CN108070956B - Non-woven fabric structure and manufacturing method thereof - Google Patents
Non-woven fabric structure and manufacturing method thereof Download PDFInfo
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- CN108070956B CN108070956B CN201611101193.5A CN201611101193A CN108070956B CN 108070956 B CN108070956 B CN 108070956B CN 201611101193 A CN201611101193 A CN 201611101193A CN 108070956 B CN108070956 B CN 108070956B
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- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 74
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- 239000000835 fiber Substances 0.000 claims abstract description 241
- 239000002131 composite material Substances 0.000 claims abstract description 107
- 239000008188 pellet Substances 0.000 claims abstract description 87
- 238000000034 method Methods 0.000 claims abstract description 9
- 238000010036 direct spinning Methods 0.000 claims abstract description 8
- 210000003746 feather Anatomy 0.000 claims description 39
- 238000009960 carding Methods 0.000 claims description 37
- 239000000463 material Substances 0.000 claims description 17
- 229920000742 Cotton Polymers 0.000 claims description 11
- 239000002861 polymer material Substances 0.000 claims description 7
- -1 polypropylene Polymers 0.000 claims description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 5
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 5
- 229920002334 Spandex Polymers 0.000 claims description 4
- 229920002972 Acrylic fiber Polymers 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 238000004321 preservation Methods 0.000 abstract description 9
- 230000000694 effects Effects 0.000 abstract description 6
- 230000000052 comparative effect Effects 0.000 description 7
- 239000004744 fabric Substances 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- 230000001965 increasing effect Effects 0.000 description 5
- 238000007664 blowing Methods 0.000 description 4
- 238000009958 sewing Methods 0.000 description 3
- 239000004759 spandex Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000005086 pumping Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 210000004177 elastic tissue Anatomy 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 230000009545 invasion Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/08—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns
Abstract
A non-woven fabric structure and a method for manufacturing the same. The non-woven fabric structure comprises a plurality of composite fiber balls and a plurality of direct spinning fibers. The composite fiber pellet comprises a plurality of layers from inside to outside, wherein the outermost layer of the plurality of layers is made of short fibers, and at least one layer of the plurality of layers is made of down. The direct-spun fibers are used to entangle the composite fiber pellets to form a nonwoven fabric structure. The non-woven fabric structure is in a flake shape and can be directly applied to down products, the manufacturing process can be simplified, and besides, the non-woven fabric structure can be supported by the composite fiber balls, so that the non-woven fabric structure is not easy to collapse, and down keeps fluffy to improve the heat preservation effect of the non-woven fabric structure.
Description
Technical Field
The invention relates to a non-woven fabric structure and a manufacturing method thereof.
Background
Down is one of the best thermal insulators in natural fibers, and can keep warm because fine air holes are distributed in the down. After absorbing heat, the down feather becomes fluffy and effectively insulates against the invasion of cold air. Thus, down is commonly used as a filler in jackets, pillows, sleeping bags, and the like.
However, in general, down products need to be sewn into a pocket, and then down is filled into the pocket by air flow and then is sewn to be fixed, so that down can easily fall out from the sewing line, and the phenomenon of feather falling is caused. In addition, only the inner cloth and the outer cloth are arranged along the sewing line, and the down feather is not existed, so that the heat preservation effect is not realized. Moreover, when manufacturing down products, manufacturers need to perform sewing, gas filling and other processes with a lot of manpower, so that the labor cost is high. These are problems that people in the relevant industries have to face while enjoying the benefits of down.
Disclosure of Invention
The invention provides a down-containing non-woven fabric structure, which is used for improving the production efficiency of down application and enhancing the heat preservation characteristic of the non-woven fabric structure.
One embodiment of the present invention provides a non-woven fabric structure, which comprises a plurality of composite fiber balls and a plurality of direct spinning fibers. The composite fiber pellet comprises a plurality of layers from inside to outside, wherein the outermost layer of the plurality of layers is made of short fibers, and at least one layer of the plurality of layers is made of down. The direct-spun fibers are used to entangle the composite fiber pellets to form a nonwoven fabric structure.
