Novel film-free bulletproof non-woven fabric manufacturing process and equipment

Abstract

The invention belongs to the technical field of production of non-woven cloth, and particularly relates to a production process and production equipment of non-film bulletproof cloth applied to manufacturing bulletproof inserting plates. Aiming at the defects in the prior art, the film-free bulletproof fabric production process provided by the invention comprises the following steps: (1) cleaning, carding, drying and flattening fibers; (2) flatly laminating the flattened tow sheet and a flat hot melt adhesive film on a laminating roller; (3) fully compounding the laminated fiber sheet and a hot melting mold on a hot pressing roller; (4) cooling the composite sheet fused with the hot melt film, and then calendaring and shaping by using a cold roll; (5) automatically cutting the cold-rolled single-layer film-free non-woven cloth into square blocks; and (6) overlapping the cut single-layer non-woven cloth according to 0 degree / 90 degrees, and pressing according to the required layer number of the plugboard. According to the production process and equipment, a film-free process route is adopted, the yarn content of the non-woven cloth is increased, and the bulletproof performance can be remarkably improved; no film restriction exists, and the pressing process is simpler; the film-free single-layer non-woven cloth is cut and then directly enters the insertion plate pressing process, so that the production process of 2UD non-woven cloth is reduced, the efficiency is improved, and the cost is reduced; through the operation, the purposes of removing the film in the plugboard (helmet), improving the yarn content, increasing the adhesive force, preventing the layer from falling off, improving the performance, improving the efficiency and reducing the cost are achieved.

Description

Technical Field

[0001] The invention belongs to the field of bulletproof composite materials, and in particular relates to a production process and equipment for a filmless bulletproof cloth used for making a bulletproof insert. Background Art

[0002] High-performance fiber bulletproof non-woven fabric is made of high-performance fiber as the base material, such as ultra-high molecular weight polyethylene fiber and aramid fiber, which is evenly laid by advanced high-tech equipment, impregnated with high-strength elastomer resin and bonded with film, and then orthogonally laminated. It has excellent properties such as soft touch, low density, abrasion resistance, impact resistance, and strong cutting toughness. The product is widely used in soft bulletproof vests, lightweight bulletproof helmets, lightweight bulletproof armor plates, stab-proof and cut-proof clothing linings and special public riot control facilities. It is the world's strongest and lightest bulletproof material.

[0003] In the prior art, bulletproof non-woven fabrics are mainly produced in two categories: 2UD and 4UD. Bulletproof plates and bulletproof helmets are made of 2UD or 4UD non-woven fabrics after cutting, multi-layer lamination and hot pressing. Both 2UD and 4UD are made of dipped unidirectional sheets as the base material through 0° / 90° orthogonal lamination and hot pressing. However, the production process of dipped unidirectional sheets is to flatten the tows and bond them with resin and film. In this way, the bulletproof plates and bulletproof helmets produced through subsequent processes will contain many layers of PE film, and the PE film not only has no bulletproof performance, but also increases the weight of the finished product. Moreover, the bonding mechanism between the fiber and the film is different from the bonding mechanism between the fibers, so it is difficult to find a suitable glue that takes into account their bonding strength at the same time, resulting in a more prominent delamination phenomenon of bulletproof plates and bulletproof helmets. Therefore, the presence of the film seriously restricts the overall performance of the downstream finished products of the bulletproof non-woven fabric.

[0004] The Chinese invention patent "CN102535021A A continuous non-woven fabric and two-layer or more cross fabric production process" discloses a process for continuously producing two or more layers of non-woven fabric, which discloses the following technical solution for making two layers of non-woven fabric: first produce a single layer of non-woven fabric, and then automatically or manually cut it into 1600 mm long non-woven fabric blocks, the length and width of the non-woven fabric blocks are both 1600 mm, manually rotated 90 degrees, and manually fed into the production line to form a 2UD product with the flattened and dipped fiber tow. The basic process principle is to replace the film with a non-woven fabric block to achieve the purpose of reducing one layer of film.

[0005] The advantage of the above technical solution is that it can continuously generate double-layer weftless cloth; and in the production process of the double-layer weftless cloth, since the single-layer weftless cloth is used to replace the PE film used in the original single-layer weftless cloth production, a double-layer weftless cloth composed of two layers of fiber and one layer of PE film can be finally obtained, which can reduce the content of PE film and increase the fiber content (yarn content) in the weftless cloth product.

[0006] However, the above process only reduces the number of film layers and does not completely remove the film.

