Preparation process of inflatable rebound low-density sponge product, product and application

Abstract

The invention relates to the field of processing of inflatable sponge products, and discloses a preparation process of an inflatable rebound low-density sponge product, the product and application. The invention relates to a preparation process of an inflatable rebound low-density sponge product. The preparation process comprises the following steps: S1, cutting at least one low-density polyurethane sponge core body and a plurality of sealing layers; s2, according to the shape of the low-density polyurethane sponge core body, a plurality of sealing layers are bonded to the surface of the low-density polyurethane sponge core body, and a closed inflatable cavity is formed; and S3, the inflation piece is installed on the sealing layer. The low-density sponge product is applied to soft supporting products such as sofas, mattresses, camping mats and yoga mats, the low-density sponge core body and the sealing layer are inflated and deflated through the inflation part, the low-density sponge core body and the sealing layer are rapidly rebounded and compressed under the action of gas pressure, the hardness of the product can be adjusted, and the product has the advantages of being simple in structure and convenient to use. And meanwhile, the low-density sponge core body is not easy to age.

Description

Technical Field

[0001] This application relates to the field of processing inflatable sponge products, and in particular to a process for preparing an inflatable, resilient, low-density sponge product, as well as its products and applications. Background Technology

[0002] With the development of the upholstered furniture, sports and leisure, and cushioning and protective products industries, the market demand for environmentally friendly, portable, hygienic, durable, stain-resistant and leak-proof products is increasing. Sponge, especially polyurethane foam, has become the core filling material for traditional upholstered products such as sofas and mattresses due to its excellent softness, support and compressibility.

[0003] In existing technologies, high-end soft products generally adopt multi-layered composite structure designs to optimize the sitting and lying experience. This involves layering sponge layers with different densities, hardness, and resilience properties, for example, setting a high-density support layer, a medium-density comfort layer, and a low-density bonding layer from bottom to top, thereby achieving multiple functions such as support, cushioning, and close-fitting wrapping in a single product. However, such sponge-based composite structure products are heavy and have a fixed volume, which not only leads to high logistics and transportation costs but also greatly limits their application in scenarios requiring high portability, such as outdoor camping, temporary rest, and flexible spaces.

[0004] To address the aforementioned issues, existing technologies have developed products that combine sponge with inflatable components. These products consist of an upper sponge comfort layer and a lower, independently inflatable layer. When not in use, the air inside the inflatable layer can be released, significantly reducing the product's volume for easy storage and transport. In use, the inflatable layer is inflated, expanding to form a rigid support base that supports the upper sponge layer, providing a comfortable surface.

[0005] However, the aforementioned products still have the following drawbacks: First, the sponge layer rebounds slowly after compression / packaging, typically taking tens of minutes to several hours to regain its shape, making it unusable immediately and resulting in a poor user experience. Second, although the inflatable layer can be compressed and stored, it can only be inflated to provide full support during use. After deflating, the inflatable layer is completely contracted, rendering the product unusable. This prevents the adjustment of the product's firmness, making it unsuitable for the diverse needs of different users for support and comfort. For example, prolonged sitting requires high firmness, leisure requires medium firmness, and naps require relaxing firmness. The single firmness design limits the product's usage scenarios. Third, as a comfort layer, the sponge is typically exposed to the ambient air over a large area, making it susceptible to erosion from oxygen, ultraviolet rays, and moisture, accelerating the oxidation and aging process. This causes the sponge to become brittle, powdery, and permanently lose its elasticity, significantly shortening the product's lifespan. Summary of the Invention

[0006] To address the problems of slow elastic recovery, inability to adjust firmness, and easy aging of existing structures combining sponge and air layers in soft support products such as mattresses and sofas, this application provides a manufacturing process, product, and application of an air-rebound low-density sponge.

