Classifications

• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41G—ARTIFICIAL FLOWERS; WIGS; MASKS; FEATHERS
  • A41G11/00—Artificial feathers
• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41G—ARTIFICIAL FLOWERS; WIGS; MASKS; FEATHERS
  • A41G11/00—Artificial feathers
  • A41G11/02—Implements or machines for making artificial feathers
• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
  • A41D31/00—Materials specially adapted for outerwear
  • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
  • A41D31/06—Thermally protective, e.g. insulating

Definitions

• the present invention relates to a stuffing material, and particularly to a stuffing and a method for manufacturing the same.
• Natural warm-keeping materials such as downs, feathers and other bulk animal hairs, and the like are frequently used as stuffing and/or warm-keeping materials in the fields of clothing, bedding products, sleeping bags and the like.
• researchers in the art are also continuously exploring various synthetic materials of imitation downs and imitation feathers.
• Stuffing and/or warm-keeping synthetic materials commonly used include a fiber cluster type and a fiber ball type.
• the fiber cluster-type materials are generally produced by forming fiber flocculus materials into fiber clusters by way of chopping, and then grabbing a given weight of fiber clusters for stuffing, to manufacture the stuffing and/or warm-keeping materials.
• the fiber ball-type materials are produced by firstly subjecting staple fibers to opening picking, then allowing, in a certain manner, the fibers to mutually wind with each other, or allowing them to form fiber balls with a bonding point.
• U.S. patent US6329052 discloses a fluffy thermal insulating material, which, according to the description therein, has fiber batt that forms short fiber cluster after cutting off, wherein the fiber cluster may contain water-repellant or silicone treated fibers, tacky fibers, or conventional dry fibers.
• Cigarette CN1966789 discloses a polyester fiber stuffing material, which, according to the description therein, is obtained by mixing conventional hollow polyester staple fibers with superfine super high hollow polyester staple fibers, and is subjected to opening picking, mixing, and carding and then air blowing of suede.
• Chinese patent publication CN101166689 discloses a stuffing material, which, according to the description therein, comprises a double-end crimped polyester fiber having an average size of 0.5 to 2.5 dtex and coated with a smoothing agent, wherein the fiber is cut to have an average length of 4 to 15 mm, and then subjected to opening picking.
• U.S. patent US4618531 discloses a polyester fiber stuffing, which, according to the description therein, has fiber balls wound spirally and randomly.
• U.S. patent US7261936B2 discloses a thermal insulating material, which, according to the description therein, has a structure like a blown shape, and is composed of a number of filaments that are fused together at one end of the filaments and are open at an opposite end, similar to a "shuttlecock".
• Fiber clusters have a certain bulking intensity and condensability, however as a result of a substantial amount fibers isotropically arranged in the fiber flocculi, the fiber cluster after cutting off will inevitably contain a substantial amount of ultra-short fibers, resulting in that the filled warm-keeping materials are easy to leak out, and have a decreased overall thickness after water wash, as well as a deteriorated warm-keeping performance.
• loose-stuffed materials are light in weight and soft in feeling.
• similar stuffing materials have great difficulty in solving problems of easy mutual entanglement and conglomeration of fibers after water wash in practical use, greatly limiting the application of this type of loose-stuffed materials.
• One objective of the present invention is to provide a stuffing, which has a good water- wash performance, that is, the stuffing can be uniformly dispersed after water wash, without notable phenomena such as agglomeration and entanglement.
• a stuffing comprising a branch and trunk structure formed with a microporous polymer, wherein the branch and trunk structure comprises a trunk, and branches formed by splitting from the trunk, and the branch and trunk structure has a maximum longitudinal length of about 10 to 130 mm on average, and a maximum lateral dimension of 2 to 15 mm on average.
• the trunk has an average lateral dimension of 1 to 10 mm.
• the branches have an average lateral dimension of 0.5 to 5 mm.
• the trunk length is equal to or less than the longitudinal length of the branch and trunk structure.
• the branches have an average length between 1 and 6 mm.
• the branches are formed by laterally splitting along the longitudinal length direction of the trunk at an interval of about 1 to 6 mm on average.
• the branches are formed by splitting at one end of the trunk.
• the branch and trunk structure has a planar two-dimensional structure.
• the branch and trunk structure has an average thickness of 0.25 to 2 mm.
