Preparation process of double-sided composite four-season dual-purpose rattan mat

Abstract

This invention discloses a manufacturing process for a double-sided composite rattan mat mattress suitable for all seasons, belonging to the field of mattress manufacturing technology. The process involves pre-treating rattan strips and weaving them into a rattan mat surface. The bottom surface of the rattan mat is then sanded and coated with a hot-melt adhesive film. A pre-compressed insulating filling layer is then layered with the rattan mat surface. A hot-pressing method with a temperature difference between the upper and lower pressure plates is used, allowing the hot-melt adhesive film to penetrate directionally under the temperature gradient, forming a hardness gradient structure within the rattan mat surface. This simultaneously achieves an integrated composite of the rattan mat surface and the insulating filling layer. This invention's process is simple and easy to operate, producing a mattress with strong interlayer bonding, good support, and comfortable feel, meeting the needs of all seasons and suitable for large-scale industrial production.

Description

Technical Field

[0001] This invention relates to the field of mattress manufacturing technology, specifically to a manufacturing process for a double-sided composite rattan mat mattress suitable for all seasons. Background Technology

[0002] Rattan mats possess natural properties of being sweat-absorbent, breathable, and cool, providing a refreshing sleep experience in summer. As consumers increasingly demand functional bedding, double-sided composite rattan mat mattresses that combine summer coolness with winter warmth are gaining market attention. These products typically have one rattan side for summer use and the other side made of warm fabric for winter use, allowing for seasonal switching by flipping the mat.

[0003] In existing double-sided rattan mattresses, the connection between the rattan surface and the insulating filling layer generally uses physical splicing methods such as edge stitching, zippers, or frame fixing. Patent CN113133610A discloses a rattan mattress and its manufacturing process. This solution uses a connector between the rattan mat and the mattress, with the connector sewn to the rattan mat by thread, and the mattress fixed to the connector. While this solution addresses the connection stability issue to some extent, the rattan surface and the insulating filling layer only have physical contact, leaving a risk of separation and slippage after long-term use. Furthermore, existing technologies typically improve the hardness of the rattan surface by soaking and softening the rattan before weaving. Patent CN107283575A discloses a softening method to improve the weaving performance of rattan. This method involves multiple steps, including freezing, steam treatment, and soaking in a softening solution, to achieve a rattan bending angle of over 80°, reducing weaving difficulty. This method is applied to the entire rattan before weaving. After softening, the rattan has a uniform hardness throughout. If such softened rattan is woven into a rattan mat for use in a mattress, the overall softness of the rattan mat will cause it to lose its proper support. However, if it is not softened, the stiff feel of the rattan mat when the user lies down will affect the comfort.

[0004] Therefore, in the process of preparing double-sided composite rattan mattresses for all seasons, how to make the rattan surface and the warm filling layer form a strong integrated composite to prevent separation and slippage between the layers, while ensuring that the bottom layer of the rattan surface has sufficient support strength and effectively reducing the hardness of the surface layer of the rattan surface to improve the user's tactile comfort, is a technical problem that urgently needs to be solved in this field.

