CN1056849A

CN1056849A - The filling of fiber and other purposes

Info

Publication number: CN1056849A
Application number: CN91103331A
Authority: CN
Inventors: 沃尔特·B·哈尔姆; 小威廉·J·琼斯; 詹姆斯·F·柯克布赖德; 伊兰·马卡斯; 阿德里安·C·施奈德; 乔治·L·沃恩
Original assignee: EI Du Pont de Nemours and Co
Current assignee: Invista Technologies Sarl
Priority date: 1990-04-12
Filing date: 1991-04-12
Publication date: 1991-12-11
Anticipated expiration: 2006-04-12
Also published as: JPH05505959A; DE69105269T2; CN1027089C; IE911212A1; CA2080363A1; CA2080363C; DE69105269D1; ES2065022T3; NZ237772A; PT97343A; EP0524240B1; WO1991016485A1; AU7654091A; EP0524240A1

Abstract

Be used to fill the fibrous nodules of purposes, it is prepared by mechanical curly fiber, and this mechanical curly fiber has the special profile that one-level is curled and secondary curls, especially special amplitude and frequency.Fibrous nodules also can contain some other fibre fractionation, especially Binder fiber.

Description

The filling of fiber and other purposes

The application is the continuation part of following unratified patent family application still, be 07/508 at application on April 12 nineteen ninety (DP-4690) application number promptly by contriver Snyder and Vaughn, 878, apply for (DP-4390-A) application number 07/549 in July 9 nineteen ninety by contriver Marcus, 818 and (DP4391) application number 07/549,847, and these above-mentioned applications are applications on December 27th, 1988, application number is the continuation part of 07/290,385 U.S. Pat of now having authorized 4940502, and this granted patent itself is again application on October 21st, 1986, application number 06/921, the continuation part of the U.S. Pat 4794038 that on December 27th, 644,1988 authorized, and US4794038 is application on May 15th, 1985, application number is 734, the continuation part of 423 U.S. Pat of now having authorized 4,618,531.

The present invention relates to improved fleeces underfill material, particularly poly-ester fibres fibrefill material, more specifically to the fiber floc material of fibrous nodules form, and this and others and purposes other fiber.

Poly-ester fibres wadding material has purposes very widely, and is used for pillow as relatively cheap fibrefill material, bed clothes, sleeping bag, clothes, furniture mat, mattress and similar products.It is normally made by polyethylene terephthalate chopped fiber (promptly cutting off), and this chopped fiber is to be formed by the long filament cut-out of curling in filling formula crimping machine.The dawn number (or dtex) of fiber is generally 5-6, and promptly to count height than cotton fiber and dawn of being used for the polyester textile fiber of clothes many for filament denier.Described fiber can be hollow or solid, also can have the cross-sectional plane of regular circular or other shape, and requires to be cut into all lengths according to final use or routing process.

Poly-ester fibres fibrefill material usually is smooth, promptly scribbles silicone, scribbles the block interpolymers of polyethylene terephthalate and polyethers recently, to reduce the friction between the fiber.Low friction has improved the feel of the final products that are made of the fleeces underfill material between fiber, produces smooth and soft hand feeling, to help the trend that reduces the fiber floc material entanglement (or becoming piece) in the product during use.

Poly-ester fibres wadding material forms fleece then usually by shredding processing, and this net is a juxtaposition, and to form a kind of oakum (also can be referred to as to make batt layer), it can be used for being filled in the product.Adopting the performance of the filling product of this filling technique all is gratifying for many years for multiple final use, but it can not reproduce natural wadding material fully, as eider down and aesthetic feeling that eider down/the feather compound is had.The structure that this natural wadding material has fundamentally is different from the poly-ester fibres wadding backing strap of machine comb; They are made of the granule with discontinuous fibrefill material; This makes granule to move in pillowcase and quilt cover fabric, and makes the shape of product be adapted to user's profile or desirable shape.We think that eider down and feather restore to the original state by shaking and patting by compaction state after its pressurized, its eider down and feather wadding material can move easily and play key role, and this advantage is referred to as shaking up property again.

Opposite with eider down and feather is, the poly-ester fibres wadding backing strap of machine comb has laminar texture, and fiber is parallel in its laminar texture.And in each net and layer with layer between all loosely be coupled to each other, therefore, they can not be to move to the eider down mode similar with feather and to shake up.But the polyester fiberfill material also has some advantages compared with natural fibrefill material, particularly aspect washability and durability.So, Marcus develops a kind of fleeces underfill material product, it is made of little, soft poly-ester fibres group or fibrous nodules, can keep original characteristic during its wearing and washing, and the user can shake up again to this product that is filled with the fleeces underfill material.These fibre agglomeratess have the shaking up property again of the good physical property of poly-ester fibres fibrefill material and washability and eider down or eider down and feather compound concurrently.

Though produced some special products in enormous quantities by standard fibers fibrefill material on improved carding machine, to be used for different final uses, this product does not also possess the special quality bedding of production or the needed performance of furniture product.Steinruck discloses a kind of improved type carding machine and process that is used for making " slubbing " in U.S. Pat 2923980.

Marcus utilizes the fiber with property to be used for a kind of new fibrous nodules manufacture method as feeding and makes later-model fibrous nodules.U.S. Pat 4618531 and US4783364 disclose preferred fibrous nodules product and have produced the process of this fibrous nodules by spirality crimping (comprise Ω curl type) fiber, because its potential natural crimp performance, under the condition that relaxes, it can be rolled, these products have all been obtained the coml success at US and European, mainly are mattress and furniture pad aspect.Marcus promptly provides the fiber of desirable random alignment with experiment showed, that spirality crimping is crucial for obtaining desirable fibrous nodules structure in each fibrous nodules, and obtains desirable low-adhesion between the surface of the fibrous nodules of adjacency.Have the curling commercial fibre of standard mechanical and can not produce the fibrous nodules with ideal structure, this fibrous nodules can provide the fibrefill product of can shaking up again required, crucial durability, high filling capacity and low-adhesion.

In order to make loading (promptly increasing capacity) and durability (promptly reducing capacitance loss during use), washing fastness the best particularly, we think, fiber in the fibrous nodules should be a random scattering, in total, have uniform density, and its entanglement degree should be enough in washing or normally keeps the characteristic of fibrous nodules in the wearing process.Be to obtain optimum filling amount and durability, we think that importantly the fiber of each in fibrous nodules should have its abundant bulking intensity and development property separately, so that it can extremely help loading and durability.For obtaining this structure of decision fibrous nodules characteristic, Marcus has used the fiber that is tending towards natural crimp, so that under the power that relaxes very much, just can produce good consolidated structures.In above-mentioned patent, Marcus discloses a kind of preferable methods obtaining this desirable fibrous nodules structure and characteristic, and he is by using spirally-crimped fibers as processing raw material fiber and carry out air and stir processing to rotate fiber under mitigation power.Resulting product has following feature: the fiber in the fibrous nodules is a random scattering, has at least 50% to be circular (ratio of upperlimit and minimum size is less than 2: 1), and has low-adhesion, and this is that former product is not available.Marcus uses under the same conditions to have the commercial fibre that standard physical curls and can not produce satisfied fibrous nodules.

