Manufacturing method of personalized spacer fabric mattress

Abstract

The invention relates to a manufacturing method of a personalized spacer fabric mattress, belongs to the technical field of mattress manufacturing, and solves the problems that in the prior art, the personalized customization efficiency of a mattress is low, the precision is poor, the cost is high, and comfort, elastic recovery and durability are difficult to consider at the same time. Comprising the following steps: acquiring human body data of a customer, performing regional division on a to-be-manufactured mattress based on the human body data, and obtaining personalized target parameters of each divided region of the to-be-manufactured mattress; on the basis of the personalized target parameters of all the divided areas of the mattress to be manufactured, the expected settlement amount and equivalent stress of all the divided areas are obtained, and then the target supporting rigidity of all the divided areas is obtained; and based on the target support stiffness of each divided area, obtaining an optimal design parameter combination of each divided area of the mattress to be manufactured, and further obtaining the personalized spacer fabric mattress of the customer.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mattress manufacturing, and particularly relates to a manufacturing method of an individualized spacer fabric mattress. BACKGROUND

[0002] With the increasing demand for individualized sleep quality, traditional standardized mattresses are difficult to meet the comprehensive requirements of support, comfort and durability for people of different body types, weights and sleeping posture preferences. 3D spacer fabric mattresses provide the possibility for individualized customization due to their strong designability and good air permeability, but existing technologies lack systematic and intelligent solutions and fail to accurately design and efficiently manufacture spacer fabric mattresses that meet the unique needs of individuals based on individual data.

[0003] Currently, the technical solutions related to individualized mattresses mainly have the following limitations:

[0004] Standardized partitioned mattress: Some mattresses use the concept of partitioning (such as head, shoulder, waist, hip, leg area), and use different hardness materials (such as different density foams or different parameter springs); but the partitioning is preset and fixed, and cannot accurately match the individual body types and pressure distribution, and the transition between partitions may not be natural; for spacer fabric mattresses, there is a lack of ability to dynamically adjust the fabric parameters (such as spacer yarn diameter, density, lapping angle, mesh structure) of each area based on individual data.

[0005] Limited customization options: Some mattresses offer size, surface hardness (overall or partitioned) options, but the adjustable parameters are very limited, usually based on simple height and weight ranges or subjective preference selection, lacking collection and analysis of key data such as individual spine curves, pressure distribution, and sleep habits, and unable to achieve true "tailor-made".

[0006] Dependence on manual measurement and design: A few customization services rely on technicians to manually measure and make experience-based judgments, which is a tedious, time-consuming and costly process with strong subjectivity and difficulty in standardization and scaling. It is difficult to quickly generate accurate manufacturing parameter instructions.

[0007] Low manufacturing efficiency: Even with customized design, traditional manufacturing methods (such as cutting and splicing different blocks) cannot achieve seamless weaving based on individualized parameters, resulting in low production efficiency, high cost, and possible impact on structural stability, limiting the feasibility of large-scale individualized customization. SUMMARY

[0008] In view of the above analysis, the embodiments of the present application aim to provide a manufacturing method of an individualized spacer fabric mattress to solve the problems of low efficiency, poor precision, high cost, and difficulty in simultaneously considering comfort, elastic recovery and durability in existing mattress individualized customization.

[0009] The embodiment of the present application provides a personalized spacer fabric mattress manufacturing method, comprising:

[0010] Obtaining human body data of a customer, performing regional division on a mattress to be manufactured based on the human body data and obtaining personalized target parameters of each divided region of the mattress to be manufactured;

[0011] Based on the personalized target parameters of each divided region of the mattress to be manufactured, obtaining expected settlement amounts and equivalent forces of each divided region, and then obtaining target support stiffnesses of each divided region;

[0012] Based on the target support stiffnesses of each divided region, obtaining optimal design parameter combinations of each divided region of the mattress to be manufactured, and then obtaining a personalized spacer fabric mattress of the customer.

[0013] Further, the human body data comprises basic physiological data, key body size data, spine curve data, body pressure distribution data and lying posture preference data; the personalized target parameters comprise areas of each divided region, body type factors, spine curvature angles, support demand indexes, lying posture average pressures and lying posture fusion average pressures, wherein the lying posture average pressures comprise supine average pressures and lateral lying average pressures.

