Method for manufacturing multilayer ball cotton flocks

Abstract

Regarding multilayer composite fiber household spinning products, specifically, the present invention provides a method for manufacturing multilayer ball cotton flocks. [Solution] The multilayer ball cotton flock includes support layers on both sides, an intermediate ball cotton layer, and a transition layer at the interface between the two. The manufacturing method involves the steps of: creating a ball cotton layer of a certain thickness by uniformly mixing ball cotton, short fibers, and low-melting-point fibers in a weight ratio; and roll-pressing both sides of the ball cotton layer using a round roll whose surface is the hook side of Velcro®; and creating a support layer of a certain thickness by mixing short fibers and low-melting-point fibers in a weight ratio; joining the two support layers to both sides of the ball cotton layer, and then heating to set the shape. [Effect] By fixing the easily deformable and agglomerated ball cotton between two support layers, the resistance of the ball cotton to external forces is improved, making it less likely to collapse or agglomerate when subjected to force.

Description

Technical Field

[0001] The present invention relates to a multi-layer composite fiber household textile product, particularly to a method for manufacturing a ball cotton flock having a multi-layer structure.

Background Art

[0002] Ball cotton is a ball-shaped fiber aggregate obtained by kneading short fibers with a kneading machine, and the aggregate of ball cotton can be filled into fabrics such as clothing, household textiles, and toys as a filling material. As an aggregate of filling materials, it has a certain degree of heat retention, and has the advantages of being thin, light, and fluffy. Due to the independent characteristics of the ball structure of ball cotton, displacement is likely to occur when force is applied. If a product filled with ball cotton is subjected to force for a long time, the internal ball cotton will sink or aggregate, and in short, the structural deformation will affect the use of the product. To solve this problem, Chinese Patent CN11101292A discloses sandwich eco-cotton and its manufacturing method. The sandwich eco-cotton has elastic upper carded cotton layers and elastic lower carded cotton layers on both sides, sandwiching a pearl ball cotton sub-layer, and the pearl ball cotton sub-layer is connected by low-melting-point fibers. The sandwich eco-cotton installs carded cotton layers having both hardness and elasticity on both sides of the pearl ball cotton sub-layer, and improves the ability to resist deformation of the pearl ball cotton sub-layer to a certain extent while maintaining the advantages of fluffiness and softness of the pearl ball cotton sub-layer. However, the bonding between the carded cotton layer and the pearl ball cotton sub-layer is insufficient, and breakage or detachment may occur between the layers after long-term use. Furthermore, in the manufacturing method of the patent application, before forming, no external force is applied between the carded cotton layer and the pearl ball cotton sub-layer to make them adhere closely. If the layers do not adhere closely during operation, defective products with separated layers will occur after heating and shaping. <00e0012>

Summary of the Invention

Problems to be Solved by the Invention

[0003] In response to the problem that after prolonged use of products filled with existing ball cotton, the ball cotton collapses or aggregates, leading to product deformation, the present invention provides a method for manufacturing a multilayer ball cotton floc comprising support layers on both sides, an intermediate ball cotton layer, and a transition layer formed at the interface between the support layer and the ball cotton layer. The thickness ratio of the ball cotton layer to the support layer is 1:(0.2~1.2). [Means for solving the problem]

[0004] The present invention provides a method for manufacturing multilayer ball cotton flocks. Step 1 involves uniformly mixing ball cotton, short fibers, and low-melting-point fibers by weight, combing them onto a mesh sheet using a cotton combing machine to create a ball cotton layer of a certain thickness, and then using a round roll with a hook surface of Velcro (registered trademark) to roll-press both sides of the ball cotton layer to extract the short fibers and low-melting-point fibers from within the ball cotton layer. Step 2 involves taking short fibers and low-melting-point fibers in Step 1 and mixing them in a weight ratio to create a support layer of a certain thickness, joining the two support layers to both sides of the ball cotton layer, and then heating and shaping them.

[0005] Specifically, the material of the ball cotton is one or more of polyester, polyamide, polyethylene, or polypropylene, the short fibers are polyester fibers, polyamide fibers, polyethylene fibers, or polypropylene fibers, and the low-melting-point fibers are polyester fibers with a melting point of 130°C or lower.

[0006] Specifically, in step 1, the ball diameter of the ball cotton is 0.1 to 1.5 cm, the weight ratio of ball cotton, short fibers, and low-melting-point fibers is 1:(0.2 to 0.5):(0.05 to 0.1), and the hook density of the magic hook surface on the round roll surface is 16 to 144 hooks / cm². 2Furthermore, in step 2, the weight ratio of short fibers to low-melting-point fibers is 1:(0.1~0.2), and the temperature at which the fibers are heated and shaped is 135°C to 160°C.

