Composite nonwoven material and preparation method therefor, and device for preparing composite nonwoven material

Abstract

The present application relates to the technical field of nonwoven materials, and in particular to a composite nonwoven material and a preparation method therefor, and a device for preparing the composite nonwoven material. According to the present application, the provision of upper and lower fiber web layers is conducive to subsequent thermal bonding, thereby greatly improving the overall strength of a dry / wet fiber web, increasing tensile strength, reducing the occurrence of structural tearing, and greatly reducing the linting rate during use. In the present application, mixed spray layers are formed by blending cellulosic fibers and polymer filaments, wherein the cellulosic fibers impart excellent hydrophilic performance and softness to the nonwoven material; and an absorbent core layer greatly improves the water absorption rate and water absorption capacity of the material. The composite nonwoven material provided by the present application has good mechanical properties, excellent water absorption and wear resistance, and relatively low linting properties.

Description

Composite nonwoven material, preparation method thereof, and equipment for preparing composite nonwoven material

[0001] This application claims priority to Chinese patent application No. CN202410355928.5, filed with the Patent Office of China on March 27, 2024, entitled "A composite nonwoven material, a method for preparing the same, and an apparatus for preparing the composite nonwoven material," the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present application belongs to the technical field of nonwoven materials, and specifically relates to a composite nonwoven material, a preparation method thereof, and equipment for preparing the composite nonwoven material. Background Art

[0003] Nonwoven fabrics are increasingly used in various fields due to their short production process, high production speed, low cost, and wide range of applicable fibers. Among them, nonwoven wiping materials are used the most, and their use will continue to rise in the coming decades. In today's life, from baby care to adult personal care, from facial cleansing wipes to skin care masks, from household wiping to car interior cleaning, from mobile phone cleaning to computer screen dust removal, and even to the cleaning of machinery and precision instruments, wiping materials are "present" everywhere. However, existing nonwoven materials have problems such as poor water absorption, poor wear resistance, low strength, and shedding (linting), which greatly reduce their user experience.

[0004] Summary of the Invention

[0005] In view of this, the present application provides a composite nonwoven material and a preparation method thereof, as well as an apparatus for preparing the composite nonwoven material. The composite nonwoven material provided in the present application has good mechanical properties, excellent water absorption and wear resistance, and low linting performance.

[0006] In order to solve the above technical problems, the present application provides a composite nonwoven material, comprising a layer structure with the following mass percentages:

[0007] The first fiber web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer and the second fiber web layer are stacked in sequence; the first mixed spray layer and the second mixed spray layer independently comprise cellulose fibers and polymer filaments;

[0008] The first fiber web layer and the second fiber web layer are respectively polymer filaments.

[0009] Preferably, the polymer filaments in the first fiber web layer and the second fiber web layer have a length greater than 5 cm and a diameter of 0.1 to 30 μm.

[0010] Preferably, the first fiber web layer and the second fiber web layer independently further comprise one or more of functional masterbatch, hydrophilic additive, hydrophilic softener, essential oil and mosquito repellent additive.

[0011] Preferably, the lengths of the cellulose fibers in the first spray-mixed layer and the second spray-mixed layer are independently 0.5 to 8 mm.

[0012] Preferably, the mass ratio of the cellulose fibers to the polymer filaments in the first spray-mixed layer and the second spray-mixed layer is independently 10-90:9.8-70.

[0013] Preferably, the absorbent core layer comprises one or more of a polymer water-absorbent resin, cellulose fibers and a polymer gel material.

[0014] The present application also provides an apparatus for preparing the composite nonwoven material described in the above technical solution, comprising a web-forming curtain 30, an air suction device 31, and a first fiber web system, a first spray-mixing molding system, an absorbent core system 13, a second spray-mixing molding system, and a second fiber web system connected in series in sequence above the web-forming curtain 30;

[0015] The first fiber web system includes a first meltblown unit or a first spunbond unit; the first mixed spray molding system includes a third meltblown unit, a first opening unit, a fourth meltblown unit and a first mixed spray molding box 09; the second mixed spray molding system includes a fifth meltblown unit, a second opening unit, a sixth meltblown unit and a second mixed spray molding box 19; the second fiber web system includes a second meltblown unit or a second spunbond unit.

[0016] Preferably, it also includes a thermal bonding system 32, a fiber web quality detection system, a finishing system 36 and a packaging system 37; the fiber web quality detection system includes a metal detection unit 33, a fiber web weight detection unit 34 and a fiber web defect detection unit 35.

[0017] Preferably, the first meltblowing unit includes a first spinning manifold 01, a first screw extruder 02, a first feeding device 03 and a first spinneret 57.

[0018] Preferably, the first spunbond unit includes a first spunbond feeding device 38 , a first spunbond screw extruder 39 , a first spunbond spinning assembly 40 , a first spunbond cooling device 41 , a first spunbond drawing device 42 and a first spunbond filament separator 43 .

[0019] Preferably, the third meltblowing unit includes a second feeding device 04, a second screw extruder 05, a third spinning manifold 06 and a third spinneret 58.

[0020] Preferably, the first opening unit comprises a first opening device 07 and a first multi-row CD injector 08;

[0021] Preferably, the fourth meltblowing unit includes a fourth feeding device 10, a fourth screw extruder 11, a fourth spinning manifold 12 and a fourth spinneret 59.

[0022] Preferably, the fifth meltblowing unit includes a fifth feeding device 14 , a fifth screw extruder 15 , a fifth spinning manifold 16 and a fifth spinneret 60 .

[0023] Preferably, the second opening unit comprises a second opening device 17 and a second multi-row CD injector 18;

[0024] Preferably, the sixth meltblowing unit includes a sixth feeding device 20, a sixth screw extruder 21, a sixth spinning manifold 22 and a sixth spinneret 61.

[0025] Preferably, the second meltblowing unit includes a second feeding device 23, a second screw extruder 24, a second spinning manifold 25 and a second spinneret 62.

[0026] Preferably, the second spunbond unit includes a second spunbond feeding device 51 , a second spunbond screw extruder 52 , a second spunbond spinning assembly 53 , a second spunbond cooling device 54 , a second spunbond drawing device 55 and a second spunbond separator 56 .

[0027] Preferably, the first melt-blowing unit further includes a first cooling spray system 26 .

[0028] Preferably, the outlet of the first spray-mixing molding box 09 is provided with a second cooling spray system 27 , and the outlet of the second spray-mixing molding box 19 is provided with a third cooling spray system 28 .

[0029] Preferably, the second melt-blowing unit further includes a fourth cooling spray system 29 .

[0030] The present application also provides a method for preparing the composite nonwoven material described in the above technical solution using the equipment described in the above technical solution, comprising the following steps:

[0031] The first polymer is melted and sprayed onto the web curtain 30 by using the first web system to obtain a first web layer;

[0032] The second polymer is melted by the third melt-blowing unit and the fourth melt-blowing unit, and the first cellulose fiber raw material is crushed by the first opening unit; the melted second polymer and the crushed first cellulose fiber raw material are conveyed to the first mixing and spraying forming box 09 for mixing and then sprayed onto the surface of the first fiber web layer to form a first mixing and spraying layer;

[0033] Spraying the water-absorbing material onto the surface of the first mixed spray layer through the absorbent core system 13 to form an absorbent core layer;

[0034] The third polymer is melted by the fifth melt-blowing unit and the sixth melt-blowing unit, and the second cellulose fiber raw material is crushed by the second opening unit; the melted third polymer and the crushed second cellulose fiber raw material are conveyed to the second spray-mixing box 19 for mixing and then sprayed onto the surface of the absorbent core layer to form a second spray-mixing layer;

[0035] The fourth polymer is melted by the second fiber web system and then sprayed onto the surface of the second mixed spray layer to obtain the second fiber web layer.

[0036] Preferably, after forming the second fiber web layer, the method further comprises: sequentially collecting, finishing and packaging the product comprising the first fiber web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer and the second fiber web layer;

[0037] The post-finishing comprises one or more of embossing, printing, perforating, texturing, surface treatment, thermal bonding, ultrasonic bonding, cutting, stacking and wet wipe processing.

[0038] The present application provides a composite nonwoven material, comprising a layer structure with the following mass percentages: 0.2-20% first web layer, 20-50% first mixed spray layer, 0-10% absorbent core layer, 20-50% second mixed spray layer and 0.2-20% second web layer; the first web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer and the second web layer are stacked in sequence; the first mixed spray layer and the second mixed spray layer independently comprise cellulose fibers and polymer filaments; the first web layer and the second web layer are respectively polymer filaments. The provision of the upper and lower web layers in the present application is conducive to subsequent thermal bonding, can greatly improve the overall strength of the dry / wet web, increase tensile strength and reduce the occurrence of structural tearing, and greatly reduce the linting rate during use by consumers. In the present application, the mixed spray layer of cellulose fibers and polymer filaments uses cellulose fibers to impart excellent hydrophilic and soft properties to the nonwoven material; the absorbent core layer greatly improves the water absorption rate and water absorption capacity of the material. The composite nonwoven material provided by the present application has good mechanical properties, excellent water absorption and wear resistance, and low linting performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 is a schematic diagram of the structures of a "slit air knife" meltblown spinneret and a "coaxial" meltblown spinneret;

[0040] FIG2 is a schematic diagram of the cross-sectional structure of a multi-row hole spinneret;

[0041] FIG3 is a front view of a multi-row spinneret;

[0042] FIG4 is a schematic diagram of the cross-sectional structure of spinnerets in a multi-row spinneret;

[0043] FIG5 is a schematic structural diagram of the device used in Example 1;

[0044] FIG6 is a schematic structural diagram of the device used in Example 2;

[0045] FIG7 is a schematic structural diagram of the device used in Example 3;

[0046] FIG8 is a schematic structural diagram of the equipment used in Example 4;

[0047] FIG9 is a schematic structural diagram of the device used in Example 5;

[0048] FIG10 is a schematic diagram of the structure of the mixed spray layer in the disinfectant wet wipes prepared in Example 2;

[0049] Figure 11 is a schematic diagram of the three-dimensional structure of the disinfectant wet wipes prepared in Example 2;

[0050] FIG12 is a schematic diagram of the cross-sectional structure of the disinfectant wipes prepared in Example 2;

[0051] FIG13 is a SEM image of the mixed spray layer of the breast pad prepared in Example 1;

[0052] FIG14 is a SEM image of the surface of the first web layer of the breast pad prepared in Example 1;

[0053] FIG15 is a SEM image of a cross section of a breast pad prepared in Example 1;

[0054] FIG16 is a SEM image of PLA on the surface of the facial wipe prepared in Example 4;

