Multifunctional composite ultramicro cotton needled felt and preparation method thereof

Abstract

The invention discloses a multifunctional composite ultramicro cotton needled felt and a preparation method thereof.The multifunctional composite ultramicro cotton needled felt comprises a needled felt body and base cloth, the needled felt body is composed of the base cloth, a filter layer, a heat insulation layer and a sound absorption layer, and the filter layer, the heat insulation layer and the sound absorption layer are sequentially distributed on the outer side of the base cloth from inside to outside; the filter layer is directly connected with and covers the outer side of the base cloth, the heat insulation layer is connected with and covers the outer side of the filter layer, and the sound absorption layer is connected with and covers the outer side of the heat insulation layer. Through the arrangement of the heat insulation layer and the combined use of the ceramic fibers and the aerogel material, the heat insulation layer can achieve an efficient heat insulation effect and remarkably reduce the heat transfer rate, and the ceramic fibers and the aerogel material are environment-friendly materials, do not contain harmful substances and do not cause harm to the environment and human health; and the materials can be recycled, so that the resource consumption and the waste generation are reduced, and the environmental protection property and the sustainability of the material are further improved.

Description

Technical Field

[0001] The invention relates to the technical field of composite ultra-fine cotton needle-punched felt, and in particular to a multifunctional composite ultra-fine cotton needle-punched felt and a preparation method thereof. Background Art

[0002] Composite ultrafine cotton needle felt is a composite material made of ultrafine fibers through a needle punching process. Needle punching is a processing method for processing short fibers into products such as felt or non-woven fabrics. In the production process of composite ultrafine cotton needle felt, ultrafine fibers are fed into a needle punching machine. Through a large number of intensive needle punching actions, the fibers are entangled with each other to form a felt-like material with a certain thickness and strength. With the continuous advancement of materials science, people's requirements for material properties are getting higher and higher. Composite ultrafine cotton needle felt combines the advantages of multiple materials, such as the high specific surface area of ​​ultrafine fibers, good adsorption properties and the durability of needle felt, thereby achieving a significant improvement in material performance.

[0003] Existing ultrafine cotton needle felt does not have good filtering performance, heat insulation and sound absorption. For example, the preparation method of glass fiber needle felt disclosed in announcement number CN117230573A, due to the lack of a multi-layer filter screen structure in this patent, ultrafine cotton needle felt is often difficult to achieve fine filtration. When facing complex or diverse particulate pollutants, a single-layer filter screen may not be able to effectively intercept all fine particles, resulting in a decrease in filtration accuracy and failure to provide sufficient heat insulation effect. Its heat insulation effect may not be able to meet high-demand application scenarios, and the needle felt does not have a multi-layer sound insulation structure, and its sound absorption effect may be relatively limited, and it cannot effectively absorb and attenuate sound waves.

[0004] Therefore, it is necessary to invent a multifunctional composite ultra-fine cotton needle felt and a preparation method thereof to solve the above problems. Summary of the invention

[0005] The purpose of the present invention is to provide a multifunctional composite ultra-fine cotton needle felt and a preparation method thereof, so as to solve the problem that the technical function does not have good filtering performance, heat insulation and sound absorption.

[0006] In order to achieve the above-mentioned purpose, the present invention provides the following technical scheme: a multifunctional composite ultra-fine cotton needle-punched felt and a preparation method thereof, comprising a needle-punched felt body and a base cloth, wherein the needle-punched felt body is composed of a base cloth, a filter layer, a heat insulation layer and a sound absorption layer, wherein the filter layer, the heat insulation layer and the sound absorption layer are sequentially distributed on the outside of the base cloth from the inside to the outside, the filter layer is directly connected to and covers the outside of the base cloth, the heat insulation layer is connected to and covers the outside of the filter layer, and the sound absorption layer is connected to and covers the outside of the heat insulation layer.

[0007] Preferably, the filter layer is connected to the base fabric by needling, the heat insulation layer is connected to the filter layer by needling, and the sound absorption layer is connected to the heat insulation layer by needling, which not only ensures the close connection between the layers, but also greatly enhances the stability and durability of the overall structure.

[0008] Preferably, the filter layer includes a pre-filter, a main filter and a fine filter, and the pre-filter, main filter and fine filter are stacked in sequence to achieve graded filtration, thereby improving filtration efficiency and filtration accuracy.

[0009] Preferably, the pre-filter, main filter and fine filter are made of membrane materials with different finenesses, and the pre-filter, main filter and fine filter are connected by acupuncture, thereby ensuring the stability of the structure and the firmness of the connection.

