Glue-free formaldehyde removal composite cloth and glue-free formaldehyde removal mattress

Abstract

The utility model provides glue-free formaldehyde-removing composite cloth and a glue-free formaldehyde-removing mattress. The glue-free formaldehyde-removing composite cloth comprises a first cloth layer, a second cloth layer and a formaldehyde catalytic powder layer located between the first cloth layer and the second cloth layer, wherein a plurality of hot melting bonding points are arranged on one side, facing the second cloth layer, of the first cloth layer, and the hot melting bonding points are bonded with the second cloth layer in a hot melting manner, so that the formaldehyde catalytic powder layer is sealed between the first cloth layer and the second cloth layer. According to the utility model, large-area gluing is replaced by the point-shaped hot melting combination part, so that the influence of an adhesive on the contact area of catalytic powder is avoided, the powder can be effectively sealed, catalytic components are prevented from falling off, the formaldehyde removal service life is lasting and efficient, and meanwhile, the production efficiency is improved.

Description

A glue-free formaldehyde-removing composite fabric and a glue-free formaldehyde-removing mattress Technical Field

[0001] This utility model belongs to the field of home mattress technology, specifically relating to a glue-free formaldehyde-removing composite fabric and a glue-free formaldehyde-removing mattress. Background Technology

[0002] Formaldehyde is a common indoor pollutant that poses a potential threat to human health. To improve indoor air quality, especially in products that come into close contact with the human body, such as textiles and furniture (e.g., mattresses), there is an urgent need for materials with formaldehyde removal capabilities.

[0003] The existing technologies for giving fabrics formaldehyde removal capabilities mainly include the following:

[0004] One approach is to modify the fabric manufacturing process by weaving activated carbon particles or other particles with adsorption or catalytic properties into the fibers. However, this method typically complicates the traditional fabric manufacturing process, increasing production difficulty and costs.

[0005] Another method is to post-treat existing fabrics, such as using an impregnation process to soak formaldehyde purifiers (like some commercially available formaldehyde purifiers) into the fabric, followed by drying. This impregnation process requires multiple steps, including soaking and drying, resulting in relatively low production efficiency. More importantly, the formaldehyde purifier adhering to the fabric surface through impregnation is prone to peeling off during use, especially when subjected to friction. This causes the fabric's formaldehyde removal performance to rapidly decline with increasing usage time, affecting its long-term effective formaldehyde removal function.

[0006] Therefore, there is still a need in this field for a new technical solution that can efficiently and persistently integrate formaldehyde removal materials into fabrics, avoid overly complex production processes, and overcome the problems of easy detachment of formaldehyde removal materials and rapid degradation of formaldehyde removal performance, thereby providing a formaldehyde removal composite fabric with stable performance and long service life and related products. Summary of the Invention

[0007] Based on the aforementioned shortcomings and deficiencies in the existing technology, one of the objectives of this utility model is to at least solve one or more of the aforementioned problems in the existing technology, or to provide a glue-free formaldehyde-removing composite fabric and a glue-free formaldehyde-removing mattress that meet one or more of the aforementioned needs.

[0008] To achieve the above-mentioned objectives, this utility model adopts the following technical solution:

[0009] This utility model provides a glue-free formaldehyde-removing composite fabric, comprising:

[0010] The first fabric layer, the second fabric layer, and the formaldehyde catalytic powder layer located between the first fabric layer and the second fabric layer;

[0011] The first fabric layer has multiple heat-fusion bonding points on the side facing the second fabric layer. These heat-fusion bonding points are bonded to the second fabric layer by heat fusion, thereby sealing the formaldehyde catalytic powder layer between the first and second fabric layers.

[0012] In a preferred embodiment, the hot-melt bonding points are distributed in a matrix or honeycomb pattern.

[0013] In a preferred embodiment, the diameter of the hot-melt joint is 0.1mm-1mm, the distance between them is 3mm-20mm, and the height is 0.1mm-0.5mm.

[0014] As a preferred embodiment, the hot-melt bonding point is made of PA material.

[0015] In one preferred embodiment, the formaldehyde catalytic powder layer is arranged in a uniformly distributed manner.

