Integrally-molded and double-sided-feeling sectional filament mattress and manufacturing method

Abstract

To provide an integrally-molded and double-sided-feeling sectional filament mattress.SOLUTION: A mattress includes an upper layer and a lower layer with different hardness. The upper layer and the lower layer include different sections. Each section has different density and length. The upper layer and the lower layer are integrally molded by continuous production. The different densities and lengths are obtained by adopting independent control systems to control corresponding screw extrusion speeds of the upper and lower layers, a speed of a conveying roller, a speed of a pulling roller, and a running time under each speed condition. The mattress is formed by adopting a filament material, has an upper / lower layer structure with different hardness and provides a double-sided feeling. The upper layer and the lower layer includes different sections, so as to improve a support condition of the spine, achieve an effect of body pressure dispersion, and improve sleep comfort. The mattress further includes a transition area with relatively low density, so that the mattress can be folded. The integral molding is adopted for the mattress so as to maintain structural stability of each section of the mattress.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to the field of mattresses, and more particularly to a one-piece, compartmentalized, double-sided, tactile filament mattress and method of manufacture. [Background technology]

[0002] Mattress products have become popular in China, and there are many types of materials, including latex, palm, memory foam, nano technology, and air mattresses. The function of mattress products is to ensure that consumers can have a healthy and comfortable sleep, and the quality of mattress performance is mainly determined by the mattress material, breathability, and mechanical support for the human body. Filament mattress refers to a mattress that uses 4D filament material as the cushion layer structure part, and the filament material is made of raw materials such as thermoplastic resin (PE, POE) or thermoplastic polyester elastomer (TPEE), which is melted at high temperature and directly sprayed to form the yarn. The entire production process does not require chemical adhesives for adhesion, has no unpleasant odor, and is completely free of formaldehyde. In addition, filament mattresses are 90% air in addition to the filaments, and have good breathability. Because the health properties of filament mattresses are excellent, improvements in the performance of filament mattresses are mainly focused on mechanical support.

[0003] The improvement of the mechanical support of the mattress can be achieved in the first embodiment by improving the filament material. For example, CN116219641A discloses a highly fatigue-resistant filament mat and its manufacturing method, and the filament components include 60-90 parts of thermoplastic elastomer resin, 10-40 parts of polyolefin resin, 1-2 parts of crosslinking agent, 0.1-0.4 parts of initiator, 0.1-0.5 parts of catalyst, 0.3-0.6 parts of antioxidant, and 0.5-2 parts of processing aid. In the second embodiment, the improvement can be achieved by improving the structure of the mattress, for example, CN215456807U adopts a multi-layer structure with different hardness to relatively improve the distribution of human body pressure. However, because the weight of different parts of the human body causes different pressure distribution in the mattress, the mattress is more suitable for compartmentalization. However, the compartment installation is generally made up of a plurality of mat bodies assembled together, for example, JP2022069693A discloses a mattress divided into a plurality of mat bodies in the longitudinal direction. Mattresses obtained by joining a plurality of mat bodies together bring about new technical problems, such as different mechanical performances on both sides of the joining position, different deformations when subjected to pressure, and the joining position shifts over time, resulting in destruction of the structure and easy accumulation of dirt. An integrally molded mattress can avoid the technical problems of assembly, but a filament mattress of different compartments molded together has not yet been reported in the literature. In addition, mattresses are generally difficult to fold, and a foldable mattress is desired for special applications (such as hospital beds) or storage. In view of the above technical problems, the present invention is particularly proposed. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Chinese Patent No. CN116219641A Publication [Patent Document 2] China Utility Model No. CN215456807U [Patent Document 3] Japanese Patent Publication No. JP2022069693A Summary of the Invention [Means for solving the problem]

[0005] In order to solve the above technical problems, the first aspect of the present invention provides an integrally molded compartmentalized double-sided filament mattress, the mattress includes an upper layer and a lower layer with different hardness, the upper layer and the lower layer include different compartments, each compartment has a different density and length, the upper layer and the lower layer are integrally molded by continuous production, the integral molding is to simultaneously and continuously produce the filaments of the upper layer and the lower layer, and set the filament production speed and production time according to the compartment to form different compartments of the different upper layer and the lower layer, and obtain an integrally molded mattress. The compartment in the present invention refers to a load-bearing compartment, a transitional compartment, or a structural compartment applicable to other mattresses.

