CN113293509A

CN113293509A - Fiber heat insulation structure and manufacturing method thereof

Info

Publication number: CN113293509A
Application number: CN202010081359.1A
Authority: CN
Inventors: 简荣富; 彭忠山; 钟楷智
Original assignee: Shinih Enterprise Co Ltd
Current assignee: Shinih Enterprise Co Ltd
Priority date: 2020-02-06
Filing date: 2020-02-06
Publication date: 2021-08-24

Abstract

The invention provides a fiber heat-insulating structure body and a manufacturing method thereof, wherein the manufacturing method of the fiber heat-insulating structure body comprises the following steps: step a): providing a first fiber layer, a second fiber layer and a third fiber layer, and clamping the third fiber layer between the first fiber layer and the second fiber layer to form a laminated structure; step b): folding the laminated structure back and forth to form a continuous structure; and step c): heating the continuous structure at a heating temperature to enable the first fiber layer to be filled between two adjacent bending units and the second fiber layer to be filled in each bending unit, and cooling to form the fiber heat-insulation structure; wherein, the melting temperature of the first fiber layer and the second fiber layer is less than or equal to the heating temperature in the step c), and the melting temperature of the third fiber layer is higher than the heating temperature in the step c).

Description

Fiber heat insulation structure and manufacturing method thereof

Technical Field

The invention relates to a fiber heat-insulation structure body and a manufacturing method thereof, in particular to a fiber heat-insulation structure body with a fluffy structure and a manufacturing method thereof.

Background

Fluffy materials are widely used in a plurality of daily necessities, such as sofas, mattresses, pillows, cushions or sleeping bags, and the like, and have certain characteristics of supporting strength, softness, air permeability, heat retention and the like due to the fluffy materials.

The sponge is one of the most common fluffy materials, is mainly prepared from soft foam in polyurethane foam materials, has a porous structure and has the advantages of light weight, good resilience and the like; however, the sponge has the disadvantages of non-recyclability, poor air permeability, and poor comfort, and in addition, the porous structure of the sponge does not provide good supporting strength, thereby limiting the applicable range.

Regarding the problems derived from the use of sponges, the prior art has attempted to provide a special resin cotton structure as the fluffy material, as shown in fig. 1, with a zigzag web 91 perpendicular to two flat webs 90, the zigzag web 91 being formed of repeating pleats 911, and each adjacent pleat 911 in the zigzag web 91 having a void 912. Through the arrangement of the special three-dimensional structure, the structural strength of the resin cotton can be improved, and good supporting strength can be provided in the vertical direction.

However, in the process of manufacturing the resin cotton structure, after the zigzag web 91 is formed by repeating the folding to generate the wrinkles 911, the flat web 90 is introduced to fix the entire structure of the zigzag web 91, and thus an additional equipment for introducing the flat web 90 must be installed, resulting in an increase in the cost of the production equipment; in addition, the smooth web 90 needs to be coated with an adhesive to adhere and fix the zigzag web 91, and in order to make the smooth web 90 adhere to the zigzag web 91 well, a period of adhesion period needs to be maintained during the preparation process, so that the overall process speed cannot be effectively increased, and the time cost is increased.

In addition, in the zigzag web 91, only the top of each wrinkle 911 is bonded to the flat web 90, and since there are gaps 912 between the wrinkles 911, the zigzag web 91 cannot be completely fixed, and thus, in addition to the insufficient support strength in the vertical direction of the resin cotton structure, the zigzag web 91 is easily separated from the flat web 90 by being subjected to a large pressure, and problems such as the wrinkles 911 fall off and deform occur therein.

Disclosure of Invention

In view of the problems of the prior art, an object of the present invention is to provide a method for manufacturing a fiber thermal insulation structure, which does not require additional equipment for introducing other layers, thereby reducing the equipment cost of production.

Another objective of the present invention is to provide a method for manufacturing a fiber thermal insulation structure, which does not require an additional step of adhering and fixing layers, thereby increasing the speed of the overall process and reducing the time cost.