[0055] In Figures 1 to 14, 01 is the first spinning manifold, 02 is the first screw extruder, 03 is the first feeding device, 04 is the second feeding device, 05 is the second screw extruder, 06 is the third spinning manifold, 07 is the first opening device, 08 is the first multi-row hole CD ejector, 09 is the first spray-mixing molding box, 10 is the fourth feeding device, 11 is the fourth screw extruder, 12 is the fourth spinning manifold, 13 is the core device, 14 is the fifth feeding device, 15 is the fifth screw extruder, 16 is the fifth spinning manifold, 17 is the second opening device, 18 is the second multi-row hole CD ejector, 19 is the second spray-mixing molding box, 20 is the sixth feeding device, 21 is the sixth screw extruder, extruder, 22 is the sixth spinning beam, 23 is the second feeding device, 24 is the second screw extruder, 25 is the second spinning beam, 26 is the first cooling spray system, 27 is the second cooling spray system, 28 is the third cooling spray system, 29 is the fourth cooling spray system, 30 is the web curtain, 31 is the suction device, 32 is the thermal bonding system, 33 is the metal detection system, 34 is the fiber web weight detection system, 35 is the fiber web defect detection system, 36 is the finishing equipment, 37 is the packaging system, 38 is the first spunbond feeding device, 39 is the first spunbond screw extruder, 40 is the first spunbond spinning assembly, 41 is the first spunbond cooling device, 42 is the first spunbond traction device , 43 is the first spunbond separator, 44 is the spinneret as a whole, 45 is the spinneret hole, 46 is the air drafting hole, 47 is the mixed spray structure, 48 is cellulose staple fiber, 49 is polymer filament, 50 is SAP, 51 is the second spunbond feeding device, 52 is the second spunbond screw extruder, 53 is the second spunbond spinning assembly, 54 is the second spunbond cooling device, 55 is the second spunbond drawing device, 56 is the second spunbond separator, 57 is the first spinneret, 58 is the third spinneret, 59 is the fourth spinneret, 60 is the fifth spinneret, 61 is the sixth spinneret, 62 is the second spinneret, 68 is the spinneret hole of the "coaxial" meltblown spinneret, 69 is the "coaxial meltblown" spinneret The air flow stretching hole of the filament plate, 70 is the spinneret hole of the "slit air knife" melt-blown spinneret, 71 is the air flow stretching hole of the "slit air knife" melt-blown spinneret, 72 is the seventh spinning box, 73 is the seventh screw extruder, 74 is the seventh feeding device, 75 is the seventh spinneret; 76 is the fifth cooling spray system, 77 is the eighth spinning box, 78 is the eighth screw extruder, 79 is the eighth feeding device, 80 is the eighth spinneret; 81 is the sixth cooling spray system, 82 is the third spunbond feeding device, 83 is the third spunbond screw extruder, 84 is the third spunbond spinning assembly, 85 is the third spunbond cooling device, 86 is the third spunbond traction device, and 87 is the third spunbond separator. DETAILED DESCRIPTION

[0056] The present application provides a composite nonwoven material comprising a layer structure having the following mass percentages:

[0057] The first fiber web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer and the second fiber web layer are stacked in sequence.

[0058] The composite nonwoven material provided herein comprises, by weight percentage, 0.2 to 20% of a first web layer, preferably 0.5 to 13%, and more preferably 1 to 10%. In the present application, the first web layer comprises polymer filaments, the raw material of which is preferably a thermoplastic polymer and / or a degradable polymer, more preferably a thermoplastic polymer. In the present application, the thermoplastic polymer preferably comprises one or more of polyolefins, polypropylene, polyethylene, polyester, polyhydroxyalkanoates, and polyhydroxybutyrates, more preferably one of polyolefins, polypropylene, polyethylene, polyester, polyhydroxyalkanoates, and polyhydroxybutyrates, and even more preferably polypropylene. In the present application, the degradable polymer preferably includes one or more of polylactic acid, polyhydroxyalkanoate, polycaprolactone, polyester amide and copolymers thereof, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives, more preferably one of polylactic acid, polyhydroxyalkanoate, polycaprolactone, polyester amide and copolymers thereof, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives. In the present application, the polymer filaments may be single-component, two-component or multi-component, and the fiber cross-section of the multi-component may be a sheath-core type, a side-by-side type, a trilobal type or a segmented type. Wherein, the bicomponent filaments are produced by a bicomponent melt spinning web forming process. The principle is that two different high molecular polymers are respectively transported to two extruders by two independent raw material output systems for heating and melting, and then enter the same spinning assembly after passing through respective melt filters, melt delivery pipes and metering pumps. The two melts are structurally combined at the spin pack outlet, forming a bicomponent melt stream. After exiting the spinneret, the melt stream is condensed in the cooling air and then entrained by the stretching airflow, stretching and thinning at a constant speed to form continuous bicomponent solid filaments, which then fall onto a forming curtain for laying. The raw materials used in these bicomponent spun-web nonwovens are primarily polypropylene (PP), polyester (PET), polyethylene (PE), and polyamide (PA). Common composite compositions include PE / PP, PE / PET, PP / PET, and PA / PET. Core-sheath fibers are soft on the outside and strong on the inside; parallel fibers have a natural three-dimensional crimp, resulting in a stretchy fabric; trilobal fibers offer high stiffness and excellent breathability; and orange-segment fibers are made by splitting a single fiber into 8, 16, or 32 pieces, creating ultrafine fibers. These fibers are soft and strong, and can be used in facial masks, filter media, and sound insulation. In the present application, the length of the polymer filaments is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filaments is preferably 0.1 to 30 μm, more preferably 1 to 20 μm; and the melt index of the polymer filaments is preferably 10 to 2000 g / 10 min.

[0059] In the present application, the first web layer preferably further comprises one or more of a functional masterbatch, a hydrophilic additive, a hydrophilic softener, an essential oil, and a mosquito repellent, more preferably a hydrophilic additive, a hydrophilic softener, or a mosquito repellent. The present application has no particular requirements for the specific types of the functional masterbatch, hydrophilic additive, hydrophilic softener, essential oil, and mosquito repellent; conventional materials in the art may be used. In the present application, the functional masterbatch preferably comprises a hydrophilic masterbatch, an elastic masterbatch, a reinforcing masterbatch, a degradable masterbatch, an antibacterial masterbatch, a cooling masterbatch, an antistatic masterbatch, a color masterbatch, an anti-rust masterbatch, or a curling masterbatch.

[0060] In terms of mass percentage, the composite nonwoven material provided in the present application includes 20-50% of the first spray-mixed layer, preferably 25-50%, and more preferably 40-45%. In the present application, the first spray-mixed layer includes cellulose fibers and polymer filaments. In the present application, the raw material type of the polymer filaments in the first spray-mixed layer is preferably consistent with the raw material type of the polymer filaments in the first fiber mesh layer, and no further details will be given here. In the present application, the length of the polymer filaments in the first spray-mixed layer is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filaments in the first spray-mixed layer is preferably 0.1-30 μm, more preferably 1-10 μm. In the present application, the raw material of the cellulose fibers in the first spray-mixed layer preferably includes wood pulp fibers, paper pulp fibers, coconut shell fibers, chitin fibers, seaweed fibers or viscose fibers. In the present application, the wood pulp in the wood pulp fiber is preferably sourced from oak, poplar, birch, pine, spruce or fir; the paper pulp in the paper pulp fiber is preferably sourced from straw pulp, reed pulp, sugarcane pulp, bamboo pulp, cotton pulp, hemp pulp or natural fiber rag pulp. In the present application, the method of obtaining wood pulp preferably includes chemical pulp, mechanical pulp or chemically modified mechanical pulp, more preferably chemical pulp. In the present application, the chemical pulp can impart excellent softness to non-woven materials. In the present application, the chemical pulp preferably includes caustic soda chemical pulp, sulfate chemical pulp or sulfite chemical pulp; the mechanical pulp preferably includes stone mill mechanical pulp, disc mill mechanical pulp or thermo-refined mechanical pulp;

[0061] In the present application, the length of the cellulose fibers in the first spray-mixed layer is preferably 0.5 to 8 mm, more preferably 0.5 to 3 mm, and even more preferably 0.5 to 1.5 mm; the mass ratio of cellulose fibers to polymer filaments in the first spray-mixed layer is preferably 10 to 90:9.8 to 70, more preferably 40 to 70:10 to 50, and even more preferably 40 to 70:15 to 40. In the present application, the first spray-mixed layer preferably further includes a functional masterbatch.

[0062] In terms of mass percentage, the composite nonwoven material provided in the present application includes 0-10% absorbent core layer, preferably 3-10%, and more preferably 4-8%. In the present application, the absorbent core layer preferably includes one or more of a polymer water-absorbing resin, cellulose fiber, a polymer gel material, and a solid additive, more preferably a polymer water-absorbing resin. In the present application, the polymer water-absorbing resin preferably includes polyacrylamide (PAA), sodium polyacrylate (SAP), hydrogenated starch (Starch Acrylate), polyvinyl alcohol (PVA), polyamide (PA), or superelastic polyurethane (PU), more preferably sodium polyacrylate. In the present application, the cellulose fiber preferably includes wood pulp fiber, paper pulp fiber, coconut shell fiber, chitin fiber, seaweed fiber, viscose fiber, lignin fiber, expanded graphite, or nanocellulose. In the present application, the polymer gel material preferably includes glass gel, polymer gel, or phenolic resin gel. In the present application, the solid additive preferably includes a surfactant, an odor absorbent, a temperature indicator, a wetting agent or an antibacterial agent.

[0063] In terms of mass percentage, the composite nonwoven material provided in the present application includes 20-50% of the second mixed spray layer, preferably 25-50%, and more preferably 40-45%. In the present application, the second mixed spray layer includes cellulose fibers and polymer filaments. In the present application, the raw materials for preparing the polymer filaments preferably include polyolefin polymers, polyester polymers, degradable polymers, polyamide 6 (PA6), polyester amide (PEA), polytriethylene, polyphenylene sulfide (PPS) or polyoxymethylene (POM). More preferably, it is a polyolefin polymer. In the present application, the polyolefin polymer preferably includes polypropylene (PP) or polyethylene (PE), more preferably polypropylene. In the present application, the polyester polymer preferably includes polyethylene terephthalate (PET), polybutylene terephthalate polymer (PBT), polycarbonate (PC), polytrimethylene terephthalate (PTT) or thermoplastic polyurethane (TPU). In the present application, the degradable polymer preferably includes polylactic acid (PLA), polybutylene terephthalate adipate (PBAT), polyhydroxyalkanoate (PHA), polycaprolactone (PCL) or polybutylene succinate (PBS).

[0064] In the present application, the length of the polymer filaments in the second spray-mixed layer is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filaments is preferably 0.1 to 30 μm, more preferably 1 to 10 μm. In the present application, the length of the cellulose fibers in the second spray-mixed layer is preferably 0.5 to 8 mm, preferably 0.5 to 3 mm, more preferably 0.5 to 1.5 mm; the mass ratio of cellulose fibers to polymer filaments in the second spray-mixed layer is preferably 10 to 90:9.8 to 70, more preferably 40 to 70:20 to 40. In the present application, the second spray-mixed layer preferably also includes a functional masterbatch.

