TWI832556B - Method for producing wadding and kapok chemical fiber wadding by preparing kapok ball particles and mixing chemical fibers - Google Patents

Abstract

A manufacturing method of wadding and kapok chemical fiber wadding by making kapok ball particles mixed with chemical fiber. The main method is to preliminarily mix and comb the kapok fiber raw materials and chemical fiber raw materials, and then use a closed mixing space to allow the kapok fiber to be absorbed. The airflow drives the small particles of kapok balls, which are mixed with chemical fibers to form chemical fiber clusters containing kapok ball particles. This is used to comb the net to form a chemical fiber wadding layer with kapok ball particles evenly mixed inside; and the kapok chemical fiber wadding material is composed of at least It is composed of a layer of chemical fiber flocs, in which the chemical fiber is laid with a density of 41~104 fibers per mg, while the kapok fiber is made with a particle size of 1~3mm and a particle density of 25000~80000 particles/ ^m2. Mix evenly into the chemical fiber mesh.

Description

Method for producing wadding material and kapok chemical fiber wadding material by mixing kapok ball particles with chemical fiber

The present invention relates to chemical fiber wadding and its manufacturing method, in particular to a wadding manufacturing method by mixing chemical fibers into kapok ball particles and the kapok chemical fiber wadding produced therefrom.

Due to its low cost and wide popularity, chemical fiber can be made into thermal insulation materials or fillers with basic thermal insulation requirements, and can be said to be the most widely used material at present; however, compared to flocculation or fillers made purely from chemical fibers, Other products made of natural fibers obviously have shortcomings such as insufficient bulk and intolerance to water washing. Moreover, after washing, the fibers tend to become tangled into clumps, resulting in reduced warmth retention and poor long-term use of the product; therefore, in Taking into account production costs, finished product performance, market demand and other aspects, the development and improvement of thermal insulation wadding is the direction of continuous research and improvement by industry players in this field.

Among the known technologies, there are technical applications that use kapok fiber and chemical fiber to mix to improve the properties of thermal insulation materials. For example, the CN-102182065A case discloses a pre-treatment method for kapok fiber, which sprays additives (silicone oil formula). Let the kapok fiber be mixed with other yarns first; another example is the method of manufacturing kapok thermal insulation materials disclosed in the CN-103015035B case. The pretreatment and mixing process of the kapok fiber involves spraying antistatic agent and mixing for more than 2 to 4 hours. Subsequently, the mixed fibers are processed into cotton batting.

The above-mentioned known mixing technologies all use additives to achieve the mixing of kapok fibers. However, this method has the following shortcomings in practice: (1) Spraying chemicals will destroy the kapok fibers. The excellent natural ingredients on the surface itself reduce the active ingredients of antibacterial and anti-mite; (2) Use antistatic agents to avoid flying. Not only is the pre-treatment process time-consuming and cumbersome, but the additives will stick to the machine equipment during the processing, causing cleaning These problems may even affect the performance of equipment components and reduce durability and processing quality.

In view of the problems of conventional technical construction methods, the inventor of this case devoted himself to researching ways to improve it, and through continuous attempts and efforts, he completed the present invention.

The main purpose of the present invention is to achieve the mixing of kapok fiber and chemical fiber through a simple and convenient process that requires no additives and generates kapok chemical fiber wadding with good properties for subsequent processing.

This invention mainly utilizes a series of mixing process equipment to allow kapok fibers with light specific gravity to be naturally dispersed and formed into small particles during the process, thereby improving the problem that they are easy to fly and difficult to mix, and can be smoothly and evenly mixed into chemical fibers. After proper carding and combing, a chemical fiber floc layer with kapok particles evenly mixed inside is generated.

Through a particularly innovative cotton blending process, the present invention can regulate the particle size and density of kapok particles in chemical fiber batting by adjusting the operating speed of the equipment, such as the feeding speed, spreading speed, carding speed, etc., thereby improving the output. The cotton batting is of better quality than 100% pure fiber or the current conventional kapok chemical fiber blend. It has the effect of reducing costs and facilitating production. It is a mixing method that does not affect the natural and good functionality of the kapok fiber itself.