[0007] In the manufacturing method provided by the present invention, before joining each support layer to the ball cotton layer, a side blow is performed on the ball cotton layer from the ball cotton layer toward the support layer. The purpose of the side blow on the ball cotton layer is to blow away the short fibers and low-melting-point fibers drawn from the surface of the ball cotton layer from the main body of the ball cotton layer, and for the support layer to push them back, thereby forming a clear transition layer.

[0008] Furthermore, the ball cotton fibers in this invention are supplemented with PCM material or heat storage material. By adding PCM material, the multilayer ball cotton floc in this invention acquires cooling properties. Alternatively, by adding heat storage material, the multilayer ball cotton floc in this invention acquires both heat absorption and heat storage properties. [Effects of the Invention]

[0009] This invention employs a multilayer structure design to fix the easily deformable and agglomerating ball cotton between two support layers, thereby improving the ball cotton's resistance to external forces, making it less prone to collapse and agglomeration when subjected to force, while maintaining the ball cotton's inherently light and fluffy properties. Furthermore, during the manufacturing process, this invention extracts short fibers and low-melting-point fibers from the ball cotton layer and, before joining them to the support layer, blows the extracted fibers away from the main body of the ball cotton layer by side blowing, forming an intertwined transition layer. In addition, some of the short fibers are woven into the support layer. During the heating and shaping process, the low-melting-point fibers melt and re-solidify, welding the entanglement points and contact points, improving the integrity of the multilayer ball cotton floc, making it less likely for the layers to separate when subjected to force, and extending the service life of the multilayer ball cotton floc. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic diagram of the equipment for a method of continuously producing multilayer ball cotton flocs provided by the present invention. [Figure 2] This is a schematic diagram of a cross-sectional view of a multilayer ball cotton flock obtained in the present invention. [Modes for carrying out the invention]

[0011] The present invention will be described below based on examples, but these examples are for illustrative purposes only and do not limit the scope of the present invention.

[0012] This is a method for sustainably producing multilayer ball cotton flocs. As shown in Figure 2, the structure of the multilayer ball cotton flocs comprises an intermediate ball cotton layer 1, upper support layers 6 and lower support layers 9 on both sides of the ball cotton layer 1, and transition layers 1-1 between the ball cotton layer 1 and the upper and lower support layers 6 and 9. The thicknesses of the ball cotton layer 1, upper support layer 6, and lower support layer 9 are 4 cm, 0.8 cm, and 1 cm, respectively, and the ball diameter of the ball cotton in the ball cotton layer 1 is 0.3 cm. The material of the ball cotton is 0.9D+3D PET short fibers, with 0.5 wt% graphene powder added to the 3D PET short fibers, the short fibers being 1.5D PET short fibers, and the low-melting-point fibers being 2080 low-melting-point polyester fibers with a melting point of 120°C.

[0013] Referring to the schematic diagram of the equipment shown in Figure 1, the method for continuously producing multilayer ball cotton flocs in this embodiment includes the following steps.

[0014] Step 1: Ball cotton, short fibers, and low-melting-point fibers are mixed equally in a weight ratio of 1:0.25:0.1. Then, short fibers and low-melting-point fibers are taken in a weight ratio of 1:0.2 and mixed equally to divide into two parts. Each of the three mixed fibers is combed using a cotton combing machine to form a continuous mesh sheet of the required thickness, namely a ball cotton layer 1, an upper support layer 6, and a lower support layer 9. Step 2: While maintaining the operation of the cotton combing machine, the ends of the continuous sheets of ball cotton layer 1, upper support layer 6, and lower support layer 9 are guided to the ball cotton layer conveyor 2, upper support layer conveyor 5, and lower support layer conveyor 8, respectively. The three conveyors are activated, and the two round rolls 3 with Velcro® attached, located in the ball cotton layer conveyor 2, are also activated to draw short fibers and low-melting-point fibers from ball cotton layer 1. The hook density on the surface of the round rolls 3 is 64 hooks / cm². 2 The roll surface of the round roll 3 protrudes 0.3 cm from the surface of the ball cotton layer conveyor 2. Furthermore, the upper dryer 4 built into the ball cotton layer conveyor 2 is activated to blow away the pulled-out short fibers and low-melting-point fibers from the upper surface of the ball cotton layer 1. Step 3: After blowing away the short fibers and low-melting-point fibers from the upper surface of the ball cotton layer 1, the upper support layer 6 on the upper support layer conveyor 5 is guided to the ball cotton layer 1 and joined together. The lower dryer 7, positioned above, is also activated to further join the upper support layer 6 and the ball cotton layer 1 while blowing away the pulled-out short fibers and low-melting-point fibers from the lower surface of the ball cotton layer 1. Step 4: After blowing away the short fibers and low-melting-point fibers from the underside of the ball cotton layer 1, the ball cotton layer 1 is guided to the lower support layer 9 on the lower support layer conveyor 8. After ensuring that each layer is joined, the lower support layer conveyor 8 introduces the stacked three-layer structure into the heating shaping box 10. The heating temperature of the heating shaping box 10 is set to 160°C to melt the low-melting-point fibers. Step 5: Remove from the heated shaping box 10, allow to cool naturally, trim off any scraps from the edges, and roll up the product.