• the microporous polymer is selected from thermal insulating materials.
• the thermal insulating materials are expanded plastics.
• the expanded plastics include one selected from the following materials: polyethylene, polyvinyl chloride, polystyrene or polyurethane.
• the stuffing has water-wash resistance.
• Another objective of the present invention is to provide a method for manufacturing a stuffing.
• the gear blade -bearing roller wheels have blades arranged at an interval and spirally distributed along an axial line thereof.
• the gear blade-bearing roller wheels have a linear velocity of about 100 to 300 mm/s.
• Advantages of the present invention are that, a relatively simple method may be used to manufacture a stuffing capable of having a good water-wash performance, and the stuffing of the present invention can still maintain at a dispersedly stuffing state after multiple washings as compared with existing materials, without notable phenomena such as agglomeration and entanglement.
• FIG. 1 is a schematic view of a method for manufacturing a stuffing of an example of the present invention
• FIG. 2 is a schematic view of a stuffing of an example of the present invention.
• FIG. 3 is a schematic view of a stuffing of another example of the present invention.
• FIG. 4 is a schematic view of a stuffing of yet another example of the present
• the present invention provides a stuffing and a method for manufacturing the same.
• a stuffing comprising a branch and trunk structure formed with a microporous polymer, wherein the branch and trunk structure comprises a trunk, and branches formed by splitting from the trunk, and the branch and trunk structure has a maximum lengthwise strength of 10 to 130 mm on average, and a maximum lateral dimension of 1 to 10 mm on average.
• This branch and trunk structure is essentially presented as a dendritic shape, and a plurality of branches are formed by splitting from the trunk.
• the plurality of branches may be, for example, formed by laterally, that is, unilaterally or bilaterally, splitting at a certain interval along the longitudinal length direction of the trunk, so that a planar branch and trunk structure can be formed, which has the plurality of branches spaced in the length direction, at an interval of, for example, 1 to 6 mm on average.
• a plurality of branches are formed on the trunk, schematically represented as shapes similar to E, F, or K shape.
• two or more branches may be formed by splitting at one end or both ends of the trunk.
• a plurality of leaves are formed on the treetop, schematically represented as shapes similar to L, T, or Y shape, and the branch and trunk structure may equally be formed unilaterally or bilaterally.
• the branches may be split from the trunk at various angles, from a smaller acute angle, for example, a Y or K shape, to an angle close to 90°, that is, an E, F, L or T shape.
• a smaller acute angle for example, a Y or K shape
• the branches may be split from the trunk at a smaller angle, for example smaller than 30°
• the branches may be split from the trunk at a greater angle, for example greater than 60°.
• the trunk and branches may be varied differently.
• the trunk may have an average lateral dimension of 0.2 to 10 mm.
• lateral means a direction perpendicular to the length direction, instead of restriction on the shape.
• cross sections of the trunk and branches may be rectangular, oblate, circular, elliptical or irregular in shape, and thus the average lateral dimension describes the average length dimension across the cross section or the dimension on the larger side.
• it may be diameter or width of a cross section, or an average size of an irregular shape, or a maximum size across a cross section.
• the branches have an average lateral dimension of optionally 0.1 to 5 mm.
• Thickness of a sheet of the microporous polymer material used for forming the stuffing will influence or determine the lateral dimension of the trunk and branches, and the plane thickness of the branch and trunk structure. Although greater changes may be present, preferably, the branch and trunk structure has an average thickness of 0.25 to 2 mm, depending on the thickness of the material.
• the trunk length may be equal to or less than the longitudinal length of the branch and trunk structure.
• the trunk length may be preferably equal to or the longitudinal length of the branch and trunk structure, or in other words, the branches after protruding do not exceed either end in the length direction of the trunk.
• part of the branches after protruding can exceed a certain end in the length direction of the trunk, so that the longitudinal length of the branch and trunk structure is greater than the trunk length.
• the average length of the branches may be between 1 and 6 mm, as described above, may or may not exceed a certain end in the length direction of the trunk.
• the trunk length is generally less than the longitudinal length of the branch and trunk structure.
• the trunk length and the maximum longitudinal length of the branch and trunk structure are 10 to 130 mm on average.
• the width of the branch and trunk structure, that is, the maximum lateral dimension is optionally 1 to 10 mm on average.
• the extension degree and angles of the branches will influence such a dimension. In such a way, these factors determine and limit the outline dimension of the branch and trunk structure.