The fiber that processes raw material that Marcus is used for making fibrous nodules is the comparison uniqueness, unserviceable and/or be expensive on some markets, and wherein most polyester staple fibers normally carries out machine crimp by the stuffer box technology.Disclose the fleeces underfill material that adopts the fibrous nodules form from Marcus, rather than be since the value of parallel fibers of combing pad type structure, people want to understand always, why the mechanical curly fiber of standard can not be made good fibrous nodules, so that a kind of and the used different fiber that processes raw material of Marcus are provided.People such as Snyder disclose another kind of job operation and the device that is used to make fibre agglomerates in the Application No. 07/508898 that awaits the reply jointly, and successfully the fiber process that processes raw material of machine crimp are become gratifying fibre agglomerates.The application's a free-revving engine provides the fiber that processes raw material of this machine crimp, and this fiber has the ability that is processed into fibre agglomerates, is referred to as fibrous nodules sometimes.Other purpose will be seen in this article significantly.

Movably, the mat that can shake up again is commonly used at present in the modern furniture style.This has just produced to the new requirement of fleeces underfill material of shaking up again, so that mat can be heaved again.Furniture also requires to have the bigger bearing capacity and the filling product of filling capacity than bedding or clothes.This also can require the fiber of high Denier, and this fiber can require to be different from the curling condition fiber of 5-6 dtex.

Disclose the fibrous nodules of being made by spiral fiber and Binder fiber in the U.S. Pat 4794038 of Marcus, wherein Binder fiber can be pressed into the fiber block of curing.In addition, spirally-crimped fibers is used to obtain desirable globosity.The very good mechanical curly fiber that to make this fibrous nodules that provides.

It will be appreciated that at this principle of the present invention also can be used for making fibre agglomerates by the fiber except poly-ester fibres wadding material.

We are surprised to find now, and the fibrous nodules with comparability can be had the mechanical curly fiber production of special curly form by some.The applicant thinks that important being characterised in that is being similar to the spirally-crimped fibers of Marcus as the fiber that processes raw material aspect the potentiality of natural crimp.The suitable fiber that processes raw material curls with the one-level with special frequency and amplitude range and secondary curls, and mixed form uses together.Wherein the accurate scope of numerical value requirement depends on various condition situations, as the dawn number and the profile of the fiber that processes raw material, and the process technology that is used to make fibrous nodules.The key condition requirement that the good heat setting that frequency and the amplitude, particularly secondary that secondary curls curled all is considered to make fibrous nodules.

According to an aspect of the present invention, the fibrous nodules of can shaking up again that is provided has uniform density, and the fiber ccasual in each fibrous nodules is arranged and is tangled, the average cross-section size that it is characterized in that fibrous nodules is about 2-20mm, the length range of single fiber is about 10-100mm, and be that one-level is curled and secondary is curling fiber is prepared to be become by having, wherein said one-level is curled and is had the average frequency that every 10cm has 14-40 volume approximately, said secondary curls and has the average frequency that every 10cm has 4-16 volume approximately, and the amplitude of place fiber axis on the aspect is at least 4 times that one-level is curled.

A kind of fibrous nodules is provided in addition, and fiber is random scattering and entanglement in each ball.Said fiber is the compound of bearing fiber and Binder fiber, it selectively contains when carrying out the processing of microwave or high frequency energy source, can heated material, the mean diameter that it is characterized in that fibrous nodules is 2-20mm, the length of single fiber is about 10-100mm, bearing fiber has one-level and curls curling with secondary, the average frequency that said one-level is curled is that every 10cm has 14-40 volume approximately, the average frequency that said secondary curls is that every 10cm has 4-16 volume approximately, therefore, the average amplitude that secondary is curling is 4 times that one-level is curled at least.

As what also want at this further fully to describe, also provide the job operation that is used to make above-mentioned fibrous nodules.

Provide in addition by the prepared molding structure of the fibrous nodules that contains Binder fiber.

Others of the present invention comprise the fiber that preferably processes raw material that is used to make fibrous nodules, and the process of making the suitable fiber that processes raw material.

According to other aspects of the present invention, the process that provides has: in stuffing box crimping machine, 13-26 thousand spies' curling load is arranged approximately with the curling width of per inch, every threads is carried out machine crimp for the tow band that hangs down some PFYs of dawn number (about 4-10 dtex), and the tow band that curls is carried out thermal finalization, with the long filament that provides some to curl, the every 10cm of average frequency that the one-level that this long filament has the every 10cm of average frequency 14-40 volume is approximately curled has the secondary of 4-16 volume to curl approximately, the average amplitude that secondary curls is 4 times of the curling average amplitude of one-level at least, be transformed into chopped fiber so that the fiber that processes raw material to be provided producing the tow band that curls, make fibrous nodules by this fiber that processes raw material, making this fibrous nodules is to stir the mechanical equipment of processing or using the manufacturing fibrous nodules with card clothing by an air, for example use improved roller canopy-type equipment or with people such as Snyder disclosed equipment in Application No. 07/508878, the curl fiber that processes raw material of preferred mechanical is made the machine use for this fibrous nodules.The similar job operation that is provided is used for some PFYs than high dtex, and the load per inch that for example curls accordingly reaches 34,000 spies.The present invention be not limited in illustrational utilization clog box machine crimp and cause suitable curling, also can expect to cause suitable structure with other method.

Figure 1A, 1B, 2A, 2B, 3,4 and 5 all is photo, and will elaborate below.

Fig. 6 is the transparent view of stuffing box crimping machine, has wherein cut away the part crimping machine, to show the curling result who is obtained.

According to the present invention, the fiber that processes raw material of some machine crimps can produce its again shaking up property and durability all to the similar fibrous nodules of fibrous nodules of under conditions of similarity, producing with spirally-crimped fibers (being referred to as spirally-crimped fibers sometimes), when adopting other fibrous nodules manufacture method, the machine crimp of the relative broad range fiber that processes raw material can be made gratifying fibrous nodules, for example people such as Snyder has described a kind of job operation in the Application No. 07/508878 that (DP-4690) of application on April 12 nineteen ninety awaits the reply jointly, can be at this with reference to disclosed technology contents, in some cases, the structure of this fibrous nodules so is similar to the fibrous nodules that is obtained by coiled-coil fiber, so that be difficult to distinguish two kinds of products, even on the electronic scanning of fibrous nodules micro-(ESM) photo, all be difficult to distinguish.Involved Figure 1A, 1B, 2A and 2B are the electron scanning micrographs that amplifies 20X..Figure 1A and 1B be described in the following embodiment 1 by the process raw material photo of fibrous nodules of fiber production of machine crimp.Fig. 2 A and 2B are by the process raw material photo of commercial fibre ball of fiber production of helix-coil.These all are described in further detail below.Generally, the straightforward procedure of curling of the fiber that processes raw material of the fibrous nodules that made of check is to find usually by some free ends that stretch out in the fibrous nodules, and the check part of stretching out ball, and need not attempt to open fibrous nodules.It is difficult that the image of suitable fibrous nodules 2 dimension spaces is provided, but the photo that electron scanning micrograph is broken forth than ordinary camera can provide better pictures.The shown similar of the electron scanning micrograph that these provided in according to the present invention with the machine crimp commodity product(s) that fiber obtained that processes raw material.

