CN114703601A - 一种具有分形孔道结构的纤维保暖絮片及其制备方法 - Google Patents
一种具有分形孔道结构的纤维保暖絮片及其制备方法 Download PDFInfo
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- CN114703601A CN114703601A CN202111463873.2A CN202111463873A CN114703601A CN 114703601 A CN114703601 A CN 114703601A CN 202111463873 A CN202111463873 A CN 202111463873A CN 114703601 A CN114703601 A CN 114703601A
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Abstract
本发明涉及铺网技术领域，尤其是涉及一种具有分形孔道结构的纤维保暖絮片及其制备方法。该纤维保暖絮片由底层纤网、中层纤网、表层纤网构成，纤维保暖絮片内部为分形孔道结构；底层纤网由三维卷曲中空纤维、细纤维制成，中层纤网由三维卷曲中空纤维、远红外纤维制成，表层纤网由超细纤维制成；孔径从底层至表层逐级减小，堆积孔道呈自相似性分形排列，大大延长了热量散失的路径，提升保暖性能。本发明还设计了适用于超细纤维的梳理针布：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为300～1000刺/in2，有助于实现对超细纤维的有效梳理，保证后续铺网均匀性。
Description
技术领域
本发明涉及铺网技术领域，尤其是涉及一种具有分形孔道结构的纤维保暖絮片及其制备方法。
背景技术
目前，市场上的天然保暖材料主要为羽绒，因其质轻、柔软、蓬松、保暖性好等特点，常用于服装填充料或保暖絮片填充层，但羽绒纤维作为填充物时易跑绒、钻绒，在使用过程中也会出现分布不均匀等现象，限制了其使用范围的进一步拓展。合成纤维保暖絮片具有连续性好、成本较低、工艺简单、回弹性好的特点，但纤维直径较粗，堆积孔道结构单一，导致其保暖性能难以进一步提升，因此如何实现超细纤维的有效梳理与絮片孔道结构的精细化调控是目前亟需解决的难题。
分形结构具有自相似的性质，其能在有限的面积中拥有无限的周长，因此将孔道的分形结构融入到保暖絮片中，延长了热量的传递路径，能够包含更多静止空气，热量从较粗孔道移动到无数个微细孔道，有效减少热量散失，大大提升保暖性能。
专利ZL201810745538.3公开了一种基于分形自相似结构的仿生纺织品，其具有类似蚕茧的多级分形自相似结构，具有良好的单向热、湿传导性能，该发明利用到了分形结构，但其是纤维形状的自相似，纤维承载的静止空气量是极其有限的，保暖性能无法大大提升；且纺织品的单层结构无法达到絮片的蓬松性，保暖效果不好。
专利CN201811233890.5公开了一种多层次、高密度的保暖絮片及其制备方法，其是将超细旦纤维、超细旦异形纤维、低熔点纤维和普通纤维混合原料进行开松梳理铺网定型，该发明利用到了超细纤维，但是没有进一步阐明如何对超细纤维进行梳理，常规纤维的梳理方法无法同时适用于超细纤维，导致产品性能难以有效提升。
发明内容
为了解决上述问题，本发明的目的是提供一种具有分形孔道结构的纤维保暖絮片及其制备方法。分形孔道结构主要是指在絮片的内部，纤维交错形成无数条孔道，竖直向上的孔道直径沿底层到表层逐级减小，近似形成了自相似性的分形结构，有粗有细的孔道可以储存大量的静止空气，热量顺着底层孔道向上发散，在中层孔道被分流，到达表层孔道再次被分流，有效阻碍热量散失；中层添加的远红外纤维可吸收远红外线，具有自发热功能；同时对于超细纤维的梳理，提供了一种有效的针布参数：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为 300～1000刺/in2。
本发明的目的可以通过以下技术方案来实现：
本发明的第一个目的是提供一种具有分形孔道结构的纤维保暖絮片，由底层纤网、中层纤网、表层纤网构成；
底层纤网由三维卷曲中空纤维、细纤维制成，底层纤网孔径为50～100μm；中层纤网由三维卷曲中空纤维、远红外纤维制成，中层纤网孔径为20～40μm；表层纤网由超细纤维制成，表层纤网孔径为1～5μm；
