CN114892339A

CN114892339A - 3D down feather forming and warming process

Info

Publication number: CN114892339A
Application number: CN202210496367.1A
Authority: CN
Inventors: 史成金; 廖廷科
Original assignee: Jiangsu Carnation Down Products Technology Co ltd
Current assignee: Jiangsu Carnation Down Products Technology Co ltd
Priority date: 2022-05-09
Filing date: 2022-05-09
Publication date: 2022-08-12

Abstract

The invention discloses a 3D down feather forming and warm keeping process which specifically comprises the following steps of fiber opening, mixing, opening and carding, laying of bottom fabric into a net, three-dimensional down feather embedding, upper fabric compounding, drying and heat setting, forming and rolling and the like. The down feather and the chemical fibers are fixed through a 3D three-dimensional forming process, the chemical fibers with different fineness are cooperatively matched to serve as a framework, and the down feather is embedded between three-dimensional structures to form a multi-layer three-dimensional net-shaped warm-keeping layer, so that the warm-keeping property of the down feather can be fully exerted. The technical invention not only keeps the fluffy and warm-keeping characteristics of the down, but also avoids the problem of flying wadding in the using or cutting process. According to the 3D down feather forming and warming process, the down feather and the chemical fibers are fixed through the 3D three-dimensional forming process, the chemical fibers serve as the support, the down feather serves as the 3D warming layer, a multi-layer three-dimensional net structure is formed in the 3D three-dimensional structure, and the warming performance of the down feather is fully exerted.

Description

3D down feather forming and warming process

Technical Field

The invention relates to the technical field of down feather, in particular to a 3D down feather forming and warm keeping process.

Background

Because each down feather filament of the down feather is formed by overlapping thousands of tiny scales, each scale is hollow, the tiny pores are full of a large amount of static air, and because the conduction coefficient of the air is the lowest, a natural barrier is formed, cold air and hot air can not convect, the static air can contract and expand along with the change of air temperature to generate the function of temperature regulation, can absorb hot air emitted by human body and isolate the invasion of external cold air, meanwhile, the unique natural spherical structure of the down feather fiber ensures that the down feather has good fluffiness, thereby forming more isolated air layers, therefore, down is the thinnest thermal material in the world at present, and is generally directly filled into quilt cores, clothes and pillow cores to form a natural thermal layer, so that the down is light, thin and thermal and has strong comfort, but the down forming thermal process in the market still has partial problems:

1. the down feather is too high in cost at present, so that the popularization and the popularization of the down feather are influenced, the down feather can naturally sink under the influence of gravity when the garment is worn, the down feather in the quilt core can fall down freely while sleeping a human body, meanwhile, the down feather is high in filling power in a natural state, but the supporting power is low, the down feather is directly filled into the quilt core and the garment and then is extruded by a fabric, the fluffy height of the down feather is reduced, the static control quantity of the down feather is reduced, and the heat preservation performance of the down feather cannot be fully delivered;

2. the existing down feather needs to quilt the shell sleeve and then fill the down feather, and the quilting seam lines of the upper and lower fabrics generally have no down feather, so that the overall heat preservation performance of the clothes and the quilt core is influenced, and meanwhile, the down feather is easy to fly out through the gaps at the quilting seam lines;

3. the traditional down feather is directly filled into the quilt core and the shell through a down feather filling machine, down feather filling equipment and manpower are required to be added, and the requirements on sewing manpower are very high particularly for clothes and quilt covers; the manual operation mode is slow, the market demand cannot be met, and meanwhile, a large amount of cost is needed manually;

therefore, a 3D down feather forming and warm keeping process is provided so as to solve the problems.

Disclosure of Invention

The invention aims to provide a 3D down feather forming and warming process, which aims to solve the problems that the cost is too high, down feathers are influenced by gravity, naturally sink, no down feathers exist at quilting lines and the production efficiency is low in the current market in the background technology.