[0006] The human spine has a normal physiological curvature, and neither a mattress that is too soft nor a mattress that is too hard can adequately support the spine. The support of the mattress on the human body is the result of the interaction between the entire mattress and the weight of the human body, and different body types and weights have different requirements for the hardness and hardness distribution of the mattress. In view of the different weight distributions in different parts of the human body, the mattress of the present invention adopts a compartmentalized type, and different load-bearing compartments of the mattress have different hardness characteristics, thereby improving the support conditions of the spine, achieving the effect of distributing body pressure, and improving the comfort of sleep.

[0007] For the same filaments, the firmness of the mattress depends primarily on the density of the filaments, the higher the density the firmer. In one or more embodiments, the upper and lower layers each include 2 to 6 load-bearing compartments.

[0008] For example, the upper layer and the lower layer each include two load-bearing regions, namely, an upper region and a lower region. Alternatively, the upper layer and the lower layer each include three load-bearing regions, namely, a head and back region, a waist and hip region, and a foot region. In this case, the densities of the upper layer head and back region, waist and hip region, and foot region are each 55 to 70 kg / m 3, 65~80kg / m 3 and 60-70kg / m 3 The percentages of the length of the upper layer are 25-30%, 30-35% and 30-40%, respectively. The density of the lower layer head and back area, lower back and buttocks area and foot area is 40-50kg / m2, respectively. 3 , 45~60kg / m 3 and 40-50kg / m 3 and the percentages of the length of the lower layer are 25-30%, 30-35%, and 30-40%, respectively.

[0009] In one typical example, as shown in Figure 1, the mattress sections include a first head and back region 1001, a first hip and waist region 1002, a first foot region 1003, a second head and back region 1004, a second hip and waist region 1005, and a second foot region 1006, each section having a different density and length. For example, a mattress with a length of 2m has a head and back region of 64cm, a hip and waist region of 60cm, and a foot region of 76cm.

[0010] In one or more embodiments, the mattress further includes a transition region located between the load bearing compartments, the transition region having a density much less than the density of the load bearing compartments. The transition region may be located between all of the load bearing compartments or between some of the load bearing compartments. The densities of the transition regions may all be the same or different, for example, between 25-30 kg / m. 3 or 25 to 28 kg / m 3 , 28~30kg / m 3 The lengths of the transition regions may all be the same or may vary, for example, each occupying 1%-3% of the length of the mattress, or 1%-2% and 2-3%, respectively.

[0011] In one exemplary embodiment, a schematic diagram of the mattress construction and folding is shown in FIG. 2, where the mattress further includes a first transition region 1007, a second transition region 1008, a third transition region 1009 and a fourth transition region 1010, where the length of the third transition region 1009 is greater than that of the first transition region 1007 and the density of the third transition region 1009 is less than that of the first transition region 1007, and the fourth transition region has a similar relationship to that of the second transition region, and due to the length and density settings of each transition region, the head and foot regions of the mattress are very easy to fold upwards.

[0012] In one exemplary embodiment, a schematic diagram of the mattress construction and folding is shown in Figure 3, where the mattress further includes a first transition region 1007, a second transition region 1008, a third transition region 1009 and a fourth transition region 1010, where the length of the third transition region 1009 is greater than the first transition region 1007 and the density of the third transition region 1009 is less than the first transition region 1007, and the fourth transition region has an inverse relationship to the second transition region. Due to the length and density settings of each transition region, the head and back regions of the mattress tend to fold upwards and the foot regions tend to fold downwards, forming a Z-fold, making the mattress more easily foldable.