[0005] In summary, there is a need in this field to develop a rattan mattress manufacturing process that can simultaneously control the surface hardness of the rattan mat during the composite process of the rattan mat surface and the thermal insulation filling layer. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a manufacturing process for a double-sided composite rattan mat mattress suitable for all seasons. By polishing the bottom surface of the rattan mat and coating it with a hot melt adhesive film, and then stacking the pre-compressed thermal insulation filling layer with the rattan mat surface, a hot pressing method with a temperature difference between the upper and lower pressure plates can be used. This allows the temperature gradient to drive the directional penetration of the hot melt adhesive film, simultaneously achieving a strong and integrated composite between the rattan mat surface and the thermal insulation filling layer, as well as the formation of a hardness gradient structure within the rattan mat surface. This effectively solves the technical problems existing in the prior art.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a manufacturing process for a double-sided composite all-season rattan mattress, the process comprising the following steps: S1. The rattan is steamed, dried, selected, and knotted before being woven into a rattan mat surface. S2, Polish the bottom surface of the rattan mat, with a polishing depth of 5%-15% of the thickness of the rattan cross section. After polishing, the surface roughness Ra is 2μm-5μm. Apply hot melt adhesive film to the bottom surface of the polished rattan mat. S3, Prepare the thermal insulation filling layer. The material of the thermal insulation filling layer is one of three-dimensional crimped polyester fiber cotton and aerogel modified polyester cotton felt. The thermal insulation filling layer is pre-compressed with a compression ratio of 40%-70%. S4. The rattan mat surface coated with hot melt adhesive film and the pre-compressed thermal insulation filling layer are stacked together in the order of rattan mat surface on top and thermal insulation filling layer on the bottom, and placed in a hot press. The upper platen of the hot press contacts the front surface of the rattan mat surface, and the lower platen contacts the bottom surface of the thermal insulation filling layer. The temperature of the upper platen is set to 80℃-110℃, and the temperature of the lower platen is set to 130℃-155℃, forming a vertical temperature gradient between the upper and lower platens. The applied pressure is 0.3MPa-0.8MPa, and the holding time is 3min-10min. Driven by the temperature gradient, the hot melt adhesive film penetrates from the bottom of the rattan mat surface to the front surface of the rattan mat surface into the gaps between the rattan fibers. The penetration depth of the hot melt adhesive film decreases as the internal temperature of the rattan decreases, forming a hardness gradient structure in the rattan mat surface where the surface hardness is lower than the bottom hardness. After cooling and shaping, the rattan mat surface and the thermal insulation filling layer form an integrated composite mattress.

[0008] By coating the bottom surface of the sanded rattan mat with a hot melt adhesive film and layering it with a pre-compressed thermal insulation filling layer, the hot melt adhesive film is driven to penetrate directionally from the bottom surface of the rattan mat to the front surface using the vertical temperature gradient formed by the upper pressure plate (80℃-110℃) and the lower pressure plate (130℃-155℃). The penetration depth of the hot melt adhesive film decreases as the internal temperature of the rattan decreases, which can form a hardness gradient structure in the rattan mat where the surface hardness is lower than the bottom layer hardness. At the same time, after cooling and shaping, the hot melt adhesive film solidifies between the rattan mat surface and the thermal insulation filling layer to form an integrated composite. This allows a single hot pressing operation to simultaneously complete the strong interlayer bonding and the control of the surface hardness of the rattan mat surface.

[0009] Furthermore, in step S2, the bottom surface of the rattan mat is polished using a sanding belt or a grinding wheel with a grit size of 80-120 mesh. The polishing process is only applied to the bottom surface of the rattan mat, and the front surface of the rattan mat is not polished.

[0010] By using sanding belts or grinding wheels with a grit of 80-120 mesh to treat only the bottom surface of the rattan mat, the natural wax layer on the surface of the rattan can be removed, and the surface roughness Ra can reach 2μm-5μm. This enhances the mechanical bonding strength between the hot melt adhesive film and the bottom surface of the rattan mat, while the front surface of the rattan mat is not sanded, thus maintaining the natural luster and smooth touch of the front surface.

[0011] Furthermore, the hot melt adhesive film is made of either modified EVA hot melt adhesive film or TPU hot melt adhesive film, the thickness of the hot melt adhesive film is 0.03mm-0.10mm, the basis weight of the hot melt adhesive film is 25g / m²-80g / m², and the hot melt adhesive film is a continuous film.

[0012] By selecting one of modified EVA hot melt adhesive film and TPU hot melt adhesive film, with a hot melt adhesive film thickness of 0.03mm-0.10mm and a basis weight of 25g / m²-80g / m², and adopting a continuous film form, the hot melt adhesive film can be uniformly melted and stably penetrated into the gaps between rattan fibers and the fiber network of the thermal insulation filling layer during the hot pressing process.

