A method for preparing a multi-layered ball cotton sheet

Abstract

The present invention relates to a multi-layer composite fiber home textile product, specifically to a method for preparing a multi-layer structured cotton wool sheet, the multi-layer structured cotton wool sheet comprising support layers on both sides, a cotton wool layer in the middle and a transition layer at the interface between the two, and the preparation method is as follows: 1. Evenly mix cotton wool, short fibers and low-melting point fibers according to a weight ratio to form a cotton wool layer of a certain thickness, and use a round roller with a Velcro hook surface to roll on both sides of the cotton wool layer; 2. Take short fibers and low-melting point fibers, mix them according to a weight ratio to form a support layer of a certain thickness, and the two support layers are respectively bonded to the two sides of the cotton wool layer as support layers, and are heated and shaped. The present invention adopts a multi-layer structure design to fix the easily deformed and agglomerated cotton wool between two support layers, so that the cotton wool's ability to resist external forces is improved, and it is not easy to collapse or agglomerate after being subjected to force, while also maintaining the light and fluffy characteristics of the cotton wool itself.

Description

Technical Field

[0001] The invention relates to a multi-layer composite fiber home textile product, in particular to a method for preparing a multi-layer structured ball cotton wool sheet. Background Art

[0002] Ball cotton is a fiber aggregate of a spherical structure formed by rolling short fibers in a ball rolling machine. The aggregate of ball cotton can be used as a filling material and filled in textiles such as clothing, home textiles and toys. As a collection of filling materials, in addition to having a certain degree of warmth retention, it also has the advantages of being light, thin and fluffy. Due to the independent characteristics of the spherical structure in ball cotton, it is easy to displace after being subjected to force. The ball cotton inside the product filled with ball cotton will collapse or agglomerate after being subjected to force for a long time, and the structural deformation affects the normal use of the product. To solve this problem, Chinese patent CN 11101292A discloses a sandwich ecological cotton and a manufacturing method thereof. The sandwich ecological cotton has an elastic upper combed cotton layer and a lower combed cotton layer on both sides, and a pearl ball cotton sublayer is sandwiched in the middle, and the pearl ball cotton sublayer is connected by low-melting point fibers. The sandwich eco-cotton has a combed cotton layer with hardness and elasticity on both sides of the pearl ball cotton sublayer, which can maintain the fluffy and soft advantages of the pearl ball cotton sublayer while improving the deformation resistance of the pearl ball cotton sublayer to a certain extent. However, the combed cotton layer and the pearl ball cotton sublayer are not tightly combined, and the interlayer will break or even fall off after long-term use. In addition, in the preparation method of the above patent application, before molding, no external force is applied between the combed cotton layer and the pearl ball cotton sublayer to make them fit tightly, and the interlayer is not tightly fitted during operation, and defective products with separated layers will appear after heating and shaping. Summary of the invention

[0003] In view of the problem that after long-term use, the cotton wool in existing products filled with cotton wool collapses or agglomerates, resulting in product deformation, the present invention provides a method for preparing a multi-layer cotton wool sheet. The multi-layer cotton wool sheet comprises support layers on both sides, a middle cotton wool layer, and a transition layer formed at the interface between the support layer and the cotton wool layer, wherein the thickness ratio of the cotton wool layer to the support layer is 1:(0.2-1.2).

[0004] The preparation method of the multi-layer ball cotton wool sheet of the present invention comprises the following steps:

[0005] 1. Mix the cotton wool, short fibers and low-melting-point fibers evenly by weight, comb them into a net through a carding machine, and make a cotton wool layer of a certain thickness. Use a round roller with a Velcro hook surface to roll on both sides of the cotton wool layer to hook out the short fibers and low-melting-point fibers in the cotton wool layer;

[0006] 2. Take the short fiber and low melting point fiber in step 1 separately, mix them according to weight ratio to make a support layer of certain thickness, and laminate the two support layers to the two sides of the obtained ball cotton layer respectively, heat and shape them, and you have it.

[0007] Specifically, the ball cotton material is a mixture of one or more of polyester, polyamide, polyethylene or polypropylene; the short fiber is one of polyester fiber, polyamide fiber, polyethylene fiber or polypropylene fiber; the low-melting point fiber is polyester fiber with a melting point ≤130°C.

[0008] Specifically, in step one of the above method, the ball diameter of the cotton ball is 0.1 to 1.5 cm, the weight ratio of the cotton ball, short fiber and low-melting point fiber is 1:(0.2 to 0.5):(0.05 to 0.1), and the hook density of the Velcro hook surface on the surface of the round roller is 16 to 144 pieces per square centimeter; in step two, the weight ratio of the short fiber and the low-melting point fiber is 1:(0.1 to 0.2), and the heating and setting temperature is 135°C to 160°C.

