Pearl cotton, its manufacturing method and a novel high-rebound material using the same, and the use of the novel high-rebound material.

Abstract

This invention provides a composition for producing pearl cotton. [Solution] This composition for producing pearl cotton contains 100 parts by weight of high-pressure low-density polyethylene, micron silica aerogel which is greater than 0 parts by weight and less than 2 parts by weight, and nanosilica which is greater than 0 parts by weight and less than 2 parts by weight. Pearl cotton products produced with this composition are quick-drying, flexible, and highly resilient. They can be used as fillings for household textiles and products such as futons, mattresses, cushions, pillows, neck pillows, carpets, carpet underlays, quilting mats, Simmons mats, bed mats, dehumidifying mats, moisture-absorbing mats, and sofas, and can also be used directly as mats for various items.

Description

[Technical Field]

[0001] This invention relates to the technical field of pearl cotton, and more specifically to pearl cotton, its manufacturing method, and its use. [Background technology]

[0002] Highly foamed polyethylene (EPE) is a product manufactured using LDPE as the main raw material, with the addition of foaming agents and other processing aids, and processed through methods such as extrusion or injection molding. It is a type of polymer material formed by the dispersion of a large number of gas micropores within solid plastic (polyethylene). It has characteristics such as high strength, light weight, sound absorption, damping, and cushioning, and is widely applied in fields such as exteriors of furniture, home appliances, instruments, and handicrafts, building waterproofing, soundproofing materials, moisture-proof and heat-insulating mats for floors, and various sports equipment. It has a non-crosslinked closed-pore structure, is flexible and highly elastic, has waterproof, moisture-proof, quick-drying, and earthquake-resistant properties, can be reused repeatedly, is non-toxic, and is an environmentally friendly material with a wide range of applications.

[0003] Chinese Patent Application Publication No. 107057166 discloses a tasteless PE foam material and a method for producing the same, mainly consisting of 50-100 parts LDPE, 10-40 parts filler, 1-10 parts modified foaming agent, 0.1-5 parts foaming accelerator, 0.1-10 parts lubricant, and 0.5-1 parts tasteless crosslinking agent. Chinese Patent Application Publication No. 116731379 discloses a method for producing an environmentally friendly EPE pearl cotton material, relating to the field of EPE pearl cotton technology, and specifically relating to a method for producing an environmentally friendly EPE pearl cotton material, which includes the following steps: S1, 7 parts titanium white powder and 8 parts calcium carbonate are placed in a ball mill at a rotation speed of 1200-1500 revolutions per minute, and an appropriate amount of anhydrous ethanol is added to perform wet ball milling. The present invention provides a method for producing flame-retardant pearl cotton material. This method involves wet ball milling titanium powder, calcium carbonate, and anhydrous ethanol, then ultrasonically dispersing the ball-milled slurry with asbestos fibers and ethylenebis-stearamide to obtain a preliminary mixture. Simultaneously, low-density polyethylene, isobutyltriethoxysilane, and sodium ligninsulfonate are kneaded first, followed by secondary kneading with polychlorobutadiene, sodium alginate, and an activator to obtain a secondary mixture. Finally, the preliminary mixture and the secondary mixture are subjected to a high-pressure, high-temperature reaction with an antistatic agent and a foaming agent, extruded, and cooled to obtain the finished material.

[0004] Japanese Patent Publication No. 2019-127143 provides a foam that can achieve both temperature sensitivity and buffering properties. The zirconia content is 0.01 to 8 parts by mass per 100 parts by mass of the resin component. In the foam, the zirconia is dispersed in the resin component as a dispersed phase with an average diameter of 10 μm or less. The foaming ratio of the foam may be 10 or more. The thermoplastic resin may be an olefin resin. The resin component may be a polyethylene resin. The foam may contain silicon dioxide. The zirconia may be located on the wall surface of the cavity and / or near the surface layer. The foam may be a temperature-sensitive foam that can release heat.

[0005] European Patent Application No. 22883264 discloses polyethylene resin foam beads containing a mixed resin of unused polyethylene (A) and recycled polyethylene (B) as a base resin, and a method for producing the same. The mixed resin contains unused polyethylene (A) and recycled polyethylene (B) in predetermined ratios. Unused polyethylene (A) is linear low-density polyethylene (A1) having predetermined physical properties, obtained by polymerizing a metallocene polymerization catalyst. Recycled polyethylene (B) is a post-consumer material containing linear low-density polyethylene (B1) and low-density polyethylene (B2), with linear low-density polyethylene (B1) being the main component.