[0016] In a preferred embodiment, the formaldehyde catalyst powder in the formaldehyde catalyst powder layer has a mesh size of 200-1000.

[0017] In a preferred embodiment, the first fabric layer and the second fabric layer are selected from one or more of nonwoven fabric and TC fabric.

[0018] As a further preferred embodiment, the first and second fabric layers are non-woven fabrics, and the edges of the first and second fabric layers are sealed by hot-melt bonding.

[0019] In a preferred embodiment, the formaldehyde catalyst in the formaldehyde catalyst layer is a supported formaldehyde removal catalyst, comprising a carrier and an active component;

[0020] The carrier is selected from at least one of porous inorganic oxides, zeolites, sepiolite, and porous carbon materials;

[0021] Among them, the porous inorganic oxide is selected from one or more of cerium dioxide, zirconium dioxide, titanium dioxide, aluminum oxide, tin dioxide, silicon dioxide, lanthanum oxide, magnesium oxide, and zinc oxide, or a mixture or composite oxide.

[0022] The active ingredient is selected from at least one of platinum, rhodium, palladium, gold, and silver.

[0023] On the other hand, this utility model also provides a glue-free formaldehyde-removing mattress, the mattress including a mattress core and a mattress cover disposed outside the mattress core, the mattress cover including a top layer, a side edge and a bottom layer, the top layer and / or the side edge including any of the above-mentioned glue-free formaldehyde-removing composite fabrics.

[0024] As a preferred embodiment, the glue-free formaldehyde-removing composite is applied to the side of the mattress cover facing the mattress core.

[0025] Compared with the prior art, the advantages of this utility model are:

[0026] This invention confines the formaldehyde catalyst powder layer within the space between the first and second fabric layers. The resulting composite fabric structure effectively restrains the formaldehyde catalyst powder, preventing leakage or spillage during use due to friction, vibration, or other external forces. This not only improves the product's cleanliness and safety but also ensures a stable dosage of formaldehyde catalyst powder, maintaining its long-lasting formaldehyde removal performance and overcoming the problem of performance degradation caused by the easy shedding of formaldehyde removal agents in existing technologies.

[0027] Meanwhile, this invention sets multiple hot-melt bonding points on the first fabric layer and bonds it to the second fabric layer via hot-melt bonding, thereby sealing the formaldehyde catalyst powder layer between the two fabric layers. This point-like, regional hot-melt bonding method achieves interference-free bonding of the formaldehyde catalyst powder, solving the problem that when attempting to use traditional composite fabric adhesive methods to sandwich formaldehyde catalyst powder, the formaldehyde catalyst powder is easily wrapped by large-area spread or melted hot melt adhesive. This avoids the active sites of the catalyst being blocked, preventing it from effectively contacting formaldehyde molecules in the air, thus greatly reducing or even eliminating its formaldehyde removal effect.

[0028] Compared to the complex process of weaving microparticles into fibers, the composite structure and thermal fusion bonding process of this invention are relatively easier to control and implement. Compared to impregnation processes that require long soaking and drying times, thermal fusion bonding typically allows for a shorter production process and improves production efficiency. Attached Figure Description

[0029] Figure 1 is an exploded view of the adhesive-free formaldehyde-removing composite cloth of Embodiment 1 of this utility model;

[0030] Figure 2 is a schematic diagram of the structure of the first fabric layer in Embodiment 1 of this utility model;

[0031] Figure 3 is a schematic diagram of the structure of the adhesive-free formaldehyde removal composite cloth of Embodiment 1 of this utility model;

[0032] Figure 4 is a schematic diagram of the structure of the adhesive-free formaldehyde removal composite cloth of Embodiment 1 of this utility model;

[0033] Figure 5 is a schematic diagram of the structure of the adhesive-free formaldehyde removal composite cloth of Embodiment 2 of this utility model;

[0034] Figure 6 is a schematic diagram of the structure of the first fabric layer in Embodiment 3 of this utility model;

[0035] Figure 7 is a structural schematic diagram of the glue-free formaldehyde-removing mattress of Embodiment 4 of this utility model;

[0036] Figure 8 is a schematic diagram of the top layer structure of Embodiment 4 of this utility model;

[0037] Figure 9 is a schematic diagram of the perimeter structure of Embodiment 4 of this utility model.

