Three-dimensional high-density filling layer structure and thermal insulation product

Abstract

The three-dimensional high-density filling layer structure is formed by combining fiber fillers, is used for heat insulation and warm keeping, and comprises a plurality of filling parts, the outer surfaces of the adjacent filling parts are in point contact and have gaps, so that the filling layer forms a three-dimensional net-shaped structure, and micropores are formed in the surfaces of the filling parts and are used for absorbing moisture and releasing sweat. The filler is made into a plurality of balls, uniformly distributed micro air bags are formed through point contact, a static air layer is stored, the use is more convenient, and the pressure resistance and the bulkiness are better.

Description

TECHNICAL FIELD

[0001] The present application relates to a filling for thermal insulation products, in particular to a three-dimensional high-density filling layer structure and a thermal insulation product. BACKGROUND

[0002] As a core component of thermal insulation and heat insulation products, the filling plays a key role in maintaining product temperature stability and ensuring user comfort. Common fillings on the current market include natural cotton, down and synthetic fiber batting. Cotton is widely used in some thermal insulation products due to its natural and skin-friendly properties. Down is light and has excellent thermal insulation and loftiness, and a high recovery rate after compression. Synthetic fiber batting occupies a certain share in many daily heat insulation products due to its low cost and easy processing.

[0003] However, these existing fillings have many defects in actual use. On the one hand, although down fillings have excellent thermal performance, they are prone to moisture and have an allergy risk. In order to obtain feathers, not only a large number of waterfowl need to be raised, but also many processes such as feather picking, sorting, disinfection, and degreasing are required, which makes the price of products using feathers as fillings high, limiting their popularity. Cotton and synthetic fiber batting have uneven fiber distribution or loose structure, which can cause problems such as insufficient thermal performance, poor air permeability, and easy clumping. Synthetic fiber materials are prone to static electricity, affecting comfort, and also attract dust, affecting product cleanliness and aesthetics.

[0004] On the other hand, from the structure, traditional fillings are mostly in sheet or fluffy form, have poor washability, cannot form a stable air layer, and have low thermal resistance efficiency, making it difficult to achieve ideal results in both cold environments for warmth and hot environments for heat insulation. SUMMARY

[0005] The present application provides a three-dimensional high-density filling layer structure and a thermal insulation product, which is convenient to use and improves the compression resistance and loftiness.

[0006] According to an aspect of the present application, in one embodiment, a three-dimensional high-density filling layer structure is provided, which is formed by a combination of fiber fillings and used for heat insulation and warmth retention, comprising: a plurality of filling parts, the outer surfaces of adjacent filling parts are point-contacted and have gaps, so that the filling layer forms a three-dimensional mesh structure, the surface of the filling part has micropores, and the micropores are used for moisture absorption and sweat release.

[0007] In another embodiment, the outer surface of the filling part is provided as an arc surface.

[0008] In another embodiment, the filling part is provided as a spherical shape.

[0009] In another embodiment, the microporous aperture is 10-50 μm.

[0010] In another embodiment, the filling part comprises a solidified layer formed on the surface of the filling part, which is used to fix the spherical surface of the filling part.

[0011] In another embodiment, the filling part is formed by winding the fiber filling into a spherical structure by high-speed airflow or mechanical friction.

[0012] In another embodiment, the outer surface of the filling part is provided with a fixing layer, which is used to connect the filling parts.

[0013] In another embodiment, the fixing layer is formed by gluing the fiber filling with a hot melt adhesive.

[0014] According to an aspect of the present application, in one embodiment, a thermal insulation product is provided, comprising: at least two layers of fabric and a three-dimensional high-density filling layer structure as described above, the filling layer being filled between any two layers of fabric.

[0015] In another embodiment, the filling layer is provided as a single layer or multiple layers, and the diameters of the layers of the filling parts are different, so as to form a density gradient.