[0010] Preferably, the thermal insulation layer includes an outer thermal insulation film and an inner thermal insulation film, and the outer thermal insulation film and the inner thermal insulation film are made of ceramic fiber material, have excellent high temperature resistance and thermal insulation performance, and can maintain a stable thermal insulation effect in a high temperature environment.

[0011] Preferably, the outer thermal insulation film and the inner thermal insulation film are connected by a needle-punching method, which not only ensures the integrity of the thermal insulation layer, but also avoids the environmental problems and performance degradation that may be caused by the use of adhesives.

[0012] Preferably, the sound-absorbing layer includes No. 1 sound-insulating cotton, No. 2 sound-insulating cotton and No. 3 sound-insulating cotton, and the No. 1 sound-insulating cotton, No. 2 sound-insulating cotton and No. 3 sound-insulating cotton are made of polypropylene fiber materials with different pore sizes. This multi-layer structure can form a complex sound wave propagation path and improve the sound absorption effect.

[0013] Preferably, the No. 1 sound insulation cotton, No. 2 sound insulation cotton and No. 3 sound insulation cotton are connected by needle punching, thereby ensuring the integrity of the sound absorbing layer and the firmness of the connection.

[0014] Preferably, the method comprises the following steps:

[0015] Step 1: First, select suitable fiber raw materials according to product requirements, and mix different types of fiber raw materials in a certain proportion. For example, for filtration, ultra-fine glass fiber can be used, and an appropriate amount of environmentally friendly adhesive (water-based polyurethane or acrylic emulsion) can be added. For thermal insulation, ceramic fiber can be used, and an appropriate amount of aerogel material (silicon dioxide aerogel) can be added. For sound absorption, polypropylene fiber can be used, and low-melting-point polypropylene fiber can be added to 0.44-0.666tex polypropylene fiber, and a certain amount of porous material (perlite, vermiculite, etc.) can be mixed into the raw material.

[0016] Step 2: Secondly, the fiber raw materials are preliminarily opened to remove large fiber clumps, make the fibers loose, and fully mix the opened fiber raw materials to ensure that various fiber components are evenly distributed in the needle felt;

[0017] Step 3: Then, the mixed fibers are combed by a combing machine to arrange the fibers in a relatively neat state and form a fiber web. The combed fiber web is sent to a web laying machine for multi-layer stacking to form a fiber stacking structure with a certain thickness and uniformity.

[0018] Step 4: Next, the laid-up fiber stacking structure is fed into a needle punching machine. Through the up and down movement of the needle punching needle, each fiber layer is repeatedly punctured. The needle punching needle weaves the fibers in each layer of material together to form a stable composite felt-like structure.

[0019] Step 5: Further, the needle-punched felt after needle-punching reinforcement is subjected to heat setting treatment and surface treatment of the needle-punched felt, such as coating with a filter coating, a heat-insulating coating and a sound-absorbing coating;

[0020] Step 6: Finally, the quality of the needle-punched felt is inspected, and the qualified needle-punched felt is packaged and stored or shipped.

[0021] In the above technical solution, the technical effects and advantages provided by the present invention are:

[0022] 1. Through the setting of the filter layer, the pre-filter as the first layer can initially block large particles and impurities. The main filter uses ultra-fine glass fiber with extremely high filtering accuracy, which can capture finer particles and provide excellent filtering effect. The fine filter as the last layer further refines the filtering effect to ensure that the air or liquid passing through reaches extremely high cleanliness standards. The multi-layer filter structure is tightly connected by acupuncture, so that each layer of fiber is interwoven to form a stable composite felt structure that is not easy to delaminate or break. In addition, environmentally friendly adhesives are used instead of traditional harmful adhesives to reduce environmental pollution during production and use, which meets the requirements of modern industry for green and environmental protection. The use of environmentally friendly materials also improves the recyclability and sustainability of the product, which is conducive to the recycling of resources;

[0023] 2. Through the setting of the heat insulation layer and the combined use of ceramic fiber and aerogel materials, the heat insulation layer can achieve a high-efficiency heat insulation effect and significantly reduce the heat transfer rate. Both ceramic fiber and aerogel materials are environmentally friendly materials, do not contain harmful substances, and will not cause harm to the environment and human health. At the same time, these materials can also be recycled and reused, reducing resource consumption and waste generation, and further improving the environmental protection and sustainability of the present invention;