[0007] In a first aspect, this application provides a manufacturing process for an inflatable, resilient, low-density sponge product, employing the following technical solution: A process for preparing an inflatable, resilient, low-density sponge product comprises the following steps: S1. Material preparation: Cut at least one low-density polyurethane foam core and several sealing layers according to the product structure. S2. Sealing and molding: Based on the shape of the low-density polyurethane foam core, multiple sealing layers are bonded to the surface of the low-density polyurethane foam core to form a closed inflatable cavity. S3. Inflatable component assembly: Install the inflatable components onto the sealing layer to obtain an inflatable and resilient low-density sponge product. The low-density polyurethane foam core is a porous polyurethane foam with a density of 5D-25D.

[0008] By adopting the above technical solution, a low-density polyurethane foam core and a sealing layer are first cut. Then, according to the shape of the low-density polyurethane foam core, the sealing layer is wrapped and bonded to the surface of the low-density polyurethane foam core to form a closed inflatable cavity. Finally, an inflatable component is installed. This allows for the production of sponge products that can be inflated and deflated through the inflatable component, allowing the low-density polyurethane foam core and sealing layer to be inflated and deflated. The 5D-25D low-density polyurethane foam core has a large number of pores, providing good softness and comfort. Under gas pressure, the product can quickly rebound and compress, solving the problem of slow elastic recovery after storage. Simultaneously, with the support of the low-density polyurethane foam core, the product's hardness can be adjusted by controlling the inflation volume. High inflation volume results in high sponge product hardness and good support; low inflation volume results in good sponge product softness. Compared to existing inflatable sponge products, this method can meet the diverse needs of different users for support and comfort. The sealing layer reduces the contact between the sponge core and oxygen, ultraviolet rays, and moisture in the environment, delaying sponge oxidation and aging, and extending product lifespan.

[0009] Preferably, the density of the low-density polyurethane foam core is 10D-20D.

[0010] By adopting the above technical solutions and further optimizing the density of the low-density polyurethane foam core, inflatable and resilient low-density foam products can maintain a certain level of support while possessing better softness and compressibility, enabling them to rebound and compress more quickly under gas pressure. If the density is too high, the inflation and deflation time will increase, or even prevent inflation, rebound, and deflation compression from being achieved. Furthermore, excessively high hardness can reduce the flexibility and adjustability of the foam product.

[0011] Preferably, the sealing layer is a TPU composite fabric or a PVC composite fabric.

[0012] By adopting the above technical solution, the sealing layer has good waterproof, flexible and wear-resistant properties, can stably cover the low-density polyurethane sponge core, and is also easy to clean.

[0013] Preferably, the thickness of the sealing layer is 0.1-0.5 mm.

[0014] By adopting the above technical solution, the sealing layer with a better thickness can not only stably cover the low-density polyurethane foam core, but also maintain the same softness as the low-density foam core.

[0015] Preferably, an adhesive layer is provided on the side of the sealing layer near the low-density polyurethane foam core. The adhesive layer is a hot melt adhesive layer or a thermosetting adhesive layer. The hot melt adhesive layer is any one of polyurethane hot melt adhesive and polyolefin hot melt adhesive, and the thermosetting adhesive layer is any one of acrylic adhesive layer and silicone adhesive layer.

[0016] By adopting the above technical solutions, these types of hot melt adhesives and binders have good adhesion and flexibility, which can ensure a tight fit between the sealing layer and the core. This makes it less likely for the sealing layer and the low-density polyurethane foam core to separate or shift during inflation and deflation, thus improving the inflation and deflation stability of the product.

[0017] Preferably, the thickness of the adhesive layer is 20-200µm.

[0018] By adopting the above technical solution, the adhesive layer with a better thickness can ensure that the sealing layer and the low-density polyurethane foam core are fully and stably bonded, ensuring that the sealing layer and the low-density polyurethane foam core will not detach during the inflation and deflation process of the sponge product, while maintaining good softness.

