A composite multilayer nonwoven material and methods and apparatuses for making the same

Abstract

The present application belongs to the technical field of non-woven fabrics, and particularly relates to a composite multi-layer non-woven material and a preparation method and device thereof. The preparation method of the composite multi-layer non-woven material of the present application can not only impart excellent instantaneous water absorption and fast water absorption performance to the material by adding a high-pressure water spraying step and setting an intermediate web layer, but also can make the long fibers obtained by the second melt blowing in the mixed spraying web play a certain supporting role when the mixed spraying web is also included in the intermediate web layer, so that the fabric is fluffy and soft, and the strength of the material is improved. The high-pressure water spraying step greatly reduces the material shedding rate on the basis of not damaging the original material performance, and further improves the strength, softness and fluffiness of the material. In addition, the present application also customizes different patterns according to customer requirements through the flat screen jacquard direct spraying, so that the appearance of the non-woven fabric is variable.

Description

Technical Field

[0001] This invention belongs to the field of nonwoven fabric technology, specifically relating to a composite multilayer nonwoven material and its preparation method and apparatus. Background Technology

[0002] Nonwoven fabrics are ubiquitous in daily life and industrial production. From baby care to adult personal care, from face towels to skin care masks, from household wiping to car interior cleaning, from mobile phone cleaning to computer screen dust removal, and even to the cleaning of machinery and precision instruments, wiping materials made of nonwoven fabrics are everywhere and have become an indispensable part of life.

[0003] Although meltblown and spunbond technologies have seen significant development in recent years, adding short fibers such as wood pulp to equipment for nonwoven fabric production still has drawbacks such as reduced fabric strength and increased lint shedding. Summary of the Invention

[0004] The purpose of this invention is to provide a composite multilayer nonwoven material and its preparation method and apparatus. The composite multilayer nonwoven material obtained by the preparation method provided by this invention has the characteristics of high water absorption, fast water absorption, high strength, fluffy fabric surface, soft hand feel, and low lint shedding rate.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] This invention provides a method for preparing a composite multilayer nonwoven material, comprising the following steps:

[0007] The first raw material is subjected to first meltblown and / or first spunbond processes to obtain a first fiber web layer. The first fiber web layer includes a plurality of first meltblown fiber webs and / or a plurality of first spunbond fiber webs stacked together. The first raw material includes a first polymer raw material.

[0008] An intermediate fiber web layer is prepared on the surface of the first fiber web layer. The intermediate fiber web layer comprises a plurality of stacked mixed-spray fiber webs and / or a plurality of air-laid fiber webs. The preparation method of the mixed-spray fiber web includes: performing a second melt-blowing process on a second raw material; pulverizing a first absorbent fiber and then performing a first air-laid process; and mixing and spraying the long fiber bundles obtained from the second melt-blowing process with the short fiber bundles formed by the first air-laid process to obtain the mixed-spray fiber web. The second raw material includes a second polymer raw material. The preparation method of the air-laid fiber web includes: pulverizing a second absorbent fiber and then performing a second air-laid process.

[0009] On the surface of the intermediate fiber web layer, a third raw material is subjected to a third meltblown process and / or a second spunbond process to form a second fiber web layer, thereby obtaining a semi-finished fiber web; the second fiber web layer includes a plurality of stacked second meltblown fiber webs and / or a plurality of second spunbond fiber webs, and the third raw material includes a third polymer raw material;

[0010] The semi-finished fiber web is hot-rolled and shaped to obtain a hot-rolled fiber web; the first fiber web layer of the semi-finished fiber web forms the lower surface of the hot-rolled fiber web, and the second fiber web layer of the semi-finished fiber web forms the upper surface of the hot-rolled fiber web;

[0011] The hot-rolled fiber web is pre-wetted and then subjected to high-pressure water spraying to obtain a jacquard high-pressure water-sprayed fiber web. The high-pressure water spraying includes sequentially performing flat-web forward spraying, rotary drum reverse spraying, rotary drum forward spraying, and flat-web jacquard forward spraying. The flat-web forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web while simultaneously drawing a vacuum on the lower surface. The rotary drum reverse spraying involves spraying water onto the lower surface of the hot-rolled fiber web on the rotating circumference of the drum. The rotary drum forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web on the rotating circumference of the drum to form a jacquard pattern while simultaneously drawing a vacuum on the lower surface.

[0012] The jacquard high-pressure water-jet fiber web is dried and then finished sequentially to obtain the composite multilayer nonwoven material.

[0013] Preferably, the first meltblown process further includes spraying a first water or a first chemical auxiliary aqueous solution onto the long fiber bundle obtained by the first meltblown process. The liquid volume of the first spray is 0 to 180 L / h and is not 0. The percentage of the first chemical auxiliary in the first chemical auxiliary aqueous solution to the total mass of the composite multilayer nonwoven material is 0.1 to 10%.

[0014] The mixed spraying process further includes spraying a second water or a second chemical auxiliary aqueous solution onto a mixed bundle formed by the short fiber bundle obtained by the first airflow web formation and the long fiber bundle obtained by the second melt-blowing. The liquid volume of the second spray is 0 to 180 L / h and is not 0. The percentage of the second chemical auxiliary in the second chemical auxiliary aqueous solution to the total mass of the composite multilayer nonwoven material is 0.1 to 10%.

[0015] The second airflow web formation further includes spraying the short fiber bundles obtained by the second airflow web formation with a third spray of water or a third chemical auxiliary agent aqueous solution. The liquid volume of the third spray is 0 to 180 L / h and is not 0. The third chemical auxiliary agent in the third chemical auxiliary agent aqueous solution accounts for 0.1 to 10% of the total mass of the composite multilayer nonwoven material.

[0016] The third meltblown process further includes spraying the long fiber bundle obtained by the third meltblown process with a fourth spray of water or a fourth chemical auxiliary agent aqueous solution. The liquid volume of the fourth spray is 0 to 180 L / h and is not 0. The percentage of the fourth chemical auxiliary agent in the fourth chemical auxiliary agent aqueous solution to the total mass of the composite multilayer nonwoven material is 0.1 to 10%.

[0017] Preferably, the mass percentage of the first raw material in the first fiber web layer is 0.2% to 20% of the total mass of the composite multilayer nonwoven material; the first raw material further includes a first functional masterbatch, and the mass percentage of the first functional masterbatch in the first fiber web layer is 0.1% to 10% of the mass of the first polymer raw material;

[0018] When the intermediate fiber web layer includes a mixed-spray fiber web, the percentage of the second raw material in the intermediate fiber web layer to the total mass of the composite multilayer nonwoven material is 0.2% to 20%; the second raw material also includes a second functional masterbatch, and the mass of the second functional masterbatch in the intermediate fiber web layer accounts for 0.1% to 10% of the mass of the second polymer raw material.

[0019] The mass percentage of the third raw material in the second fiber web layer is 0.2% to 20% of the total mass of the composite multilayer nonwoven material; the second raw material also includes a third functional masterbatch, the mass percentage of the third functional masterbatch in the second fiber web layer is 0.1% to 10% of the mass of the third polymer raw material.

[0020] Preferably, the first, second, and third polymer raw materials independently comprise biodegradable or compostable thermoplastic fibers and / or thermoplastic polymer filaments; the biodegradable or compostable thermoplastic fibers comprise one or more of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose, and hemicellulose derivatives; the thermoplastic polymer filaments comprise one or more of polyolefins, polyesters, polyhydroxyalkanoates, and polyhydroxybutyrates; the thermoplastic polymer filaments comprise single-component or bicomponent types, the bicomponent types comprising one or more of core-sheath type, side-by-side type, trefoil type, and orange-segment type; the melt index of the thermoplastic polymer filaments ranges from 100 to 1500 g / 10 min;

[0021] The spinneret temperatures of the first, second, and third meltblown ...

[0022] The long fibers obtained by the first meltblown, first spunbond, second meltblown, third meltblown and second spunbond processes have a diameter of 5-20 μm and a basis weight of 0.1-3.0 gsm.

[0023] Preferably, when the intermediate fiber web layer includes a mixed-spray fiber web, the mass of the first absorbent fiber in the intermediate fiber web layer accounts for 10-47.5% of the total mass of the composite multilayer nonwoven material;

[0024] When the intermediate fiber web layer includes an air-laid fiber web, the mass of the second absorbent fiber in the intermediate fiber web layer accounts for 10 to 47.5% of the total mass of the composite multilayer nonwoven material;

[0025] The first and second absorbent fibers independently comprise wood pulp fibers and / or paper pulp fibers; the wood pulp fibers comprise one or more of oak, poplar, birch, pine, spruce, and fir; the paper pulp fibers comprise one or more of rice straw pulp, reed pulp, sugarcane pulp, bamboo pulp, cotton pulp, hemp pulp, and natural fiber rag pulp.

[0026] The length of the short fibers obtained by the first airflow web formation and the second airflow web formation is 0.5–8 mm;

[0027] The first airflow forming and the second airflow forming are independently distributed and laid out using a CD controllable injector or by using a forming head to evenly distribute and lay out the net along the width direction. The forming head is either a dust cage type or a flat screen type.

[0028] Preferably, the hot rolling temperature is 80–200°C, and the speed is 0–1000 m / min, and not 0.

[0029] The pre-wetting water pressure is 0.1–5 MPa, preferably 0.5–4 MPa, and more preferably 0.5–3 MPa;

[0030] The water pressure of the flat-net positive spray is 0.5-10 MPa, preferably 1-10 MPa, and more preferably 3-8 MPa;

[0031] The water pressure of the rotary drum reverse spray and the rotary drum forward spray is independently 1 to 15 MPa, preferably 3 to 15 MPa, and more preferably 5 to 12 MPa;

[0032] The water pressure for the flat-net jacquard spray is 3-20 MPa, preferably 5-20 MPa, and more preferably 8-18 MPa;

[0033] The drying temperature is 90–130°C.

[0034] Preferably, the finishing process includes one or more of spraying, roll coating, and padding;

[0035] The chemical auxiliaries used in the finishing process include one or more of the following: antibacterial agents, hydrophilic agents, softeners, plasticizers, strength agents, adhesives, silicones, wetting agents, latexes, and thermochromic colorants; the latexes include acrylics and / or vinyl acetate; the strength agents include carboxymethyl cellulose and / or starch; and the adhesives include one or more of vinyl acetate, acrylics, and other elastic adhesives.

[0036] The present invention provides a composite multilayer nonwoven material prepared by the preparation method described in the above technical solution, comprising a first layer structure, an intermediate layer structure, and a second layer structure stacked sequentially; the first layer structure is formed by a plurality of first meltblown fiber webs and / or a plurality of first spunbond fiber webs; the intermediate layer structure is formed by a plurality of mixed-blown fiber webs and / or a plurality of air-blown fiber webs; and the second layer structure is formed by a plurality of second meltblown fiber webs and / or a plurality of second spunbond fiber webs.