[0013] The upper layer and the lower layer may have different hardnesses, and the upper layer may have a lower hardness and the lower layer may have a higher hardness, or the upper layer may have a higher hardness and the lower layer may have a lower hardness. The hardnesses of the upper and lower layers can be adjusted by the filament material, hollow or solid filament, the diameter of the filament, the density of the filament, etc. In one typical example, the hardness of the upper layer is smaller than that of the lower layer, the thickness of the upper layer is smaller than that of the lower layer, the thickness of the upper layer is 2 to 3 cm, and the thickness of the lower layer is 4 to 5 cm.

[0014] In one or more embodiments, the material of the upper layer and lower layer filaments is one or more selected from thermoplastic polyester elastomers (TPEE), ethylene polymers (e.g., polyethylene PE), and polyolefin thermoplastic elastomers (POE), and preferably, the material of the upper layer filaments is selected from TPEE or PE, and the material of the lower layer filaments is selected from PE.

[0015] A second aspect of the present invention further provides a manufacturing method for an integrally molded compartmentalized double-sided tactile filament mattress as described in any one of the embodiments of the present invention, in which an independent control system is adopted to control the production of the filaments of the upper and lower layers respectively, and form each compartment of the upper and lower layers according to the compartment settings.

[0016] In one or more embodiments, the method further comprises: (1) feeding the upper and lower layer materials into respective melt channels and then into a yarn delivery assembly; (2) continuously ejecting an upper layer filament thread and a lower layer filament thread by adjacent thread ejection regions in a thread ejection assembly; (3) The upper filament thread and the lower filament thread are adjacent to each other and enter vertically into water, and are transported, cooled, and hardened in water to form the upper filament and the lower filament, which are then guided and pulled out of the water surface, and the upper filament and the lower filament are maintained adjacent to each other and positioned vertically when pulled out of the water surface; (4) The filaments are pulled in sequence to set and form the upper and lower sections of the mattress in a continuous manner, thereby obtaining an integrally molded divided double-sided filament mattress.

[0017] In one or more embodiments, the step (1) further includes a raw material mixing and raw material drying operation before the raw materials are fed into the melt channel. The upper and lower raw materials are fed into the melt channel by a vacuum method, and preferably, the melt channel is a screw extrusion channel. The raw materials are further filtered before passing through the melt channel and entering the yarn-out assembly.

[0018] In one or more embodiments, in step (2), the adjacent yarn spouting regions include an upper layer yarn spouting region and a lower layer yarn spouting region, and the yarn diameter spouted by the upper layer yarn spouting region is smaller than the yarn diameter spouted by the lower layer yarn spouting region, and preferably, the yarns spouted by the upper layer yarn spouting region and the lower layer yarn spouting region are both solid yarns with yarn diameters of 0.8 to 1.5 mm and 1.0 to 2.5 mm, respectively; or the yarn spouted by the upper layer yarn spouting region is a solid yarn with a yarn diameter of 0.8 to 1.5 mm, and the yarn spouted by the lower layer yarn spouting region is a hollow yarn with an outer ring yarn diameter of 2.8 to 3.4 mm, and an inner ring hole diameter of 2.2 to 2.8 mm. Alternatively, the fibers spouted from the upper layer yarn spouting region and the lower layer yarn spouting region are hollow fibers, the outer ring yarn diameter is 2.8 to 3.4 mm, and the inner ring hole diameter is 2.2 to 2.8 mm.

[0019] In one or more embodiments, in step (3), a small amount of the upper layer filament thread adjacent to the lower layer filament thread is wrapped around each other and adhered to each other as a loop.

