A gradient wicking warmth-retaining batt and a method for manufacturing the same

Abstract

This invention relates to a gradient wicking thermal insulation wadding and its preparation method. The wadding comprises three layers of fiber web, wherein the inner layer of fiber web has a loft of 20-70 cm. 3 / g, the fiber raw materials are selected from hydrophobic fiber A and low melting point fiber C, and the bulkiness of the intermediate layer web is 50-100cm. 3 / g, the fiber raw materials are selected from hydrophilic fiber B and low melting point fiber C, and the bulkiness of the outer fiber web is 90-130cm. 3 The fiber raw materials are selected from hydrophilic fiber B and low-melting-point fiber C; wherein the mass percentage of hydrophobic fiber A or hydrophilic fiber B is 85-100%, and the mass percentage of low-melting-point fiber C is 0-15%; the preparation method includes opening and mixing, carding, web laying, drying, cooling and shaping, calendering, and winding and trimming. The gradient wicking insulation wadding of this invention has a basis weight of 40-400 g / m². 2 The material exhibits a compression elastic recovery rate ≥92%, a thermal conductivity ≤0.05 W / (m·K), a water absorption rate ≥40% / s, a liquid water diffusion rate ≥2 mm / s, and a unidirectional moisture transfer index ≥100. Compared with existing technologies, the material of this invention possesses unidirectional moisture-wicking properties, enhancing the thermal and moisture comfort of the wearer.

Description

Technical Field

[0001] This invention belongs to the field of textile processing technology and relates to a gradient wicking thermal insulation wadding and its preparation method. Background Technology

[0002] Fluff is a type of high-loft textile made of fibers. It has advantages such as being lightweight, soft, and warm. However, its thickness and long moisture transport channels cause sweat to accumulate and condense, reducing the comfort of the clothing.

[0003] Chinese patents CN113524854A, CN113524737A, and CN106926538A disclose waterproof and breathable membrane-insulating wadding composite materials and their preparation methods. These materials combine a waterproof and breathable membrane with wadding to achieve unidirectional moisture permeability. However, the waterproof and breathable properties of the membrane are concentrated only on the surface of the wadding, making it difficult to address the inherent water vapor transport issues of the wadding itself. Therefore, the overall moisture permeability of the material is poor. Chinese patents CN108265395A and CN213501227U disclose wadding with excellent moisture permeability and its preparation method, which primarily uses hydrophilic fibers and lacks flame retardancy. Summary of the Invention

[0004] The purpose of this invention is to overcome the defects of the prior art by providing a gradient wicking thermal insulation wadding and its preparation method. This invention endows the thermal insulation wadding with excellent one-way moisture-wicking function through the gradient wicking structure of the three-layer fiber web and material optimization, so that the sweat produced by the human body during wearing can be discharged from the body through the gradient wicking effect, thereby improving thermal and moisture comfort.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] One of the technical solutions of the present invention is to provide a gradient wicking insulation quilt, which comprises three layers of fiber mesh, wherein the inner layer of fiber mesh has a loft of 20-70 cm. 3 / g, the fiber raw materials are selected from hydrophobic fiber A and low melting point fiber C, and the bulkiness of the intermediate layer fiber web is 50-100cm. 3 / g, the fiber raw materials are selected from hydrophilic fiber B and low melting point fiber C, and the bulkiness of the outer fiber web is 90-130cm. 3 / g, the fiber raw materials are selected from hydrophilic fiber B and low melting point fiber C; by mass percentage, the raw materials in each layer of the fiber web are configured as follows: hydrophobic fiber A or hydrophilic fiber B accounts for 85-100%, low melting point fiber C accounts for 0-15%, the fiber proportions of each layer of the fiber web are basically similar, and low melting point fiber C is used to achieve structural bonding. The overall fiber proportion depends on the bulkiness of each layer of the fiber web.

[0007] Furthermore, the hydrophobic fiber A is selected from one or more of polyester fiber, polypropylene fiber, polyethylene-polyester composite fiber, and polyethylene-polypropylene composite fiber.

[0008] Furthermore, the hydrophobic fiber A has a fineness of 1-10D and a length of 38-64mm.

