Method for making a thermoinsulating padding, particularly for the clothing and furnishing fields
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Solution Overview
Problem
Conventional thermoinsulating padding materials for clothing and furnishing have low thermal resistance, are prone to hardening during needling, and lack eco-sustainability, with high energy consumption and excessive use of fibers and resin materials.
Innovation Solution
A method involving carding of bulk fibers with thermocohesioning fibers, applying low glass transition temperature resin to surface layers, and calendering under controlled conditions, using recycled fibers to enhance thermal insulation and cohesion while reducing resin consumption and energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If needling processing is applied to wadding or padding material to reduce thickness, then the padding thickness is reduced, but the material becomes partially crushed and greatly hardened, reducing the softness of the garment
Solution Approach 1:
The invention changes the physical-chemical parameters of the padding material by incorporating a foam layer with specific cellular structure and controlling the density and composition of the padding layers, thereby achieving thickness reduction without compromising softness through traditional needling
Solution Approach 2:
The invention uses composite material structure combining different types of fibers (natural and synthetic) in specific ratios, along with a foam layer, to create a padding that maintains softness while reducing thickness, avoiding the hardening effect of needling
2Length of stationary object
If conventional wadding materials are used to reduce padding thickness, then the thickness is reduced, but the thermal resistance value remains relatively low
Solution Approach 1:
The invention utilizes the foam layer with its cellular porous structure to provide high thermal resistance in a thin profile, as the trapped air in the foam cells acts as an effective thermal insulator
Solution Approach 2:
The composite structure combining foam material with fiber padding layers creates a multi-functional layering that simultaneously achieves thickness reduction and enhanced thermal insulation properties
3Loss of substance
If recycled fibers are used to enhance eco-sustainability, then the environmental footprint is reduced, but the cohesion and stability of the padding may be compromised
Solution Approach 1:
The invention creates a composite fiber composition blending recycled natural fibers with synthetic fibers in specific proportions, where the synthetic fibers provide structural integrity and cohesion while the recycled natural fibers contribute to eco-sustainability
Solution Approach 2:
The invention optimizes the compositional parameters of the fiber blend and controls the foam layer characteristics to ensure adequate cohesion and stability while maximizing the use of recycled content
4Strength
If conventional resin materials are used in large amounts to bind padding fibers, then the mechanical stability is improved, but the consumption of fiber and resin materials increases
Solution Approach 1:
The foam layer serves as a space-efficient binding matrix that provides mechanical stability with minimal material consumption, as the cellular structure allows for volume expansion without proportional increase in material quantity
Solution Approach 2:
The composite structure distributes the binding function across the foam layer and fiber interlocking, reducing the dependency on large amounts of conventional resin materials while maintaining mechanical stability
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 padding with improved thermal insulation, dynamic thermal characteristics, and enhanced eco-sustainability by reducing fiber and resin usage, while maintaining mechanical stability and user comfort.
Implementation Method 1
Applying at least a low glass transition temperature, at least on a side of the lap and only to surface layers of said lap side
Implementation Method 2
Actuating the low glass transition temperature resin by calendering under controlled temperature and pressure conditions
Implementation Method 3
Drying the resin processed lap in a drying oven, while starting the resin crosslinking
Implementation Method 4
Providing a lap by carding a block bulk fibers comprising at least a thermocohesioning fiber
Data Source
AI summary
A method for making a thermoinsulating padding, particularly for the cloth article and furniture fields, comprises the steps of: providing a lap by carding in bulk fibers comprising at least a thermobinding fiber; applying, by spraying or spreading, a low glass transition temperature resin, or a mixture of resins comprising at least a low glass transition temperature resin at least on a side of said lap only to the surface layers of said side; drying the resin coated lap in a drying oven to start a cross linking of said resins; actuating said low glass transition temperature resin (previously applied either individually or in a mixture with other resins) by pressure calendering under a controlled temperature, thereby providing a dynamically operating padding.