Classifications

• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
  • A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/022—Non-woven fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
  • B32B5/265—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
  • B32B5/265—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
  • B32B5/266—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/20—All layers being fibrous or filamentary

Definitions

• the invention relates to the technical field of fiber mat preparation, and in particular to a fiber mat and a preparation method thereof.
• the existing fiber pads have single property parameters such as air permeability and support.
• a first aspect of the present application provides a fiber mat comprising a first fiber layer and a second fiber layer, wherein the first fiber layer and the second fiber layer are bonded together, the first fiber layer is composed of first three-dimensional curled fibers and irregular air channels formed by the first three-dimensional curled fibers, the second fiber layer is composed of second three-dimensional curled fibers and irregular air channels formed by the second three-dimensional curled fibers, and the fiber density of the first fiber layer is different from the fiber density of the second fiber layer.
• a third fiber layer which is composed of third three-dimensional curled fibers and irregular air channels formed by the third three-dimensional curled fibers.
• the third fiber layer is bonded to the first fiber layer and/or the second fiber layer, and has a different fiber density from that of adjacent fiber layers.
• it further includes: a textile layer, wherein the textile layer is bonded to the first fiber layer or the second fiber layer.
• the longitudinal cross-sections of the first fiber layer and the second fiber layer are in any one of a wavy, elliptical, and rectangular shape.
• the cross-sections of the first three-dimensional curled fibers and the second three-dimensional curled fibers are solid or hollow.
• the thickness of the first fiber layer and the second fiber layer is any value within a preset thickness range, and the preset thickness range is between 2 mm and 20 cm.
• a second aspect of the present application provides a method for preparing a fiber mat, the method being used to prepare any one of the above-mentioned fiber mats, comprising:
• the dried mixed material is fed into a conveying screw, and the temperature of each heating zone of the conveying screw is adjusted to gradually increase the temperature and melt the mixed material;
• the filtered mixed material is fed into a wire-discharging assembly, and the mixed material is formed into fibers after passing through the wire-discharging assembly.
• the fibers naturally fall onto the water spraying plate and the water surface.
• the fibers extruded from the adjacent wire-discharging holes on the wire-discharging assembly are wound into a three-dimensional curled shape to form a fiber layer, and the fiber layer falls into the water tank;
• the fiber layer is pulled into a cooling water tank by a conveying roller in the water tank, and the fiber layer is rapidly cooled and solidified in the water tank;
• the fiber layer in the water tank is guided by a guide roller, and the fiber layer is pulled out of the water surface by a traction roller to dry and form;
• the fiber layer is cut according to actual needs, and after cutting, it is placed in an air drying box along its production direction for air drying;
• the fiber layer After the fiber layer is dried, the fiber layer is heat-pressed and shaped in a mold according to product shape requirements.
• the drying temperature range of the dryer is 60-130°C, and the drying time range is 1-5h; the temperature range of the hot pressing setting is 80°C-130°C, and the time range of the hot pressing setting is: 5min-30min.
• the conveying screw is divided into 5 heating zones, and the heating temperatures of the 5 heating zones increase step by step along the conveying direction of the conveying screw.
• the heating temperature range of the heating zone with the lowest heating temperature is 120-200°C, and the temperature range of the heating zone with the highest heating temperature is 210-250°C.
• the heating temperature setting interval between two adjacent heating zones is 10°C-15°C.