[0037] This invention provides an apparatus for the preparation method described in the above technical solution, comprising a forming curtain, a forming device disposed above the forming curtain, the forming device comprising a plurality of first meltblown devices and / or a plurality of spunbond devices, and further comprising a plurality of mixing and spraying systems and / or a plurality of second grinding devices, the second grinding device comprising a second crusher and a second airflow forming device; the mixing and spraying system comprising a plurality of second meltblown devices, a plurality of first grinding devices and a mixing and spraying forming box, the first grinding device comprising a first crusher and a first airflow forming device;

[0038] A hot rolling unit located downstream of the forming screen, a first conveying screen located downstream of the hot rolling unit, a pre-wetting unit and a first high-pressure water spraying unit located above the first conveying screen, a first vacuum dewatering unit located below the first conveying screen, a second high-pressure water spraying unit and a third high-pressure water spraying unit located downstream of the first conveying screen, a second conveying screen located downstream of the second high-pressure water spraying unit and the third high-pressure water spraying unit, a jacquard high-pressure water spraying unit located above the second conveying screen, a second vacuum dewatering unit located below the second conveying screen, a drying unit located downstream of the second conveying screen, and a finishing unit located downstream of the drying unit.

[0039] Preferably, a first spraying device is provided below the spinneret of the first meltblown device, a second spraying device is provided below the outlet of the mixing and forming box, and a third spraying device is provided below the second airflow forming device.

[0040] The spinnerets of the first meltblown device and the second meltblown device include a first spinneret, a second spinneret, or a third spinneret.

[0041] The first spinneret is provided with a single row of first spinneret holes. The first spinneret holes are inverted conical holes. The outer conical surface of the first spinneret holes is fitted with a first airflow stretching hole. The first airflow stretching hole is an inverted conical hole and coaxial with the first spinneret holes. The long fiber ejected from the first spinneret holes and the stretching gas ejected from the first airflow stretching hole converge at the top of the cone. The angle between the stretching gas and the long fiber is 30 to 70°.

[0042] The second spinneret is provided with a single row or multiple rows of second spinnerets. The second spinnerets are cylindrical holes. A second airflow stretching hole is sleeved on the outer circumferential surface of the second spinnerets. The second airflow stretching hole is an annular hole and coaxial with the second spinnerets.

[0043] The third spinneret is provided with a single row or multiple rows of third airflow stretching holes. The third airflow stretching holes are cylindrical holes. The outer circumferential surface of the third airflow stretching holes is fitted with third spinnerets. The third spinnerets are annular holes and coaxial with the third airflow stretching holes.

[0044] This invention provides a method for preparing a composite multilayer nonwoven material. The method utilizes multiple processes, including meltblowing, spunbonding, a combination of meltblowing and air-jet spinning, and separate air-jet spinning, to obtain a multilayer fiber web. This enriches the variety of fibers within the web, enabling functional blending of various fibers. After hot rolling and setting, the multilayer web is then subjected to high-pressure water spraying. Compared to existing technologies, this invention, by adding a high-pressure water spraying step, does not affect the original characteristics of the fibers, does not damage the fibers, and washes away short fibers scattered on the web surface, significantly reducing lint shedding. Furthermore, the high-pressure water spraying step, by penetrating the web with high-pressure water, causes the fibers to entangle more tightly, thereby enhancing the fabric's strength. Simultaneously, the high-pressure water spraying increases the number of micropores on the fabric surface, improving the fabric's bulkiness and breathability, as well as its high moisture absorption and fast moisture absorption performance. Compared to spunlace fabric, this invention uses fewer spunlace heads, occupies less space, and uses less water. Furthermore, while traditional spunlace fabrics aim to better entangle loose fibers for reinforcement, this invention uses high-pressure water spraying not only to better entangle the fibers without the need for adhesives, but also to improve washability. It also results in excellent breathability, high moisture absorption, and rapid moisture absorption, while minimizing lint and pilling, making the fabric fluffier and softer to the touch. In addition, this invention allows for customized patterns based on customer needs through flat-net jacquard spraying, resulting in a wide variety of non-woven fabric appearances.

[0045] Compared with the prior art, the method for preparing composite multilayer nonwoven materials provided by the present invention has the following beneficial effects:

[0046] This invention not only endows the material with excellent instant and rapid water absorption properties through the intermediate fiber web layer, but also, when the intermediate fiber web layer includes a mixed-blown fiber web, the long fibers obtained from the second meltblown process in the mixed-blown fiber web can play a certain supporting role, making the fabric fluffy and soft, and improving the strength of the material. The high-pressure water spraying step greatly reduces the lint rate of the material without damaging the original material properties, and further improves the strength, softness, and fluffiness of the material.

[0047] Meanwhile, compared to spunlace, the spunlace reinforcement process typically uses 7-12 spunlace heads and employs water pressures of 3-60 MPa. Spunlace nonwoven production consumes a large amount of water; assuming a daily output of 1 ton, approximately 50-60 tons of water are needed per hour, making water the largest cost for spunlace nonwoven fabric companies. In contrast, the high-pressure water jet process of this invention only requires 1-2 tons of water to produce 1 ton of electret nonwoven fabric. It uses 4 spunlace heads and operates at a water pressure of 0.1-15 MPa. Therefore, compared to traditional spunlace processes, this invention uses fewer spunlace heads, requires lower water pressure, occupies less space, and consumes less water. Attached Figure Description

[0048] Figure 1 This is a schematic diagram of the device structure used in Embodiment 1 of the present invention;

[0049] Figure 2 This is a schematic diagram of the device used in Embodiment 2 of the present invention;

[0050] Figure 3 This is a schematic diagram of the device used in Embodiment 3 of the present invention;

[0051] Figure 4 This is a schematic diagram of the device used in Embodiment 4 of the present invention;

[0052] Figure 5 This is a schematic diagram of the device used in Embodiment 5 of the present invention;

[0053] Figure 6 This is a cross-sectional view of the multi-row perforated spinneret in this invention;

[0054] Figure 7 This is a front view of the multi-row nozzle spinneret in this invention;

[0055] Figure 8 This is a schematic diagram of a single spinneret orifice cross-section in this invention;

[0056] Figure 9 This is a structural diagram of the mixed-spray water-absorbing layer in this invention;

[0057] Figure 10 This is a cross-sectional view of the meltblown spinneret orifice of the "slit air knife" in this invention;

[0058] In the figure: 1 is the first meltblown device; 1-1 is the first meltblown raw material supply device; 1-2 is the first screw extruder; 1-3 is the first melt filter device; 1-4 is the first spinning box; 1-5 is the first spinneret.

[0059] 2 is the second meltblown device; 2-1 is the second meltblown raw material supply device; 2-2 is the second screw extruder; 2-3 is the second melt filter device; 2-4 is the second spinning box; 2-5 is the second spinneret.

[0060] 3 is the third meltblown device; 3-1 is the third meltblown raw material supply device; 3-2 is the third screw extruder; 3-3 is the third melt filter device; 3-4 is the third spinning box; 3-5 is the third spinneret.

[0061] 4 is the fourth meltblown device; 4-1 is the fourth meltblown raw material supply device; 4-2 is the fourth screw extruder; 4-3 is the fourth melt filter device; 4-4 is the fourth spinning box; 4-5 is the fourth spinneret.

[0062] 5 represents the first grinding device; 5-1 represents the first crusher; 5-2 represents the first airflow mesh forming device;

[0063] 6 represents the fifth meltblown unit; 6-1 represents the fifth meltblown raw material supply unit; 6-2 represents the fifth screw extruder; 6-3 represents the fifth melt filtration unit; 6-4 represents the fifth spinning box; 6-5 represents the fifth spinneret.

[0064] 7 is the sixth meltblown device; 7-1 is the fourth meltblown raw material supply device; 7-2 is the fourth screw extruder; 7-3 is the fourth melt filter device; 7-4 is the fourth spinning box; 7-5 is the fourth spinneret.

[0065] 8 represents the second grinding device; 8-1 represents the second crusher; 8-2 represents the second airflow mesh forming device;

[0066] 9 represents the first mixed spray molding box;

[0067] 10 is the second mixing and spraying molding box;

[0068] 11-1 is the first spray device; 11-2 is the second spray device; 11-3 is the third spray device; 11-4 is the fourth spray device; 11-5 is the fifth spray device;

[0069] 12 is the first spunbond device; 12-1 is the first spunbond raw material supply device; 12-2 is the first spunbond screw extruder; 12-3 is the first spunbond spinning box; 12-4 is the first spunbond cooling device; 12-5 is the first spunbond traction device; 12-6 is the first spunbond splitter.

[0070] 13 is the second spunbond device; 13-1 is the first spunbond raw material supply device; 13-2 is the first spunbond screw extruder; 13-3 is the first spunbond spinning box; 13-4 is the first spunbond cooling device; 13-5 is the first spunbond traction device; 13-6 is the first spunbond splitter.

[0071] 14 is the first mixed injection system;

[0072] 15 is the second mixed injection system;

[0073] 16 is a hot rolling device; 17 is a roller pre-wetting device; 18 is a first high-pressure water spray device; 19 is a first vacuum dewatering device; 20 is a first conveyor screen; 21 is a second conveyor screen; 22 is a second high-pressure water spray device; 23 is a third high-pressure water spray device; 24 is a conveyor roller; 25 is a jacquard high-pressure water spray device; 26 is a jacquard hydroentangling machine roller; 27 is a second vacuum dewatering device; 28 is a drying device; 29 is a finishing device; 30 is a spinneret; 31 is a spinneret hole or airflow drawing hole; 32 is an airflow drawing hole or spinneret hole; 33 is a mixed-blown absorbent layer; 34 is short absorbent fiber; 35 is meltblown fiber; 36 is a "slit air knife" meltblown type spinneret hole; 37 is a "slit air knife" meltblown type airflow drawing hole; 38 is a web forming curtain; 39 is a suction device.

[0074] 40 is the third spunbond device; 40-1 is the first spunbond raw material supply device; 40-2 is the first spunbond screw extruder; 40-3 is the first spunbond spinning box; 40-4 is the first spunbond cooling device; 40-5 is the first spunbond traction device; 40-6 is the first spunbond splitter.

[0075] 41 is the seventh meltblown device; 41-1 is the seventh meltblown raw material supply device; 41-2 is the seventh screw extruder; 41-3 is the seventh melt filtration device; 41-4 is the seventh spinning box; 41-5 is the seventh spinneret.

[0076] 42 is the fourth spunbond device; 42-1 is the first spunbond raw material supply device; 42-2 is the first spunbond screw extruder; 42-3 is the first spunbond spinning box; 42-4 is the first spunbond cooling device; 42-5 is the first spunbond traction device; 42-6 is the first spunbond splitter. Detailed Implementation

[0077] This invention provides a method for preparing a composite multilayer nonwoven material, comprising the following steps:

[0078] The first raw material is subjected to first meltblown and / or first spunbond processes to obtain a first fiber web layer. The first fiber web layer includes a plurality of first meltblown fiber webs and / or a plurality of first spunbond fiber webs stacked together. The first raw material includes a first polymer raw material.