[0024] 3. Through the setting of the sound-absorbing layer, polypropylene fiber, as the main component of the sound-absorbing material, has good sound-absorbing performance. Its fiber structure can effectively capture sound waves and convert them into other forms of energy, thereby reducing the reflection and propagation of sound waves. The mixing of porous materials (perlite, vermiculite, etc.) further enhances the sound absorption effect. These porous materials contain a large number of tiny pores and channels, which can increase the propagation path and reflection times of sound waves inside the material, so that the sound wave energy is gradually dissipated inside the material. In addition, the multi-level design helps to comprehensively improve the sound absorption performance of the entire sound-absorbing layer, so that it can adapt to a wider range of sound environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the structure of the preparation process of the present invention;

[0026] Figure 2 It is a schematic diagram of the overall three-dimensional structure of the present invention;

[0027] Figure 3 Schematic diagram of the three-dimensional structure of the filter layer of the present invention

[0028] Figure 4 It is a schematic diagram of the cutaway three-dimensional structure of the heat insulation layer of the present invention;

[0029] Figure 5 It is a schematic diagram of the three-dimensional structure of the sound-absorbing layer of the present invention.

[0030] Description of reference numerals:

[0031] 1. Needle-punched felt body; 2. Base fabric; 3. Filter layer; 301. Pre-filter; 302. Main filter; 303. Fine filter; 4. Heat insulation layer; 401. External heat insulation film; 402. Internal heat insulation film; 5. Sound-absorbing layer; 501. No. 1 sound insulation cotton; 502. No. 2 sound insulation cotton; 503. No. 3 sound insulation cotton. DETAILED DESCRIPTION

[0032] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0033] The present invention provides Figure 1-5 A multifunctional composite ultrafine cotton needle-punched felt and a preparation method thereof are shown, comprising a needle-punched felt body 1 and a base cloth 2, wherein the needle-punched felt body 1 is composed of a base cloth 2, a filter layer 3, a heat-insulating layer 4 and a sound-absorbing layer 5, wherein the filter layer 3, the heat-insulating layer 4 and the sound-absorbing layer 5 are sequentially distributed on the outside of the base cloth 2 from the inside to the outside, the filter layer 3 is directly connected to and covers the outside of the base cloth 2, the heat-insulating layer 4 is connected to and covers the outside of the filter layer 3, and the sound-absorbing layer 5 is connected to and covers the outside of the heat-insulating layer 4.

[0034] The filter layer 3 is connected to the base fabric 2 by a needle punching method, the heat insulation layer 4 is connected to the filter layer 3 by a needle punching method, and the sound absorption layer 5 is connected to the heat insulation layer 4 by a needle punching method. The filter layer 3 includes a pre-filter 301, a main filter 302 and a fine filter 303. The pre-filter 301, the main filter 302 and the fine filter 303 are stacked in sequence. The pre-filter 301, the main filter 302 and the fine filter 303 are made of membrane materials with different finenesses. The pre-filter 301, the main filter 302 and the fine filter 303 are connected by a needle punching method.

[0035] The pre-filter 301 uses a membrane material with a larger pore size, which can effectively block large particles, such as dust, hair, etc., and reduce the burden on the subsequent filter layer 3. The main filter 302 uses a membrane material with medium fineness to further intercept fine particles in the air. The fine filter 303 uses a membrane material with an extremely fine pore size to filter tiny particles. The pre-filter 301, the main filter 302 and the fine filter 303 are stacked in sequence and tightly connected into a whole through a needle puncture method to ensure the filtration efficiency while maintaining the stability of the structure.

[0036] The heat insulation layer 4 comprises an outer heat insulation film 401 and an inner heat insulation film 402, and the outer heat insulation film 401 and the inner heat insulation film 402 are made of ceramic fiber material. The outer heat insulation film 401 and the inner heat insulation film 402 are connected by a needle punching method.

[0037] Both the outer thermal insulation film 401 and the inner thermal insulation film 402 are made of high-performance ceramic fiber material, which has excellent high temperature resistance and thermal insulation performance. The outer thermal insulation film 401 and the inner thermal insulation film 402 are connected by a needle punching method to form a double-layer thermal insulation structure, which effectively blocks external heat transfer while maintaining internal temperature stability.

[0038] The sound-absorbing layer 5 includes No. 1 sound-insulating cotton 501, No. 2 sound-insulating cotton 502 and No. 3 sound-insulating cotton 503. No. 1 sound-insulating cotton 501, No. 2 sound-insulating cotton 502 and No. 3 sound-insulating cotton 503 are made of polypropylene fiber materials with different pore sizes. No. 1 sound-insulating cotton 501, No. 2 sound-insulating cotton 502 and No. 3 sound-insulating cotton 503 are connected by needle punching.