[0006] European Patent Application No. 22883263 discloses a method for producing polyethylene resin expandable beads that can be manufactured into expandable bead molded articles having high flexibility and excellent surface smoothness under excellent molding conditions. Furthermore, expandable beads can be manufactured using an inorganic physicoblasting agent as the blowing agent. This avoids the use of organic physicoblasting agents and reduces the environmental impact.

[0007] Patent Document 1, Japanese Patent Publication No. 2019-38198, discloses a foamed resin laminate having a phenolic resin foam layer and a surface layer provided on at least one surface of the foam layer via a flexible surface material, wherein the surface layer is a metal layer covered with a protective layer. This document describes that the phenolic resin foam layer is used as an insulating material in various fields, and in the embodiment, it is described as being installed on a sloping roof, improving operability.

[0008] Patent Document 2, Japanese Patent Publication No. 2017-141342, discloses a foam for a skin region and a core region containing a thermoplastic resin and an elastomer. This document states that the foamed molded article may contain fillers of any component, and many inorganic compounds are listed and described, but the particle size is not described, and there is no formulation in the examples.

[0009] Patent Document 3 of Japanese Patent Publication No. 2019-38997 discloses a foam resin sheet having an adhesive layer as a resin sheet used for heat dissipation in electronic equipment. This document describes a thermal conductive adhesive as the adhesive layer, which includes first thermal conductive particles with an average particle diameter of 0.1 μm or more and less than 5 μm, and second thermal conductive particles with an average particle diameter of 5 to 30 μm, and the adhesive layer may be foam. In the example, a non-foaming adhesive layer is prepared as the adhesive layer, which includes aluminum hydroxide powder with an average particle diameter of 1 μm and aluminum hydroxide powder with an average particle diameter of 8 μm.

[0010] Patent Document 4 of Japanese Patent Publication No. 2003-327733 describes a first step of producing calcined colomanite by calcining an inorganic natural mineral colomanite, and a second step of mixing the calcined colomanite in a ratio of about 5 parts, metal oxide in a ratio of 10 to 20 parts, and polyethylene resin in a ratio of 100 parts, adding at least a foaming agent to this mixture, kneading and foaming to obtain polyethylene foam.

[0011] The fillings for household textile products such as futons, mattresses, cushions, pillows, neck pillows, carpets, carpet underlays, quilted mats, Simmons mats, bed mattresses, dehumidifying mats, moisture-absorbing mats, and sofas are required to be fluffy, flexible, have good heat retention, be washable, quick-drying, and maintain high elasticity and do not harden after multiple uses. Currently, the market uses polyester fiber cotton for fillings. Polyester fibers are loosened, carded, and crumpled through a carding machine, then fixed into a sheet using a mesh, heat melting, or spray method. While this gives them a soft and fluffy appearance, it has poor durability and elasticity. In particular, mattresses and other products with long usage times tend to sink, and after washing, there are many gaps between the fibers, making them prone to retaining a lot of moisture and difficult to dry. When exposed to rain or cloudy weather, drying becomes even more difficult, allowing a large amount of bacteria to breed, which not only affects health but also causes unpleasant odors and cannot adapt to the demands of modern, fast-paced life. [Prior art documents] [Patent Documents]

[0012]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Patent Document 5

Patent Document 6

Patent Document 7

Patent Document 8

Patent Document 9

Patent Document 10

[0016] High-density low-pressure polyethylene is abbreviated as LDPE.

[0017] In the above technical solution, preferably, the LDPE crystallinity is 55% - 60%, such as 56%, 57%, 58%, 59%, etc., but not limited thereto.

[0018] In the above technical solution, preferably, the MFR (i.e., melt flow rate) of LDPE is 1.5 - 4.5 g / 10 min, such as 2 g / 10 min, 2.5 g / 10 min, 3 g / 10 min, 3.5 g / 10 min, 4 g / 10 min, etc., but not limited thereto.

[0019] In the above technical solution, preferably, the density of LDPE is 0.9 - 1.0 g / cm 3 such as 0.91 g / cm 3 or 0.9 3 or 0.93 g / cm 3 or 0.94 g / cm 3 or 0.95 g / cm 3 or 0.96 g / cm 3 or 0.97 g / cm 3 or 0.98 g / cm 3 or 0.99 g / cm 3 etc., but not limited thereto.

[0020] In the above technical solution, preferably, the melting point range of LDPE is m1 - m2, where m1 is 100 - 110 °C (such as m1 is 101 °C, 102 °C, 103 °C, 104 °C, 105 °C, 106 °C, 107 °C, 108 °C, 109 °C, etc., but not limited thereto), and m2 is 120 - 130 °C (such as m2 is 121 °C, 122 °C, 123 °C, 124 °C, 125 °C, 126 °C, 127 °C, 128 °C, 129 °C, etc., but not limited thereto).