所述纤维保暖絮片其内部孔径从底层至表层逐级减小，堆积孔道呈自相似性分形排列；
所述纤维保暖絮片孔隙率高于96％，最高达99.8％；厚度为5～50mm，克重为 70～250g/m2，压缩回弹性达90％以上，热阻值为0.5～2m2K/W。
在本发明的一个实施方式中，所述三维卷曲中空纤维直径为20～30μm，长度为20～50mm，中空度为70～80％；所述细纤维直径为5～15μm，长度为30～40mm；所述远红外纤维直径为10～15μm，长度为30～40mm，所述超细纤维直径为0.3～5μm，长度为30～40mm。
在本发明的一个实施方式中，所述底层纤网中，三维卷曲中空纤维占比 60～80wt％，细纤维占比20～40wt％；所述中层纤网中，三维卷曲中空纤维占比 30～50wt％，远红外纤维占比50～70wt％；所述表层纤网中，超细纤维占比 80～100wt％。
在本发明的一个实施方式中，所述三维卷曲中空纤维、细纤维、超细纤维的材料选自以下材料的一种或几种的组合：棉、木棉、麻、毛、木浆、竹浆、蚕丝、木材、甲壳素、胶原蛋白、丝素蛋白、聚乳酸、聚氧化乙烯、聚乙烯醇、聚乙烯醇缩丁醛、酚醛树脂、聚丙烯酸、聚偏氟乙烯酸、聚吡咯烷酮、聚丙烯酰胺、聚乳酸乙醇酸、聚砜、聚酰亚胺、聚乙二炔、聚谷氨酸、聚己内酯、聚对苯乙炔、聚乙丙交酯、聚氨酯、聚三羟基丁酸酯、聚苯乙烯、聚丙烯腈、聚乳酸-己内酯、聚醋酸乙烯酯、聚丙烯、聚乙二醇、聚乙烯、聚氯乙烯、聚二氧环己酮、聚羟基丁酸酯、聚碳酸酯、聚醚酰亚胺、聚苯并咪唑、聚对苯二甲酰间苯二胺、聚对苯二甲酸乙二酯、聚偏氟乙烯、聚对苯二甲酰对苯二胺、聚甲基丙烯酸甲酯、聚醚醚酮、聚偏氟乙酸、聚环氧乙烷、聚乙烯咔唑、聚酰胺、聚对苯二甲酸丙二酯、聚苯胺、聚芳酰胺、聚丁二酸丁二醇酯和聚对苯二甲酸-共-丁二酸丁二醇酯；
所述远红外纤维中含有金属氧化物微粉，所述金属氧化微粉选自氧化铝微粉、氧化锆微粉或氧化镁微粉中的一种或几种。
本发明的第二个目的是提供一种具有分形孔道结构的纤维保暖絮片的制备方法，包括以下步骤：
(1)开松梳理：根据底层纤网、中层纤网、表层纤网需求进行纤维原料配置，经过开松梳理得到了三种不同的薄纤网，
(2)铺网：按照底层纤网、中层纤网和表层纤网的顺序进行铺网，获得了一种具有分形孔道结构的纤维保暖絮片，
(3)后处理：喷胶烫光，冷却定型，收卷切边。
在本发明的一个实施方式中，步骤(1)中，开松梳理时所用梳理针布材料选自非合金钢或合金钢；
所述合金钢选自高锰合金钢、高碳合金钢、低碳钢、高硅合金钢、高铬合金钢中的一种或几种。
在本发明的一个实施方式中，步骤(1)中，在表层纤维的开松梳理中，超细纤维的梳理针布为：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为300～1000刺/in2。
在本发明的一个实施方式中，步骤(2)中，所述底层纤网和中层纤网之间粘合，所述中层纤网和表层纤网之间粘合，层与层之间产生赋予纤维絮片压缩回弹性能的粘结点；
所述粘结并产生粘结点的方式为添加低熔点纤维；所述低熔点纤维在底层纤网、中层纤网、表层纤网中独立地占比0～20wt％。
在本发明的一个实施方式中，所述低熔点纤维选自聚丙烯纤维、聚酯纤维、聚酰胺纤维、聚乙烯/聚丙烯复合纤维或聚乙烯/聚酯复合纤维中的一种。
在本发明的一个实施方式中，步骤(3)中，所述喷胶的胶水选自丙烯酸酯胶粘剂、聚醋酸乙烯酯胶粘剂、聚氯乙烯粘合剂、丁二烯-苯乙烯共聚胶乳或丁二烯- 丙烯腈共聚胶乳中的一种；
所述胶水喷洒量为15～30g/m2，热风温度为90～200℃；
所述烫光处理温度为100～220℃，烫光辊间距为1～10cm；
所述冷却方式为强制风冷，上吹下吸；冷却温度为-6～2℃，冷却时间为15～20s。
一种具有分形孔道结构的纤维保暖絮片及其制备方法，该纤维保暖絮片由底层纤网、中层纤网、表层纤网构成，具有分形孔道结构的纤维保暖絮片内部为分形孔道结构，底层纤网为具有大孔径的三维卷曲中空纤维和细纤维材料，中层纤网为具有中等大小孔径结构的三维卷曲中空纤维和远红外纤维材料，表层纤网为具有小孔径结构的超细纤维材料，孔径从底层至表层逐级减小，堆积孔道呈自相似性分形排列，大大延长了热量散失的路径，提升保暖性能。同时本发明设计了适用于超细纤维的梳理针布参数：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为300～1000刺/in2，有助于实现对超细纤维的有效梳理，保证后续铺网的均匀性。本发明制得的具有分形孔道结构的保暖絮片孔隙率高于96％，最高达99.8％，热阻值达0.5～2m2K/W。
