A composite nonwoven material and a method of making the same, an apparatus for making a composite nonwoven material

Abstract

The present application belongs to the technical field of non-woven materials, and particularly relates to a composite non-woven material, a preparation method thereof, and an apparatus for preparing the composite non-woven material. The present application is provided with two layers of fiber web layers, which is beneficial to later heat bonding, can greatly improve the overall strength of dry / wet fiber web, increase the tensile strength and reduce the occurrence of structural tearing, and greatly reduce the linting rate of consumers in the use process. In the present application, the mixed jet layer of cellulose fiber and polymer filament blend utilizes the cellulose fiber to endow the non-woven material with excellent hydrophilic performance and softness; and the absorbent core layer greatly improves the water absorption rate and water absorption capacity of the material. The composite non-woven material provided by the present application has good mechanical properties, excellent water absorption and wear resistance, and low linting performance.

Description

Technical Field

[0001] This invention belongs to the field of nonwoven materials technology, specifically relating to a composite nonwoven material and its preparation method, as well as equipment for preparing the composite nonwoven material. Background Technology

[0002] Nonwoven fabrics are increasingly widely 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 have the largest usage and will continue to show an upward trend in the coming decades. In today's life, from baby care to adult personal care, from facial wipes to skin care masks, from household wiping to car interior cleaning, from mobile phone cleaning to computer screen dusting, and even the cleaning of machinery and precision instruments, wiping materials are ubiquitous. However, existing nonwoven materials have problems such as poor water absorption, poor abrasion resistance, low strength, and lint shedding, which greatly reduces their user experience. Summary of the Invention

[0003] In view of this, the present invention provides a composite nonwoven material and a method for preparing the same, as well as an apparatus for preparing the composite nonwoven material. The composite nonwoven material provided by the present invention has good mechanical properties, excellent water absorption and abrasion resistance, and low lint shedding performance.

[0004] To address the aforementioned technical problems, this invention provides a composite nonwoven material comprising a layer structure with the following mass percentages:

[0005]

[0006] 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 include cellulose fibers and polymer filaments.

[0007] The first and second fiber web layers are polymer filaments, respectively.

[0008] Preferably, the polymer filaments in the first and second fiber web layers have a length greater than 5 cm and a diameter of 0.1–30 μm.

[0009] The first and second fiber web layers also independently include one or more of the following: functional masterbatch, hydrophilic additives, hydrophilic softeners, essential oils, and mosquito repellent additives.

[0010] Preferably, the length of the cellulose fibers in the first and second mixed-spray layers is independently 0.5 to 8 mm, and the mass ratio of cellulose fibers to polymer filaments in the first and second mixed-spray layers is independently 10 to 90: 9.8 to 70.

[0011] Preferably, the absorbent core layer comprises one or more of a superabsorbent polymer, cellulose fiber, and a polymeric gel material.

[0012] The present invention also provides an apparatus for preparing the composite nonwoven material described in the above technical solution, including a web forming curtain 30, a suction device 31, and a first fiber web system, a first mixed spray forming system, an absorbent core system 13, a second mixed spray forming system, and a second fiber web system connected in series above the web forming curtain;

[0013] The first fiber web system includes a first meltblown unit or a first spunbond unit; the first mixed-blown molding system includes a third meltblown unit, a first opening unit, a fourth meltblown unit and a first mixed-blown molding box 09; the second mixed-blown molding system includes a fifth meltblown unit, a second opening unit, a sixth meltblown unit and a second mixed-blown molding box 19; the second fiber web system includes a second meltblown unit or a second spunbond unit.

[0014] Preferably, it also includes a thermal bonding system 32, a web quality inspection system, a finishing system 36, and a packaging system 37; the web quality inspection system includes a metal detection unit 33, a web weight detection unit 34, and a web defect detection unit 35.

[0015] Preferably, the first meltblown unit includes a first spinning box 01, a first screw extruder 02, a first feeding device 03, and a first spinneret 57;

[0016] 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 traction device 42, and a first spunbond splitter 43.

[0017] The third meltblown unit includes a second feeding device 04, a second screw extruder 05, a third spinning box 06, and a third spinneret 58;

[0018] The first loosening unit includes a first loosening device 07 and a first multi-row orifice CD ejector 08;

[0019] The fourth meltblown unit includes a fourth feeding device 10, a fourth screw extruder 11, a fourth spinning box 12, and a fourth spinneret 59;

[0020] The fifth meltblown unit includes a fifth feeding device 14, a fifth screw extruder 15, a fifth spinning box 16, and a fifth spinneret 60;

[0021] The second loosening unit includes a second loosening device 17 and a second multi-row CD ejector 18;

[0022] The sixth meltblown unit includes a sixth feeding device 20, a sixth screw extruder 21, a sixth spinning box 22, and a sixth spinneret 61;

[0023] 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;

[0024] 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 traction device 55, and a second spunbond splitter 56.

[0025] Preferably, the first meltblown unit further includes a first cooling spray system 26, the outlet of the first mixed spray molding box 09 is provided with a second cooling spray system 27, the outlet of the second mixed spray molding box 19 is provided with a third cooling spray system 28, and the second meltblown unit further includes a fourth cooling spray system 29.

[0026] The present invention also provides a method for preparing the composite nonwoven material described in the above-described technical solution using the equipment described in the above-described technical solution, comprising the following steps:

[0027] The first polymer is melted and sprayed onto the web forming curtain 30 using the first fiber web system to obtain the first fiber web layer;

[0028] The second polymer is melted in the third and fourth meltblown units, and the first cellulose fiber raw material is crushed in the first opening unit. The molten second polymer and the crushed first cellulose fiber raw material are transported to the first mixing and spraying molding box 09, mixed and then sprayed onto the surface of the first fiber web layer to form the first mixing and spraying layer.

[0029] The absorbent material is sprayed onto the surface of the first mixed spray layer through the absorbent core system 13 to form the absorbent core layer;

[0030] The third polymer is melted in the fifth and sixth meltblown units, and the second cellulose fiber raw material is crushed in the second opening unit. The molten third polymer and the crushed second cellulose fiber raw material are transported to the second mixing and spraying molding box 19, mixed and then sprayed onto the surface of the absorbent core layer to form the second mixing and spraying layer.

[0031] The fourth polymer is melted and sprayed onto the surface of the second mixed spray layer using the second fiber web system to obtain the second fiber web layer.

[0032] Preferably, after forming the second fiber web layer, the process further includes: sequentially collecting, sorting, and packaging the product containing 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;

[0033] The finishing process includes one or more of the following: embossing, printing, punching, deformation, surface treatment, thermal bonding, ultrasonic bonding, cutting, stacking, and wet wipe processing.

[0034] This invention provides a composite nonwoven material comprising a layered structure with the following mass percentages: 0.2–20% first fiber web layer, 20–50% first mixed-spray layer, 0–10% absorbent core layer, 20–50% second mixed-spray layer, and 0.2–20% second fiber web layer; the first fiber web layer, first mixed-spray layer, absorbent core layer, second mixed-spray layer, and second fiber web layer are sequentially stacked; the first and second mixed-spray layers independently comprise cellulose fibers and polymer filaments; the first and second fiber web layers are each composed of polymer filaments. The two-layer fiber web design facilitates subsequent thermal bonding, significantly improves the overall strength of the dry / wet fiber web, increases tensile strength, reduces structural tearing, and greatly reduces lint shedding during use. In this invention, the mixed-spray layer, a blend of cellulose fibers and polymer filaments, utilizes cellulose fibers to impart excellent hydrophilicity and softness to the nonwoven material; the absorbent core layer significantly improves the material's water absorption rate and capacity. The composite nonwoven material provided by this invention has good mechanical properties, excellent water absorption and abrasion resistance, and low lint shedding performance. Attached Figure Description

[0035] Figure 1 Schematic diagrams of the structure of "slit air knife" meltblown spinnerets and "coaxial" meltblown spinnerets;

[0036] Figure 2 This is a schematic diagram of the cross-sectional structure of a multi-row perforated spinneret.

[0037] Figure 3 A front view of a multi-row spinneret;

[0038] Figure 4 A schematic diagram of the cross-sectional structure of the spinneret holes in a multi-row spinneret.

[0039] Figure 5 This is a schematic diagram of the device used in Example 1;

[0040] Figure 6 This is a schematic diagram of the device used in Example 2;

[0041] Figure 7 This is a schematic diagram of the device used in Example 3;

[0042] Figure 8 This is a schematic diagram of the device used in Example 4;

[0043] Figure 9 This is a schematic diagram of the device used in Example 5;

[0044] Figure 10 This is a schematic diagram of the mixed spray layer structure in the disinfectant wipes prepared in Example 2;

[0045] Figure 11 This is a schematic diagram of the three-dimensional structure of the disinfectant wipes prepared in Example 2;

[0046] Figure 12 This is a schematic diagram of the cross-sectional structure of the disinfectant wipes prepared in Example 2;

[0047] Figure 13 SEM image of the mixed spray layer of the breast milk pad prepared in Example 1;

[0048] Figure 14 This is a SEM image of the surface of the first fiber web layer of the milk overflow pad prepared in Example 1;

[0049] Figure 15 SEM image of the cross-section of the breast pad prepared in Example 1;

[0050] Figure 16 SEM image of PLA on the surface of the facial wipe prepared in Example 4;

[0051] Figures 1-14In the diagram, 01 represents the first spinning box, 02 the first screw extruder, 03 the first feeding device, 04 the second feeding device, 05 the second screw extruder, 06 the third spinning box, 07 the first opening device, 08 the first multi-row orifice CD ejector, 09 the first mixing and spraying molding box, 10 the fourth feeding device, 11 the fourth screw extruder, 12 the fourth spinning box, 13 the core device, 14 the fifth feeding device, 15 the fifth screw extruder, 16 the fifth spinning box, 17 the second opening device, 18 the second multi-row orifice CD ejector, 19 the second mixing and spraying molding box, 20 the sixth feeding device, and 21 the sixth screw extruder. 22 is the sixth spinning box, 23 is the second feeding device, 24 is the second screw extruder, 25 is the second spinning box, 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 forming curtain, 31 is the suction device, 32 is the thermal bonding system, 33 is the metal detection system, 34 is the web weight detection system, 35 is the 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, and 42 is the first spunbond traction device. 43 is the first spunbond splitter; 44 is the entire spinneret; 45 is the spinneret orifice; 46 is the airflow drawing orifice; 47 is the mixed-spinning 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 traction device; 56 is the second spunbond splitter; 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 orifice of the "coaxial" meltblown spinneret; 69 is the "coaxial" meltblown spinneret. The airflow stretching holes of the spinneret are as follows: 70 is the spinneret hole of the "slit air knife" meltblown spinneret; 71 is the airflow stretching hole of the "slit air knife" meltblown 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 splitter. Detailed Implementation

[0052] This invention provides a composite nonwoven material comprising the following layered structure in weight percentages:

[0053]

[0054] 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.