In order to achieve the purpose, the invention provides the following technical scheme: A3D down feather forming and warm keeping process specifically comprises the following steps:

firstly, opening, wherein an opener and a dust collector are required in the opening process;

a. the dust collector is used for treating impurities in the opener before opening the raw materials, and adsorbing the impurities in the opener through the dust collector to prevent other raw materials from entering the interior of the down feather;

b. after the sundries are cleaned, the raw materials used for forming the down feather, namely 33D plus 51mm chemical fiber polypropylene fiber, 7D plus 51mm three-dimensional curled hollow polyester, 3D plus 51mm acrylic fiber and 7D chemical fiber, 0.8D plus 51mm superfine down feather silk fiber and 3D plus 51mm thermal bonding fiber are respectively placed into different openers, and the fiber blocks processed by the openers are loosened and enter the opening machine to improve the softness of the down feather and ensure the uniformity;

secondly, mixing and stirring;

weighing 33D 51mm polypropylene fibers, 7D 51mm three-dimensional curled hollow polyester fibers, 3D 51mm acrylic fibers, 0.8D 51mm superfine down silk fibers and 3D 51mm thermal bonding fibers after opening, preparing the raw materials according to the optimal proportion required by down, placing the 33D 51mm polypropylene fibers, 7D 51mm three-dimensional curled hollow polyester fibers, 3D 51mm acrylic fibers and 0.8D 51mm superfine down silk fibers and 3D 51mm thermal bonding fibers after opening in a specified mixing device, mixing the raw materials by a stirring rod in the mixing device, accelerating the mixing speed, controlling the stirring time to be 10 minutes, and uniformly mixing the raw materials in the mixing device;

thirdly, paving;

laying a lower-layer base fabric on a specified plate, wherein the plate has a weighing function, carding and opening the mixed material, and flatly laying a product chemical fiber layer subjected to carding and opening above the lower-layer base fabric, wherein the product chemical fiber layer is kept at about 10-20 g/square meter;

fourthly, laying down;

the method comprises the following steps of placing down feather inside a down feather box, enabling the down feather to fall on a fiber layer under the action of negative pressure or static electricity through a down feather outlet inside the down feather box, keeping the speed of the down feather box constant in the moving process, enabling the thickness of the down feather to be the same, and controlling the laying amount of the down feather;

fifthly, laying a net;

after the down feather is laid, lapping is carried out on the upper side, and weighing is needed in the lapping process, so that the condition that the material is too heavy or too light is avoided, the warm keeping degree of the down feather is ensured, and the phenomenon that the down feather is heavy is avoided;

sixthly, drying;

after reaching the specified weight, laying the upper-layer bottom cloth on the upper part, putting the upper-layer bottom cloth into a steam oven, setting the temperature of the oven at 130 ℃, and setting the machine transmission speed at 5m/min, wherein at the temperature of 130 ℃, the ES fiber surface layer based on the PE/PET skin-core structure in the chemical fibers is melted, so that the chemical fibers of different layers are linked, and the aim of locking down feather is fulfilled;

seventhly, forming and rolling;

the materials processed by the steam oven are rolled by the rolling device, so that the occupation of space is reduced, and the down feather is convenient to use.

Preferably, the length of the polypropylene fiber, the three-dimensional crimp hollow polyester fiber, the acrylic fiber, the ultra-fine down filament fiber and the thermal bonding fiber in the second step may be any one of 32mm, 38mm, 64mm and 72 mm;

the heat bonding fiber can be single-component low-melting-point fiber such as PE, PP, PET, PA, EVA and the like, and can also be sheath-core and parallel-structure bicomponent fiber such as PE/PP, PE/PET and the like;

the following precautions need to be taken in the mixing and stirring of step two:

when the thermal bonding fiber is put in, the thermal bonding fiber is put in step by step, firstly, half of the prepared thermal bonding fiber is put in a mixing device, the thermal bonding fiber is mixed and stirred for 5 minutes, then, the rest thermal bonding fiber is put in the mixing device, and the mixing time is kept for 10 minutes;

preferably, the following precautions are required in laying down in step four:

the corresponding down feather box is arranged on the lapping machine, the height of the down feather box cannot be too low or too high, the phenomenon that the down feather inside the down feather box flies due to air is avoided, the rugged state is avoided, 100% of 20kg down feather can be placed at each time, a down feather outlet with the width of 5cm and the length equal to that of 3D is formed in the lower portion of the down feather box, a negative pressure or static device is arranged on the lapping machine, and the down feather can be uniformly scattered and embedded in the 3D fiber network.

Preferably, the following precautions are required in laying down in step five:

after the down feather is paved for the first time, 10-20 g/square meter chemical fiber layer is paved on the down feather for the second time, then the down feather box moves again, the down feather box is uniformly paved on the second chemical fiber layer, the specified gram weight meeting the gram weight requirement is achieved through repeated paving of the down feather chemical fiber for many times, the paving and the paving are stopped, after the specified gram weight is achieved, the 3D down feather moves forwards through other devices below, an upper roller automatically pulls an upper-layer bottom cloth to be paved on the last down feather or the chemical fiber layer, and then the down feather box enters a steam oven along with a machine.

