Sandwich structure filling process

Abstract

The invention relates to the technical field of textile materials, in particular to a sandwich structure filler process which comprises an upper layer structure, a middle layer structure and a lower layer structure. The upper layer structure comprises at least one of polyester fibers and soybean fibers; the middle layer structure comprises wool, mulberry silk or cotton; the lower layer structure comprises at least one of polyester fibers and soybean fibers; the upper-layer structure and the lower-layer structure are symmetrically arranged and have the same components. According to the invention, through the sandwich layered structure design and the synchronous lapping technology, and in combination with the needling entanglement, atomization glue spraying and hot-melt shaping process, the natural fiber filler is distinct in gradation, three-dimensional and full, and not easy to cake and drill down, the heat retention property and rebound resilience are improved, and the problems that the traditional filler is easy to collapse and high in maintenance cost are solved.

Description

Technical Field

[0001] This invention relates to the field of textile materials technology, specifically to a sandwich structure filling process. Background Technology

[0002] The development of traditional filling materials has evolved from natural fiber blends to composite applications of chemical fibers. Early fillings primarily relied on simple blends of natural fibers such as cotton, wool, and silk. While these offered good skin-friendliness and warmth, the lack of effective bonding between fibers led to uneven distribution and clumping. With the widespread adoption of synthetic fibers, materials like polyester fibers have become widely used due to their low cost and ease of processing. However, single-fiber fillings still suffer from significant shortcomings in breathability and comfort. In recent years, to balance the comfort of natural fibers with the stability of chemical fibers, the industry has attempted to blend or layer different fibers, but this still fails to fundamentally solve key issues such as fiber migration and structural collapse.

[0003] However, existing technologies still have significant drawbacks: on the one hand, the mixed filling process leads to disordered fiber distribution, which easily causes clumping and hardening due to friction and compression during use, affecting fluffiness and warmth retention; on the other hand, traditional layered composite technologies rely heavily on simple stacking processes, resulting in insufficient interlayer bonding, allowing fibers to easily escape from the fabric, and causing delamination and deformation after machine washing. Furthermore, the high proportion of natural fibers often results in poor fluffiness retention, making it difficult to recover its original shape after prolonged compression, greatly limiting its application in high-end home textiles and apparel. These shortcomings make it difficult for existing filling materials to meet the market's demand for durable, comfortable, easy-to-maintain, and high-performance products. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the technical solution provided by the present invention is as follows:

[0005] A sandwich-structured filling material includes an upper structure, a middle structure, and a lower structure; the upper structure includes at least one of polyester fiber and soybean fiber; the middle structure includes wool, silk, or cotton; the lower structure includes at least one of polyester fiber and soybean fiber; the upper and lower structures are symmetrically arranged and have the same composition.

[0006] Furthermore, a sandwich structure filler process includes the following steps:

[0007] (1) Fiber purification: Impurities are removed from raw fiber through vortex cyclone, metal detection and optical sorting;

[0008] (2) Fiber opening: The natural fibers are opened using a special carding machine;

[0009] (3) Layered composite forming: using double carding machines to synchronize laying, taking the lower fiber web as the base, filling wool, silk or cotton in the middle layer, and covering the upper fiber web to form a three-layer whole cotton embryo;

[0010] (4) Physical puncture entanglement: passing the whole cotton embryo through a high-strength needle punching machine to vertically penetrate the three layers of fibers to make them entangle;

[0011] (5) Surface glue spraying treatment: uniformly spraying micron-sized glue on the upper and lower surfaces of the whole cotton embryo;

[0012] (6) Hot melt setting: placing the whole cotton embryo after glue spraying in a high-temperature oven to make the glue melt to form a dense network composite film.

[0013] Further, in step (1), the impurity removal includes thoroughly removing dust, plant chippings, foreign color fibers and metal particles in the wool, cotton and silk, so that the impurity residue is ≤0.3%.