[0019] Preferably, when the adhesive layer is a hot melt adhesive layer, in step S2, according to the shape of the low-density polyurethane foam core, the edges of multiple sealing layers are sealed and spliced ​​to form a receiving cavity with a reserved opening; a single low-density polyurethane foam core is embedded into the receiving cavity from the opening; the opening is completely sealed with a sealing layer to form a closed inflatable cavity containing a low-density polyurethane foam core, and then the low-density polyurethane foam core and the sealing layer are bonded together by hot pressing.

[0020] By adopting the above technical solution, the entire sealing molding process is optimized, which is more conducive to continuous industrial production; at the same time, hot pressing can fully melt the adhesive layer, so that the sealing layer and the low-density polyurethane foam core are stably bonded.

[0021] Preferably, the low-density sponge core is made from the following raw materials in parts by weight: 30-40 parts of toluene diisocyanate 35-45 parts of polyether polyol 12-20 parts of polymer polyol Foaming stabilizer 2.8-3.5 parts 4.5-5.5 parts foaming agent Catalyst 1-1.4 parts.

[0022] By adopting the above technical solution, toluene diisocyanate can react with polyether polyols and polymer polyols to form the main structure of polyurethane, providing a basic framework for the sponge core. Specifically, the polyether polyol imparts good flexibility and elasticity to the sponge core, improving its comfort; the polymer polyol enhances the strength and load-bearing capacity of the foam pore walls; the foaming stabilizer helps control the foaming process, ensuring uniform foam and forming a consistent porous structure; the foaming agent reacts with toluene diisocyanate to generate gas and achieve foaming; and the catalyst accelerates the chemical reaction rate, promotes the reaction between raw materials, and improves production efficiency. Through the synergistic crosslinking reaction of polyether polyols, polymer polyols, foaming stabilizers, and toluene diisocyanate, and the foaming reaction of toluene diisocyanate with water, a stable reaction equilibrium system is formed. The resulting low-density polyurethane sponge is less prone to expansion, breakage, and deformation during long-term repeated inflation and deflation, thus extending the service life of low-density sponge products.

[0023] Preferably, the polyether polyol is composed of polytetramethylene ether diol, allyl-terminated polyether polyol and highly hydroxylated modified polyether polyol in a weight ratio of 1:(0.3-0.6):(1-2).

[0024] By employing the above technical solutions, polytetramethylene ether glycol possesses excellent flexibility and elasticity, imparting good elasticity and a soft touch to the low-density sponge core. Allyl-terminated polyether polyols can participate in the reaction and regulate the cross-linking structure of the sponge, improving its mechanical properties and stability. Highly hydroxylated modified polyether polyols, with their highly active primary hydroxyl groups, can accelerate the reaction rate and promote foam formation and stability. The synergistic effect of these three substances allows the resulting low-density sponge products to achieve a good balance in elasticity, mechanical properties, stability, and foaming performance.

[0025] Preferably, the polymer polyol is composed of dimer acid modified polyester polyol and vinyl polymer grafted polyether polyol in a weight ratio of 1:(1.5-2).

[0026] By adopting the above technical solution, the dimer acid modified polyester polyol and the vinyl polymer grafted polyether polyol work synergistically to enhance the strength of the cell walls of low-density sponge, making the sponge cell structure more stable, thereby improving the overall performance and durability of the product.

[0027] Secondly, this application provides an inflatable, resilient, low-density sponge product, employing the following technical solution: An inflatable, resilient, low-density sponge product is obtained by the aforementioned manufacturing process of an inflatable, resilient, low-density sponge product.

[0028] Preferably, the low-density sponge product has a detachable sleeve on its outer side.

[0029] By adopting the above technical solutions, the cover has the advantages of protection and easy cleaning. At the same time, it can be replaced and assembled according to different usage scenarios, improving the overall texture and user comfort of low-density sponge products.

[0030] Thirdly, this application provides a manufacturing process for an inflatable, resilient low-density sponge product or an application of an inflatable, resilient low-density sponge product, employing the following technical solution: A manufacturing process for an inflatable, resilient, low-density sponge product or an application of an inflatable, resilient, low-density sponge product for use in home sofas, home mattresses, outdoor sofas, outdoor camping mats, yoga mats, or gymnastics cushioning mats.