[0016] The three-dimensional high-density filling layer structure and the thermal insulation product according to the above embodiments are more convenient to use because the filling layer is composed of multiple filling parts, the filling parts form a three-dimensional reticular structure through point contact, reduce heat convection, and at the same time retain air permeation channels, balance the thermal insulation and air permeability, the filling layer as a whole forms uniformly distributed micro air bags, stores a static air layer, thereby significantly improving the thermal resistance value, and further improving the pressure resistance and loftiness of the filling layer and the corresponding thermal insulation product. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 FIG. 1 is a schematic diagram of the overall structure of a three-dimensional high-density filling layer structure and a thermal insulation product according to an embodiment of the present application;

[0018] Figure 2 FIG. 2 is a schematic diagram of the overall structure of a three-dimensional high-density filling layer structure and a thermal insulation product according to another embodiment of the present application;

[0019] Figure 3 FIG. 3 is a schematic diagram of the structure of a filling part according to an embodiment of the present application;

[0020] Figure 4 FIG. 4 is a schematic diagram of the effect of a three-dimensional high-density filling layer structure and a thermal insulation product according to an embodiment of the present application.

[0021] FIG. 5 is a schematic diagram of the effect of a three-dimensional high-density filling layer structure and a thermal insulation product according to another embodiment of the present application. DETAILED DESCRIPTION FIG. 5 is a schematic diagram of the effect of a three-dimensional high-density filling layer structure and a thermal insulation product according to another embodiment of the present application.

[0022] The application will be described in further detail below with reference to the drawings. Like elements in different embodiments are denoted by like reference numerals. In the following description, numerous specific details are described to provide a thorough understanding of the application. However, it will be apparent to one skilled in the art that the application can be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail, so as not to unnecessarily obscure aspects of the application.

[0023] In addition, the features, operations or characteristics described in the specification can be combined in any appropriate manner to form various embodiments, and the steps of the operations involved in each embodiment can be sequentially adjusted or adjusted in a manner that can be easily seen by those skilled in the art. Therefore, the specification and drawings are only for the purpose of clearly describing one embodiment, and do not mean that the composition and / or order is necessary.

[0024] The serial numbers of the components in this paper, such as "first", "second", etc., are only used to distinguish the described objects, and have no technical meaning. The "connection" and "coupling" in this application include direct and indirect connections (couplings) unless otherwise specified.

[0025] The common fillers on the current market include natural cotton, down and synthetic fiber flakes; these existing fillers have exposed many defects in actual use. On the one hand, although the down filler has outstanding warmth retention performance, it is easy to get wet and has an allergy risk, and in order to obtain feathers, not only a large number of waterfowl need to be raised, but also many processes such as feather picking, sorting, disinfection and degreasing are needed, so that the price of the product using feathers as filler is high, which limits its popularity. Cotton and synthetic fiber flakes have uneven fiber distribution or loose structure, and are prone to problems such as insufficient warmth retention, poor air permeability, and easy caking. Synthetic fiber materials are prone to static electricity, affecting comfort, and also adsorbing dust, affecting the cleanliness and aesthetics of the product. On the other hand, from the structure, the traditional filler is mostly in the form of sheet or fluff, which cannot form a stable air layer, resulting in low thermal resistance efficiency, and it is difficult to achieve the ideal effect whether in cold environment or in hot environment.

[0026] The application provides a three-dimensional high-density filling layer structure and a thermal insulation product, which forms a uniform distribution of micro air bags by point contact by making the filler into a plurality of spherical shapes, and stores a static air layer, which is more convenient to use, has better pressure resistance and loftiness.

[0027] According to an aspect of the present application, please refer to Figure 1 , Figure 2 and Figure 3 , in an embodiment, a three-dimensional high-density filling layer structure is provided, which is formed by a combination of fiber fillers and used for thermal insulation, comprising: a plurality of filling parts 1, the outer surfaces of adjacent filling parts 1 are point-contacted and have gaps, so that the filling layer forms a three-dimensional network structure, the surface of the filling part 1 has micropores, and the micropores are used for moisture absorption and sweat release.

