US20170231310A1

US20170231310A1 - Stuffing and manufacturing method thereof

Info

Publication number: US20170231310A1
Application number: US15/505,805
Authority: US
Inventors: Hong Bing Xiang; Feng Xu; Guo Tong Zhao
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2014-08-29
Filing date: 2015-08-21
Publication date: 2017-08-17
Also published as: CN105385001A; JP2017532990A; WO2016032871A1; KR20170047312A; EP3185708A1; CN105385001B

Abstract

Disclosed are a stuffing (4) and a method for manufacturing the same, the stuffing (4) comprising a branch (402) and trunk (401) structure formed with a microporous polymer, and having a trunk (401), and branches (402) formed by splitting from the trunk (401). The stuffing (4) of the present invention can still maintain at a dispersedly stuffing state after multiple washings, without notable phenomena such as agglomeration and entanglement.

Description

TECHNICAL FIELD

The present invention relates to a stuffing material, and particularly to a stuffing and a method for manufacturing the same.

BACKGROUND ART

Natural warm-keeping materials, such as downs, feathers and other bulk animal hairs, and the like are frequently used as stuffing and/or warm-keeping materials in the fields of clothing, bedding products, sleeping bags and the like. At the same time, researchers in the art are also continuously exploring various synthetic materials of imitation downs and imitation feathers.
Stuffing and/or warm-keeping synthetic materials commonly used include a fiber cluster type and a fiber ball type. The fiber cluster-type materials are generally produced by forming fiber flocculus materials into fiber clusters by way of chopping, and then grabbing a given weight of fiber clusters for stuffing, to manufacture the stuffing and/or warm-keeping materials. Whereas the fiber ball-type materials are produced by firstly subjecting staple fibers to opening picking, then allowing, in a certain manner, the fibers to mutually wind with each other, or allowing them to form fiber balls with a bonding point.
As an example of the existing warm-keeping stuffing materials, for example, U.S. Pat. No. 6,329,052 discloses a fluffy thermal insulating material, which, according to the description therein, has fiber batt that forms short fiber cluster after cutting off, wherein the fiber cluster may contain water-repellant or silicone treated fibers, tacky fibers, or conventional dry fibers.
Chinese patent publication CN1966789 discloses a polyester fiber stuffing material, which, according to the description therein, is obtained by mixing conventional hollow polyester staple fibers with superfine super high hollow polyester staple fibers, and is subjected to opening picking, mixing, and carding and then air blowing of suede.
Chinese patent publication CN101166689 discloses a stuffing material, which, according to the description therein, comprises a double-end crimped polyester fiber having an average size of 0.5 to 2.5 dtex and coated with a smoothing agent, wherein the fiber is cut to have an average length of 4 to 15 mm, and then subjected to opening picking.
U.S. Pat. No. 4,618,531 discloses a polyester fiber stuffing, which, according to the description therein, has fiber balls wound spirally and randomly.
Chinese patent publication CN87107757 reveals a polyester fiber wadding, which, according to the description therein, has a spirally crimped polyester fiber wadding, arranged and entangled with a binder fiber intricately to form fiber balls.
U.S. Pat. No. 7,261,936B2 discloses a thermal insulating material, which, according to the description therein, has a structure like a blown shape, and is composed of a number of filaments that are fused together at one end of the filaments and are open at an opposite end, similar to a “shuttlecock”.
Fiber clusters have a certain bulking intensity and condensability, however as a result of a substantial amount fibers isotropically arranged in the fiber flocculi, the fiber cluster after cutting off will inevitably contain a substantial amount of ultra-short fibers, resulting in that the filled warm-keeping materials are easy to leak out, and have a decreased overall thickness after water wash, as well as a deteriorated warm-keeping performance.
Internal connection of the fiber balls is relatively weak, and the modified fiber ball structure can overcome this disadvantage, and increase rebound elasticity and durability. However, the fiber balls cannot solve the water-wash performance after filling, and particularly the disadvantage of easy mutual entanglement of the fibers after water wash.
Similarly, loose-stuffed materials are light in weight and soft in feeling. However, similar stuffing materials have great difficulty in solving problems of easy mutual entanglement and conglomeration of fibers after water wash in practical use, greatly limiting the application of this type of loose-stuffed materials.
Therefore, fiber agglomerates of various sizes formed after the water wash are extremely difficult to disperse again, such that the application thereof in fields of clothing and the like will be influenced, for example, comfortable sensation and performance when it is worn again after the wash will be influenced. As for whether bulk staple fibers, fiber balls, or down-like balls, there remains a need for solving the difficult problem of conglomeration after water wash.

