CN114892339A - 一种3d羽绒成型保暖工艺 - Google Patents
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Abstract
本发明公开了一种3D羽绒成型保暖工艺,所述3D羽绒成型保暖工艺具体包括以下步骤:纤维开松、混合、开松梳理、底层面料铺设成网、羽绒立体镶嵌、上层面料复合、烘干热定型、成型打卷等。通过3D立体成型工艺使羽绒和化纤进行固定,不同细度化纤的协同搭配作为骨架,羽绒镶嵌在立体结构之间形成多层立体网状结构的保暖层,可以充分发挥羽绒的保暖性。该技术发明既保持了羽绒的蓬松保暖特性又避免了使用或裁剪过程中飞絮的问题。该3D羽绒成型保暖工艺,通过3D立体成型工艺使羽绒和化纤进行固定,化纤作为支架,羽绒作为3D保暖层,在3D立体结构中形成多层立体网状结构,充分发挥羽绒的保暖性。
Description
技术领域
本发明涉及羽绒技术领域,具体为一种3D羽绒成型保暖工艺。
背景技术
由于羽绒的每根羽丝是由成千上万个微小的鳞片叠加而成,每个鳞片都是中空的,这些微小的孔隙,饱含着大量的静止空气,由于空气的传导系数最低,形成了天然的屏障,使冷热空气不能对流,这些静止的空气,能随气温变化而收缩膨胀,产生调温功能,可吸收人体散发的热气,隔绝外界冷空气的入侵,同时羽绒纤维独特的天然球形结构,让羽绒具有良好的蓬松性,从而形成更多的隔绝空气层,所以羽绒是目前世界上最轻薄的保暖材料,一般直接填充到被芯、服装、枕芯里面,形成天然的保暖层,轻薄保暖,舒适性强,但是目前市场上的羽绒成型保暖工艺还是存在部分问题:
1.目前羽绒的成本过高,影响羽绒的普及和推广,服装在穿着过程中,羽绒会受重力影响,自然下沉,被芯在使用过程中里面的羽绒也会睡着人体翻身自由流动,同时羽绒自然状态下蓬松度高,但支撑力低,羽绒直接填充进入被芯、服装里面后,往往会收到面料的挤压,降低了羽绒的蓬松高度,从而造成羽绒静止控制数量的下降,不能充分发货羽绒的保暖性能;
2.现有的羽绒都需要对壳套进行绗缝,再进行充绒,上下两面料的绗缝线处一般都没有羽绒,从而影响了服装和被芯整体的保暖性能,同时羽绒容易通过绗缝线处的间隙飞出;
3.传统的羽绒是通过充绒机直接填充到被芯和壳套,需要增加充绒设备和人工,特别是服装、被套,对缝制人工要求非常高;人工操作方式速度慢,满足不了市场上的需求,同时人工需要大量的成本;
所以我们提出了一种3D羽绒成型保暖工艺,以便于解决上述中提出的问题。
发明内容
本发明的目的在于提供一种3D羽绒成型保暖工艺,以解决上述背景技术提出的目前市场上成本过高、羽绒会受重力影响,自然下沉、绗缝线处没有羽绒和和生产效率低的问题。
为实现上述目的,本发明提供如下技术方案:一种3D羽绒成型保暖工艺,所述3D羽绒成型保暖工艺具体包括以下步骤:
一、开松,所述开松的过程中需要用到开松机和吸尘器;
a、吸尘器,在对原料进行开松之前需要将对开松机内部的杂质进行处理,通过吸尘器对开松机内部的杂质进行吸附,避免其他的原料进入到羽绒毛的内部;
b、开松机,杂货清理完成之后,将成型羽绒用到的原料33D*51mm化纤聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶化纤和、7D化纤0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维分别放入到不同的开松机内部,通过开松机处理之后的纤维块松散,进入提高羽绒的柔软程度,确保均匀性;
二、混合搅拌;
对开松之后的33D*51mm聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶、0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维进行称重,根据羽绒所需要的最佳比例对原料准备,将开松之后的33D*51mm聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶和0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维放置在指定的混合装置内部,通过混合装置内部的搅拌杆使原料进行混合,加快混合速度,搅拌时间控制在10分钟,使内部的原料混合均匀;