In order to achieve the above object, the present invention provides a method for manufacturing a fiber thermal insulation structure, comprising the steps of: step a): providing a first fiber layer, a second fiber layer and a third fiber layer, and clamping the third fiber layer between the first fiber layer and the second fiber layer to form a laminated structure; step b): folding the laminated structure back and forth to form a continuous structure; the continuous structure comprises a third fiber layer, a first fiber layer arranged outside the bending unit and a second fiber layer arranged inside the bending unit; the third fiber layer comprises a plurality of bending units which are mutually connected, the first fiber layer at the outer side of each bending unit is abutted against the first fiber layer at the outer side of the adjacent bending unit, and the second fiber layers adjacent to the inner sides of the bending units are abutted against each other; and step c): heating the continuous structure at a heating temperature to enable the first fiber layer to be filled between two adjacent bending units and the second fiber layer to be filled in each bending unit, and cooling to form the fiber heat-insulation structure; wherein the melting temperature of the first fiber layer is less than or equal to the heating temperature in the step c), the melting temperature of the second fiber layer is less than or equal to the heating temperature in the step c), and the melting temperature of the third fiber layer is higher than the heating temperature in the step c).

The third fiber layer with higher melting temperature is clamped between the first fiber layer and the second fiber layer with lower melting temperature at first, the first fiber layer and the second fiber layer are melted through the heating step and filled in gaps of the continuously connected bending units of the third fiber layer, and the fiber heat-insulation structure body can be fixed after cooling without additionally introducing other layers to fix the continuously bent wavy structure, so that an introducing device can be omitted to reduce the production equipment cost; in addition, the step of adhering and fixing the fiber heat-insulating structure by using other layers can be omitted, and the speed of the whole process is further effectively increased.

Preferably, the first fiber layer and the second fiber layer each independently comprise a composite fiber, the composite fiber is composed of a core material and a sheath, the sheath is formed around the core material, and the melting temperature of the sheath is lower than that of the core material.

The first fiber layer and the second fiber layer are made of composite fibers with special core-sheath structures, and in the heating process, the melting temperature of the outer sheath is lower than that of the core material, so that the core material can flow along with the core material and be dispersed among the adjacent bending units and among the bending units, and after the core material is cooled and solidified, the uniformly dispersed core material can further improve the elasticity and the resilience of the fiber heat-insulation structure body.

Preferably, the melting temperature of the core material is between 250 ℃ and 270 ℃; the sheath has a melting temperature of 100 ℃ to 150 ℃; the third fiber layer has a melting temperature of 250 to 270 ℃.

Preferably, the core material is made of polyethylene terephthalate (PET); the sheath is made of polyethylene terephthalate copolyester (CoPET).

Preferably, the third fiber layer has a melting temperature of 250 ℃ to 270 ℃, and is made of PET.

Preferably, the heating temperature is 160 ℃ to 240 ℃. The first fiber layer and the second fiber layer can be in a partially molten state by controlling the heating temperature to be in a range which is higher than the melting temperature of the outer sheaths of the first fiber layer and the second fiber layer and lower than the melting temperature of the third fiber layer, so that the first fiber layer and the second fiber layer can be filled between two adjacent bending units and in each bending unit, and the whole structure can be fixed after cooling.

Preferably, the shape and size of each bending unit of the third fiber layer are the same.

The invention also provides a fiber heat-insulating structure body, which is prepared by the preparation method of the fiber heat-insulating structure body and comprises the following components: the first fiber layer, the second fiber layer and the third fiber layer are respectively formed on two opposite surfaces of the third fiber layer; the third fiber layer comprises a plurality of bending units which are connected with each other, the first fiber layer is filled between two adjacent bending units, and the second fiber layer is filled in each bending unit; the melting temperature of the first fiber layer is lower than that of the third fiber layer, and the melting temperature of the second fiber layer is lower than that of the third fiber layer.