Preferably, the required pair is weighed before the thermal bonding fiber is placed, the weight of the 3D thermal bonding fiber and the weight of the 33D polypropylene fiber, the 7D three-dimensional crimped hollow polyester fiber, the 3D acrylic fiber and the 0.8D ultrafine down silk fiber are determined, and the remaining material inside the mixing device is required to be processed after the raw materials are mixed, so that the weight deviation is avoided.

Preferably, the side edges of the lower base fabric and the lower base fabric are attached to each other, so that the phenomenon that down feather on the side edges moves is avoided, meanwhile, materials treated by the steam oven cannot be immediately rolled, rolling can be performed only after the temperature of the materials is reduced, and the internal temperature is prevented from being too high.

Preferably, the chemical fibers and the down feather formed after mixing form a net structure, so that a warm-keeping locking function is achieved, the down feather is prevented from running, the down feather is prevented from sinking, and the position of the down feather is locked.

Compared with the prior art, the invention has the beneficial effects that: make eiderdown and chemical fibre fixed through 3D three-dimensional forming process, the chemical fibre is in coordination with the collocation as the support, the eiderdown is as the cold-proof layer of 3D, form multilayer three-dimensional network structure in 3D spatial structure, the warmth retention of full play eiderdown, thereby avoid the warmth retention waste that the eiderdown extrusion caused, 3D eiderdown only needs 30% eiderdown to account for, just can reach the cold-proof effect of 100% eiderdown, simultaneously greatly reduced the eiderdown cost, can let more human bodies test the eiderdown product of high-end higher grade, concrete content is as follows:

(1) the 3D down feather can be produced by direct quilting without shell sewing and down filling, so that the production efficiency is greatly improved, the novel 3D down feather can be produced by direct quilting through a template machine, the production efficiency of the down feather quilt core is greatly improved by more than 30%, the production efficiency of the garment is more than 20%, the 3D down feather realizes the comprehensive coverage of the down feather quilt core and the down feather garment, the product thermal insulation performance is greatly improved by including a sewing thread place, the labor cost of the down feather is further reduced, and therefore customers can purchase appropriate down feather products, and the consumption of capital is greatly reduced;

(2) through a 3D process, down feather is fixed, free flowing of the down feather is avoided, a 3D spherical structure of the down feather is kept, the warm-keeping performance of the down feather is exerted, the phenomenon that the down feather flows due to the influence of gravity and pressure is avoided, the down feather at each position is fixed in volume, large difference of the amount of the down feather at different positions is avoided, meanwhile, the down feather does not need to be flapped for multiple times in the insolation process, the insolation time is shortened, the warm-keeping degree of the down feather is increased, the phenomenon that the down feather is accumulated at one position and the temperature is uneven is avoided, and the down feather is prevented from running out through gaps;

(3) 3D three-dimensional forming process forms three-dimensional network structure, improve the warmth retention of eiderdown, avoid the eiderdown accumulational phenomenon to appear, 3D eiderdown accounts for than the volume little simultaneously, just can improve cold-proof effect greatly, avoid the eiderdown to run in inside through network structure, make inside eiderdown even, realize spacing to the eiderdown through network structure, the thickness that increases the eiderdown simultaneously improves the warmth retention property of eiderdown, avoid the accumulational phenomenon to appear in the eiderdown, prevent to absorb water too much in abluent in-process certain department to the down coat simultaneously, reduce the time of soaking, avoid the eiderdown inside to have gas, the phenomenon of explosion appears when preventing to wash with washing machine, the security performance is greatly improved.

Drawings

FIG. 1 is a flow chart of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Referring to fig. 1, the present invention provides a technical solution: A3D down feather forming and warm keeping process specifically comprises the following steps:

secondly, mixing and stirring;

weighing 33D 51mm polypropylene fibers, 7D 51mm three-dimensional curled hollow polyester fibers, 3D 51mm acrylic fibers, 0.8D 51mm superfine down silk fibers and 3D 51mm hot bonding fibers after opening, preparing the raw materials according to the optimal proportion required by down, placing the 33D 51mm polypropylene fibers, 7D 51mm three-dimensional curled hollow polyester fibers, 3D 51mm acrylic fibers, 0.8D 51mm superfine down silk fibers and 3D 51mm hot bonding fibers after opening in a specified mixing device, mixing the raw materials by a stirring rod in the mixing device, accelerating the mixing speed, controlling the stirring time to be 10 minutes, and uniformly mixing the raw materials in the mixing device;

thirdly, paving;

fourthly, laying down;

fifthly, laying a net;

sixthly, drying;

seventhly, forming and rolling;

The length of the polypropylene fiber, the three-dimensional curled hollow polyester fiber, the acrylic fiber, the superfine down silk fiber and the thermal bonding fiber in the step two can be any one of the length of 32mm, the length of 38mm, the length of 64mm and the length of 72 mm;

the heat bonding fiber can be single-component low-melting-point fiber such as PE, PP, PET, PA, EVA and the like, and can also be sheath-core and parallel-structure bicomponent fiber such as PE/PP, PE/PET and the like.