• the third aspect of the present application provides a fiber mat preparation device, which is used to achieve any of the above A fiber mat preparation method, comprising: a filament outlet assembly, a water spraying plate, a water tank, a conveying roller, a traction roller, a guide roller, a dryer and a conveying screw;
• the output end of the dryer is connected to the input end of the conveying screw, the output end of the conveying screw is connected to the input end of the wire outlet assembly, and the conveying screw includes a plurality of heating zones;
• the wire outlet assembly comprises: a spinning die, a distribution plate, and a spinning plate; the spinning die is closely fitted with the distribution plate, and the distribution plate is closely fitted with the spinning plate;
• the spinneret die is provided with a plurality of spinneret channels, and the distribution plate is provided with distribution areas corresponding to the number of the spinneret channels; the distribution area is also provided with a plurality of distribution holes; the diameter and spacing of the distribution holes on each distribution area are different; the spinneret plate is divided into a plurality of spinneret areas, and the state of any one of the spinneret areas is solid or hollow;
• the water tank is used to store cooling water;
• the conveying roller is arranged in the water tank and is completely immersed in the cooling water of the water tank;
• the wire outlet assembly is located outside the water tank;
• the water spraying plate is obliquely arranged between the wire outlet assembly and the conveying roller; the first end of the water spraying plate is in contact with the end of the conveying roller close to the water surface; the second end of the water spraying plate extends toward the wire outlet assembly, and the water spraying inclined surface of the water spraying plate faces the wire outlet surface of the wire outlet assembly;
• the water spraying plate comprises a water storage chamber and a water spraying inclined surface
• the water spraying inclined surface of the water spraying plate comprises a first inclined surface, a second inclined surface and a third inclined surface sequentially connected in a direction close to the conveying roller
• the water storage chamber is connected to the second end of the water spraying plate
• a spraying hole is provided on the water storage chamber
• the water storage chamber is used to store cooling water
• the cooling water is dropped into the water tank through the water spraying inclined surface through the spraying hole;
• a plurality of guide rollers are provided in the water tank, and a traction roller is also provided outside the water tank.
• the traction roller is used to pull the cooled fiber layer out of the water tank through the conveying roller.
• the plurality of guide rollers are arranged in sequence along the direction in which the fiber layer moves from one end of the conveying roller away from the water surface to the traction roller.
• this application provides a fiber mat with a multi-layer tightly fitting structure, and the raw materials, density, thickness, etc. of each fiber layer can be adjusted according to actual needs.
• the parameters such as air permeability and support of the product
• the parameters of one or more layers can be flexibly replaced or modified, which can meet a wider range of product requirements.
• the second aspect of the present application provides a method for preparing a fiber mat, which can produce fiber layer mats with any combination of raw materials, number of layers, and density in conjunction with a fiber mat preparation device.
• FIG1 is a schematic structural diagram of a fiber mat shown in the first exemplary embodiment of the present application.
• FIG2 is a schematic structural diagram of a fiber mat shown in a second exemplary embodiment of the present application.
• FIG. 3 is a schematic structural diagram of a fiber mat shown in a third exemplary embodiment of the present application.
• FIG4 is a schematic diagram of a process flow of a fiber mat method according to an exemplary embodiment of the present application.
• FIG5 is a schematic structural diagram of a fiber mat preparation device according to an exemplary embodiment of the present application.
• FIG6 is a front view of a water spray plate shown in an exemplary embodiment of the present application.
• FIG7 is a side view of a water spray plate shown in an exemplary embodiment of the present application.
• FIG. 8 is a schematic structural diagram of a wire outlet assembly according to an exemplary embodiment of the present application.
• 1-filament outlet assembly 2-water spraying plate; 3-water tank; 4-conveying roller; 5-traction roller; 6-guide roller; 7-dryer; 8-conveying screw; 11-spinning die; 12-distribution plate; 13-spinning plate; 21-water storage chamber; 22-water spraying slope; 111-spinning channel; 121-distribution area; 122-distribution hole; 131-spinning area; 221-first slope; 222-second slope; 223-third slope; 101-first fiber layer; 102-second fiber layer; 103-third fiber layer; 104-textile layer.
• Figure 1 shows a structural schematic diagram of a fiber mat of the first embodiment of the present application, including a first fiber layer 101 and a second fiber layer 102, the first fiber layer 101 and the second fiber layer 102 are bonded together, the first fiber layer 101 is composed of first three-dimensional curled fibers and irregular air channels formed by the first three-dimensional curled fibers, the second fiber layer 102 is composed of second three-dimensional curled fibers and irregular air channels formed by the second three-dimensional curled fibers, the three-dimensional curled fibers have a memory effect, the curled shape is persistent, and has good fluffiness and resilience.
• the fiber density of the first fiber layer 101 is different from the fiber density of the second fiber layer 102.
• the density of the fiber mat directly affects the supporting force and other properties of the product.
• the fiber density range of the present application is obtained according to the raw material type of the product. Since the first fiber layer 101 and the second fiber layer 102 can use different raw materials, the corresponding density values are also different; or, some different raw materials can obtain partially overlapping density values. In this case, different materials can be used for each layer but the uniform density can be guaranteed.
• Figure 2 is a schematic diagram of a fiber mat structure shown in the second embodiment of the present application.