[0031] In summary, this application includes at least one of the following beneficial technical effects: 1. The manufacturing process of the inflatable rebound low-density sponge product of this application involves first cutting a low-density polyurethane sponge core and a sealing layer according to the product structure, then bonding the sealing layer to the surface of the low-density polyurethane sponge core to form a closed inflatable cavity, and finally installing an inflation component. This produces a product that can be inflated and deflated by the inflation component. Under the action of gas pressure, the low-density sponge core and sealing layer quickly rebound and compress, solving the problem of slow elastic recovery after storage. At the same time, under the support of the low-density polyurethane sponge core, the softness and hardness of the product can be adjusted by controlling the inflation amount. Compared with existing inflatable sponge products, it can adapt to the different needs of different users for support and comfort. The sealing layer can reduce the contact between the sponge core and oxygen, ultraviolet rays, moisture, etc. in the environment, delay the oxidation and aging of the sponge, and extend the service life of the product.

[0032] 2. By applying hot melt adhesive or thermosetting adhesive as an adhesive layer on one side of the sealing layer, the low-density polyurethane foam core and the sealing layer can be stably bonded, improving the bonding stability between the sealing layer and the low-density polyurethane foam core, thereby improving the inflation and deflation stability.

[0033] 3. When the adhesive layer is a hot melt adhesive layer, according to the shape of the low-density polyurethane foam core, the edges of multiple sealing layers are sealed and spliced ​​to form a receiving cavity with a reserved opening; a single low-density polyurethane foam core is embedded into the receiving cavity through the opening; the opening is completely sealed using the sealing layer to form a closed, inflatable cavity containing the low-density polyurethane foam core, and then the low-density polyurethane foam core and the sealing layer are bonded together by hot pressing. The overall preparation process is simple and easy to operate, and is suitable for continuous industrial production.

[0034] 4. The low-density sponge core is made of toluene diisocyanate, polyether polyol, polymer polyol, foaming stabilizer, foaming agent and catalyst. The specific component ratio makes the low-density sponge core have a balance of uniform porosity, elasticity, softness and support. After multiple inflation and deflation uses, the low-density polyurethane sponge core will not have problems with expansion, damage and deformation. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the structure of the inflatable, resilient, low-density sponge product according to Embodiment 1 of this application.

[0036] Figure 2 yes Figure 1 A longitudinal sectional view along the length direction.

[0037] Explanation of reference numerals in the attached figures: 1. Low-density polyurethane foam core; 2. Sealing layer; 3. Adhesive layer; 4. Inflatable component. Detailed Implementation

[0038] The present application will be further described in detail below with reference to the accompanying drawings and embodiments.

[0039] It should be noted that the raw materials used in the embodiments of this application are all commercially available, including but not limited to the following models and manufacturers of raw materials, and raw materials with equivalent performance can be used.

