A sanitary material and a processing method thereof

Abstract

The present invention relates to the technical field of sanitary materials, and in particular to a sanitary material and a processing method thereof. The processing method comprises: mechanically scraping the surface of the first material layer and / or the second material layer to form a rough surface; spraying nano zinc oxide particles on the rough surface; overlapping and laying the treated first material layer and the second material layer with the rough surface as the contact surface, and welding and compounding them by ultrasonic vibration under a set pressure. The present invention utilizes an ultrasonic generator to convert high-frequency electrical energy into high-frequency vibration energy for welding non-woven fabrics and resin films, with the characteristics of instant start and stop, convenient and efficient; using electrical energy, clean, environmentally friendly, safe and efficient. It can realize the combined production of multiple different materials and meet the diverse needs of the market.

Description

Technical Field

[0001] The present invention relates to the technical field of sanitary materials, in particular to a sanitary material and a processing method thereof. Background Art

[0002] Existing lamination processes for multi-layer composite sanitary materials typically involve gluing and then drying and shaping them using thermal oil furnace heating, or direct hot pressing without gluing. However, these processes are time-consuming, energy-intensive, and require at least six hours to start and stop the machine. Furthermore, the temperature can only reach a certain level, and excessively high temperatures pose a safety hazard. This process is only suitable for laminating single materials, such as non-woven fabrics, and has poor results laminating non-woven fabrics with film products. Multi-layer lamination requires multiple steps, and care must be taken to avoid misalignment between layers. This makes it difficult to customize custom patterns due to the high cost and time required. Summary of the Invention

[0003] The object of the present invention is to overcome the above-mentioned shortcomings and provide a sanitary material and a processing method thereof.

[0004] To achieve the above objectives, the technical solution of the present invention is:

[0005] A novel processing method for a sanitary material, wherein the sanitary material comprises a first material layer and a second material layer, wherein the first material layer and the second material layer are non-woven fabric layers or synthetic resin film layers, and wherein the processing method comprises the following processing steps:

[0006] (1) mechanically scraping the surface of the first material layer and / or the second material layer to form a rough surface;

[0007] (2) The first material layer and the second material layer processed in step 2 are overlapped and laid with the rough surfaces being the contact surfaces, and are welded and composited by ultrasonic vibration under a set pressure.

[0008] Preferably, nano zinc oxide particles are sprayed on the rough surface.

[0009] Preferably, a first connecting film layer is provided between the first material layer and the second material layer, and the first connecting film layer is a low melt index resin film layer.

[0010] Preferably, the first connecting film layer is provided with a plurality of energy conducting holes, and the cross-section of the energy conducting holes is any one of a triangle, a rectangle and a semicircle.

[0011] Preferably, the sanitary material is provided with a third material layer, a first material layer and a second material layer from top to bottom, a second connecting film layer is provided between the third material layer and the first material layer, and the second connecting film layer is a resin film layer with a higher melt index than the first connecting film layer.

[0012] Preferably, the first material layer and / or the second material layer has a grammage of 100-300 g / m2.

[0013] Preferably, the first material layer and / or the second material layer is a non-woven fabric layer, and the non-woven fabric layer is made of a rectangular cross-section spinneret fiber web with an aspect ratio of 3-7:1.

[0014] Preferably, the welding time is 0.25-0.5S, the welding pressure is 110-180N, and the welding amplitude is 30-55 μm.

[0015] Preferably, after ultrasonic vibration welding and lamination, the pressure is maintained for 0.5-2s to obtain the finished product, and the pressure is maintained at 80-130N.

[0016] A sanitary material, the preparation method of which includes the novel sanitary material processing method described in claim 1, comprising a composite body welded by ultrasonic vibration. The composite body is sequentially provided with a third material layer, a second resin film layer, a first material layer, a first resin film layer, and a second material layer from top to bottom. The second resin film layer has a greater melt index than the first resin film layer. The bottom surface of the first material layer is roughened, and the first resin film layer is provided with energy conducting holes. Nano-zinc oxide particles are dispersed between the first and second material layers.

