Integral-molded compartmentalized double-sided sensory 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 specifically to a one-piece, compartmentalized, double-sided, tactile filament mattress and method of manufacture. [Background technology]

[0002] Mattresses have become popular in China, and a wide variety of materials are available, including latex, palm, memory foam, nanotechnology, and air mattresses. The function of mattresses is to ensure consumers enjoy healthy and comfortable sleep. The quality of a mattress is primarily determined by its material, breathability, and mechanical support. Filament mattresses use 4D filament materials as the cushion layer structure. The filament material is made from thermoplastic resins (PE, POE) or thermoplastic polyester elastomers (TPEE), which are melted at high temperatures and directly extruded into threads. The entire production process eliminates the need for chemical adhesives, produces no unpleasant odors, and is completely formaldehyde-free. Furthermore, filament mattresses are made up of 90% air, providing excellent breathability. Because of the health benefits of filament mattresses, improvements to their performance have focused primarily on mechanical support.

[0003] In a first aspect, improving the mechanical support of a mattress can be achieved by improving the filament material. For example, CN116219641A discloses a highly fatigue-resistant filament mat and its manufacturing method. The filament components include 60-90 parts thermoplastic elastomer resin, 10-40 parts polyolefin resin, 1-2 parts crosslinking agent, 0.1-0.4 parts initiator, 0.1-0.5 parts catalyst, 0.3-0.6 parts antioxidant, and 0.5-2 parts processing aid. In a second aspect, improving the mattress structure can be achieved. For example, CN215456807U employs a multi-layer structure with different hardness levels to improve the distribution of human body pressure. However, because pressure distribution in the mattress varies depending on the weight of different parts of the human body, the mattress is more suitable for compartmentalized installation. However, compartmentalized installations generally consist of multiple mat bodies assembled together. For example, JP2022069693A discloses a mattress divided into multiple mat bodies in the longitudinal direction. Mattresses obtained by joining multiple mat bodies together bring new technical problems, such as different mechanical properties on both sides of the joint, different deformations when subjected to pressure, misalignment of the joints over time, structural damage, and increased susceptibility to dirt accumulation. While integrally molded mattresses can avoid the technical problems of assembly, a filament mattress with different compartments molded together has not yet been reported in the literature. Furthermore, mattresses are generally difficult to fold, and a foldable mattress is desired for special applications (e.g., 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] Chinese Utility Model Patent 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, a first aspect of the present invention provides an integrally molded compartmentalized double-sided tactile filament mattress, the mattress comprising an upper layer and a lower layer with different hardness, the upper layer and the lower layer comprising different compartments, each compartment having a different density and length, the upper layer and the lower layer integrally molded by continuous production, the integral molding being achieved by simultaneously and continuously producing the filaments of the upper layer and the lower layer, and setting the filament production speed and production time according to the compartments to form different compartments of the different upper and lower layers, thereby obtaining an integrally molded mattress. The compartments referred to in this invention refer to load-bearing compartments, transitional compartments, or other structural compartments applicable to 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 provide adequate support for the spine. A mattress's support for the human body is the result of the interaction between the entire mattress and the human body weight, and different body types and weights have different requirements for mattress firmness and firmness distribution. Considering the different weight distributions in different parts of the human body, the mattress of the present invention adopts a compartmentalized design, which allows different load-bearing compartments of the mattress to have different firmness characteristics, thereby improving spinal support conditions, achieving the effect of body pressure distribution, and improving sleep comfort.

[0007] For the same filament, the firmness of the mattress depends primarily on the density of the filaments, with 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 and lower layers each include two load-bearing regions, i.e., an upper region and a lower region. Alternatively, the upper and lower layers each include three load-bearing regions, i.e., 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 60-70 kg / 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 in the head and back region, the lower back and buttock region, and the foot region is 40-50 kg / m 3 , 45-60kg / m 3 and 40-50 kg / m 3 and the percentages of the length of the lower layer are 25-30%, 30-35%, and 30-40%, respectively.

[0009] 1, the mattress has sections including 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 with a different density and length. For example, a mattress with a length of 2 m has a head and back region of 64 cm, a hip and waist region of 60 cm, and a foot region of 76 cm.

[0010] In one or more embodiments, the mattress further includes transition regions located between the load-bearing sections, the transition regions having a density much lower than the density of the load-bearing sections. The transition regions may be located between all of the load-bearing sections or between some of the load-bearing sections. The densities of the transition regions may be the same or different, for example, between 25 and 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% to 3% of the length of the mattress, or 1% to 2% and 2% to 3%, respectively.

