Carbon fiber down quilt and preparation method thereof

Abstract

The present invention relates to a carbon fiber down quilt and a preparation method thereof. The carbon fiber down quilt comprises a surface layer, a back layer, and a down layer. An elastic gauze is embedded in the down layer. The down-like filling material above the down layer is extruded and hot-melted to connect the second yarn of the surface layer, and the down-like filling material below the down layer is extruded and hot-melted to connect the second yarn of the back layer. The preparation method of the carbon fiber down quilt comprises the following steps: step 1, making a first yarn and a second yarn; step 2, making a surface layer and a back layer; step 3, quilting and sewing the four edges of the surface layer, the elastic gauze, and the back layer; step 4, filling the down material; step 5, hot-melting by suction, completing the hot-melting connection of the down-like filling material to the second yarn on the surface layer; step 6, hot-melting by suction, completing the hot-melting connection of the down-like filling material to the second yarn on the back layer; step 7, closing the filling port. The carbon fiber down quilt of the present invention has strong antistatic ability and is not easy to run down.

Description

Technical Field

[0001] The invention relates to the technical field of bedding products, in particular to a down quilt. Background Art

[0002] Most of the existing down quilts have two problems: static electricity and down escaping. Summary of the invention

[0003] The object of the present invention is to provide a carbon fiber duvet to solve the above technical problems.

[0004] The present invention also aims to provide a method for preparing a carbon fiber duvet, so as to prepare the carbon fiber duvet.

[0005] The technical problem solved by the present invention can be achieved by adopting the following technical solutions:

[0006] A carbon fiber down quilt comprises a surface layer located at the top, a back layer located at the bottom, and a down layer filled between the surface layer and the back layer, wherein the surface layer and the back layer are both woven from a first yarn and a second yarn, wherein the first yarn is a yarn spun from cotton fiber and carbon fiber, and the second yarn is a yarn spun from carbon fiber and low-melting-point fiber;

[0007] The down layer is formed by uniformly mixing down and down-like filling materials, the thickness of the down layer in a fluffy state is 20-50 mm, and the mass percentage of the down-like filling materials is not less than 20%;

[0008] A layer of elastic gauze is also buried in the middle of the down layer, and the elastic gauze is an elastic gauze with mesh holes made of polyester fiber;

[0009] When the down layer is in a fluffy state, a down-like filling material with a thickness of 2 to 5 mm above the down layer is squeezed on the surface layer and then hot-melt-connected to the second yarn on the surface layer, and a down-like filling material with a thickness of 1 to 3 mm below the down layer is squeezed on the back layer and then hot-melt-connected to the second yarn on the back layer.

[0010] Preferably, the second yarn is woven into adjacently arranged grids on the surface layer and the back layer to form a grid array, and the grid array on the surface layer and the grid array on the back layer are vertically opposite.

[0011] Preferably, the second yarn has a different color than the first yarn.

[0012] Preferably, the down-like filling is hot-melt connected to the second yarn on the surface layer in a manner that a 5-10 mm hot-melt connection point is formed at an interval of 10 cm to 30 cm, and the down-like filling is hot-melt connected to the second yarn on the back layer in a manner that a 3-8 mm hot-melt connection point is formed at an interval of 15 cm to 30 cm.

[0013] A method for preparing a carbon fiber duvet comprises the following steps:

[0014] Step 1, preparing a first yarn and a second yarn, wherein the first yarn is a yarn spun from cotton fiber and carbon fiber, and the second yarn is a yarn spun from carbon fiber and low-melting-point fiber;

[0015] Step 2, making a surface layer and a back layer, wherein the surface layer and the back layer are both woven from the first yarn and the second yarn;

[0016] Step 3: Sew the four edges of the surface layer, elastic mesh, and back layer together, leaving a filling opening on the foot side;

[0017] Step 4, filling the space between the surface layer and the back layer with down material through a filling port, wherein the down material is formed by a uniform mixture of down and down-like fillers;

[0018] Step 5: Use a vacuum device to suck air from the surface layer, control the vacuum pressure of the vacuum device, and then control the depth of the down-like filling material and the surface layer;

[0019] Then, infrared laser heating is used to form a hot melting point, completing the hot melting connection of the down-like filling to the second yarn on the surface layer;

[0020] Step 6: Use a vacuum device to suck air from the back layer, control the vacuum pressure of the vacuum device, and then control the fitting depth between the down-like filling material and the back layer;

[0021] Then, infrared laser heating is used to form a hot melting point, completing the hot melting connection of the down-like filling to the second yarn on the backing layer;

[0022] Step 7: Close the filling port to obtain a carbon fiber down quilt.