SUMMARY OF THE INVENTION

One objective of the present invention is to provide a stuffing, which has a good water-wash performance, that is, the stuffing can be uniformly dispersed after water wash, without notable phenomena such as agglomeration and entanglement.
The objective of the present invention is achieved by the following technical solution, in which a stuffing is provided, comprising a branch and trunk structure formed with a microporous polymer, wherein the branch and trunk structure comprises a trunk, and branches formed by splitting from the trunk, and the branch and trunk structure has a maximum longitudinal length of about 10 to 130 mm on average, and a maximum lateral dimension of 2 to 15 mm on average.
Optionally, the trunk has an average lateral dimension of 1 to 10 mm.
Optionally, the branches have an average lateral dimension of 0.5 to 5 mm.
Optionally, the trunk length is equal to or less than the longitudinal length of the branch and trunk structure.
Optionally, the branches have an average length between 1 and 6 mm.
Optionally, the branches are formed by laterally splitting along the longitudinal length direction of the trunk at an interval of about 1 to 6 mm on average.
Optionally, the branches are formed by splitting at one end of the trunk.
Optionally, the branch and trunk structure has a planar two-dimensional structure.
Optionally, the branch and trunk structure has an average thickness of 0.25 to 2 mm.
Optionally, the microporous polymer is selected from thermal insulating materials.
Optionally, the thermal insulating materials are expanded plastics.
Optionally, the expanded plastics include one selected from the following materials: polyethylene, polyvinyl chloride, polystyrene or polyurethane.
Optionally, the stuffing has water-wash resistance.
Another objective of the present invention is to provide a method for manufacturing a stuffing.
This objective of the present invention is achieved by the following technical solution, in which a microporous polymer sheet in a thickness of 0.25 to 2 mm is provided, and allowed to get into a pair of gear blade-bearing roller wheels rotating in reverse directions for cutting, and the gap between the two gear blade-bearing roller wheels is adjusted between 0 and 1 mm, so as to cut and mold the sheet into the branch and trunk structure.
Optionally, the gear blade-bearing roller wheels have blades arranged at an interval and spirally distributed along an axial line thereof.
Optionally, the gear blade-bearing roller wheels have a linear velocity of about 100 to 300 mm/s.
Advantages of the present invention are that, a relatively simple method may be used to manufacture a stuffing capable of having a good water-wash performance, and the stuffing of the present invention can still maintain at a dispersedly stuffing state after multiple washings as compared with existing materials, without notable phenomena such as agglomeration and entanglement.
Other features and advantages of the present invention will be further describes below in detail in conjunction with the particular illustration of accompanying drawings, which are schematic, and not drawn to scale.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a method for manufacturing a stuffing of an example of the present invention;

FIG. 2 is a schematic view of a stuffing of an example of the present invention;

FIG. 3 is a schematic view of a stuffing of another example of the present invention; and