[0011] In one exemplary embodiment, a schematic diagram of the mattress structure 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 upward.

[0012] In one exemplary embodiment, a schematic diagram of the mattress structure 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 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 the opposite relationship to the second transition region. Due to the length and density of each transition region, the head and back regions of the mattress tend to fold upward and the foot regions tend to fold downward, forming a Z-fold that makes folding easier.

[0013] The upper and lower layers may have different hardnesses, with the upper layer being lower in hardness and the lower layer being higher in hardness, or the upper layer being higher in hardness and the lower layer being lower in hardness. The hardnesses of the upper and lower layers can be adjusted by the filament material, whether the filament is hollow or solid, the diameter of the filament, the density of the filament, etc. In one typical example, the hardness of the upper layer is lower than that of the lower layer, the thickness of the upper layer is smaller than that of the lower layer, and 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 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). 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 method for manufacturing an integrally molded compartmentalized double-sided tactile filament mattress according to 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 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 from adjacent thread ejection regions of the thread ejection assembly; (3) The upper layer filament thread and the lower layer filament thread are adjacent to each other and enter vertically into the water, and are transported, cooled, and hardened in the water to form the upper layer filament and the lower layer filament, and are drawn out of the water surface through a guide, and when drawn out of the water surface, the upper layer filament and the lower layer filament are kept adjacent to each other and positioned vertically; (4) The filaments are pulled in order to 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, step (1) further includes mixing and drying the raw materials before feeding the raw materials 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 fiber discharging 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 diameter of the yarn spouted by the upper layer yarn spouting region is smaller than the diameter of the yarn spouted by the lower layer yarn spouting region. Preferably, the yarns spouted by the upper layer yarn spouting region and the lower layer yarn spouting region are both solid yarns with diameters of 0.8 to 1.5 mm and 1.0 to 2.5 mm, respectively. Alternatively, the yarn spouted by the upper layer yarn spouting region is solid yarn with a diameter of 0.8 to 1.5 mm, and the yarn spouted by the lower layer yarn spouting region is hollow yarn with an outer diameter of 2.8 to 3.4 mm and an inner diameter of 2.2 to 2.8 mm. Alternatively, the fibers ejected from the upper layer yarn ejection region and the lower layer yarn ejection region are hollow fibers, the outer diameter of which is 2.8 to 3.4 mm, and the inner diameter of which is 2.2 to 2.8 mm.

[0019] In one or more embodiments, in step (3), the upper layer filament thread and a small amount of the adjacent thread are wound around each other to form 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 specific 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 for determining the screw extrusion speed, conveying speed, and pulling speed is to set the corresponding screw extrusion speeds for the upper and lower layers according to the expected filament density of each section of the upper and lower layers, and adjust the speeds of the conveying rollers and the pulling rollers according to the difference in density distribution of the mattress. If the density needs to be increased, the speeds of the conveying rollers and the pulling rollers are reduced, and if the density needs to be decreased, the speeds of the conveying rollers and the pulling rollers are increased.

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

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

[0024] A third aspect of the present invention further provides a manufacturing apparatus for an integrally molded compartmentalized double-sided tactile filament mattress according to any one of the embodiments of the present invention, and 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 dispensing 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 transport 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 confluence valve 2, a yarn discharge die 5, an allocation plate 6, and a yarn discharge plate 7. The confluence valve 2 is connected to the conveying screw and the yarn discharge die, respectively. The yarn discharge die is closely attached to the allocation plate downward, and the allocation plate is closely attached to the yarn discharge plate downward, so that the allocation plate can balance the extrusion pressure of the molten fluid on the yarn discharge 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, and the 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 storage tank is used to store cooling water, the conveying roller is provided in the water storage tank and is completely submerged in the cooling water in the water storage tank, the yarn dispensing assembly is located outside the water storage tank, the shower plate is installed at an angle between the yarn dispensing 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 dispensing assembly, and the shower slope of the shower plate faces the yarn dispensing surface of the yarn dispensing assembly.