[0055] The composite nonwoven material provided by the present invention comprises, by weight percentage, 0.2-20% of a first fiber web layer, preferably 0.5-13%, and more preferably 1-10%. In the present invention, the first fiber web layer is a polymer filament, and the raw material of the polymer filament is preferably a thermoplastic polymer and / or a biodegradable polymer, more preferably a thermoplastic polymer. In the present invention, the thermoplastic polymer preferably includes 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 this invention, the biodegradable polymer preferably includes one or more of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, protein, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives, more preferably one of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, protein, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives. In this invention, the polymer filament can be single-component, bicomponent, or multicomponent. Multicomponent filaments can have a core-sheath type, side-by-side type, trefoil type, or orange segment type fiber cross-section. The bicomponent filament is obtained by a bicomponent melt spinning web process. The principle is that two different 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 their respective melt filters, melt delivery pipes, and metering pumps. Two melts undergo structural bonding at the outlet of the spinning assembly to form a bicomponent melt stream. After leaving the spinneret, the melt stream is condensed in cooling air and simultaneously drawn and thinned by a stretching airflow at a certain speed to form continuous bicomponent solid filaments, which then fall onto a web-forming curtain for web formation. The raw materials used in bicomponent spun nonwoven fabrics mainly include polypropylene (PP), polyester (PET), polyethylene (PE), and polyamide (PA). Commonly used composite components include PE / PP, PE / PET, PP / PET, and PA / PET. Core-sheath type fibers are soft on the outside and rigid on the inside; parallel type fibers have natural three-dimensional crimp characteristics, resulting in elastic fabrics; trilobal type fibers have high stiffness and good breathability; and orange-petal type fibers are made by splitting a single fiber into 8, 16, or 32 segments, creating ultrafine fibers that are soft and strong, suitable for use in face masks, filter materials, and sound insulation materials. In this invention, the length of the polymer filament is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filament is preferably 0.1–30 μm, more preferably 1–20 μm. In this invention, the melt flow index of the polymer filament is preferably 10–2000 g / 10 min.

[0056] In this invention, the first fiber web layer preferably further includes one or more of the following: functional masterbatch, hydrophilic auxiliaries, hydrophilic softeners, essential oils, and mosquito repellents; more preferably, it includes hydrophilic auxiliaries, hydrophilic softeners, or mosquito repellents. This invention does not have any special requirements regarding the specific types of the functional masterbatch, hydrophilic auxiliaries, hydrophilic softeners, essential oils, and mosquito repellents; conventional materials in the art can be used. In this invention, the functional masterbatch preferably includes hydrophilic masterbatch, elastic masterbatch, reinforcing masterbatch, biodegradable masterbatch, antibacterial masterbatch, cooling masterbatch, antistatic masterbatch, color masterbatch, rust-preventive masterbatch, or curled masterbatch.

[0057] The composite nonwoven material provided by this invention, by weight percentage, comprises 20-50% of a first mixed-spray layer, preferably 25-50%, and more preferably 40-45%. In this invention, the first mixed-spray layer comprises cellulose fibers and polymer filaments. In this invention, the type of raw material for the polymer filaments in the first mixed-spray layer is preferably the same as that for the polymer filaments in the first web layer, and will not be repeated here. In this invention, the length of the polymer filaments in the first mixed-spray layer is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filaments in the first mixed-spray layer is preferably 0.1-30 μm, more preferably 1-10 μm. In this invention, the raw material for the cellulose fibers in the first mixed-spray layer preferably includes wood pulp fibers, paper pulp fibers, coconut shell fibers, chitin fibers, seaweed fibers, or viscose fibers. In this invention, the wood pulp source in the wood pulp fibers is preferably oak, poplar, birch, pine, spruce, or fir; the paper pulp source in the paper pulp fibers is preferably rice straw pulp, reed pulp, sugarcane pulp, bamboo pulp, cotton pulp, hemp pulp, or natural fiber rag pulp. In this invention, the method of obtaining wood pulp preferably includes chemical pulp, mechanical pulp, or chemically modified mechanical pulp, more preferably chemical pulp. In this invention, the chemical pulp can impart excellent softness to nonwoven materials. In this invention, the chemical pulp preferably includes caustic soda process chemical pulp, sulfate process chemical pulp, or sulfite process chemical pulp; the mechanical pulp preferably includes stone mill mechanical pulp, disc mill mechanical pulp, or thermomechanical pulp.

[0058] In this invention, the length of the cellulose fibers in the first mixed-spray layer is preferably 0.5–8 mm, more preferably 0.5–3 mm, and even more preferably 0.5–1.5 mm; the mass ratio of cellulose fibers to polymer filaments in the first mixed-spray layer is preferably 10–90:9.8–70, more preferably 40–70:10–50, and even more preferably 40–70:15–40. In this invention, the first mixed-spray layer preferably also includes functional masterbatch.

[0059] The composite nonwoven material provided by this invention, by weight percentage, comprises 0-10% absorbent core layer, preferably 3-10%, and more preferably 4-8%. In this invention, the absorbent core layer preferably comprises one or more of a superabsorbent polymer, cellulose fiber, polymeric gel material, and solid additives, more preferably a superabsorbent polymer. In this invention, the superabsorbent polymer preferably comprises polyacrylamide (PAA), sodium polyacrylate (SAP), hydrogenated starch (Starch Acrylate), polyvinyl alcohol (PVA), polyamide (PA), or polyurethane (PU), more preferably sodium polyacrylate. In this invention, the cellulose fiber preferably comprises wood pulp fiber, paper pulp fiber, coconut shell fiber, chitin fiber, seaweed fiber, viscose fiber, lignin fiber, expanded graphite, or nanocellulose. In this invention, the polymeric gel material preferably comprises glass gel, polymer gel, or phenolic resin gel. In this invention, the solid additive preferably includes surfactants, odor absorbers, temperature indicators, wetting agents, or antibacterial agents.

[0060] The composite nonwoven material provided by the present invention, by weight percentage, comprises 20-50% of a second co-sprayed layer, preferably 25-50%, and more preferably 40-45%. In the present invention, the second co-sprayed layer comprises cellulose fibers and polymer filaments. In the present invention, the raw materials for preparing the polymer filaments preferably include polyolefin polymers, polyester polymers, biodegradable polymers, polyamide 6 (PA6), polyamide ester (PEA), polytriethylene, polyphenylene sulfide (PPS), or polyoxymethylene (POM). Polyolefin polymers are more preferred. In the present invention, the polyolefin polymer preferably includes polypropylene (PP) or polyethylene (PE), more preferably polypropylene. In the present invention, the polyester polymer preferably includes polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycarbonate (PC), polypropylene terephthalate (PTT), or thermoplastic polyurethane (TPU). In this invention, the biodegradable polymers preferably include polylactic acid (PLA), polybutylene terephthalate (PBAT), polyhydroxyalkanoate (PHA), polycaprolactone (PCL), or polybutylene succinate (PBS).

[0061] In this invention, the length of the polymer filaments in the second co-sprayed layer is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filaments is preferably 0.1–30 μm, more preferably 1–10 μm. In this invention, the length of the cellulose fibers in the second co-sprayed layer is preferably 0.5–8 mm, more preferably 0.5–3 mm, more preferably 0.5–1.5 mm; the mass ratio of cellulose fibers to polymer filaments in the second co-sprayed layer is preferably 10–90:9.8–70, more preferably 40–70:20–40. In this invention, the second co-sprayed layer preferably further includes functional masterbatch.

[0062] The composite nonwoven material provided by the present invention comprises, by weight percentage, 0.2-20% of a second fiber web layer, preferably 0.5-13%, and more preferably 1-10%. In the present invention, the second fiber web layer is a polymer filament, and the raw material of the polymer filament is preferably a thermoplastic polymer and / or a biodegradable polymer, more preferably a thermoplastic polymer. In the present invention, the thermoplastic polymer preferably includes 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 this invention, the biodegradable polymer preferably includes one or more of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, protein, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives, more preferably one of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, protein, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives. In this invention, the polymer filament can be single-component, bicomponent, or multicomponent; multicomponent filaments are characterized by fiber cross-sections that can be core-sheath type, side-by-side type, trefoil type, or orange segment type. In this invention, the length of the polymer filament is preferably greater than 5 cm, more preferably greater than 10 cm; the diameter of the polymer filament is preferably 0.1–30 μm, more preferably 1–20 μm. In this invention, the second fiber web layer preferably further includes one or more of the following: functional masterbatch, hydrophilic auxiliaries, hydrophilic softeners, essential oils, and mosquito repellents; more preferably, it includes hydrophilic auxiliaries, hydrophilic softeners, or mosquito repellents. This invention does not have any special requirements regarding the specific types of the functional masterbatch, hydrophilic auxiliaries, hydrophilic softeners, essential oils, and mosquito repellents; conventional materials in the art can be used. In this invention, the weights of the polymer filaments in the first and second fiber web layers can be equal or unequal. By adjusting the weight and thickness of the polymer filaments in the first and second fiber web layers, the two surfaces of the composite nonwoven material can have different feel or surface characteristics, such as one side having a rougher or higher frictional feel, while the other side has a smoother feel and lower friction.