In one or more embodiments of the present invention, the direct-spun fibers may be meltblown fibers or spunbond fibers.
In one or more embodiments of the present invention, the material of the direct-spun fiber may be a thermoplastic polymer material.
In one or more embodiments of the present invention, the innermost layer of the plurality of layers of the composite fiber pellet may be down.
In one or more embodiments of the present invention, the material of the innermost layer of the plurality of layers of the composite fiber pellet may be short fibers.
In one or more embodiments of the present invention, a portion of the direct-spun fibers may be distributed on the outer surface of the composite fiber pellet, and a portion of the direct-spun fibers may be distributed inside the composite fiber pellet.
In one or more embodiments of the present invention, the short fibers may include polypropylene fibers, polyethylene terephthalate fibers, nylon fibers, acrylic fibers, Spandex (Spandex), cotton fibers, or any combination thereof.
Another embodiment of the present invention provides a method for manufacturing a nonwoven fabric structure, comprising the steps of: (a) gathering the down feather into a carding machine; (b) gathering short fibers into a carding machine; (c) carding the down feather and the short fibers to obtain a plurality of composite fiber pellets; and (d) outputting the composite fiber pellets, and enabling the composite fiber pellets to pass through a semi-molten direct-spun fiber screen, so that the direct-spun fibers and the composite fiber pellets are entangled to form a non-woven fabric structure.
In one or more embodiments of the present invention, step (a) is performed before step (b).
In one or more embodiments of the present invention, the step (d) may further comprise passing the nonwoven fabric structure between two rollers to collect and roll the nonwoven fabric structure.
The short fibers and the down feather are made into composite fiber pellets, then the composite fiber pellets and the direct spinning fibers are intertwined to form a non-woven fabric structure, and the non-woven fabric structure can be shaped into a flocculus-shaped non-woven fabric structure through a collecting device. The elasticity of the composite fiber pellets enables the non-woven fabric structure to have good flexibility and stiffness and not to collapse easily, and further the heat preservation effect of the non-woven fabric structure is improved. In addition, the non-woven fabric structure of the wadding shape can be directly cut or sewn with the cloth, and the traditional complicated manufacturing process is omitted, so that the production efficiency can be improved, and the labor cost can be reduced.
Drawings
In order to make the aforementioned and other objects, features, and advantages of the invention, as well as others which will become apparent, reference should be made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic view of an embodiment of a machine for manufacturing a non-woven fabric structure according to the present invention;
FIGS. 2 and 3 are schematic cross-sectional views of different embodiments of composite fiber pellets in a nonwoven fabric structure according to the present invention;
fig. 4 is a schematic cross-sectional view of a non-woven fabric structure according to an embodiment of the invention.
Detailed Description
While the spirit of the invention will be described in detail and with reference to the drawings, those skilled in the art will understand that various changes and modifications can be made without departing from the spirit and scope of the invention as taught herein.
In order to solve the problems mentioned in the prior art, the present disclosure provides a non-woven fabric structure and a method for manufacturing the same, wherein down feather and short fibers are mixed into a dough (hereinafter referred to as a composite fiber pellet), and then the composite fiber pellet is entangled and shaped into a floccular non-woven fabric structure by using directly spun fibers, the floccular non-woven fabric structure can be directly applied to down feather products, so that the manufacturing process can be simplified, the non-woven fabric structure can be supported by the composite fiber pellet, the non-woven fabric structure is not easy to collapse, and the down feather is kept fluffy to improve the heat preservation effect of the non-woven fabric structure.
Referring to fig. 1, a schematic diagram of an embodiment of a machine for manufacturing the non-woven fabric structure of the invention is shown. The machine 10 includes a flow channel 20, a carding machine 30 at one end of the flow channel 20, a plurality of feeding devices 40 connected to the flow channel 20, a melt-blowing device 50 at an outlet of the carding machine 30, and a collecting device 60 below the melt-blowing device 50. The short fibers 110 and the down feathers 120 enter the flow channel 20 from different feeding devices 40 and are combed into composite fiber balls 100 by the carding machine 30, then the composite fiber balls 100 are output by the carding machine 30 and pass through a semi-molten direct spinning fiber curtain 200 ejected by the melt-blowing device 50, and are tangled and fixed by the direct spinning fibers to form a non-woven fabric structure 300, and the non-woven fabric structure 300 is collected by the collecting device 60.
