Porous Rubber Products" for water absorption rate. The breathability was tested according to GB / T 10655-2003 "Determination of Air Permeability of Polymer Porous Elastic Materials" for air permeability. The structural strength was tested according to GB / T528-2009 "Determination of Tensile Stress-Strain Properties of Vulcanized Rubber or Thermoplastic Rubber". The results are shown in Table 1.

[0077] Table 1

[0078] Experimental group Water absorption rate (%) Air permeability (%) Tensile strength (kg / cm2) Example 1 4.7 88.7 8.5 Example 2 4.4 85.9 8.7 Comparative Example 1 6.1 91.3 3.7 Comparative Example 2 2.1 71.9 4.4 Comparative Example 3 2.2 66.2 4.8 Comparative Example 4 2.7 68.6 4.7

[0079] As can be seen from Table 1, compared with Comparative Examples 1, 3 and 4, the waterproof mattress prepared in Example 1 has stronger waterproof performance, breathability and structural strength. Compared with Comparative Example 2, the waterproof mattress prepared in Example 12 has significantly better waterproof performance, breathability and structural strength. In summary, the waterproof mattress prepared by the preparation method provided by the present invention has better bonding strength, is more durable and has a longer service life, and has more comfortable softness.

[0080] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A waterproof mattress, characterized in that, include: Spring support layer; A waterproof and breathable layer is disposed on the spring support layer; A comfort layer is disposed on the side of the waterproof and breathable layer away from the spring support layer; The edging surrounds the spring support layer and is detachably connected to the waterproof and breathable layer.

2. The waterproof mattress according to claim 1, characterized in that, The edging includes a first high-hardness foam component and a second high-hardness foam component, which are connected end-to-end with each other.

3. The waterproof mattress according to claim 2, characterized in that, The waterproof and breathable layer includes a double-layer high-density fabric layer and a nano waterproof and breathable membrane layer. The double-layer high-density fabric layer is disposed on the waterproof and breathable layer on the side close to the spring support layer, and the nano waterproof and breathable membrane is disposed on the waterproof and breathable layer on the side close to the comfort layer.

4. The waterproof mattress according to claim 3, characterized in that, A copper ion layer is disposed between the double-layer high-density fabric layer and the nano waterproof and breathable membrane layer.

5. The waterproof mattress according to claim 4, characterized in that, The double-layer high-density fabric is composed of two layers of high-density textile fabric stacked together.

6. The waterproof mattress according to claim 4, characterized in that, The waterproof and breathable layer is connected to the edging via a zipper.

7. The waterproof mattress according to any one of claims 1-6, characterized in that, The comfort layer is made of a cotton-linen blend.

8. A process for preparing a waterproof and breathable layer, used to prepare the waterproof and breathable layer in the waterproof mattress as described in claims 1-7, characterized in that, Includes the following steps: S1. First, two high-density fabric layers are formed into a point-fixed connection structure by ultrasonic welding to obtain a double-layer high-density fabric layer. S2. The nano-waterproof and breathable membrane layer is composited onto one side surface of the double-layer high-density fabric layer through a high-temperature and high-pressure hot-pressing process.

9. The waterproof mattress according to claim 8, characterized in that, The temperature of the high-temperature and high-pressure hot pressing process is 110-150℃, the pressure of the high-temperature and high-pressure hot pressing process is 0.3-0.8MPa, and the hot pressing time of the high-temperature and high-pressure hot pressing process is 30-120 seconds.

10. The waterproof mattress according to claim 9, characterized in that, The nano-waterproof and breathable membrane layer is any one of polytetrafluoroethylene stretch membrane, polyurethane nanofilm, or hot-pressed composite nanofiber membrane.

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