The fibrous nodules that is had satisfactory texture by mechanical curly fiber production is practical especially, and commercial value is arranged, because the fiber with special cross section is very difficult for production and/or helix-coil or two component technology of curling, for example have the fiber and the high dawn fiber of multi-path and/or high hole.This disclosed technology can by the synthetic filaments that is actually any source produce have 3 dimension space structures, the fibrous nodules of low-adhesion and good durability, can produce the specific combination of below disclosed firsts and seconds being curled by improving the condition of curling.Those of ordinary skill in the art it will be appreciated that, the all essential certain experience of any crimp operation, as there being the experience person will be according to the special fiber that processes raw material, according to the type of curling, size and/or structure, and any requirement improves curling condition, up to result's (fibrous nodules, under the present circumstances) satisfactory, and will provide some principles at this.

For the purposes of filling, fibrous nodules is preferably circular, and has mean diameter 2-20mm, and by weight, preferably at least 50% ball has such cross-sectional plane, so that its upperlimit can not surpass the twice of minimum size.Fibrous nodules is that the fiber by random alignment, entanglement is constituted, and wherein fiber is curled with the firsts and seconds that particular frequencies and amplitude are provided by thermal finalization.The curling average frequency that has of suitable one-level is that every 10cm has 14-40 to curl approximately, preferably every 10cm has 18-28 curl (or some fiber is 32) approximately, and suitable secondary curls that to have average frequency be that every 10cm has 4-16 to curl approximately, and the average amplitude that secondary curls is 4 times that one-level is curled at least.The shearing length that the poly-ester fibres that curls has is about 20-100mm, and the linear density of about 3-30 dtex (for the purposes of fibrefill material), low dtex generally can not provide good rebound resilience or fill and support, but, if necessary, the polyester of low dtex or the fibrous nodules that other fiber also can be machined for other purpose for example are used as slubbing in flame.In fact, should understand at this value range that relates to be similar to, and will depend on various factors usually, resemble the final use of requirement for the accurate qualification of any fiber, other fiber factor resembles dawn number, shape of cross section, and the processing conditions of selecting for use especially for specialty fibers.

According to special final use, fibrous nodules can contain some other fiber, particularly Binder fiber, generally reaches 30%.To know clearly very much for this professional those of ordinary skill, we have found how to make and have been applicable to the mechanical curly fiber that is transformed into fibrous nodules and change spirally-crimped fibers (teaching as Marcus), it is possible making fibrous nodules by various fibre blends, particularly is applicable to the spirally-crimped fibers of manufacturing fibrous nodules and the compound of mechanical curly fiber.In addition, in this compound, needed accurate ratio of its fiber and curling profile will depend on these factors: resemble the technology that is used to make fibrous nodules, the dawn number and the cross-sectional plane of fiber also depend on other component of compound concerning compound.Bearing fiber can apply smoothing preparation, as silicone smooth agent or the block interpolymers formed by polyoxyalkylene and polyethylene terephthalate basically, to reduce the friction between the fiber, except the flexibility that can improve the final use product, in the process of making fibrous nodules, lubricated also is very important, makes it help a fiber in another slip above fiber during processing, and reduces their the needed power of rolling.

For the curling profile of understanding the fiber that processes raw material of the present invention with how to obtain this curling profile, briefly discussing curls has and helps understand.

In order to process the synthetic staple of rule, their initial long filament is normally handled with the form of endless tow, makes each long filament mechanically deform, under the tension force of minimum, by heating, makes it become the thermoplastic structure, to fix this distortion then.The major cause of doing so just provides interfibrous adhesive bonding property (continuity is provided and is convenient on carding machine and spinning frame further weaving procedure of processing to chopped fiber) or the bulking intensity and the desired tactile aesthetic feeling of raising is provided.This course of processing is commonly called curling, and will be described in detail in conjunction with stuffing box crimping machine shown in Figure 6.

Commerce has hairline (accurate operation all can not be known in any business activity) with crimping machine, but they are made of following elements: feeding roller 1 and 2, enter into filling chamber 3 with the feeding fiber, deform at this filling chamber fiber, and there are some to apply the device of back-pressure, for example in the exit, by a pressure load jaw 4(or the 2nd group of roller) apply back-pressure.Also have many other parts, these are crucial to later discussion.

Usually, a large amount of fiber filaments is made a tow band 5, its width is slightly less than the width of filling chamber 3, and accurately is fed in the filling chamber 3.This filling chamber can be regarded a casing with three-dimensional structure as, it has a length, can think that it is axial, flow through in order to the fiber work in-process, (with the Z direction indication) has a width, and it is slightly larger than tow bandwidth (with the Y direction indication), a thickness, it is another dimension (representing with directions X) of filling chamber 3.This filling chamber provides an instantaneous volume and storage capacity for the tow band, and connects with the device that applies back-pressure, to cause the bending volume of long filament on the Y-Z plane of filling chamber, because there is unnecessary space to realize this twisting on the Y direction for long filament.The type of curling that is produced is called serration or chevron pointing is suitable.If necessary, crimping machine can be heated, and particularly heating helps to curl in the entrance, further cools off before leaving crimping machine to help setting to curl then.If the thickness (X) of filling chamber 3 is enough big and/or to be fed into the fiber number of filling chamber enough little again, then the tow band will be bent to form a kind of sinusoidal geometric figure on the X-Z plane.Should curl usually curlingly has bigger amplitude and a lower frequency than what produce on the Y-Z plane.

In order to understand the present invention, we are curling that one-level is curled and is considered as producing on the Y-Z plane, and with curling that secondary curls and is considered as producing on the X-Z plane.These curl and are illustrated on the tow band that the crimping machine bottom is discharged among Fig. 6, and wherein 12 expression secondarys curl, and 11 expression one-levels are curled.

Two types curl can be watched on the photo of Fig. 3,4 and 5 crimped filament band.As (1cm spaces) that can see on backing paper, the magnification factor of Figure 4 and 5 is bigger than Fig. 3.All the secondary of tow bands curls to curl than one-level and sees more obviously, and except Fig. 3 top section tow has changed into the amplitude that is illustrated on the photographic plane, shown near normal ranks generally have the amplitude perpendicular to photographic plane.This secondary curls corresponding with the degree of depth (directions X) of filling chamber, and the curling secondary crimp fixing than (corresponding to Comparative examples A) shown in Figure 4 of the secondary shown in Fig. 3 (corresponding embodiment 1 hereinafter) gets better.Heat setting shown in Fig. 5 be placed in the middle between, it is better than Fig. 4, but not as Fig. 3 good.Can be observed one-level in some long filaments have been stretched the photo that separates curls, its amplitude is curling more much smaller than secondary, usually on direction, be curled into the right angle, because one-level is curled corresponding to the difference between tow band and the filled chamber width (the Y direction of filled chamber) with secondary.