Specifically, the short fibers 110 and the down feathers 120 enter the flow channel 20 from different feeding devices 40, and then the short fibers 110 and the down feathers 120 are guided to the carding machine 30 by a conveyer belt or an air flow in the flow channel 20, and are carded into the composite fiber pellets 100 by the carding machine 30. Since the short fibers 110 and the down feathers 120 enter the flow passage 20 from different feeding devices 40, the short fibers 110 and the down feathers 120 are gathered into the carding machine 30 in the form of layered cotton layers, and the composite fiber balls 100 are layered from inside to outside when the short fibers 110 and the down feathers 120 are carded into the composite fiber balls 100.
In order to prevent the down feather 120 from being directly exposed to the composite fiber pellet 100 and thus to separate the down feather 120 from the composite fiber pellet 100, the material of the outermost layer of the composite fiber pellet 100 is preferably short fibers 110, so as to capture the down feather 120 of the inner layer through the short fibers 110, and then fix the down feather 120 in the composite fiber pellet 100. In some embodiments, the number of feed units 40 is three, wherein the feed units 40 furthest from the carding machine 30 and closest to the carding machine 30 are staple fiber feed units, and the feed unit 40 therebetween is a down feed unit. In other embodiments, the number and type of the feeding devices 40 may be varied according to actual design requirements, as long as the feeding device 40 furthest from the carding machine 30 is a staple fiber feeding device.
The carding machine 30 is used to grab and comb the short fibers 110 and the down 120 to mix them into the spherical composite fiber ball 100. In some embodiments, the carding machine 30 is a mechanism capable of carding, for example, the carding machine 30 includes a roller 32 and a cylinder bed disposed on a surface of the roller 32, and the cylinder bed has a plurality of bent blades 34 thereon. As the roller 32 rotates, the blades 34 on the cylinder bed cut the cotton layer into small pieces of cotton which then roll with the roller 32 into a spherical composite fiber pellet 100 in the gap between the blades 34. An air flow source 70 is arranged near the outlet of the carding machine 30, when the composite fiber pellets 100 are formed, the composite fiber pellets 100 automatically separate from the cylinder needle bed, and then the composite fiber pellets 100 are taken away from the carding machine 30 by the air flow generated by the air flow source 70. The air flow source 220 may be a blower motor, and the air flow speed may be about 1-60 m/s.
The size of the composite fiber pellet 100 is determined by the gap between the blades 34 on the cylinder needle bed, in other words, if the gap between the blades 34 is larger, the cotton mass cut by the blades 34 is larger, and the size of the composite fiber pellet 100 is also larger, and if the gap between the blades 34 is smaller, the cotton mass cut by the blades 34 is smaller, and the size of the composite fiber pellet 100 is also reduced. Thus, the size of the composite fiber pellet 100 can be determined by selecting the appropriate cylinder bed.
As mentioned above, since the short fibers 110 and the down feathers 120 enter the flow passage 20 from different feeding devices 40, and the feeding device farthest from the carding machine 30 is the short fiber feeding device, the lowest layer of the cotton layer merged into the carding machine 30 is the short fiber layer, and after the cotton layer is carded by the carding machine 30 to form the composite fiber ball 100, the outermost layer of the composite fiber ball 100 is also the short fibers 110, so as to avoid the situation that the down feathers 120 are directly exposed and fly.
The meltblowing apparatus 50 is disposed at the outlet of the carding machine 30, and the position of the meltblowing apparatus 50 is higher than that of the carding machine 30. The meltblowing apparatus 50 is configured to provide a veil of semi-molten direct spun fibers 200, the veil of semi-molten direct spun fibers 200 comprising a plurality of semi-molten direct spun fibers 210.