[0020] In one or more embodiments, in step (4), the section settings include a filament density in the section and a section production time, the filament density corresponding to a screw extrusion speed, a conveying speed, and a pulling speed, and the section production time corresponding to a screw extrusion running time, a conveying running time, and a pulling running time at a particular set speed, preferably conveyed by a conveying roller and pulled by a pulling roller.

[0021] In one or more embodiments, in step (4), the method of determining the screw extrusion speed, conveying speed and pulling speed is to set the corresponding screw extrusion speeds of the upper and lower layers according to the expected filament density of each section of the upper and lower layers, and adjust the conveying roller speed and the pulling roller speed according to the difference in density distribution of the mattress. If the density needs to be increased, the conveying roller speed and the pulling roller speed are reduced, and if the density needs to be decreased, the conveying roller speed and the pulling roller speed are increased.

[0022] In one or more embodiments, the section production time is the ratio of section length to conveyor roller, and the pulling roll speed is 80-90% of the conveyor roller speed.

[0023] In one or more embodiments, in step (4), the longitudinal direction of the mattress is the longitudinal direction along which the product is continuously produced.

[0024] A third aspect of the present invention further provides a manufacturing apparatus for an integrally molded compartmental double-sided tactile filament mattress according to any one of the embodiments of the present invention, as shown in FIG. 4, the apparatus includes a yarn delivery assembly 1, a shower plate 8, a water storage tank 9, a conveying roller 10, a pulling roller 11, a guide roller 12, a dryer 3, a conveying screw 4 and an independent control system (not shown in FIG. 4).

[0025] The output side of the dryer is connected to the input side of the conveying screw, the output side of the conveying screw is connected to the input side of the yarn delivery assembly, and the conveying screw includes a small heating section.

[0026] The thermoplastic elastomer raw materials used in the upper and lower layers pass through the respective conveying screws and have their own independent raw material running channels and control systems, which can be controlled independently according to the density settings of the upper and lower layers.

[0027] The yarn discharge assembly includes a junction valve 2, a yarn ejection die 5, an allocation plate 6, and a yarn ejection plate 7, the junction valve 2 communicates with the conveying screw and the yarn ejection die respectively, the yarn ejection die is closely attached downward to the allocation plate, the allocation plate is closely attached downward to the yarn ejection plate, and the allocation plate can balance the extrusion pressure of the molten fluid at the yarn ejection plate.

[0028] The yarn ejection mold is provided with a number of yarn ejection channels, the allocation plate has a number of allocation areas corresponding to the number of the yarn ejection channels, and a number of allocation holes are further provided on the allocation areas, the hole diameters and pitches of the allocation holes in each allocation area are all different, the yarn ejection plate is divided into a number of yarn ejection areas, and the state of any one of the yarn ejection areas is either solid or hollow.

[0029] The water tank is used for storing cooling water, the conveying roller is provided in the water tank and is completely submerged in the cooling water of the water tank, the yarn outlet assembly is located outside the water tank, the shower plate is installed at an incline between the yarn outlet assembly and the conveying roller, and a first side of the shower plate contacts the side of the conveying roller that is close to the water surface, a second side of the shower plate extends to the yarn outlet assembly, and the shower inclined surface of the shower plate faces the yarn outlet surface of the yarn outlet assembly.

[0030] The upper part of the water storage tank further includes a far-infrared radiator, the radiation range of which covers the space from the thread ejection plate to the water surface, realizing uniform temperature throughout the thread drop space, and the far-infrared radiator maintains the temperature of the entire space at 120℃~220℃.

[0031] The widthwise two sides of the mattress between the shower plates further include a shaping mold installed, which is a device that corresponds to the angle of the shower plate inclination and can spray cyclic cooling water, and the function of the shaping mold is to compress the loose filaments on the widthwise two sides of the mattress inward, avoid the problem of re-cutting, save production materials, reduce labor intensity, and the smooth side edges make it easy to insert the mattress into the mattress cover.