[0013] Furthermore, in S4, the temperature difference between the upper pressure plate and the lower pressure plate is 20℃-75℃.

[0014] By controlling the temperature difference between the upper and lower pressure plates within 20℃-75℃, a stable penetration depth gradient of the hot melt adhesive film can be formed in the thickness direction of the rattan mat surface. This ensures that while the surface hardness of the rattan mat decreases, the bottom layer of the rattan mat maintains its original hardness to provide structural support.

[0015] Furthermore, the rattan mat surface is woven from natural rattan with a cross-sectional size of 2mm-6mm, and the warp and weft density of the rattan mat surface is 90-130 strands / 10cm.

[0016] By using natural rattan with a cross-sectional size of 2mm-6mm and weaving the rattan mat surface with a warp and weft density of 90 strands / 10cm-130 strands / 10cm, the rattan mat surface can have sufficient structural strength and a reasonable fiber gap distribution, providing uniform capillary channels for the penetration of hot melt adhesive film.

[0017] Furthermore, the pre-compression of the thermal insulation filling layer is carried out by mechanical cold pressing, with a cold pressing pressure of 0.5MPa-1.0MPa and a cold pressing holding time of 5min-10min.

[0018] By using mechanical cold pressing with a pressure of 0.5MPa-1.0MPa and a holding time of 5min-10min to pre-compress the thermal insulation filling layer, the rebound amplitude of the thermal insulation filling layer during hot pressing can be reduced, and the uniformity of interlayer stress during hot pressing composite can be improved.

[0019] Furthermore, the pre-compression of the thermal insulation filling layer adopts a micro-heat pre-compression method, with a pre-compression temperature of 40℃-60℃, a pre-compression pressure of 0.3MPa-0.6MPa, and a pre-compression holding time of 3min-5min.

[0020] By using a micro-heat pre-compression method with a pre-compression temperature of 40℃-60℃, a pre-compression pressure of 0.3MPa-0.6MPa, and a holding time of 3min-5min to pre-compress the thermal insulation filling layer, the fibers can be initially activated while compressing the thermal insulation filling layer, thereby enhancing the wetting effect between the hot melt adhesive film and the filling layer fibers during the subsequent hot pressing process.

[0021] Furthermore, in S1, the steaming temperature of the rattan is 90℃-100℃, the steaming time is 2h-4h, and the moisture content of the dried rattan is 6%-8%.

[0022] By steaming the rattan at a temperature of 90℃-100℃ for 2-4 hours and then drying it to a moisture content of 6%-8%, the flexibility of the rattan weaving can be guaranteed while avoiding the formation of a water film on the fiber surface, thus ensuring effective bonding between the hot melt adhesive and the rattan cellulose.

[0023] Furthermore, in S4, the gap between the upper and lower pressure plates of the hot press after mold closing is 95%-105% of the target thickness of the finished product.

[0024] By controlling the gap between the upper and lower pressure plates of the hot press after mold closing to 95%-105% of the target thickness of the finished product, the final thickness accuracy of the composite mattress can be controlled while ensuring that the hot melt adhesive film is fully melted and penetrated.

[0025] Furthermore, in S4, the cooling and shaping process adopts a natural cooling method, and the pressure remains constant during the cooling process.

[0026] By using natural cooling and maintaining constant pressure during the cooling process, the hot melt adhesive film can be smoothly transformed from a viscous flow state to a solid state under continuous pressure. The cured adhesive forms a dimensionally stable anchoring structure in the gaps between rattan fibers and the fiber network of the thermal insulation filling layer.

