Felt artware green body with core material and preparation method of felt artware green body

Abstract

The invention belongs to the technical field of handicraft processing, and particularly relates to a felt handicraft green body with a core material and a preparation method thereof.The felt handicraft green body with the core material comprises a main body, the main body is provided with the core material, and a coating layer is arranged on the outer side of the core material; the coating layer comprises a densified fibrofelt, and the densified fibrofelt is formed by heating first fibers with a first melting point and second fibers with a second melting point higher than the first melting point under the condition of being supported by the core material. The first fiber and the second fiber with different melting points are adopted to generate the three-dimensional flexible artware green body, the densified fibrofelt is used as a material of the artware green body, and the core material is added into the densified fibrofelt, so that the densified fibrofelt can be kept in a relatively determined shape, and the whole green body is simple to manufacture, low in cost and good in shaping property.

Description

Technical Field

[0001] The invention belongs to the technical field of handicraft processing, and in particular relates to a felt handicraft blank with a core material and a processing method thereof which is simple and fast to produce, has various shapes, rich colors and soft touch. Background Art

[0002] Handicraft ornaments are popular commodities in the market for collection, appreciation, gifting, playing and display. They are mainly made of single metal, alloy metal, plastic material, wood material, etc. In order to reduce production cost and product weight, hollow bodies have appeared in the market.

[0003] In the hollow handicraft blank and preparation method thereof 2023112431407 previously submitted by the applicant, the applicant proposed a flexible fiber handicraft blank with a special shape to replace the handicraft blank made of metal, plastic material, wood material, etc. in the prior art. Summary of the invention

[0004] The purpose of the present application is to provide a fiber handicraft blank with fillers, so that the blank has a plush feel and a relatively definite shape, and the blank is used to further process handicrafts.

[0005] The purpose of the present invention is to address the above-mentioned technical problems and to propose a felt handicraft blank with a core material, which includes a main body, wherein the main body has a core material and a coating layer is provided on the outside of the core material; the coating layer includes a densified fiber felt, and the densified fiber felt is formed by heat treatment of first fibers having a first melting point and second fibers having a second melting point higher than the first melting point under the condition of core material support.

[0006] Compared with the prior art, the present invention uses fiber material as the material of the main body of the handicraft, adopts the first fiber and the second fiber with different melting points to generate a densified fiber felt, and forms a three-dimensional shape under the support of the core. The densified fiber felt on the surface of the blank has rebound flexibility, is simple to manufacture, low cost, and has good shaping properties.

[0007] Preferably, the first fiber is of a sheath-core structure; the second fiber is a natural fiber, which is bast fiber, cotton, cellulose, wool, silk, linen or any combination thereof.

[0008] Preferably, the first fibers and the second fibers are laid in a random direction to form a fiber mesh or are oriented in a predetermined direction to form a fiber mesh, and after the fiber mesh is coated on the outside of the core material, it is heated by a mold to form a densified fiber felt.

[0009] Preferably, the second fibers are colored short fibers, the second fibers are mixed with the first fibers to form a fiber mesh, and the mixed fibers form a natural, multi-layered mixed color pattern on the surface of the fiber mesh, which is then heated by a mold to form a densified fiber felt.

[0010] The present invention also provides a method for manufacturing a felt handicraft blank with a core material, which is specifically:

[0011] S1) mixing and paving first fibers with a first melting point and second fibers with a second melting point higher than the first melting point to form a fiber web;

[0012] S2) wrapping the fiber mesh obtained above on the outside of the core material and placing it into a mold, so that the fiber mesh is shaped according to the shape of the mold body;

[0013] S3) heating the mold to the first melting point temperature of the first fiber, so that the first fiber and the second fiber are thermally bonded; cooling the mold until the first fiber is re-solidified, and the fiber mesh is processed into a densified fiber felt, and the densified fiber felt is shaped by the shape of the mold cavity.

[0014] The present invention also provides another method for manufacturing a felt handicraft blank with a core material, which is specifically:

[0015] S1) mixing and paving first fibers with a first melting point and second fibers with a second melting point higher than the first melting point to form a first fiber mesh and a second fiber mesh;

[0016] S2) wrapping the first fiber mesh obtained in step S1) on the first surface area outside the core material and placing it in a first heating process, heating it to the first melting point temperature of the first fiber, so that the first fiber and the second fiber are thermally bonded; then cooling until the first fiber is re-solidified, the first fiber mesh is processed into a densified fiber mat, and the first fiber mesh is shaped in the first surface area according to the shape of the core material body, so as to obtain an intermediate product;

[0017] S3) applying the second fiber mesh obtained in step S1) to the outside of the intermediate product, completely covering the core material corresponding to the second surface area on the outside of the core material, and then placing it in a second heating process, heating it to the first melting point temperature of the first fiber, and thermally bonding the first fiber and the second fiber; then cooling it until the first fiber re-solidifies, and the second fiber mesh is processed into a densified fiber felt, so that the second fiber mesh is shaped in the second surface area according to the shape of the core material; and obtaining a felt handicraft blank with a core material.

[0018] Preferably, in step S1), the first fiber is a low-melting-point sheath-core fiber, the second fiber is a colored staple fiber, the first fiber and the second fiber are uniformly mixed and combed into a fiber mesh with cross-mixed and interconnected fibers, wherein the weight content of the first fiber is not less than 15% and not more than 90%.

