Manufacturing method of three-dimensional nonwoven fabric

Abstract

A method for manufacturing a three-dimensional nonwoven fabric includes the following steps: Meltblown fibers are ejected using a meltblown device, wherein the single-hole ejection rate of the meltblown fibers is between 0.01 g / min and 0.5 g / min. A first portion of the meltblown fibers is received by a roller device. A second portion of the meltblown fibers is received by a collecting device, wherein the collecting device has a receiving net, and the moving speed of the receiving net is between 1 m / min and 5 m / min. The first portion of the meltblown fibers is brought to the collecting device by the rotation of the roller device. Through the above manufacturing method, the formed three-dimensional nonwoven fabric can have a certain thickness and good bulkiness.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a three-dimensional nonwoven fabric, and more particularly to a method for manufacturing a three-dimensional nonwoven fabric with high bulk. Background Technology

[0002] In the textile industry, nonwoven fabrics have become a key focus of development due to their non-woven nature. Furthermore, nonwoven fabrics offer advantages such as short processing time, high output, low cost, and a wide availability of raw materials, making them suitable for the consumer market. A broad definition of nonwoven fabric can be a cloth-like material formed using pressure or adhesive bonding. However, the manufacturing process for nonwoven fabrics can vary considerably, and the properties of the nonwoven fabric change accordingly with the different manufacturing methods.

[0003] With the development of the textile industry, manufacturers have begun to develop nonwoven fabrics with three-dimensional structures. However, due to limitations in the design of current textile equipment, the bulk and thickness of three-dimensional nonwoven fabrics cannot be effectively improved. Therefore, how to provide a three-dimensional nonwoven fabric with high bulk and thickness is a very important issue at present. Summary of the Invention

[0004] According to one embodiment of this disclosure, a method for manufacturing a three-dimensional nonwoven fabric includes the following steps: Meltblown fibers are ejected using a meltblown device, wherein the single-hole ejection rate of the meltblown fibers is between 0.01 g / min and 0.50 g / min. A first portion of the meltblown fibers is received by a roller device. A second portion of the meltblown fibers is received by a collecting device, wherein the collecting device has a receiving net, and the moving speed of the receiving net is between 1 m / min and 5 m / min. The first portion of the meltblown fibers is brought to the collecting device by the rotation of the roller device.

[0005] In some embodiments disclosed herein, the meltblown apparatus has a plurality of discharge orifices, and the density of the discharge orifices is between 35 orifices / inch and 65 orifices / inch.

[0006] In some embodiments disclosed herein, the meltblown device sprays molten fibers perpendicular to the receiving surface of the collecting device.

[0007] In some embodiments disclosed herein, the method for manufacturing three-dimensional nonwoven fabric further includes passing a first portion of meltblown fibers between the roller assembly and the collecting device through rotation of the roller assembly.

[0008] In some embodiments disclosed herein, the method for manufacturing three-dimensional nonwoven fabric further includes causing meltblown fibers to pass between the roller device and the collection device through the rotation of the roller device and the conveying of the collection device to form a three-dimensional nonwoven fabric.

[0009] In some embodiments disclosed herein, when the roller assembly rotates, the tangential direction of the side of the roller assembly adjacent to the collecting device is the same as the conveying direction of the receiving surface of the collecting device.

[0010] In some embodiments disclosed herein, the vertical distance between the roller assembly and the collecting device is between 10 mm and 100 mm.

[0011] In some embodiments disclosed herein, the bulk of the three-dimensional nonwoven fabric is between 150 cubic inches per ounce and 600 cubic inches per ounce.

[0012] In some embodiments disclosed herein, the basis weight of the three-dimensional nonwoven fabric is between 25 g / m² and 550 g / m².

[0013] In some embodiments disclosed herein, the meltblown fiber material includes polyolefin, polyester, polyurethane and nylon, and the diameter of the meltblown fiber in the three-dimensional nonwoven fabric is between 0.2 micrometers and 20 micrometers.