[0017] By adopting the above technical solution, the beneficial effects of the present invention are:

[0018] The present invention uses an ultrasonic generator to convert high-frequency electrical energy into high-frequency vibration energy, and the welding head transmits the ultrasonic energy to the non-woven fabric welding surface. The vibration energy instantly causes the molecules of the workpiece to produce friction and reach the melting point, thus achieving welding between plastics or non-woven fabrics.

[0019] 1. No longer need oil heating equipment, it can be turned on and off immediately, which is convenient and efficient;

[0020] 2. Use electricity, clean, environmentally friendly, safe and efficient. At the same time, the temperature can be adjusted according to the needs of different materials without restrictions.

[0021] 3. Realize the combined production of various materials to meet the diverse needs of the market;

[0022] 4. Customizable embossing is possible, and the cost is low to help customers expand the market.

[0023] At the same time, the present invention increases the space between layers by providing rough surfaces and energy-conducting holes, thereby avoiding the situation in which, during ultrasonic vibration welding and compounding, the two workpieces are in close contact under pressure in a plane overlapping manner, and the molten material has insufficient casting space, forming stress concentration areas where casting is not possible. Stress concentration seriously affects the welding strength, causing the welding material to decompose, become brittle, and oxidize, thereby affecting the welding quality.

[0024] Among them, nano-zinc oxide particles and energy-conducting holes can increase energy transfer, shorten welding time, and reduce edge stress concentration; the rough surface increases the surface friction coefficient of the material layer. Increasing the surface roughness of the material can reduce acoustic impedance and increase the surface energy flux density, thereby improving its welding quality; nano-zinc oxide particles as fillers can increase the hardness of polymer materials, facilitating the transmission of ultrasonic waves; the connecting film layer is more susceptible to ultrasonic waves, improving the softening and melting degree of the weld point, and expanding the range of process parameters. Through these processes and structural designs, thermal conductivity is effectively improved, which saves power output and reduces production costs.

[0025] On the other hand, the gradient reduction design of the melt index of the upper and lower connecting film layers avoids excessive wrinkling of the layer near the welding head and weak welding of the layer far from the welding head, making the welding effect more uniform, improving the flatness and comfort of the layer surface, and reducing the impact of welding wrinkles on the pattern display effect of the layer surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] This specification contains drawings to provide further understanding of the present invention and constitute a part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation of the present invention.

[0027] In the drawings, like components are given like reference numerals, and the drawings are schematic and not necessarily drawn to scale.

[0028] Figure 1 It is a structural schematic diagram of the present invention.

[0029] Explanation of the main figure marks: (1 composite body, 2 third material layer, 3 second resin film layer, 4 first material layer, 41 rough surface, 5 first resin film layer, 51 energy conducting holes, 6 second material layer, 7 nano zinc oxide particles). DETAILED DESCRIPTION

[0030] The following will describe the implementation methods of the present invention in detail with reference to the accompanying drawings and examples, so that the implementation process of how the present invention applies technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0031] Example 1

[0032] like Figure 1 As shown, a sanitary material of the present invention includes a composite body 1 welded by ultrasonic vibration. The composite body 1 is provided with a first material layer 4 and a second material layer 6 from top to bottom. The bottom surface of the first material layer 4 is a rough surface 41. The first material layer 4 is a synthetic resin layer, and the second material layer 6 is a polyester non-woven fabric layer.

[0033] The new processing method of the sanitary material is:

[0034] (1) The bottom surface of the first material layer 4 is mechanically scraped, such as by using sandpaper, a grinding wheel, etc., until the non-woven fabric surface becomes fuzzy or obvious scratches appear on the surface of the synthetic resin layer, thereby forming a rough surface 41;

[0035] (2) The first material layer 4 and the second material layer 6 processed in the above steps are overlapped and laid, with the rough surface 41 being the contact surface, and are welded and composited by ultrasonic vibration under a set pressure.