Just as described in the present application, obtaining aspect the desirable curling profile of manufacturing fibrous nodules, the crimping machine load may be a key factor.The crimping machine load represents to be fed into the amount of the endless tow (being referred to as rope sometimes) in the crimping machine, and is special next definite with per inch crimp box width thousand at this.

An important requirement is that secondary is crimped onto long filament and pulls out setting before, for example when tow comes out from crimping machine or during further processing tow.In any specific industrial practice, according to previously used method, for avoid curl measure and/or extra heat-set treatment of some back that tension force added before crimp fixing is good is desirable, various because prior art has, and can not be known therefore.The curling profile of fiber when the formation of fibrous nodules that importantly process raw material, rather than certain the instantaneous curling profile in crimp box, or curling of producing soon later on.

We have explained the importance that is used for producing around the three-dimensional heat setting profile of the fiber that processes raw material of fibre agglomerates (or fibrous nodules) now, should see also that afterwards this profile also can be obtained by the alternate manner in the broad range of the present invention.For the ease of understanding, we are illustrated this with the machine crimp course of processing of stuffing box crimping machine.

Production is used to make the fiber that processes raw material of fibrous nodules, the curling process of preferred mechanical mainly is included in curling rope yarn under the low relatively crimp box load, we have successfully used the long filament that comes crooked 4-10 dtex as per inch (crimp box width) 13-26 thousand spies' load, sometimes for the long filament of high Denier, load can reach per inch 34,000 spies.Should also be appreciated that some accurate crimp box loads will be depended on various factors, except fiber Denier, also comprise the technology and the condition that are used for the fiber that processes raw material is transformed into fibre agglomerates.We find that it is better than using improved Lorch formula equipment to adopt combing formula technology.Apply low crimp box load and help to produce secondary and curl, and influence frequency and the amplitude that secondary curls, and improve the heat setting that secondary curls to a certain extent, the fiber storage volume that it constituted reaches the curling of nature.Low crimp box load is that rope yarn stays folding forwards, backwards space, and can cause the rotation of tow band, thereby produces various variations on the curling plane that secondary curls, and these all help to produce good three-dimensional fiber spherical structure, as following described.Secondary curls for producing fibrous nodules of the present invention, is absolutely necessary, but in order to produce optimum, and it must heat setting, to fix needed curling profile as much as possible.

According to the elaboration of US4618531 and 4783364, it is disclosed to be fibrous nodules by the fiber production that processes raw material of spirality crimping.This fibrous nodules has fewer fiber by stretching out in the fibrous nodules, therefore, low adhesive bonding property is arranged between fibrous nodules.This helix-coil also to bulk density, rebound resilience and the durability of fiber floc material and again shaking up property good action is arranged; the fibrous nodules structure is to depend on curling naturally of fiber that " storage " of fiber produced to a great extent; it curl to be by bicomponent structural or to be produced by the distribution of the spinning stress of asymmetric cooling period; this potential curling naturally fibrous nodules that can make can be by the fiber production that processes raw material under the condition that relaxes very much; apply very little power, just can obtain fixing fibrous nodules structure.This fibrous nodules has the back elastic structure that fabulous fill volume and durability are arranged.

This fibrous nodules and the former key distinction between product of producing on the carding machine that is referred to as " slubbing " or similar commercial product usually are that " slubbing " contains a large amount of fibers, these fibers are present in the nuclear that highly tangles, any rebound resilience is not provided, but constitutes pure " deadweight ".These " slubbings " can fully highly tangle, and make it can bear the combing operation." slubbing " is very suitable incorporates slub yarn (berber carpet that for example is used for different visions of requirement and tactile aesthetics, kilim carpet and other textiles) into, but it does not have the desired bulk density of the purposes of filling, rebound resilience and durability.

As described, Marcus is the rebound resilience fibrous nodules of producing him by the fiber that curls with spirality, and its air stir job operation can not be by the mechanical curly fiber producd fibers ball of standard.Spirally-crimped fibers remains to be used for producing thisly to be had desired constructed products and preferably processes raw material, but, we have now found that, opposite with former experience, can produce very similarly fibrous nodules of structure by improved mechanical curly fiber, this wavy staple has the curling combination of very special firsts and seconds.It is believed that key is to allow the fiber that processes raw material have the potentiality that nature curls.Though this fiber is perhaps not necessarily always the same with bicomponent fibers firm, this curling potentiality can make fibrous nodules produce under the mitigation condition, and produce similar structure.The processing conditions that the curling profile of fiber and being used to is produced these fibers is crucial for the structure of fiber.Air stirs condition can not produce any fibrous nodules by the commercially available mechanical curly fiber with standard, but according to the present invention, can use improved mechanical curly fiber production to have the product of satisfied structure and fill volume and durability.When making the fibrous nodules with optimum structure by these improved " mechanical curly fibers ", crucial parameter is that secondary curls.It is believed that it is that the secondary of these fibers curls and to make it have the potentiality that nature curls, because it has the three-dimensional crimp profile.

Therefore, when production has improved mechanical curly fiber (for example production fibrous nodules of the present invention is desired), it is believed that crucial part is the curling well setting of secondary, makes its frequency that has be about every 10cm4-16 and curls.One-level curl it is believed that more inessential.Preferably one-level curl be every 10cm28 curl below, one-level is curled because it helps to formalize better, and make stir with fibrous nodules in the entanglement of fiber carry out easily, but, have the one-level of 40 curl (examples 1) to curl with crimp frequency approximately up to every 10cm and also obtained some good results.We are used for a kind of simple and confirmed method that the tangible secondary that obtains to formalize curls is to reduce the crimp box load, but this point also can realize by alternate manner, for example widens the crimp box narrow orifice, i.e. the size of X-direction.

The polyester rope that is used for this method is preferably put crimp box into low relatively crimp box load or density, is preferably below per inch 26,000 spies, make rope can before and after folding, in the long one section rope inner conversion direction of 10cm 8-32 time.Because this low crimp box load, be preferably the tow band not only can before and after folding, but also the angle of convertible placement so that change in the plane that secondary curls, like this, the secondary plane of might not be always curling with one-level of curling meets at right angles.Whether the heat setting of frequency, three-dimensional feature and profile that secondary curls is for making fibrous nodules with mechanical curly fiber, and structure all is very crucial.According to observing in some of production period, we think that a side of curling secondary in most of the cases the ripple knot playing a part to make the fiber buddle fibrous nodules around the turning point to opposite side, produces circular smoothing coil on the surface of fibrous nodules.Last resulting structure is very similar to by the process raw material structure of the fibrous nodules that fiber produces of helix.Frequency and amplitude that pointed secondary curls are inadequate, unless its profile that formalized.By drawn tow with loosen tow, can be easily by curling that the functional expression estimation takes place.If necessary, this function estimation can develop into the quantitative measurment method, hereinafter will explain, or casehistory (1) is settled known thousand spies' tow on an Instron machine, stretching is curled to remove secondary, then by the curling restoring force of Instron load-transducing ergograph response measurement, or (2) are by an end of fixing known thousand spies' tow, under certain elongation device effect, this tow that stretches to obtain and to measure its complete stretched length (TL), is removed elongation device then, so that tow can be bounced back, and measure retracted length (RL), and calculate CTU as two linear measures poor (TL-RL), account for the percentage of full stretched length, what but we used is the Function Estimation method, and finds that it is gratifying instructing production product of the present invention with it.

