FI85033B - VADDMATTA SAMT FOERFARANDE FOER TILLVERKNING AV DENSAMMA. - Google Patents

Description

1 85033

Quilt and the method of its manufacture

The invention relates to a non-woven mat as set out in the preamble of claim 1 and to a method for forming a non-woven mat as set out in the preamble of claim 5.

According to the current technology, the 10 mats used as padding inside bedding, furniture and clothing consist of fibers which have been brought together on a substrate, e.g. by means of an air flow. In this carpet structure, the fibers are firmly joined together to form a rather dense structure. When the mat formed by this structure is used as the inner part of the various textiles, a sufficiently good "descendability" is then not achieved, i.e. flexibility, dimensional stability and insulating ability. In addition, this method is limited to the use of relatively thick (more than 6 dtex) fibers.

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In addition, a method is known in which a mat is formed in a way inside the finished product by blowing down-like bundles of fibers there. The rug does not stay well together and, for example, in bedding, it easily accumulates 25 somewhere.

The object of the invention is to eliminate the above-mentioned drawbacks. To achieve this purpose, the batt mat according to the invention is mainly characterized by what is set forth in the characterizing part of claim 1. By forming a mat of separate fiber piles bonded together to bond fibers 11a that are different from the fibers forming the piles, the settability, shape stability and thermal insulation of the above products can be improved without compromising other properties. The non-woven processability in the manufacture of the final product also does not suffer from this.

2 85033

The appended subclaims set out preferred alternatives for the structure of the disabled according to the invention. The fiber piles may be comprised of a higher temperature softening synthetic fiber material, such as polyester fibers, and the binder fibers may be a lower temperature softening synthetic fiber, such as polyethylene.

It is also an object of the invention to provide a method by which the above-mentioned nonwoven mat can be manufactured. To achieve this object, the method according to the invention is mainly characterized by what is set forth in the characterizing part of claim 5. The wadding mat is formed by placing separate fiber piles of fibers together on a substrate, after which they are bonded together by means of bonding fibers other than the fibers forming the agglomerates. According to the alternatives set forth in the appended subclaims, the fiber piles can be bonded together by thermal bonding utilizing fibers that soften at lower temperatures than the fibers of the fiber piles in thermal bonding, in addition to which the piles can be pre-bonded together by needling.

The invention will now be described in more detail with reference to the accompanying drawings, in which Figure 1 shows a cotton mat according to the invention in cross-section, Figure 2 shows the use of a cotton mat in a finished product, and Figure 3 schematically shows a cotton mat production line.

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Figure 1 shows a non-wadding structure according to the invention. The wadding mat comprises discrete fiber agglomerations 10, 3 85033 formed by interconnected fibers which are substantially spherical in shape and consist of fibers more than twice the length, preferably more than three times the diameter of the sphere. In the spheres, the fibers are intertwined with each other to form a structure forming mainly a spool of yarn. The length of the fibers is 30-60 mm, and the diameter of the spheres is most preferably between about 3-8 mm. There are several piles on top of each other in the depth direction of the mat, and the thickness of the mat according to the invention varies within the same limits as for normal quilt mats, e.g. about 1-3 cm.

As the fibrous material, for example, 1-3 dtex polyester fiber having a high melting point can be used, which is useful for the manufacture and use of the mat.

The fiber piles 10 are bonded to each other by fibers softening at a temperature below the softening temperature of the fibrous material in the pile, which may be about 5-10 to 20% by weight of the total amount of non-woven fibers. In the case of polyester fibers, e.g. polyethylene fibers can be used as binder fibers. By performing heat transfer on the wadding, the piles 10 are adhered to each other due to the gluing effect 25 of the softening and / or fusible bonding fibers 11.

The fiber piles 10 can also be mechanically bonded together by needling prior to heat treatment. The same fibers 11, 30 which are used as heat-binding fibers are preferably used in the needling. In this case, when polyester is used as the fibers of the aggregates 10, polyethylene fibers thicker than about 7 dtex and having a length of about 50 mm can be used as the "binding fibers 11".

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Figure 2 shows the use of non-wadding in the finished product. The cotton mat according to the invention is placed between the two surface layers 12 when forming e.g.

4 85033 clothes, seat cushions, blankets, sleeping bags and pillows. In addition, the layers can be connected to each other on opposite sides by stitching in a manner known per se, and this point is illustrated by reference numeral 59 in Figure 2. As can be seen from the figure, due to the size of the mat, piles 10 also remain between stitches.

