A method for manufacturing a homogeneous fiber-shaped elastic memory material

Abstract

This invention discloses a method for manufacturing a homogeneous fiber-based irregular shape memory elastic material. The method includes: raw material preparation; raw material mixing / treatment; fiber web preparation / splitting treatment, or fiber sliver preparation / length treatment; bottom mold resetting; frame mold resetting; X / Y axis separator; metering transition storage bin; raw material falling into the X / Y axis separator; precise material feeding; mold closing and compaction; feeding into an oven; shaping and exiting the oven; sufficient cooling of the finished product after shaping; mold detachment; frame mold detachment; finished product detachment. This invention produces a novel homogeneous fiber-based irregular shape elastic material with more balanced deformation resistance in the X / Y / Z axis directions, stronger resistance to mechanical damage, a wider operating temperature range, and a broader range of applications, showing broad market prospects.

Description

Technical Field

[0001] This invention relates to the field of fiber nonwoven processing technology, specifically to a method for manufacturing a homogeneous fiber irregular elastic memory material. Background Technology

[0002] Homogeneous fiber-modified elastic memory material is a high-performance material with efficient shape memory capabilities and excellent mechanical properties. The shape memory capability of homogeneous fiber-modified elastic memory material mainly comes from its internal microphase separation structure, allowing the material to deform under external stress and automatically return to its original shape after the stress is removed. This shape memory capability gives this material significant advantages in many applications, such as flexible furniture, upholstered furniture, medical devices, aerospace, and construction. Furthermore, homogeneous fiber-modified elastic memory material also possesses excellent mechanical properties, such as high strength, high toughness, and high wear resistance. These properties make this material highly reliable and durable in various applications. In conclusion, homogeneous fiber-modified elastic memory material is a high-performance material with broad application prospects.

[0003] Patent No. ZL200510072347.8 discloses a method for manufacturing micro-clump shaping cotton with special shapes, comprising the following steps: raw material preparation, raw material mixing, homogenization, micro-clump preparation, micro-clump heating and shaping, micro-clump conformal product, weighing, special shape pre-compression, special shape heating and shaping, and special shape shaped product. The micro-clump shaping cotton prepared by different methods has basically the same resistance to deformation, but this method has the disadvantages of long process flow and high transmission power and heating power.

[0004] Therefore, this application is hereby submitted. Summary of the Invention

[0005] Therefore, this invention provides a method for manufacturing a homogeneous fiber-based irregular elastic memory material. Compared with existing technologies, this invention has the following improvements: 1. It eliminates the micro-cluster production process, simplifying the process flow and significantly shortening the production cycle; 2. It can significantly reduce transmission power and heating power by 80%, reducing production energy consumption; 3. By treating the raw material fibers with hydrophilic / hydrophobic properties, it allows for two distinctly different development directions in the application scope of the finished product, resulting in a wider range of applications; 4. It produces a novel homogeneous fiber-based irregular elastic material with more balanced deformation resistance in the X / Y / Z axis directions, stronger resistance to mechanical damage, a wider operating temperature range, and a broader range of applications, showing broad market prospects.

[0006] To achieve the above objectives, the embodiments of the present invention provide the following technical solutions:

[0007] This invention provides a method for manufacturing a homogeneous fiber-shaped elastic memory material, the method comprising the following steps:

[0008] (1) Raw material preparation: Select different fiber raw materials according to the application of the finished product, and perform hydrophilic / hydrophobic treatment according to the application of the elastic memory material.

[0009] (2) Raw material mixing / treatment: The fiber raw materials are fully mixed by mechanical airflow, and micro dust separation is carried out at the same time;

[0010] (3) Fiber web preparation / splitting treatment, or fiber sliver preparation / length treatment;

[0011] (4) Bottom mold reset;

[0012] (5) Frame mold reset;

[0013] (6) Reset the X / Y axis separator;

[0014] (7) Metering transition storage bin: The fiber web or fiber strip entering the precision metering device is accurately transported by airflow to the combined pre-storage bins in different positions according to the required amount of the special shape parts, while micro dust separation treatment is carried out at the same time.