[0027] Compared with existing technologies, this manufacturing process for a double-sided composite rattan mattress suitable for all seasons has the following advantages: I. This invention coats the bottom surface of a rattan mat with a hot melt adhesive film and overlaps it with a pre-compressed insulating filling layer. Using a hot-pressing method with a temperature difference between the upper and lower pressure plates, the hot melt adhesive film is driven to penetrate directionally from the bottom to the front of the rattan mat by utilizing a vertical temperature gradient. This creates a hardness gradient structure within the rattan mat where the surface hardness is lower than the bottom layer. Simultaneously, the hot melt adhesive film solidifies between the rattan mat surface and the insulating filling layer, forming an integrated composite structure. This solves the problem of easy separation and slippage between the rattan mat surface and the insulating filling layer in existing technologies. Furthermore, while ensuring sufficient support strength at the bottom layer of the rattan mat, it effectively reduces the surface hardness of the rattan mat, significantly improving the tactile comfort when the user lies down.

[0028] Second, this invention achieves a firm composite of the rattan mat surface and the warm filling layer, as well as the control of the surface hardness of the rattan mat surface, through a single hot pressing operation. It eliminates the need for an additional overall rattan softening process and physical connectors between layers, which can greatly simplify the production process, reduce production steps, and lower the investment in production equipment and labor costs. At the same time, it avoids the adverse effects of physical connectors on the overall flatness of the mattress and the user experience.

[0029] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0031] Figure 1 This is a flowchart of the preparation process of the present invention. Detailed Implementation

[0032] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below. Example

[0033] This embodiment discloses a specific implementation method for manufacturing a double-sided composite rattan mat mattress suitable for all seasons. The process involves pre-treating natural rattan and weaving it into a rattan mat surface. The bottom surface of the rattan mat is then directionally sanded and coated with a hot-melt adhesive film. A pre-compressed insulating filling layer is then layered with the rattan mat surface. A hot-pressing method with a temperature difference between the upper and lower pressure plates is used, allowing the hot-melt adhesive film to directionally penetrate into the gaps between the rattan fibers under the driving temperature gradient. This creates a hardness gradient structure within the rattan mat surface, where the surface hardness is lower than the bottom layer. Simultaneously, this achieves a strong, integrated composite between the rattan mat surface and the insulating filling layer. This embodiment details the specific operation procedures, equipment selection, process parameter control, and quality inspection methods for each step. The resulting double-sided composite rattan mat mattress combines the cool and breathable properties of summer with the warm and comfortable properties of winter, and the interlayer bonding is strong, preventing separation or slippage even after long-term use.

[0034] The manufacturing process of the double-sided composite rattan mattress for all seasons provided in this embodiment is implemented according to the following steps.

[0035] The rattan mat surface is prepared as follows: The first step is to screen the rattan raw materials. Natural Indonesian rattan with a growth cycle of 3-5 years is selected as the raw material. Rattan with this growth cycle has a moderate fiber density and combines good flexibility and structural strength. During screening, rattan with defects such as insect infestation, cracking, and uneven thickness is removed, and high-quality rattan with uniform diameter and smooth surface is retained.

[0036] As an alternative to this embodiment, in addition to obtaining the rattan mat surface through the aforementioned self-weaving method, it can also be directly purchased from the market as a finished rattan mat surface that meets the specifications. When using a commercially available finished rattan mat surface, it is necessary to ensure that the cross-sectional size of its rattan strips is 2mm-6mm and the warp and weft density is 90 strands / 10cm-130 strands / 10cm. The bottom surface should be sanded and coated with hot melt adhesive film according to the subsequent S2 step. The subsequent processes are exactly the same as those for self-woven rattan mat surfaces.

[0037] The selected rattan is then steamed. The rattan is neatly stacked in a steaming pot, leaving a 5mm-10mm gap between each rattan to ensure even steam contact. Saturated steam is introduced into the steaming pot, raising the temperature to 90℃-100℃, and this temperature is maintained for 2-4 hours. The steaming process softens the rattan fibers, removes impurities and insect eggs, and promotes more even moisture distribution within the rattan.

[0038] After steaming, the rattan is removed from the steaming pot and transferred to a constant temperature and humidity drying room for drying. The temperature inside the drying room is controlled at 45℃-55℃, and the relative humidity at 50%-60%, using a combination of natural and forced ventilation. The moisture content of the rattan is checked periodically during the drying process, and drying is stopped when the moisture content reaches 6%-8%. This moisture content range ensures sufficient flexibility for the rattan during subsequent weaving, preventing breakage, and also provides the necessary moisture for the micro-swelling of the rattan fibers during the subsequent hot-melt adhesive film penetration process.

