Production method of anti-cracking upright cotton

Abstract

The production method of the anti-cracking vertical cotton is characterized by comprising the following steps: S1, forming a vertical cotton main body; s2, feeding the vertical cotton main body into a snagging machine, rolling over the upper and lower surfaces of the vertical cotton main body by utilizing a crochet hook, and hooking a plurality of randomly extending drawn wires on the upper and lower surfaces of the vertical cotton main body; s3, covering the upper and lower surfaces of the upright cotton main body with the drawn wires in the same direction; s4, the drawn vertical cotton is fed into a hot air setting furnace to be heated, drawn wires are hot-melted, and anti-crack layers are formed on the upper surface and the lower surface of the vertical cotton through hot melting of the drawn wires; and S5, after the finished product is output, the finished product is wound through a winding machine. The invention has the following beneficial effects: randomly extending drawn wires are introduced to the upper and lower surfaces of the upright cotton, and the anti-crack layer is formed by using a hot melting technology, so that the anti-crack performance of the upright cotton is significantly improved, and the problem of easy layering between traditional upright cotton fiber webs is overcome, thereby enhancing the overall structural strength and durability of the product.

Description

Technical Field

[0001] The invention relates to the field of nonwoven fabrics, in particular to a method for producing crack-resistant upright cotton. Background Art

[0002] Fluffy materials play an indispensable role in various fields of modern society and are widely used in many aspects such as sound insulation materials, sofas, mattresses, office chairs, sports equipment and clothing. With the continuous development of technology, the preparation methods of fluffy materials are also constantly evolving, mainly including sponges, warp knitted spacer fabrics, three-dimensional elastic woven fabrics and non-woven fabrics.

[0003] Sponge is one of the fluffy materials with the longest history and the most widespread application. As a porous material, sponge is mainly made of soft foam in polyurethane foam. It occupies an important position in the market due to its low price, light weight, soft feel, plumpness and good resilience. However, the environmental pollution problem in the sponge production process is becoming increasingly serious, especially when the waste cannot be recycled, the unsustainability of sponges is becoming more and more prominent. What is more serious is that sponges are prone to yellowing and have poor air permeability and comfort, which limits their application in certain fields. At present, Australia and some developed European countries have taken restrictive measures due to the environmental pollution and resource waste problems of sponges.

[0004] In order to overcome the shortcomings of sponges, three-dimensional warp knitted spacer fabrics and three-dimensional elastic woven fabrics came into being. Three-dimensional warp knitted spacer fabrics are composed of two fabric surfaces connected by spacer yarns, have good environmental performance, and can be recycled. They have excellent performance in thermal and moisture comfort, warmth retention and breathability, and are soft and elastic, overcoming many shortcomings of sponges. However, due to its structural limitations, the compression resistance and resilience of three-dimensional warp knitted spacer fabrics are poor, and cannot meet the needs of some products with high requirements for compression elasticity, which greatly limits its application range.

[0005] Three-dimensional elastic woven fabric is a new type of fluffy material developed on the basis of warp knitted spacer fabric. It has excellent resilience in the thickness direction, stable structure, changeable shape, and good moisture permeability and air permeability. However, the complex weaving structure of three-dimensional elastic woven fabric leads to high manufacturing cost and difficulty in popularization and application, especially in the price-sensitive market, where its promotion faces challenges.

[0006] With the development of nonwoven fabric technology, the arrangement direction of fibers has been innovatively changed, changing the traditional lateral arrangement of fibers to vertical arrangement, thus forming a nonwoven fabric with a honeycomb structure. This structure is called upright cotton. Due to its unique upright fiber mesh structure, upright cotton performs well in elasticity, air permeability and dimensional stability. At the same time, the waste of upright cotton can be recycled, which is in line with the current social consumption concept of environmental protection and low carbon. Compared with sponge, upright cotton is not easy to yellow and has better air permeability; compared with three-dimensional elastic woven fabrics and warp knitted spacer fabrics, the production process of upright cotton is simpler, the adaptability to raw materials is stronger, the raw materials are widely available, and the production cost is relatively low, so it has broad application prospects in many fields.

[0007] However, the production of existing upright cotton still has some shortcomings, especially the fiber webs are prone to delamination, which causes the elasticity of the upright cotton to deteriorate after being used for a period of time, so it is necessary to make further improvements thereto. Summary of the invention

[0008] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide a method for producing anti-cracking upright cotton with simple structure, convenient production and processing, and effective solution to the problems of fiber web delamination and lack of anti-cracking performance in the technology.

[0009] The object of the present invention is achieved by the following method: A method for producing crack-proof upright cotton, characterized in that it comprises the following steps: S1: formed upright cotton body; S2: feeding the upright cotton body into a wire hooking machine, using a hook needle to roll over the upper and lower surfaces of the upright cotton body, and hooking a number of randomly extended wires on the upper and lower surfaces; S3: The wire drawing covers the upper and lower surfaces of the upright cotton body in the same direction; S4: sending the drawn upright cotton into a hot air shaping furnace for heating, so that the drawn cotton is hot-melted, and forming an anti-cracking layer on the upper and lower surfaces of the upright cotton by the drawing hot-melt method; S5: After the finished product is output, it is wound up by a winder.