FIG. 4 is a schematic view of a stuffing of yet another example of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a stuffing and a method for manufacturing the same. Particularly, in one aspect, provided is a stuffing, comprising a branch and trunk structure formed with a microporous polymer, wherein the branch and trunk structure comprises a trunk, and branches formed by splitting from the trunk, and the branch and trunk structure has a maximum lengthwise strength of 10 to 130 mm on average, and a maximum lateral dimension of 1 to 10 mm on average. This branch and trunk structure is essentially presented as a dendritic shape, and a plurality of branches are formed by splitting from the trunk. The plurality of branches may be, for example, formed by laterally, that is, unilaterally or bilaterally, splitting at a certain interval along the longitudinal length direction of the trunk, so that a planar branch and trunk structure can be formed, which has the plurality of branches spaced in the length direction, at an interval of, for example, 1 to 6 mm on average. For example, a plurality of branches are formed on the trunk, schematically represented as shapes similar to E, F, or K shape. Alternatively, two or more branches may be formed by splitting at one end or both ends of the trunk. For example, a plurality of leaves are formed on the treetop, schematically represented as shapes similar to L, T, or Y shape, and the branch and trunk structure may equally be formed unilaterally or bilaterally.
The branches may be split from the trunk at various angles, from a smaller acute angle, for example, a Y or K shape, to an angle close to 90°, that is, an E, F, L or T shape. Without limitation, when the plurality of branches are formed by laterally splitting at a certain interval in the longitudinal length direction of the trunk, the branches may be split from the trunk at a smaller angle, for example smaller than 30°, and when the branches are formed by splitting at one end or both ends of the trunk, the branches may be split from the trunk at a greater angle, for example greater than 60°.
Dimensions of the trunk and branches may be varied differently. For example, the trunk may have an average lateral dimension of 0.2 to 10 mm. Here, lateral means a direction perpendicular to the length direction, instead of restriction on the shape. For example, cross sections of the trunk and branches may be rectangular, oblate, circular, elliptical or irregular in shape, and thus the average lateral dimension describes the average length dimension across the cross section or the dimension on the larger side. For example, it may be diameter or width of a cross section, or an average size of an irregular shape, or a maximum size across a cross section. Similarly, the branches have an average lateral dimension of optionally 0.1 to 5 mm.
Thickness of a sheet of the microporous polymer material used for forming the stuffing will influence or determine the lateral dimension of the trunk and branches, and the plane thickness of the branch and trunk structure. Although greater changes may be present, preferably, the branch and trunk structure has an average thickness of 0.25 to 2 mm, depending on the thickness of the material.
As for the length, the trunk length may be equal to or less than the longitudinal length of the branch and trunk structure. For example, in the context that the branches are formed by splitting at an interval along the longitudinal length direction of the trunk, the trunk length may be preferably equal to or the longitudinal length of the branch and trunk structure, or in other words, the branches after protruding do not exceed either end in the length direction of the trunk. Alternatively, in one variation, part of the branches after protruding can exceed a certain end in the length direction of the trunk, so that the longitudinal length of the branch and trunk structure is greater than the trunk length. The average length of the branches may be between 1 and 6 mm, as described above, may or may not exceed a certain end in the length direction of the trunk. In another aspect, in the context that the branches are formed by splitting at one end of the trunk, the trunk length is generally less than the longitudinal length of the branch and trunk structure. In whatever context, preferably, the trunk length and the maximum longitudinal length of the branch and trunk structure are 10 to 130 mm on average. The width of the branch and trunk structure, that is, the maximum lateral dimension is optionally 1 to 10 mm on average. Generally, the extension degree and angles of the branches will influence such a dimension. In such a way, these factors determine and limit the outline dimension of the branch and trunk structure.
The stuffing of the present invention may be made of a microporous polymer, preferably may be made of a microporous polymer sheet, for example, a sheet with a thickness of 0.25 to 2 mm. Optionally, this microporous polymer is selected from some microporous polymers made of thermal insulating materials, for example, a certain expanded plastic. By way of example instead of limitation, it may be one selected from polyethylene, polyvinyl chloride, polystyrene or polyurethane and the like, or other expanded materials made of suitable materials.
Optionally, the stuffing has water-wash resistance, that is, it can essentially maintain its original shape after water wash.
In another aspect, the present invention provides a method for manufacturing a stuffing, in which a microporous polymer sheet in a thickness of 0.25 to 2 mm is provided, and allowed to get into a pair of gear blade-bearing roller wheels rotating in reverse directions for cutting, and the gap between the two gear blade-bearing roller wheels is adjusted between 0 and 1 mm, so as to cut and mold the sheet into a branch and trunk structure.
The microporous polymer sheet may be generally provided in a form of a coiled material, and thus a working roll may be mounted on the coiled material, to facilitate rotation. Therefore the coiled material is allowed to get into pull rolls, to pull the coiled material into the gear blade-bearing roller wheels for cutting.
The gear blade-bearing roller wheels have blades, which may have various different shapes and distributions, so as to cut the sheet into branch and trunk structures of different shapes. For example, a typical gear blade-bearing roller wheel has a plurality of tooth-shaped structures, to facilitate spiral rotation, and the blades may be arranged in different manners, for example, each of the tooth-shaped structures may have a blade thereon. In one example, the gear blade-bearing roller wheel has blades arranged at an interval and spirally distributed along an axial line thereof, located on each of the tooth-shaped structures respectively. The gear blade-bearing roller wheels may be selected from commercially available products.
Through selection of thickness of the material of the microporous polymer and parameters of the gear blade-bearing roller wheels, for example, perimeter, rotation velocity or corresponding linear velocity (that is, the velocity of the material of the microporous polymer sheet driven forward) of the gear blade-bearing roller wheels, the gap between the two gear blade-bearing roller wheels, blade shape, spacing and distribution mode and the like thereof, the microporous polymer sheet can be cut into branch and trunk structures of different shapes. For example, the gear blade-bearing roller wheels rotate, thereby to generate a corresponding linear velocity that may be between 100 to 300 mm/s, or in short, the gear blade-bearing roller wheels have a linear velocity of about 100 to 300 mm/s, and the gap between the two gear blade-bearing roller wheels may be between 0 to 1 mm.