[0030] The water storage tank further includes a far-infrared radiator above it, the radiation range of which covers the space from the thread discharge 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 sides of the mattress between the shower plates further include a shaping mold installed, which is a device that matches the angle of the shower plate inclination and can spray cyclic cooling water. The function of the shaping mold is to compress the loose filaments on both sides of the widthwise direction of the mattress inward, avoiding the problem of re-cutting, saving production materials and reducing 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 the cooled filament layer out of the water storage tank via the conveying roller, and the number of guide rollers are arranged along the filament layer in order 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 time at a particular speed to control the formation of the mattress sections. [Effects 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 is made of filament material and has an upper and lower layer structure with different hardness levels, providing a two-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 body pressure distribution and improves sleeping comfort.

[0034] 2. The mattress of the present invention further includes a transition region with a relatively low density, thereby enabling 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 for the upper and lower layers of the mattress of the present invention each have their own independent melting channels, yarn dispensing assemblies and control systems, and can be independently controlled according to the density settings of the upper and lower layers. In the continuous production process, by cycling the screw extrusion speed, conveying roller speed, pulling roller speed and operating time under each speed condition according to this specific program, an integrally molded compartmentalized double-sided filament mattress can be obtained, including compartments such as the head and back area, transition area, waist and hip area, transition area and foot area.

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

[0037] The drawings herein are incorporated into 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 explain the principles of the embodiments of the present invention. It is obvious that the drawings in the following description are only some embodiments of the implementation of the present invention, and those skilled in the art can derive other drawings based on these drawings without any creative effort. [Figure 1] 1 is a schematic diagram of a typical structure of a filament mattress. [Figure 2] 1A is a schematic diagram of a filament mattress and fold including a transition region. [Figure 3] FIG. 1B is a schematic diagram of a filament mattress and fold including a transition region. [Figure 4] 1 is a structural schematic diagram of a manufacturing device according to a first embodiment. [Figure 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 device according to a first embodiment. [Figure 7] FIG. 2 is a schematic diagram of a yarn-spouting area of ​​the manufacturing equipment of Example 1. DETAILED DESCRIPTION OF THE INVENTION

[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 explanations 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 approximation 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 (where 13 is the water surface of the water storage tank), as shown in Figure 4. 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 merging 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. Here, the merging 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 closely attached to the yarn ejection mold 5, the lower side of the yarn ejection mold 5 is closely attached to the upper side of the allocation plate 6, and the lower side of the allocation plate 6 is closely attached to the upper side of the yarn ejection plate 7. The junction valve 2 is provided with two first and second diverting channels 21 and 22 corresponding to the first and second conveying screws 41 and 42, respectively, 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 and second yarn ejection channels 51 and 52, which are connected to the corresponding first and second diverting channels 21 and 22, respectively. The allocation plate 6 has two allocation areas, a first allocation area 61 and a second allocation area 62, corresponding to the first yarn outlet channel 51 and the second yarn outlet channel 52. The allocation plate 6 also has a number of allocation holes communicating with the yarn outlet plate below it. The yarn outlet plate 7 has two yarn outlet areas, a first yarn outlet area 71 and a second yarn outlet area 72. Each of the yarn outlet areas 71, 72 has a number of yarn outlet holes, which are either solid or hollow, and the diameter of the hollow holes is significantly larger than the diameter of the solid holes. In this embodiment 1, the yarn outlet area 71 is a solid hole, and the yarn outlet area 72 is a hollow hole.

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

[0043] Here, the hole diameter of the allocation plate 6 is 4 mm, and it fits into 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 rows are installed crosswise, with 8 rows in each of the left and right allocation areas.

[0044] The upper layer TPEE filament thread and the lower layer PE filament thread naturally fall into the water, and the speed of the threads slows, causing adjacent threads to come into contact with each other in a loop. The thread loop layer is then transported by a transport roller into a cooling water tank at 20°C for rapid cooling and hardening. As shown in Figure 6, the upper layer TPEE filament thread and the lower layer PE filament thread and a small number of adjacent threads are wrapped around each other and adhere to each other in a loop, improving the bonding strength of the upper and lower layers.

[0045] After cooling, the yarn loop is pulled out of the water surface by a guide roller. When pulled out of the water surface, the upper and lower filaments are maintained adjacent and positioned one above the other, and are pulled by a pulling roller. An independent control system controls the screw extrusion speed, the speed of the conveying roller, and the speed of the pulling roller 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 ejection areas 71 and 72 on the yarn ejection plate 7 are that the yarn ejected by the upper layer yarn ejection area is solid and has a hole diameter of 1 mm, and that the yarn ejected by the lower layer yarn ejection area is solid and has 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 JPEG0007734355000001.jpg109170

[0048] Example 2 The differences from Example 1 are as follows: the raw materials for 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. The mattress structure and parameters obtained in Example 2 are as shown in the table below.