三、铺设;
将下层底布铺设在指定的板材上,板材具有称重的功能,将上述混合之后的物料进行梳棉开松,对梳棉开松的之后的产物化纤层平铺在下层底布上方,产物化纤层保持在10-20g/㎡左右;
四、铺设羽绒;
将羽绒放置在羽绒箱的内部,通过羽绒箱内部的出绒口在负压或静电的作用下使羽绒掉落在纤维层,羽绒箱在移动的过程中要保持速度匀速,使羽绒的厚度相同,并控制羽绒的铺设量;
五、铺网;
在铺设羽绒之后对上方进行铺网,在铺网的过程中需要进行称重,避免物料过重或者过轻,保证羽绒的保暖程度,同时避免羽绒出现笨重的现象;
六、烘干;
达到指定的重量之后将上层底布铺设在上方,放入蒸汽烘箱内部,烘箱的温度设置为130℃,机器传送速率5m/min,在130℃温度下,化纤中基于PE/PET皮芯结构的ES纤维表层熔化,从而将不同层的化纤进行链接,从而实现将羽绒锁定的目标;
七、成型打卷;
将经过蒸汽烘箱处理过后的物料通过收卷装置进行收卷,减少空间的占用,便于对羽绒的使用。
优选的,所述步骤二中所述的聚丙烯纤维、三维卷曲中空涤纶纤维、腈纶纤维、超细羽绒丝纤维和热粘合纤维的长度可以是32mm、38mm、64mm、72mm中的任意一个长度;
热粘合纤维可以是PE、PP、PET、PA、EVA等单组分低熔点纤维,也可以是PE/PP、PE/PET等皮芯、并列结构双组份纤维;
在步骤二混合搅拌中需要存在以下注意事项:
进行热粘合纤维投放时,分步进行投放,首先将提前准备好的热粘合纤维投放一半进入到混合装置内部,混合进行搅拌5分钟,然后将剩下的热粘合纤维放入在混合装置的内部,混合时间维持10分钟;
优选的,所述在步骤四铺设羽绒中需要存在以下注意事项:
将对应的羽绒箱安装在机铺网器上,羽绒箱的高度不能过低也不能过高,避免空气使羽绒箱内部的羽绒出现飞动的现象,避免出现凹凸不平的状态,每次可以放置20kg的100%羽绒,羽绒箱下方开宽度5cm,长度和3D相同长度的出绒口,在机铺网器上设有负压或静电装置,可以使羽绒均匀的洒落镶嵌在3D纤维网络中。
优选的,所述在步骤五铺设羽绒中需要存在以下注意事项:
第一次铺上羽绒后,在羽绒上面再次铺网10-20g/㎡化纤层,然后羽绒箱再次移动,均匀铺放在第二次化纤层上面,通过多次羽绒化纤重复铺网,达到满足克重要求的指定克重,停止铺网和铺绒,达到指定克重后,3D羽绒通过下方其他装置往前移动,上层辊轴自动牵引上层底布铺盖在最后一层羽绒或者化纤层上面,然后跟随机器进入蒸汽烘箱。
优选的,所述在对热粘合纤维放置之前对需要对进行称重,根据33D聚丙烯纤维、7D三维卷曲中空涤纶、3D腈纶和0.8D超细羽绒丝纤维的重量对和3D热粘合纤维重量进行判断,在对原料进行混合之后需要混合装置内部的剩余的物料进行处理,避免重量出现偏差。
优选的,所述下层底布和下层底布的侧边要相互贴合,避免侧边的羽绒出现移动的现象,同时蒸汽烘箱处理之后的物料不能立即进行收卷,需要等到物料的温度降下来之后才能进行收卷,避免内部的温度过高。
优选的,所述混合之后形成的化纤和羽绒构成网状结构结构,起到保暖锁定功能,避免羽绒出现跑动的现象,避免羽绒出现下沉的现象,对羽绒的位置进行锁定。
与现有技术相比,本发明的有益效果是:通过3D立体成型工艺使羽绒和化纤进行固定,化纤协同搭配作为支架,羽绒作为3D保暖层,在3D立体结构中形成多层立体网状结构,充分发挥羽绒的保暖性,从而避免羽绒挤压造成的保暖性浪费,3D羽绒只需要30%羽绒占比,就可以达到100%羽绒的保暖效果,同时大大降低了羽绒成本,可以让更多的人体验到高端上档次的羽绒产品,具体内容如下:
(1)3D羽绒可以直接绗缝生产,不需要壳套缝制和充绒,大大提升生产效率,新型3D羽绒则可以通过模板机直接绗缝,大大提升羽绒被芯生产效率30%以上,服装生产效率20%以上,3D羽绒实现了羽绒被芯、羽绒装的全面覆盖,包括缝纫线地方,大大提升了产品保暖性能,进而使羽绒的人工成本进行降低,进而使客户都能买到合适的羽绒产品,大大降低的资金的消耗;
(2)通过3D工艺,将羽绒进行固定,避免羽绒的自由流动,保留羽绒3D的球形结构,从而发挥羽绒的保暖性能,同时避免会重力和压力的影响羽绒出现流动的现象,使每处的羽绒体积固定,避免不同位置的羽绒量存在较大的差异,同时在暴晒的过程中不需要对羽绒进行多次拍打,减少暴晒的时间,增加羽绒的保暖程度,避免羽绒堆积在一处温度不均匀的现象,防止羽绒通过间隙跑出来;
(3)3D立体成型工艺形成立体网状结构,提高羽绒的保暖性,避免羽绒出现堆积的现象,同时3D羽绒的占比量小,就能大大提高保暖的效果,通过网状结构避免羽绒在内部跑动,使内部的羽绒均匀,通过网状结构实现对羽绒的限位,同时增加羽绒的厚度提高羽绒的保暖性能,避免羽绒出现堆积的现象,同时防止对羽绒服在清洗的过程中某一处吸水过多,减少浸泡的时间,避免羽绒内部存在气体,防止用洗衣机清洗时出现爆炸的现象,大大提高安全性能。
附图说明
图1为本发明流程图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
请参阅图1,本发明提供一种技术方案:一种3D羽绒成型保暖工艺,3D羽绒成型保暖工艺具体包括以下步骤:
一、开松,所述开松的过程中需要用到开松机和吸尘器;
a、吸尘器,在对原料进行开松之前需要将对开松机内部的杂质进行处理,通过吸尘器对开松机内部的杂质进行吸附,避免其他的原料进入到羽绒毛的内部;
b、开松机,杂货清理完成之后,将成型羽绒用到的原料33D*51mm化纤聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶化纤和、7D化纤0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维分别放入到不同的开松机内部的,通过开松机处理之后的纤维块松散,进入提高羽绒的柔软程度,确保均匀性;
二、混合搅拌;
对开松之后的33D*51mm聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶、0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维进行称重,根据羽绒所需要的最佳比例对原料准备,将开松之后的33D*51mm聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶和0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维放置在指定的混合装置内部,通过混合装置内部的搅拌杆使原料进行混合,加快混合速度,搅拌时间控制在10分钟,使内部的原料混合均匀;
三、铺设;
将下层底布铺设在指定的板材上,板材具有称重的功能,将上述混合之后的物料进行梳棉开松,对梳棉开松的之后的产物化纤层平铺在下层底布上方,产物化纤层保持在10-20g/㎡左右;
四、铺设羽绒;
将羽绒放置在羽绒箱的内部,通过羽绒箱内部的出绒口在负压或静电的作用下使羽绒掉落在纤维层,羽绒箱在移动的过程中要保持速度匀速,使羽绒的厚度相同,并控制羽绒的铺设量;
五、铺网;
在铺设羽绒之后对上方进行铺网,在铺网的过程中需要进行称重,避免物料过重或者过轻,保证羽绒的保暖程度,同时避免羽绒出现笨重的现象;
六、烘干;
达到指定的重量之后将上层底布铺设在上方,放入蒸汽烘箱内部,烘箱的温度设置为130℃,机器传送速率5m/min,在130℃温度下,化纤中基于PE/PET皮芯结构的ES纤维表层熔化,从而将不同层的化纤进行链接,从而实现将羽绒锁定的目标;
七、成型打卷;