[0063] In this invention, the finished products prepared from the composite nonwoven material preferably include face wipes, disposable paper towels, disposable bath towels, disposable napkins, baby wipes, adult wipes, cleaning wipes, wet toilet paper, cosmetic wipes, floor cleaning wipes, body cleaning wipes, disinfectant wipes, industrial wipes, nursing pads, or facial wipes; more preferably, they are body cleaning wipes, disinfectant wipes, industrial wipes, nursing pads, or facial wipes. In this invention, when the nonwoven composite material is used as a wet wipe, the liquid component in the wet wipe preferably includes at least two of the following: skin conditioning agents, waxy substances, diglycerides and triglycerides, silicone oil, acetylglycine, emulsifiers, stabilizers, surfactants, colorants, chelating agents, sunscreens, solubilizers, perfumes, emulsifiers, vitamins, viscosity modifiers, and topical analgesics. In this invention, the skin conditioning agent is preferably an emollient or moisturizer; the waxy substance preferably includes petrolatum, cholesterol, or cholesterol derivatives; the diglycerides and triglycerides are preferably provided by sunflower oil and / or shea butter; the silicone oil is preferably dimethyl silicone oil or octyl ethylene glycol; the acetylglycine ester is preferably lanolin or lanolin derivatives; the surfactant preferably includes anionic surfactants, amphoteric surfactants, cationic surfactants, and nonionic surfactants; the chelating agent is preferably EDTA; and the viscosity modifier is preferably xanthan gum.

[0064] In this invention, the weight of the finished product is preferably 10-200 gsm, more preferably 20-120 gsm, and even more preferably 30-90 gsm.

[0065] The present invention also provides an apparatus for preparing the composite nonwoven material described in the above technical solution, including a web forming curtain 30, a suction device 31, and a first fiber web system, a first mixed spray forming system, an absorbent core system 13, a second mixed spray forming system, and a second fiber web system connected in series above the web forming curtain.

[0066] In one embodiment of the present invention, the first web system includes a first meltblown unit or a first spunbond unit. In another embodiment of the present invention, the first meltblown unit includes a first spinning box 01, a first screw extruder 02, a first feeding device 03, and a first spinneret 57. In yet another embodiment of the present invention, the first spinneret 57 is a "slit-knife" meltblown type spinneret or a "coaxial" meltblown type spinneret. Figure 1This is a schematic diagram of the structure of a "slit-knife" melt-blown spinneret and a "coaxial" melt-blown spinneret. 70 represents the spinneret orifice of the "slit-knife" melt-blown spinneret, 71 represents the airflow stretching orifice of the "slit-knife" melt-blown spinneret, 68 represents the spinneret orifice of the "coaxial" melt-blown spinneret, and 69 represents the airflow stretching orifice of the "coaxial" melt-blown spinneret. In this invention, the "slit-knife" melt-blown spinneret has a single row of holes; the "coaxial" melt-blown spinneret has a single row or multiple rows of holes, preferably including 8, 14, or 16 rows of holes. Figure 2 This is a schematic diagram of the cross-sectional structure of a multi-row perforated spinneret. Figure 3 This is a front view of a multi-row spinneret. Figure 4 This is a schematic diagram of the cross-sectional structure of the spinneret holes in a multi-row air spinneret; where 44 represents the entire spinneret, 45 represents the spinneret hole, and 46 represents the airflow stretching hole. In this invention, the "slit air knife" melt-blown spinneret consists of two stretching gas streams, with the stretching gas forming an angle of approximately 30-70° with the filament flow direction. When the polymer filament leaves the spinneret hole in the melt-blown die, it is cooled and stretched by the air knife, ultimately adhering and falling onto the wire mesh. In the "coaxial" melt-blown spinneret, each spinneret hole is surrounded by an annular fluid release hole, and the stretching gas can form an angle of less than 10° with the filament flow direction, allowing the essentially parallel airflow to coaxially stretch the polymer melt. As an embodiment of this invention, the first melt-blown unit further includes a first cooling spray system 26, which is located at the outlet of the first spinneret 57. In one embodiment of the present invention, 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 traction device 42, and a first spunbond splitter 43. In this invention, cooling water or auxiliary agent solution is preferably atomized by a first cooling spray system 26. In this invention, the spray rate is preferably 0–200 L / h, more preferably 100–180 L / h, and even more preferably 120–160 L / h; the spray pressure is preferably 0–30 bar, more preferably 5–20 bar, and even more preferably 15–20 bar. After atomization by spraying, the sprayed material can quickly adhere to the fiber web layer and then dry immediately.

[0067] In one embodiment of the present invention, the first mixed-blowing molding system includes a third meltblowing unit, a first opening unit, a fourth meltblowing unit, and a first mixed-blowing molding box 09. In another embodiment of the present invention, the third meltblowing unit includes a second feeding device 04, a second screw extruder 05, a third spinning box 06, and a third spinneret 58. In another embodiment of the present invention, the first opening unit includes a first opening device 07 and a first multi-row orifice CD ejector 08. The present invention preferably uses the first opening unit to pulverize cellulose fiber raw materials. The present invention preferably uses an airflow web forming method to evenly distribute the pulverized fibers to different parts. The airflow web forming method mainly includes two types: one is to distribute and lay the web using a CD controllable ejector, and the other is to use an airflow web forming machine to evenly distribute and lay the web along the width direction. The airflow web forming machine can be a dust cage type or a flat screen type. In another embodiment of the present invention, the first opening unit also includes a metal detection system, a spark detection system, and a fire extinguishing system. In this invention, the metal detection system can detect whether cellulose fibers contain heavy metals before feeding them in and remove them in real time. This is because cellulose fibers often retain chemical residues during production, such as heavy metals (lead, cadmium, mercury, arsenic) and phthalates. These residues can irritate mucous membranes, damage cell membranes, and cause allergic reactions; in severe cases, they may even be carcinogenic. Inferior products have extremely serious negative impacts on the human body, leading to various health problems. In this invention, the spark detection system is used to detect sparks generated by the rapidly rotating blades during the opening process, which can ignite the wood pulp. It detects sparks in the fluff pulp dust using a light sensor. Once a spark signal is detected, the fire extinguishing system below the sensor automatically sprays water to extinguish the fire according to the spark's trajectory.

[0068] In one embodiment of the present invention, the fourth meltblown unit includes a fourth feeding device 10, a fourth screw extruder 11, a fourth spinning box 12, and a fourth spinneret 59. When preparing the first mixed-blown layer using the first mixed-blown forming system, the present invention can select to start any one or both of the third and fourth meltblown units.

[0069] In this invention, the meltblown products from the third and fourth meltblown units and cellulose fibers are preferably mixed and molded in a first mixing and forming box 09 to obtain a first mixed-blown layer. As an embodiment of this invention, a second cooling spray system 27 is provided at the outlet of the first mixing and forming box 09. This invention preferably utilizes the second cooling spray system 27 to atomize water or a chemical additive solution. In this invention, the spray rate is preferably 0–200 L / h, and the spray pressure is preferably 0–30 bar, more preferably 5–20 bar, and even more preferably 15–20 bar. This invention, through spray atomization, enables the sprayed material to quickly adhere to the first mixed-blown layer and then dry immediately.

[0070] The present invention preferably utilizes the absorbent core system 13 to spray out the water-absorbing material to form the absorbent core layer.

[0071] In one embodiment of the present invention, the second mixed-spray forming system includes a fifth meltblown unit, a second opening unit, a sixth meltblown unit, and a second mixed-spray forming box 19. In another embodiment, the fifth meltblown unit includes a fifth feeding device 14, a fifth screw extruder 15, a fifth spinning box 16, and a fifth spinneret 60. In another embodiment, the second opening unit includes a second opening device 17 and a second multi-row orifice CD ejector 18. In another embodiment, the sixth meltblown unit includes a sixth feeding device 20, a sixth screw extruder 21, a sixth spinning box 22, and a sixth spinneret 61. When preparing the second mixed-spray layer using the second mixed-spray forming system, the present invention allows for the selection and activation of any one or both of the fifth and sixth meltblown units.

[0072] In this invention, the meltblown products from the fifth and sixth meltblown units and cellulose fibers are preferably mixed and molded in a second mixing and forming box 19 to obtain a second mixed-blown layer. As an embodiment of this invention, a third cooling spray system 28 is provided at the outlet of the second mixing and forming box 19. This invention preferably utilizes the third cooling spray system 28 to spray water or a chemical additive solution for atomization. In this invention, the spray rate is preferably 0–200 L / h, and the spray pressure is preferably 0–30 bar, more preferably 5–20 bar, and even more preferably 15–20 bar. This invention, through spray atomization, enables the sprayed material to quickly adhere to the second mixed-blown layer and then dry immediately.

[0073] In one embodiment of the present invention, the second web system includes a second meltblown unit or a second spunbond unit. In another embodiment, 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. In yet another embodiment, the form of the second spinneret 62 is the same as that of the first spinneret 57, and will not be repeated here. In yet another embodiment, the second meltblown unit further includes a fourth cooling spray system 29, located at the outlet of the second spinneret 62. In yet another embodiment, 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 traction device 55, and a second spunbond splitter 56.

[0074] In this invention, the cooling water or additive solution is preferably atomized by a fourth cooling spray system 29. The spray rate is preferably 0–200 L / h, more preferably 100–180 L / h, and even more preferably 120–160 L / h; the spray pressure is preferably 0–30 bar, more preferably 5–20 bar, and even more preferably 15–20 bar. After atomization, the sprayed material can quickly adhere to the second fiber web layer and then dry immediately.