[0014] According to the above-described embodiments disclosed herein, the method for manufacturing three-dimensional nonwoven fabric involves rotating a roller assembly to allow a first portion of meltblown fibers to reach the receiving net of a collecting device, and together with a second portion of meltblown fibers, pass between the roller assembly and the collecting device, thereby forming a three-dimensional nonwoven fabric. By adjusting the moving speed of the receiving net within an appropriate range, the formed three-dimensional nonwoven fabric can have a certain thickness and good bulkiness. Attached Figure Description

[0015] To make the above and other objects, features, advantages and embodiments disclosed herein more apparent and understandable, the accompanying drawings are described below:

[0016] Figure 1 A side view schematic diagram of a textile apparatus according to an embodiment of the present disclosure is shown;

[0017] Figure 2 Draw Figure 1 A side view of textile equipment, in which Figure 2 The direction of the view is perpendicular to Figure 1 The perspective and direction;

[0018] Figure 3 Drawing usage Figure 1 A flowchart for manufacturing three-dimensional nonwoven fabrics using textile equipment.

[0019] [Symbol Explanation]

[0020] 100: Textile Equipment

[0021] 110: Meltblown equipment

[0022] 112: Exhaust Hole

[0023] 120: Collection device

[0024] 122: Chengjie.com

[0025] 124: Conveying elements

[0026] 126: Suction element

[0027] 130: Roller assembly

[0028] 140: Connecting element

[0029] 200: 3D nonwoven fabric

[0030] F: Meltblown fiber

[0031] F1: Part 1

[0032] F2: Part Two

[0033] L: Distance

[0034] H: Thickness

[0035] S10~S40: Steps Detailed Implementation

[0036] The following describes several embodiments of this disclosure with reference to the accompanying drawings. For clarity, many practical details will be described in the following description. However, it should be understood that these practical details should not be used to limit this disclosure. That is, in some embodiments of this disclosure, these practical details are not essential and therefore should not be used to limit this disclosure. Furthermore, for the sake of simplicity in the drawings, some known and conventional structures and components will be shown in a simple schematic manner. In addition, for the reader's convenience, the dimensions of the components in the drawings are not drawn to scale.

[0037] This disclosure provides a method for manufacturing three-dimensional nonwoven fabric, which is accomplished using textile equipment equipped with roller devices. Through the rotation of the roller devices, some of the meltblown fibers are pulled by the roller devices before reaching the collection device, thereby giving the manufactured three-dimensional nonwoven fabric a certain thickness and good bulkiness.

[0038] Figure 1The illustration shows a side view of a textile apparatus 100 according to one embodiment of the present disclosure. The textile apparatus 100 includes a meltblown device 110, a collecting device 120, and a roller assembly 130. The meltblown device 110 is configured to spray meltblown fibers F. In some embodiments, the meltblown device 110 has at least one discharge orifice 112 through which the meltblown fibers F are sprayed. The collecting device 120 is configured to collect the meltblown fibers F sprayed by the meltblown device 110. In some embodiments, the collecting device 120 has a receiving net 122 and a conveying element 124, the receiving net 122 being disposed on the surface of the conveying element 124 to continuously receive the meltblown fibers F through the actuation of the conveying element 124. Specifically, the conveying element 124 may be, for example, a combination of a conveying roller and a conveyor belt. In some embodiments, the collecting device 120 has a suction element 126 disposed on the other side of the conveying element 124 opposite to the receiving net 122, thereby providing suction to guide the meltblown fibers F to the receiving net 122. A roller assembly 130 is disposed between the meltblown device 110 and the collecting device 120, configured to receive a portion of the meltblown fibers F, and rotates to bring the received meltblown fibers F to the collecting device 120.