[0032] A number of guide rollers are provided inside the water storage tank, and a pulling roller is further provided outside the water storage tank, the pulling roller is used to pull out the cooled filament layer from the water storage tank via the conveying roller, and the number of guide rollers are arranged in order along the filament layer from the side away from the water surface of the conveying roller in the moving direction of the pulling roller, The independent control systems are used to control the screw extrusion speed, the transport roller speed, the traction roller speed and the run times at particular speeds to control the formation of the mattress sections. Effect of the Invention

[0033] Compared with the prior art, the beneficial effects of the present invention include at least the following: 1. The mattress of the present invention adopts a filament material and has an upper and lower layer structure with different hardness, providing a double-sided experience. The upper and lower layers are both divided into head and back regions, lower back and hip regions and foot regions, which improves the support conditions of the spine, achieves the effect of dispersing body pressure, and enhances sleeping comfort.

[0034] 2. The mattress of the present invention further includes a transition region having a relatively low density, thereby allowing the mattress to be folded, and by adjusting the density and length of the transition region, folding is made easier and damage to the mattress is relatively small.

[0035] 3. The raw materials of the upper and lower layers of the mattress of the present invention each have their own independent melting channel, yarn discharging assembly and control system, so that they can be controlled independently according to the density settings of the upper and lower layers. In the continuous production process, by cycling the screw extrusion speed, the conveying roller speed, the pulling roller speed and the operation time under each speed condition according to this specific program, an integrally molded compartmentalized double-sided filament mattress including compartments such as head and back area, transition area, waist and hip area, transition area and foot area can be obtained.

[0036] 4. The mattress of the present invention is manufactured in one piece, which maintains the structural stability of each section of the mattress. The one piece manufacturing process allows for continuous production, which is relatively efficient. [Brief description of the drawings]

[0037] The drawings herein are incorporated in the specification and constitute a part of this specification, show embodiments consistent with the implementation of the present invention, and are used together with the specification to interpret the principles of the embodiments of the present invention. It is obvious that the drawings in the following description are merely some embodiments of the implementation of the present invention, and those skilled in the art can obtain other drawings based on these drawings without any creative effort. [Figure 1] FIG. 1 is a schematic diagram of a typical structure of a filament mattress. [Diagram 2] FIG. 2A is a schematic diagram of a filament mattress and folds including a transition region. [Diagram 3] FIG. 1B is a schematic diagram of a filament mattress and folds including a transition region. [Figure 4] FIG. 2 is a schematic structural diagram of the manufacturing equipment according to the first embodiment. [Diagram 5] FIG. 2 is a schematic diagram of the local structure of the manufacturing equipment of Example 1. [Figure 6] 1 is a schematic cross-sectional view of a yarn dispensing assembly 1 of a manufacturing apparatus according to a first embodiment. [Figure 7] FIG. 2 is a schematic diagram of the yarn spouting area of ​​the manufacturing equipment of Example 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] In order to make the objectives, technical solutions and beneficial effects of the present invention clearer, the present invention will be described in more detail below in conjunction with the drawings and specific embodiments. Examples of the embodiments are shown in the drawings. It should be understood that the specific examples described in the following embodiments of the present invention are merely illustrative descriptions of specific embodiments of the present invention, and are intended to interpret the present invention, but are not intended to limit the present invention.

[0039] It should be understood that the endpoints of any ranges and any values ​​stated herein are not limited to that exact range or value, but that these ranges or values ​​include any approximations of these ranges.