In order to achieve the above object, the present invention is a method for manufacturing floc by mixing chemical fiber into kapok ball particles. The main steps are as follows: a) Carding the kapok fiber raw material and the chemical fiber raw material together in proportion, so that the kapok fiber raw material and the chemical fiber raw material are combed together in proportion. Fibers and chemical fibers are individually combed into balls. And entangled with each other, forming a combed mixed material; b) The combed mixed materials are sent into a cotton mixing space one by one, and the mixed materials are repeatedly scattered in the cotton mixing space through a dispersing module that continues to rotate at a high speed. in the air, and an internal airflow is formed in the mixed space to drive the kapok fibers to rotate to form a plurality of small particle kapok balls, which are then mixed with chemical fibers to form a plurality of chemical fiber groups containing kapok ball particles, and are output into the mixed space; c) with The chemical fiber groups containing kapok particles are combed and formed into a chemical fiber floc layer with the kapok particles evenly mixed inside.

According to the above-mentioned mixing process of the present invention, a further step d) can be further provided, which is to cross-stack the chemical fiber flocculation layers generated in step c) through a netting machine to form a body with a predetermined number of layers, and then double The surface is glued, heat-set in an oven, and cooled in room-temperature air. When it is finally completed, it forms a flocculation material that is slightly heated on the surface and can be used for filling.

The kapok chemical fiber wadding produced according to the present invention mainly includes at least one layer of chemical fiber wadding containing kapok fiber particles, and the chemical fiber wadding layer is mixed with 10~30wt% kapok fiber and 70~90wt% chemical fiber. , among which, the chemical fiber is composed of a mesh with a density of 41~104 fibers per mg, while the kapok fiber is evenly mixed with the chemical fiber with a particle size of 1~3mm and a particle density of 25000~80000 particles/ ^m2 . Netting in progress.

According to the above-mentioned manufacturing method of the present invention, the proportions based on step a) are kapok fiber raw materials accounting for 10~30wt% and chemical fiber raw materials accounting for 70~90wt%; and further, the selected chemical fiber raw materials can also be Among them, 0~25wt% is replaced by low melting point chemical fibers. The proportion of 70~90wt% of chemical fiber raw materials can be divided into 0~25wt% low melting point chemical fibers and 45~90wt% non-low melting point chemical fibers. .

In a feasible embodiment, the product performance is better when mixed with about 15wt% kapok fiber raw material and about 85wt% chemical fiber raw material.

In this way, the quality of the final chemical fiber batt paving product mixed with kapok ball particles can be greatly improved to be better than the quality of 100% chemical fiber. Since kapok fiber itself is not compressive and has a high moisture content after washing, by forming a granular coating The structural form covered in chemical fibers can effectively improve fluff recovery and surface water repellency. For this reason, in an appropriate ratio, good performance can be maintained even without adding low-melting point chemical fibers.

Furthermore, in another feasible embodiment, when about 25wt% of kapok fiber raw materials are used, the matching chemical fiber raw materials can be changed to about 20wt% of low-melting point chemical fiber raw materials and about 45wt% of general chemical fibers. The performance of the product made by mixing this raw material is the best; it is mainly based on the low resilience and high water absorption of the kapok fiber itself. When the ratio is higher, replacing it with an appropriate amount of low-melting point chemical fiber can help maintain the fixation The cotton-paved structure allows the product to maintain good washing resistance and rebound ability, ensuring fluffy thickness.

According to the above-mentioned manufacturing method of the present invention, step b) is carried out in a special processing cotton mixing box, which is designed with a closed cotton mixing space and pipes for feeding and discharging materials, and the dispersion module is arranged in the mixing box. The cotton space includes at least two cylinders arranged in a longitudinal arrangement. The mixed material fed in is dispersed upwards in the cotton mixed space through the cylinder's card clothing; among them, each cylinder is used to disperse the needles. The optimal distance between cloths is 1.5~2mm, and the optimal rotation speed of these cylinders is 90~150rpm.

Furthermore, the processing and mixing box is equipped with a conveyor belt for sending the mixed materials to the dispersing module one by one for dispersion, and the processing and mixing box is also equipped with an optical sensing unit for By sensing the mixed material to be processed in front of the dispersion module, the conveying speed of the conveyor belt (and adjusting the feeding speed) of the conveyor belt can be adjusted accordingly.