Figure 3 shows a side view of the production line of the non-wadding 10 according to the invention, and with reference to this figure, the production method of the non-wadding will be described below. A fibrous material in which the fibers are already intertwined due to the fact that they are "curly" can be used as a raw material. Such fibers can be made from a wide variety of synthetic and natural fibers. At point 1, the fiber bales are fed to a conveyor and the fiber bundles formed by the fibers are opened only to the extent that the fibers remain in loose fiber-20 piles in which the fibers are intertwined due to their inherent curl. In the carding apparatus of step 2, where gentle carding is performed, the binder fibers used for bonding are mixed with the fiber agglomerates at about 5-10% of the total weight of the 25 final mats, then blown to step 3. The fibers are blown into cyclone 3a, where they remain relatively long. may condense into spherical. This utilizes the suction applied to the agglomerates through the perforated plate forming the top wall of the cyclone 30. From the cyclone, the fiber piles fall on conveyors 3b, which feed them to the surface of the spike roll 4, which throws the fibers and fiber piles into an air stream forming a relatively flat mat 35 of fiber piles and binder fibers on the substrate 5 through which said fiber air flow. The resulting mat is then passed to a needling point 6, where the pre-bonding of the fiber agglomerates by means of connective fibers is performed by mechanical needling. The mat, which is already relatively well sized, is then subjected to heat bonding at point 7, where the final bonding is carried out by means of the bonding fibers as described above. After the heat-5 donna, the mat is led to a winding device 8, where it can be wound, for example, into a spool comprising a mat of 50 m in length.

The resulting intermediate can then be used in all of those applications where a conventional, previously known quilt mat is used. The advantages of using the non-wadding mat according to the invention in the clothing industry are e.g. the fact that it can replace the blowing method by which the wadding has previously been blown between the outer layers 15. The wadding mat according to the invention is easy to handle as an intermediate product because it stays well in the pile and is therefore easy to machine, e.g. cut into patterns. The quilt also stays in place better than blown fiber. The resulting garment has a "descendability" 20, i.e. flexibility, is also better than previous products. In addition, better thermal insulation is provided, because due to the properties of the carpet (shape stability), the carpet is also under stitching, which is also illustrated in Figure 2. In addition, due to its easy handling and good adhesion, the carpet can also be laminated to the fabric. In addition, more surface materials can be used than in the blowing method, because the blowing method has always required air-permeable surface materials. 30

In the furniture industry, the use of a non-wadding mat according to the invention provides the same advantages as above, in addition to which it can be mentioned that the production of seat cushions is considerably faster when using a non-woven mat 35 than with the blowing method. The manufacture of various blankets, sleeping bags and pillows also has the same advantages as above, in addition to which it can be mentioned that the quilt according to the invention stays better in place 6 85033 and does not necessarily require cross stitches in the blankets. When using synthetic fibers, all products have the advantage of good washing resistance.

5 A quilt can be made of any fiber that can be formed into separate fiber piles in which the fibers are intertwined. The "curl" in the fibers that causes entanglement can be caused to the fibers by coating the fibers of suitable length, e.g., with a heat-shrinkable material on one side, by causing stresses or the like in the manufacture of synthetic fibers in a suitable manner.

Claims (9)

A quilt mat, e.g. as a filling material for the clothing industry, the furniture-5 industry or the bedding industry, consisting mainly of fibrous material, the quilt mat consisting of separate fiber piles (10) bonded to each other, characterized in that the piles (10) are bonded to each other 10 by means of fibers (11) which are different from the fibers forming the agglomerations (10). Fiber mat according to Claim 1, characterized in that the fibers forming the fiber joints (10) are synthetic fibers. Nonwoven mat according to Claim 2, characterized in that the bonding fibers (11) are softening fibers at a temperature below the softening temperature of the fibers of the piles (10), and the piles are connected to one another by at least partially melted or softened bonding fibers (11). Quilt mat according to one of the preceding claims, characterized in that the fiber joints (10) are approximately spherical in shape and have a diameter of between 3 and 8 mm. A method of forming a batting mat, wherein the fibers 30 are brought together to form a unitary layer, the batting mat being formed by bonding separate fiber piles (10) together, characterized in that the piles are bonded together by bonding fibers (11) other than the piles (10). ) 35 forming fibers. β 85033 Method according to Claim 5, characterized in that the piles (10) are bonded to one another by means of heat bonding by utilizing the bonding fibers (11) which glue the agglomerates to one another due to heat. 5 Method according to Claim 6, characterized in that the piles (10) are mechanically bonded to one another by means of bonding fibers (11) before thermal bonding. 7 85033 Method according to Claim 7, characterized in that the mechanical bonding is carried out by needling. 9 85033