[0049] Table 2 JPEG0007734355000002.jpg82170

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

[0051] Table 3 JPEG0007734355000003.jpg104170

[0052] Example 4 The differences from Example 2 are as follows: 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 1 mm, the lower layer yarn spouting area spouts hollow yarn with an outer ring hole diameter of 3 mm, and the 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 JPEG0007734355000004.jpg70170

[0054] Finally, it should be noted that the above embodiments are merely for illustrating the technical solution of the present invention, and do not constitute limitations on the summary 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 content disclosed in the present invention, and all fall within the protection scope of the present invention. [Explanation of symbols]

[0055] 1 yarn discharge assembly, 2 confluence valve, 3 dryer, 4 conveying screw, 5 yarn ejection mold, 6 allocation plate, 7 yarn ejection plate, 8 shower plate, 9 water storage tank, 10 conveying roller, 11 traction roller, 12 guide roller, 13 water storage tank water surface, 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 1004, a second head and back region, 1005, a second waist and back region, 1006, a second foot region, 1007, a first transition region, 1008, a second transition region, 1009, a third transition region, and 1010, a fourth transition region.

Claims

1. A method for manufacturing an integrally molded compartmentalized double-sided sensory filament mattress, The mattress includes an upper layer and a lower layer having different firmness, the upper layer and the lower layer including different compartments; Each section has a different density and length, and the upper and lower layers are integrally formed 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 section, thereby forming different sections of the upper layer and the lower layer, and obtaining an integrally molded mattress; The thickness of the upper layer is 2 to 3 cm, and the thickness of the lower layer is 4 to 5 cm; The upper layer filaments are solid and have a thread diameter of 0.8 mm to 0.9 mm, and the lower layer filaments are solid and have a thread warp of 1.1 to 1.3 mm, The upper layer and the lower layer each include three load-bearing regions: a head and back region, a waist and hip region, and a foot region; The densities of the head and back region, the waist and hip region and the foot region of the upper layer are each 55 to 70 kg / m ３ , 65-80kg / m ３ and 60 to 70 kg / m ３ and The density of the head and back region, the waist and hip region and the foot region of the lower layer is 40 to 50 kg / m ３ , 45-60kg / m ３ and 40 to 50 kg / m ３ A method for manufacturing an integrally molded compartmentalized double-sided sensory filament mattress, characterized by:

2. 2. The method of claim 1, wherein the mattress has a length of 2 m, a head and back region of 64 cm, a waist and hip region of 60 cm, and a foot region of 76 cm.

3. 2. The manufacturing method according to claim 1, wherein the material of the filaments of the upper layer and the lower layer is one or more selected from the group consisting of thermoplastic polyester elastomer, polyethylene, and polyolefin thermoplastic elastomer.

4. The manufacturing method according to any one of claims 1 to 3, characterized in that an independent control system is employed to control the production of the upper layer and the lower layer filaments, respectively, to form each of the upper layer and the lower layer sections according to the section 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 from adjacent thread ejection regions of the thread ejection assembly; (3) The upper layer filament thread and the lower layer filament thread are adjacent to each other and enter vertically into the water, and are transported, cooled, and hardened in the water to form the upper layer filament and the lower layer filament, and are drawn out of the water surface through a guide, and when drawn out of the water surface, the upper layer filament and the lower layer filament are kept adjacent to each other and positioned vertically; (4) The manufacturing method of claim 4 further includes: through pulling, the filaments are sequentially and continuously divided into sections to set and form the upper and lower sections of the mattress, thereby obtaining an integrally molded divided double-sided tactile 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, The manufacturing method according to claim 5, wherein the yarns ejected from the upper layer yarn ejection area and the lower layer yarn ejection area are both solid yarns, and the yarn diameters are 0.8 to 0.9 mm and 1.1 to 1.3 mm, respectively.

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 specific set speed.

9. 9. The manufacturing method of claim 8, wherein in step (4), the screw extrusion speed, conveying speed and pulling speed are determined by setting the corresponding screw extrusion speeds for the upper and lower layers according to the expected filament density of each section of the upper and lower layers, and adjusting the conveying roller speed and 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 pulling roller speed are reduced, and if the density needs to be decreased, the conveying roller speed and pulling roller speed are increased.

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

Images