[0009] In the method of the present invention, before each support layer is attached to the ball wool layer, the ball wool layer is subjected to side blowing treatment, and the wind direction is vertically blowing from the ball wool layer to the support layer. The purpose of side blowing treatment of the ball wool layer is to blow the short fibers and low melting point fibers hooked out of the surface of the ball wool layer away from the main body of the ball wool layer, and then the support layer presses them back to form a clear transition layer.

[0010] Furthermore, PCM material or heat storage material is added to the ball cotton fiber of the present invention. The heat storage material, the addition of PCM material makes the multi-layer ball cotton sheet of the present invention have a cool feeling characteristic, and the addition of heat storage material makes the multi-layer ball cotton sheet of the present invention have the characteristics of heat absorption and heat storage.

[0011] The present invention adopts a multi-layer structure design to fix the easily deformed and agglomerated ball cotton between two supporting layers, so that the ability of the ball cotton to resist external force is improved, and it is not easy to collapse or agglomerate after being subjected to force, while maintaining the light and fluffy characteristics of the ball cotton itself; in addition, during the preparation process, the present invention hooks out the short fibers and low-melting-point fibers in the ball cotton layer, and uses side blowing to blow the hooked fibers away from the main body of the ball cotton layer before bonding with the supporting layer to form a transition layer in which the fibers are entangled with each other, and some short fibers will also be inserted into the supporting layer. During the heating and shaping process, the low-melting-point fibers will melt and then solidify to weld the entanglement points and contact points, so that the integrity of the multi-layer structure ball cotton sheet is better, the layers are not easy to separate after being subjected to force, and the service life of the multi-layer structure ball cotton sheet is extended. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 The present invention is a schematic diagram of the equipment for the continuous preparation method of the multi-layer structure ball cotton wool sheet.

[0013] Figure 2 It is a schematic cross-sectional view of the multi-layer ball cotton wool sheet obtained in the present invention.

[0014] The numbers are: 1. ball cotton layer, 1-1. transition layer, 2. ball cotton layer conveyor, 3. Velcro roller, 4. upper blower, 5. upper supporting layer conveyor, 6. upper supporting layer, 7. lower blower, 8. lower supporting layer conveyor, 9. lower supporting layer, 10. heating and setting box. DETAILED DESCRIPTION

[0015] The present invention is described below in conjunction with examples, which are only used to explain the present invention and are not used to limit the scope of the present invention.

[0016] A method for continuously preparing a multi-layer ball cotton sheet, wherein the structure of the multi-layer ball cotton sheet is as follows: Figure 2 As shown, it includes a middle cotton layer 1, an upper supporting layer 6 and a lower supporting layer 9 on both sides of the cotton layer 1, and a transition layer 1-1 between the cotton layer 1 and the upper supporting layer 6 and the lower supporting layer 9. The thicknesses of the cotton layer 1, the upper supporting layer 6 and the lower supporting layer 9 are 4 cm, 0.8 cm and 1 cm, respectively, and the diameter of the cotton balls in the cotton layer 1 is 0.3 cm; the cotton balls are made of 0.9D+3D PET short fibers, wherein 0.5wt% of graphene powder is added to the 3D PET short fibers, the short fibers are 1.5D PET short fibers, and the low-melting-point fibers are 2080 low-melting-point polyester fibers with a melting point of 120°C.

[0017] Combination Figure 1 The schematic diagram of the device shown in the figure, the continuous preparation method of the multi-layer structure ball cotton sheet of this embodiment includes the following steps:

[0018] 1. Mix the ball wool, short fibers and low-melting point fibers evenly at a weight ratio of 1:0.25:0.1, and take short fibers and low-melting point fibers at a weight ratio of 1:0.2, mix them evenly and divide them into two parts; comb the three mixed fibers into continuous mesh sheets with required thickness through a carding machine, namely, the ball wool layer 1, the upper supporting layer 6 and the lower supporting layer 9;

[0019] 2. Keep the carding machine running, guide the ends of the continuous sheets of the ball cotton layer 1, the upper supporting layer 6 and the lower supporting layer 9 to the ball cotton layer conveyor 2, the upper supporting layer conveyor 5 and the lower supporting layer conveyor 8 respectively, start the three conveyors, turn on the upper and lower Velcro rollers 3 set in the ball cotton layer conveyor 2, hook out the short fibers and low-melting-point fibers in the ball cotton layer 1, the Velcro hook density on the surface of the Velcro roller 3 is 64 pieces / square centimeter, and the roller surface of the Velcro roller 3 protrudes 0.3 cm from the surface of the ball cotton layer conveyor 2, turn on the upper blower 4 built in the ball cotton layer conveyor 2, and blow away the short fibers and low-melting-point fibers hooked out from the upper surface of the ball cotton layer 1;

