Manufacturing method of mute environment-friendly liner cotton

Abstract

The invention relates to a manufacturing method of mute environment-friendly liner cotton, which comprises the following steps: S1, respectively weighing 25-40 parts by weight of low-melting-point PET (Polyethylene Terephthalate) fiber, 25-40 parts by weight of first PET fiber, 20 parts by weight of second PET fiber and 20 parts by weight of third PET fiber; s2, the fibers in the step S1 are sequentially opened through a first opener and a second opener; s3, inputting the four kinds of opened fibers into two cotton blending machines which are connected in series for mixing twice to form loose mixed fibers; s4, the loose mixed fibers are laid into loose porous cotton blanks through a lapping machine; s5, the cotton blank is conveyed into a tunnel type heating furnace to be heated, the low-melting-point PET fibers are subjected to hot melting, the first PET fibers, the second PET fibers and the third PET fibers are bonded together, and the cotton blank is cut into the sheet-shaped mute environment-friendly liner cotton through a cutting machine. The mute environment-friendly liner cotton has the advantages of being good in sound insulation and noise reduction performance, good in formability, good in supporting performance, good in mildew resistance and few in volatile organic compound.

Description

Technical Field

[0001] The invention relates to the field of automobile padding, and in particular to a method for manufacturing silent and environmentally friendly padding cotton. Background Art

[0002] With the rapid development of the automotive industry, in-car noise control has become an important aspect of improving driving experience. And with the increasing awareness of environmental protection and the continuous advancement of technology, the automotive industry is moving towards a more environmentally friendly and efficient direction. Lightweight design can reduce energy consumption and emissions, while the application of acoustic materials can effectively reduce in-car noise and improve driving comfort. Therefore, the automotive lightweight environmentally friendly acoustic material project is in line with the current direction and trend of technological development.

[0003] However, it is often difficult to strike a balance between the sound insulation effect, environmental performance and cost-effectiveness of existing automotive cushioning materials. For example: 1. The mixed cotton cushion made of recycled fabric has the characteristics of good sound insulation, low price, strong odor and easy to mildew; 2. The pure cellulosic cotton cushion made of pure cellulosic cotton has little odor and is mildew-resistant, but the through-hole structure in the pure cellulosic cotton cushion is simple, and the sound waves do not produce enough energy loss when passing through the pure cellulosic cotton cushion, and the sound insulation and noise reduction effect is poor; 3. The PP melt-blown cotton cushion has good sound insulation and noise reduction effect, but the structure is fluffy and lacks formability and support.

[0004] The present invention aims to solve the deficiencies of the prior art through innovative material formulations and processes, and to realize a soundproofing pad material that is both environmentally friendly and highly efficient. Summary of the invention

[0005] The purpose of the present invention is to overcome the above problems existing in the prior art and provide a method for manufacturing a silent and environmentally friendly lining cotton.

[0006] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0007] A method for manufacturing a silent and environmentally friendly lining cotton comprises the following steps:

[0008] S1. Take materials, and weigh 25 to 40 parts of low melting point PET fiber, 25 to 40 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber respectively according to weight parts;

[0009] S2, opening, respectively passing the fibers in step S1 through a first opening machine and a second opening machine for opening;

[0010] S3, mixing, inputting the four opened fibers into two series-connected cotton blending machines for two times of mixing to form loose mixed fibers;

[0011] S4, laying the net, using a net laying machine to lay the loose mixed fibers into a loose and porous cotton blank;

[0012] S5, shaping, conveying the cotton blank to a tunnel heating furnace for heating, so that the low melting point PET fiber is hot-melted to bond the first PET fiber, the second PET fiber, and the third PET fiber together, and using a cutting machine to cut into sheets of silent and environmentally friendly padding cotton.

[0013] Among them, in S1, according to weight parts, 30 parts of low-melting-point PET fiber, 30 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber are weighed respectively.

