The physical process of imported latex mattress is to mix natural latex and synthetic latex, add all necessary additives such as vulcanizing agent, gelling agent and antioxidant, mechanically stir, and add soap and air at the same time. The more air, the thinner and softer the product. After that, the foam flows through the hose and is introduced into a series of molds when passing through the conveyor belt in front of the operator. When each mold is filled to the top, the mold cover is closed. At this time, the foam in the mold is gelled or solidified under the action of the gelling agent. After that, the mold was sent to the steam chamber at 1 10℃. Vulcanization or curing occurs under the action of heat. Then come out of the steam room. At this time, the mold cover will automatically open, and the latex block can be taken out for cleaning and drying.
The chemical manufacturing process of imported latex mattress is to add natural latex, vulcanizing agent, gelling agent, antioxidant and other necessary auxiliary mixtures and fill them into the mold. However, the mold is only partially filled, and the filling amount varies according to the hardness requirements of the latex block. This mold is a special aluminum mold with a large number of needles, and there are about 20 thousand needles on each mold cover and mold chassis. This kind of needle has dual functions. First, it is helpful to conduct heat to the center of latex block, because foam rubber is not a good conductor of heat, and at the same time, it forms a "pinhole", which is helpful for drying in the later process. The periphery of the mold is covered with a rubber sealing ring, and there is a hollow channel in the sealing ring, which can flow through liquids such as ethylene glycol/water for heat transfer.
After the liquid foam partially fills the mold, the mold is closed, cooled and vacuum treated. Foam expands under the action of vacuum and completely fills the whole mold. At this time, the internal auxiliary semi-transparent paper gasket can exhaust the air in the mold and prevent the liquid foam from flowing into the vacuum pipeline. After that, the mold is cooled to freeze the foam to about -30℃, and then carbon dioxide gas flows through the freezing block to "solidify" or "gel" the foam. At this point, the individual bubbles begin to connect with each other. After gelation, the mold was heated to 1 10℃ and kept for several minutes.
Heat will cause rubber to "harden" or "vulcanize", making the product have normal elasticity. Then the product is demoulded, washed and the residual soap is removed. Finally, it was dried and tested.
The main difference between the two technologies is that latex liquid is directly injected into the mold, foamed and fixed by physical techniques such as low temperature, and combined with Deng Lupu process. The latter is made by putting latex liquid into a mold after chemical foaming and then solidifying at high temperature. The latex mattress formed by the two will be porous. The former uses a large proportion of synthetic latex in raw materials, while the latter has high natural components. The former is superior to the latter in product performance.
According to the advantages and disadvantages of the two technologies, most of the good latex products on the market are foamed by the mix and match technology of the two technologies. However, domestic latex mattresses are mostly closed-cell structures.
Excerpt from Lydia official website