TWI595132B - Nonwoven fabric and manufacturing method thereof - Google Patents
Nonwoven fabric and manufacturing method thereof Download PDFInfo
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- TWI595132B TWI595132B TW105136145A TW105136145A TWI595132B TW I595132 B TWI595132 B TW I595132B TW 105136145 A TW105136145 A TW 105136145A TW 105136145 A TW105136145 A TW 105136145A TW I595132 B TWI595132 B TW I595132B
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- 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
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/08—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns
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Description
本發明是有關於一種不織布結構與其製造方法。 The present invention relates to a nonwoven structure and a method of manufacturing the same.
羽絨為天然纖維中最佳的熱絕緣體之一，羽絨之所以能夠保暖是因為羽絨上佈滿細小的氣孔。在吸熱後，羽絨會變得蓬鬆，並有效隔絕冷空氣入侵。因此，羽絨一般常應用來作為夾克、枕頭、睡袋等物品中的填料。 Down is one of the best thermal insulators in natural fibers. The reason why down is able to keep warm is because the feathers are covered with tiny pores. After the heat is absorbed, the down will become fluffy and effectively insulate the cold air from invading. Therefore, down is often used as a filler in articles such as jackets, pillows, sleeping bags, and the like.
然而，一般羽絨產品因為需要以縫合成口袋，再以氣流將羽絨灌入口袋再縫合的方式使羽絨固定，也因此羽絨會很容易從縫線處掉出來，產生掉毛的現象。另外，沿著縫線只有裡布與外布，沒有羽絨的存在，沒有保溫的效果。再者，在製作羽絨產品時，製造者需以大量的人力進行縫製、氣體充填等製程，因此使得人力成本居高不下。這些都是相關產業的人員在享受羽絨好處的同時，所不得不面對的問題。 However, in general, down products are required to be sewn into pockets, and then the down is filled into the pocket by air flow to suture the down, so that the down can easily fall out from the suture and cause hair loss. In addition, there are only linings and outer cloths along the sutures, there is no down, and there is no effect of heat preservation. Moreover, in the production of down products, the manufacturer needs to perform a process such as sewing and gas filling with a large amount of manpower, thus making the labor cost high. These are the problems that people in related industries have to face while enjoying the benefits of down.
本發明提供了一種包含羽絨的不織布結構，用以 提升羽絨應用時的生產效率以及加強不織布結構的保溫特性。 The invention provides a non-woven fabric structure comprising a down, for Improves productivity in down applications and enhances the insulation properties of non-woven structures.
本發明之一實施方式提供了一種不織布結構，包含多數個複合纖維團球，以及多數個直紡纖維。複合纖維團球由內而外包含多數個層，其中多數個層的最外層的材料為短纖維，多數個層的至少一層的材料為羽絨。直紡纖維用以纏結複合纖維團球，以形成不織布結構。 One embodiment of the present invention provides a nonwoven structure comprising a plurality of composite fiber pellets and a plurality of straight spun fibers. The composite fiber ball comprises a plurality of layers from the inside to the outside, wherein the outermost material of the plurality of layers is a short fiber, and at least one layer of the plurality of layers is a down material. Straight-spun fibers are used to entangle the composite fiber balls to form a nonwoven structure.
於本發明之一或多個實施例中，直紡纖維可為熔噴纖維或紡黏纖維。 In one or more embodiments of the invention, the staple fiber may be a meltblown fiber or a spunbond fiber.
於本發明之一或多個實施例中，直紡纖維的材料可為熱塑性高分子材料。 In one or more embodiments of the invention, the material of the staple fiber may be a thermoplastic polymer material.
於本發明之一或多個實施例中，複合纖維團球的多數個層的最內層的材料可為羽絨。 In one or more embodiments of the invention, the innermost layer of the plurality of layers of the composite fiber ball may be down.
於本發明之一或多個實施例中，複合纖維團球的多數個層的最內層的材料可為短纖維。 In one or more embodiments of the invention, the innermost layer of the plurality of layers of the composite fiber ball may be short fibers.
於本發明之一或多個實施例中，部分的直紡纖維可分布於複合纖維團球的外表面，且部分的直紡纖維可分布於複合纖維團球的內部。 In one or more embodiments of the present invention, a portion of the as-spun fibers may be distributed on the outer surface of the composite fiber ball, and a portion of the straight-spun fibers may be distributed inside the composite fiber ball.
於本發明之一或多個實施例中，短纖維可包括聚丙烯纖維、聚乙烯纖維、聚對苯二甲酸乙二酯纖維、尼龍纖維、壓克力纖維、彈性纖維(Spandex)、棉纖維或上述兩種纖維以上的任意組合。 In one or more embodiments of the present invention, the short fibers may include polypropylene fibers, polyethylene fibers, polyethylene terephthalate fibers, nylon fibers, acrylic fibers, spandex, cotton fibers. Or any combination of the above two fibers.
本發明之另一實施方式提供了一種不織布結構的製作方法，包含以下步驟：(a)匯入羽絨至梳理機中；(b) 匯入短纖維至梳理機中；(c)梳理羽絨與短纖維進而得到多數個複合纖維團球；以及(d)輸出複合纖維團球，使複合纖維團球通過半熔融直紡纖維絲幕中，使得直紡纖維與複合纖維團球纏結成不織布結構。 Another embodiment of the present invention provides a method of fabricating a nonwoven fabric structure comprising the steps of: (a) feeding into a down card to a carding machine; (b) Combining short fibers into the carding machine; (c) combing the down and short fibers to obtain a plurality of composite fiber balls; and (d) outputting the composite fiber balls to pass the composite fiber balls through the semi-molten straight-spun fiber screen The woven fiber and the composite fiber ball are entangled into a non-woven structure.