[0039] Figure 2 Draw Figure 1 A side view of a textile equipment 100, wherein... Figure 2 The direction of the view is perpendicular to Figure 1 The viewing direction. In some embodiments, the meltblown device 110 has a plurality of discharge holes 112, and the arrangement direction of the plurality of discharge holes 112 is parallel to the extension direction of the roller device 130. In some embodiments, the collecting device 120 can support the roller device 130 through a connecting element 140, and the connecting element 140 can electrically connect the collecting device 120 and the roller device 130, and further electrically connect to a central system (not shown), such as a computer, so as to transmit the movement of the receiving net 122 and the rotation of the roller device 130 to the central system in real time for appropriate control.

[0040] Figure 3 Drawing usage Figure 1 A flowchart illustrating the manufacturing process of three-dimensional nonwoven fabric using textile equipment 100. The method for manufacturing three-dimensional nonwoven fabric includes steps S10, S20, S30, and S40. In step S10, meltblown fibers are ejected using a meltblown device. In step S20, a first portion of the meltblown fibers is received by a roller device. In step S30, a second portion of the meltblown fibers is received by a collecting device. In step S40, the first portion of the meltblown fibers is brought to the collecting device by the rotation of the roller device. The above steps will be further explained in the following description.

[0041] Please also refer to Figure 1 and Figure 3In step S10, the textile equipment 100 ejects meltblown fibers F through the ejection orifices 112 of the meltblown device 110. In some embodiments, the single-orifice ejection rate of the meltblown fibers F is between 0.01 g / min and 0.50 g / min. In some embodiments, when the meltblown device 110 has multiple ejection orifices 112, the density of the ejection orifices 112 is between 35 orifices / inch and 65 orifices / inch. With the above configuration, it can be ensured that the meltblown device 110 ejects a certain weight of meltblown fibers F per unit time, thereby ensuring that the formed three-dimensional nonwoven fabric 200 has an appropriate basis weight.

[0042] In some embodiments, the meltblown device 110 sprays meltblown fibers F perpendicular to the receiving surface of the collecting device 120, wherein the receiving surface is the surface of the receiving mesh 122 facing the discharge orifice 112. In this way, when the receiving surface is parallel to the ground, the meltblown fibers F can more easily fall onto the collecting device 120 and the roller assembly 130 located between the meltblown device 110 and the collecting device 120 due to gravity. In some embodiments, the diameter of the meltblown fibers F in the formed three-dimensional nonwoven fabric 200 is between 0.2 micrometers and 20 micrometers. In some embodiments, the material of the meltblown fibers F includes polyolefins, polyesters, polyurethanes, nylon, or any combination thereof. By selecting appropriate materials, the formed three-dimensional nonwoven fabric 200 can have corresponding uses. For example, if polyolefins are used, the formed three-dimensional nonwoven fabric 200 can be used as a sound-absorbing and noise-reducing material; if polyesters are used, the formed three-dimensional nonwoven fabric 200 can be used as a thermal insulation material.

[0043] In step S20, the textile equipment 100 receives the first portion F1 of the meltblown fiber F using a roller device 130. Next, in step S30, the textile equipment 100 receives the second portion F2 of the meltblown fiber F using a collecting device 120. Specifically, since the roller device 130 is located between the meltblown device 110 and the collecting device 120, and the roller device 130 only partially overlaps with the meltblown device 110, after the meltblown device 110 sprays the meltblown fiber F, the first portion F1 of the meltblown fiber F will first reach the roller device 130, while the second portion F2 of the meltblown fiber F will directly reach the receiving net 122 of the collecting device 120.

[0044] In step S40, when the first portion F1 of the meltblown fiber F arrives at the roller device 130, it is rotated by the roller device 130 and reaches the collecting device 120. Then, the first portion F1 of the meltblown fiber F that has arrived at the collecting device 120 is rotated by the roller device 130 and moves between the roller device 130 and the collecting device 120, passing through the space between them. Simultaneously, when the second portion F2 of the meltblown fiber F arrives at the collecting device 120, it is conveyed by the conveying element 124 of the collecting device 120 and moves between the roller device 130 and the collecting device 120, passing through the space between them. In other words, through the rotation of the roller device 130 and the conveying by the collecting device 120, the entire meltblown fiber F can pass between the roller device 130 and the collecting device 120, thereby forming a three-dimensional nonwoven fabric 200.