[0014] Further, the mattress to be manufactured comprises a plurality of superimposed fabric layers, and the optimal design parameter combinations of each divided region comprise optimal design parameter combinations of each fabric layer;

[0015] The optimal design parameter combinations of each divided region of the mattress to be manufactured are obtained in the following manner:

[0016] Based on the target support stiffnesses of each divided region, layer target support stiffnesses of each fabric layer in each divided region are obtained;

[0017] Based on the layer target support stiffnesses of each fabric layer in each divided region and the constructed elastic recovery optimization model, the optimal design parameter combinations of each fabric layer in each divided region of the mattress to be manufactured are obtained.

[0018] Further, the elastic recovery optimization model comprises a multi-objective function and a fabric parameter performance database; wherein each element in the fabric parameter performance database comprises a design parameter combination and corresponding fabric support stiffness and elastic recovery rate; and the multi-objective function is expressed as:

[0019]

[0020] In the formula, ΔH represents an absolute deviation of a mattress target support stiffness and an actual support stiffness, η avg represents an average elastic recovery rate of the mattress, represents a fabric support stiffness of a fabric layer i in a divided region j, denotes the layer target support stiffness of the fabric layer i in the division region j, η j,i denotes the elastic recovery rate of the fabric layer i in the division region j, K denotes the set of division regions of the mattress to be made, N denotes the set of fabric layers of the mattress to be made, k denotes the number of elements in the set of division regions of the mattress to be made, n denotes the number of elements in the set of fabric layers of the mattress to be made, and || denotes the absolute value.

[0021] Further, the layer target support stiffness of each fabric layer in each division region is denoted as:

[0022]

[0023] In the formula, H denotes the layer target support stiffness of the fabric layer i in the division region j, H j denotes the target support stiffness of the division region j, ω j,i denotes the weight factor of the fabric layer i in the division region j.

[0024] Further, the target support stiffness of each division region is denoted as:

[0025]

[0026] In the formula, H j denotes the target support stiffness of the division region j, F j denotes the equivalent force of the division region j, Δh j denotes the expected settlement of the division region j.

[0027] Further, the equivalent force of each division region is denoted as:

[0028] F j = SDI j · P j,final · φ j · A j

[0029] In the formula, F j denotes the equivalent force of the division region j, SDI j denotes the support demand index of the division region j, P j,final denotes the lying posture fusion coefficient of the division region j, φ j denotes the area of the division region j, A j denotes the contact area of the division region j.

[0030] Further, the expected settlement of each division region is denoted as:

[0031]

[0032] wherein Δh j represents the expected settlement amount of the divided region j, P j,final represents the recumbent fusion average pressure of the divided region j, θ j represents the spinal curvature angle of the divided region j, P j,ref represents the reference pressure of the divided region j, θ j,ref represents the reference spinal curvature angle of the divided region j, f1 and f2 respectively represent the first and second empirical weighting factors.

[0033] Further, the support demand index of each divided region is represented as:

[0034] SDI j = α · P j,final + β · BMI + γ · θ j + δ · A j

[0035] wherein SDI j represents the support demand index of the divided region j, P j,final represents the recumbent fusion average pressure of the divided region j, BMI represents the body mass index of the customer, θ j represents the spinal curvature angle of the divided region j, A j represents the contact area of the divided region j, α, β, γ, δ respectively represent the first, second, third and fourth empirical weight coefficients.

[0036] Further, the recumbent fusion average pressure of each divided region is represented as:

[0037]

[0038] wherein P j,final represents the recumbent fusion average pressure of the divided region j, ω supine , ω side respectively represent the proportion of the supine and lateral position of the customer, respectively represent the supine average pressure and lateral average pressure of the divided region j.

[0039] Compared with the prior art, the present application can at least achieve the following beneficial effects:

[0040] The application provides a personalized spacer fabric mattress manufacturing method, which comprises the following steps: obtaining human body data of a customer, dividing a to-be-manufactured mattress into regions, obtaining personalized target parameters of each divided region of the to-be-manufactured mattress, obtaining expected settlement amounts and equivalent forces of each divided region, obtaining target support stiffnesses of each divided region, and obtaining optimal design parameter combinations of each divided region of the to-be-manufactured mattress, so as to complete manufacturing of the personalized spacer fabric mattress of the customer, accurately customize support characteristics and comfort of each region of the mattress according to unique body shape, weight, pressure distribution and lying posture preference of the customer, effectively relieve local high-pressure points, and provide optimal spine support, and the problems of low customization efficiency, poor accuracy, high cost, and difficulty in simultaneously considering comfort, elastic recovery and durability of the existing mattress are solved.

