Temperature-Stabilizing Fiber Fill With Soft Refluffable Clusters
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Solution Overview
Problem
Existing filling materials for bedding and garments lack temperature regulation and softness, with prior art solutions providing harsh feelings and reduced refluffability.
Innovation Solution
A method involving discrete fibre clusters with an uneven distribution of temperature stabilizing substances, such as microcapsules containing phase change materials, applied using binders and solvents to ensure even distribution and retention, mixed using turbulent gas streams for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coating of temperature stabilizing substance is applied to a nonwoven fabric substrate, then temperature stabilizing effect is achieved, but softness and refluffability are reduced
Solution Approach 1:
The invention divides the filling material into discrete fibre clusters instead of using a continuous nonwoven fabric substrate. This segmentation allows the temperature stabilizing substance to be distributed among multiple small clusters, maintaining softness and refluffability while providing temperature regulation. Each cluster acts as an independent unit that can move and compress freely.
Solution Approach 2:
The temperature stabilizing substance is applied selectively to only some of the discrete fibre clusters rather than coating the entire substrate uniformly. This creates local zones with temperature stabilizing properties while leaving other areas soft and fluffy, thus maintaining overall comfort and refluffability of the filling material.
2Temperature
If temperature stabilizing substance is applied to fibre clusters, then heat buffering effect is achieved, but distribution uniformity is poor
Solution Approach 1:
The discrete fibre clusters are prepared and distributed uniformly throughout the filling material before the temperature stabilizing substance is applied. This preliminary uniform distribution of clusters ensures that when the substance is subsequently applied to selected clusters, the overall distribution remains relatively uniform across the entire filling material.
3Reliability
If binder is used to attach temperature stabilizing substance to fibre clusters, then retention during washing is improved, but softness may be reduced
Solution Approach 1:
Instead of completely coating all fibre clusters with binder and temperature stabilizing substance, the invention applies the substance to only some clusters partially. This partial application reduces the total amount of binder needed, thereby maintaining softness while still achieving adequate retention during washing for the treated clusters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a filling material with prolonged heat buffering, softness, and good refluffability, suitable for pillows, quilts, and garments, maintaining comfort and performance during use and washing.
Implementation Method 1
the phase change material undergoes a phase change, e.g. a transition from solid state to liquid state, under absorption of heat
Implementation Method 2
under absorption of heat, thereby reducing the temperature increase in the non woven fabric substrate
Implementation Method 3
curing the binder to firmly attach the temperature stabilizing substance to the discrete fibre clusters
Implementation Method 4
evaporating the solvent, applying a binder to the discrete fibre clusters
Data Source
AI summary
A filling material for filling into articles of bedding is made byproviding a plurality of discrete fiber clusters,applying a temperature stabilizing substance to the discrete fiber clusters,mixing the discrete fiber clusters with each other, andcollecting the discrete fiber clusters thereby obtaining a filling material in which the distribution of the temperature stabilizing substance is substantially even.A device (1) for producing a filling material has an application station (22) for applying a temperature stabilizing substance to discrete fiber clusters, a curing station (24) for fixing the substance, a mixer (30) for mixing the discrete fiber clusters and a collecting station (32) for collecting the fiber clusters to form the filling material in which the distribution of the temperature stabilizing substance is substantially even.