[0036] Among them, the first material layer 4 has a weight of 150g / m 2 , the second material layer 6 has a weight of 200g / m 2 The welding time is 0.5s, the welding pressure is 140N, and the welding amplitude is 45μm. After ultrasonic vibration welding and lamination, the pressure is maintained for 1.0s to obtain the finished product, and the pressure is maintained at 120N.

[0037] Comparative Example 1

[0038] like Figure 1 As shown, a sanitary material of the present invention comprises a composite body 1 welded by ultrasonic vibration, wherein the composite body 1 is provided with a first material layer 4 and a second material layer 6 in order from top to bottom. The first material layer 4 is a synthetic resin layer, and the second material layer 6 is a polyester non-woven fabric layer.

[0039] The new processing method of the sanitary material is:

[0040] The first material layer 4 and the second material layer 6 are overlapped and laid, and are welded and compounded by ultrasonic vibration under a set pressure.

[0041] Among them, the first material layer 4 has a weight of 150g / m 2 , the second material layer 6 has a weight of 200g / m 2 The welding time is 0.5s, the welding pressure is 140N, and the welding amplitude is 45μm. After ultrasonic vibration welding and lamination, the pressure is maintained for 1.0s to obtain the finished product, and the pressure is maintained at 120N.

[0042] Composite strength test:

[0043] Test samples of the composite sanitary material prepared in Example 1 and Comparative Example 1 were taken. These test samples had a multilayer structure, with only the central portion welded. The first material layer 4 of the test sample was fixed, and a corner of the second material layer 6 was pulled with a constant force of 200 N until it could no longer be pulled. The test results are as follows:

[0044] Example 1 Comparative Example 1 Product Appearance normal normal 1 and 2 material layers are separated none yes

[0045] Example 2

[0046] like Figure 1As shown, a sanitary material of the present invention comprises an ultrasonically vibrated composite body 1. The composite body 1 is sequentially formed from top to bottom with a third material layer 2, a second resin film layer 3, a first material layer 4, a first resin film layer 5, and a second material layer 6. The second resin film layer 3 has a higher melt index than the first resin film layer 5. The bottom surface of the first material layer 4 is a rough surface 41. The first resin film layer 5 is provided with energy conducting holes 51. Nano-zinc oxide particles 7 are dispersed between the first and second material layers 4 and 6. The energy conducting holes 51 have a rectangular cross-section. Both the second and first resin film layers 3 and 5 are made of low-melt-index resins. The first material layer 4 is a synthetic resin layer, the third material layer 2 is a polypropylene non-woven fabric layer, and the second material layer 6 is a polyester non-woven fabric layer. Both the polypropylene and polyester non-woven fabric layers are made from a web of spin-formed fibers with a rectangular cross-section and an aspect ratio of 4:1.

[0047] The new processing method of the sanitary material is:

[0048] (1) The bottom surface of the first material layer 4 is mechanically scraped, such as by using sandpaper, a grinding wheel, etc., until the non-woven fabric surface becomes fuzzy or obvious scratches appear on the surface of the synthetic resin layer, thereby forming a rough surface 41;

[0049] (2) Spray nano zinc oxide particles 7 on the rough surface 41, with a dosage of 0.6 g / m 2 ;

[0050] (3) The second resin film layer 3 is placed on the upper surface of the first material layer 4, and the first resin film layer 5 is placed on the upper surface of the second material layer 6. The upper surface of the first resin film layer 5 has energy conducting holes 51 pressed out by a mold or scraped out by a scraper.

[0051] (4) The third material layer 2, the first material layer 4 and the second material layer 6 processed in the above steps are overlapped and laid, with the rough surface 41 being the contact surface, and are welded and composited by ultrasonic vibration under a set pressure.