[0041] The above technical solutions can be combined with each other in the application to achieve more preferred combination solutions. Other features and advantages of the application will be described in the subsequent description, and some advantages will become apparent from the description, or will be understood by implementing the application. The purposes and other advantages of the application can be achieved and obtained from the contents particularly pointed out in the description and the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0042] The accompanying drawings are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiments of the application and are used to explain the principles of the application, but are not used to limit the scope of the application.

[0043] Figure 1 A flowchart of the personalized spacer fabric mattress manufacturing method provided by the embodiment of the application is shown. DETAILED DESCRIPTION

[0044] The preferred embodiments of the application are specifically described below in combination with the drawings, wherein the drawings constitute a part of this application, and are used to explain the principles of the embodiments of the application, but are not used to limit the scope of the application.

[0045] One specific embodiment of the application discloses a personalized spacer fabric mattress manufacturing method, as shown in Figure 1 The method comprises the following steps:

[0046] S1, obtaining human body data of a customer, dividing a to-be-manufactured mattress into regions based on the human body data, and obtaining personalized target parameters of each divided region of the to-be-manufactured mattress.

[0047] Specifically, the human body data comprises basic physiological data, key body size data, spine curve data, body pressure distribution data and lying posture preference data; wherein,

[0048] The basic physiological data comprises height and weight.

[0049] The key body size data are key sizes of each part of the human body after the human body is divided, wherein the key sizes of each part of the human body are determined according to experience; the human body can be divided according to design requirements, including but not limited to one or more of the division modes of the head, neck, back, waist, hips and legs, and the more the human body is divided, the higher the requirement for the personalized mattress is. For example, in the embodiment, the human body is divided into the shoulder, waist and hip, and the key body size data are shoulder width, waist circumference and hip circumference, respectively; the human body can also be divided into the shoulder, waist, hip and leg, and the key body size data are shoulder width, waist circumference, hip circumference and leg circumference, respectively.

[0050] The spine curve data are the physiological curve of the spine when the customer stands;

[0051] The body pressure distribution data include the pressure distribution of each part of the body of the customer in the supine and lateral positions.

[0052] The lying position preference data include the proportion of the supine and lateral positions of the customer.

[0053] Specifically, the to-be-made mattress is divided into regions based on each part of the human body divided in the key body size data and the human body anatomical proportion, and each divided region of the to-be-made mattress corresponds to each part of the human body divided; wherein the proportion of each divided region of the to-be-made mattress is set according to the human body anatomical proportion. For example, in the embodiment, the human body parts divided in the key body size data are the shoulder, waist and hip, and the key body sizes are shoulder width, waist circumference and hip circumference, and the to-be-made mattress is divided into the shoulder region, waist region and hip region, and the interval proportions are 0.00-0.25, 0.26-0.55 and 0.56-0.70, respectively.

[0054] Specifically, the personalized target parameters include the contact area of each divided region, the body type factor, the spine curvature angle, the support demand index, the lying position average pressure and the lying position fusion average pressure; wherein the lying position average pressure includes the supine average pressure and the lateral average pressure.

[0055] More specifically, the projection area of the customer in the corresponding body part is obtained according to the proportion of each divided region of the to-be-made mattress, and then the contact area of each divided region of the to-be-made mattress is obtained. Further, the mean of the projection area of each body part in different lying positions can be taken as the contact area of each divided region of the to-be-made mattress; or the contact area obtained by weighting the projection area of each body part in different lying positions according to the lying position preference data can be taken as the contact area of each divided region of the to-be-made mattress.

[0056] More specifically, the body proportion of each key body part of the human body is obtained based on the key body part size of the human body, and then the body type factor of each divided region of the to-be-made mattress is obtained.

[0057] Exemplarily, in the embodiment, the key body dimensions are shoulder width, waist circumference and hip circumference, the mattress to be made is divided into shoulder region, waist region and hip region, the body proportions of each key body part of the human body include shoulder-to-waist ratio, waist-to-hip ratio and shoulder-to-hip ratio, and the body type factor of each divided region of the mattress to be made is represented as:

[0058] φ1=1+λ1(SWR-μ1)

[0059] φ2=1+λ2(WHR-μ2)

[0060] φ3=1-λ3(μ3-SHR)

[0061] In the formula, φ1, φ2 and φ3 respectively represent the body type factor of the shoulder region, the waist region and the hip region; SWR, WHR and SHR respectively represent the shoulder-to-waist ratio, the waist-to-hip ratio and the shoulder-to-hip ratio of the customer; λ1, λ2 and λ3 respectively represent the body type weight coefficients of the shoulder region, the waist region and the hip region, which are set according to specific needs and have a value range of 0.5-0.8; μ1, μ2 and μ3 respectively represent the reference values of the shoulder-to-waist ratio, the waist-to-hip ratio and the shoulder-to-hip ratio, which can be set according to the gender of the customer.