[0007] The film-free and weft-free cloth production process disclosed in the Chinese invention patent "CN106696436A UD weft-free cloth film-free continuous production line" adopts the method of applying the fiber bundle to the silicone oil paper after dipping, and then peeling off the silicone oil paper after drying. In this method, the silicone oil paper is used as a consumable material, which is too expensive. In addition, when peeling, the fiber dipping sheet suddenly loses the silicone oil paper and is easy to fall apart, which has a great impact on the next process. Summary of the invention

[0008] In view of the defects in the prior art, the present invention provides a novel filmless bulletproof weftless cloth production process, the purpose of which is to improve the existing weftless cloth production process, remove the 2UD production process, 1UD production does not use film and silicone oil paper, the filament bundle is directly thermally compounded with a specific adhesive film, and then cold rolled to increase the strength, and after cutting, it is directly used for pressing bulletproof inserts and bulletproof helmets, thereby improving the performance of bulletproof inserts and bulletproof helmets.

[0009] A production process of a double-layer non-woven fabric comprises the following steps: (1) Production of non-film single-layer non-weft fabric; (2) Cut the non-filmed single-layer non-weft fabric into square blocks according to the width and overlap them orthogonally at 0° and 90°; (3) The laminated single-layer non-woven fabric pieces directly enter the plug plate or helmet pressing process, and are cut and pressed according to the required size.

[0010] Preferably, step (1) specifically comprises the following steps: combing, cleaning, drying, and spreading the filaments, and then laminating them with a hot melt adhesive film, and then heating them in a heating zone, hot pressing and laminating them with rollers, cold rolling and shaping, and cutting them to obtain a single-layer non-woven fabric block; Preferably, step (1) specifically includes the following steps: (1.1) The filament bundle is combed, cleaned, dried, and spread, and then laminated with a hot melt adhesive film, and hot-pressed on a pair of rollers. Before the hot-pressed lamination, the adhesive film is melted in a heating zone and immersed in the filament bundle. During the lamination process, the hot melt adhesive film and the fiber bundle are fully fused by hot pressing on the pair of rollers; (1.2) After the filament bundle and the hot-melt film are compounded, they are cold-rolled by cold rollers for shaping and cut to obtain a single-layer non-woven cloth.

[0011] Preferably, in step (2), the single-layer non-woven fabric pieces are in the form of squares with the production width as the side length, and are orthogonally overlapped at 0° and 90°.

[0012] Preferably, the combing process of the filament bundle is carried out in a cleaning tank and cleaned simultaneously; preferably, after combing, cleaning and drying, the single bundle of fibers in the filament bundle is flattened to 3-5 mm, and more preferably, flattened to 4-4.5 mm.

[0013] Preferably, the combing roller is a cylindrical corrugated roller, and the driving roller is a heating roller. A hot air device is provided below the driving roller and a dehumidifying device is provided above the driving roller.

[0014] Preferably, the surfaces of the hot pressing roller and the cold rolling roller are sprayed with Teflon.

[0015] In step (2), the cutting is online automatic fixed-length cutting.

[0016] Preferably, there is a cooling plate in front of the cold pressing roller, and cooling water circulates inside the cooling plate and the cold pressing roller. The hot pressed composite unidirectional non-woven fabric is first quickly cooled on the upper surface of the cooling plate, and then enters the cold rolling roller for cold pressing.

[0017] The process scheme provided by the present invention has the following beneficial effects: 1. The production process of the present invention adopts a film-free process route, which increases the yarn content of the weftless cloth and can significantly improve the anti-ballistic performance; the pressing process is easier to operate without the restriction of the film, the layers are firmly bonded to each other, and the delamination phenomenon is effectively reduced; the film-free single-layer weftless cloth is cut and directly enters the process of pressing the insert (helmet), which reduces the production process of 2UD, improves efficiency and reduces costs; through the above operations, the purpose of removing the film in the insert (helmet), increasing the yarn content, preventing delamination, improving performance, improving efficiency and reducing costs is achieved.

[0018] 2. In the preferred embodiment, the combing roller 101 is immersed in a cleaning tank, and the surface of the fiber bundle becomes cleaner after being cleaned in the cleaning tank, and becomes fluffy and easy to unfold after drying. Taking 800D ultra-high molecular weight polyethylene fiber as an example, a single bundle of fibers that has not been cleaned and dried can be flattened to a width of about 3 mm, and can be flattened to about 4.5 mm after cleaning and drying, which makes it easier to make a non-weft cloth with a lower surface density. After the surface of the tow is cleaned by the cleaning tank, the tow is easier to glue, and a small amount of hot melt film can bond the fibers together, effectively reducing the glue content of the non-weft cloth. According to experimental comparison, after cleaning and drying, the non-weft cloth product can reduce the glue content by about 2% on the basis of the process without cleaning and drying. Adding a cold rolling shaping process can make the non-film non-weft cloth stable and not fall apart.