[0039] After drying, the rattan is selected and knots are removed. Uniform, undamaged rattan is selected again, and knots are removed using a specialized knot-removing machine, ensuring a clean cut and avoiding burrs. The processed rattan is then sorted by diameter, with a diameter deviation controlled within ±0.2mm to ensure the flatness of the woven rattan mat surface.

[0040] The sorted rattan is fed into an automatic weaving machine for warp and weft weaving to create the rattan mat surface. A plain weave structure is used, which offers good stability and breathability. The warp and weft density of the rattan mat surface is controlled between 90 and 130 threads / 10cm, with natural rattan cross-section dimensions of 2mm-6mm. By controlling the warp and weft density and rattan cross-section dimensions, the rattan mat surface possesses sufficient structural strength while forming a reasonable fiber spacing distribution, providing uniform capillary channels for the subsequent penetration of the hot-melt adhesive film. After weaving, the rattan mat surface undergoes preliminary cutting, with the cut size 5cm-8cm larger than the target size of the finished mattress, allowing for subsequent processing allowances.

[0041] The surface treatment and hot melt adhesive film coating of the rattan mat are as follows: The cut rattan mat surface is transferred to the sanding station for sanding. A belt sander with 80-120 mesh abrasive is used. Only the bottom surface is sanded; the front surface is left unsanded to preserve its natural luster and smooth feel. The sanding depth is controlled to 5%-15% of the rattan cross-section thickness. After sanding, a roughness tester is used to check the roughness of the bottom surface, ensuring a surface roughness Ra of 2μm-5μm.

[0042] The sanding process removes the natural wax layer from the bottom of the rattan, increasing its surface area and roughness, and enhancing the mechanical bonding strength between the hot melt adhesive film and the bottom of the rattan mat. Simultaneously, the sanding process creates numerous tiny fiber openings on the bottom of the rattan, providing channels for the hot melt adhesive film to penetrate. After sanding, a high-pressure air gun is used to remove sanding dust from the surface of the rattan mat, ensuring it is clean and free of impurities.

[0043] A hot melt adhesive film is applied to the bottom surface of the cleaned rattan mat. The hot melt adhesive film can be a modified EVA hot melt adhesive film or a TPU hot melt adhesive film; in this embodiment, a modified EVA hot melt adhesive film is used, as this material has good adhesive strength, flexibility, and aging resistance. The thickness of the hot melt adhesive film is 0.03mm-0.10mm, and the basis weight is 25g / m²-80g / m², using a continuous film form. A hot melt adhesive film laminating machine is used during coating to smoothly adhere the hot melt adhesive film to the bottom surface of the rattan mat, ensuring complete contact between the hot melt adhesive film and the bottom surface of the rattan mat, without bubbles or wrinkles. The roller temperature of the laminating machine is controlled at 60℃-70℃ to ensure initial adhesion of the hot melt adhesive film to the bottom surface of the rattan mat, preventing displacement during subsequent handling.

[0044] The preparation and pre-compression of the thermal insulation filling layer are as follows: Preparation of the thermal insulation filling layer. The material for the thermal insulation filling layer is either three-dimensional crimped polyester fiber cotton or aerogel-modified polyester cotton felt; in this embodiment, three-dimensional crimped polyester fiber cotton is selected. Three-dimensional crimped polyester fiber cotton has good elasticity, warmth retention, and breathability, and is lightweight and low in cost. The three-dimensional crimped polyester fiber cotton is processed into a cotton felt of uniform thickness through processes such as opening, carding, web formation, and needle punching. The initial thickness of the cotton felt is calculated and determined based on the target thickness of the finished mattress and the pre-compression ratio.