[0023] Preferably, the preparation method of the first yarn is: using cotton fiber as the core yarn and carbon fiber as the decorative yarn, feeding the core yarn and the decorative yarn into an air variable device, the feeding roller speed of the decorative yarn is greater than the feeding roller speed of the core yarn, and the overfeed ratio is 2-3 times, the core yarn and the decorative yarn are interwoven and entangled together in the air variable device to form the first yarn.

[0024] Carbon fibers are added to the surface layer and the back layer of the present invention, and since the carbon fibers have excellent antistatic function, the static electricity condition of the duvet is improved.

[0025] Carbon fibers are added to the surface layer and the back layer of the present invention. The carbon fibers can absorb human body heat and then generate heat for warmth circulation, thereby improving the thermal insulation performance of the duvet.

[0026] Carbon fibers are added to the surface layer and the back layer of the present invention. Since the carbon fibers have good thermal conductivity, the hot-melt connection strength between the low-melting-point fibers and the down-like filling material can be ensured.

[0027] The down layer of the present invention is additionally provided with an elastic yarn net made of polyester fiber. The polyester fiber is not only elastic and firm, but also has a natural affinity with similar down fillings, allowing the use of thinner polyester fiber lines and having a sufficiently long service life.

[0028] The present invention adopts the method of air suction hot melting to connect the down-like filling material to the surface layer and the back layer. Compared with the existing quilting and sewing (needing stitches) and hot pressing (needing to remove the down at the pressing point) methods, the process is simpler, the production efficiency is higher, and there are no seamless joints, which is not easy for down to escape.

[0029] The present invention mixes down with quasi-down filling material in the down, and connects the surface layer and the back layer with the quasi-down filling material. The quasi-down filling material plays a dual role of support and connection, and can effectively improve the unevenness of the product surface.

[0030] The present invention limits the position of the second yarn on the surface layer and the back layer to form a grid array, so that during hot melting, the down-like filling regularly connects the surface layer and the back layer to finally form a square grid, thereby effectively limiting the position of the down.

[0031] The present invention limits the colors of the first yarn and the second yarn. When the colors of the two yarns are different, not only can patterns be formed on the surface layer and the back layer, but also the manufacturer can visually see the layout of the grid structure formed after the down-like filling is hot-melt connected to the surface layer and the back layer.

[0032] The grid arrays on the surface layer and the back layer of the present invention face each other vertically, thereby increasing the number of down-like fillers connecting the surface layer at the top and the back layer at the bottom, thereby increasing the connection strength of various parts of the duvet.

[0033] The present invention limits the thickness of the down layer and the hot-melt thickness, which not only ensures general warmth and elegance, but also enables a single layer of elastic gauze to be well fixed through the adhesion of the down and down-like fillings, which is an optimized parameter to ensure the coexistence of firmness and the above advantages.

[0034] The present invention defines a method for preparing the first yarn. The first yarn prepared by the method for preparing the first yarn of the present invention has good tensile and ductile properties, thereby making the prepared fabric more supple. At the same time, a porous structure is formed on the first yarn, which is conducive to absorbing dust, moisture and sound. DETAILED DESCRIPTION

[0035] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further described below.

[0036] The carbon fiber down quilt comprises a surface layer located at the upper part, a back layer located at the lower part, a down layer filled between the surface layer and the back layer, and an elastic yarn net buried in the down layer.

[0037] About the surface layer and back layer

[0038] The surface layer and the back layer are both woven from a first yarn and a second yarn, wherein the first yarn is a yarn spun from cotton fiber and carbon fiber, and the second yarn is a yarn spun from carbon fiber and low-melting-point fiber.

[0039] Yes, the second yarn is woven into adjacently arranged grids on the surface layer and the back layer to form a grid array, and the grid array on the surface layer and the grid array on the back layer are directly opposite to each other. Thereby, the number of down-like fillings connected to the surface layer at the top and the back layer at the bottom is increased, thereby increasing the connection strength of each part of the duvet. Yes, the color of the second yarn is different from the color of the first yarn. On the one hand, the aesthetics of the surface layer and the back layer can be improved, and on the other hand, the connection position of the down-like filling can be determined according to the color of the second yarn.

[0040] About down layer and elastic mesh

[0041] The down layer is filled with down and down-like fillings mixed evenly, and the thickness of the down layer in a fluffy state is 20~50mm. This thickness not only ensures general warmth and elegance, but also a single layer of elastic gauze can be well fixed through the adhesion of down and down-like fillings, which is an optimized parameter to ensure firmness and the coexistence of the above advantages. The mass percentage of down-like fillings is not less than 20%. To ensure the connection strength. An elastic gauze is also buried in the middle of the down layer. Because the elastic gauze is used, the unevenness of the down layer is prevented from being caused by the use from the inside, while ensuring the softness of the down layer during use and ensuring the comfort during use. Preferably, the elastic gauze is an elastic gauze with mesh made of polyester fiber. Polyester fiber is not only elastic and firm, but also has a natural affinity with down-like fillings, allowing the use of thinner polyester fiber lines, and the service life is also long enough.

