Method for manufacturing a multi-layered ball cotton flock

Abstract

The present invention relates to a multi-layer composite fiber household textile product, and specifically provides a method for manufacturing a ball cotton flock having a multi-layer structure. 【Solution means】The ball cotton flock having a multi-layer structure includes support layers on both sides, a ball cotton layer in the middle, and a transition layer at the interface between the two. The manufacturing method includes evenly mixing ball cotton, short fibers, and low-melting-point fibers in a weight ratio to form a ball cotton layer having a certain thickness, and roll-pressing both sides of the ball cotton layer using a round roll having a hook surface of a magic tape (registered trademark) on the surface; and mixing short fibers and low-melting-point fibers in a weight ratio to form a support layer having a certain thickness, joining the two support layers to both sides of the ball cotton layer respectively, and heating and shaping to obtain the product. 【Effect】By fixing the ball cotton, which is prone to deformation and aggregation, between the two support layers, the resistance of the ball cotton to external forces is improved, and it is difficult to sink or aggregate when receiving force.

Description

Technical Field

[0001] The present invention relates to a multi-layer composite fiber household textile product, and 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. 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 agglomerate, and in short, the structural deformation will affect the use of the product. In order 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 is provided with carded cotton layers having both hardness and elasticity on both sides of the pearl ball cotton sub-layer, and to a certain extent improves the ability to resist deformation of the pearl ball cotton sub-layer 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 above 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. If the layers do not adhere during operation, defective products with separated layers will occur after heating and shaping.

Summary of the Invention

Problems to be Solved by the Invention

[0003] After using a product filled with existing ball cotton for a long time, there is a problem that the ball cotton sinks or aggregates, leading to deformation of the product. In view of this, the present invention provides a method for manufacturing a multi-layer structured ball cotton flock comprising two side support layers, an intermediate ball cotton layer, and a transition layer formed at the interface between the support layer and the ball cotton layer. Among them, the thickness ratio of the ball cotton layer to the support layer is 1: (0.2 to 1.2).

Means for Solving the Problems

[0004] The method for manufacturing a multi-layer structured ball cotton flock of the present invention is as follows: Step 1: Evenly mix ball cotton, short fibers, and low-melting-point fibers by weight ratio, card them onto a mesh sheet using a cotton carding machine to form a ball cotton layer with a certain thickness, and roll-press both sides of the ball cotton layer using a round roll whose surface is the hook surface of Velcro (registered trademark) to draw out the short fibers and low-melting-point fibers from the ball cotton layer; Step 2: Take the short fibers and low-melting-point fibers in Step 1 respectively, mix them by weight ratio to form a support layer with a certain thickness, bond the two support layers to both sides of the ball cotton layer respectively, and obtain the product after heating and shaping.

[0005] Specifically, the material of the ball cotton is one or a mixture of two 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.

[0006] Specifically, in Step 1, the ball diameter of the ball cotton is 0.1 to 1.5 cm, the weight ratio of the 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 surface of the round roll is 16 to 144 pieces / cm 2It is also in the step 2 that the weight ratio of the short fibers to the low-melting-point fibers is 1:(0.1 - 0.2), and the temperature for heating and shaping is 135°C - 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 towards the support layer. The purpose of performing the side blow on the ball cotton layer is to blow away the short fibers and low-melting-point fibers drawn out from the surface of the ball cotton layer from the main body of the ball cotton layer, and a distinct transition layer is formed when the support layer pushes them back.

[0008] Furthermore, a PCM material or a heat storage material is added to the fibers of the ball cotton in the present invention. By adding the PCM material, the multi-layer structured ball cotton flock in the present invention becomes characteristic of a cooling feeling. Or, by adding the heat storage material, the multi-layer structured ball cotton flock in the present invention becomes characteristic of heat absorption and heat storage.

