Multi-layered spherical cotton flakes

Abstract

To provide multi-layered spherical cotton flakes which are unlikely to crumble or aggregate after receiving force, and at the same time, the quality of the spherical cotton itself is light and can maintain fluffy properties. [Solution] From top to bottom, there are upper support layer 1-1, upper reinforcing layer 3-1, ball-shaped cotton layer 2-0, lower reinforcing layer 3-2, and lower support layer 1-2. The upper support layer and the lower support layer are made of the same short fiber material. The ball-shaped cotton layer is made of uniformly distributed fiber balls of different diameters and inter-ball fibers filled between the fiber balls. The upper reinforcing layer and the lower reinforcing layer are made of randomly distributed low melting point fibers, short fiber extensions, and inter-ball fiber extensions. The low melting point fibers melt to form welds, and two or three of the low melting point fibers, short fibers, and inter-ball fibers are entangled to form clusters. A multi-layer structure design is adopted to fix the ball-shaped cotton, which is prone to deformation and aggregation, between two support layers, and the reinforcing layer is used to further strengthen the ball-shaped cotton and the support layer, improving the ability of the ball-shaped cotton to resist external forces.

Description

[Technical field]

[0001] The present invention relates to the field of functional fiber filling, especially to multi-layered spherical cotton flakes. [Background technology]

[0002] The ball-shaped cotton is a fiber aggregate with a spherical structure formed by kneading short fibers with a ball-shaped kneading machine, and the ball-shaped cotton aggregate can be used as a filler to fill textiles such as clothing, home spinning, and toys. As a filler aggregate, it has the advantages of being thin and fluffy in addition to having a certain heat retention. Since the ball-shaped cotton has a spherical structure, it is easy to be displaced after being subjected to force, and when a product filled with the ball-shaped cotton is subjected to force for a long time, the ball-shaped cotton inside it will collapse or aggregate, which may affect the normal use of the product due to structural deformation. Summary of the Invention [Means for solving the problem]

[0003] In response to the problem that existing products filled with cotton balls tend to crumble or clump together after long-term use, resulting in deformation of the product, the present invention provides multi-layered cotton ball flakes, which include supporting fiber layers on both sides, a heat-retaining cotton ball layer in the middle, and a reinforcing layer between the supporting fiber layer and the heat-retaining cotton ball layer.

[0004] The multi-layered spherical cotton flakes of the present invention are provided, from top to bottom, with an upper support layer, an upper reinforcing layer, a spherical cotton layer, a lower reinforcing layer and a lower support layer, the upper support layer and the lower support layer being made of short fibers of the same material, the spherical cotton layer being composed of uniformly dispersed fiber balls of different diameters and inter-spherical fibers filled between the fiber balls, the upper reinforcing layer and the lower reinforcing layer being composed of disorderly dispersed low-melting point fibers, extensions of short fibers and extensions of inter-spherical fibers, the low-melting point fibers melting to form welds, and two or three types of low-melting point fibers, short fibers and inter-spherical fibers entangled to form clusters.

[0005] In the present invention, the height ratio of the upper support layer, the upper reinforcing layer, the spherical cotton layer, the lower reinforcing layer and the lower support layer is (0.2~1.2):(0.05~0.1):1:(0.05~0.1):(0.2~1.2), where the diameter of the fiber balls is 0.1~1.5cm.

[0006] Specifically, the staple fiber of the supporting fiber layer is selected from polyester fiber, polyamide fiber, polyethylene fiber or polypropylene fiber, the material of the fiber balls and the inter-ball fibers is the same, which is one of polyester, polyamide, polyethylene or polypropylene, the fiber balls and the inter-ball fibers both contain PCM material or heat storage material, the addition of PCM material gives the multi-layered cotton flakes of the present invention a cooling property, and the addition of heat storage material gives the multi-layered cotton flakes of the present invention a heat absorption and heat storage property. The material of the low melting point fiber is polyester fiber, and the melting point is ≦130℃.