与现有技术相比，本发明具有以下有益效果：
(1)本发明的一种具有分形孔道结构的纤维保暖絮片及其制备方法，通过分形结构的引入，热量在向上扩散的过程中，被级级阻碍，同时中层添加远红外纤维，使得保暖效果大大提升。最终制得的纤维保暖絮片孔隙率高于96％，最高达99.8％，厚度为5～50mm，克重为70～250g/m2，压缩回弹性达90％以上，热阻值达 0.5～2m2K/W。
(2)本发明的一种具有分形孔道结构的纤维保暖絮片及其制备方法，针对超细纤维的梳理针布参数，进行了详细的界定：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为300～1000刺/in2，对参数规格的确定有助于实现对超细纤维的有效梳理，保证后续铺网的均匀性。
具体实施方式
本发明提供一种具有分形孔道结构的纤维保暖絮片，由底层纤网、中层纤网、表层纤网构成；
底层纤网由三维卷曲中空纤维、细纤维制成，底层纤网孔径为50～100μm；中层纤网由三维卷曲中空纤维、远红外纤维制成，中层纤网孔径为20～40μm；表层纤网由超细纤维制成，表层纤网孔径为1～5μm；
所述纤维保暖絮片其内部孔径从底层至表层逐级减小，堆积孔道呈自相似性分形排列；
所述纤维保暖絮片孔隙率高于96％，最高达99.8％；厚度为5～50mm，克重为 70～250g/m2，压缩回弹性达90％以上，热阻值为0.5～2m2K/W。
在本发明的一个实施方式中，所述三维卷曲中空纤维直径为20～30μm，长度为20～50mm，中空度为70～80％；所述细纤维直径为5～15μm，长度为30～40mm；所述远红外纤维直径为10～15μm，长度为30～40mm，所述超细纤维直径为0.3～5μm，长度为30～40mm。
在本发明的一个实施方式中，所述底层纤网中，三维卷曲中空纤维占比 60～80wt％，细纤维占比20～40wt％；所述中层纤网中，三维卷曲中空纤维占比 30～50wt％，远红外纤维占比50～70wt％；所述表层纤网中，超细纤维占比 80～100wt％。
在本发明的一个实施方式中，所述三维卷曲中空纤维、细纤维、超细纤维的材料选自以下材料的一种或几种的组合：棉、木棉、麻、毛、木浆、竹浆、蚕丝、木材、甲壳素、胶原蛋白、丝素蛋白、聚乳酸、聚氧化乙烯、聚乙烯醇、聚乙烯醇缩丁醛、酚醛树脂、聚丙烯酸、聚偏氟乙烯酸、聚吡咯烷酮、聚丙烯酰胺、聚乳酸乙醇酸、聚砜、聚酰亚胺、聚乙二炔、聚谷氨酸、聚己内酯、聚对苯乙炔、聚乙丙交酯、聚氨酯、聚三羟基丁酸酯、聚苯乙烯、聚丙烯腈、聚乳酸-己内酯、聚醋酸乙烯酯、聚丙烯、聚乙二醇、聚乙烯、聚氯乙烯、聚二氧环己酮、聚羟基丁酸酯、聚碳酸酯、聚醚酰亚胺、聚苯并咪唑、聚对苯二甲酰间苯二胺、聚对苯二甲酸乙二酯、聚偏氟乙烯、聚对苯二甲酰对苯二胺、聚甲基丙烯酸甲酯、聚醚醚酮、聚偏氟乙酸、聚环氧乙烷、聚乙烯咔唑、聚酰胺、聚对苯二甲酸丙二酯、聚苯胺、聚芳酰胺、聚丁二酸丁二醇酯和聚对苯二甲酸-共-丁二酸丁二醇酯；
所述远红外纤维中含有金属氧化物微粉，所述金属氧化微粉选自氧化铝微粉、氧化锆微粉或氧化镁微粉中的一种或几种。
本发明提供一种具有分形孔道结构的纤维保暖絮片的制备方法，包括以下步骤：
(1)开松梳理：根据底层纤网、中层纤网、表层纤网需求进行纤维原料配置，经过开松梳理得到了三种不同的薄纤网，
(2)铺网：按照底层纤网、中层纤网和表层纤网的顺序进行铺网，获得了一种具有分形孔道结构的纤维保暖絮片，
(3)后处理：喷胶烫光，冷却定型，收卷切边。
在本发明的一个实施方式中，步骤(1)中，开松梳理时所用梳理针布材料选自非合金钢或合金钢；
所述合金钢选自高锰合金钢、高碳合金钢、低碳钢、高硅合金钢、高铬合金钢中的一种或几种。
在本发明的一个实施方式中，步骤(1)中，在表层纤维的开松梳理中，超细纤维的梳理针布为：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为300～1000刺/in2。
在本发明的一个实施方式中，步骤(2)中，所述底层纤网和中层纤网之间粘合，所述中层纤网和表层纤网之间粘合，层与层之间产生赋予纤维絮片压缩回弹性能的粘结点；
