High-resilience high-breathability ultra-light sheet

Abstract

The utility model provides a high resilience high air permeability ultralight sheet, including main body base material layer and functional layer, the main body base material layer is the three-dimensional stereo structure that high elasticity polyester fiber is woven by vertical netting process, the high elasticity polyester fiber is vertically arranged, the functional layer is covered above the main body base material layer, and the functional layer is arranged above the main body base material layer. And the functional layer and the main body base material layer are hot-pressed and compounded. The utility model is made of pure fibers through a vertical net forming process, has a unique vertical fiber net three-dimensional structure or a honeycomb fiber net structure, and has the characteristics of portability, high resilience, strong air permeability, strong plasticity, recoverability, quick drying and the like. The product is free of chemical additives, meets the environment-friendly health standard and is suitable for the fields of bedding, medical treatment, sports protection and the like.

Description

A high-resilience, high-breathability, ultra-lightweight sheet material Technical Field

[0001] This utility model relates to the field of sheet technology, and in particular to a high-resilience, high-breathability, ultra-light sheet. Background Technology

[0002] Traditional nonwoven materials (such as sponge, PU cotton, and EVA ethylene copolymer) are usually formed by foaming or parallel fiber web structure. However, using sponge and PU cotton will result in defects such as easy deterioration, aging, and the presence of chemical additives. Using materials such as EVA will result in defects such as poor breathability and softness. Existing cotton fiber materials usually adopt a parallel fiber web structure, and the fiber arrangement has poor compressive elasticity. Although it has a certain strength and stability, it is insufficient in terms of breathability and resilience. It is prone to deformation after long-term use, and its environmental performance also needs to be improved.

[0003] To address the aforementioned problems, this application provides a high-resilience, high-breathability, ultra-lightweight sheet material, proposing a sheet material based on a vertical fiber mesh structure of high-elasticity polyester fiber to overcome the shortcomings of traditional nonwoven materials. Summary of the Invention

[0004] This invention provides a high-resilience, high-breathability, ultra-lightweight sheet material. By technically modifying existing cushioning materials, it solves the problems of insufficient breathability and resilience of existing materials.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] A high-resilience, high-breathability, ultra-lightweight sheet material includes a main substrate layer and a functional layer. The main substrate layer is a three-dimensional structure formed by vertically weaving high-elasticity polyester fibers. The high-elasticity polyester fibers are arranged vertically. The functional layer covers and is disposed on top of the main substrate layer, and the functional layer and the main substrate layer are hot-pressed together.

[0007] Preferably, the main substrate layer is a honeycomb fiber web structure formed by vertically weaving high-elasticity polyester fibers, the thickness of the main substrate layer is 3-50mm, and the porosity is ≥85%.

[0008] Preferably, the high-elasticity polyester fiber of the main substrate layer is ELK composite fiber.

[0009] Preferably, the functional layer includes a reinforcing support layer and a waterproof layer, wherein the reinforcing support layer is disposed above the main substrate layer, and the waterproof layer is disposed above the reinforcing support layer.

[0010] Preferably, the reinforcing support layer comprises a carbon fiber mesh with a pore size of 2-10 mm, and the waterproof layer is a waterproof and breathable membrane.

[0011] Preferably, the reinforcing support layer includes a memory foam layer with a thickness of 5-20 mm.

[0012] Preferably, an antibacterial layer is provided above the waterproof layer. The antibacterial layer is a nano-silver ion coating and the thickness of the antibacterial layer is 0.1-0.5 mm.

[0013] The beneficial effects of this utility model are as follows:

[0014] This application provides a high-resilience upright cotton sheet, an innovative nonwoven three-dimensional material made from pure fibers through a vertical web-forming process. It features a unique upright fiber web three-dimensional structure or a honeycomb fiber web structure. Unlike the parallel fiber webs of traditional nonwoven materials, its fibers are arranged upright, forming a multi-layered, high-density, disordered knotted network structure with numerous internal gaps, allowing for better air circulation. It is lightweight, highly resilient, breathable, highly malleable, recyclable, and quick-drying. This product contains no chemical additives or harmful substances, is more energy-efficient and environmentally friendly, meets environmental and health standards, and is suitable for bedding, medical, and sports protective applications. Attached Figure Description

[0015] Figure 1 is a three-dimensional structural diagram of the upright fiber mesh of the main substrate layer of this utility model;

[0016] Figure 2 is a schematic diagram of the structure of Embodiment 1 of this utility model;

[0017] Figure 3 is a schematic diagram of the structure of Embodiment 2 of this utility model;

[0018] Figure 4 is a schematic diagram of the structure of Embodiment 3 of this utility model;

[0019] Figure 5 is a structural schematic diagram of Embodiment 4 of this utility model;

[0020] The diagram shows the following labels: 1. Main substrate layer; 2. Functional layer; 21. Reinforcing support layer; 22. Waterproof layer; 3. Antibacterial layer; 4. Fleece protective layer. Detailed Implementation

[0021] The specific content of this utility model will be described in detail below with reference to the accompanying drawings and embodiments.

[0022] Please refer to Figures 1-2. Specific embodiment 1 of this application provides a high-resilience, high-breathability, ultralight sheet material, including a main substrate layer 1 and a functional layer 2. The main substrate layer 1 is a three-dimensional structure formed by vertically weaving high-elasticity polyester fibers. The high-elasticity polyester fibers are arranged vertically. The functional layer 2 covers and is disposed above the main substrate layer 1, and the functional layer 2 and the main substrate layer 1 are hot-pressed together.