[0019] 3. In the preferred embodiment of the present invention, the combination of the heating zone and the hot-pressing composite roller, and the combination of the cooling plate and the cold rolling roller are adopted, which is beneficial to speeding up and increasing the production capacity of the production line.

[0020] Obviously, according to the above contents of the present invention, in accordance with common technical knowledge and customary means in the art, without departing from the above basic technical ideas of the present invention, other various forms of modification, replacement or change may be made.

[0021] The above contents of the present invention are further described in detail below through specific implementation methods in the form of embodiments. However, this should not be understood as the scope of the above subject matter of the present invention being limited to the following examples. All technologies realized based on the above contents of the present invention belong to the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a schematic diagram of the production process of the filmless bulletproof fabric according to Example 1 of the present invention; Among them: 001, fiber tow, 002, hot melt adhesive film, 003, flattened sheet, 004, dipped composite sheet, 005, single-layer non-weft cloth.

[0023] 10. Dehumidification device, 11. Hot air device.

[0024] 100. Combing roller one, 101. Combing roller two, 102. Combing roller three, 103. Cleaning tank, 104. Transmission one, 105. Transmission two, 106. Transmission three, 107. Transmission four, 108. Transmission five, 109. Transmission six, 110. Wire spreading roller one, 111. Wire spreading roller two, 112. Wire spreading roller three, 113. Laminating roller, 114. Hot melt adhesive film unwinding shaft, 115. Flattening roller one, 116. Flattening roller two, 117. Laminating pressure roller, 118. Hot pressing lower roller, 119. Hot pressing upper roller, 120. Cooling plate, 121. Cold rolling lower roller, 122. Cold rolling upper roller, 123. Guide roller, 124. Cloth storage roller, 125. Cloth guide pressure roller, 126. Cloth guide roller, 127. Automatic cutting machine.

[0025] Figure 2 This is a schematic diagram of the combing and cleaning production process of the present invention; Among them: 100, combing roller 1, 101, combing roller 2, 102, combing roller 3, 103, cleaning tank, Implementation

[0026] It should be particularly noted that in the embodiments of the present invention, the process methods not further specified can be carried out according to the relevant methods in the production process of weftless cloth in the prior art, and the structures of the devices not further specified can be set according to the structures of the relevant devices in the prior art.

[0027] In the embodiments of the present invention, the "front end" of a device or structure refers to the direction in which the tow, sheet, or hot melt adhesive film is input into the device or structure. The "rear end" of a device or structure refers to the direction in which the tow, sheet, or hot melt adhesive film is output from the device or structure.

[0028] A new type of film-free bulletproof non-woven fabric production process, the main processes include cleaning, combing, drying, pulling, yarn spreading, film spreading, laminating, hot pressing, cold rolling, cutting, etc. Figure 1 The fiber bundle 001 shown in the figure is introduced from above the warping roller 100, passes under the warping roller 2 102 and then is led out from the warping roller 3 102, and then passes through the transmission 1, transmission 2, transmission 3, transmission 4, transmission 5 and transmission 6 in sequence to enter the wire spreading system, enters from below the wire spreading roller 1 110 of the wire spreading system, passes above the wire spreading roller 2 111 and below the wire spreading roller 3 112 to form a thin sheet 003 that is fully and evenly flattened, and then is led out. The hot melt adhesive film 002 introduced above the laminating roller 113 and introduced through the laminating pressure roller 117 is laminated on the laminating roller 113. The laminating roller 113 is a heating roller. The hot melt adhesive film is heated at the laminating roller 113 and initially becomes sticky and bonds with the fiber 003. After laminating, the composite sheet is hot-pressed and compounded by the hot pressing upper roller 119 and the hot pressing lower roller 118 to form a dipped composite sheet 004. In this process, the hot melt adhesive film 002 is fully melted on the surface of the hot pressing upper roller 119 and immersed in the fiber. The dipped composite sheet 004 is quickly cooled by the cooling plate 120, and is cold-rolled by the cold rolling rollers 121 and 122. The cold-rolled single-layer non-weft cloth 005 is led out from the guide roller 123 and the cloth storage roller 124 to the automatic cutting machine 127 for automatic cutting into sheets.