於本發明之一或多個實施例中，步驟(a)在步驟(b)之前執行。 In one or more embodiments of the invention, step (a) is performed prior to step (b).
於本發明之一或多個實施例中，步驟(d)可更包含使不織布結構通過兩滾輪之間，以收集並捲取不織布結構。 In one or more embodiments of the invention, step (d) may further comprise passing the nonwoven structure between the two rollers to collect and wind the nonwoven structure.
短纖維與羽絨製作成複合纖維團球，而後再將複合纖維團球與直紡纖維纏結形成不織布結構，不織布結構可以透過收集裝置定型成為絮片狀的不織布結構。透過複合纖維團球的彈性可以使得不織布結構具有良好的柔挺性而不易塌陷，進而提升不織布結構的保溫效果。除此之外，絮片狀的不織布結構可直接進行裁切或是與布料縫合，省略了傳統繁瑣的製造工序，因此可以提升生產效率以及降低人力成本。 The short fiber and the down are made into a composite fiber ball, and then the composite fiber ball is entangled with the straight fiber to form a non-woven structure, and the non-woven structure can be shaped into a flake-like non-woven structure through a collecting device. The elasticity of the composite fiber ball can make the non-woven structure have good flexibility and not collapse, thereby improving the heat preservation effect of the non-woven structure. In addition, the flake-like non-woven fabric structure can be directly cut or sewn with the fabric, omitting the traditional cumbersome manufacturing process, thereby improving production efficiency and reducing labor costs.
10‧‧‧機台 10‧‧‧ machine
20‧‧‧流道 20‧‧‧ flow path
30‧‧‧梳理機 30‧‧‧Card machine
32‧‧‧羅拉 32‧‧‧Lola
34‧‧‧刀片 34‧‧‧blade
40‧‧‧喂入裝置 40‧‧‧Feeding device
50‧‧‧熔噴裝置 50‧‧‧melt blowing device
52‧‧‧喂入機 52‧‧‧Feeding machine
54‧‧‧加熱擠出機 54‧‧‧heating extruder
56‧‧‧噴嘴 56‧‧‧Nozzles
58‧‧‧過濾器 58‧‧‧Filter
59‧‧‧計量泵 59‧‧‧Measuring pump
60‧‧‧收集裝置 60‧‧‧Collection device
62‧‧‧真空抽氣平台 62‧‧‧Vacuum pumping platform
64‧‧‧滾輪 64‧‧‧Roller
70‧‧‧氣流源 70‧‧‧Airflow source
100‧‧‧複合纖維團球 100‧‧‧Composite fiber ball
110‧‧‧短纖維 110‧‧‧ Short fiber
120‧‧‧羽絨 120‧‧‧ Down
200‧‧‧半熔融直紡纖維絲幕 200‧‧‧ Semi-melted straight-spun fiber silk curtain
210‧‧‧直紡纖維 210‧‧‧Spun fiber
300‧‧‧不織布結構 300‧‧‧nonwoven structure
為讓本發明之上述和其他目的、特徵、優點與實施例能更明顯易懂，所附圖式之詳細說明如下：第1圖為製作本發明之不織布結構的機台一實施例的示意圖。 The above and other objects, features, advantages and embodiments of the present invention will become more <RTIgt; <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt;
第2圖與第3圖分別為本發明之不織布結構中的複合纖維團球不同實施例的剖面示意圖。 2 and 3 are schematic cross-sectional views showing different embodiments of the composite fiber ball in the non-woven structure of the present invention.
第4圖，其為本發明之不織布結構一實施例的剖面示意圖。 Figure 4 is a cross-sectional view showing an embodiment of the nonwoven structure of the present invention.
第5圖為本發明一實施例的不織布結構中的複合纖維團球的電子顯微鏡圖。 Fig. 5 is an electron micrograph of a composite fiber ball in a nonwoven structure according to an embodiment of the present invention.
第6圖則是本發明一實施例的不織布結構的成品圖。 Fig. 6 is a finished view of the nonwoven structure of an embodiment of the present invention.
以下將以圖式及詳細說明清楚說明本發明之精神，任何所屬技術領域中具有通常知識者在瞭解本發明之較佳實施例後，當可由本發明所教示之技術，加以改變及修飾，其並不脫離本發明之精神與範圍。 The spirit and scope of the present invention will be apparent from the following description of the preferred embodiments of the invention. The spirit and scope of the invention are not departed.
為了解決先前技術所提到的問題，本揭露提供了一種不織布結構與其製造方法，先將羽絨與短纖維混合成團狀物(下稱複合纖維團球)，接著再利用直紡纖維將複合纖維團球纏結定型成為絮片狀的不織布結構，此絮片狀的不織布結構可以直接應用於羽絨製品中，除了可以簡化製造工序之外，更可以藉由複合纖維團球支撐不織布結構，讓不織布結構不易塌陷，而讓羽絨維持蓬鬆以提升不織布結構的保溫效果。 In order to solve the problems mentioned in the prior art, the present disclosure provides a non-woven structure and a manufacturing method thereof, which first mixes down and short fibers into a dough (hereinafter referred to as a composite fiber ball), and then uses the straight fiber to form the composite fiber. The ball entanglement is shaped into a flake-like non-woven fabric structure. The flake-like non-woven fabric structure can be directly applied to the down products. In addition to simplifying the manufacturing process, the non-woven fabric can be supported by the composite fiber ball. The structure is not easy to collapse, and the down is kept fluffy to enhance the insulation effect of the non-woven structure.