[0065] The composite nonwoven material provided in the present application includes, by weight percentage, 0.2 to 20% of the second web layer, preferably 0.5 to 13%, and more preferably 1 to 10%. In the present application, the second web layer is a polymer filament, the raw material of which is preferably a thermoplastic polymer and / or a degradable polymer, more preferably a thermoplastic polymer. In the present application, the thermoplastic polymer preferably includes one or more of polyolefin, polypropylene, polyethylene, polyester, polyhydroxyalkanoate, and polyhydroxybutyrate, more preferably one of polyolefin, polypropylene, polyethylene, polyester, polyhydroxyalkanoate, and polyhydroxybutyrate, and even more preferably polypropylene. In the present application, the degradable polymer preferably includes one or more of polylactic acid, polyhydroxyalkanoate, polycaprolactone, polyester amide and copolymers thereof, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives, and more preferably one of polylactic acid, polyhydroxyalkanoate, polycaprolactone, polyester amide and copolymers thereof, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives. In the present application, the polymer filaments may be monocomponent, bicomponent or multicomponent, and the fiber cross-section of the multicomponent may be sheath-core, side-by-side, trilobal or segmented. In the present application, the length of the polymer filaments is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filaments is preferably 0.1 to 30 μm, more preferably 1 to 20 μm. In the present application, the second web layer preferably also includes one or more of a functional masterbatch, a hydrophilic additive, a hydrophilic softener, an essential oil, and a mosquito repellent, more preferably a hydrophilic additive, a hydrophilic softener, or a mosquito repellent. The present application has no special requirements for the specific types of the functional masterbatch, hydrophilic additive, hydrophilic softener, essential oil, and mosquito repellent, and conventional materials in the art may be used. In the present application, the weight of the polymer filaments in the first web layer and the second web layer may be equal or unequal. By adjusting the weight and thickness of the polymer filaments in the first web layer and the second web layer, the two surfaces of the composite nonwoven material can have different feel or surface characteristics, such as one side having a rougher or higher friction feel, while the other side has a higher smooth feel and a lower friction feel.

[0066] In the present application, the finished product prepared from the composite nonwoven material preferably includes a face towel, a disposable paper towel, a disposable bath towel, a disposable napkin, a baby wipe, an adult wipe, a cleaning wipe, a wet toilet paper, a cosmetic wipe, a floor cleaning wipe, a body cleansing wipe, a disinfecting wipe, an industrial wipe, a breast pad, or a facial wipe; more preferably, a body cleansing wipe, a disinfecting wipe, an industrial wipe, a breast pad, or a facial wipe. In the present application, when the nonwoven composite material is used as a wet wipe, the liquid component in the wet wipe preferably includes at least two of a skin conditioner, a waxy substance, a diglyceride and a triglyceride, a silicone oil, an acetylated glyceride, an emulsifier, a stabilizer, a surfactant, a colorant, a chelating agent, a sunscreen, a solubilizer, a perfume, an emulsifier, a vitamin, a viscosity modifier, and a topical analgesic. In the present application, the skin conditioner is preferably an emollient or a moisturizer; the waxy substance preferably includes petrolatum, cholesterol or a cholesterol derivative; the diglyceride and triglyceride are preferably provided by sunflower oil and / or shea butter; the silicone oil is preferably dimethicone or octyl glycol; the acetylated glyceride is preferably lanolin or a lanolin derivative; the surfactant preferably includes an anionic surfactant, an amphoteric surfactant, a cationic surfactant and a nonionic surfactant; the chelating agent is preferably tetracarboxylic acid ethylenediaminetetraacetic acid (EDTA); and the viscosity regulator is preferably xanthan gum.

[0067] In the present application, the grammage of the finished product is preferably 10 to 200 gsm, more preferably 20 to 120 gsm, and further preferably 30 to 90 gsm.

[0068] The present application also provides an apparatus for preparing the composite nonwoven material described in the above technical solution, comprising a mesh curtain 30, a suction device 31, and a first fiber mesh system, a first mixed spray molding system, an absorbent core system 13, a second mixed spray molding system, and a second fiber mesh system which are connected in series in sequence and are located above the mesh curtain 30.

[0069] As an embodiment of the present application, the first fiber web system includes a first meltblown unit or a first spunbond unit. As an embodiment of the present application, the first meltblown unit includes a first spinning manifold 01, a first screw extruder 02, a first feeding device 03 and a first spinneret 57. As an embodiment of the present application, the first spinneret 57 is a "slit air knife" meltblown spinneret or a "coaxial" meltblown spinneret. Figure 1 is a schematic structural diagram of a "slit air knife" meltblown spinneret and a "coaxial" meltblown spinneret, wherein 70 is the spinneret hole of the "slit air knife" meltblown spinneret, 71 is the airflow drafting hole of the "slit air knife" meltblown spinneret; 68 is the spinneret hole of the "coaxial" meltblown spinneret, and 69 is the airflow drafting hole of the "coaxial" meltblown spinneret. In this application, the "slit air knife" meltblown spinneret has a single row of holes; the "coaxial" meltblown spinneret has a single row of holes or multiple rows of holes, preferably 8 rows, 14 rows, or 16 rows of holes. Figure 2 is a schematic cross-sectional view of a multi-row spinneret, Figure 3 is a front view of a multi-row spinneret, and Figure 4 is a schematic cross-sectional view of the spinneret holes in a multi-row empty spinneret; 44 represents the spinneret as a whole, 45 represents the spinneret holes, and 46 represents the airflow drafting holes. In the present application, the "slit air knife" meltblown spinneret has two drafting gas streams, with the drafting gas forming an angle of approximately 30 to 70 degrees with the direction of the filament flow. When the polymer filaments leave the spinneret holes in the meltblown die, they are cooled and stretched by the air knives, and eventually bonded and fall onto the mesh curtain. In the "coaxial" meltblown spinneret, each spinneret hole is surrounded by an annular fluid release hole, and the drafting gas can form an angle of less than 10 degrees with the direction of the filament flow, so that the substantially parallel airflows coaxially stretch the polymer melt. As an embodiment of the present application, the first meltblowing unit also includes a first cooling spray system 26, which is located at the outlet of the first spinneret 57. As an embodiment of the present application, the first spunbond unit includes a first spunbond feeding device 38, a first spunbond screw extruder 39, a first spunbond spinning assembly 40, a first spunbond cooling device 41, a first spunbond drawing device 42, and a first spunbond filament separator 43. In the present application, the cooling water or additive solution is preferably sprayed and atomized through the first cooling spray system 26. In the present application, the spraying rate is preferably 0-200 L / h, more preferably 100-180 L / h, and even more preferably 120-160 L / h; the spraying pressure is preferably 0-30 bar, more preferably 5-20 bar, and even more preferably 15-20 bar. After spraying and atomizing, the sprayed material can quickly adhere to the fiber web layer and then dry.

[0070] As an embodiment of the present application, the first co-mixing and spraying forming system includes a third melt-blowing unit, a first opening unit, a fourth melt-blowing unit and a first co-mixing and spraying forming box 09. As an embodiment of the present application, the third melt-blowing unit includes a second feeding device 04, a second screw extruder 05, a third spinning box 06 and a third spinneret 58. As an embodiment of the present application, the first opening unit includes a first opening device 07 and a first multi-row hole CD injector 08. The present application preferably crushes the cellulose fiber raw material through the first opening unit. The present application preferably distributes the crushed fibers evenly to various parts through air-laying. There are two main types of air-laying methods: one is to distribute and lay the web through a CD controllable injector, and the other is to use an air-laying machine to evenly distribute and lay the web along the width direction. The air-laying machine can be a dust cage type or a flat screen type. As an embodiment of the present application, the first opening unit also includes a metal detection system, a spark detection system and a fire extinguishing system. In the present application, the metal detection system can detect whether the cellulose fibers contain heavy metals before feeding them and process and remove them in real time, because cellulose fibers often leave some residual chemical substances during the production process, such as heavy metals (lead, cadmium, mercury, arsenic), phthalates, etc.; these residual substances will not only irritate the mucous membranes, damage cell membranes, and cause allergic reactions in the human body, but may even cause cancer in severe cases. The negative impact of inferior products on the human body is extremely serious and will cause a variety of health problems. In the present application, the Mars detection system is used to detect the high temperature generated by the rapidly rotating blades during the opening process, causing the wood pulp to be ignited, and the sparks appearing in the fluff pulp dust are detected by light sensing. Once the spark signal is detected, the fire extinguishing system under the sensor will automatically spray water to extinguish the fire according to the movement trajectory of the spark.

[0071] As an embodiment of the present application, the fourth melt-blowing unit includes a fourth feeding device 10, a fourth screw extruder 11, a fourth spinning manifold 12 and a fourth spinneret 59. When the first mixed spray molding system is used to prepare the first mixed spray layer, either one or both of the third melt-blowing unit and the fourth melt-blowing unit can be started.

[0072] The present application preferably mixes the meltblown products of the third meltblown unit and the fourth meltblown unit and the cellulose fibers in the first mixed spray molding box 09 to obtain a first mixed spray layer. As an embodiment of the present application, the outlet of the first mixed spray molding box 09 is provided with a second cooling spray system 27. The present application preferably utilizes the second cooling spray system 27 to spray water or chemical auxiliary agent solution for atomization. In the present application, the spraying volume of the spray is preferably 0 to 200 L / h, and the spraying pressure is preferably 0 to 30 bar, more preferably 5 to 20 bar, and further preferably 15 to 20 bar. The present application can quickly attach the sprayed material to the first mixed spray layer and then dry it through spray atomization.

[0073] The present application preferably utilizes the absorbent core system 13 to spray out the water-absorbing material to form the absorbent core layer.

[0074] As an embodiment of the present application, the second co-blending molding system includes a fifth meltblowing unit, a second opening unit, a sixth meltblowing unit and a second co-blending molding box 19. As an embodiment of the present application, the fifth meltblowing unit includes a fifth feeding device 14, a fifth screw extruder 15, a fifth spinning manifold 16 and a fifth spinneret 60. As an embodiment of the present application, the second opening unit includes a second opening device 17 and a second multi-row hole CD injector 18. As an embodiment of the present application, the sixth meltblowing unit includes a sixth feeding device 20, a sixth screw extruder 21, a sixth spinning manifold 22 and a sixth spinneret 61. When the second co-blending molding system is used to prepare the second co-blending layer, the present application can select either or both of the fifth meltblowing unit and the sixth meltblowing unit to start.

[0075] The present application preferably mixes the meltblown products of the fifth meltblown unit and the sixth meltblown unit and the cellulose fibers in the second spray-mixing molding box 19 to obtain a second spray-mixed layer. As an embodiment of the present application, a third cooling spray system 28 is provided at the outlet of the second spray-mixing molding box 19. The present application preferably utilizes the third cooling spray system 28 to spray water or chemical auxiliary agent solution for atomization. In the present application, the spraying volume of the spray is preferably 0 to 200 L / h, and the spraying pressure is preferably 0 to 30 bar, more preferably 5 to 20 bar, and further preferably 15 to 20 bar. The present application can quickly attach the sprayed material to the second spray-mixed layer through spray atomization and then dry it.

[0076] As an embodiment of the present application, the second fiber web system includes a second meltblown unit or a second spunbond unit. As an embodiment of the present application, the second meltblown unit includes a second feeding device 23, a second screw extruder 24, a second spinning box 25 and a second spinneret 62. As an embodiment of the present application, the form of the second spinneret 62 is consistent with that of the first spinneret 57, and no further details are given here. As an embodiment of the present application, the second meltblown unit also includes a fourth cooling spray system 29, and the fourth cooling spray system 29 is located at the outlet of the second spinneret 62. As an embodiment of the present application, the second spunbond unit includes a second spunbond feeding device 51, a second spunbond screw extruder 52, a second spunbond spinning assembly 53, a second spunbond cooling device 54, a second spunbond drawing device 55 and a second spunbond separator 56.