[0079] An intermediate fiber web layer is prepared on the surface of the first fiber web layer. The intermediate fiber web layer comprises a plurality of stacked mixed-spray fiber webs and / or a plurality of air-laid fiber webs. The preparation method of the mixed-spray fiber web includes: performing a second melt-blowing process on a second raw material; pulverizing a first absorbent fiber and then performing a first air-laid process; and mixing and spraying the long fiber bundles obtained from the second melt-blowing process with the short fiber bundles formed by the first air-laid process to obtain the mixed-spray fiber web. The second raw material includes a second polymer raw material. The preparation method of the air-laid fiber web includes: pulverizing a second absorbent fiber and then performing a second air-laid process.

[0080] On the surface of the intermediate fiber web layer, a third raw material is subjected to a third meltblown process and / or a second spunbond process to form a second fiber web layer, thereby obtaining a semi-finished fiber web; the second fiber web layer includes a plurality of stacked second meltblown fiber webs and / or a plurality of second spunbond fiber webs, and the third raw material includes a third polymer raw material;

[0081] The semi-finished fiber web is hot-rolled and shaped to obtain a hot-rolled fiber web; the first fiber web layer of the semi-finished fiber web forms the lower surface of the hot-rolled fiber web, and the second fiber web layer of the semi-finished fiber web forms the upper surface of the hot-rolled fiber web;

[0082] The hot-rolled fiber web is pre-wetted and then subjected to high-pressure water spraying to obtain a jacquard high-pressure water-sprayed fiber web. The high-pressure water spraying includes sequentially performing flat-web forward spraying, rotary drum reverse spraying, rotary drum forward spraying, and flat-web jacquard forward spraying. The flat-web forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web while simultaneously drawing a vacuum on the lower surface. The rotary drum reverse spraying involves spraying water onto the lower surface of the hot-rolled fiber web on the rotating circumference of the drum. The rotary drum forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web on the rotating circumference of the drum to form a jacquard pattern while simultaneously drawing a vacuum on the lower surface.

[0083] The jacquard high-pressure water-jet fiber web is dried and then finished sequentially to obtain the composite multilayer nonwoven material.

[0084] In this invention, unless otherwise specified, all raw materials / components used in the preparation are commercially available products well known to those skilled in the art.

[0085] In this invention, the total mass of the composite multilayer nonwoven material is the total mass of polymer raw materials (two or three of the first polymer raw material, the second polymer raw material, and the third polymer raw material) and absorbent fibers (one or two of the first absorbent fiber and the second absorbent fiber). Preferably, it also includes chemical auxiliaries (at least one of the first chemical auxiliaries, the second chemical auxiliaries, the third chemical auxiliaries, the fourth chemical auxiliaries, and chemical auxiliaries used in finishing), and preferably includes functional masterbatch (any one of the first functional masterbatch, the second functional masterbatch, and the third functional masterbatch). The sum of the mass percentages of all raw materials used in the composite multilayer nonwoven material is 100%.

[0086] This invention involves firstly meltblowing and / or first spunbonding a first raw material to obtain a first fiber web layer. The first fiber web layer comprises a plurality of stacked first meltblown fiber webs and / or a plurality of first spunbonded fiber webs. The first raw material includes a first polymer raw material. In this invention, the first fiber web layer is also referred to as a "scrim" layer, which can reduce the shedding of short absorbent fibers in the intermediate fiber web layer and reduce lint shedding. The first polymer raw material preferably includes biodegradable or compostable thermoplastic fibers and / or thermoplastic polymer filaments; the biodegradable or compostable thermoplastic fibers include one or more of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose, and hemicellulose derivatives; the thermoplastic polymer filaments are made of one or more of polyolefins, polyesters, polyhydroxyalkanoates, and polyhydroxybutyrates; the starch derivatives preferably include... The material comprises one or more of pregelatinized starch, acid-modified starch, and oxidized starch; the chitosan derivative preferably includes one or more of chitosan oligosaccharides, chitosan quaternary ammonium salts, carboxymethyl chitosan, and hydroxypropyl chitosan; the hemicellulose derivative preferably includes one or more of nonionic hemicellulose, anionic hemicellulose, and cationic hemicellulose; the thermoplastic polymer filament preferably comprises a single component or a two-component, the two-component comprising one or more of core-sheath type, side-by-side type, trefoil type, and orange segment type; the melt index range of the thermoplastic polymer filament is preferably 100–1500 g / 10 min. The melt index range of the polymer material used in the first meltblown is preferably 300–1000 g / 10 min, more preferably 400–800 g / 10 min, and even more preferably 500–700 g / 10 min. The melt index range of the polymer material used in the first spunbond is preferably 10–100 g / 10 min, more preferably 10–60 g / 10 min, and even more preferably 25–40 g / 10 min.

[0087] The percentage of the first raw material in the first fiber web layer to the total mass of the composite multilayer nonwoven material is preferably 0.2-20%, more preferably 0.5-18%, and even more preferably 5-15%. The first raw material further includes a first functional masterbatch, which preferably includes one or more of hydrophilic masterbatch, elastic masterbatch, biodegradable masterbatch, antibacterial masterbatch, cooling masterbatch, antistatic masterbatch, and rust-preventive masterbatch. The mass of the first functional masterbatch in the first fiber web layer is preferably 0.1-10% of the mass of the first polymer raw material, more preferably 0.5-5%, and even more preferably 2-3%. The spinning temperature of the first meltblown is preferably 200℃-290℃, more preferably 220-270℃, and even more preferably 230-260℃. The hot air volume of the first meltblown is 800-2000 Nm³. 3The first meltblown process preferably further includes spraying a first aqueous solution of water or a first chemical additive onto the long fiber bundle obtained by the first meltblown process. The first aqueous solution of the chemical additive preferably includes a first chemical additive and water, and the first chemical additive preferably includes one or more of the following: antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, silicone, wetting agent, latex, and thermochromic colorant material; the latex includes acrylics and / or vinyl acetate; the strength agent includes carboxymethyl cellulose and / or starch; the adhesive includes one or more of vinyl acetate, acrylics, and other elastic adhesives. The first spray is a water mist formed by spraying water or chemical additives through high-pressure small orifices, and the first spray rate is preferably 0-180 L / h, more preferably 100-180 L / h, and even more preferably 120-150 L / h, so that the spray can quickly adhere to the filament and dry immediately. The percentage of the first chemical auxiliary agent in the first chemical auxiliary agent aqueous solution by mass of the composite multilayer nonwoven material is preferably 0.1-10%, more preferably 1-5%, and most preferably 1-3%. The diameter of the long fibers obtained by the first meltblown method is 5-20 μm, and the basis weight is 0.1-3.0 gsm. The diameter of the long fibers obtained by the first spunbond method is 5-20 μm, and the basis weight is 0.1-3.0 gsm. The compositions of the plurality of first meltblown fiber webs and / or the plurality of first spunbond fiber webs are the same or different.

[0088] After obtaining the first fiber web layer, the present invention prepares an intermediate fiber web layer on the surface of the first fiber web layer. The intermediate fiber web layer includes a plurality of stacked mixed-spray fiber webs and / or a plurality of air-laid fiber webs. The preparation method of the mixed-spray fiber web includes: performing a second melt-blowing on a second raw material, pulverizing the first absorbent fiber and then performing a first air-laid web, and mixing and spraying the long fiber bundles obtained from the second melt-blowing and the short fiber bundles formed by the first air-laid web to obtain the mixed-spray fiber web. The second raw material includes a second polymer raw material. The preparation method of the air-laid fiber web includes: pulverizing the second absorbent fiber and then performing a second air-laid web. In the present invention, the first absorbent fiber preferably includes wood pulp fiber and / or paper pulp fiber. The wood pulp fiber includes one or more of oak, poplar, birch, pine, spruce, and fir. The paper pulp fiber includes one or more of straw pulp, reed pulp, sugarcane pulp, bamboo pulp, cotton pulp, hemp pulp, and natural fiber rag pulp. The percentage of the mass of the first absorbent fiber in the intermediate fiber web layer to the total mass of the composite multilayer nonwoven material is preferably 10-47.5%, more preferably 25-45%, and even more preferably 30-45%. The pulverization is carried out in a grinding device. In this invention, the first absorbent fiber is transported to the grinding device via a transmission device for pulverization. For loose fibers such as cotton, a cutting device can be used to cut them first, followed by pulverization using the grinding device. The pulverized fibers are then evenly distributed across the web using an airflow web-forming method. The first airflow web-forming is preferably performed using a CD controllable jet or a forming head that evenly distributes the web along the width direction. The forming head is either a dust cage type or a flat screen type. The length of the short fibers obtained from the first airflow web-forming is 0.5-8 mm. The second raw material includes a second polymer raw material, which preferably includes biodegradable or compostable thermoplastic fibers and / or thermoplastic polymer filaments; the biodegradable or compostable thermoplastic fibers include 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; the thermoplastic polymer filaments are made of one or more of polyolefins, polyesters, polyhydroxyalkanoates and polyhydroxybutyrates; the starch... The powder derivative preferably includes one or more of pregelatinized starch, acid-modified starch, and oxidized starch; the chitosan derivative preferably includes one or more of chitosan oligosaccharides, chitosan quaternary ammonium salts, carboxymethyl chitosan, and hydroxypropyl chitosan; the hemicellulose derivative preferably includes one or more of nonionic hemicellulose, anionic hemicellulose, and cationic hemicellulose; the thermoplastic polymer filament preferably includes a single component or a two-component, the two-component including one or more of core-sheath type, side-by-side type, trefoil type, and orange segment type; the melt index range of the thermoplastic polymer filament is preferably 100-1500 g / 10 min.The melt flow index range of the polymer material used in the second meltblown process is preferably 300–1000 g / 10 min, more preferably 400–800 g / 10 min, and even more preferably 500–700 g / 10 min.