[0045] The prepared thermal insulation filling layer is pre-compressed. Pre-compression reduces the rebound amplitude of the thermal insulation filling layer during hot pressing and improves the uniformity of interlayer stress during hot pressing. Pre-compression can be performed by mechanical cold pressing or micro-heat pre-compression.

[0046] When using mechanical cold pressing, lay the insulation layer flat on the lower platen of the cold press, start the cold press, and slowly lower the upper platen to apply pressure. Control the cold pressing pressure between 0.5 MPa and 1.0 MPa, and hold the pressure for 5 to 10 minutes. After holding the pressure, slowly release the pressure and remove the pre-compressed insulation layer.

[0047] When using the micro-heat pre-compression method, lay the thermal insulation layer flat on the lower platen of a pre-compressor equipped with a heating function. Raise the temperature of the lower platen to 40℃-60℃, start the pre-compressor, and slowly lower the upper platen to apply pressure. Control the pre-compression pressure at 0.3MPa-0.6MPa, and hold the pressure for 3-5 minutes. Micro-heat pre-compression can initially activate the fibers while compressing the thermal insulation layer, enhancing the wetting effect between the hot melt adhesive film and the fibers of the filling layer during subsequent hot pressing. After holding the pressure, slowly release the pressure and remove the thermal insulation layer after it has cooled to room temperature.

[0048] The pre-compression ratio is controlled between 40% and 70%. The compression ratio refers to the ratio of the pre-compressed thickness of the insulation layer to its initial thickness. By controlling the pre-compression ratio, the overall thickness and firmness of the finished mattress can be adjusted to meet the needs of different users. After pre-compression, the insulation layer is cut to the same dimensions as the rattan mat surface.

[0049] Hot pressing and cooling are performed as follows: Stack the rattan mat surface coated with hot melt adhesive film and the pre-compressed thermal insulation layer together, with the rattan mat surface on top and the thermal insulation layer on the bottom. Ensure the edges of the rattan mat surface and the thermal insulation layer are aligned during stacking, without any misalignment. Place the stacked blank smoothly into the center of the lower pressure plate of the hot press.

[0050] The hot press includes an upper pressure plate, a lower pressure plate, a hydraulic drive system, and a temperature control system. Both the upper and lower pressure plates are made of stainless steel with good thermal conductivity, and their surfaces are polished to a flatness error of no more than 0.1 mm / m. The hydraulic drive system can precisely control the lifting speed and applied pressure of the pressure plates, while the temperature control system can independently control the temperature of the upper and lower pressure plates.

[0051] Start the hot press and slowly lower the upper platen until it contacts the front of the rattan mat. Continue applying pressure, maintaining it between 0.3 MPa and 0.8 MPa. Simultaneously, set the temperatures of the upper and lower platens separately using the temperature control system: upper platen temperature 80℃-110℃, lower platen temperature 130℃-155℃, with the temperature difference between the upper and lower platens controlled between 20℃ and 75℃. The gap between the upper and lower platens after mold closing should be 95%-105% of the target thickness of the finished product.

[0052] During the hot-pressing process, the high temperature of the lower pressure plate is transferred to the bottom surface of the rattan mat through the insulating filling layer, causing the hot melt adhesive film on the bottom surface of the rattan mat to melt. Because the temperature of the upper pressure plate is lower than that of the lower pressure plate, a vertical temperature gradient is formed in the thickness direction of the rattan mat surface, with the temperature gradually decreasing from the bottom surface to the front surface. Driven by the combined effect of the temperature gradient and pressure, the molten hot melt adhesive film directionally penetrates into the gaps between the rattan fibers from the bottom surface to the front surface of the rattan mat surface.

[0053] The penetration depth of the hot melt adhesive film decreases as the internal temperature of the rattan decreases. At the bottom layer of the rattan mat, the temperature is higher, resulting in better fluidity and deeper penetration of the hot melt adhesive film. This allows it to fully fill the gaps between the rattan fibers, maintaining a high degree of hardness after curing and providing good structural support. At the surface layer, the temperature is lower, leading to poorer fluidity and shallower penetration. Only a small amount of hot melt adhesive film enters the gaps between the surface fibers, resulting in a lower surface hardness after curing and improving tactile comfort when lying down. This creates a hardness gradient structure within the rattan mat, where the surface hardness is lower than the bottom layer.