參照第1圖，其為製作本發明之不織布結構的機台一實施例的示意圖。機台10包含有流道20、位於流道20一端的梳理機30、與流道20連接的多個喂入裝置40、位於梳理機30之出口的熔噴裝置50，以及位於熔噴裝置50下方的收集裝置60。短纖維110與羽絨120從不同的喂 入裝置40進入流道20後被梳理機30梳理成複合纖維團球100，而後複合纖維團球100被梳理機30輸出並通過由熔噴裝置50所噴出的半熔融直紡纖維絲幕200後，被直紡纖維纏結固定而形成不織布結構300，不織布結構300再被收集裝置60收集。 Referring to Fig. 1, there is shown a schematic view of an embodiment of a machine for fabricating the nonwoven structure of the present invention. The machine table 10 includes a flow path 20, a carding machine 30 at one end of the flow path 20, a plurality of feeding devices 40 connected to the flow path 20, a melt blowing device 50 located at the outlet of the carding machine 30, and a melt blowing device 50. The collection device 60 below. Short fiber 110 and down 120 from different feeding After the inlet device 40 enters the flow path 20, it is combed into a composite fiber ball 100 by the carding machine 30, and then the composite fiber ball 100 is output by the carding machine 30 and passed through the semi-melted straight-spun fiber silk screen 200 sprayed by the melt blowing device 50. The nonwoven fabric structure 300 is entangled by the spliced fibers, and the nonwoven fabric structure 300 is collected by the collecting device 60.
具體而言，短纖維110與羽絨120分別從不同的喂入裝置40進入流道20中，接著短纖維110與羽絨120在流道20中由輸送帶或是氣流導引至梳理機30中，再由梳理機30梳理為複合纖維團球100。由於短纖維110與羽絨120是分別從不同的喂入裝置40進入流道20中，因此，短纖維110與羽絨120會以分層的棉層的形式匯入梳理機30中，而在短纖維110與羽絨120被梳理成複合纖維團球時100，亦會使得複合纖維團球100由內而外出現分層的現象。 Specifically, the short fibers 110 and the down 120 are respectively introduced into the flow channel 20 from different feeding devices 40, and then the short fibers 110 and the down fibers 120 are guided into the carding machine 30 by the conveyor belt or the airflow in the flow channel 20, The carding machine 30 is then combed into a composite fiber ball 100. Since the short fibers 110 and the down 120 are respectively introduced into the flow path 20 from different feeding devices 40, the short fibers 110 and the down 120 are fed into the carding machine 30 in the form of a layered cotton layer, and in the short fibers. When the 110 and the down 120 are combed into a composite fiber ball 100, the composite fiber ball 100 may also be stratified from the inside to the outside.
為了避免羽絨120直接暴露於複合纖維團球100而使羽絨120脫離複合纖維團球100，複合纖維團球100中最外層的材料較佳為短纖維110，以透過短纖維110抓住內層的羽絨120，繼而將羽絨120固定於複合纖維團球100之中。於部分實施例中，喂入裝置40的數量為三個，其中最遠離梳理機30與最接近梳理機30的喂入裝置40皆為短纖維喂入裝置，而位於兩者之間的喂入裝置40為羽絨喂入裝置。於其他的實施例中，喂入裝置40的數量以及類型可以依照實際設計需求變更，只要最遠離梳理機30的喂入裝置40是短纖維喂入裝置即可。 In order to prevent the down 120 from being directly exposed to the composite fiber ball 100 and the down 120 to be detached from the composite fiber ball 100, the outermost material of the composite fiber ball 100 is preferably a short fiber 110 to grasp the inner layer through the short fiber 110. The down 120, in turn, secures the down 120 to the composite fiber ball 100. In some embodiments, the number of feeding devices 40 is three, wherein the feeding device 40 farthest from the carding machine 30 and closest to the carding machine 30 is a short fiber feeding device, and the feeding between the two is Device 40 is a down feed device. In other embodiments, the number and type of feed devices 40 can be varied according to actual design requirements, as long as the feed device 40 that is furthest from the carding machine 30 is a staple fiber feed device.
梳理機30用以抓取並梳理短纖維110與羽絨120，以將兩者混合成為球狀的複合纖維團球100。於部分實施例中，梳理機30為可進行梳棉的機構，舉例而言，梳理機30包含有羅拉32以及設置於羅拉32之表面的錫林針床，錫林針床上具有多個彎折的刀片34。當羅拉32轉動時，錫林針床上的刀片34會將棉層切割成小塊的棉塊，而後此些棉塊處於刀片34之間的間隙而隨著羅拉32一起滾動成球狀的複合纖維團球100。梳理機30的出口近處設置有氣流源70，當複合纖維團球100成型後，複合纖維團球100會自動脫離錫林針床，之後此些複合纖維團球100被氣流源70所產生的氣流帶離開梳理機30。氣流源220實際上可為一吹氣馬達，其氣流之風速可為約1~60m/s。 The carding machine 30 is used to grasp and comb the short fibers 110 and the down 120 to mix the two into a spherical composite fiber ball 100. In some embodiments, the carding machine 30 is a mechanism for carding. For example, the carding machine 30 includes a roller 32 and a cylinder needle bed disposed on the surface of the roller 32. The cylinder bed has a plurality of bends. Blade 34. When the roller 32 rotates, the blade 34 on the cylinder needle bed cuts the cotton layer into small pieces of cotton, and then the cotton pieces are in the gap between the blades 34 and roll together into a spherical composite fiber along with the roller 32. Group ball 100. A gas source 70 is disposed near the outlet of the carding machine 30. After the composite fiber ball 100 is formed, the composite fiber ball 100 is automatically separated from the cylinder needle bed, and then the composite fiber ball 100 is generated by the air source 70. The air flow belt leaves the carding machine 30. The airflow source 220 can be an air blower motor having a wind speed of about 1 to 60 m/s.