[0062] It can be understood that if the waist-to-hip ratio is large, it indicates that there is more accumulation of fat in the abdomen, and the support strength of the waist region needs to be increased; if the shoulder-to-waist ratio is large, it indicates that the upper body center of gravity is more upward, and the support strength of the shoulder region needs to be increased; if the shoulder-to-hip ratio is large, it indicates that the hips are wider, and a larger contact pressure area needs to be provided; based on this, the corresponding body type factor of each divided region of the mattress to be made is designed for subsequent mattress making.

[0063] Exemplarily, λ1, λ2 and λ3 are respectively set to 0.5, 0.6 and 0.5, μ1, μ2 and μ3 are respectively set to 1.2, 0.8 and 1.05, the shoulder width of the customer is 42 cm, the waist circumference is 70 cm, and the hip circumference is 92 cm, then the shoulder-to-waist ratio, the waist-to-hip ratio and the shoulder-to-hip ratio are respectively 0.6, 0.76 and 0.456, and the body type factors of the shoulder region, the waist region and the hip region are respectively 0.7, 0.976 and 0.73.

[0064] More specifically, the point cloud or three-dimensional mesh model of the human body standing is obtained by a three-dimensional scanning device, the sagittal plane data (i.e. slicing along the trunk axis) is extracted, the back midline point set (i.e. from the neck to the sacrum) is extracted, and then the midline curve is fitted, so as to obtain the curvature angles of each part of the spine and serve as the curvature angles of the corresponding divided region in the mattress to be made; wherein the calculation of the curvature angles of each part of the spine can adopt three-point method or polynomial fitting. It should be noted that if the divided region in the mattress to be made does not have the curvature angle of the corresponding part of the spine, it is set to 0.

[0065] Exemplarily, in the embodiment, the mattress to be made is divided into a shoulder region, a waist region and a hip region, and the thoracic kyphosis angle, the lumbar lordosis angle and the sacral inclination angle of the spine are obtained as the curvature angles of the spine of the shoulder region, the waist region and the hip region of the mattress to be made, respectively. The thoracic kyphosis angle is obtained by measuring the included angle between the first thoracic vertebra (T1) and the twelfth thoracic vertebra (T12); the lumbar lordosis angle is obtained by measuring the included angle between the first lumbar vertebra (L1) and the fifth lumbar vertebra (L5); and the sacral inclination angle is obtained by measuring the included angle between the fifth lumbar vertebra (L5) and the first sacral vertebra (S1).

[0066] It can be understood that if the curvature angle of the spine is abnormal or greater than the experience normal value interval (for example, the lumbar lordosis angle is 20°-45°, and the thoracic kyphosis angle is 20°-40°), it indicates that the corresponding divided region in the mattress to be made should be a midpoint region for support compensation. Therefore, in the embodiment, the subsequent mattress making is performed by taking this factor into consideration.

[0067] More specifically, the pressure maps of the customer in different lying positions are obtained by using a pressure pad array (such as Tekscan), and the average pressure of the corresponding body part of the customer in different lying positions is obtained according to the proportion of each divided region of the mattress to be made, that is, the average pressure of each divided region of the mattress to be made in the supine position and the average pressure of each divided region of the mattress to be made in the lateral position are obtained, and then the lying position fusion average pressure of each divided region of the mattress to be made is obtained based on the lying position preference data; wherein the lying position fusion average pressure of each divided region is represented as:

[0068]

[0069] In the formula, P j,final represents the lying position fusion average pressure of the divided region j, ω supine and ω side respectively represent the proportion of the supine position and the lateral position of the customer, respectively represent the average pressure of the divided region j in the supine position and the average pressure of the divided region j in the lateral position.