[0042] When the down layer is in a fluffy state, the down-like filling material with a thickness of 2 to 5 mm above the down layer is pressed against the surface layer and then hot-melted to connect with the second yarn on the surface layer, and the down-like filling material with a thickness of 1 to 3 mm below the down layer is pressed against the back layer and then hot-melted to connect with the second yarn on the back layer. A piece of down-like filling material may be connected to the surface layer only at the top, may be connected to the back layer only at the bottom, or may be connected to the surface layer at the top and the back layer at the bottom.

[0043] A method for preparing a carbon fiber duvet comprises the following steps:

[0044] Step 1, making a first yarn and a second yarn, wherein the first yarn is a yarn spun from cotton fiber and carbon fiber, and the second yarn is a yarn spun from carbon fiber and low-melting-point fiber. Preferably, the preparation method of the first yarn is: using cotton fiber as the core yarn and carbon fiber as the decorative yarn, feeding the core yarn and the decorative yarn into an air-changing device, the feeding roller speed of the decorative yarn is greater than the feeding roller speed of the core yarn, and the overfeed ratio is 2-3 times, and the core yarn and the decorative yarn are interwoven and entangled in the air-changing device to form the first yarn. Thereby, the first yarn has good tensile and ductile properties, thereby making the prepared fabric more supple. At the same time, a porous structure is formed on the first yarn, which is conducive to absorbing dust, moisture and sound. In the second yarn, the mass percentage of low-melting-point fiber is not less than 60%. Carbon fiber can improve the antibacterial, antistatic and thermal conductivity properties of the first yarn.

[0045] Step 2: Making a surface layer and a back layer, wherein the surface layer and the back layer are woven from the first yarn and the second yarn. Preferably, after weaving, the second yarn is woven into adjacently arranged grids on the surface layer and the back layer to form a grid array. The colors of the first yarn and the second yarn are preferably different, so that the grid array is visible to the naked eye.

[0046] Step 3, quilt and sew the four edges of the surface layer, elastic gauze, and back layer, leaving a filling opening on the foot side of the quilt. Preferably, after suturing, the grid array on the surface layer and the grid array on the back layer are directly opposite each other. The grid array can guide the direction of the infrared laser on the surface layer. Thus, the hot melt connection points can be traced. In addition, the grid array can guide the direction of the infrared laser on the back layer, so that the hot melt connection points on the back layer can be more directly opposite the hot melt connection points on the surface layer, thereby increasing the number of down-like fillings connected to the surface layer at the top and the back layer at the bottom, thereby increasing the connection strength of each part of the duvet.

[0047] Step 4: Fill the space between the surface layer and the back layer with down material through the filling port. The down material is formed by uniformly mixing down and down-like filler. The mass percentage of the down-like filler is not less than 20%. The down-like filler is preferably the down-like filler described in the patent technology with application number CN2022115153358 and patent name "A Down-like Filler and Its Production Line".

[0048] Step 5, use an exhaust device to suck air from the surface layer, control the exhaust pressure of the exhaust device, and then control the depth of the down-like filling material and the surface layer; then use infrared laser heating to form a hot melting point, and complete the hot melting connection of the down-like filling material to the second yarn on the surface layer. Preferably, the down layer is in a fluffy state, and the thickness of the down-like filling material above the down layer is 2~5mm, and the second yarn on the edge of the grid above is hot-melted after extrusion. This thickness not only ensures the firmness of the hot melt, but also ensures that the deformation is small enough, and retains sufficient aesthetics and warmth retention. This is an optimized parameter to ensure that the firmness and the above advantages coexist. The way of hot-melting the second yarn on the surface layer of the down-like filling material is to form a 5~10mm hot-melt connection point at an interval of 10cm~30cm. This length and interval ensure that the firmness of the hot melt, and the deformation is small enough, and retains sufficient aesthetics and warmth retention. This is an optimized parameter to ensure that the firmness and the above advantages coexist.

[0049] Step 6, use an exhaust device to inhale the back layer, control the exhaust pressure of the exhaust device, and then control the depth of the down-like filling material and the back layer; then use infrared laser heating to form a hot melting point, and complete the hot melting connection of the down-like filling material to the second yarn on the back layer. Preferably, the down layer is in a fluffy state, and the down-like filling material below the down layer is 1~3mm thick, and the second yarn on the edge of the mesh above is hot-melted after extrusion. The back layer adopts a shallower hot-melt structure, which is convenient for close-fitting use, and has better adhesion to the body when used close to the body, and is more comfortable, smoother and warmer. This is an optimized parameter to ensure the coexistence of firmness and the above advantages. The way in which the down-like filling material is hot-melted to the second yarn on the back layer is: a 3~8mm hot-melt connection point is formed at an interval of 15cm~30cm. The back layer adopts a sparser hot-melt structure, which is convenient for close-fitting use, and has better adhesion to the body when used close to the body, and is more comfortable, smoother and warmer. This is an optimized parameter to ensure the coexistence of firmness and the above advantages.