The meltblowing apparatus 50 includes a feeder 52, a heated extruder 54, and a nozzle 56. After the thermoplastic polymer material enters the heating extruder 54 from the feeder 52, the thermoplastic polymer material is heated and melted by, for example, a heating screw in the heating extruder 54, and is pushed by the heating screw to advance to the nozzle 56. The nozzle 56 can be energized with a high voltage to cause the thermoplastic polymer material in a molten state to leave the nozzle 56 and become filaments of the direct spun fibers 210 to form the semi-molten direct spun fiber veil 200. The direct-spun fibers 210 may be continuous spunbond fibers or discontinuous meltblown fibers.
In some embodiments, the melt blowing apparatus 50 may further include a filter 58 and a metering pump 59 disposed between the heating extruder 54 and the nozzle 56, so as to filter the oversized particles in the molten thermoplastic polymer material, such as incompletely melted polymer material particles or impurities, through the filter 58, and then control the amount of material extruded from the heating extruder 54 through the metering pump 59. The meltblowing apparatus 50 may optionally be provided with air knives at the nozzle 56 to adjust the angle of the semi-molten direct spun fiber veil 200 and the length of the direct spun fibers 210 by varying the angle and flow rate of the air knives.
As composite fiber pellets 100 are directed by the air stream generated by air stream source 70 away from carding machine 30, composite fiber pellets 100 are drawn through semi-molten direct spun fiber veil 200. After the composite fiber pellets 100 are combined into the semi-molten direct spun fiber veil 200, the semi-molten direct spun fibers 210 will be combined with the composite fiber pellets 100 below the nozzles 56 of the meltblowing apparatus 50. At this time, since the direct-spun fibers 210 are not completely solidified, the direct-spun fibers 210 will bond the composite fiber pellet 100 and solidify, so that the composite fiber pellet 100 and the direct-spun fibers 210 are combined together to form the continuous non-woven fabric structure 300.
A collecting device 60 is positioned below the meltblowing device 50 to take up and collect the nonwoven structure 300. In some embodiments, the collection device 60 includes a vacuum pumping platform 62 and two rollers 64 disposed on the vacuum pumping platform 62. The nonwoven structure 300 is drawn by the vacuum suction platform 62 and moves toward the collection device 60. After the non-woven fabric structure 300 contacts the rollers 64, the non-woven fabric structure 300 passes between the rollers 64 due to the rolling of the rollers 64, and the non-woven fabric structure 300 is formed into a flake shape by the extrusion and shaping of the rollers 64. The batt-like nonwoven structure 300 can be further collected into a roll for subsequent processing.
The roller 64 may be surface treated to prevent the direct spun fibers 210 or the composite fiber pellets 100 from adhering to the surface of the roller 64. Since the nonwoven structure 300 can be extruded through the rollers 64, the distance between the rollers 64 determines the thickness of the batt-like nonwoven structure 300. In other words, the distance between the rollers 64 can be increased if a thicker nonwoven structure 300 is desired, and the distance between the rollers 64 can be decreased if a thinner nonwoven structure 300 is desired.
In other embodiments, the rollers 64 may be replaced by perforated belts, in which case the nonwoven structure 300 is laid flat on the belts and shaped by suction from the vacuum suction platform 62.
As described above, the composite fiber pellets 100 are combed into a spherical shape by the carding machine 30, and therefore, the composite fiber pellets 100 have good elasticity, so that the nonwoven fabric structure 300 is not easy to collapse and is rich in air, and the down feather 120 has sufficient space to stretch and make the nonwoven fabric structure 300 have good heat insulation properties. In addition, the non-woven fabric 300 can be cut or sewn directly, thereby eliminating the complicated process of making down garments.
Referring to fig. 2, it is a schematic cross-sectional view of an embodiment of a composite fiber ball in a non-woven fabric structure according to the present invention. The diameter of the composite fiber pellet 100 is, for example, 0.5-12mm, and comprises a plurality of layers from inside to outside, wherein the outermost layer is made of short fibers 110, and at least one layer is made of down 120. For example, the composite fiber pellet 100 has a three-layer structure, in which the innermost layer and the outermost layer are short fibers 110, and the middle layer is down 120. Since the composite fiber pellet 100 has the short fibers 110 as the outermost layer, the down feather 120 can be caught by the short fibers 110 and fixed in the composite fiber pellet 100, thereby preventing the down feather 120 from being separated.