One-level is crimped onto in the shaping of fibrous nodules and the structure and also plays certain booster action.More satisfactory is, and it has every 10cm 28 curl following low relatively frequencies and conglobate curling ripple knots is arranged, but when not having secondary to curl, only relies on that one-level is curling also to be not enough to obtain desirable fibrous nodules structure.Now confirm, only provide low-grade one-level to curl and also be not enough to form fibrous nodules on the former described improved Lorch equipment.

We have now found that, cross-sectional plane is that the solid fiber that processes raw material is generally than the easier formation fibrous nodules of hollow cored fibre, particularly in U.S. Pat 4618531, among US4783364 and the US4794038 on the disclosed improved Lorch equipment.On some improved carding machine, only just make the ability of tow, because of the curl difference produced of secondary less.But have the fibrous nodules of desirable good structure, durability, filling capacity (bulk/bulk density) and low adhesion for production, disclosed in this invention special curl be still crucial.According to the present invention, though the generally easier coiled fibrous nodules of fiber of solid fibers and relative low dawn number,, as what will see in an embodiment, the present invention by high composite bending modulus as 13 dtexs, 4 holes, 25% hole fiber also can the producd fibers ball.It is believed that the technology of using existing technology (improved) carding machine is can not be by this high composite bending modulus fiber, or the multi-channel fiber production goes out to have the fibrous nodules of high bulk density and good durability.Perhaps, it is unique feasible method that has the fibrous nodules of ideal structure by high hole and/or multi-channel fiber production that the present invention is considered to best.Is very difficult by effusion cooling with spirality crimping production.The bi-component production method is very difficult, and as far as we know, this bicomponent fibers can't commodity production.The combination that this one-level of the present invention is curled and secondary curls makes that making fibrous nodules by this fiber that processes raw material is out of question, and the high loading that can require according to final use, but high bearing force and good patience produce good with carry out the product of filling.

The poly-ester fibres that is used to make fibrous nodules of the present invention can apply a kind of smoothing preparation, and any conventional smoothing preparation all can be used for this purpose.This material is told about in U.S. Pat 4794038.The consumption of common smoothing preparation usually uses 0.01 to 1% the Si that accounts for fibrous nodules weight.Siloxane polymer uses with the concentration (approximate value) of 0.03%-0.8% usually, is preferably 0.15-0.3%, and measured is the percentum that Si accounts for fibre weight.Smoothing preparation the effect here is the adhesiveness that reduces between long filament, can form structure preferably in the manufacturing process of fibrous nodules, improves the slickness of packing material, and reduces the adhesiveness (improving shaking up property again) between the fibrous nodules.Yet, as foregoing, the fiber that processes raw material can apply the weight that about 0.05%-1.2%(accounts for fiber) block interpolymers (polyoxygenated inferior hydrocarbon/polyethylene terephthalate), as U.S. Pat 3416952 people such as McIntyre, disclosed in 3557039 and 3619269, and the periodic copolymer that similarly comprises polyethylene terephthalate fragment and the inferior hydrocarbon fragment of polyoxygenated is disclosed in many other patent specifications.Also can use other appropriate materials that contains the inferior hydrocarbon/polyethylene oxide of graft copolymer polyoxygenated.Situation when being very similar to the employing silicone by the interfibrillar friction situation that these products obtained, but, the fiber lubricated with these materials can bond on the commercially available copolyester binder fibers, this is absolutely necessary for manufacturing is used for molded fibrous nodules, as the U. S. application 07/549847(DP-4391 that awaits the reply jointly at Marcus) and U.S. Pat 4940502 in disclosed.

Because the mat by the manufacturing of molded fiber ball requires to have high resilience and bearing force, for the 25kg/m that is made by the identical fibre compound ³Fibrous nodules piece and 45kg/m ³The piece pad, all require to account for the 5-30 of Binder fiber, preferably 10-20%.Marcus discloses the suitable binder fibre that can adopt in US4794038 and US4818599, specially that its receipts are for referencial use at this.Is 07/533607 the application of awaiting the reply by Kerawalla in the application number of June 5 nineteen ninety application, relates to the Binder fiber structure of use microwave as the high-frequency energy.

In following embodiment, the invention will be further described for the general, and wherein, fiber is all made by polyethylene terephthalate.All partial sum percentums all are weight, and are the weight in fiber, except as otherwise noted.Bulk density records (1000 fill volume) on the 80x80cm mat, and the bulk density loss amount is to dress the given percentum (%) in experiment back in imitation, the assessment of architecture quality reflects the ratio of circular fiber ball, the hair degree of fibrous nodules, and the poorest with 1(two) best to 5(two) five grades weigh the quality (loose structure, good entanglement etc.) of formed fibrous nodules.

Comparative examples A

By a kind of drawn of the fiber production of 6,7 dtexs and the rope bundle that curls, employed draft ratio is 3.5X, crimp box load per inch 29,000 spies, and 0.25%(Si with conventional approach) commercially available polysiloxane smoothing preparation.Resulting fiber have crimp frequency be 31 curl/one-level of 10cm curl with 3 curl/10cm more weak secondary curl.This rope bundle is cut into the chopped fiber of 32mm staple fiber ppd, and with the shredding on commercially available Laroche fibre-opening unit having of this chopped fiber, and is injected in the improved Lorch machine, as US4618531, disclosed in 4783364 and 4794038.This fiber rotating speed with 450rpm in the Lorch machine overturn 4 minutes, and under this condition, these fibers that process raw material do not form fibrous nodules.

Embodiment 1

Be similar to Comparative examples A, it but is the rope bundle that under reduced pressure, curls, and the crimp box load also reduces 38.5%, products obtained therefrom have crimp frequency be 39 curl/one-level of 10cm curl and crimp frequency be 4 curl/the relative stronger secondarys of 10cm are curling, it is formalized preferably, be about 0.6N/ thousand spies (being about 4 times that the secondary of the used fiber that processes raw material in the Comparative examples A curls) by the pullout forces that curls.This rope bundle is cut into the chopped fiber of 32mm staple fiber ppd, under above-mentioned condition, is converted into easily and has the good structure and the fibrous nodules of shaking up property again.Table 1B has provided the characteristic of the fibrous nodules of being produced by example 1, and with its with compare by the commercially available prod of the fiber manufacturing that processes raw material of 5 dtexs of helix-coil (with the silicone coated) according to US4618531.

Table 1A

Feature Comparative examples A example 1 curls

Number of crimp/10cm 31 39 that one-level is curled

Number of crimp/10cm 34 that secondary curls

Pullout forces (N/ktex) curls

-one-level curls 6.0 5.3

-secondary curls 0.14 0.57

Result relatively is summarised among the table 1A.