[0040] Example Example 1

[0041] Example 1 discloses a process for preparing an inflatable, resilient, low-density sponge product, comprising the following steps: Reference Figure 1 and Figure 2 Taking the manufacture of air mattresses as an example: S1. Material preparation: Based on the structure of the air mattress, cut a rectangular low-density polyurethane foam core with dimensions of 180cm*200cm*22cm and 6 sealing layers. S2. Sealing and Molding: Based on the shape of the low-density polyurethane foam core, the edges of the five sealing layers are sealed and spliced ​​using a high-frequency plastic heat sealing machine to form a cavity with a reserved opening; the low-density polyurethane foam core is embedded into the cavity through the opening; the opening is completely sealed by the remaining sealing layer to form a closed inflatable cavity containing the low-density polyurethane foam core; then the low-density polyurethane foam core and the sealing layer are bonded together by hot pressing, with a reserved mounting position for the inflatable component on one of the sealing layers; S3. Inflatable component assembly: Install the inflatable components into the mounting positions of the sealing layer to obtain an inflatable mattress; The low-density polyurethane foam core is commercially available from Changzhou Daye Pengfei Sponge Factory, 15D low-density polyurethane foam core. The sealing layer is a PVC composite fabric layer with a thickness of 0.3mm; an adhesive layer with a thickness of 20µm is provided on the side of the sealing layer near the low-density polyurethane foam core. The adhesive layer is a polyurethane hot melt adhesive layer, which is made by melting and curing polyurethane hot melt adhesive. The polyurethane hot melt adhesive is Henkel TECHNOMELT PUR 270 / 7S. The inflation component consists of an air nozzle, a one-way valve, and a sealing element. The air nozzle is fixedly installed on the sealing layer by polyurethane hot melt adhesive. One end of the air nozzle extends into the inflatable cavity. The one-way valve is detachably inserted into the air nozzle. The sealing element is used to seal the air nozzle and the one-way valve. The one-way valve is a commercially available conventional rubber gasket type one-way valve, and its specific structure will not be described in detail here.

[0042] Example 2

[0043] Taking the manufacture of modular inflatable sofas as an example: S1. Material preparation: Based on the structure of the inflatable sofa, cut four cubes of low-density polyurethane foam cores, each measuring 80cm*90cm*100cm, and 24 sealing layers. S2. Sealing and Molding: Based on the shape of the low-density polyurethane foam core, the edges of the five sealing layers are sealed and spliced ​​using a high-frequency plastic heat sealing machine to form a cavity with a reserved opening. A single low-density polyurethane foam core is embedded into the cavity through the opening. The opening is completely sealed by one sealing layer to form a closed inflatable cavity containing the low-density polyurethane foam core. Then, the low-density polyurethane foam core and the sealing layer are bonded together by hot pressing. This process produces four independently inflatable low-density foam semi-finished products. Each low-density foam semi-finished product has a reserved mounting position for an inflatable component on one of its sealing layers. S3. Inflatable component assembly: Install the four inflatable components onto the sealing layer of the four independently inflated low-density sponge semi-finished products. S4. Make through holes on the surface of the cover corresponding to the four inflatable components, and put the four low-density sponge products into the cover to make a modular inflatable sofa. The low-density polyurethane foam core is commercially available from Changzhou Daye Pengfei Sponge Factory, 20D low-density polyurethane foam core; The sealing layer is a TPU composite fabric layer with a thickness of 0.25 mm; an adhesive layer with a thickness of 50 µm is provided on the side of the sealing layer near the low-density polyurethane sponge core. The adhesive layer is a polyolefin hot melt adhesive layer, which is made by melting and curing polyolefin hot melt adhesive. The polyolefin hot melt adhesive is Henkel TECHNOMELT 0430. The structure of the air nozzle is the same as in Example 1.

[0044] Example 3

[0045] Take outdoor camping mats as an example: S1. Material preparation: Based on the structure of the outdoor camping mat, cut a low-density polyurethane foam core with a size of 200cm*150cm*8cm and 6 sealing layers. S2. Sealing and molding: Using silicone adhesive, apply it to the surface of the sealing layer, and then wrap and bond the six sealing layers to the outside of the low-density polyurethane foam core in sequence. The edges of the six sealing layers are then bonded together. After the silicone adhesive is cured, it forms an adhesive layer, so that the six sealing layers form a closed inflatable cavity. One of the sealing layers has a reserved installation position for the inflatable component. S3. Inflatable component assembly: Install the inflatable components into the mounting positions of the sealing layer to obtain an inflatable mattress; The low-density polyurethane foam core is commercially available from Changzhou Daye Pengfei Sponge Factory, 10D low-density polyurethane foam core. The sealing layer is a PVC composite fabric layer with a thickness of 0.2 mm; the adhesive layer has a thickness of 25 µm, and the silicone adhesive is Kanglibang KN-300. The structure of the inflation nozzle is the same as in Example 1.