複合纖維團球100的尺寸決定於錫林針床上之刀片34之間的間隙，換言之，若是刀片34之間的間隙越大，則刀片34切割的棉塊越大，複合纖維團球100的尺寸也越大，若是刀片34之間的間隙越小，則刀片34切割的棉塊越小，複合纖維團球100的尺寸也會隨之變小。因此，可以透過選擇適當的錫林針床決定複合纖維團球100的尺寸。 The size of the composite fiber ball 100 is determined by the gap between the blades 34 on the cylinder bed, in other words, if the gap between the blades 34 is larger, the larger the cotton piece cut by the blade 34, the size of the composite fiber ball 100. Also, if the gap between the blades 34 is smaller, the smaller the cotton piece cut by the blade 34, the smaller the size of the composite fiber ball 100. Therefore, the size of the composite fiber ball 100 can be determined by selecting an appropriate cylinder needle bed.
如前所述，由於短纖維110與羽絨120為從不同的喂入裝置40進入流道20中，且最遠離梳理機30的喂入裝置為短纖維喂入裝置，因此，匯入梳理機30之棉層的最底層會是短纖維層，當棉層經由梳理機30梳理形成複合纖維團球100之後，複合纖維團球100最外層的材料亦會是短 纖維110，以避免羽絨120直接暴露而亂飛的情形發生。 As previously mentioned, since the staple fibers 110 and the down 120 are fed into the flow channel 20 from different feeding devices 40, and the feeding device farthest from the carding machine 30 is a staple fiber feeding device, the carding machine 30 is introduced. The bottom layer of the cotton layer will be a short fiber layer. When the cotton layer is carded by the carding machine 30 to form the composite fiber ball 100, the outermost material of the composite fiber ball 100 will also be short. The fibers 110 are created to prevent the feathers 120 from being directly exposed and flying.
熔噴裝置50設置在梳理機30的出口處，且熔噴裝置50的位置高於梳理機30的位置。熔噴裝置50用以提供半熔融直紡纖維絲幕200，此半熔融直紡纖維絲幕200包含多數個半熔融的直紡纖維210於其中。 The meltblowing device 50 is disposed at the exit of the carding machine 30, and the position of the meltblowing device 50 is higher than the position of the carding machine 30. The meltblowing device 50 is used to provide a semi-molten, direct-spun fiber silk screen 200 comprising a plurality of semi-molten straight-spun fibers 210 therein.
熔噴裝置50包含喂入機52、加熱擠出機54以及噴嘴56。熱塑性高分子材料從喂入機52進入加熱擠出機54後，被加熱擠出機54中的例如是加熱螺桿加熱熔化，且被加熱螺桿推動而前進至噴嘴56。噴嘴56可通有高壓電，以讓熔融狀態的熱塑性高分子材料離開噴嘴56後變成絲狀的直紡纖維210而形成半熔融直紡纖維絲幕200。直紡纖維210可為連續的紡黏纖維或是不連續的熔噴纖維。 The meltblowing device 50 includes a feeder 52, a heating extruder 54, and a nozzle 56. After the thermoplastic polymer material enters the heating extruder 54 from the feeder 52, it is heated and melted by, for example, a heating screw in the heating extruder 54, and is pushed by the heating screw to advance to the nozzle 56. The nozzle 56 can be energized with high voltage to cause the molten thermoplastic polymer material to leave the nozzle 56 and become a filamentous straight spun fiber 210 to form a semi-molten straight-spun fiber screen 200. The staple fiber 210 can be a continuous spunbond fiber or a discontinuous meltblown fiber.
在一些實施例中，熔噴裝置50可更包含有設置在加熱擠出機54與噴嘴56之間的過濾器58以及計量泵59，以透過過濾器58過濾熔融狀態的熱塑性高分子材料中過大的顆粒，如未完全融化高分子材料顆粒或是雜質，接著透過計量泵59控制加熱擠出機54擠出的材料量。熔噴裝置50在噴嘴56處可選擇性地設置有風切機，以透過改變風切機的角度與流量調整半熔融直紡纖維絲幕200的角度與直紡纖維210的長度。 In some embodiments, the meltblowing device 50 may further include a filter 58 disposed between the heating extruder 54 and the nozzle 56 and a metering pump 59 to filter the molten polymer in the molten state through the filter 58. The particles, such as particles or impurities that are not completely melted, are then controlled by a metering pump 59 to control the amount of material extruded by the extruder 54. The meltblowing apparatus 50 is selectively provided with a wind cutter at the nozzle 56 to adjust the angle of the semi-molten straight-spun fiber silk screen 200 and the length of the straight-spun fiber 210 by changing the angle and flow rate of the wind-cutting machine.