Example 1

According to an example of the present invention, a stuffing 4 and a method for manufacturing the same can be achieved by a mode as follows. Referring to FIG. 1, in this example, an expanded polyethylene material (EPE) was selected as the microporous polymer, which is a thermal insulating material, and produced into an expanded plastic. In this example, the material with a thickness of 0.5 mm was selected, and provided in a form of a rolled coiled material. According to the present invention, firstly a working roll was mounted on the microporous polymer sheet 1 to facilitate rotation, and then the sheet 1 was pulled into a pair of gear blade-bearing roller wheels 2, wherein the pair of gear blade-bearing roller wheels 2 had a plurality of tooth-shaped structures each having a blade thereon, and the blades were arranged at an interval and spirally distributed along an axial line of the gear blade-bearing roller wheel 2. The spacing between the two gear blade-bearing roller wheels 2 could be adjusted to 0-1 mm, and adjusted to 0.1 mm in this example. The velocity of the microporous polymer sheet 1 driven forward, or the linear velocity of the gear blade-bearing roller wheels 2 was herein preferably set as 210 mm/s, and in such a way, the pair of gear blade-bearing roller wheels 2 cut the sheet 1 into the stuffing 4 having a branch and trunk structure. A storage bin 3 was provided at the lower end of the pair of gear blade-bearing roller wheels 2. An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
According to this example, the stuffing 4 formed had a shape as shown in FIG. 2, which had a branch and trunk structure, comprising a trunk 401 and a plurality of branches 402 formed by splitting from the trunk 401, wherein the branches 402 after protruding did not exceed any end of the trunk 401 in the length direction thereof, such that the length of the trunk 401 was equal to the maximum longitudinal length of the branch and trunk structure, and the width or the maximum lateral dimension of the branch and trunk structure was determined by the transcurrent degree of the branches 402. In this example, the branch and trunk structure had a maximum longitudinal length of 10 to 60 mm on average, and a maximum lateral dimension of 2 to 5 mm on average, wherein the trunk 401 had a length of about 10 to 60 mm, and a lateral width of 1 to 3 mm, and the branches 402 had a length of 1 to 6 mm, and a width of about 0.5 to 1.5 mm. A plurality of the branches were formed at intervals along the length direction of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm. The length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter, rotation velocity and corresponding linear velocity of the gear blade-bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.
Although the plurality of branches 402 in this example all extended towards one end of the trunk 401, apparently they could also extend respectively towards both ends of the trunk.
In the example as shown in FIG. 2, the branches 402 were split from the trunk 401 at smaller angles, generally distributed within a range around 30°, or smaller.
In this example, the microporous polymer sheet 1 was used to produce the stuffing 4, and the stuffing 4 having a planar branch and trunk structure was formed, so that the thickness of the branch and trunk structure thereof depended on the thickness of the microporous polymer sheet 1, which was 0.5 mm in this example. Also it is easy to understand that, in this example, the thickness of both the trunk 401 and the branches 402 are the thickness of the microporous polymer sheet 1, that is, 0.5 mm.
In this example, as a result of employment of specific gear blade-bearing roller wheels 2 and particular process parameters, cross sections of the trunk 401 and the branches 402 were formed as rectangles. Of course, the cross sections of the trunk 401 and the 402 could also be easily cut as an oblate, circular, elliptical or irregular shape by an artisan in the art with reference to the present invention.
According to the method of the present invention, as a result of features of the process and material thereof, particular shape and dimension of the stuffing 4 formed have a certain distribution. For example, the length of the trunk 401 and each branch 402 of the planar branch and trunk structure, splitting angle formed between each other, and the like will have some variations and distribution ranges, and thus each single stuffing 4 formed has a somewhat different particular shape and dimension. In such a way, in a relatively appropriate mode, the maximum size, average size or a certain range are used to describe various dimensions of the branch and trunk structure, for instance, the longitudinal length and the average value of the maximum lateral dimension of the branch and trunk structure, the lateral dimension and length of the trunk 401, the length and splitting angle of the branches 402, intervals between each of the branches 402, and the like.