[0089] In this invention, the percentage of the second raw material in the intermediate fiber web layer to the total mass of the composite multilayer nonwoven material is preferably 0.2-20%, more preferably 0.5-18%, and even more preferably 5-15%. The second raw material of the second meltblown preferably further includes a second functional masterbatch, which preferably includes one or more of hydrophilic masterbatch, elastic masterbatch, biodegradable masterbatch, antibacterial masterbatch, cooling masterbatch, antistatic masterbatch, and rust-preventive masterbatch. The mass of the second functional masterbatch in the intermediate fiber web layer accounts for 0.1-10% of the mass of the second polymer raw material, more preferably 0.5-5%, and even more preferably 2-3%. The spinning temperature of the second meltblown is preferably 200℃-290℃, more preferably 220-270℃, and even more preferably 230-260℃. The hot air volume of the second meltblown is 800-2000 Nm³. 3 / h. The mixed spraying process further includes spraying a second aqueous solution of water or a second chemical additive onto the short fiber bundles obtained by the first airflow web formation and the long fiber bundles obtained by the second meltblown process. The second spraying rate is preferably 0-180 L / h, more preferably 100-180 L / h, and even more preferably 120-150 L / h. The second spraying uses a high-pressure, small-aperture spray of water or chemical additive to form a water mist, allowing the spray to quickly adhere to the short and long fibers and dry immediately. The second aqueous solution of chemical additive preferably includes a second chemical additive and water. The second chemical additive preferably includes one or more of the following: antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, silicone, wetting agent, latex, and thermochromic colorant material; the latex includes acrylic and / or vinyl acetate; the strength agent includes carboxymethyl cellulose and / or starch; the adhesive includes one or more of vinyl acetate, acrylic, and other elastic adhesives. The percentage of the second chemical auxiliary agent in the aqueous solution of the second chemical auxiliary agent according to the total mass of the composite multilayer nonwoven material is preferably 0.1-10%, more preferably 1-5%, and most preferably 1-3%. The long fibers obtained by the second meltblown process have a diameter of 5-20 μm and a basis weight of 0.1-3.0 gsm.

[0090] When the intermediate fiber web layer comprises an air-laid fiber web, the preparation method of the air-laid fiber web includes: pulverizing the second absorbent short fiber and then air-laid it to obtain the air-laid fiber web. The second absorbent fiber preferably comprises wood pulp fiber and / or paper pulp fiber; the wood pulp fiber includes one or more of oak, poplar, birch, pine, spruce, and fir; the paper pulp fiber includes one or more of straw pulp, reed pulp, sugarcane pulp, bamboo pulp, cotton pulp, hemp pulp, and natural fiber rag pulp. The percentage of the mass of the second absorbent fiber in the intermediate fiber web layer relative to the total mass of the composite multilayer nonwoven material is preferably 10-47.5%, more preferably 25-45%, and even more preferably 30-45%. The pulverization is carried out in a grinding device. In this invention, the first absorbent fiber is transported to the grinding device for pulverization via a transmission device. If it is a loose fiber such as cotton, it can be cut first using a cutting device and then pulverized using the grinding device. The pulverized fiber is evenly distributed across its various parts by air-laid formation. The second airflow web formation is preferably performed by distributing and laying the web using a CD controllable injector or by uniformly distributing and laying the web along the width direction using a forming head, wherein the forming head is a dust cage type or a flat screen type. The short fibers obtained by the second airflow web formation have a length of 0.5–8 mm. Several mixed-jet fiber webs may have the same or different compositions. Several airflow web formations may have the same or different compositions.

[0091] The second airflow web forming process preferably further includes a third spray of water or a third chemical auxiliary agent aqueous solution onto the short fiber bundles obtained by the second airflow web forming process. The third spray rate is preferably 0-180 L / h, more preferably 100-180 L / h, and even more preferably 120-150 L / h. The third spray is a water mist formed by spraying water or chemical auxiliary agent through high-pressure small orifices, which allows the spray to quickly adhere to the short fibers and filaments and dry immediately. The third chemical auxiliary aqueous solution preferably includes a third chemical auxiliary agent and water. The third chemical auxiliary agent preferably includes one or more of the following: antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, silicone, wetting agent, latex, and thermochromic colorant material; the latex includes acrylic and / or vinyl acetate; the strength agent includes carboxymethyl cellulose and / or starch; and the adhesive includes one or more of vinyl acetate, acrylic, and other elastic adhesives. The percentage of the third chemical auxiliary agent in the aqueous solution of the second chemical auxiliary agent to the total mass of the composite multilayer nonwoven material is preferably 0.1-10%, more preferably 1-5%, and most preferably 1-3%.

[0092] After obtaining the intermediate fiber web layer, the present invention further involves applying a third raw material to the surface of the intermediate fiber web layer via third meltblowing and / or second spunbonding to form a second fiber web layer, resulting in a semi-finished fiber web. The second fiber web layer comprises a plurality of stacked second meltblown fiber webs and / or a plurality of second spunbonded fiber webs, and the third raw material comprises a third polymer raw material. In the present invention, the second fiber web layer is also referred to as a "scrim" layer, which can reduce the shedding of short absorbent fibers in the intermediate fiber web layer and reduce lint shedding. The third polymer raw material preferably comprises biodegradable or compostable thermoplastic fibers and / or thermoplastic polymer filaments; the biodegradable or compostable thermoplastic fibers include one or more of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramide and its copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose and hemicellulose derivatives; the thermoplastic polymer filaments are made of one or more of polyolefins, polyesters, polyhydroxyalkanoates and polyhydroxybutyrates; the starch derivatives preferably... The polymer filaments are selected from one or more of pregelatinized starch, acid-modified starch, and oxidized starch; the chitosan derivatives preferably include one or more of chitosan oligosaccharides, chitosan quaternary ammonium salts, carboxymethyl chitosan, and hydroxypropyl chitosan; the hemicellulose derivatives preferably include one or more of nonionic hemicellulose, anionic hemicellulose, and cationic hemicellulose; the polymer filaments are monocomponent or bicomponent, and the bicomponents include one or more of core-sheath type, side-by-side type, trefoil type, and orange segment type; the melt index of the thermoplastic polymer filaments is in the range of 100–1500 g / 10 min. The melt index of the polymer material used in the third meltblown is preferably in the range of 300–1000 g / 10 min, more preferably 400–800 g / 10 min, and even more preferably 500–700 g / 10 min. The melt index of the polymer material used in the second spunbond is preferably in the range of 10–100 g / 10 min, more preferably 10–60 g / 10 min, and even more preferably 25–40 g / 10 min.

[0093] The percentage of the third raw material in the second fiber web layer relative to the total mass of the composite multilayer nonwoven material is preferably 0.2-20%, more preferably 0.5-18%, and even more preferably 5-15%. The second raw material also includes a third functional masterbatch, which preferably includes one or more of hydrophilic masterbatch, elastic masterbatch, biodegradable masterbatch, antibacterial masterbatch, cooling masterbatch, antistatic masterbatch, and rust-preventive masterbatch. The percentage of the third functional masterbatch in the second fiber web layer relative to the mass of the third polymer raw material is preferably 0.1-10%, more preferably 0.5-5%, and even more preferably 2-3%. The spinneret temperature of the third meltblown is preferably 200℃-290℃, more preferably 220-270℃, and even more preferably 230-260℃. The hot air volume of the third meltblown is 800-2000 Nm³. 3 The third meltblown process preferably further includes a fourth spray of water or a fourth chemical additive aqueous solution onto the long fiber bundle obtained from the third meltblown process. The fourth spray is a water mist formed by spraying water or chemical additives through high-pressure small orifices, allowing the spray to quickly adhere to the short fibers and filaments and dry immediately. The fourth spray rate is preferably 0-180 L / h, more preferably 100-180 L / h, and even more preferably 120-150 L / h, allowing the spray to quickly adhere to the filaments and dry immediately. The fourth chemical additive aqueous solution preferably includes a fourth chemical additive and water, and the fourth chemical additive preferably includes one or more of the following: antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, silicone, wetting agent, latex, and thermochromic colorant material; the latex includes acrylic and / or vinyl acetate; the strength agent includes carboxymethyl cellulose and / or starch; the adhesive includes one or more of vinyl acetate, acrylic, and other elastic adhesives. The percentage of the fourth chemical auxiliary agent in the aqueous solution of the fourth chemical auxiliary agent according to the total mass of the composite multilayer nonwoven material is preferably 0.1-10%, more preferably 1-5%, and most preferably 1-3%. The diameter of the long fibers obtained by the third meltblown process is 5-20 μm, and the basis weight is 0.1-3.0 gsm. The diameter of the long fibers obtained by the second spunbond process is 5-20 μm, and the basis weight is 0.1-3.0 gsm. The compositions of the plurality of second meltblown fiber webs and / or the plurality of second spunbond fiber webs may be the same or different.

[0094] After obtaining the semi-finished fiber web, the present invention hot-rolls and shapes the semi-finished fiber web to obtain a hot-rolled fiber web. In the present invention, the hot rolling and shaping is performed using a hot rolling device to hot-roll and shape dots or other geometric shapes, wherein the rollers of the hot rolling device have a built-in heating function. The preferred temperature for hot rolling and shaping is 80-200℃, more preferably 90-150℃, and even more preferably 90-110℃. The preferred speed is 0-1000m / min, and not 0, more preferably 100-1000m / min, even more preferably 200-600m / min, and most preferably 300-500m / min. The pattern on the hot-rolling rollers is arranged in a raised pattern along the width of the web.

[0095] After obtaining the hot-rolled fiber web, this invention pre-wets the hot-rolled fiber web and then subjectes it to high-pressure water spraying to obtain a jacquard high-pressure water-sprayed fiber web. The high-pressure water spraying includes sequentially performing flat-web forward spraying, rotary drum reverse spraying, rotary drum forward spraying, and flat-web jacquard forward spraying. The flat-web forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web while simultaneously vacuuming the lower surface. The rotary drum reverse spraying involves spraying water onto the lower surface of the hot-rolled fiber web on the rotating circumference of the drum. The rotary drum forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web on the rotating circumference of the drum. The flat-web jacquard forward spraying involves jacquard water spraying onto the upper surface of the hot-rolled fiber web to form a jacquard pattern while simultaneously vacuuming the lower surface. In this invention, the hot-rolled fiber web can be conveyed to the high-pressure water spraying equipment offline or online. The hot-rolled fiber web is adsorbed onto the surface of the rotary drum during conveying. This invention dehydrates the hot-rolled fiber web by vacuuming. The pre-wetting water pressure is preferably 0.1–5 MPa, more preferably 0.5–4 MPa, and even more preferably 0.5–3 MPa. The water pressure for the flat-net forward spray is preferably 0.5–10 MPa, more preferably 1–10 MPa, and even more preferably 3–8 MPa. The water pressure for the rotary drum reverse spray is preferably 1–15 MPa, more preferably 3–15 MPa, and even more preferably 5–12 MPa. The water pressure for the rotary drum forward spray is preferably 1–15 MPa, more preferably 3–15 MPa, and even more preferably 5–12 MPa. The water pressure for the flat-net jacquard forward spray is 3–20 MPa, preferably 5–20 MPa, and even more preferably 8–18 MPa; the vacuum degree during the flat-net forward spray is preferably 15000–40000 Pa, more preferably 16000–37000 Pa, and even more preferably 25000–35000 Pa. The vacuum level during jacquard water spraying is preferably 15,000–40,000 Pa, more preferably 16,000–37,000 Pa, and even more preferably 25,000–35,000 Pa. During pre-wetting, the flat-net forward spraying, the rotary drum reverse spraying, the rotary drum forward spraying, and the flat-net jacquard forward spraying, the high-pressure water spraying equipment uses nozzles that vertically spray multiple fine water jets onto the fiber web. During the rotary drum reverse spraying and the rotary drum forward spraying, the hot-rolled fiber web adheres to the surface of the perforated roller.