[0007] Furthermore, to increase the strength of the overall structure, a certain percentage of low melting point fiber 3-3 can be added to both the support fiber layer and the spherical cotton layer. 2-30 wt% of low melting point fiber is added to the upper support layer and the lower support layer, and 2-15 wt% of low melting point fiber is added to the spherical cotton layer. Effect of the Invention

[0008] This invention adopts a multi-layered design, fixes the cotton balls, which are prone to deformation and aggregation, between two supporting layers, and uses a reinforcing layer to further strengthen the cotton balls and the supporting layer, improving the ability of the cotton balls to resist external forces, making them less likely to collapse or aggregate after being subjected to force, while at the same time maintaining the light and fluffy quality of the cotton balls themselves. The low melting point fiber in the reinforcing layer of this invention can fill the fiber gaps between the supporting layer and the cotton balls on the surface, which can further increase the binding strength between each layer after various fibers are intertwined with each other, and can avoid the problem of interlayer separation of the multi-layered cotton balls after long-term use. [Brief description of the drawings]

[0009] [Figure 1]1 is a schematic diagram of the structure of the multi-layered spherical cotton flakes of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention will be described below using examples, but the examples given are used only to explain the present invention and are not used to limit the scope of the present invention.

[0011] Example 1 As shown in FIG. 1, the multi-layered spherical cotton flakes are provided with an upper support layer 1-1, an upper reinforcing layer 3-1, a spherical cotton layer 2-0, a lower reinforcing layer 3-2, and a lower support layer 1-2 from top to bottom. The upper support layer 1-1 and the lower support layer 1-2 are made of short fibers of the same material. The spherical cotton layer 2-0 is made of uniformly dispersed fiber balls 2-1 of different diameters and inter-spherical fibers 2-1 filled between the fiber balls 2-1. 2, the upper reinforcing layer 3-1 and the lower reinforcing layer 3-2 are composed of randomly dispersed low-melting-point fibers 3-3, extensions of the short fibers and extensions of the inter-spherical fibers 2-2, the low-melting-point fibers 3-3 melt to form welds 3-4, and any two or three of the low-melting-point fibers 3-3, short fibers and inter-spherical fibers 2-2 are entangled to form clusters 3-5, and the low-melting-point fibers 3-3 are polyester fibers having a melting point of 130°C or less.

[0012] The thicknesses of the upper support layer 1-1, the upper reinforcing layer 3-1, the spherical cotton layer 2-0, the lower reinforcing layer 3-2 and the lower support layer 1-2 are 0.5 cm, 0.05 cm, 1 cm, 0.05 cm and 0.5 cm, respectively.

[0013] Example 2 As shown in FIG. 1, the multi-layered spherical cotton flakes are provided with an upper support layer 1-1, an upper reinforcing layer 3-1, a spherical cotton layer 2-0, a lower reinforcing layer 3-2, and a lower support layer 1-2 from top to bottom. The upper support layer 1-1 and the lower support layer 1-2 are made of short fibers of the same material. The spherical cotton layer 2-0 is made of uniformly dispersed fiber balls 2-1 of different diameters and inter-spherical fibers 2-1 filled between the fiber balls 2-1. 2, the upper reinforcing layer 3-1 and the lower reinforcing layer 3-2 are composed of randomly dispersed low-melting-point fibers 3-3, extensions of the short fibers and extensions of the inter-spherical fibers 2-2, the low-melting-point fibers 3-3 melt to form welds 3-4, and any two or three of the low-melting-point fibers 3-3, short fibers and inter-spherical fibers 2-2 are entangled to form clusters 3-5, and the low-melting-point fibers 3-3 are polyester fibers having a melting point of 130°C or less.

[0014] The thicknesses of the upper support layer 1-1, the upper reinforcing layer 3-1, the spherical cotton layer 2-0, the lower reinforcing layer 3-2 and the lower support layer 1-2 are 3 cm, 0.3 cm, 5 cm, 0.3 cm and 2 cm, respectively.