[0009] Furthermore, the hydrophilic fiber B is selected from one or both of cotton fiber and viscose fiber.

[0010] Furthermore, the hydrophilic fiber B has a fineness of 1-10D and a length of 38-64mm.

[0011] Furthermore, the low-melting-point fiber C is selected from one or both of low-melting-point polyester fiber and polypropylene-polyethylene composite fiber.

[0012] Furthermore, the low-melting-point fiber C has a melting point of 100-150℃, a fineness of 1-20D, and a length of 38-64mm.

[0013] One of the technical solutions of the present invention is to provide a method for preparing a gradient wicking insulation wadding, the method comprising the following steps:

[0014] (1) Opening and mixing: Hydrophobic fiber A, hydrophilic fiber B and low melting point fiber C are mixed in proportion and then opened;

[0015] (2) Carding: The opened and mixed fibers are fed into a carding machine to form uniform and dense cotton, and the cotton is carded into a web to form a quantitative fiber web composed of single fibers, which is then transported to the next process.

[0016] (3) Web laying: Fold the fiber web output from the carding machine evenly, lay it to the required width and thickness according to the three-layer structure loft setting, and convey it to the next process;

[0017] (4) Drying: The fiber web is dried by hot air penetration and convection in an oven;

[0018] (5) Cooling and shaping: The fiber web coming out of the oven is subjected to forced air cooling and rapid cooling and shaping to obtain wadding;

[0019] (6) Heat treatment: Use a heat treatment machine to heat the surface of the flakes to make the product surface smooth;

[0020] (7) Rolling and trimming: Trim, count, cut and roll the wadding, and pack it into absorbent and heat-insulating wadding.

[0021] Furthermore, in step (3), the width of the fiber web is 1000-5000mm, the thickness is 10-40mm, the web laying speed is 20-50m / min, and the fiber web output speed is 2-15m / min.

[0022] Furthermore, the drying temperature in step (4) is 80-170℃.

[0023] Thermal insulation wadding is a fluffy fiber product with a large thickness, resulting in long vapor transport channels that cause sweat to accumulate and condense, reducing clothing comfort. This invention relates to a three-layer fiber web structure, wherein the inner fiber web is a low-loft hydrophobic layer, the middle fiber web is a low-loft hydrophilic layer, and the outer fiber web is a high-loft hydrophilic layer. According to the Laplace equation, capillary force is positively correlated with the bulk of the material. Therefore, condensed sweat can move autonomously from the inside out through the gradient-increased capillary force, giving the material excellent one-way moisture-wicking ability. Simultaneously, the hydrophobic fibers in the inner layer prevent discomfort caused by sweat condensation.

[0024] Gradient wicking insulation wadding has a weight of 40-400g / m³. 2 Compression elastic recovery rate ≥92%, thermal conductivity ≤0.05W / (m·K), water absorption rate ≥40% / s, liquid water diffusion rate ≥2mm / s, and unidirectional transfer index ≥100.

[0025] Compared with the prior art, the present invention has the following advantages:

[0026] (1) The gradient core-absorbing thermal insulation wadding of the present invention has excellent one-way moisture-wicking function, which can realize the one-way export of human sweat and improve the thermal and moisture comfort during the wearing process.

[0027] (2) The inner layer of the gradient wicking thermal insulation wadding of the present invention is made of hydrophobic fibers, which can effectively avoid discomfort caused by sweat condensation. Detailed Implementation

[0028] The present invention will now be described in detail with reference to specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0029] Unless otherwise specified, the equipment used in the following embodiments is conventional equipment in the art; unless otherwise specified, the reagents used are commercially available products or prepared by conventional methods in the art. In the following embodiments, unless otherwise described in detail, conventional experimental methods in the art can be used.