所述粘结并产生粘结点的方式为添加低熔点纤维；所述低熔点纤维在底层纤网、中层纤网、表层纤网中独立地占比0～20wt％。
在本发明的一个实施方式中，所述低熔点纤维选自聚丙烯纤维、聚酯纤维、聚酰胺纤维、聚乙烯/聚丙烯复合纤维或聚乙烯/聚酯复合纤维中的一种。
在本发明的一个实施方式中，步骤(3)中，所述喷胶的胶水选自丙烯酸酯胶粘剂、聚醋酸乙烯酯胶粘剂、聚氯乙烯粘合剂、丁二烯-苯乙烯共聚胶乳或丁二烯- 丙烯腈共聚胶乳中的一种；
所述胶水喷洒量为15～30g/m2，热风温度为90～200℃；
所述烫光处理温度为100～220℃，烫光辊间距为1～10cm；
所述冷却方式为强制风冷，上吹下吸；冷却温度为-6～2℃，冷却时间为15～20s。
下面结合具体实施例对本发明进行详细说明。
实施例1
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取60wt％的三维卷曲中空纤维、20wt％的细纤维和20wt％的低熔点纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取30wt％的三维卷曲中空纤维、50wt％的远红外纤维和20wt％的低熔点纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取80wt％的超细纤维和20wt％的低熔点纤维混合均匀后进行开松，随后针对超细纤维的梳理，其针布的总高度为1.5mm，工作角为10°，针布齿密为300 刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚酯纤维，直径为20μm，长度为20mm，中空度为70％，细纤维为聚乙烯纤维，直径为15μm，长度为30mm，远红外纤维为氧化铝微粉制得，直径为15μm，长度为30mm，超细纤维为聚苯乙烯纤维，直径为5μm，长度为30mm，低熔点纤维为聚丙烯纤维。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为 90℃，丙烯酸酯粘合剂以18g/m2的喷洒量喷洒至絮片表面，烫光处理温度为 100℃，烫光辊间距为1cm，最后进行冷却定型，冷风温度为2℃，冷却时间15s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为96.4％，厚度为5mm，克重70g/m2，压缩回弹性达90％，热阻值达0.5m2K/W。
实施例2
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取70wt％的三维卷曲中空纤维和30wt％的细纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取40wt％的三维卷曲中空纤维和60wt％的远红外纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取90wt％的超细纤维和10wt％的低熔点纤维混合均匀后进行开松，随后针对超细纤维的梳理，其针布的总高度为 2.5mm，工作角为30°，针布齿密为600刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚丙烯腈纤维，直径为25μm，长度为30mm，中空度为75％，细纤维为聚苯胺纤维，直径为10μm，长度为35mm，远红外纤维为氧化锆微粉制得，直径为12μm，长度为35mm，超细纤维为聚砜纤维，直径为3μm，长度为35mm，低熔点纤维为聚酰胺纤维。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为140℃，丙烯酸酯粘合剂以22g/m2的喷洒量喷洒至絮片表面，烫光处理温度为180℃，烫光辊间距为5cm，最后进行冷却定型，冷风温度为0℃，冷却时间18s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为97.1％，厚度为19mm，克重134g/m2，压缩回弹性达93％，热阻值达0.9m2K/W。
实施例3