[0075] In this invention, the first mixed-spray forming system, the second mixed-spray forming system, and the absorbent core system can be one, two, or three sets; each side of the first fiber web system, the second fiber web system, the first mixed-spray forming system, the second mixed-spray forming system, and the absorbent core system preferably has 1 to 3 sets of spunbond units or meltblown units, and the specific composition of multiple sets of spunbond units is preferably the same, and the specific composition of multiple sets of meltblown units is preferably the same. In this invention, the temperature of the spinnerets in the first fiber web system, the second fiber web system, the first mixed-spray forming system, and the second mixed-spray forming system is preferably 150 to 300°C, more preferably 200 to 250°C; the effective spinneret width is preferably 10 to 130 inches, more preferably 15 to 100 inches, and even more preferably 15 to 80 inches.

[0076] As an embodiment of the present invention, the equipment for the composite nonwoven material further includes a thermal bonding system 32, a web quality inspection system, a finishing system 36, and a packaging system 37; the web quality inspection system includes a metal detection unit 33, a web weight detection unit 34, and a web defect detection unit 35.

[0077] The equipment provided by this invention includes a quality inspection system that can quickly detect the weight, metal impurities, and defect types of a product, identify the specific location of impurities and defects, and automatically reject them, thereby improving product quality, increasing production efficiency, and ultimately protecting product quality and consumer rights.

[0078] The present invention also provides a method for preparing the composite nonwoven material described in the above-described technical solution using the equipment described in the above-described technical solution, comprising the following steps:

[0079] The first polymer is melted and sprayed onto the web forming curtain 30 using the first fiber web system to obtain the first fiber web layer;

[0080] The second polymer is melted in the third and fourth meltblown units, and the first cellulose fiber raw material is crushed in the first opening unit. The molten second polymer and the crushed first cellulose fiber raw material are transported to the first mixing and spraying molding box 09, mixed and then sprayed onto the surface of the first fiber web layer to form the first mixing and spraying layer.

[0081] The absorbent material is sprayed onto the surface of the first mixed spray layer through the absorbent core system 13 to form the absorbent core layer;

[0082] The third polymer is melted in the fifth and sixth meltblown units, and the second cellulose fiber raw material is crushed in the second opening unit. The molten third polymer and the crushed second cellulose fiber raw material are transported to the second mixing and spraying molding box 19, mixed and then sprayed onto the surface of the absorbent core layer to form the second mixing and spraying layer.

[0083] The fourth polymer is melted and sprayed onto the surface of the second mixed spray layer using the second fiber web system to obtain the second fiber web layer.

[0084] This invention utilizes a first fiber web system to melt a first polymer and then spray it onto a forming curtain 30 to obtain a first fiber web layer. In this invention, the hot air flow rate required by the first melt-blown unit in the first fiber web system is preferably 0–6000 Nm³. 3 / h, more preferably 2500-5000 Nm 3 / h, more preferably 3000~4500Nm 3 / h; the hot air temperature is preferably 150-300℃, more preferably 190-250℃, and even more preferably 220-240℃. In this invention, the hot air flow rate per hole of the first spinneret in the first fiber web system is preferably 0-0.76 Nm. 3 The density is 0.31 to 0.63 Nm³ / h / hole, more preferably 0.37 to 0.57 Nm³ / h / hole, and even more preferably 0.31 to 0.63 Nm³ / h / hole. 3 The output rate of the first spinneret is preferably 0-0.52 g / min / hole, more preferably 0.1-0.5 g / min / hole, and even more preferably 0.15-0.4 g / min / hole; the temperature of the first spinneret is preferably 150-300℃, more preferably 195-260℃, and even more preferably 225-250℃. In this invention, the output rate of the first fiber web system is preferably 0-250 kg / h, more preferably 47-238 kg / h, and even more preferably 71-190 kg / h. In this invention, the working pressure of the first screw extruder in the first fiber web system is preferably 0-200 MPa, more preferably 50-100 MPa, and even more preferably 60-90 MPa.

[0085] After obtaining the first fiber web layer, the second polymer is melted in the third and fourth melt-blowing units, and the first cellulose fiber raw material is pulverized in the first opening unit. The molten second polymer and the pulverized first cellulose fiber raw material are then transported to the first mixing and spraying molding box 09 for mixing and spraying onto the surface of the first fiber web layer to form the first mixed-blowing layer. In this invention, the hot air flow rates required for the third and fourth melt-blowing units are preferably 0-10000 Nm³. 3 / h, more preferably 4000~8000Nm 3 / h, more preferably 5000~6500Nm 3 The hot air temperature is preferably 150–300℃, more preferably 185–245℃, and even more preferably 225–235℃; the output of the third and fourth meltblown unit systems is preferably 0–450 kg / h, more preferably 83–417 kg / h, and even more preferably 166–417 kg / h. In this invention, the hot air flow rate per hole of the spinneret in the third and fourth meltblown units is preferably 0–0.72 Nm³. 3 / h / hole, more preferably 0.28~0.58Nm 3 / h / hole, more preferably 0.36~0.47Nm 3 The spinneret's single-hole output is preferably 0–0.54 g / min / hole, more preferably 0.1–0.5 g / min / hole, and even more preferably 0.2–0.5 g / min / hole; the spinneret temperature is preferably 150–300°C, more preferably 185–250°C, and even more preferably 210–240°C. In this invention, the operating pressure of the screw extruder in the third and fourth meltblown units is preferably 0–200 MPa, more preferably 40–90 MPa, and even more preferably 50–80 MPa.

[0086] In this invention, the spraying rate during the formation of the first mixed spray layer 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.

[0087] After the first mixed spray layer is formed, the present invention 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.

[0088] After forming the absorbent core layer, the third polymer is melted in the fifth and sixth meltblown units, and the second cellulose fiber raw material is pulverized in the second opening unit. The molten third polymer and the pulverized second cellulose fiber raw material are then transported to the second mixing and forming box 19, mixed, and sprayed onto the surface of the absorbent core layer to form the second mixed-spray layer. In this invention, the process conditions for forming the second mixed-spray layer are preferably the same as those for forming the first mixed-spray layer, and will not be repeated here.

[0089] After forming the second mixed-spray layer, the present invention utilizes a second fiber web system to melt the fourth polymer and spray it onto the surface of the second mixed-spray layer to obtain the second fiber web layer. In the present invention, the process condition parameters of the second fiber web system are preferably the same as those of the first fiber web system, and will not be repeated here.

[0090] In this invention, after forming the second fiber web layer, the process preferably further includes: sequentially collecting, finishing, and packaging the product containing 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. This invention preferably utilizes a netting curtain for collection; the speed of the netting curtain is preferably 50–2000 m / min, more preferably 80–1650 m / min, and even more preferably 400–1500 m / min.

[0091] In this invention, the finishing process preferably includes one or more of embossing, printing, perforation, deformation, surface treatment, thermal bonding, ultrasonic bonding, cutting, stacking, and wet wipe processing. This invention preferably utilizes the textured protrusions of a mesh screen to form patterns for printing. This invention preferably uses a thermal bonding system to perform dot-like or other geometric hot rolling to form specific patterns or shapes; the rollers of the thermal bonding system preferably have a built-in heating function, and the percentage of the hot-bonded area is preferably 2%–15%, more preferably 4%–10%, and even more preferably 5%–7%. The hot rolling temperature in this invention is preferably 90–150°C, more preferably 90–130°C, and even more preferably 110–120°C; the speed is preferably 50–2000 m / min. In this invention, the working pressure of the thermal bonding system is preferably 1–100 bar, more preferably 30–70 bar, and even more preferably 40–45 bar. In this invention, the surface treatment preferably includes chemical additive solution treatment; the chemical additive solution treatment method preferably includes spraying, roller coating or padding; the chemical additives used in the chemical additive solution treatment preferably include one or more of hydrophilic agents, softeners, strength agents, wetting agents, thermochromic colorants, adhesives, latex and dry strength agents. In this invention, 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 fatty alcohol polyoxyethylene 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 thermosensitive inks / dyes, thermochromic materials, and display reagents; the adhesive is preferably an elastic adhesive; the elastic adhesive preferably includes ester adhesives and / or acrylic adhesives; the ester adhesive is preferably ethylene vinyl acetate (EVA); the latex preferably includes acrylic and / or EVA; and the dry strength agent preferably includes carboxymethyl cellulose and / or starch. This invention uses a finishing system 36 to impart certain functionalities to the material, for example, to make functional wet wipes.

[0092] The preparation method provided by this invention consumes less energy, produces environmentally friendly materials, improves the product's water absorption rate, strength, and abrasion resistance, reduces lint shedding, and imparts beautiful patterns to the fabric surface through a thermal bonding system, thus meeting consumers' dual needs for aesthetics and wipeability.

[0093] This invention utilizes multi-fiber co-spunlace technology, eliminating the need for hydroentanglement reinforcement and drying processes during production. This reduces the total carbon emissions over the entire lifecycle of the base fabric by 40%, making it a low-energy-consumption and environmentally friendly material. Its bulkiness is increased by more than 30% compared to traditional hydroentangled fabrics, resulting in a softer feel. It also boasts superior strength, low lint shedding, a soft hand feel, and excellent water absorption.

[0094] To further illustrate the present invention, the technical solutions provided by the present invention will be described in detail below with reference to the embodiments, but they should not be construed as limiting the scope of protection of the present invention.

[0095] Example 1

[0096] by Figure 5 The device shown in the diagram prepares composite nonwoven materials as emulsion pads, wherein the spinneret of the meltblown device is a "coaxial" meltblown type. Figure 13 This is a SEM image of the mixed spray layer of breast pads. Figure 14 This is a SEM image of the surface of the first fiber web layer of the breast pad. Figure 15 The image shows a cross-section of a breast pad, where 47 represents the mixed spray layer structure, 48 represents cellulose fibers (short cellulose fibers), and 49 represents polymer filaments.