[0021] The available LDPE options are number LD605 from China Petroleum & Chemical Corporation Beijing Yanshan Branch, number DFDA-7042 from China Coal Energy Corporation, and number PE M23D7(LD-605) from China-Japan Coal Energy Co., Ltd.

[0022] Although this is merely a comparison, the examples and comparative examples of the present invention have a crystallinity of 56%, an MFR of 4 g / 10 min, and a density of 0.922 g / cm³. 3 Therefore, we will use No. LD605, manufactured by Beijing Yanshan Branch of China Petroleum & Chemical Corporation, with a melting point range of 108°C to 125°C.

[0023] Non-limiting examples of the number of micron silica aerogel parts include, for example, 0.2 parts, 0.4 parts, 0.6 parts, 0.8 parts, 1 part, 1.2 parts, 1.4 parts, 1.6 parts, and 1.8 parts, but are not limited to these, and are more preferably 0.2 to 0.8 parts. Preferably, the particle size D95 of the silica aerogel is 10 to 100 microns, for example 15 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, 50 microns, 55 microns, 60 microns, 65 microns, 70 microns, 75 microns, 80 microns, 85 microns, 90 microns, and 95 microns, but are not limited to these. For comparison only, the micron silica aerogel used in the example is number TEP-D50, manufactured by Suzhou Thermal Silica Aerogel Technology Co., Ltd., with a particle size of 50 microns.

[0024] In the above proposed technology, the particle size D95 of the nanosilica is more preferably 5 to 60 nm (for example, D95 is 25 nm, 30 nm, 35 nm, 40 nm, 45 nm, 50 nm, 55 nm, but is not limited to these). Depending on the manufacturing process, nanosilica can be produced by precipitation or by gas phase, and both can be used in the present invention, and both yield comparable technical effects. Depending on whether the silica surface is hydrophobically treated, there is hydrophobic treated silica and untreated silica, and both can be used in the present invention, but hydrophobic treated nanosilica has better compatibility with LDPE. Regarding the particle size D95, a smaller particle size D95 is better, but a smaller particle size D95 is considered to have a higher economic cost. For comparison purposes only, the nanosilica used in this invention is nanoscale hydrophobic gas-phase silica of designation TSP-L20, manufactured by Jiangsu Tianxing New Materials Co., Ltd., which is surface-hydrophobic treated gas-phase silica with a particle size D95 of 15 nm.

[0025] In this invention, the addition of micron silica aerogel improves the flexibility and compression rebound rate of pearl cotton, and the addition of nanosilica improves the quick-drying and resilience of pearl cotton. In particular, when the amount of micron silica aerogel is 0.2 to 0.8 parts, and the total amount of micron silica aerogel and nanosilica is 1 to 3 parts (for example, the total amount of micron silica aerogel and nanosilica is 1.1 parts, 1.2 parts, 1.3 parts, 1.4 parts, 1.5 parts, 1.6 parts, 1.7 parts, 1.8 parts, 1.9 parts, 2 parts, 2.1 parts, 2.3 parts, 2.4 parts, 2.5 parts, 2.6 parts, 2.7 parts, 2.8 parts, 2.9 parts, etc., but not limited to these), pearl cotton possesses excellent quick-drying, compression rebound, and flexibility, thereby having the most desirable overall performance, making it suitable as a filling material for household spinning and household products, and can also be used directly as a mat for various articles.

[0026] In the above proposed technology, the composition preferably contains 0.5 to 5 parts of talc powder. For example, the amount of talc powder may be 1, 1.5, 2, 2.5, 3, 3.5, 4, or 4.5 parts, but is not limited to these.

[0027] In the above proposed technology, the particle size D95 of the talc powder is preferably 1 to 20 microns, such as 1.5 microns, 2 microns, 2.5 microns, 5 microns, 5.5 microns, 6 microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18 microns, 19 microns, etc., but is not limited to these, and is more preferably 1 to 10 microns. For comparison purposes only, the talc powder used in the examples and comparative examples is a foaming talc powder of the Chunxue brand manufactured by Qixia Huatai Talc Powder Co., Ltd., with a particle size D95 of 10 microns.

[0028] In the above proposed technology, the composition preferably contains 0.5 to 5 parts of a foam shrinkage inhibitor. For example, the amount of shrinkage inhibitor may be 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, or 5.5 parts, but is not limited to these.