[0054] Maintain the above pressure and temperature conditions for a holding time of 3-10 minutes. The holding time should be adjusted according to the thickness of the rattan mat surface and the type and thickness of the hot melt adhesive film to ensure that the hot melt adhesive film can fully melt and complete directional penetration.

[0055] After the pressure holding period is complete, turn off the heating system of the hot press, maintain constant pressure, and allow the composite mattress to cool and set naturally. During the cooling process, the hot melt adhesive film smoothly transitions from a viscous flow state to a solid state. The cured adhesive forms a dimensionally stable anchoring structure in the gaps between the rattan fibers and the fiber network of the insulation filling layer, making the rattan surface and the insulation filling layer an integrated composite. Once the composite mattress has cooled to room temperature, slowly release the pressure and remove the mattress.

[0056] After cooling and setting, the composite mattress is precisely cut to the target finished size. Then, the edges of the mattress are bound using a durable and breathable polyester-cotton blend fabric. After binding, the finished mattress undergoes quality inspection, including checks on appearance, dimensional accuracy, interlayer bonding strength, and firmness distribution. Once the inspection is passed, the mattress is packaged and stored.

[0057] To more intuitively demonstrate the overall process route of this embodiment, specifically, the left branch is the rattan mat surface preparation process (S1 to S2), the right branch is the insulation filling layer preparation and pre-compression process (S3), the middle branch merges into the hot pressing composite and cooling shaping process (S4), and finally the fine cutting and edge binding are carried out (S5).

[0058] The effectiveness of this embodiment is verified as follows: To verify the technical effectiveness of the process described in this embodiment, three groups of double-sided composite rattan mattress samples with different parameters were prepared according to the above process parameters, and compared with a control group sample prepared using an existing physical splicing process. The test items included interlayer peel strength, the hardness of the rattan surface and bottom layers, and the overall comfort evaluation of the mattress. The test results are shown in the table below.

[0059] Sample No. Upper Platen Temperature / ℃ Lower Platen Temperature / ℃ Pre-compression Ratio / % Interlaminar Peel Strength / N・cm⁻¹ Rattan Mat Surface Hardness / HA Rattan Mat Bottom Layer Hardness / HA Comfort Evaluation Sample 1: 85, 135, 50, 18.2±0.7, 61, 67 (Good) Sample 2: 95, 145, 60, 20.9±0.9, 59, 71 (Excellent) Sample 3: 105, 150, 65, 22.5±1.1, 57, 74 (Excellent) Control group - - - 11.3±1.2 65 65 General The test results show that the sample prepared using the process described in this embodiment has a significantly higher interlayer peel strength than the control group sample, indicating that a strong integrated composite is formed between the rattan mat surface and the insulation filling layer, effectively preventing interlayer separation and slippage during long-term use. Simultaneously, the surface hardness of the rattan mat sample prepared in this embodiment is significantly lower than that of the bottom layer, successfully achieving a hardness gradient structure. The surface hardness is moderate, providing a comfortable feel, while the bottom layer has higher hardness, offering good support performance. In contrast, the control group sample has the same hardness on both the surface and bottom layers, resulting in an overall stiffer feel and poorer comfort. The comfort evaluation results also indicate that the sample prepared in this embodiment performs excellently in terms of summer coolness, winter warmth, and overall support, meeting the needs of all four seasons.