In order to have the fibrous nodules of satisfied structure with this technology production, the effective frequency quilt heat setting well that requires secondary to curl.Though for the processing fiber of Comparative examples A and example 1, the pullout forces that one-level is curled is more or less the same,, in example 1, the pullout forces that secondary curls is 4 times of its Comparative examples A.This power is directly related with the heat setting that secondary curls, and it relates to fiber again and produces the potentiality that nature curls.

Because Comparative examples A can not form fibrous nodules under experiment condition, the fibrous nodules of example 1 have to compare with the commercial goods fibrous nodules.

Table 1B

The fibrous nodules characteristic

1. bulk density

Commercial examples 1

IH2 228mm 212mm

4N 208mm 190mm

60N 101mm 87mm

200N 44mm 39mm

2. bulk density loss

Commercial examples 1

IH2 -25.2% -21.2%

4N -25.0% -20.7%

60N -21.2% -16.4%

200N -5.7% -2.6%

3. adhesive bonding property and rank

Commercial examples 1

Adhesive bonding property 3.3N 4.3N

Quality scale 4-5 4

The results are summarized among the table 1B relatively.

The loading and the durability of the loading that fibrous nodules had of these mechanical curly fiber productions and durability and the fibrous nodules of being produced by spirally-crimped fibers are more or less the same.

Fig. 2 A and 2B be commercially available fibrous nodules (making) by 5 dtex spirality fibers by electronic scanning micro-(ESM) with the captured photo of the magnification factor of 20X.Figure 1A and 1B are the similar photos of example 1 fibrous nodules.This ESM photo has relatively shown closely similar fiber random alignment and uniform fibers density in the fibrous nodules.Fiber produces bulk fully and does not have fulling milling in two products.The bulk density of this structures shape fibrous nodules, durability and the characteristic of shaking up property again.Structural similitude interpretation shown in the photo similarity of table 1B data.

Fig. 3 and Fig. 4 are the photos of tow band.Be cut into the fiber that processes raw material by these tow bands and be used for the above-mentioned course of processing.Fig. 3 is corresponding with example 1, and Fig. 4 and Comparative examples A are corresponding, and they have clearly illustrated that secondary curls by the arrangement of photo bottom to the top.Can see that at the gap of these align tops one-level is curling, it is by single fiber is formed from the operation that tow separates.Can be observed a branch of fiber and curved turning 90 degrees of separating by tow on the top of Fig. 3.The profile that secondary curls and one-level is curled can both be observed.High-amplitude and low-frequency contrast that low amplitude that one-level is curled and high-frequency and secondary curl can clearly be observed.Difference between secondary curls among Fig. 3 and Fig. 4 is by seeing clearly on the photo.Shown in Figure 5 is the tow band of holding the single hole fiber in 6.1 minutes, it can be on improved Lorch machine the producd fibers ball, but its structure is on duty mutually.Secondary curls and looks more much better than Comparative examples A (Fig. 4), but is unsuitable for heat setting.This is adjustable, therefore, will obtain a kind of improved fiber that processes raw material.

Comparative example B.

With conventional approach by 13 dtexs, 4 holes, a kind of drawn of the fiber production of 24% hole and the rope bundle that curls, employed extensibility is 3.5X, crimp box load per inch 26,000 spies, and 0.5% copolyether/polyester commodity ZELCON5126, these commodity can be obtained by E.I. E. I. Du Pont de Nemours and Co.Prepared fiber have crimp frequency be 22 curl/one-level of 10cm curl and crimp frequency be 2 curl/secondary of the weak setting of 10cm curls.This rope bundle is cut into the chopped fiber of 50mm staple fiber ppd, and with the shredding on carding machine of this chopped fiber, is transferred to an improved roller and clearer card by air then, the fibrous nodules of the about 6.5mm of improved production mean diameter.This fibrous nodules is with 80kg/ hour speed production, and shows the relative high adhesive bonding property of significant hair and 10.5N, and a spot of prolate body.This fibrous nodules has uneven density, some highdensity parts is arranged and show limited fulling milling.This fulling milling has reduced the bulk density (being fill volume) of product, and has reduced the rebound resilience (table 2) of product on less degree.Under the condition of use-case 1, this chopped fiber can not be produced any fibrous nodules on improved Lorch machine.

Example 2.

Prepare a kind of drawn and curling tow in the mode identical with comparative example B, the nipper pressure that has but reduced crimp box is to increase secondary and curl and to improve its heat setting, use identical draft ratio 3.5X, curling load (26,000 spy/inch), with 0.5% and copolyether/polyester commodity ZELCON5126, these commodity can obtain from your E.I.Du Pont Company of E.I. sodium curtain.Resulting fiber have crimp frequency be 22 and curl/one-level of 10cm is curled and crimp frequency is about 4 and curls/secondary of 10cm curls.As if secondary curls clearly, judges that its heat setting is not best but measure according to the subjectivity of rope bundle drawing restoring force.This rope bundle is cut into the chopped fiber of 50mm staple fiber ppd, and, is transferred on the roller and clearer card improved producd fibers ball then by air with the shredding on carding machine of this chopped fiber.Under the appointed condition identical,, and low hair and the good fibrous nodules that is shaped have been shown with 95kg/ hour speed producd fibers ball with comparative example B.The mean diameter of fibrous nodules is 6.3mm, and obviously descends aspect fulling milling.Therefore, adhesiveness drops to 6.5N, and bulk density (fill volume) is also significantly improved (table 2).Under the condition of using Comparative examples A and example 1, this fiber can be produced fibrous nodules on improved Lorch equipment, but its texture ratio poor with the product of the fiber manufacturing that processes raw material of helix-coil on identical equipment.It is believed that reason is that the heat setting that secondary curls in this experiment is abundant inadequately, and that this air stirs method require the to process raw material potentiality of the natural crimp that fiber has is desired bigger than improved carding machine.

Table 2

Feature comparative example B example 2 curls

Number of crimp/10cm 22 22 that one-level is curled

Number of crimp/10cm 24 that secondary curls

Fibrous nodules feature comparative example B example 2

IH2 90mm 125mm

7.5N 67mm 88mm

60N 41mm 48mm

120N 33mm 37mm

Mm replys merit 48.5% 55%

Adhesiveness 10.5N 6.5N

(note: though the setting that the secondary of example 2 curls is better than comparative example B, subjective judgement, it does not still have high restoring force).

Result relatively is summarised in the table 2.

The product of example 2 is compared with comparative example B's, has shown higher fill volume, has 39% higher original depth and 17% higher support bulk density.Adhesiveness is obviously lower, shows that it has preferably shaking up property again.The product of example 2 has higher commodity value, and comparative example B is considered to not satisfied.