[0040] Example 1 For the integrally molded compartmentalized double-sided sensory filament mattress, the manufacturing equipment includes a junction valve 2, a dryer 3, a conveying screw 4, a yarn ejection mold 5, an allocation plate 6, a yarn ejection plate 7, a shower plate 8, a water storage tank 9, a conveying roller 10, a traction roller 11, and a guide roller 12 (here, 13 is the water surface of the water storage tank), as shown in FIG. The dryer 3 is divided into a first dryer 31 and a second dryer 32, the conveying screw 4 is divided into a first conveying screw 41 and a second conveying screw 42, the junction valve 2 is divided into a first branch channel 21 and a second branch channel 22, the yarn ejection die 5 is divided into a first yarn ejection channel 51 and a second yarn ejection channel 52, the allocation plate 6 is divided into a first allocation area 61 and a second allocation area 62, and the yarn ejection plate 7 is divided into a first yarn ejection area 71 and a second yarn ejection area 72, where the junction valve 2, the yarn ejection die 5, the allocation plate 6, and the yarn ejection plate 7 are collectively referred to as a yarn ejection assembly 1, as shown in Figures 5 to 7.

[0041] Here, the junction valve 2 is tightly attached to the yarn ejection mold 5, the lower side of the yarn ejection mold 5 is tightly attached to the upper side of the allocation plate 6, and the lower side of the allocation plate 6 is tightly attached to the upper side of the yarn ejection plate 7. The junction valve 2 is provided with two first and second diverter channels 21 and 22 corresponding to the first and second conveying screws 41 and 42 through which the thermoplastic elastomer raw material used in the upper and lower layers passes. The yarn ejection mold 5 is composed of an upper mold, a middle mold, and a lower mold, and is divided into two independent first yarn ejection channel 51 and a second yarn ejection channel 52. The first yarn ejection channel 51 and the second yarn ejection channel 52 are connected to the corresponding first diverter channel 21 and second diverter channel 22, respectively. On the allocation plate 6, there are two allocation areas 61 and 62 corresponding to the first yarn spouting channel 51 and the second yarn spouting channel 52, and on the allocation plate 6, there are further provided a number of allocation holes communicating with the lower yarn spouting plate, and the yarn spouting plate 7 is composed of two first yarn spouting areas 71 and a second yarn spouting area 72, and on any one of the yarn spouting areas 71 and 72, there are a number of yarn spouting holes, and the state of the yarn spouting holes is one of solid or hollow, where the diameter of the hollow is obviously larger than the diameter of the solid. In this embodiment 1, the yarn spouting area 71 is a solid hole, and the yarn spouting area 72 is a hollow hole.

[0042] The manufacturing method of the above equipment is as follows: the upper layer TPEE raw material and the lower layer PE raw material are dried in the dryer 3, fed into the screw 4, melted, and delivered to the merging valve 2, and then sent through the yarn ejection die 5, the allocation plate 6, and the yarn ejection plate 7 to obtain the upper layer TPEE filament yarn and the lower layer PE filament yarn.

[0043] Here, the hole diameter of the allocation plate 6 is 4 mm, and it fits with the yarn ejection mold to form two independent raw material layer allocation areas on the left and right. The number of allocation holes on the allocation plate is 106 per row, and the adjacent two rows are installed so as to cross each other, with 8 rows in each of the left and right allocation areas.

[0044] The upper layer TPEE filament yarn and the lower layer PE filament yarn naturally fall into the water, and the speed of the yarns slows down, causing adjacent yarns to come into contact in a loop. The yarn loop layer is then transported by the transport rollers into a cooling water tank at 20°C to be quickly cooled and hardened. As shown in Figure 6, the upper layer TPEE filament yarn and the lower layer PE filament yarn and a small amount of adjacent yarns are wrapped around each other and adhered to each other in a loop, improving the bonding strength of the upper and lower layers.

[0045] The cooled yarn loop is pulled out of the water surface by a guide roller, and when pulled out of the water surface, the upper layer filaments and the lower layer filaments are maintained adjacent to each other and positioned above and below each other, and are pulled by a pulling roller. An independent control system controls the screw extrusion speed, the conveying roller speed and the pulling roller speed according to set conditions, and each section of the upper and lower layers of the mattress formed successively includes a first head and back region and a second head and back region, a first waist and buttock region and a second waist and buttock region, and a first foot region and a second foot region.