[0019] Preferably, in step S1), a fluffy fiber web comprising first fibers and second fibers is formed, the fluffy fiber web is reinforced to obtain a reinforced fiber web, and the reinforced fiber web is provided as the first fiber web and / or the second fiber web to step S2).

[0020] Preferably, in step S1), a fluffy fiber mesh and a reinforced fiber mesh comprising first fibers and second fibers are formed, and the fluffy fiber mesh and the reinforced fiber mesh are stacked and provided to step S2) as the first fiber mesh and / or the second fiber mesh, and the reinforced fiber mesh is close to the core material.

[0021] Preferably, in step S2), the first fiber mesh is coated on the first surface area outside the core material and at least partially extends to cover the second surface area, and in step S3), the second fiber mesh at least partially overlaps with the first fiber mesh in the second surface area.

[0022] Beneficial effects:

[0023] In the present invention, the first fiber and the second fiber with different melting points are used to generate a three-dimensional flexible handicraft blank, and the densified fiber felt is used as the material of the handicraft blank, and a core material is added therein, so that the densified fiber felt can be kept in a relatively fixed shape. The whole blank is not only simple to manufacture, low in cost, and good in shaping, but also when the second fiber is a colored short fiber, the handicraft blank is rich in color and has an excellent feel. The problem of the traditional fiber handicraft production process being too time-consuming, requiring a huge amount of manual labor, having a single product shape, a monotonous color, and a stiff feel is solved. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 Schematic diagram of fiber arrangement in the fiber mesh of the present invention;

[0025] Figure 2 The present invention is a process for manufacturing a felt handicraft blank with a core material. Figure 1 ;

[0026] Figure 3 The present invention is a process for manufacturing a felt handicraft blank with a core material. Figure 2 ;

[0027] Figure 4 The present invention is a process for manufacturing a felt handicraft blank with a core material. Figure 2 Exploded image;

[0028] Figure 5 yes Figure 3 A cross-sectional view of the core material covering the first fiber mesh;

[0029] Figure 6 yes Figure 5 A schematic diagram of an intermediate product formed by heating and shaping the core material and the coated first fiber mesh;

[0030] Figure 7 The present invention is a process for manufacturing a felt handicraft blank with a core material. Figure 3 ;

[0031] Figure 8 The present invention is a process for manufacturing a felt handicraft blank with a core material. Figure 4 .

[0032] The symbols in the figure are:

[0033] 10. A first elastic mold body, 11. A first elastic covering body, 12. A first rigid mold body, 20. A second elastic mold body, 21. A second elastic covering body, 22. A second rigid mold body, 30. A first fiber mesh, 31. A protrusion, 32. A gap, 33. A reinforced fiber mesh, 34. A fluffy fiber mesh, 35. A second fiber mesh, 40. A core material, 41. A first surface area, 42. A second surface area. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of the present application to clearly describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments in the present application belong to the scope of protection of this application.

[0035] In the description of the present application, it should be noted that the terms used herein are only for describing specific implementations and are not intended to limit the exemplary implementations according to the present application.

[0036] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a fiber" includes aspects having two or more such fibers unless the context clearly dictates otherwise.

[0037] As used herein, the term "comprising" may include aspects of "consisting of" and "consisting essentially of. The term "comprising" may also mean "including but not limited to."

[0038] As used herein, the term "fiber" includes fibers of extreme or indeterminate length (i.e., filaments) and fibers of short length (i.e., staple fibers). It is further understood that the fibers described herein can be interpreted as comprising materials from original or recycled sources or a combination of the two. In certain aspects of the invention, the fiber comprises recycled material, wherein the recycled material includes, but is not limited to, materials or combinations thereof after consumption or industrial processes. Still in other aspects, the fiber used in the present invention comprises virgin material.

[0039] The following are specific implementation means of the present invention.

[0040] Fiber processing stage

[0041] In the fiber processing stage, this specific embodiment partially involves the web-forming process of short fibers. The fiber processing stage can be specifically summarized as: fiber preparation → fiber combing → web-forming fiber web → fiber web reinforcement (forming). After the fiber processing stage, the mold thermoforming stage is entered.

[0042] 1. Fiber Preparation

[0043] In the present invention, a fiber combination raw material including at least a first fiber and a second fiber is used. The fiber preparation stage is a process for preparing the fibers before forming a web, and is an important step in forming a web.

[0044] The main tasks of fiber preparation are:

[0045] 1) Determine the amount of raw materials to be used according to product design requirements.

[0046] 2) The fiber raw materials of various components are loosened through mixing and opening processes to separate the clumps of fibers into bundles or single fibers to achieve uniform mixing and opening requirements.

[0047] 3) Apply oil to synthetic fibers to prevent static electricity from being generated during processing.

[0048] 4) Make a uniform fiber layer and supply it to the carding machine.

[0049] Therefore, the general process flow of mixing is: grabbing cotton → feeding cotton (weighing) → mixing cotton → loosening → feeding cotton → combing.

[0050] Typical equipment for opening and mixing include plucking machines, weighing machines, cotton blending curtain openers, multi-bin mixers, and automatic blenders. After the fiber preparation stage, the first fiber and the second fiber are mixed in a predetermined ratio and supplied to the subsequent carding machine for web processing.