[0077] In the present application, the cooling water or additive solution is preferably sprayed and atomized through the fourth cooling spray system 29. In the present application, the spraying rate is preferably 0-200 L / h, more preferably 100-180 L / h, and even more preferably 120-160 L / h; the spraying pressure is preferably 0-30 bar, more preferably 5-20 bar, and even more preferably 15-20 bar. After spraying and atomizing, the sprayed material can quickly adhere to the second web layer and then dry.

[0078] In the present application, the first co-jet molding system, the second co-jet molding system and the absorbent core system can be one group, two groups or three groups; the spunbond units or meltblown units in the first fiber web system, the second fiber web system, the first co-jet molding system, the second co-jet molding system and the absorbent core system are preferably 1 to 3 sets on each side, and the specific composition of the multiple sets of spunbond units is preferably the same, and the specific composition of the multiple sets of meltblown units is preferably the same. In the present application, the temperature of the spinnerets in the first fiber web system, the second fiber web system, the first co-jet molding system and the second co-jet molding system is preferably 150 to 300°C, more preferably 200 to 250°C; the effective spinning width of the spinneret is preferably 10 to 130 inches, more preferably 15 to 100 inches, and even more preferably 15 to 80 inches.

[0079] As an embodiment of the present application, the equipment for composite nonwoven materials also includes a thermal bonding system 32, a fiber web quality detection system, a finishing system 36 and a packaging system 37; the fiber web quality detection system includes a metal detection unit 33, a fiber web weight detection unit 34 and a fiber web defect detection unit 35.

[0080] The equipment provided in this application includes a quality inspection system that can quickly detect the product's weight, metal impurities and defect types, identify the specific locations of impurities and defects, and automatically remove them, thereby improving product quality, increasing production efficiency, and ultimately protecting product quality and consumer rights.

[0081] The present application also provides a method for preparing the composite nonwoven material described in the above technical solution using the equipment described in the above technical solution, comprising the following steps:

[0082] The first polymer is melted and sprayed onto the web curtain 30 by using the first web system to obtain a first web layer;

[0083] The second polymer is melted by the third melt-blowing unit and the fourth melt-blowing unit, and the first cellulose fiber raw material is crushed by the first opening unit; the melted second polymer and the crushed first cellulose fiber raw material are conveyed to the first mixing and spraying forming box 09 for mixing and then sprayed onto the surface of the first fiber web layer to form a first mixing and spraying layer;

[0084] Spraying the water-absorbing material onto the surface of the first mixed spray layer through the absorbent core system 13 to form an absorbent core layer;

[0085] The third polymer is melted by the fifth melt-blowing unit and the sixth melt-blowing unit, and the second cellulose fiber raw material is crushed by the second opening unit; the melted third polymer and the crushed second cellulose fiber raw material are conveyed to the second spray-mixing box 19 for mixing and then sprayed onto the surface of the absorbent core layer to form a second spray-mixing layer;

[0086] The fourth polymer is melted by the second fiber web system and then sprayed onto the surface of the second mixed spray layer to obtain the second fiber web layer.

[0087] The present application utilizes a first fiber web system to melt the first polymer and then spray it onto a web curtain 30 to obtain a first fiber web layer. In the present application, the hot air flow rate required by the first melt-blowing unit in the first fiber web system is preferably 0 to 6000 Nm 3 / h, more preferably 2500 to 5000 Nm 3 / h, more preferably 3000-4500Nm 3 / h; the hot air temperature is preferably 150-300°C, more preferably 190-250°C, and even more preferably 220-240°C. In the present application, the hot air flow rate per hole of the first spinneret in the first fiber web system is preferably 0-0.76 Nm 3 / h / hole, more preferably 0.31 to 0.63 Nm 3 / h / hole, more preferably 0.37 to 0.57 Nm 3 / h / hole; the output per hole of the first spinneret is preferably 0-0.52 g / min / hole, more preferably 0.1-0.5 g / min / hole, and further preferably 0.15-0.4 g / min / hole; the temperature of the first spinneret is preferably 150-300°C, more preferably 195-260°C, and further preferably 225-250°C. In the present application, the output of the first fiber web system is preferably 0-250 kg / h, more preferably 47-238 kg / h, and further preferably 71-190 kg / h. In the present application, the operating pressure of the first screw extruder in the first fiber web system is preferably 0-200 MPa, more preferably 50-100 MPa, and further preferably 60-90 MPa.

[0088] After obtaining the first fiber mesh layer, the present application melts the second polymer through the third melt-blowing unit and the fourth melt-blowing unit, and crushes the first cellulose fiber raw material through the first opening unit; the melted second polymer and the crushed first cellulose fiber raw material are transported to the first mixed spray molding box 09 for mixing and then sprayed on the surface of the first fiber mesh layer to form the first mixed spray layer. In the present application, the hot air flow rate required for the third melt-blowing unit and the fourth melt-blowing unit is preferably 0 to 10000 Nm 3 / h, more preferably 4000 to 8000 Nm 3 / h, more preferably 5000-6500Nm 3 / h; the hot air temperature is preferably 150-300 ° C, more preferably 185-245 ° C, and further preferably 225-235 ° C; the discharge rate of the third melt-blown unit and the fourth melt-blown unit system is preferably 0-450 kg / h, more preferably 83-417 kg / h, and further preferably 166-417 kg / h. In the present application, the hot air flow rate per hole of the spinneret in the third melt-blown unit and the fourth melt-blown unit is preferably 0-0.72 Nm 3 / h / hole, more preferably 0.28 to 0.58 Nm 3 / h / hole, more preferably 0.36 to 0.47 Nm 3 / h / hole; the spinneret single hole extrusion rate is preferably 0-0.54 g / min / hole, more preferably 0.1-0.5 g / min / hole, and further preferably 0.2-0.5 g / min / hole; the temperature of the spinneret is preferably 150-300°C, more preferably 185-250°C, and further preferably 210-240°C. In the present application, the working pressure of the screw extruder in the third melt-blowing unit and the fourth melt-blowing unit is preferably 0-200 MPa, more preferably 40-90 MPa, and further preferably 50-80 MPa.

[0089] In the present application, the spraying volume during the formation of the first mixed spray layer is preferably 0-200 L / h, more preferably 100-180 L / h, and further preferably 120-160 L / h; the spraying pressure is preferably 0-30 bar, more preferably 5-20 bar, and further preferably 15-20 bar.

[0090] After the first mixed spray layer is formed, the present application sprays the water-absorbing material onto the surface of the first mixed spray layer through the absorbent core system 13 to form the absorbent core layer.

[0091] After forming the absorbent core layer, the present application melts the third polymer through the fifth and sixth melt-blowing units, and pulverizes the second cellulose fiber raw material through the second opening unit. The molten third polymer and the pulverized second cellulose fiber raw material are conveyed to the second spray-mixing molding box 19 for mixing and then sprayed onto the surface of the absorbent core layer to form a second spray-mixing layer. In this application, the process conditions and parameters for forming the second spray-mixing layer are preferably similar to those for forming the first spray-mixing layer, and will not be repeated here.

[0092] After forming the second spray-coated layer, the present application utilizes a second fiber mesh system to melt the fourth polymer and spray it onto the surface of the second spray-coated layer to obtain a second fiber mesh layer. In this application, the process parameters of the second fiber mesh system are preferably referenced to those of the first fiber mesh system and will not be repeated here.

[0093] In the present application, after forming the second fiber mesh layer, the method preferably further includes: sequentially collecting, finishing, and packaging the product comprising the first fiber mesh layer, the first spray-coated layer, the absorbent core layer, the second spray-coated layer, and the second fiber mesh layer. In the present application, the collection is preferably performed using a web-forming curtain; the speed of the web-forming curtain is preferably 50 to 2000 m / min, more preferably 80 to 1650 m / min, and even more preferably 400 to 1500 m / min.

[0094] In the present application, the post-processing preferably includes one or more of embossing, printing, perforating, texturing, surface treatment, thermal bonding, ultrasonic bonding, cutting, stacking, and wet wipe processing. In the present application, the printing is preferably achieved by using the textured protrusions of a mesh curtain to form a pattern. In the present application, a thermal bonding system is preferably used to perform hot rolling shaping of dots or other geometric shapes to form a specific pattern or shape. The rollers of the thermal bonding system are preferably self-heating, and the thermal bonding area percentage is preferably 2% to 15%, more preferably 4% to 10%, and even more preferably 5% to 7%. The temperature of the hot rolling shaping in the present application is preferably 90 to 150°C, more preferably 90 to 130°C, and even more preferably 110 to 120°C; the speed is preferably 50 to 2000 m / min. In the present application, the operating pressure of the thermal bonding system is preferably 1 to 100 bar, more preferably 30 to 70 bar, and even more preferably 40 to 45 bar. In the present application, the surface treatment preferably includes chemical additive solution treatment; the method of the chemical additive solution treatment preferably includes spraying, roller coating or padding; the chemical additive used in the chemical additive solution treatment preferably includes one or more of a hydrophilic agent, a softener, a strength agent, a wetting agent, a thermochromic colorant, an adhesive, a latex and a dry strength agent. In the present application, the hydrophilic agent preferably includes polyvinyl alcohol and / or polyacrylamide; the softener preferably includes one or more of polyether-modified silicone emulsion, quaternary ammonium salt and sodium polyoxyethylene fatty alcohol ether sulfate; the strength agent preferably includes dimethylformamide and / or toluene diisocyanate; the wetting agent preferably includes fatty alcohol sulfate and / or sodium diisooctyl succinate sulfonate; the color-changing colorant preferably includes one or more of temperature-sensitive ink / dyes, thermotropic materials and display agents; the adhesive is preferably an elastic adhesive; the elastic adhesive preferably includes an ester adhesive and / or an acrylic adhesive; the ester adhesive is preferably ethylene vinyl acetate (EVA); the latex preferably includes acrylic and / or EVA; the dry strength agent preferably includes carboxymethyl cellulose and / or starch. The present application uses the finishing system 36 to perform finishing to give the material certain functionality, such as making it into functional wet wipes.

[0095] The preparation method provided in this application has low energy consumption, produces environmentally friendly materials, improves the water absorption rate, strength, and wear resistance of the product, reduces the linting rate, and gives the fabric surface beautiful patterns through the thermal bonding system, meeting consumers' dual needs for aesthetics and wiping properties.

[0096] This application utilizes multi-fiber mixed spraying technology, eliminating the need for hydroentanglement and drying steps in production. This reduces carbon emissions by 40% over the entire lifecycle of traditional base fabrics, making it a low-energy, environmentally friendly material. Its loftiness is over 30% higher than traditional spunlace fabrics, resulting in a softer feel. It also offers superior strength, low linting, a soft feel, and excellent water absorption.

[0097] In order to further illustrate the present application, the technical solutions provided in the present application are described in detail below in conjunction with the embodiments, but they should not be understood as limiting the scope of protection of the present application.