[0046] Here, the parameters of the yarn spouting areas 71, 72 in the yarn spouting plate 7 are that the yarn spouted by the upper layer yarn spouting area is a solid yarn with a hole diameter of 1 mm, and that the yarn spouted by the lower layer yarn spouting area is a solid yarn with a hole diameter of 1.5 mm. The mattress structure and parameters obtained in Example 1 are as shown in the table below.

[0047] Table 1 JPEG2025027975000013.jpg109170

[0048] Example 2 The differences from Example 1 are as follows: the raw materials of the upper and lower layers are both PE, and the parameters of the yarn spouting areas 71 and 72 on the yarn spouting plate 7 are that the upper layer yarn spouting area spouts solid yarn with a hole diameter of 0.8 mm, and the lower layer yarn spouting area spouts solid yarn with a hole diameter of 1 mm, and the mattress structure and parameters obtained in Example 2 are as shown in the table below.

[0049] Table 2 JPEG2025027975000014.jpg82170

[0050] Example 3 The difference from Example 1 is that the first head and back region and the second head and back region, the first transition region and the third transition region, the first waist and hip region and the second waist and hip region, the second transition region and the fourth transition region, and the first foot region and the second foot region are formed in sequence. The structure schematic diagram is shown in Figure 2, and the obtained mattress structure and parameters are as shown in the table below.

[0051] Table 3 JPEG2025027975000015.jpg104170

[0052] Example 4 The differences from Example 2 are as follows: The parameters of the yarn spouting areas 71 and 72 in the yarn spouting plate 7 are that the upper layer yarn spouting area spouts solid yarns with a hole diameter of 1 mm, the lower layer yarn spouting area spouts hollow yarns with an outer ring hole diameter of 3 mm, and an inner ring hole diameter of 2.5 mm. The mattress structure and parameters obtained in Example 4 are shown in the table below.

[0053] Table 4 JPEG2025027975000016.jpg70170

[0054] Finally, it should be explained that the above embodiment is only for explaining the technical solution of the present invention, and does not constitute a limitation on the outline of the present invention. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, including combining each technical feature in any other suitable manner, and these simple modifications and combinations should also be considered as the contents disclosed in the present invention, and all belong to the protection scope of the present invention. [Explanation of symbols]

[0055] 1 yarn discharge assembly, 2 junction valve, 3 dryer, 4 conveying screw, 5 yarn ejection die, 6 allocation plate, 7 yarn ejection plate, 8 shower plate, 9 water tank, 10 conveying roller, 11 traction roller, 12 guide roller, 13 water surface of water tank, 21 first diversion channel, 22 second diversion channel, 31 first dryer, 32 second dryer, 41 first conveying screw, 42 second conveying screw, 51 first yarn ejection channel le, 52 second yarn ejection channel, 61 first allocation area, 61 second allocation area, 71 first yarn ejection area, 72 second yarn ejection area, 1001 first head and back area, 1002 first waist and buttocks area, 1003 first foot area, 1004 second head and back area, 1005 second waist and buttocks area, 1006 second foot area, 1007 first transition area, 1008 second transition area, 1009 third transition area, 1010 fourth transition area.

Claims

1. An integrally molded compartmentalized double-sided tactile filament mattress, comprising an upper layer and a lower layer of different hardness, the upper layer and the lower layer comprising different sections, each section having a different density and length, the upper layer and the lower layer being integrally molded by continuous production, the integral molding being characterized in that the filaments of the upper layer and the lower layer are continuously produced simultaneously, and the filament production speed and production time are set according to the sections, thereby forming different sections of the different upper layer and the lower layer, thereby obtaining an integrally molded mattress.

