Multi-layer sponge containing phase change material

Abstract

To provide a multi-layer sponge containing a phase-change material, which can avoid loss of the phase-change material after long-term use, maintain the effect of cooling sensation characteristics for a long time, and maintain breathability. [Solution] The multi-layer sponge containing phase change material is composed of a filling layer 1, a welding layer 2, and a sponge layer 3, from top to bottom. The filling layer is a sponge with large pores, and the sponge layer is a sponge with small pores. The welding layer is formed by attaching a low melting point polymer to the inner wall of the surface holes of the filling layer and the sponge layer, and micro-porous particles 4 are fixed to the inner wall of the holes of the filling layer, and the micro-pores of the micro-porous particles are filled with a phase change material. After the phase change material is encapsulated in the micro-porous particles, the micro-porous particles and low melting point polymer particles are filled into the pores of the large pore sponge of the filling layer, and after the low melting point polymer is melted, the micro-porous particles are firmly bonded to the inner wall of the pores of the filling layer. In addition, the low melting point polymer after melting solidifies at the shallow surface where the filling layer and the sponge layer contact each other to form a welding layer, which stably connects the two and does not block the holes of the sponge.

Description

[Technical field]

[0001] The present invention relates to a multi-functional sponge product, which belongs to the field of household products, and particularly to a multi-layer sponge containing phase change material. [Background technology]

[0002] Sponge is a porous polymer material with many advantages, including light weight, breathability, cushioning, moisture absorption, heat retention, and sound insulation, and the finished sponge is easy to cut and mold, so it is commonly used as a filling for mattresses, sofas, soft-pack walls, and other upholstery materials. In household products such as mattresses and sofas, where sponges are widely used, sponges not only provide support and cushioning, but also provide a heat retention function, but when the temperature is high, the sponge's heat retention effect can actually cause discomfort to the human body, and problems such as sweat accumulation occur when the body is in contact with the sponge for a long time. Therefore, sponge products with a refreshing feel have great future application potential.

[0003] Generally, a simple way to make a sponge feel cool is to coat the surface of the sponge with a phase change material that has heat absorption ability. By utilizing the porous property of the sponge, the phase change material can be stably attached to the shallow layer of holes on the sponge surface, so that the sponge can have a certain cooling ability. However, spraying the phase change material on the sponge surface will completely block the holes of the sponge, affecting the breathability of the sponge, and as long as the technology of spraying phase change material particles is adopted, it is inevitable that the holes of the sponge will be completely blocked.

[0004] Chinese patent CN113927515A discloses a sponge foaming process and apparatus with a PCM sheet attached on the surface, which first produces a foamed sponge, and then coats a gel layer and a PCM sheet on the sponge to produce a product in which the sponge does not penetrate into the PCM sheet, and in this method, the gel layer and the PCM sheet also affect the breathability of the sponge. Summary of the Invention [Means for solving the problem]

[0005] In response to the problem that conventional sponges containing phase change material have poor breathability, the present invention provides a multi-layer sponge containing phase change material, which is composed of a filling layer, a welding layer and a sponge layer, from top to bottom. The filling layer is a sponge with large pores, the sponge layer is a sponge with small pores, and the welding layer is formed by adhering a low-melting point polymer to the inner walls of the holes in the surface layer of the filling layer and the sponge layer, microporous particles are fixed to the inner walls of the holes in the filling layer, and the pores of the microporous particles are filled with a phase change material.

[0006] The phase change material provides the multi-layer sponge of the present invention with a cool feeling, and the phase change material is one of PCM material, dodecanol, n-hexadecane, n-heptadecane, n-octadecane, and methyl palmitate.

[0007] Specifically, the large pore diameter of the filling layer is 0.2 to 2 mm, the small pore diameter of the sponge layer is 0.1 to 1 mm, the thickness of the welded layer is the sum of the surface layer of the filling layer (0.1 to 1.5 mm) and the surface layer of the sponge layer (0.05 to 0.5 mm), and the particle diameter of the microporous particles is 0.05 to 0.3 mm.