[0096] In a specific embodiment of the present invention: the hot-rolled fiber web can be conveyed to a high-pressure water spraying device offline or online. First, the hot-rolled fiber web is pre-wetted using a roller pre-wetting device. The roller and the conveyor curtain clamp the hot-rolled fiber web, compacting the loose web and removing air from it, thus enhancing the capillary effect on the fiber surface and improving the moisture absorption performance of the textile. This also helps improve the air permeability of composite multilayer nonwoven materials. The hot-rolled fiber web is then conveyed to the high-pressure water spraying zone. The high-pressure water spraying device sprays multiple fine water jets vertically onto the fiber web. After passing through the first high-pressure water spraying device, the hot-rolled fiber web adheres to the surface of a perforated roller and is then conveyed to the second and third high-pressure water spraying devices. The perforated roller can adjust the tension of the fabric edge, preventing deviation and facilitating high-speed production. The perforated roller also helps to remove excess moisture from the fabric surface in a timely manner. Finally, it is conveyed above the second conveyor curtain by a conveyor roller. The spunlace jacquard mechanism uses a high-pressure water jet device to copy the pattern on the jacquard mechanism roller onto the composite multilayer nonwoven material on the fabric surface at high speed, and then removes excess water through a vacuum suction device.

[0097] After obtaining the jacquard high-pressure water-jet fiber web, the present invention sequentially dries and finishes the jacquard high-pressure water-jet fiber web to obtain the composite multilayer nonwoven material. In the present invention, the drying is preferably hot air drying. The drying temperature is preferably 90-130℃, more preferably 90-150℃, and even more preferably 100-130℃. The finishing treatment preferably includes one or more of spraying, roller coating, and padding; the chemical auxiliaries used in the finishing preferably include one or more of antibacterial agents, hydrophilic agents, softeners, plasticizers, strength agents, adhesives, silicones, wetting agents, latexes, and thermochromic colorants; the latex includes acrylics and / or ethylene vinyl acetate; the strength agent includes carboxymethyl cellulose and / or starch; the adhesive includes one or more of ethylene vinyl acetate, acrylics, and other elastic adhesives.

[0098] The present invention provides a composite multilayer nonwoven material prepared by the preparation method described in the above technical solution, comprising a first layer structure, an intermediate layer structure, and a second layer structure stacked sequentially; the first layer structure is formed by a plurality of first meltblown fiber webs and / or a plurality of first spunbond fiber webs; the intermediate layer structure is formed by a plurality of mixed-blown fiber webs and / or a plurality of air-blown fiber webs; and the second layer structure is formed by a plurality of second meltblown fiber webs and / or a plurality of second spunbond fiber webs.

[0099] The weight of the finished product is preferably 10-300 gsm.

[0100] This invention provides an apparatus for the preparation method described in the above technical solution, comprising a forming curtain, a forming device disposed above the forming curtain, the forming device comprising a plurality of first meltblown devices and / or a plurality of spunbond devices, and further comprising a plurality of mixing and spraying systems and / or a plurality of second grinding devices, the second grinding device comprising a second crusher and a second airflow forming device; the mixing and spraying system comprising a plurality of second meltblown devices, a plurality of first grinding devices and a mixing and spraying forming box, the first grinding device comprising a first crusher and a first airflow forming device;

[0101] A hot rolling unit located downstream of the forming screen, a first conveying screen located downstream of the hot rolling unit, a pre-wetting unit and a first high-pressure water spraying unit located above the first conveying screen, a first vacuum dewatering unit located below the first conveying screen, a second high-pressure water spraying unit and a third high-pressure water spraying unit located downstream of the first conveying screen, a second conveying screen located downstream of the second high-pressure water spraying unit and the third high-pressure water spraying unit, a jacquard high-pressure water spraying unit located above the second conveying screen, a second vacuum dewatering unit located below the second conveying screen, a drying unit located downstream of the second conveying screen, and a finishing unit located downstream of the drying unit.

[0102] In this invention, the structure of the composite multilayer nonwoven material prepared by this invention may include at least three layers and / or at least four layers and / or at least five layers and / or multiple layers. The spunbond / meltblown system may be one, two, or more sets, and the meltblown device may be only one or all of them operational; the spunbond / meltblown devices on both sides may be one set on each side, or one set or more sets on one side but none on the other.

[0103] In this invention, the web forming device above the web forming curtain is configured with a number and arrangement order of a number of first meltblown devices, a number of spunbond devices, a number of mixing and spraying systems, and a number of second grinding devices according to the layer structure of the composite multilayer nonwoven material.

[0104] In this invention, a first spraying device is provided below the spinneret of the first meltblown device, a second spraying device is provided below the outlet of the mixing and forming box, and a third spraying device is provided below the second airflow forming device.

[0105] The spinnerets of the first meltblown device and the second meltblown device include a first spinneret, a second spinneret, or a third spinneret.

[0106] like Figure 10As shown, the first spinneret is provided with a single row of first spinneret holes. The first spinneret holes are inverted conical holes. The outer conical surface of the first spinneret holes is fitted with a first airflow stretching hole. The first airflow stretching hole is an inverted conical hole and coaxial with the first spinneret holes. The long fiber ejected from the first spinneret holes and the stretching gas ejected from the first airflow stretching hole converge at the top of the cone. The angle between the stretching gas and the long fiber is 30 to 70°.

[0107] like Figure 6 , Figure 7 and Figure 8 As shown, the second spinneret is provided with a single row or multiple rows of second spinneret holes. The second spinneret holes are cylindrical holes. A second airflow stretching hole is sleeved on the outer circumferential surface of the second spinneret holes. The second airflow stretching hole is an annular hole and coaxial with the second spinneret holes.

[0108] like Figure 6 , Figure 7 and Figure 8 As shown, the third spinneret is provided with a single row or multiple rows of third airflow stretching holes. The third airflow stretching holes are cylindrical holes. The outer circumferential surface of the third airflow stretching holes is fitted with third spinnerets. The third spinnerets are annular holes and coaxial with the third airflow stretching holes.

[0109] The operating temperature of the spinnerets of the first and second meltblown devices is preferably 200℃~290℃.

[0110] In this invention, the configuration of the first meltblown device and the second meltblown device can be either a "slit air knife" meltblown type or a "coaxial" meltblown type. For example... Figure 10 As shown, the "slit air knife" meltblown type involves two converging gas streams to form a single airflow. The stretching gas forms an angle of approximately 30-70° with the filament flow direction. When the polymer filament leaves the spinneret in the meltblown die, it is cooled and stretched by the air knife, ultimately adhering and falling onto the mesh screen. The "coaxial" meltblown type has annular fluid release holes around each spinneret, 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. When the meltblown device is configured as a "slit air knife" meltblown type, the spinneret has a single row of holes; when the meltblown device is configured as a "coaxial" meltblown type, the spinneret can have a single row or multiple rows of holes, with multi-row spinnerets including 2, 3, 4, or more rows.

[0111] In this invention, the pre-wetting device is specifically a drum pre-wetting device.

[0112] In this invention, when the second and third high-pressure water spraying devices spray water onto the obtained hot-rolled fiber web, the hot-rolled fiber web is adsorbed onto the surface of the perforated roller and conveyed to the second and third high-pressure water spraying devices. The perforated roller can adjust the tension of the fabric edge, prevent deviation, and facilitate high-speed production of the machine. In addition, the perforated roller is conducive to timely removal of excess water from the fabric surface.

[0113] In this invention, the pressure of the high-pressure water spray device is 60 to 250 Bar.

[0114] In this invention, the drying device is preferably an oven, and the types of ovens include tunnel type, circular mesh type, and infrared heating type. Finally, the wiping material is finished by a finishing device to give it certain functionality.

[0115] This invention obtains a composite nonwoven fabric with high water absorption, fast water absorption, high strength, fluffy surface, soft hand feel, and low lint rate by layering or mixing short fibers with polymers sprayed by meltblown / spunbond technology and combining them with a high-pressure water spraying process.

[0116] 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.

[0117] Example 1

[0118] This embodiment adopts Figure 1 The apparatus shown is used to prepare composite multilayer nonwoven materials, such as Figure 1 The equipment shown includes: a first meltblown device, a first spraying device, a first mixed-blown system, the first mixed-blown system including a third meltblown device, a first grinding device, a fourth meltblown device and a first mixed-blown forming box, a second spraying device, a second grinding device, a third spraying device, a first spunbond device, a hot rolling device, a roller pre-wetting device, a first high-pressure water spraying device, a first vacuum dehydration device, a first conveyor screen, a second conveyor screen, a second high-pressure water spraying device, a third high-pressure water spraying device, a conveyor roller, a jacquard high-pressure water spraying device, a jacquard hydroentanglement machine roller, a second vacuum dehydration device, a drying device, a finishing device, a forming screen and a suction device;

[0119] Step 1: Using a first meltblown device, a mixture of 6% by weight of the two-component parallel polypropylene / polyester and a soft masterbatch is heated and melted, and then sprayed onto a web forming curtain to form the first meltblown fiber web layer. The soft masterbatch accounts for 1% by weight of the two-component parallel polypropylene / polyester. A first spraying device is installed on the first spinneret of the first meltblown device to spray a hydrophilic auxiliary agent accounting for 0.67% by weight of the total mass of the composite multilayer nonwoven material with high pressure small holes.

[0120] Step Two: A two-component parallel polypropylene / polyester mixture, comprising 12% of the total mass of the composite multilayer nonwoven material, is mixed and melted with water-absorbing masterbatch from the third and fourth meltblown devices. The water-absorbing masterbatch comprises 2% of the mass of the two-component parallel polypropylene / polyester mixture. Wood pulp fibers, comprising 50% of the total mass of the composite multilayer nonwoven material, are transported via a transmission device to the first grinding device for crushing. After being distributed and laid into a web by a CD controllable sprayer, the wood pulp fibers are finally mixed with the polymer material and water-absorbing masterbatch at high temperature. The resulting filaments are then mixed in a forming box to form a first mixed-blown water-absorbing layer covering the first meltblown fiber web layer. The first mixed-blown system has a spraying device that sprays a hydrophilic additive comprising 0.67% of the total mass of the composite multilayer nonwoven material at a high-pressure small orifice at a rate of 125 L / h.

[0121] Step 3: The cotton pulp fibers, comprising 18% of the total mass of the composite multilayer nonwoven material, pulverized by the second grinding device, are evenly distributed along the width direction using a forming head. The forming head is a dust cage type, forming an absorbent layer that covers the mixed-spray absorbent layer. The second grinding device has a spraying device that sprays a hydrophilic auxiliary agent, comprising 0.67% of the total mass of the composite multilayer nonwoven material, at a high-pressure small orifice at a rate of 125 L / h.