[0020] 3. After the short fibers and low-melting-point fibers on the upper surface of the ball wool layer 1 are blown off, the upper supporting layer 6 on the upper supporting layer conveyor 5 is guided onto the ball wool layer 1 to make the two fit together, and the lower blower 7 arranged above is turned on to further fit the upper supporting layer 6 and the ball wool layer 1 together while blowing off the short fibers and low-melting-point fibers hooked out from the lower surface of the ball wool layer 1;

[0021] 4. After the short fibers and low-melting-point fibers on the lower surface of the ball wool layer 1 are blown away, the ball wool layer 1 is guided to the lower supporting layer 9 on the lower supporting layer conveyor 8. When all layers are in contact, the lower supporting layer conveyor 8 guides the stacked three-layer structure into the heating setting box 10. The heating temperature of the heating setting box 10 is set to 160°C to melt the low-melting-point fibers.

[0022] 5. After exiting the heating and setting box 10, the waste material at the edge is cut off after natural cooling and the film is rolled up.

[0023] In the above step 3, after the upper supporting layer 6 is bonded to the ball cotton layer 1, turning on the lower hair dryer 7 can not only blow away the short fibers and low-melting-point fibers hooked out from the lower surface of the ball cotton layer 1, but also make the upper supporting layer 6 and the ball cotton layer 1 fit more closely; in the above step 4, the ball cotton layer 1 bonded to the upper supporting layer 6 can achieve a tight fit between its lower surface and the lower supporting layer 9 by its own weight, and after the two sides of the ball cotton layer 1 are tightly bonded to the upper supporting layer 6 and the lower supporting layer 9, they enter the heating and shaping box 10 for heating and shaping, which greatly reduces the probability of defective products caused by interlayer separation during long-distance operation.

[0024] This embodiment improves the integrity of the multi-layered ball cotton sheet from two aspects: first, the short fibers and low melting point fibers in the ball cotton layer 1 are hooked out to form an obvious transition layer 1-1, thereby increasing the interlayer bonding force between the ball cotton layer 1 and the upper supporting layer 6 and the lower supporting layer 9; second, during the preparation process, the probability of separation between the ball cotton layer 1 and the upper supporting layer 6 and the lower supporting layer 9 is reduced by combining side blowing, dead weight, and shortening the transportation distance. With the combined effect of these two aspects, the method of this embodiment can prepare a multi-layered ball cotton sheet with tight interlayer bonding.

[0025] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for preparing a multi-layer ball cotton sheet, characterized in that: The multi-layered ball cotton sheet comprises support layers on both sides, a ball cotton layer in the middle, and a transition layer formed at the interface between the support layer and the ball cotton layer. The preparation method of the multi-layered ball cotton sheet comprises the following steps:

1. Mix the cotton wool, short fibers and low-melting-point fibers evenly by weight to form a cotton wool layer of a certain thickness, and roll the two sides of the cotton wool layer with a round roller with a Velcro hook surface; 2. Take the short fiber and low melting point fiber in step 1 separately, mix them according to weight ratio to make a support layer of certain thickness, and laminate the two support layers to the two sides of the ball cotton layer obtained in step 1 respectively, heat and shape them, and you have it.

2. The method for preparing the multi-layered ball cotton sheet according to claim 1, characterized in that: The ball cotton material is a mixture of one or more of polyester, polyamide, polyethylene or polypropylene; the short fiber is one of polyester fiber, polyamide fiber, polyethylene fiber or polypropylene fiber; the low-melting point fiber is polyester fiber with a melting point ≤130°C.

3. The method for preparing the multi-layered ball cotton sheet according to claim 2, characterized in that: In step 1, the ball diameter of the ball cotton is 0.1-1.5 cm, and the weight ratio of the ball cotton, short fiber and low-melting point fiber is 1:(0.2-0.5):(0.05-0.1); in step 2, the weight ratio of the short fiber and the low-melting point fiber is 1:(0.1-0.2).

4. The method for preparing the multi-layered ball cotton sheet according to any one of claims 1 to 3, characterized in that: In step 1, the hook density of the Velcro hook surface on the surface of the round roller is 16 to 144 per square centimeter.

5. The method for preparing the multi-layered ball cotton sheet according to any one of claims 1 to 3, characterized in that: In step 2, before the support layer and the ball wool layer are attached to each other, the ball wool layer is subjected to side blowing treatment, and the wind direction is vertically blowing from the ball wool layer to the support layer.

6. The method for preparing the multi-layered ball cotton sheet according to any one of claims 1 to 3, characterized in that: In step 2, the temperature for heating and setting is 135°C to 160°C.

7. The method for preparing the multi-layered ball cotton sheet according to any one of claims 1 to 3, characterized in that: The thickness ratio of the ball cotton layer to the supporting layer is 1:(0.2-1.2).

8. The method for preparing the multi-layered ball cotton sheet according to any one of claims 1 to 3, characterized in that: PCM material or heat storage material is added to the fiber of the ball cotton.

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