[0010] Furthermore: the wire hooking machine comprises two rollers symmetrically distributed up and down, a plurality of hook needles are arranged on the cylindrical surface of the rollers, and the two rollers are driven by a power mechanism to rotate in the same direction.

[0011] Furthermore: the opening direction of the crochet needle 2 is arranged toward the discharge direction.

[0012] Furthermore, the heating temperature of the hot air shaping furnace 7 is 120°-160° Furthermore, the hot air shaping furnace 7 is connected to a cooling channel 6, and the heated upright cotton enters the cooling channel 6 for cooling and shaping.

[0013] The beneficial effects of the present invention are: 1. Simple structure, low production cost and improved market competitiveness.

[0014] 2. By introducing randomly extended wire drawing on the upper and lower surfaces of the upright cotton and using hot melt technology to form an anti-cracking layer, the crack resistance of the upright cotton is significantly improved, overcoming the problem of easy stratification between traditional upright cotton fiber webs, thereby enhancing the overall structural strength and durability of the product.

[0015] 3. The wire drawing layer in the invention not only plays an anti-cracking role, but also improves the elasticity and resilience of the product, so that the upright cotton can still maintain a good shape and elastic properties after repeated use and compression.

[0016] 4. The present invention adopts relatively simple production steps, including molding, wire drawing, hot melting and cooling and shaping. The whole process is smooth and easy to operate, and can achieve efficient production. At the same time, the equipment structure in the process is clear, easy to manufacture and maintain, and suitable for large-scale industrial production.

[0017] 5. By covering the upper and lower surfaces of the upright cotton with a drawing layer and performing heat setting, the present invention not only improves the structural strength and elasticity of the upright cotton, but also maintains the air permeability and comfort of the material, and is suitable for application scenarios with high requirements for comfort, such as mattresses and sofas. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of the wire hooking machine in the present invention.

[0019] Figure 2 Invent production flow chart. DETAILED DESCRIPTION

[0020] The present invention is further described in detail below with reference to the accompanying drawings. A method for producing crack-proof upright cotton, characterized in that it comprises the following steps: S1: formed upright cotton body 1; S2: feeding the upright cotton body 1 into a wire hooking machine, using a hook needle 2 to roll over the upper and lower surfaces of the upright cotton body 1, and hooking a number of randomly extended wires 3 on the upper and lower surfaces; S3: The wire drawing 3 covers the upper and lower surfaces of the upright cotton body 1 in the same direction; S4: sending the upright cotton after drawing 3 into the hot air setting furnace 7 for heating, so that the drawing 3 is hot-melted, and the anti-cracking layer 4 is formed on the upper and lower surfaces of the upright cotton by hot-melting the drawing 3; S5: After the finished product is output, it is wound up by a winder.

[0021] In one of the embodiments: the wire hooking machine comprises two rollers 5 symmetrically distributed up and down, a plurality of hook needles 2 are arranged on the cylindrical surface of the roller 5, and the two rollers 5 are driven by a power mechanism to rotate in the same direction.

[0022] In one embodiment, the opening direction of the crochet needle 2 is arranged toward the discharge direction.

[0023] In one embodiment, the heating temperature of the hot air shaping furnace 7 is 120°-160° In one embodiment, the hot air shaping furnace 7 is connected to a cooling channel 6, and the heated upright cotton enters the cooling channel 6 for cooling and shaping.

[0024] Detailed explanation of working principle: The present invention proposes a method for producing crack-resistant upright cotton. The core principle is to introduce and melt a wire drawing layer with crack-resistant function on the upper and lower surfaces of the upright cotton, thereby improving the overall strength and elasticity of the upright cotton and effectively preventing the phenomenon of fiber web stratification. The method includes the steps of molding, wire drawing, hot melting, cooling, etc., which ensures that the upright cotton achieves structural optimization and performance improvement during the production process.

[0025] 1. Forming the upright cotton body (step S1) First, the fiber material is formed into an upright cotton body (1) through a specific molding device. In this process, the fiber material is oriented and pressed into an upright cotton body with a certain thickness and structure. The key to this step is to ensure the uniform distribution of the fibers and the stability of the structure, so that the upright cotton body has the necessary fluffiness and elasticity, laying the foundation for the subsequent processing steps.

[0026] By optimizing the molding equipment and process parameters, an upright cotton body with good consistency and stability can be obtained. This ensures uniform effects of wire drawing and hot melting in subsequent processes, so that the final product has stable physical properties.

[0027] 2. Wire drawing process (step S2) The formed upright cotton body (1) is sent to a wire hooking machine for surface treatment. The wire hooking machine is composed of a roller (5) symmetrically distributed above and below, and a plurality of hooks (2) are arranged on the surface of the roller. When the roller rotates synchronously under the drive of the power mechanism, the hooks are inserted into and rolled over the upper and lower surfaces of the upright cotton body, and a plurality of randomly extending fiber drawstrings (3) are drawn on the surface. These drawstrings will cover the upper and lower surfaces of the upright cotton body in the same direction, forming a preliminary anti-cracking structure.