[0098] Example 1

[0099] A composite nonwoven material was prepared as a breast pad using the equipment shown in the structure of Figure 5, wherein the spinneret of the meltblowing device was a "coaxial" meltblown type; Figure 13 is an SEM image of the mixed spray layer of the breast pad, Figure 14 is an SEM image of the surface of the first fiber mesh layer of the breast pad, and Figure 15 is an SEM image of the cross-section of the breast pad, wherein 47 is the mixed spray layer structure, 48 is cellulose fiber (cellulose staple fiber), and 49 is polymer filament.

[0100] 55gsm breast pads were produced, wherein the raw materials used for the first and second web layers were polypropylene (Lyondell Basell, UK) and soft masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.). The polypropylene and soft masterbatch in the first web layer accounted for 4% of the total weight, i.e., 2.2gsm, and the soft masterbatch in the first web layer accounted for 1% of the total weight of the first web layer; the polypropylene and soft masterbatch in the second web layer accounted for 1.8% of the total weight, i.e., 0.99gsm, and the soft masterbatch in the second web layer accounted for 1% of the total weight of the second web layer; the raw materials used for the polymers in the first and second spray-coated layers were polypropylene (Lyondell Basell, UK). Basell (UK) accounts for 29.1% of the total weight, or 16 gsm. The cellulose fiber used is wood pulp (GP, USA), accounting for 60.1% of the total weight, or 33.05 gsm. The absorbent core layer is made of super absorbent polymer SAP (purchased from Shandong Noer Biotechnology Co., Ltd.), accounting for 4% of the total weight. After finishing, 1% antibacterial agent (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) is sprayed to kill and inhibit bacteria generated during use.

[0101] The preparation method comprises the following steps:

[0102] Step 1: Using the melt-blowing process, polypropylene and soft masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through an 8-row spinneret. The working pressure of the first screw extruder is 75 MPa, the output of the first melt-blowing unit is 75 kg / h, the output of the first spinneret single hole is 0.16 g / min / hole, the temperature of the first spinneret is 235 ° C, and the hot air flow rate of the air drafting hole of the first spinneret is 3000 Nm 3 / h for drawing and cooling by spray devices on both sides of the spinneret, with a spray rate of 120L / h, to form a first fiber web layer (the length of the polymer filaments in the first fiber web layer is greater than 15cm and the average diameter is 4.7μm);

[0103] Step 2: In the first mixed spraying system, the polypropylene particles are heated and melted by the third melt-blowing unit and the fourth melt-blowing unit, respectively, wherein the working pressure of the third screw extruder and the fourth screw extruder is 70 MPa, the third spinneret and the fourth spinneret are 14-row hole spinnerets, the spitting rate of the third melt-blowing unit and the fourth melt-blowing unit is 230 kg / h, the spitting rate of the third spinneret and the fourth spinneret single hole is 0.14 g / min / hole, the temperature of the third spinneret and the fourth spinneret is 225 ° C, and the hot air flow rate of the airflow drafting hole of the third spinneret and the fourth spinneret is 5000 Nm 3 / h for stretching; the pulp roll is transported to the first opening unit for crushing. The output of the first opening unit is 690kg / h, the speed of the opening roller is 5000rpm, and the cold wind force of the pulp is 4500Nm 3 / h, evenly dispersing the wood pulp in the pipeline; finally, the polypropylene filaments and wood pulp fibers formed by the third and fourth melt-blowing units are mixed and sprayed out in the first co-spray forming box, and are cooled by the spray devices on both sides of the spinneret. The spraying rate is 130L / h, forming a first co-spray layer covering the surface of the first fiber web layer (the length of the polymer filaments in the first co-spray layer is greater than 15cm and the average diameter is 5.3μm);

[0104] Step 3: Super absorbent resin SAP is sprayed out from the first core system to form an absorbent core layer covering the surface of the first mixed spray layer;

[0105] Step 4: The fifth meltblowing unit and the sixth meltblowing unit heat and melt the polypropylene particles, wherein the working pressure of the fifth screw extruder and the sixth screw extruder are 71 MPa respectively, the fifth spinneret and the sixth spinneret are 14-row hole spinnerets, the spitting amount of the fifth meltblowing unit and the sixth meltblowing unit are 230 kg / h respectively, the spitting amount of the fifth spinneret and the sixth spinneret single hole are 0.14 g / min / hole respectively, the temperature of the fifth spinneret and the sixth spinneret are 226 ° C respectively, and the hot air flow rate of the airflow drafting hole of the fifth spinneret and the sixth spinneret is 5100 Nm 3 / h for drafting; the pulp roll is transported to the second opening system for crushing. The second loosening system processes pulp at a capacity of 690kg / h, the opening roller speed is 5000rpm, and the pulp cold air force is 4600Nm 3 / h, evenly dispersing the wood pulp in the pipeline. Finally, the polypropylene filaments and wood pulp fibers formed by the fifth and sixth melt-blown units are mixed and sprayed out in the second mixed spray forming box, and cooled by the spray devices on both sides of the spinneret. The spraying volume is 130L / h, forming a second mixed spray layer covering the surface of the absorbent core layer (the length of the polymer filaments in the second mixed spray layer is greater than 15cm, and the average diameter is 5.3μm);

[0106] Step 5: Using the melt-blowing process, the polypropylene and the soft masterbatch are mixed, heated and melted, and then sprayed onto the surface of the second mixed spray layer through an 8-row spinneret. The working pressure of the second screw extruder is 76 MPa, the output of the second melt-blowing unit is 75 kg / h, the output of the second spinneret single hole is 0.16 g / min / hole, the temperature of the second spinneret is 235 ° C, and the hot air flow rate of the second spinneret airflow drafting hole is 3100 Nm 3 / h for drawing and cooling by spray devices on both sides of the spinneret with a spray rate of 120L / h to form a second fiber web layer covering the surface of the second mixed spray layer (the length of the polymer filaments in the second fiber web layer is greater than 15cm and the average diameter is 4.7μm);

[0107] Step six: The first fiber mesh layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer, and the second fiber mesh layer formed by steps one to five are collected through a mesh curtain with a speed of 500 m / min, and then point-shaped hot rolling is performed using a thermal bonding system, wherein the rollers of the thermal bonding system have their own heating function, and the thermal bonding area is 6.2%; a multi-layer composite structure non-woven material is formed with the upper and lower fiber mesh layers, the middle two mixed spray layers, and the absorbent core layer; the fiber mesh quality detection system is used to detect the gram weight, metal, and defects of the fiber mesh to ensure the quality of the product; finally, 1% antibacterial agent is sprayed through the finishing equipment, and finally the packaging system is used to package the breast pad.

[0108] Example 2

[0109] Composite nonwoven materials were prepared as disinfectant wipes using the equipment shown in FIG6 ; FIG10 is a schematic diagram of the mixed spray layer structure in the disinfectant wipes, FIG11 is a schematic diagram of the three-dimensional structure of the disinfectant wipes, and FIG12 is a schematic diagram of the cross-sectional structure of the disinfectant wipes, wherein 47 is the mixed spray layer structure, 48 is cellulose fiber (cellulose staple fiber), 49 is polymer filament, and 50 is pulp fiber;

[0110] 55gsm disinfectant wipes were produced, wherein the raw materials used in the first web layer were 1.6gsm of sheath-core polypropylene / polyester bicomponent masterbatch (Lyondell Basell, UK) with a melt index of 35g / 10min and a hydrophilic masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.), accounting for 2.9% of the total weight; the raw materials used in the second web layer were 1.6gsm of sheath-core polypropylene / polyester bicomponent masterbatch (Lyondell Basell, UK) with a melt index of 600g / 10min and a hydrophilic masterbatch, accounting for 2.9% of the total weight. The mass ratio of the hydrophilic masterbatch to the polypropylene / polyester bicomponent masterbatch was 2:98; the raw materials used in the first and second spray-mixed layers were polypropylene (Exxon Mobil, USA) and hydrophilic masterbatch. The polymers in the first and second mixed spray layers account for 32.8% of the total weight, i.e., 18 gsm. The mass ratio of the hydrophilic masterbatch to polypropylene is 2:98. The raw material used for the cellulose fibers in the first and second mixed spray layers is wood pulp (GP, USA). The cellulose fibers in the first and second mixed spray layers account for 53.4% ​​of the total weight, i.e., 29.4 gsm. The raw material used for the absorbent core layer is recycled pulp fiber, which is processed by an opening system into a slurry with a length of 0.5 to 1.5 mm, which accounts for 8% of the total weight. After finishing, a wet wipe machine is used to make 80-sheet wet wipes with a liquid content of 2%. Finally, a baler is used to package the finished disinfectant wipes.

[0111] The preparation method of disinfectant wipes comprises the following steps:

[0112] Step 1: Using a spunbond process, a core-sheath polypropylene / polyester bicomponent masterbatch and a hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto a web curtain through a multi-row spinneret (the core-sheath polypropylene / polyester bicomponent masterbatch has the advantages of a soft outer layer and a strong inner layer). The masterbatch enters the first spunbond spinning assembly 40 through a first spunbond screw extruder 39, cools the spunbond filaments through a first spunbond cooling device 41, stretches the spunbond filaments through a first spunbond drawing device 42, and is separated through a first spunbond separator 43. Finally, the filaments are laid on the web curtain 30 to form a first web layer (the length of the polymer filaments in the first web layer is greater than 20 cm and the average diameter is 18.3 μm).

[0113] Step 2: In the first mixed spraying system, the third melt-blowing unit and the fourth melt-blowing unit heat and melt the polypropylene particles, wherein the working pressure of the third screw extruder and the fourth screw extruder are 69 MPa respectively, the third spinneret and the fourth spinneret are 16-row hole spinnerets, the spitting rate of the third melt-blowing unit and the fourth melt-blowing unit are both 247 kg / h, the spitting rate of the third spinneret and the fourth spinneret single hole is 0.15 g / min / hole respectively, the temperature of the third spinneret and the fourth spinneret is 226 ° C, and the hot air flow rate of the airflow drafting hole of the third spinneret and the fourth spinneret is 5100 Nm 3 / h for stretching; the pulp roll is transported to the first opening system for crushing. The output of the first loosening system is 700kg / h, the opening roller speed is 5000rpm, and the cold wind force of the pulp is 4600Nm 3 / h, evenly dispersing the wood pulp in the pipeline; finally, the polypropylene filaments and wood pulp fibers formed by the third and fourth melt-blowing units are mixed and sprayed out in the first mixed spray forming box, and are cooled by the spray devices on both sides of the spinneret. The spraying rate is 130L / h, forming a first mixed spray layer (the length of the polymer filaments in the first mixed spray layer is greater than 20cm and the average diameter is 4.9μm) covering the surface of the first fiber web layer;

[0114] Step 3: Pulp fibers are sprayed out from the absorbent core system to form an absorbent core layer covering the surface of the first mixed spray layer;