In the present invention, among the kapok fiber raw materials and chemical fiber raw materials used, the average length of the kapok fiber is shorter than the average length of the chemical fiber; more specifically, the average length of the kapok fiber is The average length ranges from 5 to 25mm, the average length of chemical fibers ranges from 30 to 60mm, and the denier number ranges from 1.5D to 7D.

The present invention uses kapok fiber ball particles to improve the thickness and fluffiness of the chemical fiber batts. By maintaining the good properties of the chemical fiber batts, it overcomes the problem that the kapok fibers in the past were tangled after washing, had reduced thickness, and had high water absorption, which could not maintain good warmth and durability. Quality issues can effectively improve the warmth and durability of kapok products.

In order to gain a more detailed understanding of the above-mentioned purpose, effect and characteristics of the present invention, a preferred embodiment is given and described as follows with reference to the accompanying drawings:

10: Chemical fiber

20:kapok fiber

21:Kapok ball particles

30: Processing mixed cotton box

31:Feeding pipe

32: Discharge pipe

33: Mixed cotton space

34: Hook and scatter module

341:Xilin

342: Motor

351, 352, 353, 354: Conveyor belt

355: Motor

36: Fashionable tools

37: Optical sensing unit

S01~S05: steps

A:Mixed materials

B: Chemical fiber mass containing kapok particles

[Figure 1] is a schematic structural diagram of a conventional chemical fiber flocculation material.

[Fig. 2] is a schematic process flow diagram of an embodiment of the present invention.

[Fig. 3] is a schematic structural diagram of the cotton processing box according to the embodiment of the present invention.

[Fig. 4] is a schematic structural diagram of kapok chemical fiber wadding according to an embodiment of the present invention.

[Fig. 5] is an appearance view of the kapok chemical fiber wadding according to the embodiment of the present invention.

It is known that the cotton batting material composed purely of chemical fiber 10 has an overview of its structure as shown in Figure 1. Compared with natural fiber cotton batting, it has shortcomings such as insufficient bulk and intolerance to water washing. It is currently common to add other fibers to improve performance. Improvement technology; in the present invention, it relates to the category of mixing kapok fiber and chemical fiber to make wadding. However, in the known construction method, since kapok fiber is easy to fly, the use of additives will damage the product and equipment to some extent, and resist The electrostatic process It is too cumbersome and time-consuming, causing trouble during mixing processing.

Therefore, the present invention provides a method for manufacturing floc by mixing chemical fiber into kapok ball particles. It mainly uses self-developed processing and mixing equipment to form a special mixing process to achieve the mixing of kapok fiber and chemical fiber without additives. The effect is to improve the previous problem that kapok fibers are easy to fly and difficult to mix.

As shown in Figures 2 and 3, the method adopted in the present invention mainly includes the material preparation step S01, the preliminary mixing and carding step S02, the kapok ball processing and mixing step S03, the carding step S04 and the shaping step S05.

In step S01, an appropriate amount of kapok fiber raw materials and chemical fiber raw materials are mainly prepared in proportion; in the present invention, the kapok fiber raw materials used account for 10~30wt% of the total amount, and the chemical fiber raw materials account for 70~30wt% of the total amount. 90wt%.

In step S02, the kapok fiber raw materials and the chemical fiber raw materials are mainly sent to the carding and opening equipment together, so that the two can be carded together in proportion, so that the kapok fiber and the chemical fiber are separately carded into balls, and both The two materials are intertwined with each other at least in some areas to form a combed mixed material A.

After step S02 is completed, step S03 is performed, and the mixed material A completed in step S02 is put into a processing mixing box 30; in practice, the carding and opening equipment of step S02 and step S03 can be directly connected by pipelines. The processing and mixing box 30 allows the mixed material A completed in step S02 to be directly supplied to the feed pipe 31 of the processing and mixing box 30 and put into the processing and mixing box 30 .

The processing cotton mixing box 30 is mainly equipped with a closed cotton mixing space 33 inside, and is matched with the design of the feeding pipe 31 and the discharging pipe 32 to achieve the effect of closed processing.