[0014] Among them, the fineness of the low-melting point PET fiber is 4.4d~6.67d, the fineness of the first PET fiber is 4.4d~6.67d, the fineness of the second PET fiber is 2d~2.5d, and the fineness of the third PET fiber is 0.8d~2d; the length of the low-melting point PET fiber, the length of the first PET fiber, the length of the second PET fiber, and the length of the third PET fiber are all 51mm.

[0015] Among them, the morphological structure of the first PET fiber is solid straight fiber, or three-dimensional hollow fiber, or high curled fiber; the morphological structure of the second PET fiber is solid straight fiber, or three-dimensional hollow fiber, or high curled fiber, and the morphological structure of the third PET fiber is fine fiber.

[0016] The melting point of the low-melting-point PET fiber is between 150 and 200°C, and the melting points of the first PET fiber, the second PET fiber and the third PET fiber are all between 250 and 255°C.

[0017] As a preferred embodiment, in S4, a horizontal web laying machine is used to lay the loose mixed fibers layer by layer in a flat laying manner to form a loose and porous cotton blank.

[0018] As another preferred embodiment, in S4, a vertical web laying machine is used to lay the loose mixed fibers in a wavy manner to form a loose and porous cotton blank.

[0019] As another preferred method, in S4, a horizontal web laying machine is first used to lay the loose mixed fibers in a flat manner to form a loose and porous cotton blank bottom layer, and then a vertical web laying machine is used to lay the loose mixed fibers in a wavy manner on the top of the cotton blank bottom layer to form a loose and porous cotton blank core layer, and finally a horizontal web laying machine is used to lay the loose mixed fibers in a flat manner on the top of the cotton blank core layer to form a loose and porous cotton blank top layer, and the cotton blank bottom layer, cotton blank core layer, and cotton blank top layer are overlapped in sequence from bottom to top to form a cotton blank with a sandwich structure.

[0020] The thickness of the bottom layer of the cotton blank is 20% of the thickness of the cotton blank, the thickness of the core layer of the cotton blank is 60% of the thickness of the cotton blank, and the thickness of the top layer of the cotton blank is 20% of the thickness of the cotton blank.

[0021] Furthermore, in S5, a blower is used to blow cold air between the tunnel heating furnace and the cutting machine for cooling.

[0022] The beneficial effects of the present invention are: 1. Four kinds of pure chemical fibers, namely low-melting-point PET fiber, first PET fiber, second PET fiber and third PET fiber, are used without adding plant fibers such as recycled cotton, and the fiber has the advantage of mildew resistance; low-molecular volatile organic compounds are not added, and the fiber has the advantage of less volatile organic matter; 2. PET fibers of different deniers are interwoven with low-melting-point PET fibers to form holes of different sizes, which is beneficial to the energy loss of sound waves of different wavelengths and improves the sound insulation and noise reduction effect; 3. After the low-melting-point PET fiber is hot-melted, the three interwoven PET fibers are bonded and fixed, thereby improving the formability of the silent and environmentally friendly lining cotton, improving the stiffness of the silent and environmentally friendly lining cotton, and improving the supporting performance of the silent and environmentally friendly lining cotton in the thickness direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0024] Figure 1 1 is a schematic structural diagram of a cross section of a sound-proof and environmentally friendly liner cotton in Embodiment 1 of the present invention;

[0025] Figure 2 1 is a schematic structural diagram of a cross section of a soundproof and environmentally friendly liner in Embodiment 2 of the present invention;

[0026] Figure 3 It is a structural schematic diagram of the cross section of the silent and environmentally friendly lining cotton in the third embodiment of the present invention. DETAILED DESCRIPTION

[0027] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0028] like Figure 1 The first embodiment shown is a method for manufacturing a silent and environmentally friendly lining cotton, comprising the following steps:

[0029] S1. Take materials. According to the weight percentage, weigh 25 parts of low-melting-point PET fiber, 40 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber respectively; the fineness of the low-melting-point PET fiber is 4.4d-6.67d, the fineness of the first PET fiber is 5.6d, the fineness of the second PET fiber is 2.5d, and the fineness of the third PET fiber is 2d; the length of the low-melting-point PET fiber, the length of the first PET fiber, the length of the second PET fiber, and the length of the third PET fiber are all 51mm; the morphological structure of the first PET fiber is a high-curl fiber; the morphological structure of the second PET fiber is a three-dimensional hollow fiber, and the morphological structure of the third PET fiber is a fine fiber; the melting point of the low-melting-point PET fiber is between 150 and 200°C, and the melting points of the first PET fiber, the second PET fiber, and the third PET fiber are all between 250°C and 255°C.

[0030] S2, opening, the fibers in step S1 are opened by passing through a first opener and a second opener in sequence.

[0031] S3, mixing, inputting the four opened fibers into two series-connected cotton blending machines for two blendings to form loose mixed fibers.

[0032] S4, laying the net, using a horizontal laying machine to lay the loose mixed fibers layer by layer in a flat laying manner to form a loose and porous cotton blank.

[0033] S5, shaping, conveying the cotton blank to a tunnel-type heating furnace for heating, so that the low-melting-point PET fiber is hot-melted to bond the first PET fiber, the second PET fiber, and the third PET fiber together, and then using a cutting machine to cut the silent and environmentally friendly padding cotton 100 into sheets.

[0034] like Figure 2 The second embodiment shown is a method for manufacturing a silent and environmentally friendly lining cotton, comprising the following steps:

[0035] S1. Take materials. According to the weight percentage, weigh 40 parts of low-melting-point PET fiber, 25 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber respectively; the fineness of the low-melting-point PET fiber is 4.4d-6.67d, the fineness of the first PET fiber is 6.67d, the fineness of the second PET fiber is 2.3d, and the fineness of the third PET fiber is 1d; the length of the low-melting-point PET fiber, the length of the first PET fiber, the length of the second PET fiber, and the length of the third PET fiber are all 51mm; the morphological structure of the first PET fiber is a three-dimensional hollow fiber; the morphological structure of the second PET fiber is a highly curled fiber, and the morphological structure of the third PET fiber is a fine fiber; the melting point of the low-melting-point PET fiber is between 150 and 200°C, and the melting points of the first PET fiber, the second PET fiber, and the third PET fiber are all between 250°C and 255°C.

[0036] S2, opening, the fibers in step S1 are opened by passing through a first opener and a second opener in sequence.

[0037] S3, mixing, inputting the four opened fibers into two series-connected cotton blending machines for two blendings to form loose mixed fibers.

[0038] S4, laying the net, using a vertical laying machine to lay the loose mixed fibers in a wavy manner into a loose and porous cotton blank.

[0039] S5, shaping, conveying the cotton blank to a tunnel-type heating furnace for heating, so that the low-melting-point PET fiber is hot-melted to bond the first PET fiber, the second PET fiber, and the third PET fiber together, and then using a cutting machine to cut the silent and environmentally friendly padding cotton 200 into sheets.

[0040] like Figure 3 The third embodiment shown is a method for manufacturing a silent and environmentally friendly lining cotton, comprising the following steps:

[0041] S1. Take materials. According to the weight percentage, weigh 30 parts of low-melting-point PET fiber, 30 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber respectively; the fineness of the low-melting-point PET fiber is 4.4d-6.67d, the fineness of the first PET fiber is 4.4d, the fineness of the second PET fiber is 2d, and the fineness of the third PET fiber is 0.8d; the length of the low-melting-point PET fiber, the length of the first PET fiber, the length of the second PET fiber, and the length of the third PET fiber are all 51mm; the morphological structure of the first PET fiber is solid straight fiber; the morphological structure of the second PET fiber is solid straight fiber, and the morphological structure of the third PET fiber is fine fiber; the melting point of the low-melting-point PET fiber is between 150 and 200°C, and the melting points of the first PET fiber, the second PET fiber, and the third PET fiber are all between 250°C and 255°C.