[0115] Step 4: The fifth meltblowing unit and the sixth meltblowing unit heat and melt the polypropylene particles, wherein the working pressure of the fifth screw extruder and the sixth screw extruder are 69 MPa respectively, the fifth spinneret and the sixth spinneret are 16-row hole spinnerets, the spitting amount of the fifth meltblowing unit and the sixth meltblowing unit are both 247 kg / h, the spitting amount of the fifth spinneret and the sixth spinneret single hole are 0.15 g / min / hole respectively, the temperature of the fifth spinneret and the sixth spinneret is 226 ° C, and the hot air flow rate of the airflow drafting hole of the fifth spinneret and the sixth spinneret is 5100 Nm 3 / h for drafting; the pulp roll is transported to the second opening system for crushing. The second loosening system processes pulp at a capacity of 700kg / h, the opening roller speed is 5000rpm, and the pulp cold air force is 4600Nm 3 / h, the wood pulp in the pipeline is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the fifth and sixth melt-blown units are mixed and sprayed out in the second mixed spray forming box, and are cooled by the spray devices on both sides of the spinneret. The spraying rate is 130L / h, forming a second mixed spray layer (the length of the polymer filaments in the second mixed spray layer is greater than 20cm and the average diameter is 4.9μm) to cover the absorbent core layer;

[0116] Step 5: Using the melt-blowing process, the polypropylene / polyester two-component masterbatch and the soft masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through a 10-row spinneret. The working pressure of the first screw extruder is 76 MPa, the output of the first melt-blowing unit is 75 kg / h, the output of the first spinneret single hole is 0.16 g / min / hole, the temperature of the first spinneret is 235 ° C, and the hot air flow rate of the airflow drafting hole of the first spinneret is 3100 Nm 3 / h for drawing and cooling by the spray devices on both sides of the spinneret, with a spray rate of 120L / h, to form a second fiber web layer (the length of the polymer filaments in the second fiber web layer is greater than 20cm and the average diameter is 4.3μm) covering the second mixed spray layer;

[0117] Step six: The first web layer, the first cellulose fiber and polymer filament mixed spray layer, the absorbent core layer, the second cellulose fiber and polymer filament mixed spray layer and the second web layer formed by steps one to five are collected through a web curtain at a speed of 527 m / min, and then hot-rolled using a thermal bonding system to form a pattern of kittens and puppies, wherein the rollers of the thermal bonding system have a heating function and a thermal bonding area of ​​5.9%; a non-woven material with a multi-layer composite structure of upper and lower web layers, two middle mixed spray layers and an absorbent core layer is formed; the web quality detection system is used to detect the weight, metal and defects of the web to ensure the quality of the product; finally, the wet wipes equipment is used to perform a 2% liquid addition treatment to make disinfectant wipes, and finally the packaging system is used to package the disinfectant wipes.

[0118] Example 3:

[0119] The composite nonwoven material as an industrial wipe (excluding the absorbent core layer) is prepared using the equipment of the structure shown in FIG7 , including a first web layer, a first mixed spray layer, a second mixed spray layer, and a second web layer bonded sequentially from bottom to top.

[0120] A 55gsm industrial wipe was produced, wherein the raw materials used for the first and second web layers were blue polypropylene masterbatch (Exxon Mobil, USA) with a melt index of 40g / 10min. The blue polypropylene in the first and second web layers each accounted for 8% of the total weight, and the total weight was 4.4gsm. The polymer raw material used for the first and second spray-coated layers was polypropylene (Exxon Mobil, USA), accounting for 29.1% of the total weight, and the total weight was 16gsm. The cellulose fiber raw material used for the first and second spray-coated layers was wood pulp (GP, USA), accounting for 51.9% of the total weight, and the total weight was 28.55gsm. A 2% hydrophilic additive (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) was sprayed using the equipment's built-in spray system, and a 1% adhesive (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) was applied to the finishing roller to reduce the linting rate during use.

[0121] The preparation method of industrial wipes comprises the following steps:

[0122] Step 1: Using a spunbond process, a blue polypropylene masterbatch and a hydrophilic additive are mixed, heated, and melted, and then sprayed onto a web curtain through a multi-row spinneret. The mixture enters a first spunbond spinning assembly 40 through a first spunbond screw extruder 39, cools the spunbond filaments through a first spunbond cooling device 41, stretches the spunbond filaments through a first spunbond drawing device 42, and is separated through a first spunbond separator 43. Finally, the mixture is laid on the web curtain 30 to form a first web layer (the length of the polymer filaments in the first web layer is greater than 20 cm, and the average diameter is 19.4 μm).

[0123] Step 2: In the first mixed spraying system, the third melt-blowing unit and the fourth melt-blowing unit heat and melt the polypropylene particles, wherein the working pressure of the third screw extruder and the fourth screw extruder are 71 MPa respectively, the third spinneret and the fourth spinneret are 14-row hole spinnerets, the spitting rate of the third melt-blowing unit and the fourth melt-blowing unit are both 250 kg / h, the spitting rate of the third spinneret and the fourth spinneret single hole is 0.15 g / min / hole respectively, the temperature of the third spinneret and the fourth spinneret is 225 ° C, and the hot air flow rate of the airflow drafting hole of the third spinneret and the fourth spinneret is 5000 Nm 3 / h for drafting; the pulp roll is transported to the first opening system for crushing. The output of the first loosening system is 695kg / h, the opening roller speed is 5000rpm, and the cold wind force of the pulp is 4600Nm 3 / h, the wood pulp in the pipeline is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third and fourth melt-blowing units are mixed and sprayed out in the first mixed spray forming box, and the spray devices on both sides of the spinneret are sprayed with hydrophilic additives, which can both cool and increase the hydrophilicity of the material. The spraying rate is 125L / h, forming a first mixed spray layer (the length of the polymer filaments in the first mixed spray layer is greater than 15cm and the average diameter is 5.7μm) covering the first fiber web layer;

[0124] Step 3: The fifth melt-blowing unit and the sixth melt-blowing unit heat and melt the polypropylene particles, wherein the working pressure of the fifth screw extruder and the sixth screw extruder are 71 MPa respectively, the fifth spinneret and the sixth spinneret are 14-row hole spinnerets, the spitting rate of the fifth melt-blowing unit and the sixth melt-blowing unit are both 250 kg / h, the spitting rate of the fifth spinneret and the sixth spinneret single hole is 0.15 g / min / hole respectively, the temperature of the fifth spinneret and the sixth spinneret is 225 ° C, and the hot air flow rate of the airflow drafting hole of the fifth spinneret and the sixth spinneret is 5000 Nm 3 / h for stretching; the pulp roll is transported to the second opening system for crushing. The second loosening system processes pulp at a rate of 695kg / h, with an opening roller speed of 5000rpm and a cold wind force of 4600Nm 3 / h, the wood pulp in the pipeline is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the fifth and sixth melt-blown units are mixed and sprayed out in the second mixed spray forming box, and the spray devices on both sides of the spinneret are used to spray hydrophilic additives, which can both cool and increase the hydrophilicity of the material. The spraying rate is 125L / h, forming a second mixed spray layer (the length of the polymer filaments in the second mixed spray layer is greater than 15cm and the average diameter is 5.7μm) covering the first mixed spray layer;

[0125] Step 4: Using the spunbond process, the blue polypropylene masterbatch and the hydrophilic additive are mixed, heated and melted, and then sprayed onto the mesh curtain through a multi-row hole spinneret. The mixture enters the first spunbond spinning assembly 53 from the first spunbond screw extruder 52, and the spunbond filaments are cooled by the first spunbond cooling device 54. The spunbond filaments are stretched by the first spunbond drawing device 55, separated by the first spunbond separator 56, and finally spread on the mesh curtain 30 to form a second fiber mesh layer (the length of the polymer filaments in the second fiber mesh layer is greater than 20 cm, and the average diameter is 19.4 μm).

[0126] Step 5: The first fiber mesh layer, the cellulose fiber and polymer filament mixed spray layer, and the second fiber mesh layer formed by steps 1 to 5 are collected through a mesh curtain at a speed of 569 m / min, and then a thermal bonding system is used for point or other geometric shapes. The rollers of the thermal bonding system have a heating function, and the thermal bonding area is 6.3%; a multi-layer composite structure of a non-woven material with two fiber mesh layers and two middle mixed spray layers is formed; the fiber mesh quality detection system is used to detect the weight, metal and defects of the fiber mesh to ensure the quality of the product; finally, 1% adhesive is roller-coated through the finishing equipment, and finally the packaging system is used for packaging to obtain industrial wipes.

[0127] Example 4:

[0128] A composite nonwoven material is prepared as a facial wipe using an apparatus with a structure as shown in FIG8 (the first web system includes two meltblown systems; the second web system includes two meltblown systems), including the 1-1 web layer, the 1-2 web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer, the 2-1 web layer, and the 2-2 web layer bonded sequentially from bottom to top; the two meltblown systems in the first web system form the 1-1 web layer and the 1-2 web layer, respectively; the two meltblown systems in the second web system form the 2-1 web layer and the 2-2 web layer, respectively; the 1-1 web layer and the 1-2 web layer are the first web layer, and the 2-1 web layer and the 2-2 web layer are the second web layer

[0129] 55gsm biodegradable facial wipes were produced, wherein the raw materials used for the 1-1 web layer, the 1-2 web layer, the 2-1 web layer, and the 2-2 web layer were polylactic acid PLA (Lyondell Basell, UK) and softening masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.), the polylactic acid and softening masterbatch in the 1-1 web layer, the 1-2 web layer, the 2-1 web layer, and the 2-2 web layer respectively accounted for 1.625% of the total weight and 0.9gsm, and the mass ratio of the softening masterbatch to polylactic acid was 2:98. The raw material used for the polymer in the first mixed spray layer and the second mixed spray layer is polylactic acid (Lyondell Basell, UK), accounting for 25.3% of the total weight, which is 13.9 gsm. The raw material used for the cellulose fiber in the first mixed spray layer and the second mixed spray layer is wood pulp (GP, USA), accounting for 61.4% of the total weight, which is 33.77 gsm. The raw material used for the absorbent core layer is bamboo pulp (purchased from Sichuan Fuhua Bamboo Pulp and Paper Co., Ltd.), which accounts for 4.8% of the total weight. After finishing, 2% hydrophilic additive (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) is sprayed.