[0028] In the present embodiment, by setting the corresponding filler as a special-shaped filling part 1, the filling layer is composed of a plurality of filling parts 1, which is more convenient to use, the filling parts 1 form a three-dimensional network structure through point contact, reduce heat convection, and at the same time retain air permeation channels, balance the thermal insulation and air permeability, the filling layer as a whole forms uniformly distributed micro air bags, stores a layer of static air, thereby significantly improves the thermal resistance value, and further improves the pressure resistance and loftiness of the filling layer and the corresponding thermal insulation product.

[0029] Further, please refer to Figure 1 , Figure 2 and Figure 3 , the outer surface of the filling part 1 is set as a curved surface; the contact between the curved surfaces can achieve point contact, reduce the contact area, and increase the space layer; specifically, the filling part 1 is set as a spherical shape, and the diameter range is preferably 2mm-10mm, the adjacent spherical bodies are point-contacted through the outer surfaces to form a three-dimensional network structure, and the outer surface of the spherical shape can ensure that the point contact forms the largest space air bag, and the warmth can be improved by 20%-40%.

[0030] Further, please refer to Figure 3 , the filling part 1 winds the fiber filler into a spherical structure by high-speed airflow; the filling part 1 includes a solidification layer formed on the surface of the filling part, and the solidification layer is used to fix the spherical surface of the filling part. There will be a single fiber branch on the surface of the fiber sphere, which is solidified by modifying the fiber to enhance the pressure resistance of the sphere (such as pressure resistance ≥50kPa) and prevent deformation after long-term use. The filling part of the spherical structure is solidified after special surface treatment (such as plasma modification or bio-based coating), which reduces the shedding of fibers, prolongs the service life, and can be selected from natural and environmentally friendly materials and degradable materials (such as cotton fibers, PLA fibers, etc.).

[0031] Further, please refer to Figure 1 , the filling part 1 is arranged after being formed into a spherical shape and being solidified, and a fixing layer is arranged on the outer surface of the plurality of spherical shapes, and the fixing layer is used to connect the plurality of filling parts 1. In the present embodiment, the fixing layer is formed by adhering the fiber filler with a hot melt adhesive; that is, by a mechanical-airflow composite process, the short fibers are wound into a spherical core by high-speed airflow or mechanical friction, arranged according to requirements, and supplemented with a hot melt adhesive.

[0032] In the present embodiment, the hot melt adhesive can adopt existing adhesive materials, and the filling part 1 is subjected to staged particle size screening after forming, and a multi-stage vibrating screening device is adopted to ensure that the standard deviation of the ball diameter of the filling part 1 is ≤1 mm, thereby improving the filling uniformity.

[0033] Further, the micropores are uniformly distributed on the surface of the ball, and the pore size is preferably in the range of 10 μm-50 μm, and the pore density is 50-80 per square centimeter, thereby enhancing the moisture absorption and sweat releasing function.

[0034] In the present application, the fiber filling of the filling part 1 is pretreated, such as impurity removal and oiling, during the forming process, and then the short fibers are wound into a ball core by using a mechanical-air flow combined process through high-speed airflow, and the filling part 1 is subjected to staged particle size screening after forming by using a multi-stage vibrating screening device, the ball of the filling part 1 is subjected to surface treatment to enhance the compression strength of the ball, and the fixed and arranged ball is subjected to hot melt setting by using a hot melt adhesive, and finally the finished product is packaged for subsequent use.

[0035] Further, the filling layer, i.e. the plurality of filling parts 1, forms a three-dimensional network structure through point contact, thereby being compatible with a variety of fiber materials (cotton, polyester, regenerated fiber, etc.) and ball forming processes (hot melt bonding, airflow balling, mechanical friction balling), and reducing the production cost.