Example 2

According to another example of the present invention, as can be shown similarly in FIGS. 1 and 2, a stuffing 4 could be produced by equally using an expanded polyethylene material (EPE), with a thickness of 2 mm. Firstly the microporous polymer sheet 1 was mounted into a working roll, and then the sheet 1 was charged into a pair of gear blade-bearing roller wheels 2 by way of pulling, wherein a spacing between the two gear blade-bearing roller wheels 2 was adjusted to 0.5 mm in this example, the microporous polymer sheet 1 was driven forward at a linear velocity set at 300 mm/s in this example, such that the pair of gear blade-bearing roller wheels 2 cut and molded the sheet 1 into the stuffing 4 having a branch and trunk structure. A storage bin 3 was provided at the lower end of the gear blade-bearing roller wheels 2. An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
In this example, a stuffing 4 having a branch and trunk structure was formed, comprising a trunk 401 and a plurality of branches 402 formed by splitting from the trunk 401, as shown in FIG. 2. However, its dimension was different from that of the first example of the present invention, in that the branch and trunk structure had a maximum longitudinal length of 10 to 40 mm on average, a maximum lateral dimension of about 2 to 4 mm on average, wherein the trunk 401 had a length of about 10 to 40 mm, and a lateral width of 1 to 2 mm, and the branches 402 had a length of 1 to 6 mm, and a width of about 0.5 to 1 mm. A plurality of the branches were formed at intervals along the length direction of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm. Similarly, the length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter of the gear blade-bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.