[0130] The method for preparing the facial wipes comprises the following steps:

[0131] Step 1: Using the melt-blowing process, polylactic acid and soft masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through a 14-row spinneret. The working pressure of the seventh screw extruder is 75 MPa, the output of the seventh melt-blown unit is 79 kg / h, the output of the seventh spinneret single hole is 0.17 g / min / hole, the temperature of the seventh spinneret is 233 ° C, and the hot air flow rate of the seventh spinneret airflow drafting hole is 3100 Nm 3 / h for drawing and cooling by spray devices on both sides of the spinneret, with a spray rate of 130L / h, to form the 1-1 fiber web layer (the length of the polymer filaments in the 1-1 fiber web layer is greater than 15cm and the average diameter is 4.1μm);

[0132] Step 2: Using the melt-blowing process, the polylactic acid and soft masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through a 14-row spinneret. The working pressure of the first screw extruder is 76 MPa, the output of the first melt-blowing unit is 79 kg / h, the output of the first spinneret single hole is 0.17 g / min / hole, the temperature of the first spinneret is 234 ° C, and the hot air flow rate of the airflow drafting hole of the first spinneret is 3150 Nm 3 / h for drawing and cooling by spray devices on both sides of the spinneret, with a spray rate of 130L / h, to form the 1-2 fiber web layer (the length of the polymer filaments in the 1-2 fiber web layer is greater than 15cm and the average diameter is 4.1μm) covering the 1-1 fiber web layer;

[0133] Step 3: In the first mixed spraying system, the third melt-blowing unit and the fourth melt-blowing unit heat and melt the polylactic acid particles, wherein the working pressure of the third screw extruder and the fourth screw extruder are 69 MPa respectively, the third spinneret and the fourth spinneret are 20-row hole spinnerets, the spitting rate of the third melt-blowing unit and the fourth melt-blowing unit are both 225 kg / h, the spitting rate of the third spinneret and the fourth spinneret single hole is 0.14 g / min / hole respectively, the temperature of the third spinneret and the fourth spinneret is 224 ° C, and the hot air flow rate of the airflow stretching hole of the third spinneret and the fourth spinneret is 5000 Nm 3 / h for stretching; the pulp roll is transported to the first opening system for crushing. The output of the first loosening system is 700kg / h, the opening roller speed is 5000rpm, and the cold wind force of the pulp is 4600Nm 3 / h, the wood pulp in the pipeline is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third and fourth melt-blowing units are mixed and sprayed in the first mixed spray forming box, and the spray devices on both sides of the spinneret are sprayed with hydrophilic additives, which can both cool and increase the hydrophilicity of the material. The spraying rate is 130L / h, forming a first mixed spray layer (the length of the polymer filaments in the first mixed spray layer is greater than 15cm and the average diameter is 4.7μm) covering the 1-2 fiber web layers;

[0134] Step 4: Bamboo pulp fibers are sprayed out from the absorbent core system to form an absorbent core layer covering the surface of the first mixed spray layer;

[0135] Step 5: In the second mixed spraying system, the fifth melt-blowing unit and the sixth melt-blowing unit heat and melt the polylactic acid particles, wherein the working pressure of the fifth screw extruder and the sixth screw extruder are 69 MPa respectively, the fifth spinneret and the sixth spinneret are 20-row hole spinnerets, the spitting amount of the fifth melt-blowing unit and the sixth melt-blowing unit are both 225 kg / h, the single-hole spitting amount of the fifth spinneret and the sixth spinneret are 0.14 g / min / hole respectively, the temperature of the fifth spinneret and the sixth spinneret is 226 ° C, and the hot air flow rate of the airflow drafting hole of the fifth spinneret and the sixth spinneret is 5000 Nm 3 / h for drafting; the pulp roll is transported to the second opening system for crushing. The second opening system processes pulp at a capacity of 700kg / h, the opening roller speed is 5000rpm, and the pulp cold air force is 4600Nm 3 / h, the wood pulp in the pipeline is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the fifth and sixth melt-blown units are mixed and sprayed out in the second mixed spray forming box, and the spray devices on both sides of the spinneret are sprayed with hydrophilic additives, which can both cool and increase the hydrophilicity of the material. The spraying rate is 130L / h, forming a second mixed spray layer (the length of the polymer filaments in the second mixed spray layer is greater than 15cm and the average diameter is 4.7μm) to cover the absorbent core layer;

[0136] Step 6: Using the melt-blowing process, the polylactic acid and soft masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through a 14-row spinneret. The working pressure of the second screw extruder is 75 MPa, the output of the second melt-blowing unit is 79 kg / h, the output of the second spinneret single hole is 0.17 g / min / hole, the temperature of the second spinneret is 233 ° C, and the hot air flow rate of the second spinneret airflow drafting hole is 3150 Nm 3 / h for drawing and cooling by the spray devices on both sides of the spinneret with a spray volume of 130L / h, forming the 2-1 fiber web layer (the length of the polymer filaments in the 2-1 fiber web layer is greater than 15cm and the average diameter is 4.1μm) covering the second mixed spray layer.

[0137] Step 7: Using the melt-blowing process, the polylactic acid and the soft masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through a 14-row spinneret. The working pressure of the eighth screw extruder is 75 MPa, the output of the eighth melt-blown unit is 79 kg / h, the output of the eighth spinneret single hole is 0.17 g / min / hole, the temperature of the eighth spinneret is 233 ° C, and the hot air flow rate of the eighth spinneret airflow drafting hole is 3100 Nm 3 / h for stretching and cooling by the spray devices on both sides of the spinneret with a spray volume of 130L / h, forming the 2-2 fiber web layer (the length of the polymer filaments in the 2-2 fiber web layer is greater than 15cm and the average diameter is 4.1μm) covering the 2-1 fiber web layer.

[0138] Step 8: The composite nonwoven material formed from steps 1 to 7, the 1-1 web layer, the 1-2 web layer, the first mixed spray layer of cellulose fibers and polymer filaments, the absorbent core layer, the second mixed spray layer of cellulose fibers and polymer filaments, the 2-1 web layer, and the 2-2 web layer, is collected through a mesh curtain at a speed of 506 m / min. The composite nonwoven material is then hot-rolled into point-shaped or other geometric shapes using a thermal bonding system. The rollers of the thermal bonding system have a built-in heating function, and the thermal bonding area is 6%. This forms a multi-layer composite nonwoven material comprising the four upper and lower web layers, the two middle mixed spray layers, and the absorbent core layer. The web is inspected for weight, metal content, and defects using a web quality inspection system to ensure product quality. A 2% hydrophilic additive is sprayed on the finished product, and the product is packaged using a packaging system to obtain facial wipes.

[0139] Example 5:

[0140] A composite nonwoven material is prepared using the apparatus shown in FIG9 (the first web system includes two spunbond systems and one meltblown system) as a body cleansing wipe, comprising a 1-1 web layer, a 1-2 web layer, a 1-3 web layer, a first mixed spray layer, an absorbent core layer, a second mixed spray layer, and a second web layer, which are sequentially bonded from bottom to top; the 1-1 web layer, the 1-2 web layer, and the 1-3 web layer form a first web layer;

[0141] 55 gsm body cleansing wipes were produced, wherein the raw materials used for the first and second web layers were parallel bicomponent polyester / polyamide masterbatch (Lyondell Basell, UK) with a melt index of 40 g / 10 min (this is a method of combining two polymers with different heat shrinkage and wet shrinkage properties, and then generating spiral curls after heat treatment to improve elasticity and fluffiness) and hydrophilic masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.), and the raw materials used for the first and second web layers were polypropylene (Exxon Mobil, USA) and hydrophilic masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.), the parallel bicomponent polyester / polyamide masterbatch and hydrophilic masterbatch in the 1-1 fiber web layer and the 1-2 fiber web layer account for 5% of the total weight of 2.75gsm, and the mass ratio of hydrophilic masterbatch to parallel bicomponent polyester / polyamide masterbatch is 2:98; the polypropylene masterbatch and hydrophilic masterbatch in the 1-3 fiber web layer account for 1.5% of the total weight of 0.825gsm, and the polypropylene masterbatch and hydrophilic masterbatch in the second fiber web layer account for 3.5% of the total weight of 1.925gsm, and the mass ratio of hydrophilic masterbatch to polypropylene masterbatch in the 1-3 fiber web layer and the second fiber web layer is 2:98; the raw material used for the polymer of the first mixed spray layer and the second mixed spray layer is polypropylene (Exxon Mobil (USA) and hydrophilic masterbatch. The polymer in the first and second spray-on layers accounts for 30% of the total weight, totaling 16.5 gsm. The mass ratio of hydrophilic masterbatch to polypropylene is 2:98. The cellulose fiber in the first and second spray-on layers is wood pulp (GP, US). The cellulose fiber in the first and second spray-on layers accounts for 53% of the total weight, totaling 29.15 gsm. The absorbent core layer uses a surfactant with cleaning properties that foams when rubbed with water. The surfactant accounts for 6% of the total weight. After finishing, 1% antibacterial softener (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) is sprayed.

[0142] The preparation method comprises the following steps:

[0143] Step 1: Using a spunbond process, the parallel bicomponent polyester / polyamide and the hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto a web curtain through a multi-row spinneret. The mixed fibers enter the third spunbond spinning assembly 84 through a third spunbond screw extruder 83, and are cooled by a third spunbond cooling device 85. The spunbond filaments are stretched by a third spunbond drawing device 86, separated by a third spunbond separator 87, and finally laid on the web curtain 30 to form a 1-1 web layer (the length of the polymer filaments in the 1-1 web layer is greater than 20 cm, and the average diameter is 17.3 μm).

[0144] Step 2: Using a spunbond process, the parallel bicomponent polyester / polyamide and the hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto a web curtain by a multi-row spinneret. The mixed fibers enter the first spunbond spinning assembly 40 through a first spunbond screw extruder 39, and are cooled by a first spunbond cooling device 41. The spunbond filaments are stretched by a first spunbond drawing device 42, separated by a first spunbond separator 43, and finally laid on the web curtain 30 to form the 1-2 web layer (the length of the polymer filaments in the 1-2 web layer is greater than 20 cm and the average diameter is 17.3 μm) covering the 1-1 web layer.

[0145] Step 3: Using the melt-blowing process, polypropylene and hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through an 8-row spinneret. The working pressure of the first screw extruder is 76 MPa, the output of the first melt-blowing unit is 79 kg / h, the output of the first spinneret single hole is 0.17 g / min / hole, the temperature of the first spinneret is 232 ° C, and the hot air flow rate of the airflow drafting hole of the first spinneret is 3180 Nm 3 / h for drawing and cooling by spray devices on both sides of the spinneret, with a spray rate of 131L / h, to form the first to third fiber web layers (the length of the polymer filaments in the first to third fiber web layers is greater than 15cm and the average diameter is 4.2μm) covering the first and second fiber web layers;

[0146] Step 4: In the first mixed spraying system, the third melt-blowing unit and the fourth melt-blowing unit mix and heat the polypropylene and the hydrophilic masterbatch, wherein the working pressure of the third screw extruder and the fourth screw extruder is 71 MPa respectively, the third spinneret and the fourth spinneret are 16-row hole spinnerets, the spitting amount of the third melt-blowing unit and the fourth melt-blowing unit is 247 kg / h, the spitting amount of the third spinneret and the fourth spinneret single hole is 0.15 g / min / hole respectively, the temperature of the third spinneret and the fourth spinneret is 227 ° C, and the hot air flow rate of the airflow drafting hole of the third spinneret and the fourth spinneret is 5150 Nm 3 / h for drafting; the pulp roll is transported to the first opening system for crushing. The output of the first loosening system is 701kg / h, the opening roller speed is 5000rpm, and the cold wind force of the pulp is 4600Nm 3 / h, evenly blowing the wood pulp in the pipeline; finally, the polypropylene filaments and wood pulp fibers formed by the third and fourth melt-blowing units are mixed and sprayed out in the first mixed spray forming box, and are cooled by the spray devices on both sides of the spinneret. The spraying rate is 132L / h, forming a first mixed spray layer (the length of the polymer filaments in the first mixed spray layer is greater than 15cm and the average diameter is 4.2μm) covering the surface of the 1st to 3rd fiber web layers;

[0147] Step 5: The recycled colored yarn is cut, opened, and ground, and then sprayed out from the absorbent core system to form an absorbent core layer covering the surface of the first mixed spray layer;