[0014] The advantages of the present application are:

[0015] 1. The present application finely opens natural fibers by a special carding machine, forms a three-layer sandwich structure of a lower base, a middle core fiber filling and an upper surface by combining double carding machine synchronization laying technology, so that the filling inside is clear in hierarchy; and then vertically penetrates the three layers of fibers by a high-strength needle punching machine to form a natural skeleton with deep entanglement, effectively prevents the entanglement and clumping of fibers in long-term use, realizes that the filling always maintains the visual effect and tactile experience of three-dimensional fullness, and completely solves the problem of disorder of traditional mixed filling.

[0016] 2. The present application builds a firm fiber network on the surface and between the layers of the filling through the synergistic effect of physical puncture entanglement, micron-sized atomized glue spraying and high-temperature oven hot melting to form a dense network composite film; the double barrier can effectively lock various fibers and prevent them from drilling out of fine fabrics such as high-count cotton and silk, so as to maintain zero drilling wool state no matter machine washing or long-term use, and significantly reduce maintenance cost.

[0017] 3. The present application disperses external pressure relying on the physical support force of the sandwich layered structure itself, combines needle punching and entanglement with glue spraying and hot setting process, maximizes the activation and maintenance of the lofting potential of natural fibers such as wool, silk and cotton; after repeated sitting, machine washing or long-term compression, the filling can still quickly recover to the original fullness, provides durable and stable warmth and deformation resistance, and overcomes the defect of easy flattening of natural fibers. DETAILED DESCRIPTION

[0018] The detailed description of the following embodiments is used to exemplarily illustrate the principles of the present application, but cannot be used to limit the scope of the present application, i.e. the sandwich structure filling process of the present application is not limited to the described embodiments.

[0019] A sandwich structure filler, comprising an upper layer structure, a middle layer structure and a lower layer structure; the upper layer structure comprises at least one of polyester fiber and soybean fiber; the middle layer structure comprises wool, mulberry silk or cotton; the lower layer structure comprises at least one of polyester fiber and soybean fiber; the upper layer structure and the lower layer structure are symmetrically arranged and have the same components.

[0020] The upper layer and the lower layer use polyester fiber or soybean fiber or a mixture of both, the middle layer uses wool, mulberry silk or cotton, and the components of the upper layer and the lower layer are symmetrically the same. This layered structure design effectively solves the uneven distribution and easy migration problems of traditional fillers caused by fiber mixing by concentrating high-value natural fibers in the middle layer and wrapping with symmetric upper and lower layers.

[0021] In specific embodiments,

[0022] Further, a sandwich structure filler process, comprising the following steps:

[0023] (1) Fiber purification: removing impurities from raw fibers by vortex cyclone, metal detection and optical sorting;

[0024] (2) Fiber opening: opening natural fibers through a special carding machine;

[0025] (3) Layered composite molding: using double carding machines to synchronize web laying, taking the lower layer fiber web as the base, filling wool, mulberry silk or cotton in the middle layer, and covering the upper layer fiber web to form a three-layer whole cotton embryo;

[0026] (4) Physical needling entanglement: passing the whole cotton embryo through a high-strength needle punching machine to vertically penetrate the three layers of fibers with hooks to entangle them;

[0027] (5) Surface glue spraying treatment: uniformly spraying micron-sized glue on the upper and lower surfaces of the whole cotton embryo;

[0028] (6) Hot melt setting: placing the whole cotton embryo after glue spraying in a high-temperature oven to melt the glue to form a dense network composite film.

[0029] The double carding machine synchronous web laying technology is used to realize precise layering of the lower layer base, the middle layer core fiber and the upper layer cover, and then the needle punching entanglement and the atomized glue spraying double consolidation process are used to form a stable structure. The needle punching process makes the three layers of fibers deeply entangled to form a natural skeleton, and the glue spraying and hot melting process forms a dense network composite film on the surface. For example, the minimum weight in this embodiment is: upper layer 40g, middle layer 20g, lower layer 40g.

[0030] Further, in step (1), the impurity removal includes thoroughly removing dust, plant chaff, off-color fibers and metal particles in wool, cotton and silk, so that the impurity residue is ≤0.3%.