[0015] (8) Raw materials fall into the X / Y axis separator: When feeding the product, the same or different amounts of fibers from different locations are simultaneously fed into a specific area in the prefabricated model. At the same time, a negative pressure suction system under the bottom mold evenly adsorbs the falling fibers onto the top of the bottom mold and performs micro-dust separation.

[0016] (9) After precise material feeding, the pre-set area isolation device / prepared storage bin in the mold is removed at the same time, and micro dust separation treatment is carried out simultaneously.

[0017] (10) Press the fibers in the mold into the required special shape to reach the preset elastic recovery position, and at the same time perform micro-dust separation treatment to obtain the product to be shaped.

[0018] (11) The product to be shaped is sent into the heating box and heated to the required temperature.

[0019] (12) After the finished product is shaped, it is removed from the oven, cooled fully, the cover mold is removed, the frame mold is removed, the finished product is removed, and the finished product is completed.

[0020] Further, in step (1), the fiber raw materials include, by weight percentage: 15% to 50% composite bicomponent fiber, 0% to 85% high modulus fiber, and 0% to 85% ultra-high modulus inorganic fiber.

[0021] Further, in step (3), the fiber web preparation / segmentation process includes: by setting / adjusting the width when segmenting the fiber web, the purpose of conveying different fiber quantities can be achieved under the same time conditions, while performing micro-dust separation treatment;

[0022] The fiber preparation / length processing: By setting and adjusting the difference in operating time under the condition of equal delivery, the purpose of delivering different quantities of fibers can be achieved;

[0023] The fibers are fed into a precision metering device via a special conveying device, while simultaneously undergoing micro-dust separation.

[0024] Furthermore, in step (10), the pre-compression ratio is 20% to 85% under natural conditions.

[0025] Furthermore, in step (11), the process temperature is required to be 20°C to 120°C higher than the melting point of the low-melting-point component of the composite fiber, and the process time is 3 minutes to 15 minutes.

[0026] Furthermore, in step (11), the heating medium used in the heating box is uniformly input through precise positioning.

[0027] The embodiments of the present invention have the following advantages:

[0028] 1. Advantages of one-time molding to meet specific needs, eliminating waste and allowing for precise metering, conveying, positioning, and shaping of homogeneous fiber elastic products according to set shapes; 2. After product failure, it can be restored to a new product with the shortest process flow, effectively achieving zero carbon recycling; 3. It can replace traditional elastic materials (such as polyurethane foam, micro-cluster molded cotton, bamboo, and coconut fiber products) in many fields, significantly improving thermal insulation performance and greatly expanding the applicable working temperature range (-200℃~900℃); 4. It can significantly improve the uniformity and homogeneity of X / Y / Z three-dimensional deformation resistance; 5. It can significantly reduce the volumetric weight ratio while maintaining the same thermal insulation efficiency; 6. It can expand the application fields of new technology products in both directions. Attached Figure Description

[0029] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0030] Figure 1 This is a manufacturing process flow diagram of a homogeneous fiber-shaped elastic memory material provided in an embodiment of the present invention. Detailed Implementation

[0031] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] See Figure 1 This invention provides a method for manufacturing a homogeneous fiber-shaped shape memory elastic material, comprising the following steps:

[0033] S1: Raw Material Preparation

[0034] The fiber formulation selection is as follows:

[0035] A. Composite bicomponent fiber, percentage: 15%–50%;

[0036] B. High modulus fibers: chemical / synthetic / man-made / animal / plant fibers, accounting for 0% to 85%;

[0037] C. Ultra-high modulus inorganic fibers: accounting for 0% to 85%;

[0038] D. The selected fibers are treated with hydrophilic / hydrophobic agents according to the intended use of the elastic memory material.