[0070] More specifically, the support demand index of each divided region is represented as:

[0071] SDI j = α·P j,final + β·BMI + γ·θ j + δ·A j

[0072] In the formula, SDI j represents the support demand index of the divided region j, P j,final represents the lying position fusion average pressure of the divided region j, BMI represents the body mass index of the customer, θ j represents the curvature angle of the spine of the divided region j, and A jrepresents the contact area of the divided region j, and α, β, γ, and δ respectively represent the first, second, third, and fourth empirical weight coefficients. Among them, the body mass index BMI of the customer is the ratio of the normalized weight to the square of the height, the unit of weight is kilogram, and the unit of height is meter.

[0073] Exemplarily, the first, second, third, and fourth empirical weight coefficients α, β, γ, and δ are respectively set to 0.4, 0.1, 0.3, and 0.2.

[0074] S2, based on the personalized target parameters of each divided region of the to-be-made mattress, the expected settlement amount and the equivalent force of each divided region are obtained, and then the target support stiffness of each divided region is obtained.

[0075] In implementation, the expected settlement amount of each divided region is represented as:

[0076]

[0077] In the formula, Δh j represents the expected settlement amount of the divided region j, P j,final represents the average pressure of the lying posture fusion of the divided region j, θ j represents the curvature angle of the spine of the divided region j, P j,ref represents the reference pressure of the divided region j, θ j,ref represents the reference curvature angle of the spine of the divided region j, and f1 and f2 respectively represent the first and second empirical weighting factors. Among them, the reference pressure of the divided region is set according to the average pressure of the supine position of the standard weight person in the corresponding region, and the gender factor can be considered; the reference curvature angle of the spine of the divided region can be set according to the normal value interval.

[0078] In implementation, the equivalent force of each divided region is represented as:

[0079] F j = SDI j · P j,final · φ j · A j

[0080] In the formula, F j represents the equivalent force of the divided region j, SDI j represents the support demand index of the divided region j, P j,final represents the lying posture fusion coefficient of the divided region j, φ j represents the area of the divided region j, A j represents the contact area of the divided region j.

[0081] In implementation, the target support stiffness of each division area is used to represent the reaction force under unit deformation of each division area, and is represented as:

[0082]

[0083] In the formula, H j represents the target support stiffness of the division area j, F j represents the equivalent force of the division area j, and Δh j represents the expected settlement of the division area j.

[0084] S3, based on the target support stiffness of each division area, obtain the optimal design parameter combination of each division area of the mattress to be made, and further obtain the personalized spacer fabric mattress of the customer.

[0085] Specifically, the design parameters include the material combination of the fabric, the spacer yarn diameter, the inlay angle, the mesh structure, and the number of weaving layers; wherein the material combination is the spacer yarn material, such as polyester / PA / elastane blend; the spacer yarn diameter is the yarn diameter, such as 0.15, 0.20; the inlay angle is the angle between the weft and the warp, such as 30°, 45°, 60°; the mesh structure includes rhombus and hexagon; and the number of weaving layers is single layer, double layer or multiple layers.

[0086] Specifically, the mattress to be made includes a plurality of superimposed fabric layers, and the optimal design parameter combination of each division area includes the optimal design parameter combination of each fabric layer.

[0087] In implementation, the optimal design parameter combination of each division area of the mattress to be made is obtained by the following method:

[0088] S31, based on the target support stiffness of each division area, obtain the layer target support stiffness of each fabric layer in each division area.

[0089] In specific implementation, the layer target support stiffness of each fabric layer in each division area is represented as:

[0090]

[0091] In the formula, represents the layer target support stiffness of the fabric layer i in the division area j, H j represents the target support stiffness of the division area j, and ω j,i represents the weight factor of the fabric layer i in the division area j. Wherein, the weight factor of each fabric layer in each division area is set according to specific requirements.

[0092] Specifically, in this embodiment, the mattress to be made includes three fabric layers, which are top layer, middle layer and bottom layer, wherein the functional positioning and stiffness distribution principle of each fabric layer are shown in Table 1.

[0093] Table 1: Function positioning and stiffness distribution principle of each fabric layer

[0094]

[0095] For example, the top layer of the mattress to be made is divided into a shoulder region, a waist region and a hip region, and the weight factor settings of each fabric layer in each divided region are shown in Table 2:

[0096] Table 2: Weight factor settings of each fabric layer in each divided region

[0097]

[0098] S32, based on the layer target support stiffness of each fabric layer in each divided region and the constructed elastic recovery optimization model, obtaining the optimal design parameter combination of each fabric layer in each divided region of the mattress to be made.