[0122] Step 4: Using the first spunbond device, 10% of the total mass of the composite multilayer nonwoven material is mixed, heated and melted, and then sprayed onto the spunbond screen to form the first spunbond fiber web layer covering the absorbent layer.

[0123] Step 5: The meltblown fiber web layer, mixed-blown absorbent layer, absorbent layer and spunbond fiber web layer formed in steps 1 to 4 are stacked on the web forming curtain and the geometric shape is hot rolled and shaped using a hot rolling mill at a temperature of 105℃, forming a semi-finished product with two layers of spunbond and meltblown fiber web layers on the top and bottom, and a mixed-blown absorbent layer and absorbent layer in the middle.

[0124] Step Six: First, use a dotted pattern for hot rolling to fix the product. Then, transfer the semi-finished product from Step Five to the high-pressure water spraying equipment offline or online. First, pre-wet the semi-finished product from Step Five at a pressure of 0.5 MPa. Then, transfer it to the first high-pressure water spraying device at a pressure of 8 MPa, with a vacuum degree of 25000 Pa in the vacuum dehydration chamber. The second high-pressure water spraying device has a pressure of 12 MPa, and the third high-pressure water spraying device has a pressure of 11 MPa. Finally, it is conveyed by conveyor rollers to the top of the second conveyor screen.

[0125] Step 7: The spunlace jacquard mechanism uses a high-pressure water spray device to copy the pattern on the jacquard mechanism roller onto the semi-finished product from Step 6 onto the fabric surface traveling at high speed. The pressure of the jacquard high-pressure water spray device is 15 MPa, and the vacuum degree of the vacuum dehydration box is 27,000 Pa, forming a jacquard pattern on the surface of the semi-finished product from Step 6.

[0126] Step 8: The semi-finished product from Step 7 after dehydration is conveyed by a conveyor screen to a hot air flow penetration oven. The hot air drying temperature is 110℃. Finally, the product is finished by a finishing device. The finishing process uses 2% antibacterial agent to enhance the antibacterial properties of the material and meet the special needs of consumers, resulting in a composite multilayer nonwoven material.

[0127] The composite multilayer nonwoven material prepared in this embodiment is used to produce 70gsm maternity pads. The composite material in this embodiment consists of four fiber web layers: a first meltblown fiber web layer, a first mixed-blown absorbent layer, an absorbent layer, and a first spunbond fiber web layer. The meltblown polymer material used in the first meltblown device is a two-component side-by-side polypropylene / polyester (Ryander Basel, London, UK) with a melt index of 650g / 10min, and a softening masterbatch (Dawn, China). The total mass of the softening masterbatch and the meltblown polymer material accounts for 6% of the total weight of the composite multilayer nonwoven material prepared in this embodiment, and the softening masterbatch accounts for 1% of the polymer material in the first meltblown device. The polymer materials used in the third and fourth meltblown devices are also two-component side-by-side polypropylene / polyester with a melt index of 650g / 10min. The total mass of the ester (Ryander Basel, London, UK) and the water-absorbing masterbatch (Dawn, China) used in the third meltblown device accounts for 6% of the total weight of the composite multilayer nonwoven material prepared in this embodiment, wherein the water-absorbing masterbatch used in the third meltblown device accounts for 2% of the polymer material in the third meltblown device; the total mass of the water-absorbing masterbatch and the meltblown polymer material used in the fourth meltblown device accounts for 6% of the total weight of the composite multilayer nonwoven material prepared in this embodiment, wherein the water-absorbing masterbatch used in the fourth meltblown device accounts for 2% of the polymer material in the fourth meltblown device. The spraying process uses a hydrophilic additive (Zhejiang Chuanhua Chemical), which accounts for 2% of the total weight. The first spunbonding unit uses polypropylene (Zhejiang Jinchun Polymer Materials Co., Ltd.) with a melt index of 35 g / 10 min, and the spunbonding polypropylene raw material accounts for 10% of the total weight. The short fiber in the first mixed spray absorbent layer uses wood pulp (GP Company, USA), and the wood pulp accounts for 50% of the total weight. The absorbent layer uses 18% cotton pulp (Manas Xiangyun Chemical Fiber Co., Ltd.). In step eight, 2% antibacterial agent (Zhejiang Chuanhua Chemical) is used.

[0128] Example 2

[0129] This embodiment adopts Figure 2 The apparatus shown is used to prepare composite multilayer nonwoven materials, such as Figure 2The equipment shown includes: a first meltblown device, a first spraying device, a first mixed-blown system, the first mixed-blown system including a third meltblown device, a first grinding device, a fourth meltblown device and a first mixed-blown forming box, a second spraying device, a second mixed-blown system, the second mixed-blown system including a fifth meltblown device, a second grinding device, a sixth meltblown device and a first mixed-blown forming box, a third spraying device, a second meltblown device, a fourth spraying device, a hot rolling device, a roller pre-wetting device, a first high-pressure water spraying device, a first vacuum dehydration device, a first conveyor screen, a second conveyor screen, a second high-pressure water spraying device, a third high-pressure water spraying device, a conveyor roller, a jacquard high-pressure water spraying device, a jacquard hydroentangling machine roller, a second vacuum dehydration device, a drying device, a finishing device, a forming screen and a suction device;

[0130] Step 1: Using the first meltblown device, 8% of the total mass of the composite multilayer nonwoven material is mixed with polypropylene and hydrophilic soft masterbatch, heated and melted, and then sprayed onto the forming curtain to form the first meltblown fiber web layer. The hydrophilic soft masterbatch accounts for 3% of the mass of polypropylene. The first spraying device is set up with the first spinneret of the first meltblown device, and ultrapure water is sprayed at 120L / h through high-pressure small holes to cool the meltblown filaments.

[0131] Step Two: In the third meltblown unit, 6% of the total mass of the composite multilayer nonwoven material is mixed with elastomer masterbatch and heated to melt, where the elastomer masterbatch accounts for 2% of the polypropylene mass. In the fourth meltblown unit, 6% of the total mass of the composite multilayer nonwoven material is mixed with polypropylene elastomer masterbatch and heated to melt, where the elastomer masterbatch accounts for 2% of the polypropylene mass. Wood pulp fiber raw material, accounting for 28.5% of the total mass of the composite multilayer nonwoven material, is transported to the first grinding unit via a transmission device for crushing. After being evenly distributed through a flat screen forming head, the wood pulp fiber is finally mixed with the polypropylene and water-absorbing masterbatch at high temperature and sprayed into filaments in the forming box, forming a mixed-spray water-absorbing layer that covers the first meltblown fiber web layer.

[0132] Step 3: In the fifth meltblown unit, 6% of the total mass of the composite multilayer nonwoven material is mixed with elastomer masterbatch and heated to melt, where the elastomer masterbatch accounts for 2% of the polypropylene mass. In the sixth meltblown unit, 6% of the total mass of the composite multilayer nonwoven material is mixed with elastomer masterbatch and heated to melt, where the elastomer masterbatch accounts for 2% of the polypropylene mass. Wood pulp fiber raw material, accounting for 28.5% of the total mass of the composite multilayer nonwoven material, is transported to the second grinding unit via a transmission device for crushing. After being evenly distributed through a flat screen forming head, the wood pulp fiber is finally mixed with the polypropylene water-absorbing masterbatch at high temperature and sprayed into filaments, which are then mixed in the forming box to form a second mixed-spray water-absorbing layer covering the first mixed-spray water-absorbing layer.

[0133] Step 4: Using a second meltblown device, 8% by weight of polypropylene (a composite multilayer nonwoven material) is mixed with hydrophilic soft masterbatch, heated and melted, and then sprayed onto the forming screen. The hydrophilic soft masterbatch accounts for 3% of the polypropylene mass, forming a second meltblown fiber web layer that covers the second mixed-blown absorbent layer. A first spray device is installed near the fourth spinneret of the second meltblown device, using high-pressure small orifices to spray ultrapure water at a rate of 120 L / h to cool the meltblown filaments.

[0134] Step 5: The first meltblown fiber web layer, the first mixed-blown absorbent layer, the second mixed-blown absorbent layer and the second meltblown fiber web layer formed in steps 1 to 4 are stacked on the web forming curtain and the geometric shape is hot rolled and shaped using a hot rolling mill at a temperature of 103°C, forming a semi-finished product with two upper and lower layers, namely a spunbond fiber web layer and a meltblown fiber web layer, and a mixed-blown absorbent layer in the middle.

[0135] Step Six: First, use a hot rolling mill to fix the nonwoven fabric in a point-like manner. Then, convey the semi-finished product from Step Five to the high-pressure water spraying equipment offline or online. First, pre-wet the semi-finished product from Step Five at a pressure of 0.6 MPa. Then, convey it to the first high-pressure water spraying device at a pressure of 7 MPa. The vacuum degree of the vacuum dehydration chamber is 26000 Pa. The pressure of the second and third high-pressure water spraying devices is 11.5 MPa. Then, it is conveyed above the second conveyor screen via conveyor rollers.

[0136] Step 7: The spunlace jacquard mechanism uses a high-pressure water spray device to copy the pattern on the jacquard mechanism roller onto the semi-finished product from Step 6 onto the fabric surface traveling at high speed. The pressure of the jacquard high-pressure water spray device is 13 MPa, and the vacuum degree of the vacuum dehydration box is 25000 Pa, forming a jacquard pattern on the surface of the semi-finished product from Step 6.

[0137] Step 8: The dehydrated semi-finished product from Step 7 is conveyed to the rotary screen drying oven by the conveyor screen. The hot air drying temperature is 100℃. Finally, it is finished by the finishing equipment. The finishing process uses 3% hydrophilic additive for spray finishing to enhance the moisture absorption performance of the material and obtain a composite multilayer nonwoven material.

[0138] The composite multilayer nonwoven material prepared in this embodiment is used to produce 70gsm disposable shirt fabric. The composite multilayer nonwoven material of this embodiment consists of four fiber web layers: a first meltblown fiber web layer, a first mixed-blown absorbent layer, a second mixed-blown absorbent layer, and a second meltblown fiber web layer. The third, fourth, fifth, and sixth meltblown devices use polypropylene (Ryander Basel, London, UK) and elastomer masterbatch (Dawn, China) with a melt index of 650g / 10min. The elastomer masterbatch accounts for 2% of the mass of polypropylene. The total mass of polypropylene and elastomer masterbatch in each of the third, fourth, fifth, and sixth meltblown devices accounts for 6% of the total weight of the composite multilayer nonwoven material prepared in this embodiment; the elastomer masterbatch accounts for 2% of the mass of polypropylene in each of the third, fourth, fifth, and sixth meltblown devices.