[0042] S2, opening, the fibers in step S1 are opened by passing through a first opener and a second opener in sequence.

[0043] S3, mixing, inputting the four opened fibers into two series-connected cotton blending machines for two blendings to form loose mixed fibers.

[0044] S4, laying the net, first use a horizontal net laying machine to lay the loose mixed fibers in a flat manner to form a loose and porous cotton blank bottom layer 1, then use a vertical net laying machine to lay the loose mixed fibers in a wavy manner on the top of the cotton blank bottom layer to form a loose and porous cotton blank core layer 2, and finally use a horizontal net laying machine to lay the loose mixed fibers in a flat manner on the top of the cotton blank core layer to form a loose and porous cotton blank top layer 3. The cotton blank bottom layer 1, the cotton blank core layer 2, and the cotton blank top layer 3 overlap from bottom to top to form a cotton blank with a sandwich structure. The thickness of the cotton blank bottom layer 1 is 20% of the thickness of the cotton blank, the thickness of the cotton blank core layer 2 is 60% of the thickness of the cotton blank, and the thickness of the cotton blank top layer 3 is 20% of the thickness of the cotton blank. The cotton blank bottom layer 1 and the cotton blank top layer 3 are used to protect the bottom and top of the cotton blank core layer 2 respectively to prevent the cotton blank core layer 2 from being torn due to pressure along the thickness direction of the silent environmental protection pad cotton 300.

[0045] S5, shaping, conveying the cotton blank to a tunnel-type heating furnace for heating, so that the low-melting-point PET fiber is hot-melted to bond the first PET fiber, the second PET fiber, and the third PET fiber together, and the cotton blank is cut into sheets of silent and environmentally friendly padding cotton 300 by a cutting machine.

[0046] In order to increase the cooling speed of the silent and environmentally friendly lining cotton after heating and shaping, in S5, a hair dryer is used to blow cold air between the tunnel heating furnace and the cutting machine for cooling.

[0047] In a comparative experiment, mixed cotton and upright cotton for manufacturing car pads were purchased from the market, and the manufacturing method of Example 3 of the present invention was used to manufacture silent and environmentally friendly padding cotton. The mixed cotton, upright cotton and the manufactured silent and environmentally friendly padding cotton were tested for odor, VOC and mildew. The test results are shown in Table 1 below.

[0048] Table 1. Test results of mixed cotton, upright cotton and silent environmentally friendly padding cotton

[0049]

[0050] From the test results in Table 1 above, it can be seen that the silent and environmentally friendly lining cotton manufactured according to the manufacturing method of Example 3 of the present invention has less odor, no mildew, and less volatile substances than the purchased mixed cotton and upright cotton.

[0051] In addition, the sound-proof and environmentally friendly padding cotton manufactured according to the manufacturing method of Example 3 of the present invention was subjected to accelerated aging test and durability test. The test results showed that even under extreme temperature and humidity conditions, the padding material of the present invention can maintain stable sound insulation performance and physical properties.

[0052] The principle of selecting PET fibers with different morphological structures: fine fibers have a smaller diameter than conventional PET fibers, which increases the surface area of ​​the silent and environmentally friendly pad, thereby improving the sound wave absorption efficiency; the internal structure of 3D hollow fibers helps to scatter and absorb sound waves inside the silent and environmentally friendly pad; high-curl fibers improve the acoustic damping characteristics by increasing the curvature of the fibers. The introduction of these special fibers not only improves the acoustic performance of the silent and environmentally friendly pad, but also meets the requirements of environmental protection and durability.

[0053] In order to further improve the sound insulation effect and formability of the silent and environmentally friendly liner, the present invention optimizes the process flow. For example, by accurately controlling the heating temperature and time, the melting degree of the low-melting-point PET fiber can be adjusted to achieve the best bonding effect; by adjusting the fiber mixing ratio, the liner material with different density and porosity can be customized to meet the needs of different application scenarios.