The first fiber layer filled between two adjacent bending units and the second fiber layer filled in each bending unit can provide an adhesion function to fix the third fiber layer comprising a plurality of mutually connected bending units, thereby avoiding deformation when bearing larger pressure and improving the stability of the whole structure; in addition, the first fiber layer and the second fiber layer can also provide supporting force, so that the supporting strength of the fiber heat-insulating structure body is further improved; moreover, the fiber heat-insulating structure body has a special three-dimensional structure with a plurality of bending units, so that the heat exchange rate in the spaces at two sides of the structure can be effectively reduced, and a good heat-insulating effect is achieved.

Preferably, the bending units are mutually erected and leaned.

Preferably, the bending units incline and lean against the horizontal plane at an included angle towards the same direction, and the included angle is smaller than 90 degrees.

Preferably, the melting temperature of the third fiber layer is between 250 ℃ and 270 ℃.

In some embodiments of the present invention, the first and second fiber layers include uniformly dispersed core materials, and the core materials dispersed between two adjacent bending units and among the bending units can further improve the elasticity and recovery of the fiber thermal insulation structure.

In the specification, the "melting temperature" refers to a temperature at which the object starts to change from a solid state to a liquid state, and the object starts to assume a molten state and has a flowing ability.

In the specification, a range represented by "a small value to a large value" means a range from greater than or equal to the small value to less than or equal to the large value, if not specifically indicated. For example: from 250 ℃ to 270 ℃, i.e., ranges from "greater than or equal to 250 ℃ to less than or equal to 270 ℃".

Drawings

FIG. 1 is a schematic representation of a prior art resin wool construction;

FIG. 2 is a schematic side view of a process for example 1 of the present invention;

FIG. 3 is a side view of example 1 of the present invention before heating;

FIG. 4 is a side view of example 1 of the present invention after heating.

Detailed Description

The following embodiments are provided to illustrate the embodiments of the present invention, and those skilled in the art can easily understand the advantages and effects of the present invention through the content of the present specification, and make various modifications and alterations without departing from the spirit of the present invention to implement or apply the content of the present invention.

Referring to fig. 2, a third fiber layer 11 is sandwiched between a first fiber layer 12 and a second fiber layer 13 to form a laminated structure 1, the laminated structure 1 passes through a swing driving device 2, the swing driving device 2 reciprocates to repeatedly swing and fold the laminated structure 1, a continuous structure 4 having a plurality of bending units 5 is formed in a channel space formed by a first conveyor belt 31 and a second conveyor belt 32, the continuous structure 4 is sent into a channel space formed by a third conveyor belt 33 and a fourth conveyor belt 34, and the ambient temperature is simultaneously raised to be higher than the melting temperature of the first fiber layer 12 and the second fiber layer 13 but lower than the melting temperature of the third fiber layer 11, so that the first fiber layer 12 and the second fiber layer 13 can be respectively filled between two adjacent bending units 5 and in each bending unit 5, and then cooling to form the fiber heat-insulating structure body.

The following examples were all prepared in the same manner as the above-described method to obtain the fiber heat insulating structure of the present invention.

Example 1

The third fiber layer of example 1 was made of PET fiber, and the first and second fiber layers were made of conjugate fiber, wherein the conjugate fiber had a structure of a core material and a sheath formed around the core material, the core material was made of PET, and the sheath was made of CoPET; the melting temperature of the third fiber layer is between 250 ℃ and 270 ℃, the melting temperature of the core material is between 100 ℃ and 150 ℃, and the melting temperature of the sheath is between 250 ℃ and 270 ℃.

According to the above-mentioned manufacturing method, after the continuous structure is fed into the channel space formed by the third conveyor belt and the fourth conveyor belt, a hot wind with a temperature of 200 ℃ is provided to blow and dry the continuous structure, so that the outer sheaths of the composite fibers in the first fiber layer and the second fiber layer are melted, the whole is in a flowable state and is filled between two adjacent bending units and in each bending unit, and after cooling, the fiber thermal insulation structure of example 1 is obtained.