In this embodiment, the processing and mixing box 30 is provided with several conveyor belts 351, 352, 353, and 354 inside, and is provided with a dispersing module 34 in the mixing space 33, and is provided with an outlet in the discharge pipe 32. The wind appliance 36 is provided with an optical sensing unit 37 at an appropriate position. The dispersion module 34 includes at least two cylinders 341 arranged longitudinally, which are driven by a motor 342 to disperse the fed mixed material A upward in the mixing space 33. Lin 341 is provided with card clothing to provide the dispersing effect, and the distance between the card clothings is set to 1.5~2mm; the conveyor belt 351 is set between the feeding place and the dispersing module 34, and is driven by the motor 355 together with the conveyor belt 352. The drive is used to transport the penetrated material (mixed material A) to the dispersion module 34, and the conveyor belts 352, 353, and 354 are respectively arranged on the back side of the dispersion module 34 to the discharge point. To output the processed product.

In step S03, after the mixed material A, which is mainly combed, is put into the processing mixing box 30, it is sent into the mixing space 33 one by one via the conveyor belt 351, and sent to the dispersion module 34. By the dispersion module 34 The continuous high-speed rotation of the double cylinder 341 allows the mixed material A to be repeatedly scattered in the air of the cotton mixing space 33. Through the high-speed rotation of the cylinder 341 and the action of the air outlet device 36 of the discharge pipe 32, the mixed material A can be dispersed in the air of the cotton mixing space 33. Internal circulation convection airflow is formed in the space 33, driving the kapok fiber 20 to rotate to form a plurality of small-sized kapok ball particles 21, which are then mixed with the chemical fiber 10 to form a plurality of chemical fiber groups B containing the kapok ball particles, and the mixed cotton space is output. 33.

During the operation of step S03, the rotation speed of the cylinder 341 is preferably 90 to 150 rpm. In addition, during the material feeding part, the optical sensing unit 37 can sense the material to be processed in front of the dispersion module 34. The accumulated amount of mixed material A is used to control the feeding and conveying speed of the conveyor belt 351 to achieve the purpose of feeding the material into the process one by one. That is, when there is too much mixed material A to be processed, the feeding speed is reduced to avoid spherical processing or The problem of incomplete mixing, indeed the output contains kapok particles Chemical fiber group B.

In step S04, the mixed chemical fiber groups B containing kapok particles are sent to a carding and cotton feeding machine for carding and web forming. Through relevant parameter control (the cylinder speed of the carding and cotton feeding machine is controlled at 250~500rpm/mins), so that the kapok particles 21 can still maintain a granular structure and be mixed in the carded chemical fiber 10, as shown in Figure 4 and Figure 5, and the kapok particles 21 are evenly mixed inside. layer of chemical fiber wadding.

In step S05, the layers of chemical fiber wadding are cross-stacked through a web laying machine to form a shape with a predetermined number of layers. Then double-sided gluing is performed on both sides and heat-setting in an oven. Finally, it can be cooled down in room temperature air to form a surface. Slightly blanching can be used for filled wadding (as shown in Figure 5). In this step, gluing is carried out by spraying glue on the surface, and acrylic resin can be used to make the finished product that has been shaped and processed lightly water-repellent.

In the present invention, the kapok fiber raw material used is unprocessed natural kapok fiber, and the chemical fiber raw material is chemical fiber (including low melting point fiber) with a denier between 1.5D and 7D. Kapok fiber and chemical fiber, the average length of kapok fiber is shorter than the average length of chemical fiber, more specifically, the average length of kapok fiber is between 5~25mm, while the average length of chemical fiber is between 30~60mm. In addition, the chemical fiber raw materials accounting for 70~90wt% of the total can also be further divided into 0~25wt% low melting point chemical fibers and 45~90wt% non-low melting point chemical fibers (i.e. normal chemical fibers).

The wadding made of kapok particles 21 mixed with chemical fibers according to the manufacturing method of the present invention is also a type of kapok chemical fiber wadding, which mainly includes at least one layer of chemical fiber wadding containing kapok particles 21, and the chemical fiber wadding The layer system is composed of 10~30wt% kapok fiber and 70~90wt% chemical fiber; among them, the chemical fiber series 10 has a density of 41~104 fibers per milligram, while the kapok fiber series 20 has a particle size of 1~3mm. The particle size and particle density of 25,000~80,000 particles/ ^m2 are evenly mixed in the chemical fiber 10 laying net.