[0051] 2. Fiber combing

[0052] The loosened mixed first fiber and second fiber (in block / bundle form) are combed into a thin fiber web composed of single fibers for laying into a web or directly consolidating the web or air-forming the web. The main tasks of combing are: to thoroughly comb the mixed fiber raw materials into a single fiber state; to further evenly mix the first fiber and the second fiber in the raw material; to further remove impurities in the raw material; and to make the fibers parallel and straight.

[0053] The general process of carding is: fiber feeding → pre-carding → carding → web forming (single-layer or double-layer fiber web). The carding machine is mainly composed of feeding mechanism, pre-carding mechanism, carding mechanism, messing device, web forming mechanism, etc. The functions of each mechanism are as follows:

[0054] ① Feeding mechanism (raw material feeding): feed the fiber raw materials regularly, quantitatively and evenly in the form of cotton rolls or mat cotton.

[0055] ② Pre-combing mechanism: pre-combing the fed fibers.

[0056] ③ Combing mechanism: Each working roller combs the fibers carefully.

[0057] ④ Chaos device: Make some fibers randomly arranged, increase the disorder of fiber arrangement, and reduce the longitudinal and transverse performance differences of the fiber web. Fiber carding is an important step in dry web forming. The thin web output from the carding machine directly affects the uniformity and structure of the fiber web.

[0058] 3. Web-forming fiber mesh

[0059] The purpose of the fiber web forming step is to generate a fluffy fiber web. It can be a mechanical web laying, the task is to stack the fiber web output by the carding machine to increase its surface density and thickness, and then stretch it through a random drafting device to increase the disorder of the fiber arrangement. The optional web laying methods can be parallel web laying and cross web laying. The parallel web laying method is to stack the thin webs output by multiple carding machines into a certain thickness and then output them. The uniformity of the fiber web is good, but the thickness and width of the fiber web are limited by the carding equipment. The cross web laying method is to process the thin web output by a carding machine. The thickness and width of the fiber web can be adjusted by adjusting the relevant process parameters of the web laying equipment, but the uniformity of the fiber web is not as good as the parallel web laying method, and the thinner the fiber web, the worse the uniformity.

[0060] The web-forming fiber sheet can also be air-laid, that is, the fiber is fed into a high-speed rotating cylinder or licker-in roller, further combed into a single fiber state, and then under the combined action of the centrifugal force of the cylinder or licker-in roller and the airflow, the fiber falls off the saw teeth and condenses on the web curtain (or dust cage). The air-laid technology uses airflow to strip the fiber from the carding machine and transport it to the web curtain.

[0061] However, in this specific embodiment, there is no limitation on laying the web, and it is based on the principle of being able to generate a fluffy fiber web.

[0062] 4. Fiber mesh reinforcement

[0063] The purpose of the fiber mesh reinforcement step is to improve the overall strength of the fiber mesh. According to experiments, if only the unreinforced fluffy fiber mesh is directly used for the subsequent mold heat setting process, the resulting felt layer will have low strength and poor resilience. Therefore, it is necessary to improve the strength of the fiber mesh in this step and reinforce the fluffy fiber mesh into a reinforced fiber mesh.

[0064] The reinforcement methods include needle punching and hydroentanglement, both of which are existing technologies.

[0065] The principle of needle reinforcement is to use a needle with a triangular (or other shaped) cross-section and a barbed hook on the edge to repeatedly puncture the fluffy fiber mesh, forming many "pins" composed of fiber bundles and nailing them into the fiber mesh, so that the fiber mesh is compressed and cannot be restored, forming a reinforced fiber mesh with certain strength, density and elasticity.

[0066] Hydroentanglement is also called hydroentanglement, hydraulic jetting, or jet spunlace. It uses high-speed and high-pressure water flow to impact the fluffy fiber mesh, causing the fibers to entangle and embrace each other to achieve the purpose of reinforcing the fiber mesh. During the process of the water needle impacting the fiber mesh, some surface fibers are displaced under the action of water force and are brought from the surface to the bottom of the mesh, causing the fibers to entangle and embrace each other, forming countless mechanical bonds, thereby reinforcing the fiber mesh and finally obtaining a reinforced fiber mesh.

[0067] Die hot forming stage

[0068] In this stage, the reinforced fiber mesh is wrapped with the core material and heated in the mold. The first fiber with a first melting point and the second fiber with a second melting point higher than the first melting point are treated by heat, and a thermal bonding reinforcement effect occurs, and a densified fiber mat is formed. In the thermal bonding reinforcement stage, the first fiber with a low melting point softens, melts, and produces flow properties (thermoplasticity) after being heated, and the intersections of the first fiber and the second fiber are bonded together. After cooling, the molten polymer is solidified, and the fibers are thus bonded together. The thermal bonding process is a process of heating, deformation, melting, flowing, and solidifying into cloth.