[0099] In a specific implementation, the elastic recovery optimization model includes a multi-objective function and a fabric parameter performance database; each element in the fabric parameter performance database includes a design parameter combination and corresponding fabric support stiffness and elastic recovery rate; and the multi-objective function is expressed as:

[0100]

[0101] In the formula, ΔH represents the absolute deviation of the target support stiffness and the actual support stiffness of the mattress, η avg represents the average elastic recovery rate of the mattress, represents the fabric support stiffness of fabric layer i in divided region j, represents the layer target support stiffness of fabric layer i in divided region j, η j,i represents the elastic recovery rate of fabric layer i in divided region j, K represents the set of divided regions of the mattress to be made, N represents the set of fabric layers of the mattress to be made, k represents the number of elements in the set of divided regions of the mattress to be made, n represents the number of elements in the set of fabric layers of the mattress to be made, and || represents the absolute value.

[0102] Specifically, the fabric support stiffness and the elastic recovery rate in the fabric parameter performance database are obtained according to experiments.

[0103] It should be noted that, based on the multi-objective function in the elastic recovery optimization model, the optimal parameter combination can be found in the fabric parameter performance database, and a multi-objective genetic algorithm can be used for solving.

[0104] Preferably, a buffer zone is provided between each divided region of the mattress to be made, so as to avoid the case of "stiffness mutation" at the boundary caused by directly using different design parameters in each divided region, thereby affecting the comfort and durability.

[0105] Specifically, the buffer width is set according to specific requirements, preferably the buffer width is set to 20 cm; wherein the intermediate value material combination is used for linear interpolation between the structure parameters (wire diameter, angle) in the design parameters to make the buffer band.

[0106] It can be understood that, based on the multi-objective function in the elastic recovery optimization model, the materials and structures with excellent fatigue resistance are preferentially selected and combined, that is, even if the region designed to meet the local softness requirement (such as the shoulder), the parameter combination adopted is optimized to ensure that the region can still maintain good recovery in long-term use; the mattress designed in this embodiment has a thickness loss rate and a support force decrease amplitude that are significantly lower than those of a non-optimized personalized scheme (such as simply using a softer foam) of the same comfort level after undergoing a specified number (such as 5000 times) of compression fatigue tests, and even better than some standardized high-performance mattresses, ensuring that the thickness loss rate is ≤5% (the traditional mattress ≥15%) in long-term use, prolonging the service life by more than 2 times, and ensuring that the customized mattress has both immediate comfortable fit and long-term support retention.

[0107] In implementation, the personalized spacer fabric mattress of the customer based on the optimal design parameter combination of each divided region of the mattress to be made comprises:

[0108] Based on the optimal design parameter combination of each divided region of the mattress to be made, the design parameter combination corresponding to each coordinate point of the mattress to be made under the construction of the mattress coordinate system is obtained, and then an instruction file for driving the weaving equipment is generated; the weaving equipment seamlessly and continuously weaves out the personalized spacer fabric mattress according to the instruction file.

[0109] Specifically, the weaving equipment is a multi-bar warp knitting machine.

[0110] In specific implementation, the seamless and continuous weaving of the personalized spacer fabric mattress by the weaving equipment according to the instruction file comprises:

[0111] (1) Based on the design parameter combination corresponding to each coordinate point of the mattress to be made under the construction of the mattress coordinate system, a dynamic control instruction (DBL / TEX code) for driving the multi-bar warp knitting machine is obtained.

[0112] (2) Device execution action and conversion mode of design parameters

[0113] ① The spacer yarn diameter d is controlled by adjusting the speed of the let-off motor and the yarn tension let-off mechanism; specifically, a diameter-tension mapping function T(d) = k·d is established 2 wherein k is the material elastic coefficient, and the spacer yarn diameter needs to be reduced to reduce the tension to avoid breakage; by calculating the change amount of the spacer yarn diameter d in real time, a let-off roller speed instruction V is generated feed= C / T(d); where C is the constant of the warp.

[0114] For example, when the spacing wire diameter d of the waist region is 0.15 mm, the rotation speed is increased by 20% to ensure the yarn supply.

[0115] 2. The lapping angle θ is changed by driving the transverse movement mechanism of the guide bar to move horizontally; specifically, the transverse movement distance is calculated using a geometric algorithm: ΔX = L tan(θ); where L is the base value of the stitch length; the lapping angle θ is discretized by segmenting the coordinate position, and the guide bar displacement sequence instruction is generated.

[0116] For example, when the lapping angle θ of the shoulder region is 30, the transverse movement distance ΔX is 5 mm; when the lapping angle θ of the waist region is 45, the transverse movement distance ΔX is 8 mm.