2. The compartmentalized double-sided tactile filament mattress of claim 1, characterized in that the upper and lower layers each include two to six load-bearing compartments, and preferably the mattress further includes a transition area located between some or all of the load-bearing compartments, and the density of the transition area is much less than the density of the load-bearing compartments.

3. The compartmented double-sided filament mattress described in claim 2, characterized in that the hardness of the upper layer is less than that of the lower layer, the thickness of the upper layer is less than that of the lower layer, and preferably the material of the upper and lower layer filaments is one or more selected from thermoplastic polyester elastomers (TPEE), ethylene polymers (e.g., polyethylene PE), and polyolefin thermoplastic elastomers (POE).

4. A manufacturing method for a compartmentalized double-sided tactile filament mattress described in any one of claims 1 to 3, characterized in that an independent control system is adopted to control the production of the filaments of the upper and lower layers, respectively, and to form each compartment of the upper and lower layers according to the compartment settings.

5. The manufacturing method includes: (1) feeding the upper and lower layer materials into respective melt channels and then into a yarn delivery assembly; (2) continuously ejecting an upper layer filament thread and a lower layer filament thread by adjacent thread ejection regions in a thread ejection assembly; (3) The upper layer filament thread and the lower layer filament thread are adjacent to each other and enter vertically into water, and are transported, cooled, and hardened in water to form the upper layer filament and the lower layer filament, and are guided and pulled out from the water surface, and when pulled out from the water surface, the upper layer filament and the lower layer filament are maintained adjacent to each other and positioned vertically; (4) The manufacturing method of claim 4 further includes: through traction, the filaments are sequentially and continuously sectioned to set and form each section of the upper and lower layers of the mattress, thereby obtaining an integrally molded sectioned double-sided filament mattress.

6. In the step (2), the adjacent yarn spouting areas include an upper layer yarn spouting area and a lower layer yarn spouting area, and the yarn diameter spouted by the upper layer yarn spouting area is smaller than the yarn diameter spouted by the lower layer yarn spouting area, Preferably, the yarns spouted from the upper layer yarn spouting area and the lower layer yarn spouting area are both solid yarns, and the yarn diameters are 0.8 to 1.5 mm and 1.0 to 2.5 mm, respectively; Alternatively, the upper layer yarn ejection region ejects a solid yarn, the yarn diameter of which is 0.8 to 1.5 mm, and the lower layer yarn ejection region ejects a hollow yarn, the outer ring yarn diameter of which is 2.8 to 3.4 mm, and the inner ring hole diameter of which is 2.2 to 2.8 mm; or the fibers spouted from the upper layer yarn spouting region and the lower layer yarn spouting region are hollow fibers, the outer ring yarn diameter is 2.8 to 3.4 mm, and the inner ring hole diameter is 2.2 to 2.8 mm.

7. 6. The manufacturing method according to claim 5, wherein in step (1), the melt channel is a screw extrusion channel, in step (3), the conveying is conveying by a conveying roller, and in step (4), the pulling is pulling by a pulling roller.

8. 8. The manufacturing method according to claim 7, wherein in step (4), the section settings include a filament density in the section and a section production time, the filament density corresponding to a screw extrusion speed, a conveying speed and a pulling speed, and the section production time corresponding to a screw extrusion running time, a conveying running time and a pulling running time at a particular set speed.

9. The manufacturing method according to claim 8, characterized in that in step (4), the method of determining the screw extrusion speed, conveying speed and pulling speed is to set the corresponding screw extrusion speeds of the upper and lower layers according to the expected filament density of each section of the upper and lower layers, and adjust the conveying roller speed and the pulling roller speed according to the difference in density distribution of the mattress, so that if the density needs to be increased, the conveying roller speed and the pulling roller speed are reduced, and if the density needs to be decreased, the conveying roller speed and the pulling roller speed are increased.

10. 9. The method of claim 8, wherein the section production time is the ratio of section length to conveying rollers, and the speed of the pulling rollers is 80-90% of the speed of the conveying rollers.

Images