Advantages of the Invention

[0009] The present invention adopts a multi-layer structure design to fix the ball cotton, which is easy to deform and aggregate, between two support layers, thereby improving the resistance of the ball cotton to external forces, making it difficult to sink or aggregate when receiving force, and maintaining the light and fluffy characteristics of the ball cotton itself. Also, in the manufacturing process, the present invention draws out the short fibers and low-melting-point fibers of the ball cotton layer, and before joining with the support layer, the drawn fibers are blown away from the main body of the ball cotton layer by side blow to form a transition layer where the fibers are intertwined. Furthermore, some short fibers are woven into the support layer. In the process of heating and shaping, when the low-melting-point fibers melt and re-solidify, they weld the intertwined points and contact points, making the integrity of the multi-layer structured ball cotton flock better, making it difficult for the layers to separate when receiving force, and extending the service life of the multi-layer structured ball cotton flock.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Embodiments for Carrying Out the Invention

[0011] Hereinafter, the present invention will be described based on examples. However, the examples are for explaining the present invention and do not limit the scope of the present invention.

[0012] A method for continuously manufacturing a multi-layered ball cotton flock. The structure of the multi-layered ball cotton flock is as shown in FIG. 2, and includes an intermediate ball cotton layer 1, an upper support layer 6 and a lower support layer 9 on both sides of the ball cotton layer 1, and transition layers 1-1 between the ball cotton layer 1, the upper support layer 6 and the lower support layer 9. Among them, the thicknesses of the ball cotton layer 1, the upper support layer 6, and the 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. Also, the material of the ball cotton is 0.9D + 3D PET short fibers, 0.5 wt% of graphene powder is added to the 3D PET short fibers, the short fibers are 1.5D PET short fibers, and the low melting point fibers are 2080 low melting point polyester fibers with a melting point of 120°C.

[0013] Referring to the schematic diagram of the equipment shown in FIG. 1, the method for continuously manufacturing the multi-layered ball cotton flock of this embodiment includes the following steps.

[0014] Step 1: Evenly mix the ball cotton, short fibers, and low melting point fibers at a weight ratio of "1:0.25:0.1". Further, take the short fibers and low melting point fibers at a weight ratio of "1:0.2", evenly mix them and divide them into two parts. Comb each of the three mixed parts of fibers with a cotton carding machine to form a continuous mesh sheet having the required thickness, that is, the ball cotton layer 1, the upper support layer 6, and the lower support layer 9. Step 2: While maintaining the operation of the cotton carding machine, guide the ends of the continuous sheets of the ball cotton layer 1, the upper support layer 6, and the lower support layer 9 to the conveyor 2 of the ball cotton layer, the conveyor 5 of the upper support layer, and the conveyor 8 of the lower support layer, respectively. Start the three conveyors, and also start the round roll 3 with the upper and lower two magic tapes (registered trademark) installed in the conveyor 2 of the ball cotton layer, and draw out the short fibers and low-melting-point fibers from the ball cotton layer 1. Among them, the hook density on the surface of the round roll 3 is 64 pieces / cm 2 and the roll surface of the round roll 3 protrudes 0.3 cm from the surface of the conveyor 2 of the ball cotton layer. Further, start the upper dryer 4 built in the conveyor 2 of the ball cotton layer to blow away the short fibers and low-melting-point fibers drawn out from the upper surface of the ball cotton layer 1. Step 3: After blowing away the short fibers and low-melting-point fibers on the upper surface of the ball cotton layer 1, guide the upper support layer 6 on the conveyor 5 of the upper support layer to the ball cotton layer 1 and join the two. Also, start the lower dryer 7 arranged above to further join the upper support layer 6 and the ball cotton layer 1 while blowing away the short fibers and low-melting-point fibers drawn out from the lower surface of the ball cotton layer 1. Step 4: After blowing away the short fibers and low-melting-point fibers on the lower surface of the ball cotton layer 1, guide the ball cotton layer 1 to the lower support layer 9 on the conveyor 8 of the lower support layer. After ensuring the joining of each layer, the conveyor 8 of the lower support layer introduces the stacked three-layer structure into the heat setting box 10. Set the heating temperature of the heat setting box 10 to 160°C to melt the low-melting-point fibers. Step 5: After coming out of the heat setting box 10 and cooling naturally, cut off the edge scraps and wind up the product.