[0015] In step 3, activating the lower dryer 7 after joining the upper support layer 6 and the ball cotton layer 1 not only blows away any pulled-out short fibers or low-melting-point fibers from the underside of the ball cotton layer 1, but also makes the bond between the upper support layer 6 and the ball cotton layer 1 tighter. In step 4, the ball cotton layer 1 joined to the upper support layer 6 can join its underside to the lower support layer 9 by its own weight. both sides After the upper support layer 6 and the lower support layer 9 are tightly joined, the ball cotton layer 1 is introduced into the heated shaping box 10 and heated or shaped, significantly reducing the probability of separation between layers and resulting in defective products during long-distance transportation.

[0016] In this embodiment, the integrity of the multilayer ball cotton floc is improved in two ways: by drawing out short fibers and low-melting-point fibers from the ball cotton layer 1 to form distinct transition layers 1-1, thereby increasing the interlayer bonding force between the ball cotton layer 1 and the upper support layer 6 and lower support layer 9; and by reducing the probability of separation between the layers of the ball cotton layer 1 and the upper support layer 6 and lower support layer 9 during the manufacturing process by combining side blowing, self-weight, and shortening the transport distance. Through these two aspects, the method of this embodiment makes it possible to produce a multilayer ball cotton floc with tightly bonded layers.

[0017] The foregoing description represents only preferred embodiments of the present invention and does not limit it. Any modifications, equivalent substitutions, improvements, etc., made in accordance with the spirit and principles of the present invention are all within the scope of protection of the present invention. [Explanation of Symbols]

[0018] 1. Ball cotton layer; 1-1. Transition layer; 2. Ball cotton layer conveyor; 3. Round roll with Velcro®; 4. Upper dryer; 5. Upper support layer conveyor; 6. Upper support layer; 7. Lower dryer; 8. Lower support layer conveyor; 9. Lower support layer; 10. Heated shaping box.

Claims

1. A method for manufacturing multilayer ball cotton flocks, The multilayer ball cotton floc comprises support layers on both sides, an intermediate ball cotton layer, and a transition layer formed at the interface between the support layer and the ball cotton layer, and the method for manufacturing the multilayer ball cotton floc is as follows: Step 1 involves uniformly mixing ball cotton, short fibers, and low-melting-point fibers by weight to create a ball cotton layer of a certain thickness, and then roll-pressing both sides of the ball cotton layer using a round roll whose surface is the hook side of Velcro (registered trademark). A method for producing a multilayer ball cotton floc, characterized by comprising step 2, which involves mixing short fibers and low-melting-point fibers in a weight ratio to create a support layer of a certain thickness, joining the two support layers to both sides of a ball cotton layer, and heating to set the shape.

2. A method for producing a multilayer ball cotton floc according to claim 1, characterized in that the material of the ball cotton is one or more of polyester, polyamide, polyethylene, or polypropylene, the short fibers are any of polyester fibers, polyamide fibers, polyethylene fibers, or polypropylene fibers, and the low melting point fibers are polyester fibers with a melting point of 130°C or lower.

3. A method for producing a multilayer ball cotton floc according to claim 2, characterized in that, in step 1, the ball diameter of the ball cotton is 0.1 to 1.5 cm, the weight ratio of ball cotton, short fibers and low-melting-point fibers is 1:(0.2 to 0.5):(0.05 to 0.1), and in step 2, the weight ratio of short fibers to low-melting-point fibers is 1:(0.1 to 0.2).

4. In step 1, the hook density of the magic hook surface on the round roll surface is 16 to 144 hooks / cm². ２ A method for producing a multilayer ball cotton flock according to any one of claims 1 to 3, characterized in that

5. A method for manufacturing a multilayer ball cotton floc according to any one of claims 1 to 3, characterized in that, in step 2, before joining the support layer to the ball cotton layer, a side blow is performed on the ball cotton layer from the ball cotton layer toward the support layer.

6. A method for producing a multilayer ball cotton floc according to any one of claims 1 to 3, characterized in that the temperature at which the ball cotton floc is heated and shaped in step 2 is 135°C to 160°C.

7. A method for producing a multilayer ball cotton floc according to any one of claims 1 to 3, characterized in that the thickness ratio of the ball cotton layer to the support layer is 1:(0.2 to 1.2).

8. A method for producing a multilayer ball cotton floc according to any one of claims 1 to 3, characterized in that a PCM material or a heat storage material is added to the ball cotton fibers.

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