[0029] The type of anti-shrinkage agent is not particularly limited, and those skilled in the art can make a rational selection without requiring creative work. For example, the anti-shrinkage agent may be a nonionic surfactant, preferably selected from at least one of the group of substances consisting of monoglyceryl fatty acids, polyoxyethylene alkyl ethers, polyoxyethylene fatty acids, and fatty acid monoethanolamides. The fatty acids referred to here may be independently selected from fatty acids having 10 to 18 carbon atoms, such as, for example, fatty acids with 11 carbon atoms, 12 carbon atoms, 13 carbon atoms, 14 carbon atoms, 15 carbon atoms, 16 carbon atoms, and 17 carbon atoms, but are not limited to these. Fatty acid glyceryls include monoglyceryl fatty acids, diglyceryl fatty acids, and triglyceryl fatty acids, and experiments have shown that only monoglyceryl fatty acids are useful for anti-shrinkage during the foaming process. For comparison only, in the examples of the present invention, glycerol monostearate is commonly used as the anti-shrinkage agent. The fatty alcohol referred to herein may be a fatty alcohol having 10 to 18 carbon atoms, for example, a fatty alcohol with 11 carbon atoms, 12 carbon atoms, 13 carbon atoms, 14 carbon atoms, 15 carbon atoms, 16 carbon atoms, or 17 carbon atoms, but is not limited to these. For comparison purposes only, the anti-shrinkage agent used in the examples of the present invention is the Jialishi brand Plastic Treasure SP-1 type anti-shrinkage agent, whose component is glycerol monostearate, and is manufactured by Jialishi Additives (Hai'an) Co., Ltd.

[0030] In the above proposed technology, the preferred composition includes a foaming agent.

[0031] Those skilled in the art can make a rational selection without requiring any creative labor. The blowing agent may be an inorganic blowing agent or an organic blowing agent, and inorganic and organic blowing agents each include physical blowing agents and chemical blowing agents. In the case of a physical blowing agent, the volume simply decreases during foaming, and no chemical change occurs in the blowing agent itself during this process. During the foaming of a chemical blowing agent, the blowing agent itself undergoes a decomposition reaction and generates gas.

[0032] As a non-limiting example, among inorganic blowing agents, nitrogen, argon, helium, carbon dioxide, air, and water belong to the category of physical blowing agents, while sodium bicarbonate belongs to the category of chemical blowing agents, and sodium bicarbonate is thermally decomposed to produce gas.

[0033] As a non-limiting example, among organic blowing agents, hydrocarbon blowing agents (mainly C3-C5 hydrocarbons) and halogenated hydrocarbon blowing agents (e.g., chlorofluorocarbons) belong to the category of physical blowing agents, while among organic blowing agents, azo group-containing blowing agents (e.g., azodicarbonamide) or blowing agents with a hydrazine structure (e.g., p-toluenesulfonyl hydrazide, diphenylsulfone-3,3'-disulfonyl hydrazide) have the property of generating nitrogen through thermal decomposition and are therefore chemical blowing agents.

[0034] For comparison purposes only, the embodiments of this invention commonly use butane as a foaming agent.

[0035] The amount of foaming agent used depends on the type of foaming agent and the target product of the composition, and can be reasonably selected by those skilled in the art without requiring any creative work.

[0036] For example, the present invention uses butane as a blowing agent, in amounts of 10 to 45 parts. For instance, the amount of blowing agent used may be 15, 20, 25, 30, 35, or 40 parts, and is not limited to these amounts, but 15 to 40 parts is more preferred. The butane used as the blowing agent may be n-butane and / or isobutane. For comparison only, the blowing agent used in the present invention is n-butane manufactured by Qingdao Fengcheng Beiling Liquefied Gas Co., Ltd.

[0037] The second objective of the present invention is to provide a material.

[0038] To achieve the second objective, the technical proposal is as follows:

[0039] A novel, fast-drying, flexible, high-rebound material comprises a skeletal material and a foam dispersed in the skeletal material, wherein the skeletal material consists of a composition described in any one of the first technical proposals for the above purpose, wherein the composition does not contain a foaming agent.

[0040] The third object of the present invention is to provide a method for producing the above-mentioned material.

[0041] To achieve the third objective, the technical proposal is as follows:

[0042] The method for manufacturing the material described in the second technical proposal for the above purpose is: Step (1) involves uniformly mixing the required amount of LDPE mother particles, the required amount of talc powder, the required amount of nanosilica, the required amount of silica aerogel, and the required amount of shrinkage inhibitor to obtain material I. Step (2) involves mixing material I with a shrinkage inhibitor to obtain material II, Step (3) involves mixing material II with a foaming agent to obtain material III, Step (4) involves extruding material III, The process includes step (5) of shaping to obtain a pearl cotton product.