• the fiber mat of the present application also includes: a third fiber layer 103, the third fiber layer is composed of third three-dimensional curled fibers and irregular air channels formed by the third three-dimensional curled fibers, the third fiber layer is bonded to the first fiber layer and/or the second fiber layer, and has a different fiber density from that of adjacent fiber layers.
• FIG3 is a schematic diagram of a fiber pad structure shown in the third embodiment of the present application, and the fiber pad of the present application further includes: a textile layer 104, and the textile layer 104 is bonded to the first fiber layer 101 or the second fiber layer 102.
• the textile layer 104 is the surface layer that directly contacts the user when the fiber pad of the present application is used, and can be made of a thinner skin-friendly material, which does not affect the functional use of the fiber pad, and can also provide a good touch, and the textile layer 104 can also be replaced with different materials according to actual needs to meet different usage scenarios.
• the longitudinal cross-sectional shape of the first fiber layer 101 and the second fiber layer 102 is any one of a wave shape, a cylinder shape, and a rectangle shape.
• the fiber pad of the present application can be applied to products with supporting functions such as mattresses, pillows, and cushions.
• the longitudinal cross-sectional shape of the fiber pad can be arbitrarily designed or selected according to product needs. In addition to wave shape, oval shape, and rectangle shape, it can also be other shapes. There is no restriction on applications.
• the cross-section of the first three-dimensional curled fiber and the second three-dimensional curled fiber is one of solid or hollow.
• the cross-sectional structure of the fiber of the fiber mat in the embodiment of the present application can be arbitrarily matched, specifically, the first three-dimensional curled fiber is solid, and the second three-dimensional curled fiber is hollow; the first three-dimensional curled fiber is hollow, and the second three-dimensional curled fiber is solid; the first three-dimensional curled fiber is solid, and the second three-dimensional curled fiber is solid; the first three-dimensional curled fiber is hollow, and the second three-dimensional curled fiber is hollow.
• the number of fiber layers of the fiber mat may be more than two layers, for example, three layers, four layers, etc.
• the cross-sectional structure of the three-dimensional curled fibers in the fiber layer may also be adjusted as needed.
• the third fiber layer 103 is composed of third three-dimensional curled fibers and irregular air channels formed by the third three-dimensional curled fibers.
• the cross-sections of the first three-dimensional curled fibers and the third three-dimensional curled fibers may be solid, and the cross-section of the second three-dimensional curled fibers may be hollow. Since the cross-section of the three-dimensional curled fibers is hollow and hard, they can be used for support. Since they are solid and soft, they can ensure comfort, thereby ensuring that the fiber mat has sufficient supporting force while ensuring the air permeability of the fiber mat.
• the thickness of the first fiber layer 101 and the second fiber layer 102 is any value in a preset thickness range.
• the preset thickness range is between 2 mm and 20 cm, and the fiber density of the first fiber layer 101 and the second fiber layer 102 can also be any value in the preset density range.
• the overall thickness of the fiber pad can be obtained according to the actual product requirements, and then the thickness size of each layer can be specifically allocated. According to various performance requirements, the thickness of each layer can be set to be different or the same.
• the thickness of the first fiber layer 101 can be greater than the thickness of the second fiber layer 102, the thickness of the first fiber layer 101 can also be equal to the thickness of the second fiber layer 102, and the thickness of the first fiber layer 101 can also be less than the thickness of the second fiber layer 102.
• the first aspect of the present application provides a fiber pad with two layers of tightly fitting structure, and the density, thickness, etc. of the first fiber layer 101 and the second fiber layer 102 of the fiber pad can be adjusted according to actual needs, so that the fiber pad can meet the usage requirements of two different types of users at the same time.
• the second aspect of the present application provides a method for preparing a fiber mat, as shown in FIG4 , the method is used to prepare any of the above-mentioned fiber mats, comprising the steps of:
• S002 Add the mixture into the dryer by vacuum method, and adjust the temperature and drying time of the dryer according to the material type of the mixture; in actual use, the drying temperature range of the dryer is 60-130°C, and the drying time range is 1-5h; the temperature and time in the raw material drying step are selectively used according to the type of raw materials used.
• S003 Feed the dried mixed material into the conveying screw, adjust the temperature of each heating zone of the conveying screw, and heat and melt the mixed material step by step.