[0039] No. 1 sound insulation cotton 501, No. 2 sound insulation cotton 502 and No. 3 sound insulation cotton 503 are respectively made of polypropylene fiber materials with different pore sizes to form a gradient sound absorption effect. No. 1 sound insulation cotton 501 has a larger pore size and is mainly used to absorb low-frequency noise; No. 2 sound insulation cotton 502 has a moderate pore size and is aimed at medium-frequency noise; No. 3 sound insulation cotton 503 has the finest pore size and effectively absorbs high-frequency noise. The three layers of sound insulation cotton are connected by needle punching to form a continuous sound absorption layer 5, which significantly improves the overall sound absorption effect.

[0040] The following steps are involved:

[0041] Step 1: First, select suitable fiber raw materials according to product requirements, and mix different types of fiber raw materials in a certain proportion. For example, for filtration, ultra-fine glass fiber can be used, and an appropriate amount of environmentally friendly adhesive (water-based polyurethane or acrylic emulsion) can be added. For thermal insulation, ceramic fiber can be used, and an appropriate amount of aerogel material (silicon dioxide aerogel) can be added. For sound absorption, polypropylene fiber can be used, and low-melting-point polypropylene fiber can be added to 0.44-0.666tex polypropylene fiber, and a certain amount of porous material (perlite, vermiculite, etc.) can be mixed into the raw material.

[0042] Step 2: Secondly, the fiber raw materials are preliminarily opened to remove large fiber clumps, make the fibers loose, and fully mix the opened fiber raw materials to ensure that various fiber components are evenly distributed in the needle felt;

[0043] Step 3: Then, the mixed fibers are combed by a combing machine to arrange the fibers in a relatively neat state and form a fiber web. The combed fiber web is sent to a web laying machine for multi-layer stacking to form a fiber stacking structure with a certain thickness and uniformity.

[0044] Step 4: Next, the laid-up fiber stacking structure is fed into a needle punching machine. Through the up and down movement of the needle punching needle, each fiber layer is repeatedly punctured. The needle punching needle weaves the fibers in each layer of material together to form a stable composite felt-like structure.

[0045] Step 5: Further, the needle-punched felt after needle-punching reinforcement is subjected to heat setting treatment and surface treatment of the needle-punched felt, such as coating with a filter coating, a heat-insulating coating and a sound-absorbing coating;

[0046] Step 6: Finally, the quality of the needle-punched felt is inspected, and the qualified needle-punched felt is packaged and stored or shipped.

[0047] Working principle of the present invention:

[0048] Refer to the instruction manual Figure 1-2When using the present invention, firstly, suitable fiber raw materials are selected, different types of fiber raw materials are proportioned according to a certain ratio, and appropriate amounts of environmentally friendly adhesives, aerogel materials and porous materials are added to improve the filtering, heat insulation and sound absorption performance of the product, the fiber raw materials are preliminarily loosened, large fiber clumps are removed, and the fibers become loose, and the opened fiber raw materials are fully mixed to ensure that various fiber components are evenly distributed in the needle-punched felt, and the evenly mixed fibers are combed by a combing machine to arrange the fibers in a relatively neat state, and Forming a fiber web, feeding the combed fiber web into a web laying machine, and performing multi-layer laying to form a fiber layered structure with a certain thickness and uniformity, and stacking the laid base cloth 2, filter layer 3, heat insulation layer 4 and sound absorption layer 5 into a needle punching machine, and repeatedly puncturing each layer through the up and down movement of the needle punching needle, so that the fibers in each layer of material are interwoven together to form a stable composite felt-like structure, and then, heat setting treatment and surface treatment are performed on the needle punched felt after needle punching reinforcement, such as coating with filter coating, heat insulation coating and sound absorption coating, so as to enhance its specific functions;

[0049] Refer to the instruction manual Figure 3-5 When using the present invention, the prepared composite ultra-fine cotton needle-punched felt is stacked and connected by acupuncture in sequence through the pre-filter 301, the main filter 302 and the fine filter 303 to form an efficient filtration system, and the outer insulation film 401 and the inner insulation film 402 are connected by acupuncture to form a double-layer insulation structure, which effectively blocks external heat transfer and keeps the internal temperature stable. At the same time, the No. 1 sound insulation cotton 501, the No. 2 sound insulation cotton 502 and the No. 3 sound insulation cotton 503 are connected by acupuncture to form a gradient sound absorption structure. Polypropylene fiber materials with different pore sizes absorb low-frequency, medium-frequency and high-frequency noise respectively, which significantly improves the overall sound absorption effect.