當複合纖維團球100被氣流源70所產生的氣流導引離開梳理機30，複合纖維團球100會被牽引通過半熔融直紡纖維絲幕200。當複合纖維團球100匯入半熔融直紡纖維絲幕200後，半熔融的直紡纖維210將於熔噴裝置50 的噴嘴56下方與複合纖維團球100結合。此時由於直紡纖維210尚未完全凝固，因此直紡纖維210將會黏合複合纖維團球100並固化，使得複合纖維團球100及直紡纖維210結合在一起成連續的不織布結構300。 When the composite fiber ball 100 is directed away from the carding machine 30 by the airflow generated by the airflow source 70, the composite fiber ball 100 is drawn through the semi-molten direct spinning fiber screen 200. After the composite fiber ball 100 is merged into the semi-molten straight-spun fiber screen 200, the semi-molten straight-spun fiber 210 will be in the melt-blown device 50. Below the nozzle 56 is combined with the composite fiber ball 100. At this time, since the straight-spun fiber 210 has not been completely solidified, the straight-spun fiber 210 will adhere to the composite fiber ball 100 and solidify, so that the composite fiber ball 100 and the straight-spun fiber 210 are combined to form a continuous nonwoven structure 300.
收集裝置60位在熔噴裝置50的下方，用以捲取並收集不織布結構300。於部分實施例中，收集裝置60包含有真空抽氣平台62以及位於真空抽氣平台62上的兩滾輪64。不織布結構300受到真空抽氣平台62的吸引而向收集裝置60移動。當不織布結構300接觸到滾輪64之後，不織布結構300會因滾輪64滾動而通過滾輪64之間，不織布結構300經由滾輪64的擠壓定型而成為絮片狀。絮片狀的不織布結構300可再進一步被收集成布捲以便於後續加工。 The collection device 60 is positioned below the meltblown device 50 for taking up and collecting the nonwoven structure 300. In some embodiments, the collection device 60 includes a vacuum pumping platform 62 and two rollers 64 on the vacuum pumping platform 62. The nonwoven fabric structure 300 is moved toward the collecting device 60 by the suction of the vacuum pumping platform 62. After the nonwoven fabric structure 300 contacts the roller 64, the nonwoven fabric structure 300 passes between the rollers 64 due to the rolling of the rollers 64, and the nonwoven fabric structure 300 is formed into a flake shape by extrusion molding of the rollers 64. The flake-like nonwoven structure 300 can be further collected into a roll for subsequent processing.
滾輪64可進行表面處理，以防止直紡纖維210或是複合纖維團球100黏附在滾輪64的表面。由於不織布結構300可透過滾輪64擠壓成型，因此滾輪64之間的距離會決定絮片狀不織布結構300的厚度。換言之，若是需要較厚的不織布結構300，則可增加滾輪64之間的距離，若是需要較薄的不織布結構300，則可縮減滾輪64之間的距離。 The roller 64 can be surface treated to prevent the staple fiber 210 or the composite fiber ball 100 from adhering to the surface of the roller 64. Since the nonwoven structure 300 can be extruded through the rollers 64, the distance between the rollers 64 determines the thickness of the tile-like nonwoven structure 300. In other words, if a thicker nonwoven structure 300 is desired, the distance between the rollers 64 can be increased, and if a thinner nonwoven structure 300 is desired, the distance between the rollers 64 can be reduced.
於其他實施例中，滾輪64可以被有孔的輸送帶取代，此時不織布結構300為平舖在輸送帶上，透過真空抽氣平台62的吸力而定型。 In other embodiments, the roller 64 can be replaced by a perforated conveyor belt, in which case the nonwoven structure 300 is tiled onto the conveyor belt and shaped by the suction of the vacuum pumping platform 62.
承上所述，複合纖維團球100透過梳理機30梳理 成具有球狀的外型，因此，複合纖維團球100本身具有良好的彈性，使得不織布結構300不易塌陷而富含空氣，進而讓羽絨120有足夠的空間舒展而使得不織布結構300具有良好的保溫特性。除此之外，絮片狀的不織布結構300可直接進行裁切或是車縫，省略了傳統製作羽絨衣物的繁瑣工序。 As described above, the composite fiber ball 100 is combed through the carding machine 30. The composite fiber ball 100 has good elasticity, so that the non-woven structure 300 is not easy to collapse and is rich in air, so that the down 120 has sufficient space to stretch and the non-woven structure 300 has good heat preservation. characteristic. In addition, the flake-like non-woven fabric structure 300 can be directly cut or sewn, omitting the cumbersome process of traditionally making down garments.
參照第2圖，其為本發明之不織布結構中的複合纖維團球一實施例的剖面示意圖。複合纖維團球100的直徑例如是0.5-12mm，且由內而外包含多數個層，其中最外層的材料為短纖維110，而至少一層的材料為羽絨120。舉例而言，複合纖維團球100為三層結構，則最內層與最外層皆為短纖維110，中間層為羽絨120。由於複合纖維團球100最外層為短纖維110，羽絨120可被短纖維110抓住而固定在複合纖維團球100內，因此可以避免羽絨120脫離。 Referring to Fig. 2, there is shown a cross-sectional view of an embodiment of a composite fiber ball in a nonwoven structure of the present invention. The composite fiber ball 100 has a diameter of, for example, 0.5 to 12 mm, and contains a plurality of layers from the inside to the outside, wherein the outermost material is the short fibers 110, and at least one layer of the material is the down 120. For example, the composite fiber ball 100 has a three-layer structure, and the innermost layer and the outermost layer are both short fibers 110, and the intermediate layer is a down 120. Since the outermost layer of the composite fiber ball 100 is the short fiber 110, the down 120 can be caught by the short fiber 110 and fixed in the composite fiber ball 100, so that the feather 120 can be prevented from being detached.