• the conveying screw is divided into 5 heating zones, and the heating temperatures of the 5 heating zones increase step by step along the conveying direction of the conveying screw.
• the heating temperature range of the heating zone with the lowest heating temperature is 120-200°C
• the temperature range of the heating zone with the highest heating temperature is 210-250°C.
• the heating temperature setting interval of two adjacent heating zones is 10°C-15°C.
• the filtered mixed material is fed into a wire-discharging assembly, and the mixed material is formed into fibers after passing through the wire-discharging assembly.
• the fibers naturally fall onto the water sprinkling plate and the water surface.
• the fibers extruded from adjacent wire-discharging holes on the wire-discharging assembly are wound into a three-dimensional curled shape to form a fiber layer, and the fiber layer falls into the water tank.
• S008 Cut the fiber layer according to actual needs, and place it in an air drying box along its production direction after cutting for blow drying.
• the fiber layer is heat-pressed and shaped in a mold according to the product shape.
• the temperature range of heat-pressing and shaping is 80°C-130°C
• the time range of heat-pressing and shaping is: 5min-30min.
• the third aspect of the present application provides a fiber mat preparation device for implementing any of the above fiber mat preparation methods, as shown in FIG5, comprising: a fiber outlet assembly 1, a water spray plate 2, a water tank 3, a conveying roller 4. Pulling roller 5, guide roller 6, dryer 7 and conveying screw 8.
• the output end of the dryer 7 is connected to the input end of the conveying screw 8, and the output end of the conveying screw 8 is connected to the input end of the wire outlet assembly 3.
• the conveying screw 8 includes several heating zones.
• the dryer 7 and the conveying screw 8 are used to process the raw materials. They are first dried to prevent the mixing of water vapor and thus affect the product quality, and then heated and melted for later extrusion into wires.
• the water tank 3 is used to store cooling water; the conveying roller 4 is arranged in the water tank 3 and is completely immersed in the cooling water of the water tank 3.
• the conveying roller 4 is in the cooling water and is used to adjust the moving direction of the fiber layer in the cooling water to ensure the molding of the fiber layer;
• the wire drawing component 1 is located outside the water tank 3, and the water sprinkling plate 2 is obliquely arranged between the wire drawing component 1 and the conveying roller 4, and the first end of the water sprinkling plate 2 is in contact with the end of the conveying roller 4 close to the water surface, and the second end of the water sprinkling plate 2 extends toward the wire drawing component 1, and the water sprinkling inclined surface of the water sprinkling plate 2 faces the wire drawing surface of the wire drawing component 1; after the fiber layer is squeezed out of the wire drawing component 1, it falls vertically into the water sprinkling plate 2 and the water surface, and the cooling water in the water sprinkling plate 2 first contacts
• the water spraying plate 2 includes a water storage chamber 21 and a water spraying slope 22.
• the water storage chamber 21 is connected to the second end of the water spraying plate.
• a spray hole 211 is provided on the water storage chamber 21.
• the water storage chamber 21 is used to store cooling water, and the cooling water falls into the water tank 3 through the water spraying slope 22 through the spray hole 211; the spray hole 211 of the water storage chamber 21 on the water spraying plate 2 is located above the water spraying slope 22.
• the main benefit is that the distance between the spinneret 2 and the cooling water can be reduced, which is beneficial to increase the temperature of the fiber layer when it falls on the spray plate 2 or the water surface, and ensure the bonding strength between the contact points of adjacent fiber layers.
• a plurality of guide rollers 6 are provided in the water tank 3, and a traction roller 5 is also provided outside the water tank 3.
• the traction roller 5 is used to pull the cooled fiber layer out of the water tank 3 through the conveying roller 4.
• the plurality of guide rollers 6 are arranged in sequence along the direction in which the fiber layer moves from the end of the conveying roller 4 away from the water surface to the traction roller 5.
• the guide roller 6 can solve the deformation problem caused by the uneven force of the buoyancy of water on the fiber layer. Specifically, in the actual production process, the density of the production raw material is between 0.85-1.1 kg/m3, and the porosity of the fiber layer structure is large, so that its overall density is less than that of water. Under the action of upward buoyancy, by adding actively rotating or non-rotating guide rollers 6, the impact of the upward buoyancy on the fiber layer can be avoided.
