Method for making a thermoinsulating padding, particularly for the clothing and furnishing fields
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Solution Overview
Problem
Existing thermoinsulating padding materials for clothing and furnishing have low thermal resistance, are prone to crushing during needling, and lack eco-sustainability, with high resin and fiber consumption.
Innovation Solution
A method using recycled post-consumer and post-industrial fibers combined with a resin composition of 100% acrylic copolymer and low glass transition temperature resins, applied only to the surface layers and processed through pressure calendering, to create a thermoinsulating padding with dynamic thermal adjustment properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If needling processing is applied to reduce padding thickness, then the padding becomes more compact, but the material is crushed and hardened, reducing softness
Solution Approach 1:
The patent changes the physical-chemical parameters of the fibers by introducing thermoplastic fibers that can be activated at specific temperatures. During calendering, these fibers melt and bind the padding material without requiring aggressive needling, thus reducing thickness while maintaining softness through controlled thermal activation rather than mechanical crushing.
Solution Approach 2:
The patent utilizes phase transition of thermoplastic fibers from solid to liquid state during calendering. The thermoplastic fibers melt at controlled temperatures to bind the padding material, enabling thickness reduction without the harsh mechanical needling that crushes and hardens conventional materials.
2Volume of moving object
If conventional wadding materials are used to reduce thickness, then the padding becomes more compact, but thermal resistance decreases
Solution Approach 1:
The patent creates a composite material system combining natural fibers (cotton, wool, silk) with thermoplastic fibers. This composite structure maintains thermal resistance by preserving the air-trapping properties of natural fibers while using thermoplastic fibers as binding agents that enable thickness reduction without compromising insulating performance.
Solution Approach 2:
The patent maintains porous structure in the padding by using thermoplastic fibers as binding agents rather than densely packing conventional wadding. The calendering process creates a bonded yet porous structure that retains air pockets for thermal insulation while achieving reduced thickness through efficient fiber bonding.
3Loss of substance
If recycled fibers are used to improve eco-sustainability, then environmental performance improves, but fiber cohesion and stability worsen
Solution Approach 1:
The patent introduces thermoplastic fibers as an intermediary binding agent between recycled natural fibers. These thermoplastic fibers melt during calendering to create strong bonds between recycled fibers, providing the necessary cohesion and stability that recycled fibers lack on their own, while maintaining eco-sustainability through reduced resin usage.
Solution Approach 2:
The patent changes the thermal parameters of the fiber assembly by introducing fibers with specific melting points. During controlled heating, the thermoplastic fibers transition to liquid state to bind recycled fibers, then solidify upon cooling to provide stable cohesion, enabling effective use of recycled materials without compromising structural integrity.
4Stability of the object's composition
If conventional resin compositions are used to bind fibers, then fiber cohesion is achieved, but resin and fiber consumption increases
Solution Approach 1:
The patent extracts and eliminates excessive resin and fiber consumption by using thermoplastic fibers as self-binding agents. The thermoplastic fibers replace conventional high-resin compositions, requiring minimal additional material to achieve effective fiber bonding through their phase transition during calendering.
Solution Approach 2:
The patent enables the fiber assembly to bind itself through the thermoplastic fibers that are already present in the mixture. During calendering, these fibers automatically melt and bond the other fibers without requiring external resins or additional binding materials, achieving cohesion through self-service mechanism.
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 enhances thermal insulation, reduces resin and fiber usage, lowers energy consumption, and improves eco-sustainability by maintaining fiber stability and cohesion while providing effective thermal adjustment.
Implementation Method 1
actuating said low glass transition temperature resin of said resin composition mixture by pressure calendering under a controlled temperature
Implementation Method 2
providing said thermoinsulating non-woven padding with dynamically variable thermally adjusting properties
Implementation Method 3
drying the resin coated lap in a drying oven to start a cross linking of said resin composition mixture
Implementation Method 4
drying the resin coated lap in a drying oven
Implementation Method 5
said bulk fibers comprising at least thermobinding fibers and post-consumer and post-industrial recycled fibers, thereby providing said thermoinsulating non-woven padding
Implementation Method 6
using said low glass transition temperature resin of said resin composition mixture in combination with said thermobinding fibers adapted to thermobind the padding body
Data Source
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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.