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取60wt％的三维卷曲中空纤维和40wt％的细纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取50wt％的三维卷曲中空纤维和50wt％的远红外纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取100wt％的超细纤维进行开松，随后针对超细纤维的梳理，其针布的总高度为4mm，工作角为50°，针布齿密为1000刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚乙烯纤维，直径为30μm，中空度为80％，长度为50mm，细纤维为聚氨酯纤维，直径为5μm，长度为40mm，远红外纤维为氧化镁微粉制得，直径为10μm，长度为40mm，超细纤维为聚酰胺纤维，直径为0.3μm，长度为40mm。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为200℃，聚氯乙烯粘合剂以30g/m2的喷洒量喷洒至絮片表面，烫光处理温度为220℃，烫光辊间距为10cm，最后进行冷却定型，冷风温度为-6℃，冷却时间20s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为97.4％，厚度为30mm，克重200g/m2，压缩回弹性达96％，热阻值达2m2K/W。
实施例4
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取65wt％的三维卷曲中空纤维、25wt％的细纤维和10wt％的低熔点纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取35wt％的三维卷曲中空纤维、55wt％的远红外纤维和10wt％的低熔点纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取80wt％的超细纤维和20wt％的低熔点纤维混合均匀后进行开松，随后针对超细纤维的梳理，其针布的总高度为2mm，工作角为30°，针布齿密为500刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚二氧环己酮纤维，直径为24μm，长度为43mm，中空度为74％，细纤维为聚丙烯腈纤维，直径为9μm，长度为32mm，远红外纤维为氧化铝微粉制得，直径为13μm，长度为36mm，超细纤维为聚苯胺纤维，直径为4μm，长度为34mm，低熔点纤维为聚酯纤维。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为170℃，聚氯乙烯粘合剂以15g/m2的喷洒量喷洒至絮片表面，烫光处理温度为 190℃，烫光辊间距为8cm，最后进行冷却定型，冷风温度为-1℃，冷却时间17s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为96.4％，厚度为17mm，克重140g/m2，压缩回弹性达92％，热阻值达0.7m2K/W。
实施例5
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取78wt％的三维卷曲中空纤维、20wt％的细纤维和2wt％的低熔点纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取45wt％的三维卷曲中空纤维、50wt％的远红外纤维和5wt％的低熔点纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取90wt％的超细纤维和10wt％的低熔点纤维混合均匀后进行开松，随后针对超细纤维的梳理，其针布的总高度为3mm，工作角为40°，针布齿密为500刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚谷氨酸纤维，直径为22μm，长度为30mm，中空度为77％，细纤维为聚偏氟乙烯纤维，直径为10μm，长度为 37mm，远红外纤维为氧化锆微粉制得，直径为11μm，长度为34mm，超细纤维为聚苯乙烯纤维，直径为2μm，长度为39mm，低熔点纤维为聚酰胺纤维。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为150℃，聚醋酸乙烯酯粘合剂以28g/m2的喷洒量喷洒至絮片表面，烫光处理温度为200℃，烫光辊间距为8cm，最后进行冷却定型，冷风温度为0℃，冷却时间17s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为98.1％，厚度为40mm，克重208g/m2，压缩回弹性达94％，热阻值达1.2m2K/W。