[0069] For hot-melt materials, hot-melt materials are thermoplastic polymers with low melting points, such as hot-melt fibers. Commonly used hot-melt fibers include polypropylene (PP), polyethylene (PE), polyvinyl chloride, etc. New hot-melt fibers include composite fibers such as ES, PP / PE, and PP / PET. ES is a two-component composite fiber of polypropylene and high-density polyethylene. The composite structure has two types: "core-wrapped" and "parallel". Generally, the skin of the core-wrapped type is polyethylene with a melting point of 110-130°C. PP / PE is a composite fiber of polypropylene and polyethylene. PP / PET is a composite fiber of polypropylene and polyester. When these fibers are heated, only the low-melting-point component melts and flows, while the high-melting-point component still maintains its original fiber characteristics.

[0070] The heating method can be physical heat conduction or hot air heating, so that the reinforced fiber mesh is melted and formed at the intersections between the fibers to achieve the consolidation of the fiber mesh and produce a thermal bonding reinforcement effect, and then a felt-like handicraft blank with a core material can be obtained. For details, please refer to the following embodiments.

[0071] Embodiment 1:

[0072] In this embodiment, a felt handicraft blank with a core material is provided, which includes a main body, wherein the main body has a core material and a coating layer is provided on the outside of the core material; the coating layer includes a densified fiber felt, and the densified fiber felt is formed by heat treatment of first fibers having a first melting point and second fibers having a second melting point higher than the first melting point.

[0073] Among them, the term "dense" refers to the density of the fiber mesh formed by the mixed laying of the first melting point fibers and the second melting point fibers before heating treatment. The term "dense" in this embodiment is consistent with the general density understanding of felt products by technical personnel in this field.

[0074] The material of the core material can be selected from foam plastics, which is a type of polymer material formed by a large number of gas micropores dispersed in solid plastics. It has the characteristics of light weight, heat insulation, sound absorption, shock absorption, and dielectric properties are better than those of matrix resins, and it has a wide range of uses. Almost all kinds of plastics can be made into foam plastics, and foaming molding has become an important field in plastic processing. Foam plastics can be pre-determined in shape according to the shape of handicrafts, and then used as core material to produce felt handicraft blanks. In addition, the core material in the present embodiment needs to have a certain heat resistance, and can still maintain the shape of the core material when the first fiber shell melts. General foam plastics can have such performance.

[0075] In the present embodiment, since the first fiber and the second fiber with different melting points are used to generate a three-dimensional handicraft blank with a flexible covering layer, the densified fiber felt is used as the surface material of the handicraft blank to give it a plush feel, and the core material is used to determine the shape of the handicraft blank. The production is simple, the cost is low, and the shaping is good, and it is more suitable for displaying and playing with as a handicraft.

[0076] Embodiment 2:

[0077] In addition to the contents of the aforementioned embodiments, this embodiment also includes: the first fiber is a skin-core structure, and the second fiber is a colored short fiber with a soft touch. The first fiber is a skin-core structure, and the core material of the skin-core structure is preferably made of PET (polyethylene terephthalate) and other materials that will not melt due to the heat during heating. The skin part of the skin-core structure preferably uses a material that can melt due to the heat during heating, and polyolefin resins such as polypropylene resin and polyethylene resin are all suitable materials. In particular, the skin part preferably uses a polypropylene resin that has good compatibility with the polypropylene resin as a substrate. Therefore, during the heating process, although the skin part of the skin-core structure of the first fiber will melt at the heating temperature during forming and bond with the second fiber, the core material will not melt and can maintain its original shape, so the occurrence of pothole defects can be prevented. Thereby basically maintaining the shape determined by the inner cavity of the good craft mold.

[0078] As for the fiber of skin-core structure, it is generally difficult to be dyed. The fiber is roughly white or black, and its fiber stiffness is high and not soft enough. Therefore, in order to increase the color richness of the handicraft on the one hand and improve the soft hand feeling experience of the handicraft on the other hand, the second fiber can be selected from colored short fibers with soft touch. By mixing the first fiber and the second fiber, the purpose of forming the expected color effect in the handicraft blank is achieved. Preferably, the second fiber is a natural fiber, which is bast fiber, cotton, cellulose, wool, silk, linen or any combination thereof, which is easy to be dyed and has a different hand feel and touch from the first fiber, i.e., the skin-core fiber.

[0079] Embodiment 3:

[0080] In addition to the contents of the aforementioned embodiments, this embodiment also includes: after the first fibers and the second fibers are laid in a random direction to form a fiber mesh or are oriented in a predetermined direction to form a fiber mesh, they are heated by a mold to form a densified fiber felt.

[0081] This embodiment further emphasizes the fiber web structure of the fiber web. The fiber web structure refers to the arrangement of fibers in the fiber web, which is expressed by the fiber orientation degree (orientation degree). Fibers arranged along the machine output direction are longitudinally arranged, fibers arranged perpendicular to the machine output direction are transversely arranged, and fibers arranged in all directions are randomly arranged. The degree of the number of fibers arranged in a single direction in the fiber web is called the orientation degree, and the uniformity of the number of fibers arranged in all directions of the fiber web is called the disorder degree. Figure 1 Shown is a schematic diagram of fiber arrangement in a fiber mesh.

[0082] The fiber mesh is laid in random directions, and the resulting densified fiber mat has excellent thickness, quality, stability and identity. However, when there is a specific need, the fibers need to be laid in a directional manner, such as when it is necessary to form animal feathers and fur at a specific location on the craft, the fibers are combed and placed in a special and regular manner, and then specific surface features of the craft are formed.