[0015] In the step 3, after joining the upper support layer 6 and the ball cotton layer 1, starting the lower dryer 7 can not only blow away the drawn short fibers or low melting point fibers on the lower surface of the ball cotton layer 1, but also make the joining between the upper support layer 6 and the ball cotton layer 1 tighter. In the step 4, the ball cotton layer 1 joined to the upper support layer 6 can join its lower surface and the lower support layer 9 by its own weight. After the Both sides of the ball cotton layer 1 is tightly joined to the upper support layer 6 and the lower support layer 9, introducing the ball cotton layer 1 into the heat setting box 10 and heating or shaping it can greatly reduce the probability of layer separation and defective products during the long-distance transportation process.

[0016] In this embodiment, the short fibers and low melting point fibers in the ball cotton layer 1 are drawn out to form an obvious transition layer 1-1, which can enhance the interfacial bonding force between the ball cotton layer 1, the upper support layer 6 and the lower support layer 9. In the manufacturing process, from two aspects of combining side blowing, self-weight and shortening the transportation distance to reduce the probability of separation between the ball cotton layer 1, the upper support layer 6 and the lower support layer 9, the integrity of the multi-layer ball cotton flock is improved. Through these two aspects, according to the method of this embodiment, a multi-layer ball cotton flock with layers closely adhering can be produced.

[0017] The above description is only a preferred embodiment of the present invention and does not limit the present invention. Any changes, equivalent substitutions, improvements, etc. made based on the spirit and principle of the present invention are all included in the protection scope of the present invention.

Description of reference numerals

[0018] 1. Ball cotton layer; 1-1. Transition layer; 2. Conveyor of the ball cotton layer; 3. Round roll with magic tape (registered trademark); 4. Upper dryer; 5. Conveyor of the upper support layer; 6. Upper support layer; 7. Lower dryer; 8. Conveyor of the lower support layer; 9. Lower support layer; 10. Heat setting box.

Claims

1. A method for manufacturing a multi-layered ball cotton flock, comprising: wherein the multi-layered ball cotton flock includes support layers on both sides, a middle 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 multi-layered ball cotton flock comprises: Step 1: evenly mixing ball cotton, short fibers, and low-melting-point fibers by weight ratio to form a ball cotton layer with a certain thickness, and performing roll pressing on both sides of the ball cotton layer using a round roll whose surface is the hook surface of a magic tape (registered trademark); Step 2: mixing short fibers and low-melting-point fibers by weight ratio to form a support layer with a certain thickness, joining two support layers to both sides of the ball cotton layer respectively, and heating and shaping them. A method for manufacturing a multi-layered ball cotton flock, characterized by the above.

2. The material of the ball cotton is one or a mixture of two or more of polyester, polyamide, polyethylene, or polypropylene. The short fibers are any of polyester fibers, polyamide fibers, polyethylene fibers, or polypropylene fibers. The low-melting-point fibers are polyester fibers with a melting point of 130°C or lower. The method for manufacturing a multi-layered ball cotton flock according to Claim 1.

3. In Step 1, the ball diameter of the ball cotton is 0.1 to 1.5 cm, and the weight ratio of the ball cotton, short fibers, and low-melting-point fibers is 1:(0.2 to 0.5):(0.05 to 0.1). In Step 2, the weight ratio of the short fibers to the low-melting-point fibers is 1:(0.1 to 0.2). The method for manufacturing a multi-layered ball cotton flock according to Claim 2.

4. In the step 1, the hook density of the magic hook surface on the surface of the round roll is 16 to 144 pieces / cm ２ A method for manufacturing a multi-layered ball cotton flock according to any one of claims 1 to 3, characterized in that it is as described above.

5. 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 towards the support layer. The method for manufacturing a multi-layered ball cotton flock according to any one of Claims 1 to 3.

6. In Step 2, the temperature for heating and shaping is 135°C to 160°C. The method for manufacturing a multi-layered ball cotton flock according to any one of Claims 1 to 3.

7. The manufacturing method of the multi-layered ball cotton flock 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. The manufacturing method of the multi-layered ball cotton flock according to any one of claims 1 to 3, characterized in that a PCM material or a heat storage material is added to the fibers of the ball cotton.

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