[0052] Among them, the third material layer 2 has a weight of 200g / m 2 , the first material layer 4 has a weight of 150g / m 2 , the second material layer 6 has a weight of 200g / m 2 The melt index of the first connecting film layer was 15, and the melt index of the second connecting film layer was 25. The welding time was 0.5s, the welding pressure was 140N, and the welding amplitude was 45μm. After ultrasonic vibration welding and lamination, the pressure was maintained for 1.0s, and the finished product was obtained at a holding pressure of 120N.

[0053] Example 3

[0054] like Figure 1As shown, a sanitary material of the present invention comprises a composite body 1 welded by ultrasonic vibration. The composite body 1 is provided with, from top to bottom, a third material layer 2, a second resin film layer 3, a first material layer 4, a first resin film layer 5, and a second material layer 6. The second resin film layer 3 has a greater melt index than the first resin film layer 5. The bottom surface of the first material layer 4 is a rough surface 41. The first resin film layer 5 is provided with energy conducting holes 51. Nano zinc oxide particles 7 are dispersed between the first material layer 4 and the second material layer 6. The energy conducting holes 51 are semicircular in cross-section. The second resin film layer 3 and the first resin film layer 5 are both low melt index resins. The first material layer 4 is a synthetic resin layer, the third material layer 2 is a polypropylene non-woven fabric layer, and the second material layer 6 is a polyester non-woven fabric layer. The polypropylene non-woven fabric layer and the polyester non-woven fabric layer are both made of a rectangular cross-section spinneret fiber web with an aspect ratio of 7:1.

[0055] The new processing method of the sanitary material is:

[0056] (1) The bottom surface of the first material layer 4 is mechanically scraped, such as by using sandpaper, a grinding wheel, etc., until the non-woven fabric surface becomes fuzzy or obvious scratches appear on the surface of the synthetic resin layer, thereby forming a rough surface 41;

[0057] (2) Spray nano zinc oxide particles 7 on the rough surface 41, with a dosage of 1g / m 2 ;

[0058] (3) The second resin film layer 3 is coated on the upper surface of the first material layer 4, and the first resin film layer 5 is placed on the upper surface of the second material layer 6. The upper surface of the first resin film layer 5 has energy conducting holes 51 pressed out by a mold or scraped out by a scraper.

[0059] (4) The third material layer 2, the first material layer 4 and the second material layer 6 processed in the above steps are overlapped and laid, with the rough surface 41 being the contact surface, and are welded and composited by ultrasonic vibration under a set pressure.

[0060] Among them, the third material layer 2 has a weight of 150g / m 2 , the first material layer 4 has a weight of 200g / m 2 , the second material layer 6 has a weight of 150g / m 2 The melt index of the first connecting film layer was 10, and the melt index of the second connecting film layer was 20. The welding time was 0.3 seconds, the welding pressure was 120 Newtons, and the welding amplitude was 35 μm. After ultrasonic vibration welding and lamination, the pressure was maintained for 0.5 seconds, and the finished product was obtained at a holding pressure of 80 Newtons.

[0061] Comparative Example 1: The difference between Comparative Example 1 and Example 2 is that the bottom surface of the first material layer 4 is not roughened.

[0062] Comparative Example 2: The difference between Comparative Example 2 and Example 2 is that no energy conducting holes 51 are provided on the first resin film layer 5.

[0063] Comparative Example 3: The difference between Comparative Example 3 and Example 2 is that no nano zinc oxide particles 7 are provided between the first material layer 4 and the second material layer 6.

[0064] Comparative Example 4: The difference between Comparative Example 4 and Example 2 is that the first resin film layer 5 is not provided.

[0065] Comparative Example 5: The difference between Comparative Example 4 and Example 2 is that the second resin film layer 3 is not provided.

[0066] Comparative Example 2

[0067] The third material layer 2, the first material layer 4 and the second material layer 6 are overlapped and laid, and are welded and compounded by ultrasonic vibration under a set pressure.