[0097] The production of 55gsm breast pads uses polypropylene (LyondellBasell, UK) and softening masterbatch (purchased from Hunan Shengjin New Material Co., Ltd.) as raw materials for the first and second fiber web layers. In the first fiber web layer, polypropylene and softening masterbatch account for 4% of the total weight (2.2gsm), and the softening masterbatch accounts for 1% of the total weight of the first fiber web layer. In the second fiber web layer, polypropylene and softening masterbatch account for 1.8% of the total weight (0.99gsm), and the softening masterbatch accounts for 1% of the total weight of the second fiber web layer. The polymer used in the first and second mixed-spray layers is polypropylene (LyondellBasell...). Basell (UK) accounts for 29.1% of the total weight at 16 gsm, while the cellulose fiber raw material is wood pulp (GP, USA), accounting for 60.1% of the total weight at 33.05 gsm. The absorbent core layer uses superabsorbent polymer (SAP) (purchased from Shandong Nuoer Biotechnology Co., Ltd.), which accounts for 4% of the total weight. A 1% antibacterial agent (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) is sprayed during the finishing process to kill and inhibit bacteria generated during use.

[0098] The preparation method includes the following steps:

[0099] Step 1: Using a melt-blown process, polypropylene and flexible masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through an 8-row spinneret. The operating pressure of the first screw extruder is 75 MPa, the output rate of the first melt-blown unit is 75 kg / h, the output rate per orifice of the first spinneret is 0.16 g / min / orifice, the temperature of the first spinneret is 235℃, and the hot air flow rate of the airflow drawing holes in the first spinneret is 3000 Nm³. 3 The fibers are stretched at a rate of 120 L / h and cooled by spray devices on both sides of the spinneret to form the first fiber web layer (the polymer filaments in the first fiber web layer are longer than 15 cm and have an average diameter of 4.7 μm).

[0100] Step 2: In the first melt-blowing system, the polypropylene granules are heated and melted using the third and fourth melt-blowing units respectively. The operating pressure of the third and fourth screw extruders is 70 MPa, and the third and fourth spinnerets are 14-row spinnerets. The output rates of the third and fourth melt-blowing units are 230 kg / h, the single-hole output rate of the third and fourth spinnerets is 0.14 g / min / hole, the temperature of the third and fourth spinnerets is 225℃, and the hot air flow rate of the airflow drawing holes of the third and fourth spinnerets is 5000 Nm³. 3 The pulp is stretched at a rate of 690 kg / h; the pulp rolls are then transported to the first opening unit for pulverization. The first opening unit processes 690 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4500 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third meltblown unit and the fourth meltblown unit are mixed and sprayed out in the first mixed spray molding box, and cooled by the spraying device on both sides of the spinneret. The spraying volume is 130L / h, forming the first mixed spray layer covering the surface of the first fiber web layer (the length of the polymer filaments in the first mixed spray layer is greater than 15cm and the average diameter is 5.3μm).

[0101] Step 3: Superabsorbent polymer (SAP) resin is sprayed from the first core system to form an absorbent core layer that covers the surface of the first mixed spray layer;

[0102] Step 4: The fifth and sixth meltblown units heat and melt the polypropylene granules. The operating pressure of the fifth and sixth screw extruders is 71 MPa. The fifth and sixth spinnerets are 14-row spinnerets. The output rate of the fifth and sixth meltblown units is 230 kg / h, the single-hole output rate of the fifth and sixth spinnerets is 0.14 g / min / hole, the temperature of the fifth and sixth spinnerets is 226℃, and the hot air flow rate of the airflow drawing holes of the fifth and sixth spinnerets is 5100 Nm³. 3 The pulp is stretched at a rate of 690 kg / h; the pulp rolls are then transported to the second opening system for pulverization. The second opening system processes 690 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipeline is evenly dispersed. Finally, the polypropylene filaments and wood pulp fibers formed by the fifth and sixth meltblown units are mixed and sprayed out in the second mixed-blown molding box, and cooled by the spraying devices on both sides of the spinneret. The spraying rate is 130L / h, forming a second mixed-blown layer covering the surface of the absorbent core layer (the length of the polymer filaments in the second mixed-blown layer is greater than 15cm and the average diameter is 5.3μm).

[0103] Step 5: Using a melt-blown process, polypropylene and flexible masterbatch are mixed, heated, and melted, then sprayed onto the surface of the second mixed-blown layer through an 8-row spinneret. The operating pressure of the second screw extruder is 76 MPa, the output rate of the second melt-blown unit is 75 kg / h, the output rate per orifice of the second spinneret is 0.16 g / min / orifice, the temperature of the second spinneret is 235℃, and the hot air flow rate of the airflow stretching orifice of the second spinneret is 3100 Nm³. 3 The fibers are stretched at a rate of 120L / h and cooled by spray devices on both sides of the spinneret. This forms a second fiber web layer covering the surface of the second mixed-spinning layer (the polymer filaments in the second fiber web layer are longer than 15cm and have an average diameter of 4.7μm).

[0104] Step Six: The first fiber web layer, first mixed spray layer, absorbent core layer, second mixed spray layer, and second fiber web layer formed in steps one through five are used to collect the composite nonwoven material through a web-forming curtain at a speed of 500 m / min. Then, a hot-pressing system is used for dot-shaped hot rolling and shaping. The rollers in the hot-pressing system have a built-in heating function, and the hot-pressing area is 6.2%. This forms a multi-layered composite nonwoven material with two upper and lower fiber web layers, two middle mixed spray layers, and an absorbent core layer. The fiber web weight, metal content, and defects are inspected using a fiber web quality inspection system to ensure product quality. Finally, a 1% antibacterial agent is sprayed onto the surface using a finishing device, and the product is packaged using a packaging system to obtain the breast milk pad.

[0105] Example 2

[0106] by Figure 6 The device with the structure shown is used to prepare composite nonwoven materials for use as disinfectant wipes; Figure 10 This is a schematic diagram of the mixed spray layer structure in disinfectant wipes. Figure 11 This is a schematic diagram of the three-dimensional structure of disinfectant wipes. Figure 12 This is a schematic diagram of the cross-sectional structure of disinfectant wipes, where 47 is the mixed spray layer structure, 48 is cellulose fiber (short cellulose fiber), 49 is polymer filament, and 50 is pulp fiber;

[0107] The production of 55gsm disinfectant wipes comprises the following raw materials: the first fiber web layer uses a core-sheath type polypropylene / polyester bicomponent masterbatch (Lyondell Basell, UK) with a melt index of 35g / 10min and a hydrophilic masterbatch (purchased from Hunan Shengjin New Material Co., Ltd.), accounting for 2.9% of the total weight, totaling 1.6gsm; the second fiber web layer uses a core-sheath type 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, both totaling 1.6gsm. The mass ratio of hydrophilic masterbatch to polypropylene / polyester bicomponent masterbatch is 2:98. The polymers used in the first and second co-spray layers are polypropylene (Exxon... Mobil (USA) and hydrophilic masterbatch, the polymer in the first and second co-spray layers together accounts for 32.8% of the total weight, 18 gsm, and the mass ratio of hydrophilic masterbatch to polypropylene is 2:98; the raw material for the cellulose fibers in the first and second co-spray layers is wood pulp (GP, USA), and the cellulose fibers in the first and second co-spray layers together account for 53.4% ​​of the total weight, 29.4 gsm; the raw material for the absorbent core layer is recycled pulp fiber, which is processed by an opening system to a length of 0.5-1.5 mm, and this pulp accounts for 8% of the total weight. The finishing process uses a wet wipe machine to make 80-sheet wet wipes, the liquid content of the wet wipes is set to 2%, and finally the wet wipes are packaged into finished disinfectant wet wipes by a packaging machine.

[0108] The preparation method of disinfectant wipes includes the following steps:

[0109] Step 1: Using spunbond technology, the core-sheath type polypropylene / polyester bicomponent masterbatch and hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto the forming curtain through a multi-row spinneret. (This core-sheath type polypropylene / polyester bicomponent masterbatch has the advantages of a soft outer layer and a high inner layer.) The spunbond filaments enter the first spunbond spinning assembly 40 through the first spunbond cooling device 41, are cooled by the first spunbond traction device 42, are stretched by the first spunbond filament separator 43, and finally laid on the forming curtain 30 to form the first fiber web layer (the polymer filaments in the first fiber web layer are longer than 20 cm and have an average diameter of 18.3 μm).

[0110] Step Two: In the first meltblown system, the third and fourth meltblown units heat and melt the polypropylene granules. The operating pressure of the third and fourth screw extruders is 69 MPa, and the third and fourth spinnerets are 16-row spinnerets. The output rate of both the third and fourth meltblown units is 247 kg / h, the single-hole output rate of the third and fourth spinnerets is 0.15 g / min / hole, the temperature of the third and fourth spinnerets is 226℃, and the hot air flow rate of the airflow drawing holes of the third and fourth spinnerets is 5100 Nm³. 3The pulp is stretched at a rate of 700 kg / h; the pulp rolls are then transported to the first opening system for pulverization. The first opening system processes 700 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third meltblown unit and the fourth meltblown unit are mixed and sprayed out in the first mixed spray molding box, and cooled by the spraying device on both sides of the spinneret. The spraying volume is 130L / h, forming the 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.

[0111] Step 3: Pulp fibers are ejected from the absorbent core system to form an absorbent core layer that covers the surface of the first mixed-blown layer;

[0112] Step 4: The fifth and sixth meltblown units heat and melt the polypropylene granules. The operating pressure of the fifth and sixth screw extruders is 69 MPa. The fifth and sixth spinnerets are 16-row spinnerets. The output rate of both the fifth and sixth meltblown units is 247 kg / h. The single-hole output rate of the fifth and sixth spinnerets is 0.15 g / min / hole. The temperature of the fifth and sixth spinnerets is 226℃. The hot air flow rate of the airflow drawing holes in the fifth and sixth spinnerets is 5100 Nm³. 3 The pulp is stretched at a rate of 700 kg / h; the pulp rolls are then transported to the second opening system for pulverization. The second opening system processes 700 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipeline is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the fifth meltblown unit and the sixth meltblown unit are mixed and sprayed out in the second mixed spray molding box, and cooled by the spraying device on both sides of the spinneret. The spraying volume 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) covering the absorbent core layer.