短纖維110為不連續的纖維且具有柔挺性及壓縮回彈性，且其長度例如是21-75mm。短纖維110的材料可為人造纖維或是天然纖維，如聚丙烯纖維、聚乙烯纖維、聚對苯二甲酸乙二酯纖維、尼龍纖維、壓克力纖維、彈性纖維(Spandex)、棉纖維或上述兩種纖維以上的任意組合。若是複合纖維團球100中包含有兩層以上短纖維110，則兩層短纖維110的材料可以相同或是不同。 The staple fibers 110 are discontinuous fibers and have flexibility and compression resilience, and have a length of, for example, 21 to 75 mm. The short fiber 110 may be made of rayon or natural fiber, such as polypropylene fiber, polyethylene fiber, polyethylene terephthalate fiber, nylon fiber, acrylic fiber, spandex, cotton fiber or Any combination of the above two types of fibers. If the composite fiber ball 100 includes two or more short fibers 110, the materials of the two short fibers 110 may be the same or different.
參照第3圖，其為本發明之不織布結構中的複合纖維團球另一實施例的剖面示意圖。於本實施例中，複合 纖維團球100可為雙層的結構，則此時外層的材料為短纖維110，內層的材料為羽絨120。 Referring to Figure 3, there is shown a cross-sectional view of another embodiment of a composite fiber ball in a nonwoven structure of the present invention. In this embodiment, the composite The fiber ball 100 can be a two-layer structure, in which case the material of the outer layer is the short fiber 110, and the material of the inner layer is the down 120.
複合纖維團球100的層數與材料可以透過調整第1圖中之喂入裝置40的數量與材料決定，越接近梳理機30之喂入裝置40所放入的材料會在複合纖維團球100的越內層，而越遠離梳理機30之喂入裝置40所放入的材料會在複合纖維團球100的越外層。從上述實施例可以得知，若是複合纖維團球100的層數為奇數層，則最外層與最內層的材料皆為短纖維110；若是複合纖維團球100的層數是偶數層，則最外層的材料為短纖維110，最內層的材料為羽絨120。 The number and material of the composite fiber ball 100 can be determined by adjusting the number and material of the feeding device 40 in Fig. 1, and the material placed in the feeding device 40 closer to the carding machine 30 will be in the composite fiber ball 100. The inner layer of the inner layer, and the material placed in the feeding device 40 farther away from the carding machine 30 will be on the outer layer of the composite fiber ball 100. It can be seen from the above embodiment that if the number of layers of the composite fiber ball 100 is an odd layer, the material of the outermost layer and the innermost layer is the short fiber 110; if the number of layers of the composite fiber ball 100 is an even layer, The outermost layer of material is staple fiber 110 and the innermost layer of material is down 120.
參照第4圖，其為本發明之不織布結構一實施例的剖面示意圖。不織布結構300包含有多個複合纖維團球100，以及用以纏結複合纖維團球100的直紡纖維210。複合纖維團球100的材料包含短纖維與羽絨，其中短纖維與羽絨為由內而外分層地分布在複合纖維團球100中，且複合纖維團球100最外層的材料為短纖維，以防止羽絨直接暴露於複合纖維團球100而脫離的問題發生。 Referring to Figure 4, there is shown a cross-sectional view of an embodiment of the nonwoven structure of the present invention. The nonwoven structure 300 includes a plurality of composite fiber pellets 100, and a straight spun fiber 210 for entanglement of the composite fiber pellets 100. The material of the composite fiber ball 100 comprises short fibers and down, wherein the short fibers and the down are layered in the composite fiber ball 100 from the inside to the outside, and the outermost material of the composite fiber ball 100 is short fibers, The problem of preventing the feather from being directly exposed to the composite fiber ball 100 and detaching occurs.
直紡纖維210纏結複合纖維團球100，再經定型以成為不織布結構300。具體而言，當複合纖維團球100通過半熔融直紡纖維絲幕後會與直紡纖維210結合，藉以透過未固化的直紡纖維210的黏性將複合纖維團球100黏住，而讓複合纖維團球100與直紡纖維210纏結在一起而形成不織布結構300。又因為複合纖維團球100在梳理機 中是透過羅拉轉動錫林針床而成型，因此，複合纖維團球100在離開梳理機進入半熔融直紡纖維絲幕時亦會隨著慣性而繼續旋轉，使得大部分的直紡纖維210會附著於複合纖維團球100的外表面。由於直紡纖維210的直徑極細，故部分的直紡纖維210滲入複合纖維團球100的內部並與其纏結。 The straight spun fiber 210 entangles the composite fiber ball 100 and is shaped to form the nonwoven structure 300. Specifically, when the composite fiber ball 100 is passed through the semi-molten straight-spun fiber silk curtain, it is combined with the straight-spun fiber 210, whereby the composite fiber ball 100 is adhered through the viscosity of the uncured straight-spun fiber 210, and the composite is allowed to be compounded. The fiber ball 100 is entangled with the straight fiber 210 to form a nonwoven structure 300. And because the composite fiber ball 100 is in the carding machine The middle is formed by rotating the cylinder needle bed by the roller. Therefore, the composite fiber ball 100 will continue to rotate with the inertia when leaving the carding machine to enter the semi-melted straight-spun fiber screen, so that most of the straight-spun fiber 210 will Attached to the outer surface of the composite fiber ball 100. Since the diameter of the straight-spun fiber 210 is extremely fine, part of the straight-spun fiber 210 penetrates into and is entangled with the inside of the composite fiber ball 100.