• the stuffing of the present invention may be made of a microporous polymer, preferably may be made of a microporous polymer sheet, for example, a sheet with a thickness of 0.25 to 2 mm.
• this microporous polymer is selected from some microporous polymers made of thermal insulating materials, for example, a certain expanded plastic.
• it may be one selected from polyethylene, polyvinyl chloride, polystyrene or polyurethane and the like, or other expanded materials made of suitable materials.
• the stuffing has water-wash resistance, that is, it can essentially maintain its original shape after water wash.
• the present invention provides a method for manufacturing a stuffing, in which a microporous polymer sheet in a thickness of 0.25 to 2 mm is provided, and allowed to get into a pair of gear blade-bearing roller wheels rotating in reverse directions for cutting, and the gap between the two gear blade-bearing roller wheels is adjusted between 0 and 1 mm, so as to cut and mold the sheet into a branch and trunk structure.
• the microporous polymer sheet may be generally provided in a form of a coiled material, and thus a working roll may be mounted on the coiled material, to facilitate rotation. Therefore the coiled material is allowed to get into pull rolls, to pull the coiled material into the gear blade-bearing roller wheels for cutting.
• the gear blade-bearing roller wheels have blades, which may have various different shapes and distributions, so as to cut the sheet into branch and trunk structures of different shapes.
• a typical gear blade-bearing roller wheel has a plurality of tooth-shaped structures, to facilitate spiral rotation, and the blades may be arranged in different manners, for example, each of the tooth-shaped structures may have a blade thereon.
• the gear blade-bearing roller wheel has blades arranged at an interval and spirally distributed along an axial line thereof, located on each of the tooth-shaped structures respectively.
• the gear blade -bearing roller wheels may be selected from commercially available products.
• the microporous polymer sheet can be cut into branch and trunk structures of different shapes.
• the gear blade-bearing roller wheels rotate, thereby to generate a corresponding linear velocity that may be between 100 to 300 mm/s, or in short, the gear blade-bearing roller wheels have a linear velocity of about 100 to 300 mm/s, and the gap between the two gear blade-bearing roller wheels may be between 0 to 1 mm.
• a stuffing 4 and a method for manufacturing the same can be achieved by a mode as follows.
• an expanded polyethylene material EPE
• the microporous polymer which is a thermal insulating material
• the material with a thickness of 0.5 mm was selected, and provided in a form of a rolled coiled material.
• a working roll was mounted on the microporous polymer sheet 1 to facilitate rotation, and then the sheet 1 was pulled into a pair of gear blade-bearing roller wheels 2, wherein the pair of gear blade -bearing roller wheels 2 had a plurality of tooth-shaped structures each having a blade thereon, and the blades were arranged at an interval and spirally distributed along an axial line of the gear blade-bearing roller wheel 2.
• blade-bearing roller wheels 2 could be adjusted to 0 - 1 mm, and adjusted to 0.1 mm in this example.
• the velocity of the microporous polymer sheet 1 driven forward, or the linear velocity of the gear blade-bearing roller wheels 2 was herein preferably set as 210 mm/s, and in such a way, the pair of gear blade-bearing roller wheels 2 cut the sheet 1 into the stuffing 4 having a branch and trunk structure.
• a storage bin 3 was provided at the lower end of the pair of gear blade-bearing roller wheels 2.
• An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
• the stuffing 4 formed had a shape as shown in FIG. 2, which had a branch and trunk structure, comprising a trunk 401 and a plurality of branches 402 formed by splitting from the trunk 401, wherein the branches 402 after protruding did not exceed any end of the trunk 401 in the length direction thereof, such that the length of the trunk 401 was equal to the maximum longitudinal length of the branch and trunk structure, and the width or the maximum lateral dimension of the branch and trunk structure was determined by the transcurrent degree of the branches 402.
• the branch and trunk structure had a maximum longitudinal length of 10 to 60 mm on average, and a maximum lateral dimension of 2 to 5 mm on average, wherein the trunk 401 had a length of about 10 to 60 mm, and a lateral width of 1 to 3 mm, and the branches 402 had a length of 1 to 6 mm, and a width of about 0.5 to 1.5 mm.
• a plurality of the branches were formed at intervals along the length direction of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm.
• the length and width of the trunk 401 , the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter, rotation velocity and corresponding linear velocity of the gear blade-bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.