[0068] Among them, the third material layer 2 has a weight of 200g / m 2 , the first material layer 4 has a weight of 150g / m 2 , the second material layer 6 has a weight of 200g / m 2 The welding time is 0.5S, the welding pressure is 140N, and the welding amplitude is 45μm. After ultrasonic vibration welding and lamination, the pressure is maintained for 1.0S to obtain the finished product, and the pressure is maintained at 120N.

[0069] Composite strength test:

[0070] Test samples of composite sanitary materials prepared in Examples 2-3, Comparative Examples 1-5, and Control Example 2 were taken. These test samples had a multilayer structure, with only the central portion welded. The third material layer 2 of the test sample was fixed, and a corner of the second material layer 6 was pulled with a constant tensile force of 200 N until it could no longer be pulled. The test results are as follows:

[0071] Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Comparative Example 5 Comparative Example 2 Product Appearance normal normal normal normal normal wrinkles wrinkles wrinkles 1 and 2 material layers are separated none none yes yes yes yes yes yes 1 and 3 material layers are separated none none none none none none yes yes

[0072] It should be understood that the embodiments disclosed herein are not limited to the specific processing steps or materials disclosed herein, but should extend to equivalent substitutions of such features as would be understood by a person of ordinary skill in the relevant art. It should also be understood that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting.

[0073] The "embodiment" mentioned in the specification means that a particular feature or characteristic described in conjunction with the embodiment is included in at least one embodiment of the present invention. Therefore, the phrase or "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment.

[0074] In addition, the described features or characteristics may be combined in any other suitable manner into one or more embodiments. In the above description, some specific details, such as thickness, quantity, etc., are provided to provide a comprehensive understanding of the embodiments of the present invention. However, those skilled in the relevant art will understand that the present invention can be implemented without one or more of the above specific details, or can also be implemented using other methods, components, materials, etc. Therefore, any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for processing a sanitary material, wherein the sanitary material comprises, from top to bottom, a third material layer, a first material layer, and a second material layer, wherein a first connecting film layer is provided between the first and second material layers, and the first connecting film layer is a low melt index resin film layer; the first connecting film layer is provided with a plurality of energy conducting holes, and the cross-section of the energy conducting holes is any one of triangular, rectangular, and semicircular; a second connecting film layer is provided between the third material layer and the first material layer, and the second connecting film layer is a resin film layer with a higher melt index than the first connecting film layer; the first and second material layers are non-woven fabric layers or synthetic resin film layers, characterized in that: The processing steps include: (1) mechanically scraping the surface of the first material layer and / or the second material layer to form a rough surface; and spraying nano zinc oxide particles on the rough surface; (2) The first material layer and the second material layer processed in step (1) are overlapped and laid with the rough surfaces being the contact surfaces, and are welded and composited by ultrasonic vibration under a set pressure.

2. The sanitary material processing method according to claim 1, characterized in that: The first material layer and / or the second material layer has a grammage of 100-300 g / m2.

3. The sanitary material processing method according to claim 2, characterized in that: The first material layer and / or the second material layer is a non-woven fabric layer, and the non-woven fabric layer is made of a rectangular cross-section spinneret fiber web with an aspect ratio of 3-7:

1.

4. The sanitary material processing method according to claim 3, characterized in that: The welding time is 0.25-0.5S, the welding pressure is 110-180N, and the welding amplitude is 30-55μm.

5. The sanitary material processing method according to claim 3, characterized in that: After ultrasonic vibration welding and lamination, the pressure is maintained for 0.5-2S to obtain the finished product, and the pressure is maintained at 80-130N.

6. A sanitary material, characterized in that: It is prepared by the sanitary material processing method according to claim 1, and the sanitary material includes a composite body welded by ultrasonic vibration. The composite body is provided with a third material layer, a second resin film layer, a first material layer, a first resin film layer and a second material layer from top to bottom. The melt index of the second resin film layer is greater than that of the first resin film layer. The bottom surface of the first material layer is a rough surface. The first resin film layer is provided with energy conducting holes. Nano zinc oxide particles are dispersed between the first material layer and the second material layer.

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