[0038] Figure label:

[0039] 10-Glue-free formaldehyde-removing composite fabric, 11-First fabric layer, 12-Second fabric layer, 13-Formaldehyde catalytic powder layer, 111-Hot-melt bonding point, 112-Edge binding fabric, 1120-Sewing thread, 20-Mattress core, 31-Top layer, 311-Surface fabric, 312-Quilted filling, 32-Edge, 321-Outer fabric, 322-Edge filling, 33-Bottom layer. Detailed Implementation

[0040] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.

[0041] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The following description with reference to the accompanying drawings is provided to aid in understanding exemplary embodiments of the present invention as defined by the claims and their equivalents. It includes various specific details to aid understanding, but these are to be considered exemplary only. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present invention. Furthermore, to make the specification clearer and more concise, detailed descriptions of functions and structures well known in the art will be omitted.

[0042] Example 1:

[0043] This embodiment provides a glue-free formaldehyde-removing composite fabric. Referring to Figure 1, the glue-free formaldehyde-removing composite fabric includes a first fabric layer 11, a second fabric layer 12, and a formaldehyde catalytic powder layer 13 disposed between the first fabric layer 11 and the second fabric layer 12. Preferably, the materials of the first fabric layer 11 and the second fabric layer 12 can be selected from non-woven fabric and TC fabric. In this embodiment, to achieve good air permeability and structural stability, the first fabric layer 11 can specifically be made of non-woven fabric, and the second fabric layer 12 can specifically be made of TC fabric.

[0044] The key structural feature is that the inner side of the first fabric layer 11 facing the second fabric layer 12 has a plurality of discretely distributed heat-fusion bonding points 111. Referring to Figure 2, these heat-fusion bonding points 111 are distributed on the surface of the first fabric layer 11 and are pre-bonded to the first fabric layer 11, and are preferably arranged in a regular matrix.

[0045] The hot-melt bonding point 111 is preferably made of PA material, which has good thermoplasticity and adhesion to fabrics, and is environmentally friendly and harmless.

[0046] The heat-fusion bonding point 111 is pre-bonded to the microfiber structure of the first fabric layer, thus adhering firmly to the first fabric layer 11. Because the heat-fusion bonding point 111 is firmly attached to the first fabric layer 11, when the heat-fusion bonding point 111 is bonded to another fabric, the other fabric will be firmly fixed to the first fabric layer 11. In one specific configuration of this embodiment, the heat-fusion bonding point can be set on the first fabric layer 111 using a drip molding process.

[0047] Figure 3 is a schematic diagram of the structure of the formaldehyde-removing adhesive composite cloth after bonding in this embodiment. After the first fabric layer 11 and the second fabric layer 12 are attached together, by applying appropriate heat and pressure, the heat-melting bonding point 111 of the PA material melts and achieves a firm heat-melting bond with the corresponding area in contact with the second fabric layer 12, so that the first fabric layer 11 and the second fabric layer 12 are fixed together.

[0048] The formaldehyde catalytic powder layer 13 is pre-set between the first fabric layer 11 and the second fabric layer 12. After the first fabric layer 11 and the second fabric layer 12 are bonded and fixed through discrete hot-melt bonding points 111, the formaldehyde catalytic powder layer 13 is sealed in the interlayer space defined by the first fabric layer 11 and the second fabric layer 12. Except for the hot-melt bonding points 111, the other areas are directly attached to the first fabric layer 11 and the second fabric layer 12. This point-like sealing method ensures that the formaldehyde catalytic powder is not covered by the continuous adhesive layer.

[0049] In one specific configuration of this embodiment, to achieve good bonding strength and sufficient powder containment space, the aforementioned hot-melt bonding points 111 are approximately dot-shaped and arranged in a regular rectangular array. Their dimensional parameters can be selected as follows: the diameter of a single hot-melt bonding point 111 ranges from 0.1 mm to 1 mm; the center-to-center distance between adjacent hot-melt bonding points 111 ranges from 3 mm to 20 mm; and the approximate height of the hot-melt bonding points 111 on the first fabric layer 11 before hot-melting ranges from 0.1 mm to 0.5 mm. These parameter ranges ensure good performance in terms of adhesive strength, the softness and breathability of the adhesive-free formaldehyde-removing composite fabric, and the effective loading and contact area of ​​the formaldehyde catalyst powder.