实施例6
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取60wt％的三维卷曲中空纤维、25wt％的细纤维和15wt％的低熔点纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取45wt％的三维卷曲中空纤维、50wt％的远红外纤维和5wt％的低熔点纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取100wt％的超细纤维进行开松，随后针对超细纤维的梳理，其针布的总高度为 2mm，工作角为10°，针布齿密为750刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚丙烯酸纤维，直径为27μm，长度为40mm，中空度为79％，细纤维为聚乙烯纤维，直径为14μm，长度为37mm，远红外纤维为氧化镁微粉制得，直径为15μm，长度为39mm，超细纤维为聚丙烯酰胺纤维，直径为2μm，长度为 34mm，低熔点纤维为聚丙烯纤维。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为180℃，聚氯乙烯粘合剂以 15g/m2的喷洒量喷洒至絮片表面，烫光处理温度为160℃，烫光辊间距为3cm，最后进行冷却定型，冷风温度为-5℃，冷却时间18s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为99.8％，厚度为50mm，克重250g/m2，压缩回弹性达95％，热阻值达1.7m2K/W。
实施例7
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取70wt％的三维卷曲中空纤维、24wt％的细纤维和6wt％的低熔点纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取35wt％的三维卷曲中空纤维、50wt％的远红外纤维和15wt％的低熔点纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取80wt％的超细纤维和20wt％的低熔点纤维混合均匀后进行开松，随后针对超细纤维的梳理，其针布的总高度为3.5mm，工作角为40°，针布齿密为800刺 /in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚酯纤维，直径为22μm，长度为46mm，中空度为73％，细纤维为聚甲基丙烯酸甲酯纤维，直径为11μm，长度为38mm，远红外纤维为氧化铝微粉制得，直径为10μm，长度为32mm，超细纤维为聚乳酸纤维，直径为2μm，长度为31mm，低熔点纤维为聚丙烯纤维。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为170℃，聚氯乙烯粘合剂以20g/m2的喷洒量喷洒至絮片表面，烫光处理温度为160℃，烫光辊间距为5cm，最后进行冷却定型，冷风温度为1℃，冷却时间15s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为97.6％，厚度为44mm，克重213g/m2，压缩回弹性达94％，热阻值达1.6m2K/W。
实施例8
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取65wt％的三维卷曲中空纤维和35wt％的细纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取44wt％的三维卷曲中空纤维和56wt％的远红外纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取100wt％的超细纤维进行开松，随后针对超细纤维的梳理，其针布的总高度为4mm，工作角为50°，针布齿密为 1000刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚酯纤维，直径为 30μm，中空度为80％，长度为50mm，细纤维为聚氨酯纤维，直径为5μm，长度为40mm，远红外纤维为氧化铝微粉制得，直径为10μm，长度为40mm，超细纤维为聚砜纤维，直径为0.3μm，长度为40mm。