[0043] In the manufacturing method described above, the mixing temperature in step (1) is preferably 125°C or higher and less than 220°C, for example, 130°C, 140°C, 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, 210°C, etc., but is not limited to these. More preferably, the mixing is performed at a T1 temperature of 125°C to 150°C, and then at a T2 temperature of 180°C or higher and less than 220°C.

[0044] In the manufacturing method described above, the mixing temperature T3 in step (2) is preferably 220 to 240°C, such as 225°C, 230°C, or 235°C, but is not limited to these.

[0045] In the manufacturing method described above, the mixing temperature T4 in step (3) is preferably 190°C or higher and lower than 220°C, such as 195°C, 200°C, 205°C, 210°C, 215°C, etc., but is not limited to these.

[0046] In the manufacturing method described above, the extrusion temperature in step (4) is preferably 80°C to 100°C, for example 85°C, 90°C, 95°C, etc., but is not limited to these.

[0047] In the manufacturing method described above, the purpose of molding is to prevent the extruded material from sticking in step (4). Therefore, it is necessary to lower the temperature to a level where the extruded material does not stick. Based on this principle, those skilled in the art can reasonably determine the molding temperature without requiring any creative labor. For example, in the manufacturing method of the present invention, the molding temperature in step (5) is optionally 50°C or lower, such as -40°C, -35°C, -30°C, -25°C, -20°C, -15°C, -10°C, -5°C, 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, etc., but is not limited to these, and is more preferably -15°C to 45°C. For comparison only, the molding temperature in the present invention is 30°C in all cases.

[0048] In the manufacturing method described above, preferably, the single-screw extruder includes a bucket, a screw positioned in the bucket, and a die head at the end of the extruder.

[0049] In the manufacturing method described above, the ratio of the major axis to the major axis of the screw is preferably 50 to 60, for example 51, 52, 53, 54, 55, 56, 57, 58, 59, etc., but is not limited to these.

[0050] In the manufacturing method described above, preferably, the bucket is set to 10 temperature regions, which are sequentially designated as bucket region 1, bucket region 2, bucket region 3, bucket region 4, bucket region 5, bucket region 6, bucket region 7, bucket region 8, bucket region 9, and bucket region 10 from the start of the bucket to the end of the bucket.

[0051] In the manufacturing method described above, the temperatures of the bucket 1 area, bucket 2 area, bucket 3 area, bucket 4 area, bucket 5 area, bucket 6 area, bucket 7 area, bucket 8 area, bucket 9 area, and bucket 10 area are represented by T1, T2, T3, T4, T5, T6, T7, T8, T9, and T10 in sequence. Preferably, T1 < T2 < T3, and preferably, T3 > T4 > T5 > T6 > T7 > T8 > T9. More preferably, 125°C ≤ T1 ≤ 150°C, 180°C ≤ T2 < 220°C, 220°C ≤ T3 ≤ 240°C, 190°C ≤ T4 < 220°C, 170°C ≤ T5 < 190°C, 150°C ≤ T6 < 170°C, 130°C ≤ T7 < 150°C, 110°C ≤ T8 < 130°C, 95°C ≤ T9 < 110°C, 80°C ≤ T10 < 95°C.

[0052] In the manufacturing method described above, preferably, a main supply port for adding a preliminary mixture of the main material (LDPE masterbatch) and auxiliary materials other than the anti-shrinkage agent and the foaming agent (required amounts of talc powder, required amounts of nanosilica, required amounts of silica aerogel) is provided in the bucket 1 area.

[0053] In the manufacturing method described above, preferably, an anti-shrinkage agent supply port for injecting the anti-shrinkage agent is provided in the bucket 3 area.

[0054] In the manufacturing method described above, preferably, a foaming agent supply port for injecting the foaming agent is provided in the bucket 4 area.

[0055] In the manufacturing method described above, the temperature of the die head is preferably 80°C to 100°C, such as 85°C, 90°C, 95°C, etc., but is not limited thereto.

[0056] In the manufacturing method described above, optionally, the molding operation in step (5) is performed on a molding drum.

[0057] The shape of pearl cotton products is related to the die head used during extrusion. Those skilled in the art can rationally select an extrusion die head with an appropriate structure according to the end use of the pearl cotton product, without requiring creative labor and achieving comparable technical results.