[0031] In this embodiment, a triple purification system of vortex cyclone, metal detection and optical sorting is adopted to strictly control the impurity residue to be less than 0.3%. The fine purification treatment provides high-quality raw material basis for the subsequent process, effectively avoids the adverse effects of impurities on product performance, and ensures the safety and performance of the filler.

[0032] In specific embodiments, the following ratios can be implemented respectively:

[0033] The upper and lower layers each use 100% wool, and the middle layer is 100% polyester.

[0034] The upper and lower layers each use 100% wool, and the middle layer is 20% soybean and 80% polyester mixture.

[0035] The upper and lower layers each use 100% silk, and the middle layer is 100% polyester.

[0036] The upper and lower layers each use 100% silk, and the middle layer is 20% soybean and 80% polyester mixture.

[0037] The upper and lower layers each use 30% soybean and 70% polyester mixture, and the middle layer is 100% wool.

[0038] The upper and lower layers each use 100% polyester, and the middle layer is 100% wool.

[0039] The upper and lower layers each use 20% soybean and 80% polyester mixture, and the middle layer is 100% silk.

[0040] The upper and lower layers each use 100% polyester, and the middle layer is 100% silk.

[0041] The upper and lower layers each use 100% wool, and the middle layer is 100% polyester.

[0042] The upper and lower layers each use 100% wool, and the middle layer is a mixture of soybean and polyester.

[0043] The upper and lower layers each use 100% silk, and the middle layer is 100% polyester.

[0044] The upper and lower layers each use 100% silk, and the middle layer is a mixture of soybean and polyester.

[0045] The upper and lower layers each use a mixture of soybean and polyester, and the middle layer is 100% wool.

[0046] The upper and lower layers each use 100% polyester, and the middle layer is 100% wool.

[0047] The upper and lower layers each use a mixture of soybean and polyester, and the middle layer is 100% silk.

[0048] The upper and lower layers each use 100% polyester, and the middle layer is 100% silk.

[0049] The upper layer uses a soybean and polyester mixture, the middle layer is 100% cotton.

[0050] The upper layer is 100% polyester, the middle layer is 100% cotton, and the lower layer is 100% polyester.

[0051] It should be noted that the combination of various technical features in the case is not limited to the combination of the claims in the case or the combination of the specific embodiments described in the case. All technical features described in the case can be freely combined or combined in any way, unless contradictory to each other.

[0052] It should also be noted that the above examples are only specific embodiments of the present application. Obviously, the present application is not limited to the above examples, and similar changes or modifications made in accordance with the disclosure of the present application are directly derived or easily conceived by those skilled in the art, and should all fall within the scope of protection of the present application.

Claims

1. A sandwich structure filling, characterized by The upper layer structure includes at least one of polyester fiber and soybean fiber; the middle layer structure includes wool, silk or cotton; the lower layer structure includes at least one of polyester fiber and soybean fiber; the upper layer structure and the lower layer structure are symmetrically arranged and have the same components.

2. A sandwich structure filler process characterized by, The method comprises the following steps: (1) Fiber purification: removing impurities from raw fibers by vortex cyclone, metal detection and optical sorting; (2) Fiber opening: opening natural fibers by a special carding machine; (3) Layered composite forming: adopting double carding machines to synchronously lay a fiber web, taking the lower layer fiber web as a base, filling wool, silk or cotton in the middle layer, and covering the upper layer fiber web to form a three-layer whole cotton embryo; (4) Physical needling and entangling: vertically penetrating the three layers of fibers with hooks to make them entangle by a high-strength needle punching machine; (5) Surface glue spraying treatment: uniformly spraying glue in micrometer level on the upper and lower surfaces of the whole cotton embryo; (6) Hot melting and setting: placing the whole cotton embryo after glue spraying in a high-temperature oven to make the glue melt and form a dense net-shaped composite film. In step (1), the impurity removal includes thoroughly removing dust, plant chippings, foreign fibers and metal particles in wool, cotton and silk, so that the impurity residue is less than or equal to 0.3%.

3. A sandwich structure filler process according to claim 2, characterized in that: ​