[0023] Furthermore, the main substrate layer 1 is a honeycomb fiber web structure formed by vertically weaving high-elasticity polyester fibers. The thickness of the main substrate layer 1 is 3-50mm, and the porosity is ≥85%. The fibers are formed into an upright three-dimensional mesh structure by vertical weaving equipment, containing a large number of small pores (0.1-1mm) to achieve layer-by-layer air permeability and rapid moisture discharge.

[0024] It dries quickly, with a water absorption rate of <5%, and its moisture evaporation rate is more than 3 times faster than traditional cotton products, making it suitable for humid environments. It contains no protein or sugar, retains more than 90% of its natural fiber color, and is not prone to aging.

[0025] Furthermore, the high-elasticity polyester fiber of the main substrate layer 1 is ELK composite fiber. ELK fiber has excellent anti-yellowing properties, can maintain its original color even after long-term use, and has a low density, light weight, and good resilience.

[0026] Furthermore, the functional layer 2 includes a reinforcing support layer 21 and a waterproof layer 22. The reinforcing support layer 21 is disposed above the main substrate layer 1, and the waterproof layer 22 is disposed above the reinforcing support layer 21.

[0027] Further, as shown in Figure 3, in specific embodiment 2, the reinforcing support layer 21 includes a carbon fiber mesh with a pore size of 2-10 mm, and the waterproof layer 22 is a waterproof and breathable membrane.

[0028] Furthermore, in another embodiment, the reinforcing support layer 21 includes a memory foam layer with a thickness of 5-20 mm.

[0029] Furthermore, as shown in Figure 4, in specific embodiment 3, an antibacterial layer 3 is also provided above the waterproof layer 22. The antibacterial layer 3 is a nano-silver ion coating, and the thickness of the antibacterial layer 3 is 0.1-0.5 mm. Combined with the waterproof layer 22, stains are easily washed away, and microorganisms are less likely to grow.

[0030] Furthermore, as shown in Figure 5, in specific embodiment 4, a fleece protective layer 4 is also provided below the main substrate layer 1.

[0031] The following steps are used when preparing the main substrate layer 1 of the product:

[0032] S1. Fiber selection: ELK composite fiber (polyester / polyolefin bicomponent fiber) is used, which has high strength, heat resistance and thermal bonding performance.

[0033] S2. Vertical Web Weaving: Using vertical web-laying equipment, fibers are evenly distributed in an upright state, forming a web with controllable thickness (3-50mm) and adjustable density (30-150kg / m²). 3 The three-dimensional structure of );

[0034] S3, High-temperature thermal bonding: The fiber web is hot-pressed and shaped at 130-180℃, and the low-melting-point components of ELK fiber are used to achieve joint bonding without the need for adhesives or additives.

[0035] S4. Post-processing: slitting and cold pressing to ensure thickness uniformity (error ≤ ±0.5mm) and surface flatness.

[0036] This application provides a high-resilience upright cotton sheet, an innovative nonwoven three-dimensional material made from pure fibers through a vertical web-forming process, featuring a unique upright fiber web three-dimensional structure or honeycomb fiber web structure. Unlike the parallel fiber webs of traditional nonwoven materials, its fibers are arranged upright, forming a multi-layered, high-density, disordered knotted network structure. The numerous internal gaps allow for smoother airflow. It possesses characteristics such as lightweight, high resilience, strong breathability, high plasticity, recyclability, and quick-drying properties. This product contains no chemical additives, meets environmental and health standards, and is suitable for bedding, medical, and sports protective applications.

[0037] This application uses vertically woven pure fiber products, without any chemical additives. It is green, non-toxic, odorless, environmentally friendly, and recyclable. The vertical web laying method provides excellent resilience, breathability, antibacterial properties, quick-drying, washability, and easy cleaning. This application is easy to process and can be made into rolls, sheets, and irregular shapes according to customer requirements. It has excellent resilience and environmental performance, and can be post-processed into composite functional materials with even higher resilience, larger volume, lighter weight, and better breathability. It has strong processing adaptability.

[0038] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

[0039] All standard parts used in this utility model can be purchased from the market, and irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art. In addition, the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here.

[0040] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or a connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

Claims

1. A high-resilience, high-breathability, ultralight sheet material, characterized in that, It includes a main substrate layer and a functional layer. The main substrate layer is a three-dimensional structure formed by vertically weaving high-elasticity polyester fibers. The high-elasticity polyester fibers are arranged vertically. The functional layer is disposed on top of the main substrate layer and is hot-pressed together with the main substrate layer.

2. The high-resilience, high-breathability, ultralight sheet material according to claim 1, characterized in that, The main substrate layer is a honeycomb fiber network structure formed by vertically weaving high-elasticity polyester fibers. The thickness of the main substrate layer is 3-50mm, and the porosity is ≥85%.

3. The high-resilience, high-breathability, ultralight sheet material according to claim 1, characterized in that, The high-elasticity polyester fiber of the main substrate layer is ELK composite fiber.

4. The high-resilience, high-breathability, ultralight sheet material according to claim 1, characterized in that, The functional layer includes a reinforcing support layer and a waterproof layer. The reinforcing support layer is disposed above the main substrate layer, and the waterproof layer is disposed above the reinforcing support layer.

5. The high-resilience, high-breathability, ultralight sheet material according to claim 4, characterized in that, The reinforcing support layer includes a carbon fiber mesh with a pore size of 2-10 mm, and the waterproof layer is a waterproof and breathable membrane with a thickness of 0.2-0.5 mm.

6. The high-resilience, high-breathability, ultralight sheet material according to claim 4, characterized in that, The reinforcing support layer includes a memory foam layer with a thickness of 5-20 mm.

7. The high-resilience, high-breathability, ultralight sheet material according to claim 4, characterized in that, An antibacterial layer is also provided above the waterproof layer. The antibacterial layer is a nano silver ion coating with a thickness of 0.1-0.5 mm.

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