[0039] Depending on the intended use of the elastic memory material products, the fiber raw materials undergo hydrophilic / hydrophobic treatment. Hydrophilic / hydrophobic treatment of fiber raw materials is a conventional technique in this field. As an example, hydrophilic treatment methods for fibers include introducing hydrophilic groups, such as hydroxyl, carboxyl, or amide groups, onto the fiber surface through chemical or physical methods, thereby improving the fiber's water absorption properties. Hydrophobic treatment of fibers is used to improve the waterproof performance of fiber materials. Hydrophobic treatment methods for fibers include: surface coating methods, such as coating the fiber surface with a hydrophobic polymer coating; chemical modification methods, i.e., introducing hydrophobic groups onto the fiber molecular chains through chemical modification of the fiber, such as grafting, block polymerization, etc., thereby improving the fiber's waterproof performance, etc.

[0040] S2: Raw material mixing / processing

[0041] The fibers, mixed together according to the specified ratio, are further thoroughly mixed by mechanical airflow. This process requires micro-dust separation.

[0042] S3: Includes S31: Web preparation / splitting treatment; and S32: Sliver preparation / length treatment.

[0043] S31: Fiber Web Preparation / Separation Process

[0044] After thorough mixing, the fibers are formed into a web using mechanical / airflow methods. By setting / adjusting the width when dividing the web, different quantities of fibers can be transported within the same time frame. This process requires micro-dust separation.

[0045] S32: Sliver Preparation / Length Treatment

[0046] After thorough mixing, the fibers are processed into strips using mechanical / airflow methods. By adjusting the difference in operating time under equal conveying conditions, different quantities of fibers can be conveyed.

[0047] The fibers are fed into a precision metering device via a special conveying device, while simultaneously undergoing micro-dust separation.

[0048] S4: Bottom mold reset

[0049] After the fiber-shaped elastic memory product is separated from the bottom mold after the previous shaping and cooling, the bottom mold returns to the starting position of the next cycle.

[0050] S5: Frame mold reset

[0051] After the frame mold detaches from the bottom mold and fully exposes the shaped and cooled fiber shape memory elastic product in the Z-axis direction, it returns to the position where the frame mold falls.

[0052] S6: X / Y axis separator reset

[0053] In the previous instance, the combined separator, which effectively distributed raw materials in equal / unequal amounts in the X / Y axis directions, fell into the frame mold.

[0054] S7: Metering Transition Storage Bin

[0055] The fibers entering the precision metering device are accurately transported by airflow to the combined pre-storage bins in different locations according to the required amount for the special shape parts. During this process, the fibers need to be separated from the dust.

[0056] S8: Raw material falls into the X / Y axis separator.

[0057] When feeding materials into the product, equal or different quantities of fibers from different locations are simultaneously fed into specific areas of the precast mold. At the same time, a negative pressure suction system under the bottom mold evenly adsorbs the falling fibers onto the top of the bottom mold. During this process, micro-dust separation treatment is required.

[0058] S9: After precise material placement

[0059] After the metering transition storage bin and X / Y axis separator have finished feeding, they are removed: the preset area isolation device / prepared storage bin in the mold is removed at the same time. During this process, micro-dust separation treatment is required.

[0060] S10: Mold closing and compaction

[0061] After the pre-set area isolation device / prepared storage bin in the mold is removed, the fibers in the mold are pressurized to the required special shape to reach the preset elastic recovery capacity position. The pre-compression ratio is 20% to 85% under natural conditions. During this process, micro-dust separation treatment is required.

[0062] S11: Place in the drying oven

[0063] After pre-compression, the product to be shaped is sent into the shaping heating box and heated to the required process temperature (20-120°C higher than the melting point of the low melting point component of the composite fiber). The temperature is kept constant for a period of time (3-15 minutes). After the process requirements are met, the finished product is removed from the heating box.

[0064] S12: Precise Heat Distribution

[0065] Precise positioning and uniform input of heating medium: The input of heating medium is equipped with a dedicated precise positioning and conveying device, which can make full use of thermal energy and reduce kinetic energy by about 85%; thanks to the precise positioning and conveying device of heating medium, the thermal energy consumption of heating medium can be reduced by about 80%.

[0066] S13: Remove from oven after setting.

[0067] Exit the oven while maintaining the pressure of the mold cover; this will improve the efficiency of the work process.