[0117] 3. The mesh structure is controlled by programming the loop or weft timing sequence combination of the knitting needle; specifically, a preset needle method database is called (for example, diamond → needle sequence code GB1:0-2 / 2-0 / / , hexagon → GB1:0-2 / 4-6 / 6-4 / 2-0 / / ); according to the structure type of the current coordinate point, the corresponding needle method instruction is inserted in real time.

[0118] 4. The material combination is controlled by switching the yarn carrier to supply the yarn type and proportion; specifically, the material combination is converted into yarn carrier index instructions (for example, PET / PA70:30 is converted into YarnCarrier1 = PET, FeedRate = 70%; YarnCarrier2 = PA, FeedRate = 30%); the material gradient is realized by the fade-in and fade-out algorithm at the boundary of the region.

[0119] 5. The layer density ρ is controlled by adjusting the speed of the pull roller to control the fabric bulk density; specifically, the layer density ρ is inversely proportional to the roller speed; the roller speed is reduced in high-density areas to prolong the yarn interweaving time.

[0120] (3) Manufacturing process closed-loop feedback

[0121] The fabric thickness is monitored online by a laser range finder (to verify the thickness loss rate control), and the yarn tension is detected by a tension sensor (to prevent yarn breakage);

[0122] When the thickness deviation is greater than 5%, the warp supply is automatically adjusted.

[0123] It can be understood that, in the embodiment, according to the obtained optimal design parameter combination, the needle action, yarn tension, let-off amount and the like are changed in real time when weaving into different positions of the mattress, so that the “one-piece” spacer fabric mattress core material with the gradient parameters is seamlessly and continuously woven, and the integrity and optimal performance of the overall structure are ensured. In the embodiment, the automatic process (data->analysis->mapping->design->instruction) greatly shortens the customization period, and the design generation time is shortened from the artificial hours / day level to the minute level, the dependence on professional technicians and the labor cost are reduced; the “one-piece” digital weaving avoids the cutting, blocking and splicing links, eliminates the splicing process, the production efficiency is improved by ≥40%, and the material loss is reduced by ≥15%; the obtained mattress is a seamless overall structure, has no potential problems of adhesives, has strong interlayer bonding force, and the overall stability and durability are improved.

[0124] Compared with the prior art, the embodiment provides a manufacturing method of a personalized spacer fabric mattress. The human body data of a customer is obtained, the to-be-manufactured mattress is regionally divided, and the personalized target parameters of each divided region of the to-be-manufactured mattress are obtained, and then the expected settlement amount and the equivalent stress of each divided region are obtained, and then the target support stiffness of each divided region is obtained, so that the optimal design parameter combination of each divided region of the to-be-manufactured mattress is obtained, and the manufacturing of the personalized spacer fabric mattress of the customer is completed. The support characteristics and comfort of each region of the mattress can be accurately customized according to the unique body shape, weight, pressure distribution and lying posture preference of the customer, the local high-pressure point is effectively relieved, the best spine support is provided, and the problems of low efficiency, poor precision and high cost of the personalized customization of the existing mattress, and the difficulty in simultaneously considering the comfort, elastic recovery and durability are solved.

[0125] Those skilled in the art can understand that all or part of the processes of the above-mentioned embodiments can be completed by a computer program instructing related hardware, and the program can be stored in a computer readable storage medium. The computer readable storage medium includes a magnetic disk, an optical disk, a read-only memory or a random access memory.

[0126] The above is only a preferred specific embodiment of the present application, but the protection scope of the present application is not limited thereto. Any changes or replacements within the technical range disclosed in the present application can be easily thought by those skilled in the art, and should be covered within the protection scope of the present application.

Claims

1. A method for manufacturing a personalized spacer fabric mattress, characterized in that, include: Obtain the customer's human body data, divide the mattress to be made into regions based on the human body data, and obtain personalized target parameters for each region of the mattress to be made. Based on the personalized target parameters of each division area of ​​the mattress to be manufactured, the expected settlement and equivalent force of each division area are obtained, and then the target support stiffness of each division area is obtained. Based on the target support stiffness of each divided area, the optimal combination of design parameters for each divided area of ​​the mattress to be manufactured is obtained, thus resulting in a personalized spaced fabric mattress for the customer.