[0058] For comparison purposes only, the pearl cotton products obtained from the extrusion die heads used in the examples and comparative examples of the present invention are in the form of a 4 mm thick film. Based on the principles of the present invention, those skilled in the art will understand that the present invention can still achieve comparable technical effects when the pearl cotton products are made into other geometric shapes using the die heads used.

[0059] In the embodiments and comparative examples of the present invention, the extruder specifically used is a product of Longkou Jinmeng Machinery Co., Ltd., model number 135, with a screw diameter of 135 mm and a screw length of 7425 mm.

[0060] For comparison purposes only, the set temperatures for each region of the bucket, the die head, and the molding drum in the example and comparison example are shown in the table below.

[0061] [Table 1] In the examples and comparative examples, a main supply port is provided in bucket 1, through which a preliminary mixture of auxiliary materials other than the shrinkage inhibitor and foaming agent (required amount of talc powder, required amount of nanosilica, required amount of silica aerogel) and the main material (LDPE mother particles) is added. A shrinkage inhibitor supply port is provided in bucket 3, through which the shrinkage inhibitor is injected. A foaming agent supply port is provided in bucket 4, through which the foaming agent is injected.

[0062] The fourth objective of the present invention is to provide the use of the above-mentioned quick-drying, flexible, and highly resilient material in household spinning and household products.

[0063] For example, it can be used as a new filling material in household textiles and household products such as futons, mattresses, cushions, pillows, neck pillows, carpets, carpet underlays, quilted mats, Simmons mats, bed mats, dehumidifying mats, moisture-absorbing mats, and sofas. It can also be used directly as a mat for various items, such as cup mats and storage box mats. In addition to filling mattresses, carpets, quilted mats, Simmons mats, and sofas, it can also be used by placing it directly under mattresses, carpets, quilted mats, Simmons mats, and sofas.

[0064] Performance evaluation of the novel fast-drying, flexible, and highly resilient material of the present invention. In the newly manufactured, quick-drying, flexible, and highly resilient material, the gas in the foam is a foaming agent, and the foaming agent in the foam, left for 4 to 7 days, naturally dissipates at room temperature and is simultaneously replaced by air. In specific embodiments of the present invention, the pearl cotton products all needed to be left at room temperature for 10 days to undergo performance testing.

[0065] 1) The evaluation method for quick-drying properties was as follows:

[0066] 1000 grams of the novel fast-drying, flexible, and highly resilient material obtained in the examples and comparative examples of the present invention were placed in a washing machine and washed using the C4M method based on the Japanese Household Laundry Test Method for Textile Products JIS L 1930-2014. After washing, the test products were removed and subjected to a constant temperature and humidity indoor environment with a wind speed of 5 m / min, a temperature of 25°C, and a relative humidity of 65%. The mass of the PE foam material was tested every 10 minutes, and if the mass was 1100 grams or less, the usage time was recorded, and the fast-drying effect was evaluated according to Table 2.

[0067] [Table 2]

[0068] 2) Evaluation of compression rebound properties The novel high-rebound material, which is quick-drying and flexible, obtained in the examples and comparative examples of the present invention, was cut into samples measuring 20 cm in length*width*20 cm. Ten samples were folded into a transparent container with a base of 20 cm*20 cm and a height of 20 cm. These were placed under the pressure arm of a single-arm type textile strength meter of model HD026. Using a press disc with a diameter of 20 cm, the material was pressed with a force of 4.9 Newtons for 10 minutes, and the total height H0 of the 10 foamed materials was measured. The pressure was then increased to 196 Newtons, and the 10 foamed materials were pressed for 120 hours, and the total height H1 of the 10 foamed materials was measured. The pressure was then removed, and the material was pressed again with a force of 4.9 Newtons for 10 minutes, and the total height H2 of the 10 foamed materials was measured. The compression rebound rate was (H2-H1) / (H0-H1)*100%, and the leveling method is shown in Table 3 below.

[0069] [Table 3]

[0070] 3) Evaluation of flexibility The novel fast-drying, flexible, and highly resilient material obtained in the examples and comparative examples of the present invention was cut into 20cm x 20cm samples. Ten samples were folded into a transparent container with a base of 20cm x 20cm and a height of 20cm. These were placed under the pressure arm of a single-arm type fabric strength meter of model HD026. A 20cm diameter press disc was used to apply 4.9N of force for 10 minutes. The total height H1 of the ten foamed materials was measured. The pressure on the pressure arm was increased to compress the H1 height to 60%, and the maximum pressure value of the pressure arm was read. The level was determined according to Table 4.