[0139] The first and second meltblown devices use 8% polypropylene and hydrophilic soft masterbatch (Dawn, China) with a melt index of 650 g / 10 min, wherein the hydrophilic soft masterbatch accounts for 3% of the mass of polypropylene; the total mass of polypropylene and hydrophilic soft masterbatch in the first and second meltblown devices each accounts for 8% of the total weight of the composite multilayer nonwoven material prepared in this embodiment; wherein the hydrophilic soft masterbatch accounts for 3% of the mass of polypropylene in the first and second meltblown devices.

[0140] The raw material used for short fibers is wood pulp (GP Company, USA), which accounts for 57% of the total weight. The hydrophilic additive in step eight (Zhejiang Chuanhua Chemical) accounts for 3% of the total weight.

[0141] Example 3

[0142] This embodiment adopts Figure 3 The apparatus shown is used to prepare composite multilayer nonwoven materials, such as Figure 3 The equipment shown includes: a second spunbond unit, a first meltblown unit, a first spraying unit, a first grinding unit, a third spraying unit, a second meltblown unit, a fourth spraying unit, a hot rolling unit, a roller pre-wetting unit, a first high-pressure water spraying unit, a first vacuum dewatering unit, a first conveyor screen, a second conveyor screen, a second high-pressure water spraying unit, a third high-pressure water spraying unit, a conveyor roller, a jacquard high-pressure water spraying unit, a jacquard hydroentangling machine roller, a second vacuum dewatering unit, a drying unit, a finishing unit, a web forming screen, and a suction unit;

[0143] Step 1: Using the second spunbond device, biodegradable polyesteramide, which accounts for 12% of the total mass of the composite multilayer nonwoven material, and hydrophilic soft masterbatch are heated, melted, and sprayed onto the web forming curtain. The hydrophilic soft masterbatch accounts for 3% of the mass of the biodegradable polyesteramide, forming the first spunbond fiber web layer.

[0144] Step 2: Using the first meltblown device, 9% of the total mass of the composite multilayer nonwoven material is made of biodegradable polylactic acid and hydrophilic soft masterbatch, which are heated and melted and then sprayed onto the web forming curtain. The hydrophilic soft masterbatch accounts for 3% of the mass of the biodegradable polyester amide, forming the first meltblown fiber web layer covering the first spunbond fiber web layer.

[0145] Step 3: The wood pulp fibers, which account for 68% of the total mass of the composite multilayer nonwoven material, are transported to the first grinding device by a transmission device for crushing. They are then evenly distributed through a flat screen forming head to form an absorbent layer that is laid in layers along the width direction on the first meltblown fiber web layer.

[0146] Step 4: Using a third spraying device, 9% of the total mass of the composite multilayer nonwoven material is heated and melted with hydrophilic soft masterbatch and sprayed onto the forming screen. The hydrophilic soft masterbatch accounts for 3% of the mass of the degradable polyester amide, forming a second meltblown fiber web layer that covers the absorbent layer.

[0147] Step 5: The first spunbond fiber web layer, the first meltblown fiber web layer, the absorbent layer, and the second meltblown fiber web layer formed in steps 1 to 4 are stacked on the web forming curtain and geometrically shaped using a hot rolling mill at a temperature of 105°C, forming a semi-finished product with two layers, a spunbond fiber web layer and a meltblown fiber web layer, and an absorbent layer and the first meltblown layer in the middle.

[0148] Step Six: First, use a hot rolling mill to fix the nonwoven fabric in a point-like manner. Then, the semi-finished composite multilayer nonwoven material from Step Five can be conveyed to the high-pressure water spraying equipment offline or online. First, the semi-finished composite multilayer nonwoven material from Step Five is pre-wetted at a pressure of 0.5 MPa. Then, it is conveyed to the first high-pressure water spraying device at a pressure of 7 MPa, with a vacuum degree of 26000 Pa in the vacuum dehydration chamber. The second and third high-pressure water spraying devices each have a pressure of 12 MPa. Finally, it is conveyed by conveyor rollers to the top of the second conveyor screen.

[0149] Step 7: The spunlace jacquard mechanism uses a high-pressure water spray device to copy the pattern on the jacquard mechanism roller onto the semi-finished product from Step 6 onto the fabric surface traveling at high speed. The pressure of the jacquard high-pressure water spray device is 15 MPa, and the vacuum degree of the vacuum dehydration box is 25000 Pa, forming a jacquard pattern on the surface of the semi-finished product from Step 6.

[0150] Step 8: The dehydrated semi-finished product from Step 7 is conveyed to the rotary screen drying oven by the conveyor screen. The hot air drying temperature is 102℃. Finally, it is finished by the finishing equipment. The finishing process uses 2% hydrophilic additive for roller coating to enhance the moisture absorption performance of the material and obtain a composite multilayer nonwoven material.

[0151] The composite multilayer nonwoven material prepared in this embodiment is used to produce 70gsm disposable biodegradable bath towel material. The composite material in this embodiment consists of 4 fiber web layers: a first spunbond fiber web layer, a first meltblown fiber web layer, an absorbent layer, and a second meltblown fiber web layer. The first and second meltblown devices use biodegradable polylactic acid (Lyander Basel, London, UK) with a melt index of 450 g / 10 min and hydrophilic soft masterbatch (Dawn, China). The total mass of the hydrophilic soft masterbatch and meltblown biodegradable polylactic acid in the first and second meltblown devices each accounts for 9% of the total weight of the composite multilayer nonwoven material prepared in this embodiment, with the hydrophilic soft masterbatch accounting for 3% of the biodegradable polylactic acid in each of the first and second meltblown devices. The second spunbond device uses biodegradable polylactic acid (LG, South Korea) with a melt index of 45 g / 10 min and hydrophilic soft masterbatch accounting for 12% of the total weight of the composite multilayer nonwoven material prepared in this embodiment. The hydrophilic soft masterbatch accounts for 3% of the biodegradable polylactic acid in the second spunbond device. The raw material for the short fiber is wood pulp (GP, USA), which accounts for 68% of the total weight. The hydrophilic auxiliary agent (Zhejiang Chuanhua Chemical) in step eight accounts for 2% of the total mass.

[0152] Example 4

[0153] This embodiment adopts Figure 4 The apparatus shown is used to prepare composite multilayer nonwoven materials, such as Figure 4 The equipment shown includes: a second spunbond device, a third spunbond device, a first mixing and spraying system, the first mixing and spraying system including a third meltblown device, a first grinding device, a fourth meltblown device and a first mixing and spraying forming box, a second spraying device, a second meltblown device, a fourth spraying device, a seventh meltblown device, a fifth spraying device, a hot rolling device, a roller pre-wetting device, a first high-pressure water spraying device, a first vacuum dehydration device, a first conveyor screen, a second conveyor screen, a second high-pressure water spraying device, a third high-pressure water spraying device, a conveyor roller, a jacquard high-pressure water spraying device, a jacquard hydroentanglement machine roller, a second vacuum dehydration device, a drying device, a finishing device, a forming screen and a suction device;

[0154] Step 1: Using the second spunbond device, 12% of the total mass of the composite multilayer nonwoven material is heated and melted into a bicomponent polyester / polyamide masterbatch and sprayed onto the web forming curtain to form the first spunbond fiber web layer.

[0155] Step 2: Using a third spunbond device, 12% of the total mass of the composite multilayer nonwoven material is heated and melted into a bicomponent polyester / polyamide masterbatch and sprayed onto the web forming curtain to form the second spunbond fiber web layer.

[0156] Step 3: The third and fourth meltblown devices respectively mix and melt 12% of the total mass of the composite multilayer nonwoven material polyester and reinforcing masterbatch, wherein the reinforcing masterbatch accounts for 1% of the polyester mass, and 26% of the wood pulp fiber raw material is transported to the grinding device for crushing via the transmission device. After being evenly distributed through the flat screen forming head, the wood pulp fiber is finally mixed with the polypropylene / polyester and water-absorbing masterbatch at high temperature and sprayed into filaments in the forming box to form the first mixed spray water-absorbing layer covering the second spunbond fiber web layer.

[0157] Step 4: Using a second meltblown device, polyester accounting for 12% of the total mass of the composite multilayer nonwoven material is mixed with reinforcing masterbatch, heated and melted, and then sprayed onto the web forming curtain. The reinforcing masterbatch accounts for 1% of the polyester mass, forming a second meltblown fiber web layer covering the first mixed-blown absorbent layer.

[0158] Step 5: Using the seventh meltblown device, polyester accounting for 12% of the total mass of the composite multilayer nonwoven material is mixed with reinforcing masterbatch, heated and melted, and then sprayed onto the forming curtain. The reinforcing masterbatch accounts for 1% of the mass of polyester, forming a third meltblown fiber web layer covering the second meltblown fiber web layer.

[0159] Step Six: The first spunbond fiber web layer, the second spunbond fiber web layer, the first mixed-spray water-absorbing layer, the second meltblown fiber web layer, and the third meltblown fiber web layer formed in Steps One to Five are stacked on a web forming curtain and their geometric shape is hot-rolled and shaped using a hot rolling mill at a temperature of 100°C, forming a semi-finished product with two upper and lower layers, namely a spunbond fiber web layer and a meltblown fiber web layer, and the second spunbond fiber web layer, the first mixed-spray water-absorbing layer, and the second meltblown layer in the middle.

[0160] Step 7: First, use a hot rolling mill to fix the nonwoven fabric in a point-like manner. Then, the semi-finished product from Step 6 can be conveyed to the high-pressure water spraying equipment offline or online. First, the semi-finished product from Step 6 is pre-wetted at a pressure of 0.6 MPa. Then, it is conveyed to the first high-pressure water spraying device at a pressure of 7 MPa, and the vacuum degree of the vacuum dehydration chamber is 24500 Pa. The pressure of the second high-pressure water spraying device is 10 MPa, and the pressure of the third high-pressure water spraying device is 10 MPa. Then, it is conveyed to the top of the second conveyor screen via conveyor rollers.

[0161] Step 8: The spunlace jacquard mechanism uses a high-pressure water spray device to copy the pattern on the jacquard mechanism roller onto the semi-finished product from Step 7 onto the fabric surface traveling at high speed. The pressure of the jacquard high-pressure water spray device is 12 MPa, and the vacuum degree of the vacuum dehydration box is 23000 Pa, forming a jacquard pattern on the surface of the semi-finished product from Step 7.

[0162] Step Nine: The dehydrated semi-finished product from Step Eight is conveyed to the rotary screen drying oven by the conveyor screen. The hot air drying temperature is 100℃. Finally, it is processed by the finishing equipment. The finishing process uses 2% antibacterial hydrophilic additive for spray finishing to enhance the antibacterial and moisture absorption properties of the material, meet the needs of consumers for the product, and obtain a composite multilayer nonwoven material.