[0083] One feasible fiber mixing method is that the second fiber is mixed with the first fiber to form a fluffy fiber mesh, and the second fiber forms a colored, multi-layered pattern on the surface of the fluffy fiber mesh, which is then reinforced and heated by a mold to form a densified fiber mat. The handicraft blank in this embodiment is particularly suitable for making a blank for handicrafts with animal shapes or fur texture.

[0084] Embodiment 4:

[0085] In this embodiment, a method for manufacturing a felt handicraft blank with a core material is provided, specifically:

[0086] S1) Mixing and paving a first fiber with a first melting point and a second fiber with a second melting point higher than the first melting point to form a fiber mesh; the fiber mesh is a fiber flocculent sheet, and after a subsequent heating operation, the fiber flocculent sheet will shrink to produce a felt-like suede with a lower thickness and a relatively flat surface. Therefore, during the paving process, if necessary, it will be necessary to consider the applicable mold or the final three-dimensional configuration of the craft to appropriately increase or decrease the thickness of the fiber flocculent sheet.

[0087] S2) Wrapping the fiber mesh obtained above on the outside of the core material and placing it into a mold, so that the fiber mesh is shaped according to the shape of the mold body; the shape of the mold body can be selected and designed according to actual needs, but the best is a three-dimensional configuration, and the handicraft blank corresponding to the three-dimensional configuration mold body is also a three-dimensional configuration.

[0088] S3) The mold is heated to the first melting point temperature of the first fiber, and the first fiber and the second fiber are thermally bonded; the mold is cooled until the first fiber is re-solidified, and the fiber mesh is processed into a densified fiber felt, and the densified fiber felt is shaped by the shape of the mold cavity and the core material is wrapped therein.

[0089] It needs to be explained and emphasized that, in the present embodiment, the fiber mesh is heated and shaped under the condition of being coated on the outside of the core material. The densified fiber felt in the handicraft blank produced in this way has good fit with the outer surface of the core material, which is completely different from the handicraft blank formed by processing the cloth-like densified fiber felt and then coating the outside of the core material.

[0090] Embodiment 5:

[0091] In conjunction with the instruction manual Figure 2-8 To explain in detail the method of manufacturing a felt handicraft blank with a core material, Figure 4 It can be seen that the core material 40 includes a first surface area 41 and a second surface area 42. In the mechanized assembly line production process of felt handicraft blanks, it is difficult to cover the entire outer surface of the core material 40 with a fiber mesh at one time for subsequent heat setting operations. Therefore, the applicant proposes a feasible segmented covering and heating method in this embodiment:

[0092] S1) mixing and paving first fibers with a first melting point and second fibers with a second melting point higher than the first melting point to form a first fiber mesh and a second fiber mesh;

[0093] S2) wrapping the first fiber mesh obtained in step S1) on the first surface area 41 outside the core material and placing it in a first heating process, heating it to the first melting point temperature of the first fiber, so that the first fiber and the second fiber are thermally bonded; then cooling until the first fiber is re-solidified, the first fiber mesh is processed into a densified fiber mat, and the first fiber mesh is shaped in the first surface area 41 according to the shape of the core material body, so as to obtain an intermediate product;

[0094] For step S2), see Figure 2 First, the first fiber mesh is coated on the first surface area 41 outside the core material. Figure 5 The first fiber mesh is coated on the first surface area 41 outside the core material. Figure 6 The intermediate product is further hot pressed to become an intermediate product. The intermediate product is covered by the first fiber mesh 30 in the first surface area 41 of the core material 40, but there is a gap 32 in the second surface area 42, and the missing fiber mesh needs to be supplemented in the subsequent operation.

[0095] Figure 7In the intermediate product, the fiber mesh is completed on the second surface of the core material 40. S3) The second fiber mesh 35 obtained in step S1) is applied to the outside of the intermediate product, corresponding to the second surface area 42 of the outer side of the core material to completely cover the core material, and then placed in the second heating process, heated to the first melting point temperature of the first fiber, the first fiber and the second fiber are thermally bonded; then cooled until the first fiber is re-solidified, the second fiber mesh 35 is processed into a densified fiber felt, so that the second fiber mesh 35 is fixed in the second surface area 42 according to the shape of the core material body; a felt handicraft blank with a core material is obtained.

[0096] In the craft blank, the densified fiber felt completely wraps the core material therein, and the surface of the densified fiber felt presents a plush texture. The texture of the densified fiber felt is related to the type and fiber mixing ratio of the first fiber and the second fiber. For example, in step S1, the first fiber is a low-melting-point sheath-core fiber, and the second fiber is a colored short fiber. The first fiber and the second fiber are evenly mixed and combed into a fiber mesh with cross-mixed and linked fibers, wherein the weight content of the first fiber is not less than 15% and not more than 90%, which can achieve the purpose of the present invention.

[0097] In step S1, a fluffy fiber mesh including the first fiber and the second fiber is formed, and the fluffy fiber mesh is reinforced to obtain a reinforced fiber mesh, and the reinforced fiber mesh is provided to step S2 as the first fiber mesh and / or the second fiber mesh. The manufacturing process of the reinforced fiber mesh has been described in the previous text and will not be repeated here. In the process of making the felt handicraft blank, the applicant found that if only fluffy fiber mesh is used to make the densified fiber felt, the final felt structure is soft and lacks elasticity, so at least a reinforced fiber mesh should be used to make the fiber mesh.