• the branches 402 were split from the trunk 401 at smaller angles, generally distributed within a range around 30°, or smaller.
• the microporous polymer sheet 1 was used to produce the stuffing 4, and the stuffing 4 having a planar branch and trunk structure was formed, so that the thickness of the branch and trunk structure thereof depended on the thickness of the microporous polymer sheet 1, which was 0.5 mm in this example. Also it is easy to understand that, in this example, the thickness of both the trunk 401 and the branches 402 are the thickness of the microporous polymer sheet 1, that is, 0.5 mm.
• cross sections of the trunk 401 and the branches 402 were formed as rectangles.
• the cross sections of the trunk 401 and the 402 could also be easily cut as an oblate, circular, elliptical or irregular shape by an artisan in the art with reference to the present invention.
• the maximum size, average size or a certain range are used to describe various dimensions of the branch and trunk structure, for instance, the longitudinal length and the average value of the maximum lateral dimension of the branch and trunk structure, the lateral dimension and length of the trunk 401, the length and splitting angle of the branches 402, intervals between each of the branches 402, and the like.
• a stuffing 4 could be produced by equally using an expanded polyethylene material (EPE), with a thickness of 2 mm.
• EPE expanded polyethylene material
• the microporous polymer sheet 1 was mounted into a working roll, and then the sheet 1 was charged into a pair of gear blade-bearing roller wheels 2 by way of pulling, wherein a spacing between the two gear blade-bearing roller wheels 2 was adjusted to 0.5 mm in this example, the microporous polymer sheet 1 was driven forward at a linear velocity set at 300 mm/s in this example, such that the pair of gear blade-bearing roller wheels 2 cut and molded the sheet 1 into the stuffing 4 having a branch and trunk structure.
• a storage bin 3 was provided at the lower end of the gear blade-bearing roller wheels 2.
• An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
• a stuffing 4 having a branch and trunk structure comprising a trunk 401 and a plurality of branches 402 formed by splitting from the trunk 401 , as shown in FIG. 2.
• the branch and trunk structure had a maximum longitudinal length of 10 to 40 mm on average, a maximum lateral dimension of about 2 to 4 mm on average, wherein the trunk 401 had a length of about 10 to 40 mm, and a lateral width of 1 to 2 mm, and the branches 402 had a length of 1 to 6 mm, and a width of about 0.5 to 1 mm.
• a plurality of the branches were formed at intervals along the length direction of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm.
• the length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter of the gear blade -bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.
• a stuffing 4 and a method for manufacturing the same are as shown in FIGs. 1 and 3.
• a polyurethane material (PU) of a plastic texture was selected as the microporous polymer sheet 1 , which is a thermal insulating material, and similarly, also produced into an expanded plastic.
• the material selected had a thickness of 2 mm.
• the microporous polymer sheet 1 was mounted into a working roll, and then the microporous polymer sheet 1 was charged into a pair of gear blade-bearing roller wheels 2 by way of pulling, wherein the pair of gear blade -bearing roller wheels 2 had a plurality of tooth-shaped structures each having a blade thereon, and the blades were arranged at an interval and spirally distributed along an axial line of the gear blade-bearing roller wheel 2.
• the spacing between the two gear blade-bearing roller wheels 2 was adjusted to 0.2 mm in this example, and the rotation velocity was set at 150 mm/s.
• a storage bin 3 was provided at the lower end of the gear blade-bearing roller wheels 2.
• An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
• a stuffing 4 having a branch and trunk structure was formed, as shown in FIG. 3, comprising a trunk 401 and branches 402 formed by splitting at one end of the trunk 401.
• the stuffing 4 had a maximum longitudinal length of 10 to 80 mm on average, and a maximum lateral dimension of 2 to 10 mm on average, wherein the trunk 401 had a length of about 10 to 80 mm, and a lateral width of 1 to 6 mm, and the branches 402 had a length of 1 to 6 mm, and a width of about 0.5 to 3 mm.
• One or more branches 402 could be formed by splitting at one end of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm.
• the length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter of the gear blade-bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.
• an expanded polyethylene (EPE) material of a plastic texture was selected as the microporous polymer sheet 1 , which is a thermal insulating material, and similarly, also produced into an expanded plastic.
• EPE expanded polyethylene
• the material with a thickness of 0.25 mm was selected.
