KR20090110450A - Erect honeycomb fiber foam and its manufacturing method - Google Patents

Abstract

PURPOSE: A manufacturing method of vertical honeycomb fiber foam is provided to offer high elasticity and force of restitution to overcome weak points of the fiber foam. CONSTITUTION: A manufacturing method of vertical honeycomb fiber foam includes the following steps of: mixing two fiber to a predetermined rate; opening the fibers by an opening machine; carding the fibers to a successive fiber net(10) after transferring the fiber to a carding machine; processing the successive fiber net to a consecutive stacked state in a cutter; drying the successive fiber net with compressed and heated wind after transferring the fiber net to an oven; and forming cross-section cellular structure of the PET fiber after melting the low-melting PET fiber.

Description

Erect honeycomb fiber foam and its manufacturing method {ERECT HONEYCOMB FIBER FOAM AND ITS MANUFACTURING METHOD}

TECHNICAL FIELD The present invention relates to an upright honeycomb fiber foam and a method for manufacturing the same, and more particularly, to blend a highly shrinkable fiber and a low melt fiber, and to reform the blended fibers by an opening machine, An elastic upright honeycomb fiber foam which is carded with a fiber net by a carding machine and is laminated in a 90 degree upright state by a cutter. Highly shrinkable fibers are heated and spirally contracted and combined with low melt fibers when the fibers are highly crimped, so that the stacked upright fiber layers are entangled into complex cellular forms such as honeycomb, which are solidified to upright honeycomb fibers. Heated to form a foam.

Methods of making traditional products such as sponges and foams do not relate to the present invention. The method of making the breathable cotton simply forms the cotton bed of the plain net after carding the fibers, and places the cotton bed in a dryer for shaping and forming. The product is a flat cotton object that cannot provide good elasticity.

In current elastomeric products, there are still no elastomers with fiber structure except chemicals with molecular structures such as sponges and foams. Elastomers having a fibrous structure, in particular a structure of upright cellular fiber nets, can meet current stringent requirements for environmental protection and recycling. Chemical fibers can be manufactured with different physical properties as required by using different manufacturing techniques: absorbent, fire resistant, antiseptic, anti-odor, fiber length, crimp, change with temperature, fineness (fineness) and ductility (hard) Physical properties, including, cause a change in the fabric produced. The properties of these fibers and the method of forming uprights are used to make elastomers with significant elasticity.

In view of the foregoing, the present invention is to open and cotton the fibers, laminating the net cotton bed in the cutting process to form an upright net cotton bed, place the upright net cotton bed in the dryer to erect the net cotton bed by hot air Flat net cotton beds are made by shrinking with honeycomb fiber foam. Thus, upright honeycomb fiber foams with high elasticity and resilience are produced to overcome the above-mentioned disadvantages.

It is a main object of the present invention to provide an upright honeycomb fiber foam and a method for producing the same.

In order to achieve the above object, the method of the present invention blends two or more fibers (low melt PET fibers and self crimped PET fibers), and other fibers such as natural cotton, recycled fabric, waste fabric, worn carpet and recycled cotton Depending on the purpose of use, they are added to follow different melting points of the two PET fibers. After the fibers are blended, the fibers are opened with a carding machine, and then the blended fibers are delivered to a carding machine for unfolding into a continuous fiber net. The fiber net is delivered to the delivery machine, cut into 90 degree vertical and parallel lamination, and delivered to the oven to blow dry with compressed hot air, so that the PET fibers are crimped when heated, and the PET fibers are melted to upright low melt PET It is entangled with fibers to produce upright honeycomb fiber foams with excellent elasticity and resilience. In addition, fibers of various composition contents may be added to satisfy the required elasticity, which includes natural cotton, recycled fabric, waste fabric, worn carpet and recycled cotton to control elasticity.

The objects, features and advantages of the present invention will become apparent from the following detailed description of preferred embodiments with reference to the accompanying drawings.

The invention will become more apparent from the following description taken in conjunction with the accompanying drawings which show preferred embodiments according to the invention for purposes of illustration only.

According to the present invention, an upright honeycomb fiber foam having high elasticity and restoring force can be produced to overcome conventional disadvantages.