将经过蒸汽烘箱处理过后的物料通过收卷装置进行收卷,减少空间的占用,便于对羽绒的使用。
步骤二中所述的聚丙烯纤维、三维卷曲中空涤纶纤维、腈纶纤维、超细羽绒丝纤维和热粘合纤维的长度可以是32mm、38mm、64mm、72mm中的任意一个长度;
热粘合纤维可以是PE、PP、PET、PA、EVA等单组分低熔点纤维,也可以是PE/PP、PE/PET等皮芯、并列结构双组份纤维。
在步骤二混合搅拌中需要注意以下事项:
进行热粘合纤维投放时,分步进行投放,首先将提前准备好的热粘合纤维投放一半进入到混合装置内部,混合进行搅拌5分钟,然后将剩下的热粘合纤维放入在混合装置的内部,混合时间维持10分钟。
在步骤四铺设羽绒中需要存在以下注意事项:
将对应的羽绒箱安装在机铺网器上,羽绒箱的高度不能过低也不能过高,避免空气使羽绒箱内部的羽绒出现飞动的现象,避免出现凹凸不平的状态,每次可以放置20kg的100%羽绒,羽绒箱下方开宽度5cm,长度和3D相同长度的出绒口,在机铺网器上设有负压或静电装置,可以使羽绒均匀的洒落镶嵌在3D纤维网络中。
在步骤五铺设羽绒中需要存在以下注意事项:
第一次铺上羽绒后,在羽绒上面再次铺网10-20g/㎡化纤层,然后羽绒箱再次移动,均匀铺放在第二次化纤层上面,通过多次羽绒化纤重复铺网,达到满足克重要求的指定克重,停止铺网和铺绒,达到指定克重后,3D羽绒通过下方其他装置往前移动,上层辊轴自动牵引上层底布铺盖在最后一层羽绒或者化纤层上面,然后跟随机器进入蒸汽烘箱。
在对热粘合纤维放置之前对需要对进行称重,根据33D聚丙烯纤维、7D三维卷曲中空涤纶、3D腈纶和0.8D超细羽绒丝纤维的重量对和3D热粘合纤维重量进行判断,在对原料进行混合之后需要混合装置内部的剩余的物料进行处理,避免重量出现偏差。
下层底布和下层底布的侧边要相互贴合,避免侧边的羽绒出现移动的现象,同时蒸汽烘箱处理之后的物料不能立即进行收卷,需要等到物料的温度降下来之后才能进行收卷,避免内部的温度过高。
混合之后形成的化纤和羽绒构成网状结构结构,起到保暖锁定功能,避免羽绒出现跑动的现象,避免羽绒出现下沉的现象,对羽绒的位置进行锁定。
尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种3D羽绒成型保暖工艺,其特征在于:所述3D羽绒成型保暖工艺具体包括以下步骤:
一、开松,所述开松的过程中需要用到开松机和吸尘器;
a、吸尘器,在对原料进行开松之前需要将对开松机内部的杂质进行处理,通过吸尘器对开松机内部的杂质进行吸附,避免其他的原料进入到羽绒毛的内部;
b、开松机,杂货清理完成之后,将成型羽绒用到的原料33D*51mm化纤聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶化纤和、7D化纤0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维分别放入到不同的开松机内部,通过开松机处理之后的纤维块松散,进入提高羽绒的柔软程度,确保均匀性;
二、混合搅拌;
对开松之后的33D*51mm聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶、0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维进行称重,根据羽绒所需要的最佳比例对原料准备,将开松之后的33D*51mm聚丙烯纤维、7D*51mm三维卷曲中空涤纶、3D*51mm腈纶和0.8D*51mm超细羽绒丝纤维和3D*51mm热粘合纤维放置在指定的混合装置内部,通过混合装置内部的搅拌杆使原料进行混合,加快混合速度,搅拌时间控制在10分钟,使内部的原料混合均匀;
三、铺设;
将下层底布铺设在指定的板材上,板材具有称重的功能,将上述混合之后的物料进行梳棉开松,对梳棉开松的之后的产物化纤层平铺在下层底布上方,产物化纤层保持在10-20g/㎡左右;
四、铺设羽绒;