[0045] In some embodiments, when the roller assembly 130 rotates, the tangential direction of the side of the roller assembly 130 adjacent to the collecting device 120 is the same as the conveying direction of the receiving surface of the collecting device 120. This allows each meltblown fiber F between the roller assembly 130 and the collecting device 120 to move in the same direction, resulting in a neat and stable structure for the formed three-dimensional nonwoven fabric 200, and giving the meltblown fibers F in the three-dimensional nonwoven fabric 200 a meniscus structure with a consistent orientation. The spaces between the meltblown fibers F with the meniscus structure can act as air chambers to accommodate air, thereby increasing the bulkiness of the three-dimensional nonwoven fabric 200.

[0046] In some embodiments, the moving speed of the receiving net 122 of the collecting device 120 is between 1 meter / minute and 5 meters / minute. By adjusting the moving speed of the receiving net 122 of the collecting device 120 within the above-mentioned suitable range, the formed three-dimensional nonwoven fabric 200 can have a better thickness H. Specifically, if the moving speed of the receiving net 122 is too large, the number of meltblown fibers F that the receiving net 122 can receive per unit area is too small, resulting in the formed three-dimensional nonwoven fabric 200 being too thin; if the moving speed of the receiving net 122 is too small, the number of meltblown fibers F that the receiving net 122 can receive per unit area is too large, resulting in the formed three-dimensional nonwoven fabric 200 being too thick. Furthermore, if the moving speed of the receiving net 122 is too large, the formed three-dimensional nonwoven fabric 200 will not be able to form a highly entangled fiber web due to insufficient number of meltblown fibers F, thereby affecting the stability of the three-dimensional nonwoven fabric 200 structure.

[0047] In some embodiments, the vertical distance L between the roller assembly 130 and the collecting device 120 is between 10 mm and 100 mm. By adjusting the vertical distance L between the roller assembly 130 and the collecting device 120 to the aforementioned suitable range, the formed three-dimensional nonwoven fabric 200 can also have a better thickness H. Specifically, the vertical distance L between the roller assembly 130 and the collecting device 120 can determine the stacking thickness of the meltblown fibers F therebetween, and thus can affect the thickness H of the formed three-dimensional nonwoven fabric 200. In some embodiments, the thickness H of the three-dimensional nonwoven fabric 200 is between 0.5 mm and 100 mm.

[0048] In some embodiments, the three-dimensional nonwoven fabric 200 achieves good bulkiness through the interplay between its base fabric weight and its thickness H. As previously mentioned, since the base fabric weight of the three-dimensional nonwoven fabric 200 is related to the single-hole output rate of the meltblown fiber F, and the thickness H of the three-dimensional nonwoven fabric 200 is related to the moving speed of the receiving net 122 and the vertical distance L between the roller assembly 130 and the collecting device 120, the bulkiness of the three-dimensional nonwoven fabric 200 can be improved by adjusting the single-hole output rate of the meltblown fiber F, the moving speed of the receiving net 122, and the vertical distance L between the roller assembly 130 and the collecting device 120 within appropriate ranges. In some embodiments, the base fabric weight of the three-dimensional nonwoven fabric 200 is between 25 g / m² and 550 g / m². In some embodiments, the bulkiness of the three-dimensional nonwoven fabric 200 is between 150 cubic inches / ounce and 600 cubic inches / ounce.

[0049] In the following description, the three-dimensional nonwoven fabrics of Embodiments 1 to 6 and Comparative Example 1 disclosed herein will be further illustrated. The three-dimensional nonwoven fabrics of each embodiment are manufactured by performing steps S10 to S40, while the comparative example is manufactured by using a known two-roller spinning apparatus with known steps. Detailed descriptions of each embodiment and comparative example are shown in Table 1.