Claims

1. A multifunctional composite ultra-fine cotton needle felt and a preparation method thereof, comprising a needle felt body (1) and a base fabric (2), characterized in that: The needle felt body (1) is composed of a base fabric (2), a filter layer (3), a heat insulation layer (4) and a sound absorption layer (5); the filter layer (3), the heat insulation layer (4) and the sound absorption layer (5) are sequentially distributed on the outer side of the base fabric (2) from the inside to the outside; the filter layer (3) is directly connected to and covers the outer side of the base fabric (2); the heat insulation layer (4) is connected to and covers the outer side of the filter layer (3); and the sound absorption layer (5) is connected to and covers the outer side of the heat insulation layer (4).

2. The multifunctional composite ultra-fine cotton needle felt and its preparation method according to claim 1, characterized in that: The filter layer (3) is connected to the base fabric (2) by a needle punching method, the heat insulation layer (4) is connected to the filter layer (3) by a needle punching method, and the sound absorption layer (5) is connected to the heat insulation layer (4) by a needle punching method.

3. A multifunctional composite ultra-fine cotton needle felt and a preparation method thereof according to claim 2, characterized in that: The filter layer (3) comprises a pre-filter (301), a main filter (302) and a fine filter (303), and the pre-filter (301), the main filter (302) and the fine filter (303) are stacked in sequence.

4. The multifunctional composite ultra-fine cotton needle felt and its preparation method according to claim 3, characterized in that: The pre-filter (301), the main filter (302) and the fine filter (303) are made of membrane materials with different finenesses, and the pre-filter (301), the main filter (302) and the fine filter (303) are connected by a needle puncture method.

5. The multifunctional composite ultra-fine cotton needle felt and its preparation method according to claim 2, characterized in that: The heat insulation layer (4) comprises an outer heat insulation film (401) and an inner heat insulation film (402), and the outer heat insulation film (401) and the inner heat insulation film (402) are made of ceramic fiber material.

6. The multifunctional composite ultra-fine cotton needle felt and the preparation method thereof according to claim 5, characterized in that: The outer thermal insulation film (401) and the inner thermal insulation film (402) are connected by a needle punching method.

7. The multifunctional composite ultra-fine cotton needle felt and its preparation method according to claim 2, characterized in that: The sound absorbing layer (5) comprises a first sound insulation cotton (501), a second sound insulation cotton (502) and a third sound insulation cotton (503), wherein the first sound insulation cotton (501), the second sound insulation cotton (502) and the third sound insulation cotton (503) are made of polypropylene fiber materials with different pore sizes.

8. The multifunctional composite ultra-fine cotton needle felt and the preparation method thereof according to claim 7, characterized in that: The No. 1 sound insulation cotton (501), the No. 2 sound insulation cotton (502) and the No. 3 sound insulation cotton (503) are connected by a needle punching method.

9. The multifunctional composite ultra-fine cotton needle felt and the preparation method thereof according to claim 1, characterized in that: The following steps are involved: Step 1: First, select suitable fiber raw materials according to product requirements, and mix different types of fiber raw materials in a certain proportion. For example, for filtration, ultra-fine glass fiber can be used, and an appropriate amount of environmentally friendly adhesive (water-based polyurethane or acrylic emulsion) can be added. For thermal insulation, ceramic fiber can be used, and an appropriate amount of aerogel material (silicon dioxide aerogel) can be added. For sound absorption, polypropylene fiber can be used, and low-melting-point polypropylene fiber can be added to 0.44-0.666tex polypropylene fiber, and a certain amount of porous material (perlite, vermiculite, etc.) can be mixed into the raw material. Step 2: Secondly, the fiber raw materials are preliminarily opened to remove large fiber clumps, make the fibers loose, and fully mix the opened fiber raw materials to ensure that various fiber components are evenly distributed in the needle felt; Step 3: Then, the mixed fibers are combed by a combing machine to arrange the fibers in a relatively neat state and form a fiber web. The combed fiber web is sent to a web laying machine for multi-layer stacking to form a fiber stacking structure with a certain thickness and uniformity. Step 4: Next, the laid-up fiber stacking structure is fed into a needle punching machine. Through the up and down movement of the needle punching needle, each fiber layer is repeatedly punctured. The needle punching needle weaves the fibers in each layer of material together to form a stable composite felt-like structure. Step 5: Further, the needle-punched felt after needle-punching reinforcement is subjected to heat setting treatment and surface treatment of the needle-punched felt, such as coating with a filter coating, a heat-insulating coating and a sound-absorbing coating; Step 6: Finally, the quality of the needle-punched felt is inspected, and the qualified needle-punched felt is packaged and stored or shipped.

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