将羽绒放置在羽绒箱的内部,通过羽绒箱内部的出绒口在负压或静电的作用下使羽绒掉落在纤维层,羽绒箱在移动的过程中要保持速度匀速,使羽绒的厚度相同,并控制羽绒的铺设量;
五、铺网;
在铺设羽绒之后对上方进行铺网,在铺网的过程中需要进行称重,避免物料过重或者过轻,保证羽绒的保暖程度,同时避免羽绒出现笨重的现象;
六、烘干;
达到指定的重量之后将上层底布铺设在上方,放入蒸汽烘箱内部,烘箱的温度设置为130℃,机器传送速率5m/min,在130℃温度下,化纤中基于PE/PET皮芯结构的ES纤维表层熔化,从而将不同层的化纤进行链接,从而实现将羽绒锁定的目标;
七、成型打卷;
将经过蒸汽烘箱处理过后的物料通过收卷装置进行收卷,减少空间的占用,便于对羽绒的使用。
2.根据权利要求1所述的一种3D羽绒成型保暖工艺,其特征在于:步骤二中所述的聚丙烯纤维、三维卷曲中空涤纶纤维、腈纶纤维、超细羽绒丝纤维和热粘合纤维的长度可以是32mm、38mm、64mm、72mm中的任意一个长度;
热粘合纤维可以是PE、PP、PET、PA、EVA等单组分低熔点纤维,也可以是PE/PP、PE/PET等皮芯、并列结构双组份纤维;
在步骤二混合搅拌中需要注意以下事项:
进行热粘合纤维投放时,分步进行投放,首先将提前准备好的热粘合纤维投放一半进入到混合装置内部,混合进行搅拌5分钟,然后将剩下的热粘合纤维放入在混合装置的内部,混合时间维持10分钟。
3.根据权利要求1所述的一种3D羽绒成型保暖工艺,其特征在于:在步骤四铺设羽绒中需要注意以下事项:
将对应的羽绒箱安装在机铺网器上,羽绒箱的高度不能过低也不能过高,避免空气使羽绒箱内部的羽绒出现飞动的现象,避免出现凹凸不平的状态,每次可以放置20kg的100%羽绒,羽绒箱下方开宽度5cm,长度和3D相同长度的出绒口,在机铺网器上设有负压或静电装置,可以使羽绒均匀的洒落镶嵌在3D纤维网络中。
4.根据权利要求1所述的一种3D羽绒成型保暖工艺,其特征在于:在步骤五铺设羽绒中需要存在以下注意事项:
第一次铺上羽绒后,在羽绒上面再次铺网10-20g/㎡化纤层,然后羽绒箱再次移动,均匀铺放在第二次化纤层上面,通过多次羽绒化纤重复铺网,达到满足克重要求的指定克重,停止铺网和铺绒,达到指定克重后,3D羽绒通过下方其他装置往前移动,上层辊轴自动牵引上层底布铺盖在最后一层羽绒或者化纤层上面,然后跟随机器进入蒸汽烘箱。
5.根据权利要求1所述的一种3D羽绒成型保暖工艺,其特征在于:在对热粘合纤维放置之前对需要对进行称重,根据33D聚丙烯纤维、7D三维卷曲中空涤纶、3D腈纶和0.8D超细羽绒丝纤维的重量对和3D热粘合纤维重量进行判断,在对原料进行混合之后需要混合装置内部的剩余的物料进行处理,避免重量出现偏差。
6.根据权利要求1所述的一种3D羽绒成型保暖工艺,其特征在于:所述下层底布和下层底布的侧边要相互贴合,避免侧边的羽绒出现移动的现象,同时蒸汽烘箱处理之后的物料不能立即进行收卷,需要等到物料的温度降下来之后才能进行收卷,避免内部的温度过高。
7.根据权利要求1所述的一种3D羽绒成型保暖工艺,其特征在于:混合之后形成的化纤和羽绒构成网状结构结构,起到保暖锁定功能,避免羽绒出现跑动的现象,避免羽绒出现下沉的现象,对羽绒的位置进行锁定。
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CN103306050A (zh) * | 2013-06-26 | 2013-09-18 | 鑫缘茧丝绸集团股份有限公司 | 一种可裁剪、可水洗丝绵絮片的制备方法 |
US20170071367A1 (en) * | 2015-09-16 | 2017-03-16 | Ronie Reubon | Composite down feather sheet with elastic webs |
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