[0046] Furthermore, in some preferred embodiments, the density of the low-density polyurethane foam core can also be 5D, 7.5D, 12.5D, 17.5D, 22.5D, and 25D; the thickness of the sealing layer can also be 0.1 mm, 0.15 mm, 0.35 mm, 0.4 mm, 0.45 mm, and 0.5 mm; and the thickness of the adhesive layer can also be 15µm, 30µm, 40µm, 75µm, 80µm, 100µm, 125µm, 150µm, 175µm, and 200µm. The adhesive layer can also be an acrylic adhesive layer or other hot melt adhesive layers; the bonding between the sealing layer and the low-density polyurethane foam core can also be achieved by directly melting the surface of the low-density polyurethane foam core or the surface of the sealing layer using a high-frequency plastic heat sealing machine; or a separate hot melt adhesive film can be used as the adhesive layer, and the hot melt adhesive layer can be placed between the sealing layer and the low-density polyurethane foam core, and the sealing layer and the low-density polyurethane foam core can be bonded together by hot pressing.

[0047] Example 4

[0048] The difference between Example 4 and Example 1 is that the low-density polyurethane foam core is prepared by the following steps: 35 kg of polyether polyol, 12 kg of polymer polyol, 2.5 kg of foaming stabilizer, 4.5 kg of foaming agent and 1 kg of catalyst were mixed evenly, and then 30 kg of toluene diisocyanate was added and mixed evenly. The stirring speed was controlled at 300 r / min and the material temperature was 20℃. Then it was injected into a mold for foaming. The foaming parameters were as follows: injection pressure was 2.5 MPa, injection rate was 6 kg / min, foaming temperature was controlled at 140℃ and air flow rate was 1 L / min. After foaming, it was cured at room temperature of 25℃ for 4 days to obtain a low-density polyurethane sponge core. The polytetramethylene ether glycol is PTMEG2000 with a hydroxyl value of 54.7-57.5 mgKOH / g; the allyl-terminated polyether polyol is Dexin Federal SZF-650F with a hydroxyl value of 10 mgKOH / g; the high-primary hydroxylated modified polyether polyol is Haoyi New Materials P2000 with a hydroxyl value of 60 mgKOH / g; the dimer acid modified polyester polyol is Baiyuan Chemical BY3026 with a hydroxyl value of 37-43 mgKOH / g; the vinyl polymer grafted polyether polyol is Dexin Federal POP-15 with a hydroxyl value of 43 mgKOH / g; the alkyl-terminated polyether polyol is Dexin Federal SZF-280W with a hydroxyl value of 5 mgKOH / g; the polyether modified polysiloxane is BYK 301; the amine catalyst is diethylenetriamine; and the organotin catalyst is dibutyltin dilaurate.

[0049] Examples 5-6 The difference between Examples 5-6 and Example 4 lies in the amount of raw materials used and the preparation process parameters, as detailed in Table 1 below.

[0050] Table 1 Parameter table for Examples 4-6

[0051] Example 7

[0052] The difference between Example 7 and Example 4 is that the allyl-terminated polyether polyol in the polyether polyol is replaced with an equal amount of polytetramethylene ether diol, while the rest is the same as in Example 4.

[0053] Example 8

[0054] The difference between Example 8 and Example 4 is that the highly primary hydroxylated modified polyether polyol in the polyether polyol is replaced by an equal amount of allyl-terminated polyether polyol, while the rest is the same as in Example 4.

[0055] Example 9

[0056] The difference between Example 9 and Example 4 is that the dimer acid modified polyester polyol in the polymer polyol is replaced with an equal amount of vinyl polymer grafted polyether polyol, while the rest is the same as in Example 4.

[0057] Example 10

[0058] The difference between Example 10 and Example 4 is that the alkyl-terminated polyether polyol in the foaming stabilizer is replaced with an equal amount of polyether-modified polysiloxane, while the rest is the same as in Example 4.