[0050] In this embodiment, specific selections were made for the size parameters of the heat fusion bonding point 111. The diameter of a single heat fusion bonding point 111 was set to 0.1 mm, the center distance between adjacent heat fusion bonding points 111 was set to 3 mm, and the approximate height of the heat fusion bonding point 111 arranged on the first fabric layer 11 before heat fusion was 0.1 mm.

[0051] The formaldehyde catalytic powder in the formaldehyde catalytic powder layer 13 is a supported formaldehyde removal catalyst used for formaldehyde catalysis, and its composition includes a support and active components.

[0052] The carrier can be selected from at least one of porous inorganic oxides, zeolites, sepiolite, and porous carbon materials. The porous inorganic oxide can be selected from one of cerium dioxide, zirconium dioxide, titanium dioxide, aluminum oxide, tin dioxide, silicon dioxide, lanthanum oxide, magnesium oxide, and zinc oxide, or from a mixture of one or more of the above oxides, or from a composite oxide of one or more of the above oxides.

[0053] The active ingredient is selected from at least one of platinum, rhodium, palladium, gold, and silver.

[0054] In this embodiment, as a specific and non-limiting example, the formaldehyde catalyst powder can be specifically configured with the following components: the porous inorganic oxide support is selected from porous carbon materials such as activated carbon, and the active component is selected from platinum.

[0055] To achieve a uniform formaldehyde removal effect, formaldehyde catalytic powder is evenly spread on the first fabric layer 11 or the second fabric layer 12, forming a formaldehyde catalytic powder layer 13. To ensure catalytic efficiency and the stability of the powder in the adhesive-free formaldehyde removal composite fabric structure, the mesh size of the formaldehyde catalytic powder is preferably controlled between 200 mesh and 1000 mesh, and the average thickness of the formaldehyde catalytic powder layer 13 is preferably controlled between 0.05 mm and 0.2 mm. This particle size range ensures a large specific surface area, which is beneficial to the catalytic reaction, while also reducing the risk of penetrating the gaps between the fabric fibers.

[0056] The formaldehyde-removing adhesive composite fabric of this embodiment is also edge-sealed. As shown in Figure 4, an edge-sealing fabric 112 is provided at the edges of the first fabric layer 11 and the second fabric layer 12. The two sides of the edge-sealing fabric 112 cover the edges of the first fabric layer 11 and the second fabric layer 12 respectively. The sewing thread 1120 sews the first fabric layer 11, the second fabric layer 12 and the edge-sealing fabric 112 together, so that the edge-sealing fabric 112 closes the edges of the first fabric layer 11 and the second fabric layer 12.

[0057] In this embodiment, the first fabric layer 11 and the second fabric layer 12 are connected and fixed via discretely distributed hot-melt bonding points 111, rather than using traditional hot-melt adhesive mesh or film for full-coverage bonding. This allows most of the formaldehyde catalytic powder particles to be directly exposed in the gaps defined by the hot-melt bonding points 111, and to effectively exchange substances with the air outside the adhesive-free formaldehyde removal composite fabric through the breathable first and second fabric layers 11 and 12. When formaldehyde-containing air penetrates from one side of the adhesive-free formaldehyde removal composite fabric to the other, the air can flow through the gaps between the formaldehyde catalytic powder particles, making full contact with them. At this time, the formaldehyde molecules are catalytically oxidized and decomposed under the action of the catalytic powder, thereby achieving the purpose of removing formaldehyde from the air.

[0058] The significant advantage of the dot-matrix bonding method of this invention is that it maximizes the surface area of ​​the formaldehyde catalyst powder that can flow through the air, avoiding the problem that can occur with traditional adhesive composite fabrics where the formaldehyde catalyst powder is completely encapsulated by hot melt adhesive. Simultaneously, the formaldehyde catalyst powder is well physically sealed within the adhesive-free formaldehyde removal composite fabric, protected by two layers of fabric, without requiring additional processes to weave or impregnate it with the fabric layers. This prevents the formaldehyde catalyst component from aging and falling off due to prolonged friction, thus ensuring that the adhesive-free formaldehyde removal composite fabric has a highly efficient and long-lasting formaldehyde removal function and improving production efficiency.