除此之外，由於收集裝置的設計，半熔融直紡纖維絲幕的周邊部分的直紡纖維210會因為吸力或是滾輪擠壓的關係而收攏於不織布結構300的兩側，使得不織布結構300兩側的直紡纖維210的分布密度會大於不織布結構300中間的直紡纖維210的分布密度。換言之，直紡纖維210會在不織布結構300的外層形成連續的棉網，且複合纖維團球100之間亦透過直紡纖維210纏結而固定。 In addition, due to the design of the collecting device, the straight spun fibers 210 of the peripheral portion of the semi-molten straight-spun fiber silk curtain may be gathered on both sides of the non-woven fabric structure 300 due to suction or roller pressing, so that the non-woven fabric structure 300 The distribution density of the straight spun fibers 210 on both sides may be greater than the distribution density of the straight spun fibers 210 in the middle of the nonwoven fabric structure 300. In other words, the staple fiber 210 forms a continuous web of cotton on the outer layer of the nonwoven structure 300, and the composite fiber balls 100 are also entangled by the skein fibers 210 to be fixed.
請同時配合參閱第5圖與第6圖，其中第5圖為本發明一實施例的不織布結構中的複合纖維團球的電子顯微鏡圖，第6圖則是本發明一實施例的不織布結構的成品圖。從第5圖可以得知，藉由將羽絨與短纖維梳理成球狀的複合纖維團球後，確實可以將羽絨固定在複合纖維團球內，有效避免製作羽絨衣物時羽絨脫離的問題。除此之外，從第6圖中可以得知，直紡纖維可以與複合纖維團球纏結並形成蓬鬆的絮片狀不織布結構，此不織布結構可以直接進行裁切、車縫，大幅地節約了羽絨衣物的製作工序以及人力成本。 Please refer to FIG. 5 and FIG. 6 together, wherein FIG. 5 is an electron micrograph of the composite fiber ball in the non-woven fabric structure according to an embodiment of the present invention, and FIG. 6 is a non-woven fabric structure according to an embodiment of the present invention. Finished drawing. It can be seen from Fig. 5 that by combing the down and the short fibers into a spherical composite fiber ball, it is possible to fix the down in the composite fiber ball, thereby effectively avoiding the problem of feather drop when the down clothes are made. In addition, as can be seen from Fig. 6, the straight-spun fiber can be entangled with the composite fiber ball and form a fluffy flake-like non-woven structure, which can directly cut and sew, greatly saving The production process of down clothing and labor costs.
請參照回第1圖，本發明之另一技術態樣是在提 供一種上述不織布結構300的製造方法，其包含下列步驟(應瞭解到，在本實施方式中所提及的步驟，除特別敘明其順序者外，均可依實際需要調整其前後順序，甚至可同時或部分同時執行。 Please refer back to FIG. 1 , another technical aspect of the present invention is A manufacturing method for the above-described nonwoven fabric structure 300, which comprises the following steps (it should be understood that the steps mentioned in the present embodiment can be adjusted according to actual needs, except for the order in which the sequence is specifically stated, or even Can be executed simultaneously or partially simultaneously.
(1)匯入羽絨120至梳理機30中。 (1) The feather 120 is fed into the carding machine 30.
(2)匯入短纖維110至梳理機30中。 (2) The short fibers 110 are fed into the carding machine 30.
(3)梳理短纖維110與羽絨120進而得到多個複合纖維團球100。 (3) Combining the short fibers 110 and the down 120 to obtain a plurality of composite fiber balls 100.
(3)輸出複合纖維團球100，使複合纖維團球100通過半熔融直紡纖維絲幕200中，使得直紡纖維210與複合纖維團球100纏結成不織布結構300。 (3) The composite fiber ball 100 is output, and the composite fiber ball 100 is passed through the semi-molten straight-spinning fiber screen 200, so that the straight-spun fiber 210 and the composite fiber ball 100 are entangled into the non-woven structure 300.
在本發明一或多個實施方式中，上述之不織布結構的製造方法更包含下列步驟： In one or more embodiments of the present invention, the manufacturing method of the non-woven fabric structure further includes the following steps:
(4)使不織布結構300通過滾輪64之間，以收集並捲取不織布結構300。 (4) The nonwoven fabric structure 300 is passed between the rollers 64 to collect and wind up the nonwoven fabric structure 300.
在本發明一或多個實施方式中，步驟(1)及步驟(2)為交替執行，以提供分層的棉層匯入梳理機30中。 In one or more embodiments of the invention, steps (1) and (2) are performed alternately to provide a layered cotton layer into the carding machine 30.
在本發明一或多個實施方式中，至少部分的羽絨120會先於短纖維110匯入梳理機30，使得複合纖維團球100最外層的材料為短纖維110，且羽絨120不會直接暴露於複合纖維團球100，藉以避免羽絨120脫離的問題發生。 In one or more embodiments of the present invention, at least a portion of the down 120 will be introduced into the carding machine 30 prior to the staple fibers 110 such that the material of the outermost layer of the composite fiber ball 100 is the staple fiber 110, and the down 120 is not directly exposed. In the composite fiber ball 100, the problem of avoiding the detachment of the down 120 occurs.
不織布結構透過球狀的複合纖維團球提供的彈性，可以使得不織布結構不易塌陷而具有良好的保溫效果，且具有良好的柔挺性，以下配合實驗數據說明。 The elasticity provided by the non-woven structure through the spherical composite fiber ball can make the non-woven structure not easy to collapse and has good thermal insulation effect, and has good flexibility, and the following experimental data is used for explanation.