[0113] Step 5: Using a melt-blown process, the polypropylene / polyester bicomponent masterbatch and the flexible masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through a 10-row spinneret. The operating pressure of the first screw extruder is 76 MPa, the output rate of the first melt-blown unit is 75 kg / h, the output rate per orifice of the first spinneret is 0.16 g / min / orifice, the temperature of the first spinneret is 235℃, and the hot air flow rate of the airflow drawing holes in the first spinneret is 3100 Nm³. 3 The fibers are stretched at a rate of 120L / h and cooled by spray devices on both sides of the spinneret. This forms a second fiber web layer (in which the polymer filaments are longer than 20cm and have an average diameter of 4.3μm) that covers the second mixed-spinning layer.

[0114] Step Six: The first fiber 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 fiber web layer formed in steps one to five are collected by a web-forming curtain at a speed of 527 m / min. Then, a thermal bonding system is used for hot rolling to form a cat and dog pattern. The rollers of the thermal bonding system have a built-in heating function, and the thermal bonding area is 5.9%. This forms a multi-layered composite nonwoven material with two upper and lower fiber web layers, two middle mixed spray layers, and an absorbent core layer. The fiber web weight, metal content, and defects are inspected by a fiber web quality inspection system to ensure product quality. Finally, a 2% liquid addition process is used to produce disinfectant wipes, which are then packaged using a packaging system to obtain the disinfectant wipes.

[0115] Example 3:

[0116] by Figure 7 The device shown prepares a composite nonwoven material as an industrial wipe (excluding the absorbent core layer), comprising a first fiber web layer, a first mixed spray layer, a second mixed spray layer, and a second fiber web layer bonded together from bottom to top.

[0117] The production of 55 gsm industrial wipes involves using blue polypropylene masterbatch (Exxon Mobil, USA) with a melt index of 40 g / 10 min for the first and second fiber web layers, each containing 4.4 gsm and accounting for 8% of the total weight. The polymers used in the first and second mixed-spray layers are also polypropylene (Exxon Mobil, USA), comprising 29.1% of the total weight (16 gsm). The cellulose fibers used in the first and second mixed-spray layers are made from wood pulp (GP, USA), comprising 51.9% of the total weight (28.55 gsm). A 2% hydrophilic additive (purchased from Zhejiang Transfar Chemical Group Co., Ltd.) is sprayed using the equipment's built-in spray system, and a 1% adhesive (purchased from Zhejiang Transfar Chemical Group Co., Ltd.) is applied using a finishing roller to reduce lint shedding during use.

[0118] The preparation method of industrial wiping wipes includes the following steps:

[0119] Step 1: Using the spunbond process, blue polypropylene masterbatch and hydrophilic additives are mixed, heated and melted, and then sprayed onto the spinning curtain through a multi-row spinneret. The spunbond filaments are then fed into the first spunbond spinning assembly 40 through the first spunbond screw extruder 39. After being cooled by the first spunbond cooling device 41, the spunbond filaments are stretched by the first spunbond traction device 42 and separated by the first spunbond filament splitter 43. Finally, they are laid on the spinning curtain 30 to form the first fiber web layer (the polymer filaments in the first fiber web layer are longer than 20 cm and have an average diameter of 19.4 μm).

[0120] Step 2: In the first meltblown system, the third and fourth meltblown units heat and melt the polypropylene granules. The operating pressure of the third and fourth screw extruders is 71 MPa, and the third and fourth spinnerets are 14-row spinnerets. The output rate of both the third and fourth meltblown units is 250 kg / h, the single-hole output rate of the third and fourth spinnerets is 0.15 g / min / hole, the temperature of the third and fourth spinnerets is 225℃, and the hot air flow rate of the airflow stretching holes of the third and fourth spinnerets is 5000 Nm³. 3 The pulp is stretched at a rate of 695 kg / h; the pulp rolls are then transported to the first opening system for pulverization. The first opening system processes 695 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third meltblown unit and the fourth meltblown unit are mixed and sprayed out in the first mixed spray molding box, and the hydrophilic additives are sprayed by the spraying devices on both sides of the spinneret, which can both cool and increase the hydrophilicity of the material. The spraying amount is 125L / h, forming the 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;

[0121] Step 3: The fifth and sixth meltblown units heat and melt the polypropylene granules. The operating pressure of the fifth and sixth screw extruders is 71 MPa. The fifth and sixth spinnerets are 14-row spinnerets. The output rate of both the fifth and sixth meltblown units is 250 kg / h. The single-hole output rate of the fifth and sixth spinnerets is 0.15 g / min / hole. The temperature of the fifth and sixth spinnerets is 225℃. The hot air flow rate of the airflow drawing holes in the fifth and sixth spinnerets is 5000 Nm³. 3 The pulp is stretched at a rate of 695 kg / h; the pulp rolls are then transported to the second opening system for pulverization. The second opening system processes 695 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the fifth meltblown unit and the sixth meltblown unit are mixed and sprayed out in the second mixed spray molding box, and the hydrophilic additives are sprayed by the spraying devices on both sides of the spinneret, which can both cool and increase the hydrophilicity of the material. The spraying amount 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;

[0122] Step 4: Using the spunbond process, blue polypropylene masterbatch and hydrophilic additives are mixed, heated and melted, and then sprayed onto the spinning curtain through a multi-row spinneret. The spunbond filaments enter the first spunbond spinning assembly 53 through the first spunbond screw extruder 52, are cooled by the first spunbond cooling device 54, are stretched by the first spunbond traction device 55, and are separated by the first spunbond filament splitter 56. Finally, they are laid on the spinning curtain 30 to form the second fiber web layer (the polymer filaments in the second fiber web layer are longer than 20 cm and have an average diameter of 19.4 μm).

[0123] Step 5: The first fiber web layer, the cellulose fiber and polymer filament mixed spray layer, and the second fiber web layer formed in steps 1 to 5 are collected by a mesh curtain to form the composite nonwoven material at a speed of 569 m / min. Then, a thermal bonding system is used to perform dot-shaped or other geometric hot rolling and shaping. The rollers of the thermal bonding system have a built-in heating function, and the thermal bonding area is 6.3%. This forms a multi-layer composite nonwoven material with two upper and lower fiber web layers and two middle mixed spray layers. The fiber web weight, metal content, and defects are inspected by a fiber web quality inspection system to ensure product quality. Finally, a 1% adhesive is applied by roller coating through a finishing equipment, and the product is packaged by a packaging system to obtain an industrial wiping cloth.

[0124] Example 4:

[0125] by Figure 8 The apparatus shown (the first fiber web system includes two meltblown systems; the second fiber web system includes two meltblown systems) prepares a composite nonwoven material as a facial wipe, comprising, from bottom to top, a first-1 fiber web layer, a first-2 fiber web layer, a first mixed-blown layer, an absorbent core layer, a second mixed-blown layer, a second-1 fiber web layer, and a second-2 fiber web layer; the two meltblown systems in the first fiber web system respectively form the first-1 fiber web layer and the first-2 fiber web layer; the two meltblown systems in the second fiber web system respectively form the second-1 fiber web layer and the second-2 fiber web layer; the first-1 fiber web layer and the first-2 fiber web layer constitute the first fiber web layer, and the second-1 fiber web layer and the second-2 fiber web layer constitute the second fiber web layer.

[0126] The production of 55gsm biodegradable facial wipes uses polylactic acid (PLA) (Lyondell Basell, UK) and softening masterbatch (purchased from Hunan Shengjin New Material Co., Ltd.) as raw materials for the first, second, third, and fourth fiber web layers. The polylactic acid and softening masterbatch in the first, second, third, and fourth fiber web layers each account for 1.625% of the total weight, which is 0.9gsm. The mass ratio of softening masterbatch to polylactic acid is 2:98. The polymers used in the first and second co-spray layers are polylactic acid (Lyondell Basell, UK), accounting for 25.3% of the total weight (13.9 gsm). The cellulose fibers used in the first and second co-spray layers are wood pulp (GP, USA), accounting for 61.4% of the total weight (33.77 gsm). The absorbent core layer uses bamboo pulp (purchased from Sichuan Fuhua Bamboo Pulp & Paper Co., Ltd.), accounting for 4.8% of the total weight. 2% hydrophilic additive (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.) is sprayed during finishing.

[0127] The preparation method of facial wipes includes the following steps:

[0128] Step 1: Using a melt-blown process, polylactic acid and flexible masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through a 14-row spinneret. The operating pressure of the seventh screw extruder is 75 MPa, the output rate of the seventh melt-blown unit is 79 kg / h, the output rate per orifice of the seventh spinneret is 0.17 g / min / orifice, the temperature of the seventh spinneret is 233℃, and the hot air flow rate of the airflow drawing holes in the seventh spinneret is 3100 Nm³. 3 The fibers are stretched at a rate of 130 L / h and cooled by spray devices on both sides of the spinneret, forming the first 1-1 fiber web layer (the polymer filaments in the first 1-1 fiber web layer are longer than 15 cm and have an average diameter of 4.1 μm).

[0129] Step 2: Using a melt-blown process, polylactic acid and flexible masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through a 14-row spinneret. The operating pressure of the first screw extruder is 76 MPa, the output rate of the first melt-blown unit is 79 kg / h, the output rate per orifice of the first spinneret is 0.17 g / min / orifice, the temperature of the first spinneret is 234℃, and the hot air flow rate of the airflow drawing holes in the first spinneret is 3150 Nm³. 3 The fibers are stretched at a rate of 130 L / h and cooled by spray devices on both sides of the spinneret. This forms the first and second fiber web layers (the polymer filaments in the first and second fiber web layers are longer than 15 cm and have an average diameter of 4.1 μm) covering the first and second fiber web layers.