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为200℃，聚醋酸乙烯酯粘合剂以25g/m2的喷洒量喷洒至絮片表面，烫光处理温度为220℃，烫光辊间距为10cm，最后进行冷却定型，冷风温度为-6℃，冷却时间20s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为99.1％，厚度为31mm，克重128g/m2，压缩回弹性达92％，热阻值达1.1m2K/W。
实施例9
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取80wt％的三维卷曲中空纤维和20wt％的细纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取45wt％的三维卷曲中空纤维和55wt％的远红外纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取100wt％的超细纤维进行开松，随后针对超细纤维的梳理，其针布的总高度为3.5mm，工作角为40°，针布齿密为 600刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚丙烯腈纤维，直径为22μm，中空度为74％，长度为43mm，细纤维为聚苯乙烯纤维，直径为9μm，长度为37mm，远红外纤维为氧化镁微粉制得，直径为11μm，长度为34mm，超细纤维为聚乙二醇纤维，直径为4μm，长度为33mm。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为170℃，丁二烯-苯乙烯共聚粘合剂以16g/m2的喷洒量喷洒至絮片表面，烫光处理温度为 180℃，烫光辊间距为5cm，最后进行冷却定型，冷风温度为1℃，冷却时间15s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为98.3％，厚度为36mm，克重178g/m2，压缩回弹性达91％，热阻值达0.9m2K/W。
实施例10
本实施例为一种具有分形孔道结构的纤维保暖絮片的制备方法，具体包括以下步骤：
抓取77wt％的三维卷曲中空纤维和23wt％的细纤维混合均匀后进行开松，随后梳理得到底层纤网；抓取30wt％的三维卷曲中空纤维和70wt％的远红外纤维混合均匀后进行开松，随后梳理得到中层纤网；抓取100wt％的超细纤维进行开松，随后针对超细纤维的梳理，其针布的总高度为3mm，工作角为45°，针布齿密为 550刺/in2。梳理后得到表层纤网；其中，三维卷曲中空纤维为聚氧化乙烯纤维，直径为25μm，中空度为76％，长度为44mm，细纤维为聚酯纤维，直径为7μm，长度为36mm，远红外纤维为氧化镁微粉制得，直径为11μm，长度为31mm，超细纤维为聚苯胺纤维，直径为3μm，长度为36mm。串联三台铺网机，按照底层、中层和表层的顺序铺网，随后对复合纤网层进行热风处理，热风温度为150℃，丙烯酸酯粘合剂以26g/m2的喷洒量喷洒至絮片表面，烫光处理温度为170℃，烫光辊间距为8cm，最后进行冷却定型，冷风温度为-4℃，冷却时间17s。
最终得到具有分形孔道结构的纤维保暖絮片，孔隙率为97.8％，厚度为44mm，克重210g/m2，压缩回弹性达95％，热阻值达1.7m2K/W。
上述的对实施例的描述是为便于该技术领域的普通技术人员能理解和使用发明。熟悉本领域技术的人员显然可以容易地对这些实施例做出各种修改，并把在此说明的一般原理应用到其他实施例中而不必经过创造性的劳动。因此，本发明不限于上述实施例，本领域技术人员根据本发明的揭示，不脱离本发明范畴所做出的改进和修改都应该在本发明的保护范围之内。
Claims (10)
1.一种具有分形孔道结构的纤维保暖絮片，其特征在于，由底层纤网、中层纤网、表层纤网构成；
底层纤网由三维卷曲中空纤维、细纤维制成，底层纤网孔径为50～100μm；中层纤网由三维卷曲中空纤维、远红外纤维制成，中层纤网孔径为20～40μm；表层纤网由超细纤维制成，表层纤网孔径为1～5μm；