[0054] The present invention can use recycled PET fibers as the main raw material, thereby increasing the reuse rate of chemical materials and reducing the burden on the environment.

[0055] By optimizing the production process and material utilization, the present invention can achieve effective cost control without sacrificing the performance of the silent and environmentally friendly liner.

[0056] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to 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 manufacturing a silent and environmentally friendly lining cotton, characterized in that: The following steps are involved: S1. Take materials, and weigh 25 to 40 parts of low melting point PET fiber, 25 to 40 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber respectively according to weight parts; S2, opening, respectively passing the fibers in step S1 through a first opening machine and a second opening machine for opening; S3, mixing, inputting the four opened fibers into two series-connected cotton blending machines for two times of mixing to form loose mixed fibers; S4, laying the net, using a net laying machine to lay the loose mixed fibers into a loose and porous cotton blank; S5, shaping, conveying the cotton blank to a tunnel heating furnace for heating, so that the low melting point PET fiber is hot-melted to bond the first PET fiber, the second PET fiber, and the third PET fiber together, and using a cutting machine to cut into sheets of silent and environmentally friendly padding cotton.

2. The manufacturing method according to claim 1, characterized in that: In S1, 30 parts of low-melting-point PET fiber, 30 parts of first PET fiber, 20 parts of second PET fiber, and 20 parts of third PET fiber are weighed respectively according to weight.

3. The manufacturing method according to claim 1, characterized in that: The fineness of the low-melting-point PET fiber is 4.4d~6.67d, the fineness of the first PET fiber is 4.4d~6.67d, the fineness of the second PET fiber is 2d~2.5d, and the fineness of the third PET fiber is 0.8d~2d; the length of the low-melting-point PET fiber, the length of the first PET fiber, the length of the second PET fiber, and the length of the third PET fiber are all 51mm.

4. The manufacturing method according to claim 1, characterized in that: The morphological structure of the first PET fiber is solid straight fiber, or three-dimensional hollow fiber, or high curled fiber; the morphological structure of the second PET fiber is solid straight fiber, or three-dimensional hollow fiber, or high curled fiber, and the morphological structure of the third PET fiber is fine fiber.

5. The manufacturing method according to claim 1, characterized in that: The melting point of the low-melting-point PET fiber is between 150 and 200° C., and the melting points of the first PET fiber, the second PET fiber, and the third PET fiber are all between 250 and 255° C.

6. The manufacturing method according to claim 1, characterized in that: In S4, a horizontal web laying machine is used to lay the loose mixed fibers layer by layer in a flat laying manner to form a loose and porous cotton blank.

7. The manufacturing method according to claim 1, characterized in that: In S4, a vertical web laying machine is used to lay the loose mixed fibers in a wave-shaped laying manner to form a loose and porous cotton blank.

8. The manufacturing method according to claim 1, characterized in that: In S4, a horizontal web laying machine is first used to lay the loose mixed fibers in a flat manner to form a loose and porous cotton blank bottom layer, and then a vertical web laying machine is used to lay the loose mixed fibers in a wavy manner on the top of the cotton blank bottom layer to form a loose and porous cotton blank core layer. Finally, a horizontal web laying machine is used to lay the loose mixed fibers in a flat manner on the top of the cotton blank core layer to form a loose and porous cotton blank top layer. The cotton blank bottom layer, cotton blank core layer, and cotton blank top layer are overlapped in sequence from bottom to top to form a cotton blank with a sandwich structure.

9. The manufacturing method according to claim 8, characterized in that: The thickness of the bottom layer of the cotton blank is 20% of the thickness of the cotton blank, the thickness of the core layer of the cotton blank is 60% of the thickness of the cotton blank, and the thickness of the top layer of the cotton blank is 20% of the thickness of the cotton blank.

10. The manufacturing method according to claim 1, characterized in that: In the above S5, cooling is performed by blowing cold air between the tunnel type heating furnace and the cutting machine using a blower.

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