[0015] Preferably, the fiber ball 2-1 has a maximum diameter of 1.5 cm and is a multi-layered fiber assembly, which is composed of a support layer, a heat-retaining layer and a flexible layer from the inside to the outside, the support layer being a coarse polyester fiber having a fineness of 2.5 to 15D and a length of 25 to 51 mm, the heat-retaining layer being a heat-retaining polyethylene fiber with graphene powder added thereto having a fineness of 2.5 to 7D and a length of 25 to 51 mm, the flexible layer being a thin PA6 fiber having a fineness of 0.3 to 2.5D and a length of 25 to 51 mm, the weight ratio of the support layer being 10% to 50%, the weight ratio of the heat-retaining layer being 10% to 50%, and the weight ratio of the flexible layer being 5% to 40%.

[0016] In this embodiment, each layer is welded using low melting point polyester fiber. The available manufacturing method is as follows: first, the short fiber of the supporting layer and the low melting point fiber are mixed in a mass ratio of 4:1, the ball-shaped cotton is rubbed into a ball shape, and then the low melting point fiber is mixed in a mass ratio of 9:1. Each single layer is stacked continuously according to the thickness, and a certain pressure is applied through a press roll. After that, the low melting point polyester fiber is melted in an oven, cooled, and finished to complete the manufacturing process.

[0017] The above is only a preferred embodiment of the present invention, and does not need to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention. [Explanation of symbols]

[0018] 1-1, upper supporting layer; 1-2, lower supporting layer; 2-0, spherical cotton layer; 2-1, fiber balls; 2-2, inter-sphere fibers; 3-1, upper reinforcing layer; 3-2, lower reinforcing layer; 3-3, low melting point fiber; 3-4, welding point; 3-5, entanglement cluster.

Claims

1. A multi-layered spherical cotton flake, The multi-layered spherical cotton flakes are provided with an upper support layer 1-1, an upper reinforcing layer 3-1, a spherical cotton layer 2-0, a lower reinforcing layer 3-2, and a lower support layer 1-2, in that order from top to bottom. The upper support layer 1-1 and the lower support layer 1-2 are made of the same short fiber material, The ball-shaped cotton layer 2-0 is composed of uniformly dispersed fiber balls 2-1 having different diameters and inter-ball fibers 2-2 filled between the fiber balls 2-1. The upper reinforcing layer 3-1 and the lower reinforcing layer 3-2 are composed of randomly dispersed low-melting-point fibers 3-3, extensions of the short fibers and extensions of the inter-spherical fibers 2-2, the low-melting-point fibers 3-3 melt to form welds 3-4, and any two or three of the low-melting-point fibers 3-3, the short fibers and the inter-spherical fibers 2-2 are entangled to form clusters 3-5.

2. The multilayered spherical cotton flakes described in claim 1, characterized in that the height ratio of the upper support layer, the upper reinforcing layer, the spherical cotton layer, the lower reinforcing layer and the lower support layer is (0.2-1.2):(0.05-0.1):1:(0.05-0.1):(0.2-1.2).

3. 2. The multi-layered spherical cotton flakes according to claim 1, wherein the staple fibers are selected from the group consisting of polyester fibers, polyamide fibers, polyethylene fibers and polypropylene fibers.

4. The multi-layered spherical cotton flakes described in claim 1, characterized in that the material of the fiber balls 2-1 and the inter-ball fibers 2-2 is the same, which is one of polyester, polyamide, polyethylene or polypropylene, and the fibers of the fiber balls 2-1 and the inter-ball fibers 2-2 both contain PCM material or heat storage material.

5. The multi-layered spherical cotton flakes according to claim 1, characterized in that the diameter of the fiber balls 2-1 is 0.1 to 1.5 cm.

6. 2. The multi-layered spherical cotton flakes according to claim 1, wherein the low melting point fiber is polyester fiber having a melting point of ≦130° C.

7. 2. The multi-layered spherical cotton flakes according to claim 1, wherein the upper support layer 1-1 and the lower support layer 1-2 contain 2 to 30 wt % of the low melting point fibers 3-3.

8. 2. The multi-layered ball-shaped cotton flakes according to claim 1, wherein the ball-shaped cotton layer 2-0 contains 2 to 15 wt % of the low melting point fiber 3-3.

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