[0008] The multi-layer sponge product containing the phase change material of the present invention is in the form of a sheet, and can be used as a filling for household items such as sofas, mattresses, or cushions. The present invention is made by stacking large-pore sponges and small-pore sponges with different thicknesses, specifically, the thickness of the filling layer is 1mm-2.5cm, and the thickness of the sponge layer is 3mm-10cm.

[0009] The method for producing the multi-layer sponge containing phase change material of the present invention is as follows: after sieving the microporous particles with a desired mesh size, add them to the liquid phase change material, thoroughly stir and mix, so that the phase change material penetrates into the porous structure of the microporous particles, and then cool after filtration, so that the phase change material solidifies inside the microporous particles; thoroughly stir and mix the microporous particles with polymer ultrafine powder such as PA6, PA66 or PET, so that the polymer ultrafine powder seals the surface micropores of the microporous particles, so that the phase change material cannot easily escape from the microporous particles; after sieving and separating the microporous particles and the ultrafine powder, further mix low-melting polymer particles (selected from low-melting polyester particles or low-melting EVA particles, which have a lower melting point than the sponge) with the same particle size as the microporous particles at a certain ratio, and thoroughly fill the pores of the sponge with the large pore size of the filling layer with the mixed particles under ultrasonic vibration. The sponge layer is at the bottom, and the filling layer is at the top to bond the two together, and the side of the filling layer is uniformly flowed with high-temperature nitrogen gas, and the low-melting polymer particles in the pores of the large-pore sponge melt under the high-temperature nitrogen gas flow and flow to the sponge layer below. Because the sponge layer is not flowed by high-temperature nitrogen gas and has a low temperature, the molten low-melting polymer solidifies on the shallow surfaces of the filling layer and the sponge layer to form a thin welding layer, and the welding layer welds the filling layer and the sponge layer together. When the high-temperature nitrogen gas flow is stopped, the micro-pore particles adhere to the pore walls of the filling layer, and the particle diameter of the micro-pore particles is lower than the pore diameter of the large-pore sponge, so that the breathability of the large-pore sponge is maintained. Finally, the multi-layer sponge after cooling is cut into the desired size.

[0010] After the phase change material is encapsulated in the microporous particles, the microporous particles and low melting point polymer particles are filled into the pores of the large pore sponge of the filling layer, and after the low melting point polymer is melted, the microporous particles are firmly attached to the inner wall of the pores of the filling layer, thereby avoiding the loss of phase change material after long-term use, and the multi-layer sponge containing the phase change material of the present invention has long-lasting cooling properties. After melting, the low melting point polymer solidifies at the shallow surface where the filling layer and the sponge layer contact each other to form a welded layer, which stably connects the two and does not block the holes in the sponge, thereby maintaining the breathability of the sponge, and the partially melted low melting point polymer also penetrates into the micropores on the surface of the microporous particles, and after solidification, it bonds the polymer ultrafine powder to strengthen the blockage of the microporous particles to the phase change material. [Brief description of the drawings]

[0011] [Figure 1] 1 is a schematic diagram of the structure of a multi-layer sponge containing a phase change material according to the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present invention will be described below using examples, but the examples given are used only to explain the present invention and are not used to limit the scope of the present invention.

[0013] Example 1 The multi-layer sponge block containing a phase change material is 200 cm×150 cm×10 cm in size, and its cross section is shown in FIG. 1, which is made up of a filling layer 1, a welded layer 2, and a sponge layer 3 from top to bottom.

[0014] The filling layer 1 is 2 cm thick and made of sponge with a pore diameter of 2 mm, with microporous particles 4 with a particle diameter of 0.3 mm fixed to the inner walls of the pores, the micropores inside the microporous particles 4 are filled with PCM material, and the micropores on the surface of the microporous particles 4 are sealed with PA66 ultrafine powder. The sponge layer 3 is 8 cm thick and made of sponge with a pore diameter of 1 mm. The welding layer 2 is formed by attaching low-melting point polyester to the inner walls of the surface pores of the filling layer 1 and the sponge layer 3, with the low-melting point polyester attached to a thickness of 1.5 mm in the filling layer 1 and 0.5 mm in the sponge layer 3.