[0059] Comparative Example Comparative Example 1 The difference between Comparative Example 1 and Example 1 is that the density of the low-density polyurethane foam core is 40D, while the rest is the same as in Example 1.

[0060] Performance testing I. The following tests were conducted on the tear strength of the low-density polyurethane foam cores in Examples 1-10: 1. Density test: The density (D, kg / m³) of the low-density polyurethane foam core was tested according to the test method in ASTM D3574-17. 3 Test and record the test results; 2. Tear strength test: Following the test method in ASTM D3574-17, using trouser-shaped specimens, the tear strength (unit: N / mm) of the low-density polyurethane foam core was tested at a tensile rate of 500 mm / min, and the test results were recorded.

[0061] The following are the performance test data of the low-density polyurethane foam cores prepared in Examples 1-10, as detailed in Table 2 below.

[0062] Table 2 Performance data of low-density polyurethane foam cores in Examples 1-10

[0063] Based on Examples 4-6 and Examples 7-10, it can be concluded that the low-density polyurethane foam core prepared by reacting the polyether polyol, polymer polyol and foaming stabilizer prepared by this application with toluene diisocyanate and foaming under the action of the foaming agent can meet the density requirements of this application and has a tear strength superior to commercially available products. In Example 7, replacing an equal amount of allyl-terminated polyether polyol with polytetramethylene ether glycol resulted in a decrease in the density and tear strength of the low-density polyurethane foam core. In Example 8, replacing an equal amount of highly hydroxylated modified polyether polyol with allyl-terminated polyether polyol significantly increased the tear strength density of the low-density polyurethane foam core, but significantly reduced the tear strength. This may be because the reduced elasticity of the low-density polyurethane foam core also reduced the stability of the foam cells, making stress more easily concentrated during tearing. In Examples 9-10, changing the type of polymer polyol and the type of foaming stabilizer significantly increased the tear strength density of the low-density polyurethane foam core, but significantly reduced the tear strength. This may be due to reduced foam cell uniformity and structural stability.

[0064] This demonstrates that the low-density polyurethane foam core prepared using this application meets the requirements of this application in terms of density, and has a tear strength superior to commercially available low-density polyurethane foam cores, thus better resisting deformation problems caused by long-term inflation and deflation.

[0065] II. The following are application tests on the low-density sponge products prepared in Examples 1-10 and Comparative Example 1: Under a temperature of 25℃, the low-density sponge product is fully inflated and held for 10 minutes, then completely deflated and held for 5 minutes. This cycle is repeated 50 times. After that, the low-density polyurethane sponge core is removed. When the low-density polyurethane sponge core recovers to the point where its thickness no longer changes, the thickness change rate of the low-density polyurethane sponge core is measured (unit: %). Thickness change rate = (thickness before test - thickness after test) / thickness before test * 100%. A thickness change rate of less than 5% is considered qualified. At the same time, the low-density polyurethane sponge core is observed for any damage, and the test results are recorded.

[0066] The following are the performance test data of the inflatable rebound low-density sponge products prepared in Examples 1-10 and Comparative Example 1, as detailed in Table 3 below.

[0067] Table 3 Performance data of the air-inflated, resilient low-density sponge products of Examples 1-10 and Comparative Example 1

[0068] Based on Examples 1-3 and Examples 4-6 and Table 3, it can be concluded that low-density sponge products prepared using the low-density polyurethane sponge core of this application have a smaller deformation rate after long-term inflation and deflation. However, all of Examples 1-6 meet the requirement of a deformation rate of less than 5%, and none of them are damaged.

[0069] In Examples 7-10 and Comparative Example 1, varying degrees of damage occurred after long-term inflation and deflation, with a thickness change rate exceeding 5%. This further verifies that the low-density polyurethane foam core prepared in this application, using polyether polyol, polymer polyol, and foaming stabilizer prepared from specific components, reacts with toluene diisocyanate and foams under the action of a foaming agent. This process offers significant advantages for preparing low-density foam products, achieving the required density and exhibiting a smaller deformation rate after long-term inflation and deflation. In contrast, Comparative Example 1, using a higher-density polyurethane foam core, showed a greater deformation rate and minor damage after long-term inflation and deflation. This may be due to excessive hardness reducing the elasticity of the polyurethane foam core, leading to over-expansion and breakage.