[0130] Step 3: In the first mixed-blowing system, the third and fourth meltblowing units heat and melt the polylactic acid particles. The operating pressure of the third and fourth screw extruders is 69 MPa, and the third and fourth spinnerets are 20-row spinnerets. The output rate of both the third and fourth meltblowing units is 225 kg / h, the single-orifice output rate of the third and fourth spinnerets is 0.14 g / min / orifice, the temperature of the third and fourth spinnerets is 224℃, and the hot air flow rate of the airflow stretching holes of the third and fourth spinnerets is 5000 Nm³. 3 The pulp is stretched at a rate of 700 kg / h; the pulp rolls are then transported to the first opening system for pulverization. The first opening system processes 700 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third meltblown unit and the fourth meltblown unit are mixed and sprayed out in the first mixed spray molding box, and the hydrophilic additives are sprayed by the spraying devices on both sides of the spinneret, which can both cool and increase the hydrophilicity of the material. The spraying amount is 130L / h, forming the 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 first-second fiber web layer;

[0131] Step 4: Bamboo pulp fibers are sprayed out by the absorbent core system to form an absorbent core layer that covers the surface of the first mixed spray layer;

[0132] Step 5: In the second mixed-blowing system, the fifth and sixth meltblowing units heat and melt the polylactic acid particles. The operating pressure of the fifth and sixth screw extruders is 69 MPa, and the fifth and sixth spinnerets are 20-row spinnerets. The output rate of both the fifth and sixth meltblowing units is 225 kg / h, the single-orifice output rate of the fifth and sixth spinnerets is 0.14 g / min / orifice, the temperature of the fifth and sixth spinnerets is 226℃, and the hot air flow rate of the airflow drawing holes of the fifth and sixth spinnerets is 5000 Nm³. 3 The pulp is stretched at a rate of 700 kg / h; the pulp rolls are then transported to the second opening system for pulverization. The second opening system has a pulp production capacity of 700 kg / h, an opening roller speed of 5000 rpm, and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the fifth and sixth meltblown units are mixed and sprayed out in the second mixed spray molding box, and the hydrophilic additives are sprayed by the spraying devices on both sides of the spinneret, which can both cool and increase the hydrophilicity of the material. The spraying amount 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) covering the absorbent core layer.

[0133] Step Six: Using a melt-blown process, polylactic acid and flexible masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through a 14-row spinneret. The operating pressure of the second screw extruder is 75 MPa, the output rate of the second melt-blown unit is 79 kg / h, the output rate per orifice of the second spinneret is 0.17 g / min / orifice, the temperature of the second spinneret is 233℃, and the hot air flow rate of the airflow drawing holes in the second spinneret is 3150 Nm³. 3 The fibers are stretched at a rate of 130 L / h and cooled by spray devices on both sides of the spinneret. This forms the second-first fiber web layer (in which the polymer filaments are longer than 15 cm and have an average diameter of 4.1 μm) covering the second mixed-spinning layer.

[0134] Step 7: Using a melt-blown process, polylactic acid and flexible masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through a 14-row spinneret. The operating pressure of the eighth screw extruder is 75 MPa, the output rate of the eighth melt-blown unit is 79 kg / h, the output rate per orifice of the eighth spinneret is 0.17 g / min / orifice, the temperature of the eighth spinneret is 233℃, and the hot air flow rate of the airflow stretching orifice of the eighth spinneret is 3100 Nm³. 3 The fibers are stretched at a rate of 130 L / h and cooled by spray devices on both sides of the spinneret. This forms the second-second fiber web layer (in which the polymer filaments are longer than 15 cm and have an average diameter of 4.1 μm) which covers the second-first fiber web layer.

[0135] Step 8: The composite nonwoven material formed in Steps 1 to 7, consisting of the first 1-1 fiber web layer, the first 1-2 fiber web layer, the first mixed-spray layer of cellulose fiber and polymer filament, the absorbent core layer, the second mixed-spray layer of cellulose fiber and polymer filament, the second 2-1 fiber web layer, and the second 2-2 fiber web layer, is collected through a mesh curtain at a speed of 506 m / min. It is then hot-rolled and shaped into dotted or other geometric shapes using a thermal bonding system. The rollers in the thermal bonding system have a built-in heating function, and the thermal bonding area is 6%. This forms a multi-layered composite nonwoven material with four fiber web layers, two mixed-spray layers, and an absorbent core layer. The fiber web weight, metal content, and defects are inspected using a fiber web quality inspection system to ensure product quality. A 2% hydrophilic additive is sprayed on as a finishing agent, and finally, the product is packaged using a packaging system to obtain the facial wipes.

[0136] Example 5:

[0137] by Figure 9The equipment shown (the first fiber web system includes two spunbond systems and one meltblown system) is used to prepare a composite nonwoven material for body cleaning wipes, comprising, from bottom to top, a first-1 fiber web layer, a first-2 fiber web layer, a first-3 fiber web layer, a first mixed-blown layer, an absorbent core layer, a second mixed-blown layer, and a second fiber web layer; the first-1 fiber web layer, the first-2 fiber web layer, and the first-3 fiber web layer form the first fiber web layer;

[0138] The production of 55gsm body cleaning wipes utilizes a side-by-side bicomponent polyester / polyamide masterbatch (LyondellBasell, UK) with a melt index of 40g / 10min for the first and second fiber web layers. This masterbatch combines two polymers with different heat and moisture shrinkage properties, creating a spiral curl after heat treatment to enhance elasticity and fluffiness. It also includes a hydrophilic masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.). The raw materials used for the first to third fiber web layers and the second fiber web layer are polypropylene (ExxonMobil, USA) and hydrophilic masterbatch (purchased from Hunan Shengjin New Materials Co., Ltd.). In the first and second fiber web layers, the parallel-type bicomponent polyester / polyamide masterbatch and hydrophilic masterbatch account for 5% of the total weight, with a content of 2.75 gsm. The mass ratio of hydrophilic masterbatch to parallel-type bicomponent polyester / polyamide masterbatch is 2:98. In the first to third fiber web layers, the polypropylene masterbatch and hydrophilic masterbatch account for 5% of the total weight... The first layer contains 1.5% polypropylene masterbatch (0.825 gsm), and the second layer contains 3.5% polypropylene masterbatch and hydrophilic masterbatch (1.925 gsm). The mass ratio of hydrophilic masterbatch to polypropylene masterbatch in the first-third and second layers is 2:98. The polymers used in the first and second mixed-spray layers are polypropylene (ExxonMobil, USA) and hydrophilic masterbatch. The polymers in the first and second mixed-spray layers together account for 30% of the total weight (16.5 gsm), and the mass ratio of hydrophilic masterbatch to polypropylene is 2:98. The cellulose fibers used in the first and second mixed-spray layers are wood pulp (GP, USA). The cellulose fibers in the first and second mixed-spray layers together account for 53% of the total weight (29.15 gsm). The absorbent core layer uses a surfactant with cleaning properties that foams upon contact with water and friction. This surfactant accounts for 6% of the total weight. The finishing spray contains 1% antibacterial softener (purchased from Zhejiang Chuanhua Chemical Group Co., Ltd.).

[0139] The preparation method includes the following steps:

[0140] Step 1: Using the spunbond process, the parallel bicomponent polyester / polyamide and hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto the spinning curtain through a multi-row spinneret. The spunbond filaments are then fed into the third spunbond spinning assembly 84 through the third spunbond screw extruder 83. After being cooled by the third spunbond cooling device 85, the spunbond filaments are stretched by the third spunbond traction device 86 and separated by the third spunbond filament splitter 87. Finally, they are laid on the spinning curtain 30 to form the first-1 fiber web layer (the polymer filaments in the first-1 fiber web layer are longer than 20 cm and have an average diameter of 17.3 μm).

[0141] Step 2: Using the spunbond process, the parallel bicomponent polyester / polyamide and hydrophilic masterbatch are mixed, heated and melted, and then sprayed onto the spinning curtain through a multi-row spinneret. The spunbond filaments are then fed into the first spunbond spinning assembly 40 through the first spunbond screw extruder 39. After being cooled by the first spunbond cooling device 41, the spunbond filaments are stretched by the first spunbond traction device 42 and separated by the first spunbond filament splitter 43. Finally, they are laid on the spinning curtain 30 to form the first-second fiber web layer (the polymer filaments in the first-second fiber web layer are longer than 20 cm and have an average diameter of 17.3 μm) covering the first-first fiber web layer.

[0142] Step 3: Using a melt-blown process, polypropylene and hydrophilic masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through an 8-row spinneret. The operating pressure of the first screw extruder is 76 MPa, the output rate of the first melt-blown unit is 79 kg / h, the output rate per orifice of the first spinneret is 0.17 g / min / orifice, the temperature of the first spinneret is 232℃, and the hot air flow rate of the airflow stretching orifice of the first spinneret is 3180 Nm³. 3 The fibers are stretched at a rate of 131 L / h and cooled by spray devices on both sides of the spinneret. This forms the first to third fiber web layers (the polymer filaments in the first to third fiber web layers are longer than 15 cm and have an average diameter of 4.2 μm) covering the first to second fiber web layers.