[0071] [Table 4]

[0072] The present invention will be described in detail below with reference to examples and comparative examples. [Modes for carrying out the invention] [Examples]

[0073] [Example 1] 1. Prescription LDPE parent particles, 100 parts, Nanosilica, 1.0 part, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0074] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, nanosilica, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0075] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 64 minutes, Level 2. Compression rebound: Compression rebound rate 73%, Level 3. Flexibility: Indentation hardness 426N, Level 5.

[0076] [Example 2] 1. Prescription LDPE parent particles, 100 parts, Nanosilica, 2.0 parts, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0077] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, nanosilica, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0078] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 47 minutes, Level 1. Compression rebound: Compression rebound rate 82%, Level 2. Flexibility: Indentation hardness 334N, Level 5.

[0079] [Example 3] 1. Prescription LDPE parent particles, 100 parts, Micron silica aerogel, 0.8 parts, Nanosilica, 1.2 parts, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0080] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, micron silica aerogel, nanosilica, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0081] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 75 minutes, Level 2. Compression rebound properties: Compression rebound rate 86%, Level 2. Flexibility: Indentation hardness 52N, Level 1.

[0082] [Example 4] 1. Prescription LDPE parent particles, 100 parts, Micron silica aerogel, 0.5 parts, Nanosilica, 1.5 parts, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0083] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, micron silica aerogel, nanosilica, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0084] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 56 minutes, Level 1. Compression rebound: Compression rebound rate 93%, Level 1. Flexibility: Indentation hardness 63N, Level 1.

[0085] [Example 5] 1. Prescription LDPE parent particles, 100 parts, Micron silica aerogel, 0.2 parts, Nanosilica, 1.8 parts, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0086] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, micron silica aerogel, nanosilica, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0087] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 50 minutes, Level 1. Compression rebound: Compression rebound rate 81%, Level 2. Flexibility: Indentation hardness 124N, Level 2.

[0088] [Example 6] 1. Prescription LDPE parent particles, 100 parts, Micron silica aerogel, 0.5 parts, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0089] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, micron silica aerogel, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0090] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 191 minutes, Level 3. Compression rebound: Compression rebound rate 76%, Level 3. Flexibility: Indentation hardness 105N, Level 2.

[0091] [Example 7] 1. Prescription LDPE parent particles, 100 parts, Micron silica aerogel, 1.0 part, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0092] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, micron silica aerogel, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0093] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 216 minutes, Level 3. Compression rebound: Compression rebound rate 88%, Level 2. Flexibility: Indentation hardness 59N, Level 1.

[0094] [Comparative Example 1] 1. Prescription LDPE parent particles, 100 parts, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0095] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0096] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 94 minutes, Level 2. Compression rebound: Compression rebound rate 36%, Level 5. Flexibility: Indentation hardness 362N, Level 5.

[0097] [Comparative Example 2] 1. Prescription Except for using an equal weight of micron silica instead of micron silica gel, the other components in the formulation were the same as in Example 7, and the formulation was specifically as follows:

[0098] LDPE parent particles, 100 parts, Micron silica, 1.0 part, Talc powder, 3.0 parts Shrinkage inhibitor, 3.0 parts, Foaming agent, 26 parts.

[0099] The micron silica among them was D95 55 microns, manufactured by Guangzhou Xijian Chemical Co., Ltd., with the number CE923.

[0100] 2. Pearl Cotton Manufacturing At room temperature, the required amount of LDPE mother particles, micron silica, and talc powder were uniformly mixed to obtain a preliminary mixture. The necessary temperatures for each bucket area, die head, and molding drum were set according to the parameters in Table 1, and the apparatus was started to confirm that it was ready for use. The preliminary mixture was added to the extruder through the main supply port in bucket area 1, the shrinkage inhibitor was added to the extruder through the shrinkage inhibitor supply port in bucket area 3, and the foaming agent was added to the extruder through the foaming agent supply port in bucket area 4. The extruded material from the extruder die head was molded in the molding drum to obtain pearl cotton. After the operation of the apparatus stabilized, the obtained pearl cotton product was left at 26±2℃ for 10 days and a performance test was performed.

[0101] 3. Pearl Cotton Performance Test According to the tests, the performance was as follows: Fast drying: Drying time 86 minutes, Level 2. Compression rebound: Compression rebound rate 65%, Level 3. Flexibility: Indentation hardness 531N, Level 5.