[0028] The design of the hook and the synchronous rotation of the drum allow the drawing to be evenly and randomly distributed on the surface of the upright cotton. This treatment not only increases the thickness of the surface layer of the upright cotton, but also provides a certain anti-cracking effect through the randomly distributed fiber filaments, increasing the surface strength of the product.

[0029] 3. Wire drawing covering (step S3) After the drawing process, these fiber filaments (3) naturally cover the upper and lower surfaces of the upright cotton body (1) in the same direction. The covered drawing layer increases the surface thickness of the upright cotton and enables the drawing to be closely combined with the upright cotton body in the subsequent hot melting process to form a strong anti-cracking layer.

[0030] The wire drawing covering process does not require complicated mechanical operations and can be achieved through natural accumulation, which not only simplifies the process flow but also ensures uniform coverage of the wire drawing layer. This layer of wire drawing not only improves the elasticity of the upright cotton, but also provides a sufficient material basis for subsequent hot melt processing, making the formation of the anti-cracking layer more effective.

[0031] 4. Hot melt shaping (step S4) Next, the upright cotton body covered with the wire drawing is sent into a hot air shaping furnace. The temperature in the furnace is controlled within the range of 120°C to 160°C, so that the wire drawing (3) is thermally melted. The wire drawing after thermal melting is tightly combined with the upper and lower surfaces of the upright cotton body to form a dense and strong anti-cracking layer (4). This anti-cracking layer effectively prevents the problem of fiber web delamination during the use of the upright cotton, while increasing the overall strength and elasticity of the product.

[0032] The hot melt shaping process not only gives the upright cotton an anti-cracking layer, but also retains the softness and breathability of the upright cotton. Through precise temperature control, the uniform melting and shaping of the drawing layer is ensured, so that the anti-cracking layer on the surface of the upright cotton is both strong and has good elasticity, which significantly improves the durability and service life of the product.

[0033] 5. Cooling, shaping and winding (step S5) After leaving the hot air shaping furnace, the heated upright cotton body enters the cooling channel (6) for cooling and shaping. During the cooling process, the heat-melted anti-cracking layer gradually solidifies and is tightly combined with the upright cotton body, eventually forming a stable structure. After cooling, the finished product is rolled up by a winding machine and output.

[0034] The cooling process further consolidates the structure of the anti-cracking layer, making it less likely to shrink or deform during the cooling process, ensuring the dimensional stability and structural integrity of the final product. Through the effective cooling of the cooling channel, the anti-cracking layer solidifies quickly, maintaining the high elasticity and surface strength of the upright cotton, providing a guarantee for the high quality of the final product.

[0035] The present invention realizes structural optimization of upright cotton through a series of innovative process steps, combined with processes such as molding, wire drawing, hot melting and cooling and shaping, and finally produces anti-cracking upright cotton with high crack resistance and excellent elasticity. This material not only overcomes the shortcomings of traditional upright cotton such as easy stratification and insufficient elasticity, but also significantly improves its service life and durability while maintaining softness and breathability. Through the technical solution of the present invention, the application field of upright cotton can be further expanded, meeting the market demand for high-strength, high-elasticity fluffy materials, and also conforming to the social development trend of environmental protection and low carbon, so it can be widely promoted and used.

[0036] 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 by the above embodiments, and 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, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A method for producing crack-proof upright cotton: characterized in that: It includes the following steps: S1: molded upright cotton body (1); S2: feeding the upright cotton body (1) into a wire hooking machine, using a hook needle (2) to roll over the upper and lower surfaces of the upright cotton body (1), and hooking a plurality of randomly extending wires (3) on the upper and lower surfaces; S3: The wire drawing (3) covers the upper and lower surfaces of the upright cotton body (1) in the same direction; S4: sending the upright cotton after drawing (3) into a hot air shaping furnace (7) for heating, so that the drawing (3) is hot-melted, and forming an anti-cracking layer (4) on the upper and lower surfaces of the upright cotton by hot-melting the drawing (3); S5: After the finished product is output, it is wound up by a winder.

2. The method for producing crack-resistant upright cotton according to claim 1, characterized in that: The wire hooking machine comprises two rollers (5) symmetrically distributed up and down, a plurality of hook needles (2) are arranged on the cylindrical surface of the rollers (5), and the two rollers (5) are driven by a power mechanism to rotate in the same direction.

3. The method for producing crack-proof upright cotton according to claim 2, characterized in that: The opening direction of the hook needle (2) is arranged toward the material discharge direction.

4. The method for producing crack-resistant upright cotton according to claim 1, characterized in that: The heating temperature of the hot air shaping furnace (7) is 120°-160°.

5. The method for producing crack-resistant upright cotton according to claim 1 or 4, characterized in that: The hot air shaping furnace (7) is connected to a cooling channel (6), and the heated upright cotton enters the cooling channel (6) for cooling and shaping.

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