The staple fibers 110 are discontinuous fibers and have stiffness and compression resilience, and their length is, for example, 21 to 75 mm. The material of the short fibers 110 may be artificial fibers or natural fibers, such as polypropylene fibers, polyethylene terephthalate fibers, nylon fibers, acrylic fibers, elastic fibers (Spandex), cotton fibers, or any combination of the above two fibers. If the composite fiber pellet 100 includes more than two layers of the short fibers 110, the two layers of the short fibers 110 may be made of the same material or different materials.
Referring to fig. 3, it is a cross-sectional view of another embodiment of the composite fiber ball in the non-woven fabric structure of the present invention. In this embodiment, the composite fiber pellet 100 may have a double-layer structure, in which the outer layer is made of short fibers 110 and the inner layer is made of down 120.
The number of layers and materials of the composite fiber pellets 100 can be determined by adjusting the number and materials of the feeding devices 40 in fig. 1, the closer the feeding device 40 to the carding machine 30 is to the inner layer of the composite fiber pellets 100, and the farther the feeding device 40 from the carding machine 30 is to the outer layer of the composite fiber pellets 100. As can be seen from the above embodiments, if the number of the composite fiber pellets 100 is odd, the outermost layer and the innermost layer are both made of short fibers 110; if the number of layers of the composite fiber pellets 100 is an even number, the outermost layer is made of short fibers 110, and the innermost layer is made of down 120. After the down feather 120 and the short fibers 110 are carded into the spherical composite fiber ball 100, the down feather 120 can be fixed in the composite fiber ball 100, and the problem that the down feather is separated when down feather clothes are made is effectively avoided.
Referring to fig. 4, a cross-sectional view of an embodiment of the nonwoven fabric structure of the invention is shown. The nonwoven fabric structure 300 includes a plurality of composite fiber pellets 100, and direct-spun fibers 210 for entangling the composite fiber pellets 100. The composite fiber pellet 100 is made of short fibers and down feather, wherein the short fibers and the down feather are distributed in the composite fiber pellet 100 from inside to outside in a layered manner, and the outermost layer of the composite fiber pellet 100 is made of the short fibers, so that the problem that the down feather is directly exposed to the composite fiber pellet 100 and is separated from the composite fiber pellet 100 is solved.
The direct-spun fibers 210 are entangled with the composite fiber pellets 100 and then shaped to form the nonwoven structure 300. Specifically, after passing through the semi-molten directly spun fiber screen, the composite fiber pellets 100 are bonded to the directly spun fibers 210, so that the uncured directly spun fibers 210 adhere the composite fiber pellets 100 together, and the composite fiber pellets 100 and the directly spun fibers 210 are entangled to form the nonwoven structure 300. Also, because the composite fiber pellet 100 is formed in the carding machine by rotating the cylinder bed through the rollers, the composite fiber pellet 100 will continue to rotate with inertia as it exits the carding machine and enters the semi-molten direct spun fiber curtain, so that most of the direct spun fibers 210 will adhere to the outer surface of the composite fiber pellet 100. Since the diameter of the direct-spun fibers 210 is extremely fine, a portion of the direct-spun fibers 210 penetrate into and entangle with the interior of the composite fiber pellet 100.
In addition, due to the design of the collecting device, the direct-spun fibers 210 at the peripheral portion of the semi-molten direct-spun fiber curtain are gathered at the two sides of the nonwoven structure 300 due to the suction or the roller extrusion, so that the distribution density of the direct-spun fibers 210 at the two sides of the nonwoven structure 300 is greater than that of the direct-spun fibers 210 in the middle of the nonwoven structure 300. In other words, the direct-spun fibers 210 form a continuous web on the outer layer of the nonwoven structure 300, and the composite fiber balls 100 are fixed by entanglement of the direct-spun fibers 210. The directly spun fibers 210 can be entangled with the composite fiber pellets 100 to form a fluffy floccular non-woven fabric structure 300, and the non-woven fabric structure 300 can be directly cut and sewn, so that the manufacturing process and labor cost of down clothes are greatly saved.