The following matters need to be taken into account in the mixing and stirring of the second step:

when the thermal adhesive fiber is fed, the thermal adhesive fiber is fed in steps, half of the prepared thermal adhesive fiber is fed into a mixing device, the thermal adhesive fiber and the prepared thermal adhesive fiber are mixed and stirred for 5 minutes, and then the remaining thermal adhesive fiber is fed into the mixing device, and the mixing time is maintained for 10 minutes.

The following considerations are required in laying down in step four:

The following considerations are required in laying down in step five:

The method comprises the steps of weighing the required pairs before placing the thermal bonding fibers, judging the weight of the 3D thermal bonding fibers according to the weight pairs of the 33D polypropylene fibers, the 7D three-dimensional curled hollow polyester fibers, the 3D acrylic fibers and the 0.8D superfine down silk fibers, and processing the residual materials in a mixing device after mixing the raw materials to avoid weight deviation.

The side of lower floor's backer and lower floor's backer will laminate each other, avoids the eiderdown of side to appear the phenomenon of removing, and the material after the steam oven handles can not carry out the rolling immediately simultaneously, need wait until the temperature of material can carry out the rolling after dropping, avoids inside high temperature.

The chemical fibers and the down feather formed after mixing form a net-shaped structure, the function of keeping warm and locking is achieved, the down feather is prevented from running, the down feather is prevented from sinking, and the position of the down feather is locked.

Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that various changes in the embodiments and/or modifications of the invention can be made, and equivalents and modifications of some features of the invention can be made without departing from the spirit and scope of the invention.

Claims

1. A3D down feather forming and warm keeping process is characterized in that: the 3D down feather forming and warm keeping process specifically comprises the following steps:

a. the dust collector is used for treating impurities in the loosening machine before loosening the raw materials, and adsorbing the impurities in the loosening machine to prevent other raw materials from entering the interior of down feather;

secondly, mixing and stirring;

thirdly, paving;

fourthly, laying down;

fifthly, laying a net;

lapping is carried out on the upper part after the down feather is laid, and the down feather needs to be weighed in the lapping process, so that the condition that the material is too heavy or too light is avoided, the warm keeping degree of the down feather is ensured, and the heavy phenomenon of the down feather is avoided;

sixthly, drying;

seventhly, forming and rolling;

materials processed by the steam oven are rolled by the rolling device, so that the occupation of space is reduced, and the down feather is convenient to use.

2. The 3D down feather forming and warming process according to claim 1, which is characterized in that: the length of the polypropylene fiber, the three-dimensional curled hollow polyester fiber, the acrylic fiber, the superfine down silk fiber and the thermal bonding fiber in the step two can be any one of the length of 32mm, the length of 38mm, the length of 64mm and the length of 72 mm;

3. The 3D down feather forming and warming process according to claim 1, which is characterized in that: the following matters need to be noted in the step four down feather laying:

4. The 3D down feather forming and warming process according to claim 1, which is characterized in that: the following considerations are required in laying down in step five:

5. The 3D down feather forming and warming process according to claim 1, which is characterized in that: the method comprises the steps of weighing the required pairs before placing the thermal bonding fibers, judging the weight of the 3D thermal bonding fibers according to the weight pairs of the 33D polypropylene fibers, the 7D three-dimensional curled hollow polyester fibers, the 3D acrylic fibers and the 0.8D superfine down silk fibers, and processing the residual materials in a mixing device after mixing the raw materials to avoid weight deviation.

6. The 3D down feather forming and warming process according to claim 1, which is characterized in that: the side of lower floor's backer and lower floor's backer will laminate each other, avoids the eiderdown of side to appear the phenomenon of removal, and the material after the steam oven is handled simultaneously can not carry out the rolling immediately, need wait until the temperature of material falls can carry out the rolling after, avoids inside high temperature.

7. The 3D down feather forming and warming process according to claim 1, which is characterized in that: the chemical fibers and the down feather formed after mixing form a net-shaped structure, so that a warm-keeping locking function is achieved, the down feather is prevented from running, the down feather is prevented from sinking, and the position of the down feather is locked.