2. The method for manufacturing a personalized spacer fabric mattress according to claim 1, characterized in that, The human body data includes: basic physiological data, key body size data, spinal curve data, body pressure distribution data, and lying posture preference data; the personalized target parameters include: area of ​​each divided region, body shape factor, spinal curvature angle, support demand index, average lying posture pressure, and average lying posture fusion pressure, wherein the average lying posture pressure includes average pressure in supine position and average pressure in lateral position.

3. The method for manufacturing a personalized spacer fabric mattress according to claim 2, characterized in that, The mattress to be manufactured comprises multiple stacked fabric layers, and the optimal design parameter combination for each divided area includes the optimal design parameter combination for each fabric layer. The optimal combination of design parameters for each zone of the mattress to be manufactured is obtained through the following method: Based on the target support stiffness of each divided region, the layer target support stiffness of each fabric layer in each divided region is obtained. Based on the target support stiffness of each fabric layer in each divided region and the constructed elastic recovery optimization model, the optimal combination of design parameters for each fabric layer in each divided region of the mattress to be manufactured is obtained.

4. The method for manufacturing a personalized spacer fabric mattress according to claim 3, characterized in that, The elastic recovery optimization model includes a multi-objective function and a fabric parameter performance database; wherein, each element in the fabric parameter performance database includes a combination of design parameters and the corresponding fabric support stiffness and elastic recovery rate; the multi-objective function is expressed as: In the formula, ΔH represents the absolute deviation between the target support stiffness and the actual support stiffness of the mattress, and η avg This indicates the average elastic recovery rate of the mattress. This represents the fabric support stiffness of fabric layer i within the divided region j. η represents the target support stiffness of fabric layer i in the divided region j. j,i Let represent the elastic recovery rate of fabric layer i in region j, K represent the set of regions to be divided for the mattress to be made, N represent the set of fabric layers to be made for the mattress to be made, k represent the number of elements in the set of regions to be divided for the mattress to be made, n represent the number of elements in the set of fabric layers to be made for the mattress to be made, and || represent the absolute value.

5. The method for manufacturing a personalized spacer fabric mattress according to claim 3, characterized in that, The target support stiffness of each fabric layer in each of the defined regions is expressed as follows: In the formula, H represents the target support stiffness of fabric layer i in the divided region j. j ω represents the target support stiffness of region j. j,i This represents the weighting factor of fabric layer i in the divided region j.

6. The method for manufacturing a personalized spacer fabric mattress according to claim 1, characterized in that, The target support stiffness of each divided region is expressed as: In the formula, H j F represents the target support stiffness of region j. j Δh represents the equivalent force on region j. j This represents the expected settlement of region j.

7. The method for manufacturing a personalized spacer fabric mattress according to claim 2, characterized in that, The equivalent forces in each of the divided regions are expressed as follows: F j =SDI j ·P j,final ·φ j ·A j In the formula, F j SDI represents the equivalent force in region j. j P represents the support demand index for region j. j,final φ represents the recumbent posture fusion coefficient for region j. j Let A represent the area of ​​region j. j This represents the contact area of ​​the divided region j.

8. The method for manufacturing a personalized spacer fabric mattress according to claim 2, characterized in that, The expected settlement of each divided region is expressed as follows: In the formula, Δh j P represents the expected settlement of region j. j,final θ represents the mean pressure in the supine position within region j. j P represents the spinal curvature angle of region j. j,ref θ represents the reference pressure for dividing region j. j,ref The reference spinal curvature angle for dividing region j is represented by f1 and f2, which represent the first empirical weighting factor and the second empirical weighting factor, respectively.

9. The method for manufacturing a personalized spacer fabric mattress according to claim 2, characterized in that, The support demand index for each of the defined regions is expressed as follows: SDI j =α·P j,final +β·BMI+γ·θ j +δ·A j In the formula, SDI j P represents the support demand index for region j. j,final The mean pressure in the supine position is represented by the division area j, BMI represents the customer's body mass index, and θ represents the mean pressure in the supine position. j A represents the spinal curvature angle of region j. j The contact area of ​​region j is represented by α, β, γ, and δ, which represent the first, second, third, and fourth empirical weight coefficients, respectively.

10. The method for manufacturing a personalized spacer fabric mattress according to claim 2, characterized in that, The average pressure in each subdivided region during the supine position is expressed as follows: In the formula, P j,final ω represents the mean pressure in the supine position within region j. supine ω side These represent the proportions of the customer's supine and lateral sleeping positions, respectively. These represent the average pressure in the supine and lateral positions of region j, respectively.

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