[0030] Example 1:

[0031] A gradient wicking thermal insulation wadding and its preparation method, the preparation method comprising the following steps:

[0032] Weigh and unpack 92wt% polyester fiber (1.5D fineness, 51mm length) and 8wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as inner layer fiber web material; weigh and unpack 95wt% cotton fiber (2D fineness, 51mm length) and 5wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as middle layer fiber web material; weigh and unpack 92wt% cotton fiber (2D fineness, 51mm length) and 8wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as outer layer fiber web material. After being opened and mixed and carded by a double cylinder double doffer double random carding machine, a uniform quantitative fiber web is formed. After web laying, a web with a thickness of 20 mm and a width of 3000 mm is formed (web laying speed of 30 m / min, web output speed of 5 m / min), and a bulk of 55 cm is formed. 3 / g (inner layer), 100cm 3 / g (middle layer) and 120cm 3 / g (outer layer) of wadding, after the fiber web is dried at 140℃, is subjected to forced air cooling, with upward blowing and downward suction, rapid cooling and shaping, followed by ironing, rolling and trimming.

[0033] The final gradient wicking insulation wadding weighed 150g / m². 2 The compression elastic recovery rate is 97.2%, the thermal conductivity is 0.031 W / (m·K), the afterburn time is 0 s, the damage length is 1.9 mm, the thermal shrinkage rate (260℃, 5 min) is 6.1% in the transverse direction and 5.5% in the longitudinal direction, there is no melting, the water absorption rate is 45% / s, the liquid water diffusion rate is 3 mm / s, and the unidirectional transfer index is 120.

[0034] Example 2:

[0035] A gradient wicking thermal insulation wadding and its preparation method, the preparation method comprising the following steps:

[0036] Weigh and unpack 95wt% polypropylene fiber (1.5D fineness, 51mm length) and 5wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as inner layer fiber web material; weigh and unpack 95wt% cotton fiber (2D fineness, 51mm length) and 5wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as middle layer fiber web material; weigh and unpack 92wt% cotton fiber (2D fineness, 51mm length) and 8wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as outer layer fiber web material. After being opened, mixed, and carded by a double-cylinder, double-doffer, double-randomized carding machine, a uniform quantitative fiber web is formed. After web laying, a web with a thickness of 20 mm and a width of 3000 mm (web laying speed 30 m / min, web output speed 5 m / min) and a bulkiness of 50 cm⁻¹ is formed. 3 / g (inner layer), 80cm 3 / g (intermediate layer) and 130cm 3 / g (outer layer) of wadding, after the fiber web is dried at 140℃, is subjected to forced air cooling, with upward blowing and downward suction, rapid cooling and shaping, followed by ironing, rolling and trimming.

[0037] The final gradient wicking insulation wadding weighed 155g / m². 2 The compression elastic recovery rate is 96.5%, the thermal conductivity is 0.035 W / (m·K), the afterburn time is 0 s, the damage length is 2.2 mm, the thermal shrinkage rate (260℃, 5 min) is 7.8% in the transverse direction and 5.1% in the longitudinal direction, there is no melting, the water absorption rate is 55% / s, the liquid water diffusion rate is 8 mm / s, and the unidirectional transfer index is 140.

[0038] Example 3:

[0039] A gradient wicking thermal insulation wadding and its preparation method, the preparation method comprising the following steps:

[0040] Weigh and unpack 95wt% polyester fiber (1.5D fineness, 51mm length) and 5wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as inner layer fiber web material; weigh and unpack 95wt% viscose fiber (2D fineness, 51mm length) and 5wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as middle layer fiber web material; weigh and unpack 92wt% viscose fiber (2D fineness, 51mm length) and 8wt% polypropylene-polyethylene composite fiber (melting point 110℃, fineness 3D, length 51mm) as outer layer fiber web material. After being opened, mixed, and carded by a double-cylinder, double-doffer, double-randomized carding machine, a uniform quantitative fiber web is formed. After web laying, a web with a thickness of 20 mm and a width of 3000 mm (web laying speed 30 m / min, web output speed 5 m / min) and a bulkiness of 50 cm⁻¹ is formed. 3 / g (inner layer), 80cm 3 / g (intermediate layer) and 130cm 3 / g (outer layer) of wadding, after the fiber web is dried at 140℃, is subjected to forced air cooling, with upward blowing and downward suction, rapid cooling and shaping, followed by ironing, rolling and trimming.

[0041] The final gradient wicking insulation wadding weighed 175g / m². 2 The compression elastic recovery rate is 97.5%, the thermal conductivity is 0.032 W / (m·K), the afterburn time is 0 s, the damage length is 4.1 mm, the thermal shrinkage rate (260℃, 5 min) is 6.6% in the transverse direction and 6.2% in the longitudinal direction, there is no melting, the water absorption rate is 42% / s, the liquid water diffusion rate is 6 mm / s, and the unidirectional transfer index is 115.