[0015] Example 2 The multi-layer sponge block containing phase change material is 80 cm×40 cm×3 cm in size, and its cross section is shown in FIG. 1, which is made up of a filling layer 1, a welded layer 2, and a sponge layer 3 from top to bottom.

[0016] The filling layer 1 is 1 cm thick and made of sponge with a pore size of 1 mm, with microporous particles 4 with a particle size of 0.1 mm fixed to the inner walls of the pores, the micropores inside the microporous particles 4 are filled with n-octadecane phase change material, and the micropores on the surface of the microporous particles 4 are sealed with PCT ultrafine powder. The sponge layer 3 is 2 cm thick and made of sponge with a pore size of 0.3 mm. The welding layer 2 is formed by attaching low-melting point EVA to the inner walls of the surface pores of the filling layer 1 and the sponge layer 3, with the low-melting point EVA attached to a thickness of 0.5 mm in the filling layer 1 and 0.2 mm in the sponge layer 3.

[0017] Example 3 The multi-layer sponge block containing phase change material is 50 cm×30 cm×4 cm in size, and its cross section is shown in FIG. 1, which is made up of a filling layer 1, a welded layer 2, and a sponge layer 3 from top to bottom.

[0018] The filling layer 1 is 1 cm thick and made of sponge with a pore size of 0.2 mm, with microporous particles 4 with a particle size of 0.05 mm fixed to the inner walls of the pores, the pores inside the microporous particles 4 are filled with methyl palmitate phase change material, and the pores on the surface of the microporous particles 4 are sealed with PA6 ultrafine powder. The sponge layer 3 is 3 cm thick and made of sponge with a pore size of 0.1 mm. The welding layer 2 is formed by attaching low-melting polyester to the inner walls of the surface pores of the filling layer 1 and the sponge layer 3, with the low-melting polyester attached to a thickness of 0.1 mm in the filling layer 1 and 0.05 mm in the sponge layer 3.

[0019] The above is only a preferred embodiment of the present invention, and does not need to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention. [Explanation of symbols]

[0020] 1, filling layer; 2, welding layer; 3, sponge layer; 4, microporous particles.

Claims

1. 1. A multi-layer sponge comprising a phase change material, The multilayer sponge containing a phase change material is characterized in that, from top to bottom, it is made up of a filling layer 1, a welding layer 2, and a sponge layer 3, the filling layer 1 being a sponge with a large pore diameter, the sponge layer 3 being a sponge with a small pore diameter, the welding layer 2 being formed by adhering a low melting point polymer to the inner walls of the surface holes of the filling layer 1 and the sponge layer 3, microporous particles 4 being fixed to the inner walls of the holes of the filling layer 1, and the micropores of the microporous particles 4 being filled with a phase change material.

2. 2. The multi-layer sponge according to claim 1, wherein the phase change material is one of PCM material, dodecanol, n-hexadecane, n-heptadecane, n-octadecane, and methyl palmitate.

3. 2. The multi-layer sponge containing a phase change material according to claim 1, wherein the large pore diameter of the filling layer 1 is 0.2 to 2 mm.

4. 2. The multi-layer sponge containing a phase change material according to claim 1, wherein the small pore diameter of the sponge layer 3 is 0.1 to 1 mm.

5. A multilayer sponge containing a phase change material as described in claim 3 or claim 4, characterized in that the thickness of the welding layer 2 is the sum of the surface layer of the filling layer 1 of 0.1 to 1.5 mm and the surface layer of the sponge layer 3 of 0.05 to 0.5 mm.

6. 5. The multi-layer sponge containing a phase change material according to claim 3 or 4, wherein the particle diameter of the microporous particles (4) is 0.05 to 0.3 mm.

7. The multi-layer sponge containing phase change material according to claim 3 or 4, characterized in that the filling layer 1 has a thickness of 1 mm to 2.5 cm.

8. The multi-layer sponge containing a phase change material according to claim 3 or 4, characterized in that the thickness of the sponge layer 3 is between 3 mm and 10 cm.

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