[0070] In summary, the inflatable, resilient low-density sponge product of this application seals and bonds the low-density polyurethane sponge core using a sealing layer. It rebounds quickly after inflation and compresses rapidly after deflation, facilitating storage and transportation. It achieves lightweight, frameless construction, rapid rebound, and a fully sealed, waterproof, oxidation-proof, and impermeable surface. The firmness can be adjusted according to different usage needs and scenarios, making it suitable for various environments, including home and outdoor settings. It overcomes the shortcomings of traditional products, such as poor portability, difficulty in cleaning, short lifespan, and poor adaptability, while also being environmentally friendly and practical.

[0071] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A manufacturing process for an inflatable, resilient, low-density sponge product, characterized in that, Includes the following steps: S1. Material preparation: Cut at least one low-density polyurethane foam core and several sealing layers according to the product structure. S2. Sealing and molding: Based on the shape of the low-density polyurethane foam core, multiple sealing layers are bonded to the surface of the low-density polyurethane foam core to form a closed inflatable cavity. S3. Inflatable component assembly: Install the inflatable components onto the sealing layer to obtain an inflatable and resilient low-density sponge product. The low-density polyurethane foam core is a porous polyurethane foam with a density of 5D-25D.

2. The manufacturing process of an inflatable, resilient, low-density sponge product according to claim 1, characterized in that, The density of the low-density polyurethane foam core is 10D-20D.

3. The manufacturing process of an inflatable, resilient, low-density sponge product according to claim 1, characterized in that, The sealing layer is a TPU composite fabric or a PVC composite fabric.

4. The preparation process of an inflatable, resilient, low-density sponge product according to claim 2, characterized in that, The thickness of the sealing layer is 0.1-0.5 mm.

5. The manufacturing process of an inflatable, resilient, low-density sponge product according to any one of claims 1-4, characterized in that, An adhesive layer is provided on the side of the sealing layer near the low-density polyurethane foam core. The adhesive layer is a hot melt adhesive layer or a thermosetting adhesive layer. The hot melt adhesive layer is any one of polyurethane hot melt adhesive and polyolefin hot melt adhesive. The thermosetting adhesive layer is any one of acrylic adhesive layer and silicone adhesive layer.

6. The manufacturing process of an inflatable, resilient, low-density sponge product according to claim 5, characterized in that, The thickness of the adhesive layer is 20-200µm.

7. The preparation process of an inflatable, resilient, low-density sponge product according to claim 5, characterized in that, When the adhesive layer is a hot melt adhesive layer, in step S2, according to the shape of the low-density polyurethane foam core, the edges of multiple sealing layers are sealed and spliced ​​to form a receiving cavity with a reserved opening; a single low-density polyurethane foam core is embedded into the receiving cavity from the opening. The opening is completely sealed using a sealing layer to form a closed, inflatable cavity containing a low-density polyurethane foam core. The low-density polyurethane foam core and the sealing layer are then bonded together by hot pressing.

8. A low-density sponge product with air-filled resilience, characterized in that, It is prepared by the manufacturing process of an inflatable, resilient, low-density sponge product as described in any one of claims 1-7.

9. The inflatable, resilient, low-density sponge product according to claim 8, characterized in that, The low-density sponge product has a detachable sleeve on its outer side.

10. A manufacturing process for an inflatable, resilient, low-density sponge product as described in any one of claims 1-7, or an application of an inflatable, resilient, low-density sponge product as described in any one of claims 8-9, characterized in that, It can be used in home sofas, home mattresses, outdoor sofas, outdoor camping mats, yoga mats, or gymnastics cushioning mats.

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