[0148] Step 6: The fifth melt-blown unit and the sixth melt-blown unit heat and melt the polypropylene and the hydrophilic masterbatch, wherein the working pressure of the fifth screw extruder and the sixth screw extruder is 69 MPa respectively, the fifth spinneret and the sixth spinneret are 16-row hole spinnerets, the spitting amount of the fifth melt-blown unit and the sixth melt-blown unit is 247 kg / h, the spitting amount of the fifth spinneret and the sixth spinneret single hole is 0.15 g / min / hole respectively, the temperature of the fifth spinneret and the sixth spinneret is 226 ° C, and the hot air flow rate of the airflow drafting hole of the fifth spinneret and the sixth spinneret is 5100 Nm 3 / h for drafting; the wood pulp roll is transported to the second opening system for crushing. The output of the processed wood pulp of the second loose system is 700kg / h, the speed of the opening roller is 5000rpm, and the cold wind force of the wood pulp is 4600Nm3 / h, which evenly blows the wood pulp in the pipeline; finally, the polypropylene filaments and wood pulp fibers formed by the fifth meltblown unit and the sixth meltblown unit are mixed and sprayed in the second mixed spray forming box, and cooled by the spray devices on both sides of the spinneret. The spraying volume is 130L / h to form a second mixed spray layer (the length of the polymer filaments in the second mixed spray layer is greater than 15cm and the average diameter is 4.2μm) to cover the absorbent core layer;

[0149] Step 7: Using the melt-blowing process, polypropylene and hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto the mesh curtain through an 8-row spinneret. The working pressure of the second screw extruder is 76 MPa, the output of the second melt-blowing unit is 75 kg / h, the output of the second spinneret single hole is 0.16 g / min / hole, the temperature of the second spinneret is 238 ° C, and the hot air flow rate of the second spinneret airflow drafting hole is 3100 Nm 3 / h for drawing and cooling by the spray devices on both sides of the spinneret, with a spray rate of 132L / h, to form a second fiber web layer (the length of the polymer filaments in the second fiber web layer is greater than 15cm and the average diameter is 4.2μm) covering the second mixed spray layer;

[0150] Step 8: The 1-1 fiber mesh layer, 1-2 fiber mesh layer, 1-3 fiber mesh layer, first cellulose fiber and polymer filament mixed spray layer, absorbent core layer, second cellulose fiber and polymer filament mixed spray layer and second fiber mesh layer formed by steps 1 to 7 are collected through a mesh curtain with a speed of 545m / min, and then a thermal bonding system is used for point-shaped hot rolling shaping, wherein the roller of the thermal bonding system has its own heating function and the thermal bonding area is 6.1%; a multi-layer composite structure non-woven material is formed, which includes the above four fiber mesh layers, the middle two mixed spray layers of the next fiber mesh layer and the absorbent core layer; the fiber mesh is inspected for gram weight, metal and defects by a fiber mesh quality inspection system to ensure the quality of the product, and 1% antibacterial softener is sprayed on the finished product, and finally the body cleaning wipes are packaged by a packaging system.

[0151] Comparative Example 1

[0152] Commercially available Huggies-PURE baby wipes were used as a comparative example.

[0153] The properties of the nonwoven materials of Examples 1 to 5 and Comparative Example 1 were tested according to relevant testing standards, and the results are listed in Table 1.

[0154] Table 1 Performance test results of composite nonwoven sanitary products of Examples 1 to 5 and Comparative Example 1

[0155] It can be seen from Table 1 that the thickness of the composite nonwoven material made by the equipment of the present application is on average 35% higher than that of the general products on the market; the longitudinal strength and transverse strength of the composite nonwoven materials of Examples 1 to 5 are 57% and 39% higher than those of ordinary products respectively; the water absorption rate of the composite nonwoven materials of Examples 1 to 4 when SAP is added is 3 times that of ordinary commercial products, and the water absorption rate of the product without SAP is also more than 1.5 times higher than that of ordinary commercial products; the water absorption rate of the composite nonwoven materials of Examples 1 to 5 is generally less than or equal to 5 seconds; the composite nonwoven materials of Examples 1 to 5 have a dense fiber mesh added to the surface. layer, which makes the lint coefficient better than that of ordinary commercially available products, and the best lint coefficient can reach 3.59; the composite non-woven materials of Examples 1 to 5 have greatly improved softness compared with ordinary commercially available products, with the best MD direction being 10.6 and CD direction being 8.1; the composite non-woven materials of Examples 1 to 5 have excellent wear resistance, and ordinary commercially available products break the layer after 200 wear tests, while the products of the present application can reach level -3 without breaking the layer after 200 wear tests; the composite non-woven materials of Examples 1 to 5, the outer layer polymer fineness sprayed out by meltblowing is generally 3 to 5 μm, and the inner layer polymer fineness is about 4 to 6 μm.

[0156] Although the above embodiment provides a detailed description of the present application, it is only a part of the embodiments of the present application, not all of the embodiments. People can also obtain other embodiments based on this embodiment without creativity, and these embodiments all fall within the scope of protection of the present application.

Claims

1. A composite nonwoven material, characterized in that The layer structure includes the following mass percentages: The first fiber web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer and the second fiber web layer are stacked in sequence; The first spray-mixed layer and the second spray-mixed layer independently comprise cellulose fibers and polymer filaments; The first fiber web layer and the second fiber web layer are respectively polymer filaments.

2. The composite nonwoven material according to claim 1, characterized in that: The polymer filaments in the first fiber web layer and the second fiber web layer have a length greater than 5 cm and a diameter of 0.1 to 30 μm.

3. The composite nonwoven material according to claim 1, characterized in that: The first fiber web layer and the second fiber web layer independently further comprise one or more of functional masterbatch, hydrophilic additive, hydrophilic softener, essential oil and mosquito repellent additive.

4. The composite nonwoven material according to claim 1, characterized in that: The lengths of the cellulose fibers in the first spray-mixed layer and the second spray-mixed layer are independently 0.5 to 8 mm.

5. The composite nonwoven material according to claim 1 or 4, characterized in that: The mass ratio of cellulose fibers to polymer filaments in the first spray-mixed layer and the second spray-mixed layer is independently 10-90:9.8-70.

6. The composite nonwoven material according to claim 1, characterized in that: The absorbent core layer includes one or more of a high molecular water-absorbent resin, cellulose fibers and a high molecular gel material.

7. An apparatus for preparing the composite nonwoven material according to any one of claims 1 to 6, comprising a web-forming curtain (30), a suction device (31), and a first fiber web system, a first spray-mixing molding system, an absorbent core system (13), a second spray-mixing molding system, and a second fiber web system, which are connected in series in sequence and are located above the web-forming curtain (30); The first fiber web system includes a first meltblown unit or a first spunbond unit; the first mixed spray molding system includes a third meltblown unit, a first opening unit, a fourth meltblown unit and a first mixed spray molding box (09); the second mixed spray molding system includes a fifth meltblown unit, a second opening unit, a sixth meltblown unit and a second mixed spray molding box (19); the second fiber web system includes a second meltblown unit or a second spunbond unit.

8. The device according to claim 7, characterized in that It also includes a thermal bonding system (32), a fiber web quality detection system, a finishing system (36) and a packaging system (37); the fiber web quality detection system includes a metal detection unit (33), a fiber web weight detection unit (34) and a fiber web defect detection unit (35).

9. The device according to claim 7, characterized in that The first meltblowing unit comprises a first spinning manifold (01), a first screw extruder (02), a first feeding device (03) and a first spinneret (57).

10. The device according to claim 7, characterized in that The first spunbond unit includes a first spunbond feeding device (38), a first spunbond screw extruder (39), a first spunbond spinning assembly (40), a first spunbond cooling device (41), a first spunbond drawing device (42) and a first spunbond filament separator (43).

11. The device according to claim 7, characterized in that The third meltblowing unit includes a second feeding device (04), a second screw extruder (05), a third spinning manifold (06) and a third spinneret (58).

12. The device according to claim 7, characterized in that The first opening unit comprises a first opening device (07) and a first multi-row hole CD injector (08).

13. The device according to claim 7, characterized in that The fourth meltblowing unit includes a fourth feeding device (10), a fourth screw extruder (11), a fourth spinning manifold (12) and a fourth spinneret (59).

14. The device according to claim 7, characterized in that The fifth meltblowing unit includes a fifth feeding device (14), a fifth screw extruder (15), a fifth spinning manifold (16) and a fifth spinneret (60).

15. The device according to claim 7, characterized in that The second opening unit comprises a second opening device (17) and a second multi-row hole CD injector (18).

16. The device according to claim 7, characterized in that The sixth meltblowing unit includes a sixth feeding device (20), a sixth screw extruder (21), a sixth spinning manifold (22) and a sixth spinneret (61).

17. The device according to claim 7, characterized in that The second meltblowing unit includes a second feeding device (23), a second screw extruder (24), a second spinning manifold (25) and a second spinneret (62).

18. The device according to claim 7, characterized in that The second spunbond unit includes a second spunbond feeding device (51), a second spunbond screw extruder (52), a second spunbond spinning assembly (53), a second spunbond cooling device (54), a second spunbond drawing device (55) and a second spunbond filament separator (56).

19. The device according to claim 7 or 9, characterized in that The first meltblowing unit also includes a first cooling spray system (26).

20. The device according to claim 7, characterized in that The outlet of the first spray-mixing molding box (09) is provided with a second cooling spray system (27), and the outlet of the second spray-mixing molding box (19) is provided with a third cooling spray system (28).

21. The device according to claim 7 or 17, characterized in that The second melt-blowing unit also includes a fourth cooling spray system (29).

22. A method for preparing the composite nonwoven material according to any one of claims 1 to 6 using the apparatus according to any one of claims 7 to 21, comprising the following steps: Using a first fiber web system, a first polymer is melted and then sprayed onto a web curtain (30) to obtain a first fiber web layer; The second polymer is melted by the third melt-blowing unit and the fourth melt-blowing unit, and the first cellulose fiber raw material is crushed by the first opening unit; the melted second polymer and the crushed first cellulose fiber raw material are conveyed to the first mixed spray forming box (09), mixed, and then sprayed onto the surface of the first fiber web layer to form a first mixed spray layer; spraying the water-absorbing material onto the surface of the first mixed spray layer through the absorbent core system (13) to form an absorbent core layer; The third polymer is melted by the fifth melt-blowing unit and the sixth melt-blowing unit, and the second cellulose fiber raw material is crushed by the second opening unit; the melted third polymer and the crushed second cellulose fiber raw material are conveyed to the second mixed spray forming box (19), mixed and then sprayed on the surface of the absorbent core layer to form a second mixed spray layer; The fourth polymer is melted by the second fiber web system and then sprayed onto the surface of the second mixed spray layer to obtain the second fiber web layer.

23. The preparation method according to claim 22, characterized in that: After the second fiber web layer is formed, the method further includes: sequentially collecting, finishing and packaging the products including the first fiber web layer, the first mixed spray layer, the absorbent core layer, the second mixed spray layer and the second fiber web layer; The post-finishing comprises one or more of embossing, printing, perforating, texturing, surface treatment, thermal bonding, ultrasonic bonding, cutting, stacking and wet wipe processing.

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