Referring back to fig. 1, another aspect of the present invention is to provide a method for manufacturing the above-mentioned nonwoven fabric structure 300, which comprises the following steps (it should be understood that the steps mentioned in the present embodiment, except for the specific sequence mentioned above, can be performed simultaneously or partially simultaneously, and the sequence can be adjusted according to the actual requirement.
(1) Into the down 120 to the carding machine 30.
(2) The staple fibers 110 are collected into the carding machine 30.
(3) The short fibers 110 and the down feather 120 are carded to obtain a plurality of composite fiber pellets 100.
(4) The composite fiber pellets 100 are output and the composite fiber pellets 100 are passed through a semi-molten direct-spun fiber screen 200 such that the direct-spun fibers 210 are entangled with the composite fiber pellets 100 into a nonwoven structure 300.
In one or more embodiments of the present invention, the method for manufacturing the non-woven fabric structure further includes the following steps:
(5) the nonwoven structure 300 is passed between the rollers 64 to collect and roll the nonwoven structure 300.
In one or more embodiments of the present invention, steps (1) and (2) are performed alternately to provide a layered cotton layer that is fed into carding machine 30.
In one or more embodiments of the present invention, at least a portion of the down feather 120 is fed into the carding machine 30 before the short fibers 110, so that the material of the outermost layer of the composite fiber ball 100 is the short fibers 110, and the down feather 120 is not directly exposed to the composite fiber ball 100, thereby avoiding the problem of the separation of the down feather 120.
The elasticity that the non-woven fabric structure provided through globular composite fiber balling can make the non-woven fabric structure be difficult for collapsing and have good heat preservation effect, and have good flexibility and stiffness, cooperation experimental data explanation below.
TABLE comparison of example with comparative examples one to four
The first comparative example in the above table is a nonwoven fabric structure comprising only direct-spun fibers. The second comparative example is a nonwoven fabric structure comprising only direct-spun fibers and staple fibers. Comparative example three is a nonwoven fabric structure comprising only direct-spun fibers and down. The fourth comparative example is a nonwoven fabric structure comprising direct-spun fibers, down and staple fibers. The experimental example included a non-woven fabric structure in which composite fiber pellets made of short fibers and down and direct-spun fibers were entangled. The short fiber is PET fiber with elasticity of 0.8-15D and length of 21-75mm, the directly spun fiber is also PET, and the diameter of the composite fiber ball is 0.5-12.5 mm.
The fluffiness in the table is expressed by the reciprocal of the density, which is measured by using the national standard CNS13333, and the fluffiness is better when the value is larger at 23 ℃ (plus or minus 3 ℃). The stiffness in the table is expressed as sag, which is measured by national standard CNS 5615, and a smaller value indicates better stiffness. The heat retention is expressed by CLO value, and the higher the CLO value is, the better the heat retention is.
As can be seen from the comparison analysis of the above table, in the comparative example, if the bulkiness and the heat retaining property are improved, the basis weight of the fabric is greatly increased (as shown in the second and fourth comparative examples), which also means that the material cost is increased. After the composite fiber balls are introduced, as shown in the embodiment, the fluffiness, the stiffness and the heat preservation performance are all good, and the basis weight of the cloth is not obviously increased, so that the structure used in the embodiment can still have good fluffiness, stiffness and heat preservation performance under the condition of not increasing the material cost.
In conclusion, the short fibers and the down feather are made into the composite fiber pellets, and then the composite fiber pellets and the direct spinning fibers are entangled to form the non-woven fabric structure, and the non-woven fabric structure can be shaped into a flocculus-shaped non-woven fabric structure through the collecting device. The elasticity of the composite fiber pellets enables the non-woven fabric structure to have good flexibility and stiffness and not to collapse easily, and further the heat preservation effect of the non-woven fabric structure is improved. In addition, the non-woven fabric structure of the wadding shape can be directly cut or sewn with the cloth, and the traditional complicated manufacturing process is omitted, so that the production efficiency can be improved, and the labor cost can be reduced.
Although the present invention has been described with reference to the above embodiments, it should be understood that various changes and modifications can be made therein by those skilled in the art without departing from the spirit and scope of the invention.