Referring to FIG. 1 for an enlarged view of a method of making an upright honeycomb fiber foam according to the present invention, the present invention mixes two or more fibers, one of which is a low melt PET fiber 12 and the other of the fiber itself. Crimped PET fiber 11. Depending on the purpose of use, other fibers may be added to these two basic fibers. These other fibers include natural cotton, recycled fabrics, waste fabrics, worn carpets and recycled cotton. The two basic materials are blended in different proportions according to the required elasticity, the composition content of the low melt PET fiber 12 is in the range of 30% to 70%, and the composition content of the self crimped PET fiber 11 is in the range of 30% to In the range of 70% and the composition content of the other fibers in the range of 5% to 40%. After all the fibers have been blended, the fibers are reclaimed with a delaminator and then delivered to the carding machine to spread the blended fibers into a continuous fiber net 10, thereby evenly distributing the fibers and then transferring the fiber net 10 to the delivery machine. As shown in FIG. 1, the cut is performed in a vertical and parallel upright stacking state of 90 degrees. Finally, the upright fiber net 10 is delivered to an oven and baked with compressed hot air to crimp the self crimped PET fiber when it is heated. The change in the various temperatures of the self crimped PET fiber 11 is shown in FIG. 2. The higher the temperature, the more the fibers are crimped. Upright honeycomb fiber foams with different crimps have different elasticity. The self crimped PET fiber 11 is melted and entangled with the low melt PET fiber 12 to form the upright honeycomb fiber foam 20 shown in FIG. 3, wherein the highly shrinkable PET fiber 11 contained in each fiber layer While melted helically shrinks when heated, low melt fiber 12 melts and entangles. The fibers 11 are highly crimped and evenly distributed. After the fibers have been heated and solidified, an upright honeycomb fiber foam 20 having a cross-sectional cell structure is formed as shown in the AA cross section of FIG. This may be an excellent independent elastomer. Upright honeycomb fiber foams made from chemical fibers are uniform in elasticity and resilience, and also meet environmental protection requirements. In the whole manufacturing process, the generated fiber waste can be used repeatedly in the above-described manufacturing process, so that no waste is produced. The whole process also adds no chemicals at all, so it is not involved in chemical contamination in manufacturing.

The upright honeycomb fiber foams of the present invention can be cut to the desired thickness and used in a variety of articles that require elastomers such as chair cushions, shoe insoles, mattresses, crash protection materials to replace existing foams. The present invention can also use its cellular structure for absorbing noise, insulating and the like. The upright honeycomb fiber foam can also be used as a filter to uniformly filter and adsorb impurities into the upright honeycomb fiber foam.

The composition content of the low melt PET fiber 12 according to the preferred embodiment of the present invention is in the range of 45% to 50%, the composition content of the self crimped PET fiber 11 is in the range of 45% to 50%, and other fibers Are in the range of 5% to 10%. These ranges meet the specifications of the manufacturing process for making upright honeycomb fiber foams.

In a preferred embodiment of the invention, two or more fibers are blended and carded. The two or more fibers are blended according to the following ratios and then revised by the carding machine and delivered to the carding machine to card the fiber into a continuous fiber net. The proportion of blended fibers is as follows by weight percent. Low melt PET fiber / self crimped PET fiber / other fibers = (45-50%) / (45-50%) / (5-10%).

In the process of cutting and baking the fibers, the continuous fiber net 10 is cut by a cutter into a vertical, parallel, continuous stack of 90 degrees and then transferred to an oven and blow-dried by compressed hot air. The fibers are spirally crimped when heated, and when the fibers are highly crimped, the PET fibers 11 are helically bonded and evenly distributed to each other when heated, so that the low melt PET fibers 12 are melted and solidified to stand up. The honeycomb fiber foam 20 is formed. The upright honeycomb fiber foam 20 can be used in related applications such as chair cushions and mattresses in place of existing foams. The upright honeycomb fiber foam can be wrapped with other materials for applications that absorb and insulate noise, so that the upright honeycomb fiber foam of the present invention is industrially useful.

While the invention has been described in terms of specific embodiments, many changes and modifications can be made by those skilled in the art without departing from the scope and spirit of the invention as set forth in the claims.

While the embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that other embodiments may be made without departing from the scope of the present invention.

1 is a schematic representation of an erect honeycomb fiber foam made by blending two or more fibers in accordance with the present invention.

Figure 2 is a schematic view showing that the crimp changes at various temperatures in the high crimp PET fibers of the upright honeycomb fiber foam according to the present invention.

3 is a schematic view showing melting and bonding upright cotton layers of an upright honeycomb fiber foam according to the present invention.

Claims (4)

(a) blending two fibers in a predetermined ratio, wherein one of the two or more fibers is 45% to 50% by weight of self crimped PET fiber, and the other fiber is a low melt PET fiber Steps, (b) reclaiming the fibers by a face machine; (c) delivering the fibers to a carding machine for carding the fibers into a continuous fiber net; (d) treating the continuous fiber net by a cutter in a vertical, parallel, continuous stack of 90 degrees; (e) transferring the continuous fiber net to an oven and blowing dry with compressed hot air; (f) melting the low melt PET fibers in the oven and tangling the low melt PET fibers wound in a spiral form to the self crimped PET fibers to form a cross-sectional cell structure. Method for producing an upright honeycomb fiber foam comprising a. The method of claim 1 wherein the fibers add natural cotton, recycled fabric, waste fabric, worn carpet or recycled cotton, depending on the required elasticity. The method of claim 2, wherein the composition of the low-melt PET fibers is 45% to 50%. The method of claim 3 wherein the composition content of the additional fibers is between 5% and 10%.

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