Example 3

According to another example of the present invention, a stuffing 4 and a method for manufacturing the same are as shown in FIGS. 1 and 3. In this example, a polyurethane material (PU) of a plastic texture was selected as the microporous polymer sheet 1, which is a thermal insulating material, and similarly, also produced into an expanded plastic. In this example, the material selected had a thickness of 2 mm. Firstly the microporous polymer sheet 1 was mounted into a working roll, and then the microporous polymer sheet 1 was charged into a pair of gear blade-bearing roller wheels 2 by way of pulling, wherein the pair of gear blade-bearing roller wheels 2 had a plurality of tooth-shaped structures each having a blade thereon, and the blades were arranged at an interval and spirally distributed along an axial line of the gear blade-bearing roller wheel 2. The spacing between the two gear blade-bearing roller wheels 2 was adjusted to 0.2 mm in this example, and the rotation velocity was set at 150 mm/s. A storage bin 3 was provided at the lower end of the gear blade-bearing roller wheels 2. An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
In this example, a stuffing 4 having a branch and trunk structure was formed, as shown in FIG. 3, comprising a trunk 401 and branches 402 formed by splitting at one end of the trunk 401. The stuffing 4 had a maximum longitudinal length of 10 to 80 mm on average, and a maximum lateral dimension of 2 to 10 mm on average, wherein the trunk 401 had a length of about 10 to 80 mm, and a lateral width of 1 to 6 mm, and the branches 402 had a length of 1 to 6 mm, and a width of about 0.5 to 3 mm. One or more branches 402 could be formed by splitting at one end of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm. Similarly, the length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter of the gear blade-bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.

Example 4

According to still another example of the present invention, a stuffing 4 and a method for manufacturing the same are as shown in FIGS. 1 and 4. In this example, an expanded polyethylene (EPE) material of a plastic texture was selected as the microporous polymer sheet 1, which is a thermal insulating material, and similarly, also produced into an expanded plastic. In this example, the material with a thickness of 0.25 mm was selected. Firstly the microporous polymer sheet 1 was mounted into a working roll, and then the microporous polymer sheet 1 was charged into a pair of gear blade-bearing roller wheels 2 by way of pulling, wherein the pair of gear blade-bearing roller wheels 2 had a plurality of tooth-shaped structures each having at least one blade thereon, and the blades were arranged at an interval and spirally distributed along an axial line of the gear blade-bearing roller wheel 2. The spacing between the two gear blade-bearing roller wheels 2 was adjusted to 0.3 mm in this example, and the rotation velocity was set at 210 mm/s. A storage bin 3 was provided at the lower end of the gear blade-bearing roller wheels 2. An evacuation device (not shown) was provided in the storage bin 3, and the device was used for collecting the stuffing 4 after the machine molding at the upper end.
In this example, a stuffing 4 having a branch and trunk structure was formed, as shown in FIG. 4, comprising a trunk 401 and a plurality of branches 402 formed by splitting from the trunk 401. The plurality of branches 402 extended towards both ends of the trunk 401 respectively, part of the branches 402 could exceed a certain end of the trunk 401 in the length direction thereof. The branch and trunk structure had a maximum longitudinal length of 10 to 130 mm on average, a maximum lateral dimension of about 5 to 15 mm on average, wherein the trunk 401 had a length of about 5 to 110 mm, and a lateral width of 3 to 10 mm, and the branches 402 had a length of 5 to 20 mm, and a width of about 1.5 to 4 mm. The plurality of the branches 402 were formed at intervals along the length direction of the trunk 401. For example, the average interval between each of the branches 402 was 1 to 6 mm. Similarly, the length and width of the trunk 401, the length and width of the branches 402, and the average interval between each of the branches 402 could be determined by adjusting the perimeter of the gear blade-bearing roller wheels 2, the spacing between the blades, the spacing between the two gear blade-bearing roller wheels 2, and the like.
In order to judge the water-wash performance, the stuffing formed in Example 1 of the present invention was tested for its warm-keeping values before and after water wash, and observed for its uniformity. Therefore, a 50 cm×50 cm cloth packet was made up employing 190T blue nylon cloths, and 40 g of the stuffing formed in Example 1 was distributed uniformly therein to produce a test sample packet, to carry out water wash, and tests for warm-keeping values before and after the water wash, according to standard methods. Wherein, the water wash was carried out by 10 washings according to a GB/T8629-2001:7A procedure, and the warm-keeping value test was carried out according to ASTM1868 Part C, to test a warm-keeping index, the Clo value. The warm-keeping index Clo value is expressed as such that, when a person sitting still or engaged in mild mental labour (with metabolic heat production of 209.2 KJ/m2·h) feels comfortable, at room temperature of 21° C., relative humidity less than 50%, and a wind speed not more than 0.1 m/s, the thermal resistance value of clothes worn by the person is 1 Clo.
The test result was as follows: the Clo value of the test sample packet was 2.4 before the water wash, and the Clo value was 2.38 after 10 washings. A Clo conservation rate after the water wash was as high as 99.1%. This result showed that the water wash had hardly any effect on the warm-keeping performance of this material, indicating that the water wash did not significantly cause agglomeration, entanglement, and the like of the stuffing to influence variation in the warm-keeping performance. Uniformity was judged by a method in which the sample packet was placed onto a glass table with illumination, and the distribution situation of the stuffing within the sample packet was judged by observing the overall color uniformity of the sample packet. More uniform color stands for more uniform distribution of the stuffing within the sample packet. On the contrary, it indicates that agglomeration and entanglement are present. In another aspect, the stuffing was taken out from the sample packet, and it was found by observation that the stuffing was essentially in a state of single fibers both before and after the water wash, nearly without agglomeration and significant variation.
According to the present invention, a stuffing and a method for manufacturing the same are provided, so as to obtain stuffing of different shapes and dimensions. Although the particular shape and dimension can be varied, the branch and trunk structure formed by the microporous polymer provides very excellent water-wash performance, without entanglement or agglomeration, and can maintain and display a good state of single fibers, so that can remain uniformly dispersed after the water wash. When the branch and trunk structure is used in a warm-keeping material, it can maintain a good warm-keeping performance.