[0042] The above description of the embodiments is provided to enable those skilled in the art to understand and use the invention. It will be apparent to those skilled in the art that various modifications can be made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the invention should be within the protection scope of the present invention.

Claims

1. A gradient wicking insulation sheet, characterized in that, The wadding consists of three layers of fiber web, with the innermost layer having a loft of 20-70 cm. 3 / g, the fiber raw materials are selected from hydrophobic fiber A and low melting point fiber C, and the bulkiness of the intermediate layer fiber web is 50-100cm. 3 / g, the fiber raw materials are selected from hydrophilic fiber B and low melting point fiber C, and the bulkiness of the outer fiber web is 90-130 cm. 3 / g, the fiber raw materials are selected from hydrophilic fiber B and low melting point fiber C; by mass percentage, the raw materials in each layer of the fiber web are configured as follows: hydrophobic fiber A or hydrophilic fiber B account for ≥85%, low melting point fiber C account for ≤15%, low melting point fiber C is used to achieve structural bonding, and the overall fiber ratio depends on the bulkiness of each layer of the fiber web. The low-melting-point fiber C is selected from one or both of low-melting-point polyester fiber and polypropylene-polyethylene composite fiber; The aforementioned wadding involves a three-layer fiber web structure, wherein the inner fiber web is a low-loft hydrophobic layer, the middle fiber web is a low-loft hydrophilic layer, and the outer fiber web is a high-loft hydrophilic layer. According to the Laplace equation, capillary force is positively correlated with the loft of the material. Therefore, the condensed sweat can move autonomously from the inside to the outside through the gradient-increased capillary force, giving the material a one-way moisture-wicking ability. At the same time, the hydrophobic fibers in the inner layer prevent discomfort caused by sweat condensation.

2. The gradient wicking insulation sheet according to claim 1, characterized in that, The hydrophobic fiber A is selected from one or more of polyester fiber, polypropylene fiber, polyethylene-polyester composite fiber, and polyethylene-polypropylene composite fiber.

3. The gradient wicking insulation sheet according to claim 2, characterized in that, The hydrophobic fiber A has a fineness of 1-10 D and a length of 38-64 mm.

4. The gradient wicking insulation sheet according to claim 1, characterized in that, The hydrophilic fiber B is selected from one or both of cotton fiber and viscose fiber.

5. The gradient wicking insulation sheet according to claim 4, characterized in that, The hydrophilic fiber B has a fineness of 1-10 D and a length of 38-64 mm.

6. The gradient wicking insulation sheet according to claim 1, characterized in that, The low-melting-point fiber C has a melting point of 100-150 ℃, a fineness of 1-20 D, and a length of 38-64 mm.

7. A method for preparing a gradient wicking insulating wadding as described in any one of claims 1 to 6, characterized in that, The preparation method includes the following steps: (1) Opening and mixing: Hydrophobic fiber A, hydrophilic fiber B and low melting point fiber C are mixed in proportion and then opened; (2) Carding: The opened and mixed fibers are carded into a uniform and dense cotton web, which is then processed into a quantitative fiber web composed of single fibers and transported to the next process. (3) Laying the net: Fold the fiber net evenly, and lay it to the required width and thickness according to the three-layer structure fluffiness setting, and then transport it to the next process; (4) Drying: Drying the fiber web; (5) Cooling and shaping: The fiber web is cooled and shaped to obtain wadding; (6) Polishing: Polishing the surface of the flakes to make the product surface smooth; (7) Rolling and trimming: Trim, count, cut and roll the wadding, and pack it into core-absorbing and heat-insulating wadding.

8. The method for preparing a gradient wicking insulating wadding according to claim 7, characterized in that, In step (3), the width of the fiber web is 1000-5000 mm, the thickness is 10-40 mm, the web laying speed is 20-50 m / min, and the fiber web output speed is 2-15 m / min.

9. The method for preparing a gradient wicking insulating wadding according to claim 7, characterized in that, The drying temperature in step (4) is 80-170 ℃.