In the method of making kapok ball particles mixed with chemical fibers of the present invention, the kapok chemical fiber wadding produced has the best performance when the ratio is between 10~30wt% of kapok fiber 20 and 70~90wt% of chemical fiber 10; When the chemical fiber 10 uses normal chemical fibers (not low-melting point chemical fibers), the optimal ratio is 15% kapok fiber and 85% chemical fiber. In actual operation, the material preparation steps mentioned above are carried out in sequence according to this ratio. S01. Preliminary mixing and carding step S02, and then the mixed material A is subjected to the kapok ball processing and mixing step S03 to generate a chemical fiber mass B containing kapok particles 21, and then the carding step S04 is performed to obtain a uniform mixture of the kapok balls inside. The chemical fiber wadding layer of the particles 21 can finally be made into kapok chemical fiber wadding material with an appropriate number and thickness by the shaping step S05 for filling or application in various products.

Furthermore, in the actual operation of the present invention, when the ratio of the kapok fiber 20 used is increased, in order to ensure that the produced kapok chemical fiber wadding can still have good characteristics, an appropriate amount of low-melting point chemicals are used in the chemical fiber 10. Fiber replacement. After actual experiments and tests, the optimal ratio of this formula is 25% kapok fiber, 55% chemical fiber (non-low melting point) and 20% low melting point chemical fiber. With this ratio, proceed to the aforementioned material preparation steps S01, The preliminary mixing and combing step S02, the kapok ball processing and mixing step S03, the carding step S04, the shaping step S05 and other steps can produce the kapok chemical fiber wadding material with good performance of the present invention.

In the following, the kapok particle-containing product 21 (Examples 1 and 2) made from the two best proportions of the above-mentioned embodiments of the present invention and the mixed cotton products mixed with kapok fiber on the market (mixed kapok products 1, 2, 3) The characteristics of products made of purified fiber (purified fiber products 1, 2, and 3) are tested and compared as follows:

It can be seen from the above comparison table that the kapok chemical fiber wadding product containing kapok ball particles 21 developed by the present invention is an embodiment of two preferred ratios. The CLO values of the warmth retention test of the specification 100gsm are 2.30 and 1.92 respectively, and the warmth retention and bulkiness are Better than products made purely from chemical fibers. Generally speaking, the performance of the product made by the present invention (mixed with kapok particles 21) is as follows:

(1) The thermal insulation CLO per unit gram weight can maintain more than 0.0192clo/gsm. When the unit area is 60gsm, the optimal thermal insulation CLO per unit gram weight can even reach 0.0297clo/gsm. When the products of the present invention are applied, their thermal insulation properties are generally excellent. For general pure chemical fiber products.

(2) The thickness recovery rate after washing remains at about 81% to 91%, which is slightly better than ordinary pure chemical fiber products, but significantly better than other kapok chemical fiber mixed products on the market.

(3) The thickness per unit weight is maintained at about 0.014~0.015cm/gsm. Compared with general pure chemical fiber products and kapok chemical fiber mixed products, it can have better fluffy properties, and for products of the same thickness, the applications are The product of the present invention has the advantage of being lightweight.

(4) The moisture content after washing (before drying) is about 36~40%. Although it is not as low as the low moisture content of ordinary pure chemical fiber products, the present invention can greatly improve the conventional wood by utilizing the structural characteristics of kapok particles 21. Disadvantages of high moisture content of fiber-cotton products after washing.

Furthermore, during the construction method of the present invention, water-repellent glue can be used for surface spraying in the shaping step S05. This can greatly reduce the moisture content after washing, so that the kapok particles 21 contained in the product produced by the construction method of the present invention can be completed. Kapok chemical fiber wadding has better water-repellent effect and enhances the overall competitiveness of the product.

To sum up, by generating a special structure of kapok ball particles 21 in the construction method, the present invention can effectively improve the fluffy thickness effect of kapok chemical fiber blended products after washing and improve the warmth retention of CLO. It can use equipment in series to form a series of simple processes. , and there is no need to add additives during the process, which reduces the internal pollution and wear of the machine parts, forming an invention and creation that has many excellent functions such as convenient production, stable quality, and optimized product characteristics. We have filed a patent application in accordance with the law.