[0098] In step S1, a fluffy fiber mesh and a reinforced fiber mesh containing the first fiber and the second fiber are formed, and the fluffy fiber mesh and the reinforced fiber mesh are stacked and provided to step S2 as the first fiber mesh and / or the second fiber mesh, and the reinforced fiber mesh is close to the core material. Figure 5 and Figure 6 After the reinforcing fiber mesh 33 and the fluffy fiber mesh 34 are compounded, a first fiber mesh 30 is formed and then applied to the core material 40. Moreover, the reinforcing fiber mesh 33 is close to the core material 40.

[0099] In addition, in step S2), the first fiber mesh is coated on the first surface area 41 outside the core material and at least partially extends to cover the second surface area 42, which is reflected in Figure 6In the figure, the convex edge 31 is bent at the junction of the first surface area 41 and the second surface area 42, and is covered at the second surface area 42. After hot pressing, the convex edge 31 is fitted with the second surface area 42. This processing method can ensure the quality of the first surface area 41 being covered by the first fiber mesh 30 in the first heating process, and all excess materials and errors are accumulated in the form of the convex edge 31 to the second surface area 42, and then the convex edge 31 and the gap 32 are covered together with the second fiber mesh, and then the second heating process is carried out. Therefore, in step S3), the second fiber mesh and the first fiber mesh at least partially overlap in the second surface area 42.

[0100] The first fiber is a low-melting-point core-sheath fiber, and the second fiber is a colored short fiber with a soft touch. The first fiber and the second fiber are evenly mixed and combed with a carding machine into a fiber mesh formed by cross-mixing and interlinking of the fibers. The core-sheath multi-component fiber contains polyester as a core component and polyethylene as a sheath component. For example, the core-sheath multi-component fiber contains polyester with a high melting point as a core component and polyester with a low melting point as a sheath component. Further, in step S1), the second fiber forms a colored, multi-layered pattern on the surface of the fiber mesh. The so-called multi-layered means that the second fiber itself is a colored fiber, which is mixed in multiple layers of the fiber mesh, and after hot pressing, a multi-layered pattern is naturally formed.

[0101] Example 6

[0102] In this embodiment, a feasible mold structure will be described in detail to manufacture a felt handicraft blank with a core material.

[0103] In this embodiment, the core material covered with the fiber mesh is placed in a mold body and the mold is closed, the fiber mesh is positioned into a predetermined shape, and then heated to produce a thermal bonding effect of the fibers, and then cooled, thereby producing a felt handicraft blank with a core material.

[0104] According to Example 5, the entire processing process requires at least a first heating process and a second heating process, so the mold that can be selected can be a set of molds that completes the two-stage heating process in succession; or it can be two sets of molds that complete the first heating process and the second heating process respectively.

[0105] by Figure 2For example, the mold includes a first elastic mold body 10 and a first rigid mold body 12. The first elastic mold body 10 and the first rigid mold body 12 are used together to limit the material to be processed to a predetermined area. The first elastic mold body 10 includes a first elastic coating body 11. When the first elastic mold body 10 and the first rigid mold body 12 are molded together, the first elastic coating body 11 can bias the material to be processed onto the first rigid mold body 12. Since the first elastic coating body 11 is not a traditional rigid mold, after being loaded by the first elastic coating body 11, the fiber mesh located outside the core material can still properly retain the fiber gap inside the fiber layer. Therefore, the texture of the felt structure produced after thermal bonding has a fluffy feel and an excellent hand feel. It can be seen that the first elastic coating body 11 is not a rigid molding mold with a fixed shape in the traditional sense. The final shape of the handicraft blank is related to multiple factors such as the shape of the core material 40, the thickness of the fiber mesh, and the elastic deformation ability of the first elastic coating body 11.

[0106] The use of the first elastic covering body 11 is a very important inventive concept of the present invention. The handicraft blank cannot be processed according to the production process of high-density sheet fiber products such as carpets and felts in other life fields. It needs to meet many requirements such as comfortable softness and elastic feel that users can play with, and the blank is a three-dimensional spatial structure. The hot pressing technology of fiber processing in the prior art mostly adopts roller processing, that is, the loose fiber web is transported between a pair of heated rollers. As the fiber web passes through the rolling point, the fibers are heated and pressed by the rollers, melted, and bonded at the intersections between the fibers. Because roller processing is suitable for continuously produced fiber sheets or strips, it is not suitable for the processing of the handicraft blank of the present invention.

[0107] When the first elastic mold body 10 adopts the first elastic covering body 11, the first elastic covering body 11 is preferably made of mesh cloth material. Since the cloth structure has mesh holes arranged in a matrix (randomly arranged mesh holes can also achieve this effect), when the first elastic covering body 11 is loaded onto the first fiber mesh, the shape of the mesh holes will change. Therefore, the first elastic covering body 11 provides good deformation ability and can better adapt to the shape of the core material 40, so that the first fiber mesh can be fully combined with the outer surface of the first surface area 41 of the core material 40. On the other hand, hot air can be used to heat the first fiber mesh, and the hot air can pass through the mesh holes of the first elastic covering body 11 to directly heat the first fiber mesh 30, thereby improving the heating efficiency.