To further illustrate the structural features of the fibrous insulation structure of example 1, please refer to fig. 3 and 4. Before the hot air drying, as shown in fig. 3, a first fiber layer 12 is arranged on the outer side of each bending unit 5, and a second fiber layer 13 is arranged on the inner side of each bending unit 5; then, after the fiber heat-insulating structure body of the embodiment 1 is obtained by blowing, drying and cooling with hot air, as shown in fig. 4, through the heating step, the first fiber layer 12 can be filled between two adjacent bending units 5, and the second fiber layer 13 can be filled in each bending unit 5, and then the first fiber layer 12 and the second fiber layer 13 are solidified through the cooling step, so as to achieve the effects of adhesion and fixation, and to stabilize the overall structure of the fiber heat-insulating structure body; in addition, since the core materials contained in the first fiber layer 12 and the second fiber layer 13 are not melted and can flow along with the core materials in the heating process, the core materials can be dispersed in two adjacent bending units 5 and each bending unit 5, and the fiber heat insulation structure is further provided with better elasticity and resilience.

In summary, the method for manufacturing the fiber thermal insulation structure of the present invention does not need to fix the whole structure by other layers, and thus, the manufacturing speed does not need to be reduced to allow other layers to adhere well, so that the method has the advantages of high speed, low equipment cost, low time cost, etc., and moreover, the fiber thermal insulation structure manufactured by the method has the characteristics of good structural stability, recovery, supporting strength, thermal insulation, etc., thereby further improving the commercially applicable scope and value of the present invention.

Claims

1. A method for manufacturing a fiber heat-insulating structure is characterized by comprising the following steps:

step a): providing a first fiber layer, a second fiber layer and a third fiber layer, and clamping the third fiber layer between the first fiber layer and the second fiber layer to form a laminated structure;

step b): folding the laminated structure back and forth to form a continuous structure; the continuous structure comprises a third fiber layer, a first fiber layer arranged outside the bending unit and a second fiber layer arranged inside the bending unit; the third fiber layer comprises a plurality of bending units which are mutually connected, the first fiber layer at the outer side of each bending unit is abutted against the first fiber layer at the outer side of the adjacent bending unit, and the second fiber layers adjacent to the inner sides of the bending units are abutted against each other; and

step c): heating the continuous structure at a heating temperature to enable the first fiber layer to be filled between two adjacent bending units and the second fiber layer to be filled in each bending unit, and cooling to form the fiber heat-insulation structure;

wherein the melting temperature of the first fiber layer is less than or equal to the heating temperature in the step c), the melting temperature of the second fiber layer is less than or equal to the heating temperature in the step c), and the melting temperature of the third fiber layer is higher than the heating temperature in the step c).

2. The method of claim 1, wherein the first fiber layer and the second fiber layer each independently comprise a conjugate fiber, the conjugate fiber is composed of a core material and a sheath, the sheath is formed around the core material, and the melting temperature of the sheath is lower than that of the core material.

3. The method of claim 2, wherein the core material has a melting temperature of 250 ℃ to 270 ℃; the sheath has a melting temperature of 100 ℃ to 150 ℃.

4. The method of claim 1, wherein the third fiber layer has a melting temperature of 250 ℃ to 270 ℃.

5. The method of claim 1, wherein the heating temperature in step c) is 160 ℃ to 240 ℃.

6. A fibrous insulation structure produced by the method for producing a fibrous insulation structure according to any one of claims 1 to 5, comprising: the first fiber layer, the second fiber layer and the third fiber layer are respectively formed on two opposite surfaces of the third fiber layer;

the third fiber layer comprises a plurality of bending units which are connected with each other, the first fiber layer is filled between two adjacent bending units, and the second fiber layer is filled in each bending unit;

the melting temperature of the first fiber layer is lower than that of the third fiber layer, and the melting temperature of the second fiber layer is lower than that of the third fiber layer.

7. The fibrous insulation structure of claim 6 wherein the folding units are upstanding from one another.

8. The fiber thermal insulation structure of claim 6, wherein the bending units are inclined and lean against the horizontal plane in the same direction at an included angle smaller than 90 degrees.

9. The fibrous insulation structure of claim 6, wherein the third fibrous layer has a melting temperature of from 250 ℃ to 270 ℃.