[0050] Table 1

[0051]

[0052]

[0053] Next, the base fabric weight, thickness, bulkiness, compression recovery rate, horizontal tensile strength, and horizontal peel strength of the three-dimensional nonwoven fabrics of Examples 1 to 6 and Comparative Example 1 of this disclosure will be measured to further verify the effectiveness of this disclosure. The test results are shown in Table 2 below.

[0054] Table 2

[0055]

[0056]

[0057] As shown in Table 2, after the same manufacturing time, the three-dimensional nonwoven fabrics of Examples 1 to 6 have a larger base fabric weight, thickness, and better bulkiness compared to the three-dimensional nonwoven fabric of Comparative Example 1. Furthermore, the three-dimensional nonwoven fabrics of Examples 1 to 6 have good compression recovery rate, meaning they possess good elasticity. Additionally, the three-dimensional nonwoven fabrics of Examples 1 to 6 have certain horizontal tensile strength and horizontal peel strength, indicating a stable structure.

[0058] According to the above-described embodiment disclosed herein, the textile equipment, through the rotation of the roller device, allows a first portion of the meltblown fiber to reach the collecting device and pass together with a second portion of the meltblown fiber between the roller device and the collecting device, thereby forming a three-dimensional nonwoven fabric. By adjusting the moving speed of the receiving net of the collecting device, the single-hole output rate of the meltblown fiber, and the vertical distance between the roller device and the collecting device to a suitable range, the formed three-dimensional nonwoven fabric can have a certain thickness and good bulkiness.

[0059] Although the present disclosure has been described above with reference to embodiments, it is not intended to limit the present disclosure. Anyone with ordinary knowledge in the art to which this disclosure pertains may make various modifications and refinements without departing from the spirit and scope of this disclosure. Therefore, the scope of protection of this disclosure shall be determined by the scope defined in the appended claims.

Claims

1. A method for manufacturing a three-dimensional nonwoven fabric, characterized in that, include: Meltblown fibers are ejected using a meltblown device, wherein the single-hole ejection rate of the meltblown fibers is between 0.01 g / min and 0.50 g / min; The first portion of the meltblown fiber is received by a roller device; A second portion of the meltblown fiber is received by a collecting device, wherein the collecting device has a receiving net, the moving speed of the receiving net is between 1 meter / minute and 5 meters / minute, and the vertical distance between the roller device and the collecting device is between 10 mm and 100 mm; The first portion of the meltblown fiber is brought to the collecting device by the rotation of the roller device; as well as Through the rotation of the roller device and the conveying of the collecting device, the first and second portions of each meltblown fiber pass between the roller device and the collecting device, so that each first and second portion together form a crescent-shaped structure to form the three-dimensional nonwoven fabric.

2. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, The meltblown device has a plurality of discharge holes, and the density of the discharge holes is between 35 holes / inch and 65 holes / inch.

3. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, The meltblown device sprays the meltblown fiber perpendicular to the receiving surface of the collecting device.

4. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, It also includes allowing the first portion of the meltblown fiber to pass between the roller assembly and the collecting device through the rotation of the roller assembly.

5. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, When the roller device rotates, the tangential direction of the side of the roller device adjacent to the collecting device is the same as the conveying direction of the receiving surface of the collecting device.

6. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, The bulk of the three-dimensional nonwoven fabric is between 150 cubic inches per ounce and 600 cubic inches per ounce.

7. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, The base fabric of the three-dimensional nonwoven fabric has a weight between 25 g / m² and 550 g / m².

8. The method for manufacturing three-dimensional nonwoven fabric according to claim 1, characterized in that, The meltblown fibers are made of polyolefins, polyesters, polyurethanes and nylons, and the diameter of the meltblown fibers in the three-dimensional nonwoven fabric is between 0.2 micrometers and 20 micrometers.

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