[0068] S14: After shaping, the finished product should be fully cooled.

[0069] When the shaped fiber elastic memory product cools to room temperature.

[0070] S15 mold release

[0071] After the finished product has cooled to room temperature: remove the cover mold.

[0072] S16 frame mold detachment

[0073] Remove the cover mold from the finished product, and then remove the frame mold.

[0074] S17 finished products are separated

[0075] When the finished product is transferred to the part where it separates from the bottom mold, it is transferred by conveyor belt to the outer coating production line to complete the final product.

[0076] The key to this invention lies in the fact that the homogeneous fiber irregular elastic memory material enters the next process cycle of the product to be manufactured. With the above-described implementation scheme, a more balanced resistance to deformation in the X / Z axis direction, stronger resistance to mechanical damage, and a wider temperature range under working conditions can be obtained. Due to the hydrophilic / hydrophobic and water-treated selected fibers, a brand-new homogeneous fiber irregular elastic material with a wider range of applications has broad market prospects.

[0077] Although the present invention has been described in detail above with general descriptions and specific embodiments, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of the present invention fall within the scope of protection claimed by the present invention.

Claims

1. A method for manufacturing a homogeneous fiber-shaped elastic memory material, characterized in that, The method includes the following steps: (1) Raw material preparation: Select different fiber raw materials according to the application of the finished product, and perform hydrophilic / hydrophobic treatment according to the application of the elastic memory material. (2) Raw material mixing / treatment: The fiber raw materials are fully mixed by mechanical airflow, and micro dust separation is carried out at the same time; (3) Fiber web preparation / splitting treatment, or fiber sliver preparation / length treatment; (4) Reset the bottom mold; (5) Frame mold reset; (6) Reset the X / Y axis separator; (7) Metering transition storage bin: The fiber web or fiber strip entering the precision metering device is accurately transported by airflow to the combined pre-storage bins in different positions according to the required amount of the special shape part, and micro dust separation treatment is carried out at the same time. (8) Raw materials fall into the X / Y axis separator: When feeding the product, the same or different amounts of fibers from different locations are simultaneously fed into a specific area in the prefabricated model. At the same time, a negative pressure suction system under the bottom mold evenly adsorbs the falling fibers onto the top of the bottom mold and performs micro-dust separation treatment. (9) After precise material feeding, the pre-set area isolation device / prepared storage bin in the mold is removed at the same time, and micro-dust separation treatment is carried out simultaneously; (10) Press the fibers in the mold into the required special shape to reach the preset elastic recovery position, and at the same time perform micro-dust separation treatment to obtain the product to be shaped; (11) Place the product to be shaped into a heating box and heat it to the required temperature. (12) After the finished product is shaped, it is removed from the oven, cooled completely, the cover mold is removed, the frame mold is removed, the finished product is removed, and the finished product is completed; In step (3), The fiber web preparation / segmentation process includes: by setting / adjusting the width when segmenting the fiber web, different fiber quantities can be conveyed within the same time frame, while simultaneously performing micro-dust separation. The fiber preparation / length processing: By setting and adjusting the difference in operating time under the condition of equal delivery, the purpose of delivering different quantities of fibers can be achieved; The fibers are fed into a precision metering device via a special conveying device, while simultaneously undergoing micro-dust separation. In step (11), the heating medium used in the heating box is uniformly input through precise positioning.

2. The method for manufacturing the homogeneous fiber-shaped elastic memory material according to claim 1, characterized in that, In step (1), the fiber raw materials include, by weight percentage: 15%~50% composite bicomponent fiber, 0%~85% high modulus fiber, and 0%~85% ultra-high modulus inorganic fiber.

3. The method for manufacturing the homogeneous fiber-shaped elastic memory material according to claim 1, characterized in that, In step (10), the pre-compression ratio is 20%~85% under natural conditions.

4. The method for manufacturing the homogeneous fiber-shaped elastic memory material according to claim 1, characterized in that, In step (11), the process requires a temperature 20°C to 120°C higher than the melting point of the low-melting-point component of the composite fiber, and a process time of 3 to 15 minutes.

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