[0036] The spherical filling part disclosed in the present embodiment can be stored separately, and the three-dimensional high-density filling layer structure formed by combining the same can also be stored separately, and both of them can be used to replace the traditional down, cotton, chemical fiber fluffy or sheet-shaped filling material according to requirements.

[0037] In the present application, the production process flow of the three-dimensional high-density filling layer structure includes the following steps:

[0038] Fiber selection: the fiber filling of the three-dimensional high-density filling layer structure can select cotton fiber, wool fiber, silk, chemical fiber, etc. according to requirements; the fiber length is selected to be 25 mm-35 mm, which is beneficial to three-dimensional winding, is not easy to disperse, and can reduce the amount of adhesive;

[0039] Opening: the baled fibers are unpacked to form a fluffy fluffy fiber collection;

[0040] Impurity removal: the impurities attached to the fibers are removed to ensure the purity of the fibers;

[0041] Carding: the fibers are carded into fiber bundles with a certain orientation, and further impurities are removed, such as removing impurities and short fibers in the fibers, to ensure the ball forming quality;

[0042] Highly random fiber laying: the fiber web after carding is laid in multiple layers to form a fiber web with a multi-layer structure, improving the anisotropy of the fiber and the randomness, which is beneficial to the subsequent fiber entanglement;

[0043] Cotton grabbing: a cotton grabbing machine or other mechanical equipment is used to grab a certain weight of fiber web. In this embodiment, the mechanical equipment is equipped with a high-precision weight detector, and the grabbed cotton is weighed to ensure that the weight of each bundle of grabbed cotton is 0.2g-0.8g;

[0044] Mechanical friction balling: the grabbed fiber bundle is rubbed into a ball under a mechanical platform, i.e., the filling part 1 in this embodiment (for example, a mechanical-airflow composite process is used to wind short fibers into a ball core by high-speed airflow), with a diameter of 2mm-10mm;

[0045] Further, in this embodiment, the diameter of the filling part 1 of the garment is preferably 2mm-5mm, and the diameter of the filling part 1 of the bedding is preferably 5mm-10mm;

[0046] Screening of the ball: the ball-shaped filling part 1 is screened according to the diameter, and the ball-shaped filling part 1 with the same diameter and weight is sucked into a forming cavity through a screen;

[0047] Surface solidification: after the fiber ball filling part 1 is formed, single fibers may protrude from the surface. The surface of the ball-shaped filling part 1 is solidified to prevent the ball from being deformed by extrusion. For example, biological glue (such as starch glue) is sprayed on the surface of the filling part 1 to fix the surface of the single ball, or a siloxane coupling agent or other adhesives with the function of solidifying the surface of the ball are applied to the surface of the filling part 1, thereby forming a solidification layer in this embodiment to solidify the surface of the filling part 1. The amount of biological glue used is 3%-5%;

[0048] Beating: the solidified fiber ball filling part 1 is placed in an airflow bin and rolled up and down to beat, so that the fibers inside the ball are rearranged to restore the loftiness;

[0049] Atomization bonding: the ball-shaped filling part 1 is arranged as required, and an atomized adhesive (hot melt adhesive) is sprayed to fix the filling parts of multiple single-layer balls, thereby forming a fixing layer in this embodiment. After the multiple balls are bonded, a single-layer three-dimensional high-density filling layer structure is formed. The amount of adhesive used is 5%-8%. If the amount of adhesive is too small, the balls are easy to scatter, and if the amount of adhesive is too large, the balls are easy to harden and lose elasticity. Finally, a three-dimensional high-density filling layer structure in this embodiment is formed.

[0050] According to this embodiment, when making a garment filler or bedding filler, different sizes and combinations of ball-shaped filling parts can be selected for stacking, which has better loftiness than traditional fillers and can be washed multiple times.