上表中的比較例一為僅包含直紡纖維的不織布結構。比較例二為僅包含直紡纖維與短纖維的不織布結構。比較例三為僅包含直紡纖維與羽絨的不織布結構。比較例四為包含直紡纖維、羽絨與短纖維的不織布結構。實驗例則是包含由短纖維與羽絨製作而成之複合纖維團球與直紡纖維纏結而成的不織布結構。上述短纖維為彈性0.8-15D，長度21-75mm的PET纖維，直紡纖維的材料亦為PET，且複合纖維團球的直徑為0.5-12.5mm。 The first comparative example in the above table is a non-woven fabric structure containing only straight-spun fibers. Comparative Example 2 is a nonwoven structure comprising only straight-spun fibers and short fibers. Comparative Example 3 is a nonwoven structure comprising only straight spun fibers and down. Comparative Example 4 is a nonwoven structure comprising straight-spun fibers, down and short fibers. The experimental example is a non-woven fabric structure in which a composite fiber ball made of short fibers and down is entangled with a straight fiber. The short fibers are PET fibers having a elasticity of 0.8-15D and a length of 21-75 mm, and the material of the straight-spun fibers is also PET, and the diameter of the composite fiber balls is 0.5-12.5 mm.
表中的蓬鬆度量測方式是以密度的倒數表示，其 量測方式是採用國家標準CNS 13333進行量測，在23℃(正負3℃)下量測的值，其值越大表示蓬鬆度越佳。表中的柔挺性則是以懸垂度表示，其量測方式是採用國家標準CNS 5615進行量測，其值越小表示挺性越佳。保溫性以CLO值表示，CLO值越大表示保溫性能越佳。 The fluffy measurement method in the table is expressed by the reciprocal of density, The measurement method is a measurement measured by the national standard CNS 13333, measured at 23 ° C (positive and negative 3 ° C), and the larger the value, the better the bulkiness. The softness in the table is expressed by the drape, and the measurement method is measured by the national standard CNS 5615. The smaller the value, the better the stiffness. Insulation is expressed as CLO value, and a larger CLO value indicates better insulation performance.
根據上表的比對分析可以得知，在比較例中，若是要提升蓬鬆度以及保溫性，則布料的基重會大幅地增加(如比較例二及比較例四所示)，這也代表著材料成本會隨之增加。而在引入複合纖維團球後，如實施例所示，蓬鬆度、柔挺性以及保溫性皆有良好的表現，且布料的基重亦不會有顯著的增加，因此，實施例所使用的結構可以在不增加材料成本的狀況下仍具有良好的蓬鬆度、柔挺性以及保溫性。 According to the comparison analysis in the above table, in the comparative example, if the bulkiness and the heat preservation property are to be improved, the basis weight of the fabric will be greatly increased (as shown in Comparative Example 2 and Comparative Example 4), which also represents The cost of materials will increase. After the introduction of the composite fiber ball, as shown in the examples, the bulkiness, the softness and the heat retention are all good, and the basis weight of the cloth is not significantly increased. Therefore, the embodiment uses The structure can still have good bulkiness, flexibility and heat retention without increasing material costs.
綜上所述，短纖維與羽絨製作成複合纖維團球，而後再將複合纖維團球與直紡纖維纏結形成不織布結構，不織布結構可以透過收集裝置定型成為絮片狀的不織布結構。透過複合纖維團球的彈性可以使得不織布結構具有良好的柔挺性而不易塌陷，進而提升不織布結構的保溫效果。除此之外，絮片狀的不織布結構可直接進行裁切或是與布料縫合，省略了傳統繁瑣的製造工序，因此可以提升生產效率以及降低人力成本。 In summary, the short fibers and the down are made into a composite fiber ball, and then the composite fiber ball is entangled with the straight fiber to form a non-woven structure, and the non-woven structure can be shaped into a flake-like non-woven structure through a collecting device. The elasticity of the composite fiber ball can make the non-woven structure have good flexibility and not collapse, thereby improving the heat preservation effect of the non-woven structure. In addition, the flake-like non-woven fabric structure can be directly cut or sewn with the fabric, omitting the traditional cumbersome manufacturing process, thereby improving production efficiency and reducing labor costs.
雖然本發明已以實施例揭露如上，然其並非用以限定本發明，任何熟習此技藝者，在不脫離本發明之精神和範圍內，當可作各種之更動與潤飾，因此本發明之保護 範圍當視後附之申請專利範圍所界定者為準。 Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention, and the present invention can be modified and retouched without departing from the spirit and scope of the present invention. The scope is subject to the definition of the scope of the patent application attached.
100‧‧‧複合纖維團球 100‧‧‧Composite fiber ball
210‧‧‧直紡纖維 210‧‧‧Spun fiber
300‧‧‧不織布結構 300‧‧‧nonwoven structure
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| TW201348547A (en) * | 2012-05-25 | 2013-12-01 | Taiwan Textile Res Inst | Nonwoven fabric and method and apparatus for manufacturing the same |
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| JP2948259B2 (en) * | 1990-03-29 | 1999-09-13 | 日本エステル株式会社 | Fiber ball for filling |
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| CN1043259C (en) * | 1993-08-16 | 1999-05-05 | 北京市超纶无纺技术公司 | Production method and equipment of chemical fiber and fluff composite wadding |
| GB9720436D0 (en) * | 1997-09-26 | 1997-11-26 | Fibretech Limited | Improvements in or relating to a polyester fibre filling |
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| CN103276535B (en) * | 2013-06-19 | 2015-08-26 | 天津泰达洁净材料有限公司 | A kind of double-component melt-blown non-woven material and manufacture method thereof |
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| TW201348547A (en) * | 2012-05-25 | 2013-12-01 | Taiwan Textile Res Inst | Nonwoven fabric and method and apparatus for manufacturing the same |
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