Comparative example C

Prepare a kind of drawn and curling rope bundle in the mode identical with comparative example B.With the core-skin type bicomponent binder fibers of this rope Shu Liantong 17 dtexs together (its weight ratio is 88: 22) be cut into 50mm, and with chopped fiber shredding on carding machine, be transferred on the roller and clearer card by air then, be about the fibrous nodules of 6.5mm with improved production mean diameter.This fibrous nodules is with 74kg/ hour speed production, and shown the relative high adhesiveness of tangible hair and 12N, has a small amount of prolate body.The density unevenness of this fibrous nodules is even, the density height of some part, and show some limited fulling millings.This fulling milling has reduced the bulk density (being fill volume) of product and reduced the rebound resilience (table 3) of product on less degree.

Example 3

With the method identical with example 2 by the fiber production drawn of 13 dtexs, 4 holes, 24% hole and curling rope bundle.The sheath-core bicomponent fibre rope Shu Yiqi (weight ratio 88: 22) of this rope Shu Liantong 17 dtexs is cut into the chopped fiber of 50mm staple fiber ppd, and with the shredding on carding machine of this chopped fiber, be transferred on the roller and clearer card by air then, with improved producd fibers ball.With comparative example C same apparatus condition under, with 87kg/ hour speed producd fibers ball, show low hair and the good fibrous nodules that is shaped, the mean diameter of this fibrous nodules is 6.5mm, and obviously descends aspect fulling milling.Therefore, adhesiveness drops to about 7.5N, and as can be seen from Table 3, its bulk density (fill volume) is compared with comparative example C also and obviously improved.

Table 3

Comparative example C example 3

IH2 93mm 136mm

7.5N 68mm 92mm

60N 41mm 48mm

120N 33mm 36mm

Reply merit 48.6% 55%

Adhesiveness 12.0% 7.5N

These employed a lot of experiments all mentioned in this article have earlier in the patent on the books.

The bulk density that mat carries out is measured:

In traditional Instron airborne measurements bulk density, to measure the height of compressive force and mat.This measurement is to be that the presser feet of 10cm is finished by being attached to diameter on the Instron machine.At first, sample is compressed to the maximum pressure of 60N, unclamps then.Can find the elemental height (IH2) of test material by second compression line, carrying bulk density (SB7.5N) is promptly at the height of mat under the power of 7.5N with at 60N(B60N) power under the height of mat.(RS, promptly AS accounts for IH with relative indicatrix with absolute index (AS, i.e. IH2-SB7.5N) ₂Percentum) estimation flexibility.Rebound resilience is measured with the form (WR%) of replying merit, i.e. the percentum that is calculated by the ratio at the area under the whole recovery curve and area under whole compression line.

Durability:

Simulate long-time normal the use; allow testing fatigue instrument (FTP) that a mat is alternately done mechanical work (promptly compress and recover); in 18 hours about repeatedly 6000 times; use a series of overlapping shearing motions; then Fast Compression is so that be created in regular meeting occurs during the long-term use fiber floc material caking, become pad and fibers interlock.Wadding material amount in the mat is very big to result's influence, and therefore, (80 * 80cm) all jet loads the 1000g packing material to each mat, unless otherwise mentioned.

Importantly between normal used life, mat should keep recovering the ability of its original form and volume (highly), otherwise this mat will lose its visual sense of beauty and comfort.Therefore, bulk density loss is in a conventional manner, with mat with above-mentioned handled by the labor tester before and handle after mensuration.Visual sense of beauty, bulk density and flexibility are problems that has individual and/or tradition preference, and importantly, the mat characteristic variations should as much as possible little (being the durability of mat) during dressing.The measurement of bulk density is carried out on " Instron " machine, and to measure compressive force and mat height, mat is to compress with the presser feet that is attached to the diameter 288mm on the Instron machine.Can find elemental height (IH2) (cm of unit), carrying bulk density (at the height that records under the compressive force of 60N) and the height under the 200N compressive force of experiment material by the Instron curve.Flexibility is weighed with absolute index (IH2-carries bulk density) and relative indicatrix (accounting for the percentum of IH2) dual mode.No matter whether these parameters remain unchanged after the testing fatigue instrument is handled, and these two indexs are all very important.

Adhesiveness is measured:

This experiment is to be used for detection fibers wadding material to allow ability that object passes through, and it and by having comparable characteristic, relevant as the shaking up property again of the fibrous nodules of the fiber manufacturing of dawn number, smoothing preparation etc.Adhesive force is to use the fiber floc material by 6 fixing metal bar clampings that closely are provided with in pairs on every limit of rectangle plane upwards to draw the needed power of this vertical rectangular.The diameter of all metal bars all is 4mm, and is that corrosion-resistant steel is made.Rectangle is vertical by long 30mm() and the 160mm(level) rod constituted.This rectangle is attached on the Instron machine, and its rod under is suspended on apart from the top of the plasticity transparent cylinder bottom 3mm of diameter 180mm.(by the hole on the cylindrical wall fixing metal bar is inserted subsequently, and on every limit of rectangle, places) with being partitioned into over the ground of 20mm.But, before these rods insert, put the 50g fiber floc material into cylinder, and adjust the zero line of Instron, with the weight of compensation rectangle and fiber floc material.Weight fibre under compression wadding with 402g was expected 2 minutes.Then, with 6 rods (fixing) in couples level insert, as described, per 3 rods are in a side of rectangle, a pair of another on, with the perpendicular separation that is positioned at from the lowermost a pair of rod of cylinder bottom 30mm be 20mm.Remove weight then.At last, by this rectangle of fibrous nodules pull-up between three pairs of hold-down barss, measure the Newton force of being set up by the Si Telang machine.

Circular percentum:

As indicated, because tailfiber, i.e. the compression cylinder of fiber floc material has reduced the shaking up property again (and having increased adhering numerical value) of the fibrous nodules that the present invention produced.This tailfiber is undesirable, therefore, designs the ratio that following method is determined circular and prolate body.Extract one of about 1g(out) fiber floc material, be used for appearance test and be divided into 3 bundles: obviously circular is a branch of, and obviously prolate body is a branch of, ambiguous a branch of, measures respectively.All have aspect ratio all circular at last less than 2: 1 cross-sectional plane.

From aesthetic angle, the dawn number of the size of fibrous nodules and fiber is all very important, but should be known in that As time goes on aesthetic preference can and change really.In order to make the fibrous nodules of desirable low hair, should pay the utmost attention to shearing length.As what proposed in this area, the mixing of various fiber Denier is desirable for aesthetic feeling.

Determining of crimp frequency:

Use the crimp balance Zi Weige S-160(Crimp Balance Zweigle S-160 that buys by Zi Weige Reutlingen (Zweigle Reutlingen) (West Germany)) measure crimp frequency.

Determining of one-level crimp frequency:

The curling number of counting one-level when sample is in than the low-tension state.Like this, single fiber is fixed on the crimp balance machine and the weight of a 2mg/ dtex is placed on the suspension hook, curl with the counting one-level.(the measurement length records is L ₁) frequency computation part is based on the extended length L of sample under the high tension ₂Extended length L ₂Be under the weight of 45mg/ dtex, to determine.Calculate crimp frequency according to L2 then.