Claims (10)
1. A nonwoven fabric structure, comprising:
the composite fiber pellets comprise a plurality of layers from inside to outside, wherein the outermost layer of the layers is made of short fibers, at least one layer of the layers is made of down, and the diameter of each composite fiber pellet is 0.5-12.5 mm; and
a plurality of direct-spun fibers for entangling the composite fiber pellets to form the nonwoven fabric structure.
2. The nonwoven fabric structure of claim 1, wherein the direct-spun fibers are meltblown fibers or spunbond fibers.
3. The nonwoven fabric structure of claim 1 wherein the material of the direct-spun fibers is a thermoplastic polymer material.
4. The nonwoven fabric structure of claim 1, wherein the material of the innermost layer of the plurality of layers is down.
5. The nonwoven fabric structure of claim 1, wherein the material of the innermost layer of the plurality of layers is staple fibers.
6. The nonwoven fabric structure of claim 1, wherein a portion of the direct-spun fibers are distributed on an outer surface of the composite fiber pellet and a portion of the direct-spun fibers are distributed on an interior of the composite fiber pellet.
7. The nonwoven fabric structure of claim 1 wherein the staple fibers comprise polypropylene fibers, polyethylene terephthalate fibers, nylon fibers, acrylic fibers, elastane fibers, cotton fibers, or any combination of two or more of the foregoing.
8. A method of making a nonwoven fabric structure, comprising the steps of:
(a) gathering the down feather into a carding machine;
(b) gathering short fibers into the carding machine;
(c) carding the down feather and the short fibers to obtain a plurality of composite fiber pellets, wherein the composite fiber pellets comprise a plurality of layers from inside to outside, the material of the outermost layer of the plurality of layers is the short fibers, the material of at least one layer of the plurality of layers is the down feather, and the diameter of the composite fiber pellets is 0.5-12.5 mm; and
(d) and outputting the composite fiber pellets, and enabling the composite fiber pellets to pass through a semi-molten direct spinning fiber screen, so that the direct spinning fibers and the composite fiber pellets are intertwined into the non-woven fabric structure.
9. The method of claim 8, wherein step (a) is performed before step (b).
10. The method of claim 8, wherein step (d) further comprises passing the nonwoven structure between two rollers to collect and roll the nonwoven structure.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW105136145A TWI595132B (en) | 2016-11-07 | 2016-11-07 | Nonwoven fabric and manufacturing method thereof |
| TW105136145 | 2016-11-07 |
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| CN108070956A CN108070956A (en) | 2018-05-25 |
| CN108070956B true CN108070956B (en) | 2020-08-21 |
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| CN111636576A (en) * | 2020-06-09 | 2020-09-08 | 刘纯科 | Civil silencing decorative wallpaper |
| CN115522321A (en) * | 2022-10-13 | 2022-12-27 | 合隆企业（深圳）有限公司 | Wool yarn blended fiber ball and preparation method thereof |
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|---|---|---|---|---|
| JPS59150153A (en) * | 1983-02-08 | 1984-08-28 | 中谷 洋 | Fiber sphere, method and apparatus for producing same |
| JP2948259B2 (en) * | 1990-03-29 | 1999-09-13 | 日本エステル株式会社 | Fiber ball for filling |
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| TWI521112B (en) * | 2012-05-25 | 2016-02-11 | 財團法人紡織產業綜合研究所 | Nonwoven fabric and method and apparatus for manufacturing the same |
| CN103276535B (en) * | 2013-06-19 | 2015-08-26 | 天津泰达洁净材料有限公司 | A kind of double-component melt-blown non-woven material and manufacture method thereof |
| CN205133935U (en) * | 2015-09-11 | 2016-04-06 | 称道新材料科技(上海)有限公司 | Melt and spout fiber non -woven fabric and manufacture equipment thereof |
-
2016
- 2016-11-07 TW TW105136145A patent/TWI595132B/en active
- 2016-12-05 CN CN201611101193.5A patent/CN108070956B/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| TW201817934A (en) | 2018-05-16 |
| TWI595132B (en) | 2017-08-11 |
| CN108070956A (en) | 2018-05-25 |
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