• the water spraying inclined surface 22 of the water spraying plate 2 includes a first inclined surface 221, a second inclined surface 222 and a third inclined surface 223 connected in sequence in the direction close to the conveying roller 4, and the slopes of the three inclined surfaces increase in sequence.
• the first inclined surface 221 serves as a receiving plane for water outlet from the spray hole, ensuring that the spray water forms a uniform water flow layer on the second inclined surface 222, avoiding the uneven problem caused by the difference in the cooling rate of the surface fiber layer due to the uneven water layer;
• the second inclined surface 222 serves to make the fibers loop, bond and contact, so that the fibers sprayed from the filament assembly 1 curl to form three-dimensional curled fibers;
• the third inclined surface 223 The function of 223 is to increase the contact bonding time between the three-dimensional curled fibers, to prevent the three-dimensional curled fibers from entering the cooling water too early before they are firmly bonded, thereby avoiding the problem of poor bonding effect caused by cooling of the contact points between the three-dimensional curled fibers due to too short a contact time, and to improve the mechanical properties of the fiber mat.
• the present application increases the length of the third inclined surface 223 in the water spraying plate 2.
• the circulating water is blocked from quickly replacing the surface water temperature directly below the spinneret, thereby ensuring the temperature difference of the water temperature directly below the spinneret.
• the high-temperature water surface layer is used to extend the bonding time of the fiber layer, solving the problem of rapid cooling and shaping of the fiber layer when it falls into the water, and poor bonding effect at the contact points between the three-dimensional curled fibers.
• the spinning assembly 1 includes: a spinning die 11, a distribution plate 12, and a spinning plate 13.
• the spinning die 11 is tightly fitted with the distribution plate 12, and the distribution plate 12 is tightly fitted with the spinning plate 13;
• the spinning die 11 is provided with a plurality of spinning channels 111, and the distribution plate 12 is provided with a plurality of distribution areas 121 corresponding to the spinning channels 111;
• the distribution area 121 is also provided with a plurality of distribution holes 122;
• the spinning plate 13 is divided into at least two spinning areas 131, and any one of the spinning areas 131 contains a plurality of spinning holes.
• Each spinning channel 111 corresponds to the working area of each conveying screw 8, distribution plate 12, and spinning plate 13, so that different raw materials can be produced simultaneously, and when spinning, part of the three-dimensional curled fibers of the fiber layers of different raw materials can be tightly wound together, so that different fiber layers are combined to form a multi-layer fiber mat.
• the aperture spacing of the distribution holes 122 can be adjusted arbitrarily according to actual conditions. Specifically, for example, the aperture of the distribution holes is 4 mm, the number is 106 per row, and the adjacent rows are arranged crosswise; each distribution area 121 has 8 rows.
• the density and aperture of the spinneret holes of each spinneret area 131 on the spinneret plate 13 are the same, multiple layers of fiber mats with the same density can be produced.
• the density or aperture of the spinneret holes of each spinneret area 131 is different, multiple layers of fiber mats with different densities can be produced.
• Different raw materials can be placed in the two dryers 7 and the conveying screw 8 at the same time, and fiber mats with any combination of raw materials, number of layers and density can be produced through the configuration of the above raw materials and component structures.
• the first aspect of the present application provides a fiber mat, including a first fiber layer and a second fiber layer, the first fiber layer and the second fiber layer are bonded together, the first fiber layer is composed of first three-dimensional curled fibers and irregular air channels formed by the first three-dimensional curled fibers, the second fiber layer is composed of second three-dimensional curled fibers and irregular air channels formed by the second three-dimensional curled fibers, and the fiber density of the first fiber layer is different from the fiber density of the second fiber layer.
• Different fiber layers have different properties such as air permeability and support. This allows the fiber mat to meet the usage needs of two different types of users at the same time.
• the second aspect of the application provides a method for preparing a fiber mat, which can be used in conjunction with a preparation device to produce the above-mentioned fiber mat.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Nonwoven Fabrics (AREA)

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Citations (10)

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• 2022
  • 2022-10-19 CN CN202211281654.7A patent/CN115486661A/zh active Pending
  • 2022-10-31 JP JP2022174194A patent/JP7356194B1/ja active Active
• 2023
  • 2023-08-11 WO PCT/CN2023/112600 patent/WO2024082790A1/zh unknown

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