所述纤维保暖絮片其内部孔径从底层至表层逐级减小，堆积孔道呈自相似性分形排列；
所述纤维保暖絮片孔隙率高于96％，最高达99.8％；厚度为5～50mm，克重为70～250g/m2，压缩回弹性达90％以上，热阻值为0.5～2m2K/W。
2.根据权利要求1所述的一种具有分形孔道结构的纤维保暖絮片，其特征在于，所述三维卷曲中空纤维直径为20～30μm，长度为20～50mm，中空度为70～80％；所述细纤维直径为5～15μm，长度为30～40mm；所述远红外纤维直径为10～15μm，长度为30～40mm，所述超细纤维直径为0.3～5μm，长度为30～40mm。
3.根据权利要求1所述的一种具有分形孔道结构的纤维保暖絮片，其特征在于，所述底层纤网中，三维卷曲中空纤维占比60～80wt％，细纤维占比20～40wt％；所述中层纤网中，三维卷曲中空纤维占比30～50wt％，远红外纤维占比50～70wt％；所述表层纤网中，超细纤维占比80～100wt％。
4.根据权利要求1所述的一种具有分形孔道结构的纤维保暖絮片，其特征在于，所述三维卷曲中空纤维、细纤维、超细纤维的材料选自以下材料的一种或几种的组合：棉、木棉、麻、毛、木浆、竹浆、蚕丝、木材、甲壳素、胶原蛋白、丝素蛋白、聚乳酸、聚氧化乙烯、聚乙烯醇、聚乙烯醇缩丁醛、酚醛树脂、聚丙烯酸、聚偏氟乙烯酸、聚吡咯烷酮、聚丙烯酰胺、聚乳酸乙醇酸、聚砜、聚酰亚胺、聚乙二炔、聚谷氨酸、聚己内酯、聚对苯乙炔、聚乙丙交酯、聚氨酯、聚三羟基丁酸酯、聚苯乙烯、聚丙烯腈、聚乳酸-己内酯、聚醋酸乙烯酯、聚丙烯、聚乙二醇、聚乙烯、聚氯乙烯、聚二氧环己酮、聚羟基丁酸酯、聚碳酸酯、聚醚酰亚胺、聚苯并咪唑、聚对苯二甲酰间苯二胺、聚对苯二甲酸乙二酯、聚偏氟乙烯、聚对苯二甲酰对苯二胺、聚甲基丙烯酸甲酯、聚醚醚酮、聚偏氟乙酸、聚环氧乙烷、聚乙烯咔唑、聚酰胺、聚对苯二甲酸丙二酯、聚苯胺、聚芳酰胺、聚丁二酸丁二醇酯和聚对苯二甲酸-共-丁二酸丁二醇酯；
所述远红外纤维中含有金属氧化物微粉，所述金属氧化微粉选自氧化铝微粉、氧化锆微粉或氧化镁微粉中的一种或几种。
5.一种具有分形孔道结构的纤维保暖絮片的制备方法，其特征在于，包括以下步骤：
(1)开松梳理：根据底层纤网、中层纤网、表层纤网需求进行纤维原料配置，经过开松梳理得到了三种不同的薄纤网，
(2)铺网：按照底层纤网、中层纤网和表层纤网的顺序进行铺网，获得了一种具有分形孔道结构的纤维保暖絮片，
(3)后处理：喷胶烫光，冷却定型，收卷切边。
6.根据权利要求5所述的一种具有分形孔道结构的纤维保暖絮片的制备方法，其特征在于，步骤(1)中，开松梳理时所用梳理针布材料选自非合金钢或合金钢；
所述合金钢选自高锰合金钢、高碳合金钢、低碳钢、高硅合金钢、高铬合金钢中的一种或几种。
7.根据权利要求5所述的一种具有分形孔道结构的纤维保暖絮片的制备方法，其特征在于，步骤(1)中，在表层纤维的开松梳理中，超细纤维的梳理针布为：总高度范围为1.5～4mm，工作角范围为10～50°，针布齿密范围为300～1000刺/in2。
8.根据权利要求5所述的一种具有分形孔道结构的纤维保暖絮片的制备方法，其特征在于，步骤(2)中，所述底层纤网和中层纤网之间粘合，所述中层纤网和表层纤网之间粘合，层与层之间产生赋予纤维絮片压缩回弹性能的粘结点；
所述粘结并产生粘结点的方式为添加低熔点纤维；所述低熔点纤维在底层纤网、中层纤网、表层纤网中独立地占比0～20wt％。
9.根据权利要求8所述的一种具有分形孔道结构的纤维保暖絮片的制备方法，其特征在于，所述低熔点纤维选自聚丙烯纤维、聚酯纤维、聚酰胺纤维、聚乙烯/聚丙烯复合纤维或聚乙烯/聚酯复合纤维中的一种。
10.根据权利要求5所述的一种具有分形孔道结构的纤维保暖絮片的制备方法，其特征在于，步骤(3)中，所述喷胶的胶水选自丙烯酸酯胶粘剂、聚醋酸乙烯酯胶粘剂、聚氯乙烯粘合剂、丁二烯-苯乙烯共聚胶乳或丁二烯-丙烯腈共聚胶乳中的一种；
所述胶水喷洒量为15～30g/m2，热风温度为90～200℃；
所述烫光处理温度为100～220℃，烫光辊间距为1～10cm；
所述冷却方式为强制风冷，上吹下吸；冷却温度为-6～2℃，冷却时间为15～20s。
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