However, the content of the above description is only an illustration of the preferred embodiments of the present invention. Any extension, modification, simple change or equivalent substitution based on the technical means of the present invention shall also fall within the scope of the patent application of the present invention.

10: Chemical fiber

20:kapok fiber

21:Kapok ball particles

30: Processing mixed cotton box

31:Feeding pipe

32: Discharge pipe

33: Mixed cotton space

34: Hook and scatter module

341:Xilin

342: Motor

351, 352, 353, 354: Conveyor belt

355: Motor

36: Fashionable tools

37: Optical sensing unit

A:Mixed materials

B: Chemical fiber mass containing kapok particles

Claims (9)

A method for manufacturing wadding by mixing chemical fibers into kapok ball particles, which includes the following steps: a) carding the kapok fiber raw materials and chemical fiber raw materials together in proportion, so that the kapok fibers and chemical fibers are loosened into balls. And entangled with each other, forming a combed mixed material; b) The combed mixed materials are sent into a cotton mixing space one by one, and the mixed materials are repeatedly scattered in the cotton mixing space through a dispersing module that continues to rotate at a high speed. in the air, and use the high-speed rotation of the dispersing module to form an internal airflow in the mixing space that can drive the kapok fibers to rotate, so that the kapok fibers rotate to form a plurality of small particles of kapok balls, which are then mixed with chemical fibers respectively. Generate a plurality of chemical fiber groups containing kapok particles, and output the mixed cotton space; c) use the chemical fiber groups containing kapok particles to form a comb, and generate a chemical fiber wadding layer with the kapok particles evenly mixed inside. , among which, the generated chemical fiber floc layer has a comb density between 41 and 104 chemical fibers per mg, and the density of the kapok particles contained in it is 25,000 ~ 80,000 particles/m ² , and the particle size of the kapok particles is Between 1~3mm. The wadding manufacturing method described in claim 1, wherein there is a step d) after step c), which is to cross-stack the chemical fiber wadding layers generated in step c), and then perform double-sided gluing and heat baking to set the shape. , forming flocculation for filling. The flocculation manufacturing method described in claim 1, wherein the proportions in step a) are 10~30wt% of kapok fiber raw materials and 70~90wt% of chemical fiber raw materials. The flocculation manufacturing method described in claim 3, wherein the chemical fiber raw material accounting for 70~90wt% is further divided into low melting point chemical fiber accounting for 0~25wt% and non-low melting point chemical fiber accounting for 45~90wt% Chemical fibers. The wadding manufacturing method described in claim 1, wherein the dispersion module in step b) is installed in the cotton mixing space and includes at least two cylinders arranged generally in a longitudinal direction, each of which is There are card clothings used for spreading. The distance between the card clothes is 1.5~2mm, and the mixed material is scattered upwards in the mixed space at a rotation speed of 90~150rpm. The flocculation manufacturing method as described in claim 1, wherein wood in the kapok fiber raw material The average length of cotton fibers is shorter than the average length of chemical fibers in chemical fiber raw materials. The wadding manufacturing method described in claim 6, wherein the average length of the kapok fiber is between 5~25mm, the average length of the chemical fiber is between 30~60mm, and the denier number is between 1.5D~7D. The wadding manufacturing method as described in claim 1, wherein in step b), a conveyor belt is used to transport the mixed material to the dispersion module in the cotton mixing space, and the gradual feeding is based on an optical The sensing unit senses the mixed material to be processed in front of the dispersion module to adjust the conveying speed of the conveyor belt. A kind of kapok chemical fiber wadding material, which includes at least one layer of chemical fiber wadding material containing kapok fiber particles, and the chemical fiber wadding material layer is made of a mixture of 10~30wt% kapok fiber and 70~90wt% chemical fiber, wherein the chemical fiber is The mesh is composed of a density of 41 to 104 fibers per milligram, and the kapok fiber is evenly mixed in the chemical fiber mesh with a particle size of 1 to 3 mm and a particle density of 25,000 to 80,000 particles/ ^m2 .

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