Claims

1. It is pearl cotton, 100 parts by weight of high-pressure low-density polyethylene (LDPE), A micron silica aerogel that is larger than 0 parts by weight and smaller than 2 parts by weight, It contains nanosilica that is greater than 0 parts by weight and less than 2 parts by weight, The particle size D95 of the silica aerogel is 10 to 100 microns, and / or the LDPE crystallinity is 55% to 60%, and / or the MFR (melt flow rate) of the LDPE is 1.5 to 4.5 g / 10 min, and / or the density of the LDPE is 0.9 to 1.0 g / cm³. ３ And / or, the melting point range of LDPE is m １ ~m ２ And, m １ The temperature is 100-110°C, and m ２ Pearl cotton is characterized by having a temperature of 120-130°C.

2. The pearl cotton according to claim 1, characterized in that the particle size D95 of the nanosilica is 5 to 60 nm.

3. The pearl cotton according to claim 1, characterized in that it contains 0.5 to 5 parts of talc powder, the particle size D95 of the talc powder being 1 to 20 microns, and / or contains 0.5 to 5 parts of a foam shrinkage inhibitor.

4. The anti-shrinkage agent is a nonionic surfactant, selected from at least one of the group of substances consisting of monofatty acid glycerin, polyoxyethylene alkyl ether, polyoxyethylene fatty acid, and fatty acid monoethanolamide, as described in claim 3.

5. The pearl cotton according to claim 1, characterized by containing a foaming agent.

6. A method for manufacturing pearl cotton, Step (1) involves uniformly mixing the required amount of LDPE mother particles, the required amount of talc powder, the required amount of nanosilica, the required amount of silica aerogel, and the required amount of shrinkage inhibitor to obtain material I. Step (2) involves mixing material I with a shrinkage inhibitor to obtain material II, Step (3) involves mixing material II with a foaming agent to obtain material III, Step (4) involves extruding material III, A method for producing pearl cotton, characterized by comprising the step (5) of molding to obtain a pearl cotton product.

7. The mixing temperature in step (1) is 125°C or higher and less than 220°C, further mixing at a T1 temperature of 125°C to 150°C, and then mixing at a T2 temperature of 180°C or higher and less than 220°C. And / or, the mixing temperature T3 in step (2) is 220 to 240°C. and / or, the mixing temperature T4 in step (3) is 190°C or higher and lower than 220°C. And / or, the extrusion temperature in step (4) is 80°C to 100°C. The manufacturing method according to claim 6, characterized in that the molding temperature in step (5) is 50°C or lower.

8. The above manufacturing method is carried out in an apparatus including a single-screw extruder, the single-screw extruder including a bucket, a screw positioned in the bucket, and a die head at the end of the extruder. The ratio of the screw's major axis to its major axis is 50-60. The buckets are set to 10 temperature regions, and from the start of the bucket to the end of the bucket, they are sequentially designated as bucket region 1, bucket region 2, bucket region 3, bucket region 4, bucket region 5, bucket region 6, bucket region 7, bucket region 8, bucket region 9, and bucket region 10. The temperatures in bucket regions 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 are denoted as T1, T2, T3, T4, T5, T6, T7, T8, T9, and T10 respectively, where T1 < T2 < T3 and T3 > T4 > T5 > T6 > T7 > T8 > T9. Furthermore, 125°C ≤ T1 ≤ 150°C, 180°C ≤ T2 < 220°C, 220°C ≤ T3 ≤ 240°C, 190°C ≤ T4 < 220°C, 170°C ≤ T5 < 190°C, 150°C ≤ T6 < 170°C, 130°C ≤ T7 < 150°C, 110°C ≤ T8 < 130°C, 95°C ≤ T9 < 110°C, and 80°C ≤ T10 < 95°C. A main supply port is provided in bucket area 1. A shrinkage inhibitor supply port is provided in the bucket 3 area. Bucket 4 is provided with a foaming agent supply port. The manufacturing method according to claim 7, characterized in that the temperature of the die head is 80°C to 100°C.

9. A novel high-rebound material that is quick-drying and flexible, comprising a skeletal material and foam dispersed in the skeletal material, wherein the skeletal material is made of pearl cotton as described in any one of claims 1 to 5.

10. The novel high-rebound material that is quick-drying and flexible, as described in 9, can be used in household spinning and household products, characterized in that it can be used as a new filling material in futons, mattresses, cushions, pillows, neck pillows, carpets, carpet underlays, quilted mats, Simmons mats, bed mats, dehumidifying mats, moisture-absorbing mats, sofas, and household products, can be used directly as a mat, cup mat, or storage box mat, and in addition to being used as a filling in mattresses, carpets, quilted mats, Simmons mats, and sofas, it can also be used by placing it directly on mattresses, carpets, quilted mats, Simmons mats, and sofas.

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