[0059] Example 2:

[0060] This embodiment provides another implementation of a glue-free formaldehyde-removing composite fabric.

[0061] The main difference between this embodiment and Embodiment 1 is that the materials of the first fabric layer 11 and the second fabric layer 12 are different, as is the setting of the edge sealing structure.

[0062] Specifically, in this embodiment, both the first fabric layer 11 and the second fabric layer 12 are made of non-woven fabric. The edge sealing structure is shown in Figure 5. The first fabric layer 11 and the second fabric layer 12 are in direct contact around the entire edge of the composite fabric. Since non-woven fabric has heat-melting properties, the edges of the first fabric layer 11 and the second fabric layer 12 are bonded together by using a heat-melting process, thereby achieving the edge sealing of the adhesive-free formaldehyde-removing composite fabric.

[0063] Example 3:

[0064] This embodiment provides another implementation of a glue-free formaldehyde-removing composite fabric.

[0065] The main difference between this embodiment and Embodiment 1 lies in the distribution and specific dimensional parameters of the heat-fusion bonding points 111. Specifically, as shown in Figure 6, in this embodiment, the multiple heat-fusion bonding points 111 disposed on the first fabric layer 11 are distributed in a honeycomb matrix, rather than the rectangular array preferred in Embodiment 1. The honeycomb distribution is also a regular and stable arrangement, which can ensure the effective bonding between the first fabric layer 11 and the second fabric layer 12.

[0066] Meanwhile, in this embodiment, specific selections were made for the size parameters of the heat fusion bonding point 111. The diameter of a single heat fusion bonding point 111 was set to 1 mm, the center distance between adjacent heat fusion bonding points 111 was set to 20 mm, and the approximate height of the heat fusion bonding point 111 arranged on the first fabric layer 11 before heat fusion was 0.5 mm.

[0067] The parameter selection of the adhesive-free formaldehyde removal composite fabric in this embodiment results in a larger size of the adhesive-free formaldehyde removal composite fabric and a stronger bond between the first fabric layer 11 and the second fabric layer 12.

[0068] Other structures can be found in Example 1.

[0069] Example 4:

[0070] This embodiment provides a glue-free formaldehyde-removing mattress. Referring to FIG7, the glue-free formaldehyde-removing mattress typically includes a mattress core 20 and a mattress cover disposed on the outside of the mattress core 20. The mattress core 20 serves as a support structure, and the mattress cover covers the outer surface of the mattress core 20, including a top layer 31 that comes into contact with the user, an edge 32 that forms the side facade of the mattress, and a bottom layer 33.

[0071] At least one of the top layer 31 and the edge 32 uses a glue-free formaldehyde-removing composite fabric 10 for formaldehyde purification. In this embodiment, both the top layer 31 and the edge 32 of the mattress cover use a glue-free formaldehyde-removing composite fabric 10, which can be the specific structure described in Embodiment 1 or Embodiment 2.

[0072] In order to improve the efficiency of the formaldehyde catalytic powder layer 13 and reduce the wear of the glue-free formaldehyde removal composite cloth 10, the glue-free formaldehyde removal composite cloth 10 is specially positioned on the side of the mattress cover facing the mattress core 20, and also on the inside of the mattress cover, in the top layer 31 and the edge 32.

[0073] As shown in Figure 8, the top layer 31 includes, from the outside to the inside, a surface fabric 311, quilted filling 312, and a formaldehyde-removing adhesive-free composite fabric 10, with the formaldehyde-removing adhesive-free composite fabric 10 positioned closest to the mattress core 20. Similarly, as shown in Figure 9, the edge 32 includes, from the outside to the inside, an outer fabric 321, edge filling 322, and a formaldehyde-removing adhesive-free composite fabric 10, which is also positioned on the side of the edge 32 facing the mattress core 20.