Claims

1. A stuffing, characterized in that the stuffing comprises a branch and trunk structure formed by a microporous polymer, wherein the branch and trunk structure comprises a trunk and branches formed by splitting from the trunk, and wherein the branch and trunk structure has a maximum longitudinal length of about 10 to about 130 mm on average and a maximum lateral dimension of about 2 to about 15 mm on average.

2. The stuffing of claim 1, characterized in that the trunk has an average lateral dimension of about 1 to about 10 mm.

3. The stuffing of claim 1, characterized in that the branches have an average lateral dimension of about 0.5 to about 5 mm.

4. The stuffing of claim 1, characterized in that the trunk length is equal to or less than the longitudinal length of the branch and trunk structure.

5. The stuffing of claim 1, characterized in that the branches have an average length between about 1 and about 6 mm.

6. The stuffing of claim 1, characterized in that the branches are formed by laterally splitting along a longitudinal length direction of the trunk at an interval of about 1 to about 6 mm on average.

7. The stuffing of claim 1, characterized in that the branches are formed by splitting at one end of the trunk.

8. The stuffing of claim 1, characterized in that the branch and trunk structure has a planar two-dimensional structure.

9. The stuffing of claim 8, characterized in that the branch and trunk structure has an average thickness of about 0.25 to about 2 mm.

10. The stuffing of claim 1, characterized in that the microporous polymer is selected from thermal insulating materials.

11. The stuffing of claim 10, characterized in that the thermal insulating materials are expanded plastics.

12. The stuffing of claim 11, characterized in that the expanded plastics include expanded materials produced from one of the following materials: polyethylene, polyvinyl chloride, polystyrene or polyurethane.

13. The stuffing of claim 1, characterized in that the stuffing has water-wash resistance.

14. A method for manufacturing a stuffing, including providing a microporous polymer sheet having a thickness of about 0.25 to about 2 mm, allowing the sheet to be positioned between two gear blade-bearing roller wheels rotating in reverse directions for cutting, and adjusting a gap between the two gear blade-bearing roller wheels to between 0 and about 1 mm so as to cut and mold the sheet into a branch and trunk structure.

15. The method of claim 14, characterized in that the gear blade-bearing roller wheels have blades arranged at an interval and spirally distributed along an axial line thereof.

16. The method of claim 14, characterized in that the gear blade-bearing roller wheels have a linear velocity of about 100 to about 300 mm/s.