Determining of secondary crimp frequency:

Extended length L ₂Determine sample is loosened fully making it get back to 60% of extended length then as mentioned above.According to the extended length under the 45mg/ dtex, the counting secondary curls and calculates its frequency then.

The measurement of the curling uncoiling stress of secondary:

The foundation that the heat setting that secondary curls helps fiber to curl and store naturally.The secondary required force measurement of uncoiling that curls, directly relevant with the natural crimp potential of fiber.Weak power is represented weak heat setting.Even when frequency of curling at secondary and amplitude were all suitable, weak setting also may cause the fibrous nodules structure of difference.

One bundle fiber that will be cut into by 0.7 thousand spies' rope bundle is fixed on the Instron machine with clip, and with constant elongation speed this bundle fiber that stretches, becomes straight line up to final curling.This bundle fiber makes marks at clip height place, and by removing on the Instron machine.This fibrous bundle is weighed, calculating its accurate thousand spies, and the weight that hangs 2mg/ thousand spies, to determine the length (promptly to secondary curl uncoiling tension force) between two marks.With this length records on load-deformation curve, so that determine the uncoiling stress that secondary curls.Uncoiling stress for one-level is curled can prolong by the straight line portion with load-deformation curve, calculates up to intersecting with bottom line.By the standardized vertical line of point of crossing, intersect up to it and load-deformation curve.What the stress of reading from this point of crossing was equivalent to fibrous bundle always separates crimp force, the uncoiling power of coming first order calculation to curl by the difference of always separating the uncoiling power that crimp force and secondary curl.One-level is curled the order of magnitude of required uncoiling power usually above the secondary required uncoiling power of curling.

Be readily appreciated that the present invention is specially adapted to be used for the fleeces underfill material of fibrefill and the poly-ester fibres with the feature that is fit to this purpose, but the present invention is not limited thereto.As by the application number 07/508 that awaits the reply, 878(DP-4690) in as can be seen, fibre agglomerates also can be made by other fiber, and be not limited to employed fiber Denier and be used to fill purpose.In addition, for this professional those of ordinary skill, other variation also is conspicuous.For example, fibre agglomerates can be made by the compound of different materials, with the acquisition advantage and improve characteristic.By in same fibre agglomerates structure, mixing different fibrous appearances, resemble curling and/or the dawn number, and/or fiber structure, so that the effect maximum of various fibers can obtain good especially result.And the dissimilar mixing of curling also has advantage on same fiber, can improve the potentiality of making fibre agglomerates, and/or improve the characteristic of gained fibre agglomerates.In addition, as indicated, the method that those of ordinary skills can design many different filling formula crimping machines produces the three-dimensional multi-turn structure of long filament, so that the long filament of this multi-turn is suitable on suitable machine, as forming silk group (being used for cutting short-forming fiber) on improved Lorch equipment or the improved carding machine.For instance, this alternative curling mode also can comprise fill out that case jetly curls, false twist texturing and aerojet distortion.The present invention is not limited to method or the device that this paper enumerates for explanation.

Claims

1, a kind of fibrous nodules, fiber is random alignment and tangles in each fibrous nodules, it is characterized in that, the mean diameter of these fibrous nodules is about 2-20mm, the length of single fiber is about 10-100mm, and is by having fiber production that firsts and seconds curls, and the frequency that said one-level is curled is about 14-40 and curls/10cm, the frequency that said secondary curls is about 4-16 curls/10cm, and the average amplitude that secondary curls is 4 times of the curling average amplitude of one-level at least.

2, fibrous nodules according to claim 1, wherein said fiber is a poly-ester fibres.

3, fibrous nodules according to claim 2, it has shaking up property again.

4,, wherein have at least the fibrous nodules of 50% weight to have such cross-sectional plane according to each described fibrous nodules among the claim 1-3; The cross-sectional dimension of each fibrous nodules is no more than 2 times of minimum transverse cross-sectional dimension.

5, according to each described fibrous nodules among the claim 1-3, wherein fiber is coated with smoothing preparation, and used smoothing preparation is a siloxane polymer, and consumption is about the Si(of 0.01-1% in fibre weight).

6, according to each described fibrous nodules among the claim 1-3, wherein fiber applies the smoothing preparation (in fibre weight) of the 0.05-1.2% that has an appointment, and this smoothing preparation is actually by the periodic copolymer of inferior hydrocarbon of polyoxygenated and polyethylene terephthalate to be formed.

7, a kind of fibrous nodules, in each fibrous nodules, fiber is random alignment and tangles, said fiber is the compound of bearing fiber and Binder fiber, and Binder fiber can contain selectively can be by the material of microwave or high-frequency energy heating, it is characterized in that, the mean diameter of fibrous nodules is about 2-20mm, the length of single fiber is about 10-100mm, bearing fiber has one-level and curls curling with secondary, the frequency that said one-level is curled is about 14-40 curling/10cm, and the frequency that said secondary curls is about 4-16 curls/10cm, and the average amplitude that secondary curls is 4 times of the curling average amplitude of one-level at least.

8, fibrous nodules according to claim 7, wherein Binder fiber accounts for about 5-30% of fibre blend weight, is poly-ester fibres and carry long and slender.

9, according to claim 7 or 8 described fibrous nodules, wherein Binder fiber is the sheath-core bicomponent fibre or the collateral fiber of polymerization, and it mainly is made of than a kind of polymers compositions of low 50 ℃ of the melt temperature of another aggregate combinations at least its tack temperature.

10, according to claim 7 or 8 described fibrous nodules, wherein Binder fiber is a simple fraction polymeric adhesive fiber, and its tack temperature is lower than 50 ℃ of the melt temperatures of bearing fiber at least.

11, be used for making the method for each described fibrous nodules of claim 1-8, it is characterized in that, stir the fiber that processes raw material facing to wall of container by air.

12, be used for making the method for each described fibrous nodules of claim 1-8, it is characterized in that, allow the fiber that processes raw material of shredding pass through roller and clearer card.

13, be used for making the method for each described fibrous nodules of claim 1-8, it is characterized in that, allow the fiber that processes raw material of shredding pass through flat caiding machine capable.

14, a kind of compression-molded structures is characterized in that, claim 7 or 8 fibrous nodules are prefabricated shape, and Binder fiber wherein passes through heat-activated.

15, a kind of compression-molded structures is characterized in that, claim 7 or 8 fibrous nodules are prefabricated shape, and Binder fiber wherein is by microwave or high frequency energy source activation.

16, a kind of compression-molded structures is characterized in that, the fibrous nodules of claim 9 is prefabricated shape, and Binder fiber wherein is by microwave or the activation of the high-frequency energy.

17, a kind of compression-molded structures is characterized in that the fibrous nodules of claim 10 is prefabricated shape, and wherein Binder fiber is by microwave or the activation of the high-frequency energy.

18, a kind of compression-molded structures is characterized in that the fibrous nodules of claim 9 is prefabricated shape, and wherein Binder fiber passes through heat-activated.

19, a kind of compression-molded structures is characterized in that the fibrous nodules of claim 10 is prefabricated shape, and wherein Binder fiber passes through heat-activated.