[0108] Of course, the first elastic covering body 11 may also be made of a rubber-like material and have a closed surface. It is only necessary to provide an elastic loading force to the first elastic covering body 11. If a first elastic covering body 11 with a closed surface is used, the first elastic covering body 11 itself can transfer heat to the first fiber web, that is, the external heating airflow can indirectly heat the first fiber web.

[0109] exist Figure 2 In the process, since the second fiber mesh 35 needs to be added to the intermediate product during the second heating process, the first elastic coating body 11 is located at the lower mold position, and the first fiber mesh 30 is placed above the first elastic mold body 10. The core material 40 is fed downward, and the core material 40 drives the first fiber mesh 30 to fill into the first elastic coating body 11. The first rigid mold body 12 is pressed downward as an upper mold to fix the material to be processed in a predetermined area, and then a hot air flow is supplied to the first fiber mesh 30. The hot air flow can pass through the mesh holes of the first elastic coating body 11 to directly provide heat to the first fiber mesh 30. After a predetermined time, the surface layer of the first fiber is fully melted. At this time, a cold air flow is supplied to the material to be processed for cooling. The material to be processed is processed into an intermediate product, and the first heating process is completed.

[0110] In the second heating process, the mold is opened, the first rigid mold body 12 is lifted up, and then the second fiber mesh 35 is applied to the intermediate product to completely cover the core material 40 with the fiber mesh. The first rigid mold body 12 is lowered again. At this time, at least the first rigid mold body 12 is in a heated state, and the second fiber mesh 35 in the corresponding heating area is processed into a densified fiber felt, so that the second fiber mesh is kept in the shape of the core material in the second surface area; a felt handicraft blank with a core material is obtained.

[0111] Of course, the intermediate product can also be placed in a second set of molds to complete the second heating process. Figure 7 and Figure 8 As shown, the second set of molds includes a second elastic mold body 20 and a second rigid mold body 22. Similar to the structure of the aforementioned first elastic mold body 10, the second elastic mold body 20 also includes a second elastic covering body 21. In this embodiment, the second elastic mold body 20 serves as an upper mold to press the intermediate product downward so that the intermediate product is more closely combined with the second fiber mesh 35 and is at least heated by the second rigid mold body 22. The second fiber mesh 35 in the corresponding heating area is processed into a densified fiber felt, so that the second fiber mesh is kept in shape in the second surface area according to the shape of the core material shape; a felt handicraft blank with a core material is obtained.

[0112] Considering production efficiency, the first and second elastic mold bodies may have a plurality of elastic covering bodies, and the elastic covering bodies may be arranged in a matrix.

[0113] In the single-layer fiber mesh embodiment, the first fiber mesh 30 and the second fiber mesh 35 can both be reinforced fiber meshes, such as fiber meshes reinforced by needle punching. The applicant has tried to directly process the handicraft blank using only fluffy fiber meshes, but the processed product felt layer lacks stiffness and feels too soft, which is not suitable for display as a handicraft or playing with hands. Therefore, it is necessary to use a reinforced fiber mesh, which has a certain strength. After being heated by the mold, the strength and elasticity will be further increased due to the formation of a densified fiber felt, and the effect will be better.

[0114] However, sometimes due to the size of the reinforced fiber mesh or its own high strength, the reinforced fiber mesh cannot fit perfectly with the surface of the core material 40, and wrinkles will form on the outer surface of the processed handicraft blank, affecting the visual perception and feel. Therefore, the applicant proposed a double-layer fiber mesh embodiment. That is, Figure 5-6 A corresponding embodiment, in which the fiber mesh includes two layers, a layer close to the core material 40 is a reinforced fiber mesh 33, which is responsible for providing strength and elasticity to the final product, and outside the reinforced fiber mesh 33 is a layer of fluffy fiber mesh 34. Because it is very fluffy and soft, it will form a blank surface with a smooth feel and uniform texture after the mold is heated, completely covering the wrinkles of the lower reinforced fiber mesh.

[0115] It should be noted that, according to the previous records, the fluffy fiber mesh becomes a reinforced fiber mesh after reinforcement, but this embodiment does not limit or imply that the fluffy fiber mesh and the reinforced fiber mesh must be made of the same material or that the reinforced fiber mesh is a post-process product of the fluffy fiber mesh. Those skilled in the art can fully understand that the inner layer of the reinforced fiber mesh can be made of a lower-priced fiber mixture, which is mainly responsible for providing strength, while the outer layer of the fluffy fiber mesh can be made of a fiber mixture with the required color and performance to provide a high-quality blank surface, as long as the fluffy fiber mesh and the inner layer of the reinforced fiber mesh can produce the expected thermal bonding effect when heated in the mold.

[0116] As for the heating means, this embodiment does not make too many restrictions. For the elastic mold body, a hot air supply system can be used, such as placing the elastic mold body in an air duct structure with a cover body. For the rigid mold body, a heat-conducting fluid medium pipeline or electronic components can be used for temperature control.