[0029] like Figure 1 As shown, in this embodiment, a cleaning tank 103 is provided below the combing rollers 100, 101, and 102, and the height of the cleaning tank can be adjusted up and down to control the fiber immersion depth, so as to be suitable for cleaning fibers of different properties; the driving rollers 104, 105, 106, 107, 108, and 109 are heating rollers, and the heating temperature can be adjusted from room temperature to 90°C, and are used to dry the fibers after cleaning. A dehumidification device is provided above the driving rollers for quickly extracting the water vapor from the heating and drying, and a hot air device is provided below the driving rollers to blow hot air to the fibers to quickly dry the fibers; the spreading rollers 1, 2, and 3 are arranged in sequence behind the driving roller 6, and the spreading roller 1 is a polygonal roller, which is conducive to combing and flattening the fibers; the flattening sheet 003 is bonded with the flattened hot melt mold 002 on the bonding roller 113, and the bonding roller 113 is a heating roller. The upper hot-pressing roller and the lower hot-pressing roller are installed behind the laminating roller. The upper hot-pressing roller is a fixed roller with Teflon sprayed on the surface, and the lower hot-pressing roller is a rubber roller with hydraulic control lifting. As a preferred solution, this embodiment further includes a cleaning tank, and the combing roller is installed directly above the cleaning tank. Figure 2As shown, the combing roller 101 is immersed in the liquid in the cleaning tank. The height of the cleaning tank can be adjusted up and down to control the depth of the combing roller 101 immersed in the liquid. After the tow 001 is cleaned in the cleaning tank, the surface becomes cleaner, and the tow is fluffy and easy to unfold. Taking 800D ultra-high molecular weight polyethylene fiber as an example, a single bundle of fibers that has not been cleaned can be flattened to a width of about 3.5mm, and can be flattened to about 4.5mm after cleaning, which makes it easier to make a non-woven fabric with a lower surface density. After the surface of the tow is cleaned by the cleaning tank, the tow is easier to glue, and a small amount of glue can bond the fibers together, effectively reducing the glue content of the non-woven fabric product.

[0030] As a preferred solution, the combing rollers 101 and 102 are cylindrical corrugated rollers, and semi-cylinders with a diameter of about 2.5 cm are evenly distributed on the rollers. Figure 1 The fiber path of the preferred solution shown must ensure that the fiber can still contact the roller surface to be stressed and spread after passing through the semi-cylinder. Bearings and fixing wrenches are installed at both ends of the combing rollers 100, 101, and 102, and they can be controlled to rotate freely or be fixed according to the combing conditions.

Claims

1. A filmless bulletproof cloth production process and production line equipment for making bulletproof inserts, characterized in that: The steps include: (1) Warping, cleaning, drying and flattening of fiber tows; (2) Flattening the flattened tow sheet and the flat hot melt adhesive film on a laminating roller; (3) The bonded fiber sheet and the hot melt mold are fully compounded on the hot pressing roller; (4) After the composite sheet fused with the hot melt film is cooled, it is calendered and shaped with a cold roller; (5) The single-layer non-film and non-weft fabric after cold rolling is automatically cut into square blocks; (6) Overlap the cut single-layer non-woven fabric at 0° / 90° and press it according to the number of layers required for the plug board.

2. The filmless bulletproof cloth production process and production line equipment for making bulletproof inserts according to claim 1, characterized in that: Step (1) specifically comprises the following steps: combing, cleaning, drying and flattening the filament bundle to obtain a flattened sheet; Preferably, step (1) specifically includes the following steps: (1.1) The filament bundle is combed, cleaned, dried and flattened, wherein the combing is achieved by a combing roller installed above a cleaning tank, and the fibers are cleaned during the combing process; (1.2) After combing and cleaning, the filament bundles need to be quickly dried on a transmission roller. The transmission roller is a heating roller. There is a hot air device under the transmission roller and a dehumidification device above the transmission roller.

3. The filmless bulletproof cloth production process and production line equipment for making bulletproof inserts according to claim 1, characterized in that: The combing process of the tow is carried out in a cleaning tank; preferably, after being cleaned, combed and dried, the single bundle of fibers in the tow is easy to unfold and can be flattened to 4-5 mm; more preferably, it is flattened to 4.5-5 mm.

4. The filmless bulletproof cloth production process and production line equipment for making bulletproof inserts according to claim 1, characterized in that: In step (2), the filament sheet and the hot melt adhesive film are laminated on a laminating roller, and the laminating roller is a heating roller with controllable temperature.

5. The filmless bulletproof cloth production process and production line equipment for making bulletproof inserts according to claim 1, characterized in that: There is a cooling plate in front of the cold pressing roller, and cooling water circulates inside the cooling plate and the cold pressing roller. The hot pressed composite unidirectional non-woven fabric is first quickly cooled on the upper surface of the cooling plate, and then enters the cold rolling roller for cold pressing.

6. The filmless bulletproof cloth production process and production line equipment for making bulletproof inserts according to claim 1, characterized in that: The combing rollers 101 and 102 are cylindrical corrugated rollers, and semi-cylinders with a diameter of about 2.5 cm are evenly distributed on the rollers. The fiber path must ensure that the fiber can still contact the roller surface to be stressed and spread after passing through the semi-cylinders.

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