[0050] Step 7, closing the filling port to obtain a carbon fiber duvet. The present invention heats first and then seals, which can effectively remove or replenish the air between the surface layer and the back layer, and avoid expansion and deformation of the down layer during the heating and adsorption process.

[0051] Note: The air suction hot melting in the present invention is hot melting while suctioning. That is, by using the air suction equipment to suction the surface layer, at the same time, by infrared laser heating to form a hot melting point on the surface layer, the top part of the down-like filling is hot-melted to the surface layer. By using the air suction equipment to suction the back layer, at the same time, by infrared laser heating to form a hot melting point on the back layer, the bottom part of the down-like filling is hot-melted to the back layer.

[0052] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A carbon fiber down quilt, comprising a surface layer located at the top, a back layer located at the bottom, and a down layer filled between the surface layer and the back layer, characterized in that: The surface layer and the back layer are both woven from a first yarn and a second yarn, wherein the first yarn is a yarn spun from cotton fiber and carbon fiber, and the second yarn is a yarn spun from carbon fiber and low-melting-point fiber; The down layer is formed by uniformly mixing down and down-like filling materials, the thickness of the down layer in a fluffy state is 20-50 mm, and the mass percentage of the down-like filling materials is not less than 20%; A layer of elastic gauze is also buried in the middle of the down layer, and the elastic gauze is an elastic gauze with mesh holes made of polyester fiber; When the down layer is in a fluffy state, a down-like filling material with a thickness of 2 to 5 mm above the down layer is squeezed on the surface layer and then hot-melt-connected to the second yarn on the surface layer, and a down-like filling material with a thickness of 1 to 3 mm below the down layer is squeezed on the back layer and then hot-melt-connected to the second yarn on the back layer.

2. The carbon fiber duvet according to claim 1, characterized in that: The second yarns are woven into adjacently arranged grids on the surface layer and the back layer to form a grid array, and the grid array on the surface layer and the grid array on the back layer are vertically opposite to each other.

3. The carbon fiber duvet according to claim 1, characterized in that: The second yarn has a color different from the first yarn.

4. The carbon fiber duvet according to claim 1, characterized in that: The down-like filling is hot-melt-connected to the second yarn on the surface layer in such a manner that a 5-10 mm hot-melt connection point is formed at intervals of 10 cm to 30 cm; the down-like filling is hot-melt-connected to the second yarn on the back layer in such a manner that a 3-8 mm hot-melt connection point is formed at intervals of 15 cm to 30 cm.

5. The method for preparing the carbon fiber duvet according to any one of claims 1 to 4, characterized in that: The steps include: Step 1, preparing a first yarn and a second yarn, wherein the first yarn is a yarn spun from cotton fiber and carbon fiber, and the second yarn is a yarn spun from carbon fiber and low-melting-point fiber; Step 2, making a surface layer and a back layer, wherein the surface layer and the back layer are both woven from the first yarn and the second yarn; Step 3: Sew the four edges of the surface layer, elastic mesh, and back layer together, leaving a filling opening on the foot side; Step 4, filling the space between the surface layer and the back layer with down material through a filling port, wherein the down material is formed by a uniform mixture of down and down-like fillers; Step 5: Use a vacuum device to suck air from the surface layer, control the vacuum pressure of the vacuum device, and then control the depth of the down-like filling material and the surface layer; Then, infrared laser heating is used to form a hot melting point, completing the hot melting connection of the down-like filling to the second yarn on the surface layer; Step 6: Use a vacuum device to suck air from the back layer, control the vacuum pressure of the vacuum device, and then control the fitting depth between the down-like filling material and the back layer; Then, infrared laser heating is used to form a hot melting point, completing the hot melting connection of the down-like filling to the second yarn on the backing layer; Step 7: Close the filling port to obtain a carbon fiber down quilt.

6. The method for preparing a carbon fiber duvet according to claim 5, characterized in that: The preparation method of the first yarn is: using cotton fiber as the core yarn and carbon fiber as the decorative yarn, feeding the core yarn and the decorative yarn into an air-changing device, the feeding roller speed of the decorative yarn is greater than the feeding roller speed of the core yarn, and the overfeed ratio is 2-3 times, the core yarn and the decorative yarn are interwoven and entangled together in the air-changing device to form the first yarn.