[0074] The aforementioned structure, by placing the adhesive-free formaldehyde removal composite fabric on the inside, reduces wear caused by relative movement or external friction, helping to protect the structural integrity of the fabric itself. This, in turn, maintains effective sealing of the formaldehyde catalytic powder layer for a longer period, extending its effective service life. Furthermore, placing the adhesive-free formaldehyde removal composite fabric on the inside allows the outer surface fabric to be used with a more aesthetically pleasing and comfortable material, resulting in a more comfortable user experience.

[0075] The glue-free formaldehyde-removing mattress of this embodiment not only provides physical comfort and support, but also actively and continuously purifies the air that permeates from the mattress to the outside, creating a healthier and safer sleeping environment for the user. Furthermore, since the glue-free formaldehyde-removing composite fabric used is itself glue-free, it avoids introducing new sources of air pollution. In addition, this mattress combines the advantages of the glue-free formaldehyde-removing composite fabric of the aforementioned embodiments, offering a long service life and a simpler manufacturing process.

[0076] Example 5:

[0077] This embodiment provides a glue-free formaldehyde-removing mattress, which is similar in structure to the mattress described in Embodiment 3. The mattress in this embodiment also includes a mattress core (20) and a mattress cover (30) disposed outside the mattress core (20). The mattress cover (30) includes a top layer (31), a perimeter (32), and a bottom layer (33).

[0078] The feature of this embodiment is that the bottom layer (33) also uses the adhesive-free formaldehyde-removing composite fabric described in the previous embodiment. This further enhances the overall formaldehyde purification capacity of the mattress, forming a complete coverage of the top, sides, and bottom of the mattress by the adhesive-free formaldehyde-removing composite fabric, achieving a more comprehensive removal of formaldehyde from the inside of the mattress.

[0079] Other structures can be found in Example 4.

Claims

1. A glue-free formaldehyde-removing composite fabric, characterized in that, include: The first fabric layer (11), the second fabric layer (12), and the formaldehyde catalyst powder layer (13) located between the first fabric layer (11) and the second fabric layer (12); wherein, the first fabric layer (11) has a plurality of hot-melt bonding points (111) on the side facing the second fabric layer (12), and the hot-melt bonding points (111) are bonded to the second fabric layer (12) by hot-melt method, thereby sealing the formaldehyde catalyst powder layer (13) between the first fabric layer (11) and the second fabric layer (12).

2. The formaldehyde-removing adhesive composite fabric as described in claim 1, characterized in that, The hot-melt bonding points (111) are distributed in a matrix or honeycomb pattern.

3. The formaldehyde-removing adhesive composite fabric as described in claim 1, characterized in that, The diameter of the hot-melt bonding point (111) is 0.1mm-1mm, the distance between them is 3mm-20mm, and the height is 0.1mm-0.5mm.

4. The formaldehyde-removing adhesive composite fabric as described in claim 1, characterized in that, The hot-melt bonding point (111) is made of PA material.

5. The formaldehyde-removing adhesive composite fabric as described in claim 1, characterized in that, The formaldehyde catalytic powder in the formaldehyde catalytic powder layer (13) has a mesh size of 200-1000.

6. The formaldehyde-removing adhesive composite fabric as described in claim 1, characterized in that, The first fabric layer (11) and the second fabric layer (12) are selected from one or more of nonwoven fabric and TC fabric.

7. The formaldehyde-removing adhesive composite fabric as described in claim 6, characterized in that, The first fabric layer (11) and the second fabric layer (12) are non-woven fabrics, and the edges of the first fabric layer (11) and the second fabric layer (12) are sealed by hot melt bonding.

8. The formaldehyde-removing adhesive composite fabric as described in claim 1, characterized in that, The formaldehyde catalyst in the formaldehyde catalyst layer (13) is a supported formaldehyde removal catalyst.

9. A glue-free formaldehyde-removing mattress, the mattress comprising a mattress core (20) and a mattress cover disposed outside the mattress core (20), the mattress cover comprising a top layer (31), a perimeter (32), and a bottom layer (33), characterized in that, The top layer (31) and / or the surrounding edge (32) comprise the formaldehyde-removing adhesive composite fabric (10) as described in any one of claims 1-8.

10. A glue-free formaldehyde-removing mattress as described in claim 9, characterized in that, The glue-free formaldehyde-removing composite fabric (10) is located on the side of the mattress cover facing the mattress core (20).

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