[0051] Specifically, according to another aspect of the present application, please refer to Figure 1 ,Figure 2 、 Figure 3 and Figure 4 In one embodiment, a thermal insulation product is provided, comprising at least two layers of fabric 2 and a three-dimensional high-density filling layer structure as described above, the filling layer being filled between any two layers of fabric 2, the filling layer being arranged as a single layer or multiple layers, in this embodiment, the filling layer is arranged as multiple layers, the three-dimensional high-density filling layer structure is arranged as a multi-layer structure, and the diameters of the filling parts 1 of each layer are different to form a density gradient, preferably the surface microspheres (2mm-3mm) are closely arranged to fit the fabric 2 to improve the fit comfort, and the inner layer macro-spheres (3mm-5mm) form a thick air layer to enhance the thermal insulation.

[0052] Please refer to Figure 1 、 Figure 2 and Figure 4 The three-dimensional high-density filling layer structure can be arranged as two layers, three layers or more, and the arrangement of the filling parts of each layer can be distributed in a fixed and uniform manner, or in a staggered and dispersed manner. Specifically, it can be selected according to different materials, application scenarios and thicknesses.

[0053] On the basis of the embodiments of the present application, the diameter of the filling part 1 of the garment is preferably 2mm-5mm, and the diameter of the filling part 1 of the bedding is preferably 5mm-10mm. By controlling the diameter of the microspheres (such as 2mm-10mm), different application scenarios can be adapted, and the problem of local accumulation or collapse of traditional fillers can be avoided.

[0054] In other embodiments, the two layers of fabric 2 are selected according to the environment, the inner layer can use pure cotton skin-friendly fabric, and the outer layer can use nylon tear-resistant fabric for better durability, a diamond quilting pattern is used to fix the filling layer, and high-frequency welding is used to fix the edge of the thermal insulation product. Through structural optimization and process innovation, the thermal insulation, comfort and durability are significantly improved, and the diversified market demand is met.

[0055] The above application of specific examples to the present application is only used to help understand the present application and does not limit the present application. For those skilled in the art to which the present application belongs, according to the idea of the present application, a number of simple deductions, modifications or substitutions can be made.

Claims

1. A three-dimensional volumetric high-density packing layer structure formed by combining a fiber filler and used for thermal insulation, characterized by, The application relates to a three-dimensional high-density filling layer structure, comprising: a plurality of filling parts (1), adjacent filling parts (1) are in point contact and have gaps between outer surfaces of the filling parts (1), so that the filling layer forms a three-dimensional net structure, the surface of the filling part (1) has micropores, and the micropores are used for moisture absorption and sweat release.

2. The three-dimensional, high-density packing layer structure of claim 1, wherein, The outer surface of the filling part (1) is provided as a curved surface.

3. The three-dimensional, high-density packing layer structure of claim 2, wherein, The filling part (1) is provided as a spherical shape.

4. The three-dimensional, high-density packing layer structure of claim 1, wherein, The micropore aperture is 10-50 microns.

5. The three-dimensional, high-density packing layer structure of claim 1, wherein, The filling part (1) comprises a solidified layer formed on the surface of the filling part, and the solidified layer is used for fixing the spherical surface of the filling part (1).

6. The three-dimensional, high-density packing layer structure of claim 3, wherein, The filling part (1) is wound into a spherical structure by high-speed airflow or mechanical friction.

7. The three-dimensional, high-density packing layer structure of claim 6, wherein, The outer surface of the plurality of filling parts (1) is provided with a fixing layer, and the fixing layer is used for connecting the plurality of filling parts (1).

8. The three-dimensional, high-density packing layer structure of claim 7, wherein, The fixing layer is formed by using hot melt adhesive to bond the fiber filling.

9. An insulating product, characterized in that The application further relates to a fabric structure, comprising: at least two layers of fabric (2) and the three-dimensional high-density filling layer structure according to any one of claims 1-8, the three-dimensional high-density filling layer structure being arranged between any two layers of fabric (2).

10. The insulating product according to claim 9, characterized in that The filling layer is provided as a single layer or multiple layers, and the diameters of the multiple layers of the filling part (1) are different, so as to form a density gradient.

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