[0117] Regarding temperature control, the mold can be heated to between 110-250°C according to the first melting point, and the temperature can be maintained until the surface shell of the low-melting-point sheath-core fiber of the first fiber melts. The mold is cooled to below 110°C, the surface shell of the low-melting-point sheath-core fiber of the first fiber is re-solidified, and the fiber mesh is felted and shaped according to the shape of the mold cavity, generating a densified fiber felt.

[0118] A specific application of felt handicrafts can be atmosphere lights for festivals. By wrapping a luminous light strip around the outside of the felt handicraft body, a lamp can be made and placed in a celebration venue. The luminous light strip is powered by a battery or an external power source.

[0119] The embodiments of the present application are described above in conjunction with the accompanying drawings. In the absence of conflict, the embodiments in the present application and the features in the embodiments can be combined with each other. The present application is not limited to the above-mentioned specific implementation methods. The above-mentioned specific implementation methods are merely illustrative and not restrictive. Under the guidance of the present application, ordinary technicians in this field can also make many forms without departing from the purpose of the present application and the scope of protection of the claims, all of which are within the protection of the present application.

Claims

1. A felt handicraft blank with a core material, comprising a main body, wherein the main body has a core material and a coating layer is provided on the outer side of the core material; It is characterized in that The covering layer comprises a densified fiber felt, which is formed by heating a first fiber having a first melting point and a second fiber having a second melting point higher than the first melting point under a condition of core material support.

2. The felt handicraft blank with a core material according to claim 1, characterized in that: The first fiber is of a sheath-core structure; the second fiber is a natural fiber, which is bast fiber, cotton, cellulose, wool, silk, flax or any combination thereof.

3. The felt handicraft blank with a core material according to claim 2, characterized in that: The first fibers and the second fibers are laid in a random direction to form a fiber mesh or in a predetermined direction to form a fiber mesh. After the fiber mesh is wrapped around the outside of the core material, it is heated to form a densified fiber felt.

4. The felt handicraft blank with a core material according to claim 3, characterized in that: The second fibers are colored short fibers. The second fibers are mixed with the first fibers to form a fiber mesh. The mixed fibers form a natural, multi-layered mixed color pattern on the surface of the fiber mesh, and a densified fiber felt is formed by heating.

5. A method for manufacturing a felt handicraft blank with a core material, characterized in that: S1) mixing and paving first fibers with a first melting point and second fibers with a second melting point higher than the first melting point to form a fiber web; S2) wrapping the fiber mesh obtained above on the outside of the core material and placing it into a mold, so that the fiber mesh is shaped according to the shape of the core material and the mold body; S3) heating the mold to the first melting point temperature of the first fiber, so that the first fiber and the second fiber are thermally bonded; cooling the mold until the first fiber is re-solidified, and the fiber mesh is processed into a densified fiber felt, thereby obtaining a felt handicraft blank with a core material.

6. A method for manufacturing a felt handicraft blank with a core material, characterized in that: S1) mixing and paving first fibers with a first melting point and second fibers with a second melting point higher than the first melting point to form a first fiber mesh and a second fiber mesh; S2) After the first fiber mesh is coated on the first surface area (41) outside the core material, a first heating step is performed to heat the first fiber to the first melting point temperature, so that the first fiber and the second fiber are thermally bonded; then the first fiber is cooled until the first fiber is re-solidified, and the first fiber mesh is processed into a densified fiber felt, so that the first fiber mesh is shaped in the first surface area (41) according to the shape of the core material body, and an intermediate product is obtained; S3) applying the second fiber mesh (35) to the outside of the intermediate product, completely covering the core material corresponding to the second surface area (42) on the outside of the core material, and then placing it in the second heating process, heating it to the first melting point temperature of the first fiber, so that the first fiber and the second fiber are thermally bonded; then cooling until the first fiber is re-solidified, the second fiber mesh (35) is processed into a densified fiber felt, so that the second fiber mesh (35) is kept fixed in the second surface area (42) according to the shape of the core material body; and a felt handicraft blank with a core material is obtained.

7. The method for manufacturing a felt handicraft blank with a core material according to claim 5 or 6, characterized in that: In step S1), the first fiber is a low-melting-point sheath-core fiber, and the second fiber is a colored short fiber. The first fiber and the second fiber are uniformly mixed and combed into a fiber mesh with cross-mixed and interconnected fibers, wherein the weight content of the first fiber is not less than 15% and not more than 90%.

8. The method for manufacturing a felt handicraft blank with a core material according to claim 5 or 6, characterized in that: In step S1), a fluffy fiber mesh including first fibers and second fibers is formed, and the fluffy fiber mesh is reinforced to obtain a reinforced fiber mesh, which is provided as the first fiber mesh and / or the second fiber mesh to step S2).

9. The method for manufacturing a felt handicraft blank with a core material according to claim 5 or 6, characterized in that: In step S1), a fluffy fiber mesh and a reinforced fiber mesh containing first fibers and second fibers are formed. The fluffy fiber mesh and the reinforced fiber mesh are stacked and provided to step S2) as the first fiber mesh and / or the second fiber mesh, and the reinforced fiber mesh is close to the core material.

10. The method for manufacturing a felt handicraft blank with a core material according to claim 6, characterized in that: In step S2), the first fiber mesh is coated on the first surface area (41) of the core material and at least partially extends to cover the second surface area (42). In step S3), the second fiber mesh at least partially overlaps with the first fiber mesh in the second surface area (42).

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