[0143] Step 4: In the first meltblown system, the third and fourth meltblown units mix and heat the polypropylene and hydrophilic masterbatch to melt. The operating pressure of the third and fourth screw extruders is 71 MPa, and the third and fourth spinnerets are 16-row spinnerets. The output rate of both the third and fourth meltblown units is 247 kg / h, the single-hole output rate of the third and fourth spinnerets is 0.15 g / min / hole, the temperature of the third and fourth spinnerets is 227℃, and the hot air flow rate of the airflow stretching holes of the third and fourth spinnerets is 5150 Nm³. 3 The pulp is stretched at a rate of 701 kg / h; the pulp rolls are then transported to the first opening system for pulverization. The first opening system processes 701 kg / h of pulp, with an opening roller speed of 5000 rpm and a pulp cooling air force of 4600 Nm. 3 / h, the wood pulp in the pipe is evenly blown away; finally, the polypropylene filaments and wood pulp fibers formed by the third meltblown unit and the fourth meltblown unit are mixed and sprayed out in the first mixed spray molding box, and cooled by the spraying device on both sides of the spinneret. The spraying volume is 132L / h, forming the 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 first-3 fiber web layers;

[0144] Step 5: The recycled colored yarn is cut and opened and ground, then sprayed out by the absorbent core system to form an absorbent core layer that covers the surface of the first mixed spray layer;

[0145] Step Six: The fifth and sixth meltblown units mix and melt the polypropylene and hydrophilic masterbatch. The operating pressure of the fifth and sixth screw extruders is 69 MPa. The fifth and sixth spinnerets are 16-row spinnerets. The output rate of both the fifth and sixth meltblown units is 247 kg / h. The single-hole output rate of the fifth and sixth spinnerets is 0.15 g / min / hole. The temperature of the fifth and sixth spinnerets is 226℃. The hot air flow rate of the airflow drawing holes in the fifth and sixth spinnerets is 5100 Nm³. 3 The pulp is stretched at a rate of 700 kg / h; the pulp roll is transported to the second opening system for crushing. The pulp processing capacity of the second opening system is 700 kg / h, the opening roller speed is 5000 rpm, and the pulp cooling air force is 4600 Nm3 / h, which evenly disperses the pulp in the pipe; finally, the polypropylene filaments and pulp fibers formed by the fifth and sixth meltblown units are mixed and sprayed out in the second mixed-blown forming box, and cooled by the spraying devices on both sides of the spinneret at a spray rate of 130 L / h, forming a second mixed-blown layer (the polymer filaments in the second mixed-blown layer are longer than 15 cm and have an average diameter of 4.2 μm) covering the absorbent core layer;

[0146] Step 7: Using a melt-blown process, polypropylene and hydrophilic masterbatch are mixed, heated, and melted, then sprayed onto a web forming screen through an 8-row spinneret. The operating pressure of the second screw extruder is 76 MPa, the output rate of the second melt-blown unit is 75 kg / h, the output rate per orifice of the second spinneret is 0.16 g / min / orifice, the temperature of the second spinneret is 238℃, and the hot air flow rate of the airflow stretching orifice of the second spinneret is 3100 Nm³. 3 The fibers are stretched at a rate of 132 L / h and cooled by spray devices on both sides of the spinneret. This forms a second fiber web layer (in which the polymer filaments are longer than 15 cm and have an average diameter of 4.2 μm) that covers the second mixed-spinning layer.

[0147] Step 8: The composite nonwoven material formed in Steps 1 to 7, consisting of the first-1 fiber web layer, the first-2 fiber web layer, the first fiber 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 fiber web layer, is collected through a mesh curtain at a speed of 545 m / min. Then, a hot-rolling and shaping process is performed using a thermal bonding system. The rollers in the thermal bonding system have a built-in heating function, and the thermal bonding area is 6.1%. This forms a multi-layer composite nonwoven material with the above four fiber web layers, the next fiber web layer, the two mixed spray layers in between, and the absorbent core layer. The fiber web weight, metal content, and defects are inspected using a fiber web quality inspection system to ensure product quality. A 1% antibacterial softener is then sprayed on as a finishing agent, and finally, the product is packaged using a packaging system to obtain the body cleaning wipes.

[0148] Comparative Example 1

[0149] The commercially available Huggies-PURE baby wipes were used as a comparison.

[0150] The performance of the nonwoven materials in Examples 1-5 and Comparative Example 1 was tested according to relevant testing standards, and the results are listed in Table 1.

[0151] Table 1. Performance test results of composite nonwoven sanitary products in Examples 1-5 and Comparative Example 1.

[0152]

[0153]

[0154] Table 1 shows that the thickness of the composite nonwoven material produced by the equipment of this invention is on average more than 35% greater than that of ordinary 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 ratio of the composite nonwoven materials of Examples 1 to 4, when SAP is added, is 3 times that of ordinary commercially available products, and the water absorption ratio of the products without SAP is also more than 1.5 times higher than that of ordinary commercially available products; the water absorption speed 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 web on their surface. The composite nonwoven materials of Examples 1 to 5 exhibit significantly improved softness compared to commercially available products, with the best softness coefficient reaching 3.59. The composite nonwoven materials of Examples 1 to 5 also demonstrate excellent abrasion resistance; while commercially available products break down after 200 abrasion tests, the products of this invention achieve a non-breakage level of -3 after 200 abrasion tests. The outer polymer layer of the composite nonwoven materials of Examples 1 to 5, produced by meltblowing, typically has a fineness of 3–5 μm, while the inner polymer layer has a fineness of approximately 4–6 μm.

[0155] Although the above embodiments have provided a detailed description of the present invention, they are only some embodiments of the present invention, and not all embodiments. People can obtain other embodiments based on these embodiments without creative effort, and these embodiments all fall within the protection scope of the present invention.

Claims

1. A composite nonwoven material, characterized in that, The layered structure includes the following mass percentages: The first fiber web layer is 0.2% to 20%; The first mixed spray layer is 20-50%; Absorbing core layer 0~10%; The second mixed spray layer is 20-50%; The second fiber web layer is 0.2% to 20%; 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 sequentially; the first fiber web layer and the second fiber web layer are polymer filaments; 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 0.1~30 μm; The absorbent core layer comprises one or more of the following: superabsorbent polymer, cellulose fiber, and superabsorbent polymer gel material. The first and second mixed-spray layers independently comprise cellulose fibers and polymer filaments; the length of the cellulose fibers in the first and second mixed-spray layers is independently 0.5~8mm, and the mass ratio of cellulose fibers to polymer filaments in the first and second mixed-spray layers is independently 10~90:9.8~70.

2. The composite nonwoven material according to claim 1, characterized in that, The first and second fiber web layers also independently include one or more of the following: functional masterbatch, hydrophilic additives, hydrophilic softeners, essential oils, and mosquito repellent additives.

3. An apparatus for preparing the composite nonwoven material of claim 1 or 2, comprising a web forming curtain (30), a suction device (31), and a first fiber web system, a first mixed spray forming system, an absorbent core system (13), a second mixed spray forming system, and a second fiber web system connected in series above the web forming curtain; The first fiber web system includes a first meltblown unit or a first spunbond unit; the first mixed-blown molding system includes a third meltblown unit, a first opening unit, a fourth meltblown unit and a first mixed-blown molding box (09); the second mixed-blown molding system includes a fifth meltblown unit, a second opening unit, a sixth meltblown unit and a second mixed-blown molding box (19); the second fiber web system includes a second meltblown unit or a second spunbond unit; The first meltblown unit includes a first spinning box (01), a first screw extruder (02), a first feeding device (03), and a first spinneret (57). 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 traction device (42), and a first spunbond splitter (43). The third meltblown unit includes a second feeding device (04), a second screw extruder (05), a third spinning box (06), and a third spinneret (58). The first loosening unit includes a first loosening device (07) and a first multi-row CD ejector (08); The fourth meltblown unit includes a fourth feeding device (10), a fourth screw extruder (11), a fourth spinning box (12), and a fourth spinneret (59). The fifth meltblown unit includes a fifth feeding device (14), a fifth screw extruder (15), a fifth spinning box (16), and a fifth spinneret (60). The second loosening unit includes a second loosening device (17) and a second multi-row CD ejector (18); The sixth meltblown unit includes a sixth feeding device (20), a sixth screw extruder (21), a sixth spinning box (22), and a sixth spinneret (61). 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); 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 traction device (55), and a second spunbond splitter (56).

4. The device according to claim 3, characterized in that, It also includes a thermal bonding system (32), a web quality inspection system, a finishing system (36) and a packaging system (37); the web quality inspection system includes a metal detection unit (33), a web weight detection unit (34) and a web defect detection unit (35).

5. The device according to claim 3, characterized in that, The first meltblown unit further includes a first cooling spray system (26), the outlet of the first mixed spray molding box (09) is provided with a second cooling spray system (27), the outlet of the second mixed spray molding box (19) is provided with a third cooling spray system (28), and the second meltblown unit further includes a fourth cooling spray system (29).

6. A method for preparing the composite nonwoven material of claim 1 or 2 using the apparatus according to any one of claims 3 to 5, comprising the following steps: The first polymer is melted and sprayed onto the forming curtain (30) using the first fiber web system to obtain the first fiber web layer; The second polymer is melted in the third and fourth meltblown units, and the first cellulose fiber raw material is crushed in the first opening unit. The molten second polymer and the crushed first cellulose fiber raw material are transported to the first mixing and spraying molding box (09) for mixing and then sprayed onto the surface of the first fiber web layer to form the first mixing and spraying layer. The absorbent material is sprayed onto the surface of the first mixed spray layer through the absorbent core system (13) to form the absorbent core layer; The third polymer is melted in the fifth and sixth meltblown units, and the second cellulose fiber raw material is crushed in the second opening unit. The molten third polymer and the crushed second cellulose fiber raw material are transported to the second mixing and spraying molding box (19) for mixing and then sprayed onto the surface of the absorbent core layer to form the second mixing and spraying layer. The fourth polymer is melted and sprayed onto the surface of the second mixed spray layer using the second fiber web system to obtain the second fiber web layer.

7. The preparation method according to claim 6, characterized in that, After the second fiber web layer is formed, the process also includes: sequentially collecting, sorting and packaging the products containing 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 finishing process includes one or more of the following: embossing, printing, punching, deformation, surface treatment, thermal bonding, ultrasonic bonding, cutting, stacking, and wet wipe processing.

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