[0060] This embodiment details the specific implementation process of a double-sided composite rattan mat mattress suitable for all seasons. The rattan is pre-treated through steaming, drying, and weaving to create the rattan mat surface. The bottom surface of the rattan mat surface is then directionally sanded and coated with a hot-melt adhesive film. A pre-compressed insulating filling layer is then layered with the rattan mat surface. A hot-pressing method with a temperature difference between the upper and lower pressure plates is used, leveraging the temperature gradient to drive the directional penetration of the hot-melt adhesive film. This creates a hardness gradient structure within the rattan mat surface, where the surface hardness is lower than the bottom layer, simultaneously achieving a strong and integrated composite between the rattan mat surface and the insulating filling layer.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A manufacturing process for a double-sided composite all-season rattan mattress, characterized in that, The process includes the following steps: S1. The rattan is steamed, dried, selected, and knotted before being woven into a rattan mat surface. S2, Polish the bottom surface of the rattan mat, with a polishing depth of 5%-15% of the thickness of the rattan cross section. After polishing, the surface roughness Ra is 2μm-5μm. Apply hot melt adhesive film to the bottom surface of the polished rattan mat. S3, Prepare the thermal insulation filling layer. The material of the thermal insulation filling layer is one of three-dimensional crimped polyester fiber cotton and aerogel modified polyester cotton felt. The thermal insulation filling layer is pre-compressed with a compression ratio of 40%-70%. S4. The rattan mat surface coated with hot melt adhesive film and the pre-compressed thermal insulation filling layer are stacked together in the order of rattan mat surface on top and thermal insulation filling layer on the bottom, and placed in a hot press. The upper platen of the hot press contacts the front surface of the rattan mat surface, and the lower platen contacts the bottom surface of the thermal insulation filling layer. The temperature of the upper platen is set to 80℃-110℃, and the temperature of the lower platen is set to 130℃-155℃, forming a vertical temperature gradient between the upper and lower platens. The applied pressure is 0.3MPa-0.8MPa, and the holding time is 3min-10min. Driven by the temperature gradient, the hot melt adhesive film penetrates from the bottom of the rattan mat surface to the front surface of the rattan mat surface into the gaps between the rattan fibers. The penetration depth of the hot melt adhesive film decreases as the internal temperature of the rattan decreases, forming a hardness gradient structure in the rattan mat surface where the surface hardness is lower than the bottom hardness. After cooling and shaping, the rattan mat surface and the thermal insulation filling layer form an integrated composite mattress.

2. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, In step S2, the bottom surface of the rattan mat is polished using a sanding belt or a grinding wheel with a grit size of 80-120 mesh. The polishing process is only applied to the bottom surface of the rattan mat, and the front surface of the rattan mat is not polished.

3. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, The hot melt adhesive film is made of either modified EVA hot melt adhesive film or TPU hot melt adhesive film. The thickness of the hot melt adhesive film is 0.03mm-0.10mm, the basis weight of the hot melt adhesive film is 25g / m²-80g / m², and the hot melt adhesive film is a continuous film.

4. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, In step S4, the temperature difference between the upper pressure plate and the lower pressure plate is 20℃-75℃.

5. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, The rattan mat surface is woven from natural rattan with a cross-sectional size of 2mm-6mm and a warp and weft density of 90-130 strands / 10cm.

6. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, The pre-compression of the thermal insulation filling layer is carried out by mechanical cold pressing, with a cold pressing pressure of 0.5MPa-1.0MPa and a cold pressing holding time of 5min-10min.

7. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, The pre-compression of the thermal insulation filling layer adopts a micro-heat pre-compression method, with a pre-compression temperature of 40℃-60℃, a pre-compression pressure of 0.3MPa-0.6MPa, and a pre-compression holding time of 3min-5min.

8. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, In step S1, the steaming temperature of the rattan is 90℃-100℃, the steaming time is 2h-4h, and the moisture content of the dried rattan is 6%-8%.

9. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, In step S4, the distance between the upper and lower pressure plates of the hot press after mold closing is 95%-105% of the target thickness of the finished product.

10. The manufacturing process of a double-sided composite all-season rattan mattress according to claim 1, characterized in that, In step S4, the cooling and shaping process adopts natural cooling, and the pressure remains constant during the cooling process.

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