• the microporous polymer sheet 1 was mounted into a working roll, and then the microporous polymer sheet 1 was charged into a pair of gear blade-bearing roller wheels 2 by way of pulling, wherein the pair of gear blade -bearing roller wheels 2 had a plurality of tooth-shaped structures each having at least one blade thereon, and the blades were arranged at an interval and spirally distributed along an axial line of the gear blade-bearing roller wheel 2.
• the spacing between the two gear blade-bearing roller wheels 2 was adjusted to 0.3 mm in this example, and the rotation velocity was set at 210 mm/s.
• a storage bin 3 was provided at the lower end of the gear blade-bearing roller wheels 2.
• An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
• a stuffing 4 having a branch and trunk structure was formed, as shown in FIG. 4, comprising a trunk 401 and a plurality of branches 402 formed by splitting from the trunk 401.
• the plurality of branches 402 extended towards both ends of the trunk 401 respectively, part of the branches 402 could exceed a certain end of the trunk 401 in the length direction thereof.
• the branch and trunk structure had a maximum longitudinal length of 10 to 130 mm on average, a maximum lateral dimension of about 5 to 15 mm on average, wherein the trunk 401 had a length of about 5 to 110 mm, and a lateral width of 3 to 10 mm, and the branches 402 had a length of 5 to 20 mm, and a width of about 1.5 to 4 mm.
• the plurality of the branches 402 were formed at intervals along the length direction of the trunk 401.
• the average interval between each of the branches 402 was 1 to 6 mm.
• the length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter of the gear blade -bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.
• Example 1 of the present invention was tested for its warm-keeping values before and after water wash, and observed for its uniformity. Therefore, a 50 cm X 50 cm cloth packet was made up employing 190T blue nylon cloths, and 40 g of the stuffing formed in Example 1 was distributed uniformly therein to produce a test sample packet, to carry out water wash, and tests for warm-keeping values before and after the water wash, according to standard methods. Wherein, the water wash was carried out by 10 washings according to a
• the warm-keeping index Clo value is expressed as such that, when a person sitting still or engaged in mild mental labour (with metabolic heat production of 209.2 KJ/m2-h) feels comfortable, at room temperature of 21°C, relative humidity less than 50%, and a wind speed not more than 0.1 m/s, the thermal resistance value of clothes worn by the person is 1 Clo.
• the test result was as follows: the Clo value of the test sample packet was 2.4 before the water wash, and the Clo value was 2.38 after 10 washings. A Clo conservation rate after the water wash was as high as 99.1 %. This result showed that the water wash had hardly any effect on the warm-keeping performance of this material, indicating that the water wash did not significantly cause agglomeration, entanglement, and the like of the stuffing to influence variation in the warm-keeping performance. Uniformity was judged by a method in which the sample packet was placed onto a glass table with illumination, and the distribution situation of the stuffing within the sample packet was judged by observing the overall color uniformity of the sample packet. More uniform color stands for more uniform distribution of the stuffing within the sample packet.
• the stuffing was taken out from the sample packet, and it was found by observation that the stuffing was essentially in a state of single fibers both before and after the water wash, nearly without agglomeration and significant variation.
• a stuffing and a method for manufacturing the same are provided, so as to obtain stuffing of different shapes and dimensions.
• the branch and trunk structure formed by the microporous polymer provides very excellent water-wash performance, without entanglement or agglomeration, and can maintain and display a good state of single fibers, so that can remain uniformly dispersed after the water wash.
• the branch and trunk structure is used in a warm-keeping material, it can maintain a good warm-keeping performance.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
• Mattresses And Other Support Structures For Chairs And Beds (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

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Family Applications (1)

Country Status (6)

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• 2014
  • 2014-08-29 CN CN201410448727.6A patent/CN105385001B/zh not_active Expired - Fee Related
• 2015
  • 2015-08-21 WO PCT/US2015/046201 patent/WO2016032871A1/en active Application Filing
  • 2015-08-21 EP EP15762836.3A patent/EP3185708A1/en not_active Withdrawn
  • 2015-08-21 JP JP2017511635A patent/JP2017532990A/ja active Pending
  • 2015-08-21 KR KR1020177007982A patent/KR20170047312A/ko unknown
  • 2015-08-21 US US15/505,805 patent/US20170231310A1/en not_active Abandoned

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