[0163] The composite multilayer nonwoven material prepared in this embodiment is used to produce disposable slipper material with a density of 70gsm. The composite material in this embodiment consists of 5 fiber web layers: a first spunbond fiber web layer, a second spunbond fiber web layer, a first mixed-blown absorbent layer, a second meltblown fiber web layer, and a third meltblown fiber web layer. The first and second spunbond devices use 12% bicomponent polyester / polyamide masterbatch (Ryander Basel, London, UK) with a melt index of 35 g / 10 min; the second, third, fourth, and seventh meltblown devices use polyester (Ryander Basel, London, UK) and reinforcing masterbatch, each accounting for 12% of the total weight of the composite multilayer nonwoven material prepared in this embodiment, with a melt index of 650 g / 10 min. The reinforcing masterbatch accounts for 1% of the polyester mass in each of the second, third, fourth, and seventh meltblown devices. The raw material for the short fiber is wood pulp (GP Company, USA), which accounts for 26% of the total weight. The antibacterial hydrophilic auxiliary agent (Zhejiang Chuanhua Chemical) in step nine accounts for 2% of the total weight.

[0164] Example 5

[0165] This embodiment adopts Figure 5 The apparatus shown is used to prepare composite multilayer nonwoven materials, such as Figure 5 The equipment shown includes: a second spunbond device, a third spunbond device, a fourth spunbond device, a first mixing and spraying system, the first mixing and spraying system including a third meltblown device, a first grinding device, a fourth meltblown device and a first mixing and spraying forming box, a second spraying device, a second meltblown device, a fourth spraying device, a hot rolling device, a roller pre-wetting device, a first high-pressure water spraying device, a first vacuum dehydration device, a first conveyor screen, a second conveyor screen, a second high-pressure water spraying device, a third high-pressure water spraying device, a conveyor roller, a jacquard high-pressure water spraying device, a jacquard hydroentanglement machine roller, a second vacuum dehydration device, a drying device, a finishing device, a forming screen and a suction device;

[0166] Step 1: Using the second spunbond device, 10% of the total mass of the composite multilayer nonwoven material is mixed with the reinforcing masterbatch, heated and melted, and then sprayed onto the web forming curtain, wherein the reinforcing masterbatch accounts for 1% of the mass of the polyester masterbatch, to form the first spunbond fiber web layer.

[0167] Step 2: Using a third spunbond device, 10% of the total mass of the composite multilayer nonwoven material is mixed with the reinforcing masterbatch, heated and melted, and then sprayed onto the web forming curtain. The reinforcing masterbatch accounts for 1% of the mass of the polyester masterbatch, forming a second spunbond fiber web layer that covers the first spunbond fiber web layer.

[0168] Step 3: Using the fourth spunbond device, 10% of the total mass of the composite multilayer nonwoven material is mixed with the reinforcing masterbatch, heated and melted, and then sprayed onto the web forming curtain. The reinforcing masterbatch accounts for 1% of the mass of the polyester masterbatch, forming a third spunbond fiber web layer that covers the second spunbond fiber web layer.

[0169] Step 4: The third and fourth meltblown devices respectively mix and heat the polyester masterbatch, which accounts for 9% of the total mass of the composite multilayer nonwoven material, and the 40% rag pulp fiber raw material is transported to the grinding device for crushing via the transmission device. After being evenly distributed through the flat screen forming head, the rag pulp fiber is finally mixed with the polypropylene / polyester and water-absorbing masterbatch at high temperature and sprayed into filaments in the forming box to form the first mixed spray water-absorbing layer covering the third spunbond fiber web layer.

[0170] Step 5: Using a second meltblown device, polyester masterbatch accounting for 9% of the total mass of the composite multilayer nonwoven material is mixed, heated and melted, and then sprayed onto the web forming curtain to form a second meltblown fiber web layer covering the first mixed-blown absorbent layer.

[0171] Step Six: The first spunbond fiber web layer, the second spunbond fiber web layer, the third spunbond fiber web layer, the first mixed-spray water-absorbing layer, and the second meltblown fiber web layer formed in Steps One to Five are stacked on the web forming curtain and geometrically shaped using a hot rolling mill at a temperature of 115°C, forming a semi-finished product with two layers, a spunbond fiber web layer and a meltblown fiber web layer, and the second spunbond fiber web layer, the third spunbond fiber web layer, and the first mixed-spray water-absorbing layer in the middle.

[0172] Step 7: First, use a hot rolling mill to fix the nonwoven fabric in a point-like manner. Then, the semi-finished product from Step 6 can be conveyed to the high-pressure water spraying equipment offline or online. First, the semi-finished product from Step 6 undergoes pre-wetting treatment at a pressure of 1 MPa. Then, it is conveyed to the first high-pressure water spraying device at a pressure of 8 MPa, with a vacuum degree of 27,000 Pa in the vacuum dehydration chamber. The second and third high-pressure water spraying devices each have a pressure of 12 MPa. Finally, it is conveyed by conveyor rollers to the top of the second conveyor screen.

[0173] Step 8: The spunlace jacquard mechanism uses a high-pressure water spray device to copy the pattern on the jacquard mechanism roller onto the semi-finished product from Step 7 onto the fabric surface traveling at high speed. The pressure of the jacquard high-pressure water spray device is 15 MPa, and the vacuum degree of the vacuum dehydration box is 26000 Pa, forming a jacquard pattern on the surface of the semi-finished product from Step 7.

[0174] Step Nine: The dehydrated semi-finished product is conveyed to the rotary screen drying oven by the conveyor screen. The hot air drying temperature is 120℃. Finally, the product is sprayed with 3% cleaning agent by the finishing equipment. Then, the material is cut into 6×6 cm products and stacked into 5 layers. The top and bottom edges are hot rolled by about 0.5 cm at high temperature to bond the 5 layers together to meet the consumer's needs for product use, thus obtaining a composite multilayer nonwoven material.

[0175] The composite multilayer nonwoven material prepared in this embodiment is used to produce 70gsm disposable toilet cleaning brush material. The composite material in this embodiment consists of 5 fiber web layers. The second, third, and fourth spunbonding devices each use polyester (Lyander Basel, London, UK) and reinforcing masterbatch (Dawn, China) with a melt index of 35g / 10min, each accounting for 10% of the total weight of the composite multilayer nonwoven material prepared in this embodiment. The reinforcing masterbatch accounts for 1% of the polyester mass in each of the second, third, and fourth spunbonding devices. The second, third, and fourth meltblown devices use 9% polyester masterbatch (Lyander Basel, London, UK) with a melt index of 650g / 10min. The short fiber raw material is recycled rag pulp, accounting for 40% of the total weight. The cleaning agent in step nine (Zhejiang Chuanhua Chemical) accounts for 3% of the total weight.

[0176] Table 1 shows the performance test results of Examples 1-5 and the commercially available product (Mujin Diary Feather-Feel Cotton Towel).

[0177] Table 1. Performance test results of composite nonwoven materials in Examples 1-5 compared to commercially available Mujin Diary Feather-Feel Cotton Soft Towels.

[0178]

[0179] As shown in Table 1:

[0180] (1) Under the same weight conditions, the materials prepared in Examples 1-5 have a higher thickness (fluffiness) than commercially available products, which is about 55% higher. Since the intermediate layer of the examples includes a meltblown layer or a spunbond layer, the strength of the composite nonwoven material is improved by more than 50%. Furthermore, a certain proportion of reinforcing masterbatch can be mixed into the raw materials. Therefore, Examples 4 and 5 can obtain better strength, with the strength of the added product increasing by 86% compared to the same period last year, thus increasing the service life of the material.

[0181] (2) The present invention also provides a spraying device at the meltblown system nozzle and the mixing spraying system. The hydrophilic additive is sprayed by the spraying device, which greatly improves the hydrophilicity of the nonwoven fabric and the water absorption is more than 50% higher than that of commercially available products.

[0182] As can be seen from the above embodiments, by adding an online or offline high-pressure water spray device, the present invention significantly reduces the lint shedding coefficient and greatly improves the air permeability, which is more than 1.2 times higher than that of commercially available products.

[0183] 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. Other embodiments can be obtained based on these embodiments without creative effort, and these embodiments all fall within the protection scope of the present invention.

Claims

1. A method for preparing a composite multilayer nonwoven material, characterized in that, Includes the following steps: The first raw material is subjected to a first melt-blown process to obtain a first fiber web layer. The first raw material includes a first polymer raw material and a first functional masterbatch. The first functional masterbatch includes one or more of hydrophilic masterbatch, elastic masterbatch, biodegradable masterbatch, antibacterial masterbatch, cooling masterbatch, antistatic masterbatch, and rust-preventive masterbatch. The first melt-blowing process also includes spraying a first chemical auxiliary aqueous solution onto the long fiber bundle obtained by the first melt-blowing process. The first chemical auxiliary aqueous solution includes a first chemical auxiliary and water. The first chemical auxiliary includes one or more of antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, organosilicon, wetting agent, latex, and thermochromic colorant material. The first spraying rate is 100~180 L / h. An intermediate fiber web layer is prepared on the surface of the first fiber web layer, the intermediate fiber web layer comprising stacked mixed-jet fiber web and air-laid fiber web; The method for preparing the mixed-spray fiber web includes: performing a second melt-blowing on a second raw material; pulverizing a first absorbent fiber and then performing a first air-blowing web formation; and mixing and spraying the long fiber bundles obtained from the second melt-blowing and the short fiber bundles formed by the first air-blowing to obtain the mixed-spray fiber web. The second raw material includes a second polymer raw material and a second functional masterbatch. The second functional masterbatch includes one or more of hydrophilic masterbatch, elastic masterbatch, biodegradable masterbatch, antibacterial masterbatch, cooling masterbatch, antistatic masterbatch, and rust-preventive masterbatch. The mixing and spraying process also includes spraying a second chemical auxiliary aqueous solution onto the mixed fiber bundle formed by the short fiber bundles obtained from the first air-blowing web formation and the long fiber bundles obtained from the second melt-blowing. The second chemical auxiliary aqueous solution includes a second chemical auxiliary and water. The second chemical auxiliary includes one or more of antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, organosilicon, wetting agent, latex, and thermochromic colorant materials. The liquid volume of the second spray is 100~180L / h. The method for preparing the air-laid fiber web includes: pulverizing the second absorbent fiber and then performing a second air-laid web formation. The second air-laid web formation further includes spraying a third chemical auxiliary aqueous solution onto the short fiber bundles obtained by the second air-laid web formation. The third chemical auxiliary aqueous solution includes a third chemical auxiliary agent and water. The third chemical auxiliary agent includes one or more of the following materials: antibacterial agent, hydrophilic agent, softener, plasticizer, strength agent, adhesive, organosilicon, wetting agent, latex, and thermochromic colorant. The liquid volume of the third spray is 100~180L / h. On the surface of the intermediate fiber web layer, a third raw material is spunbonded in a second manner to form a second fiber web layer, thereby obtaining a semi-finished fiber web; the third raw material includes a third polymer raw material; The semi-finished fiber web is hot-rolled and shaped to obtain a hot-rolled fiber web; the first fiber web layer of the semi-finished fiber web forms the lower surface of the hot-rolled fiber web, and the second fiber web layer of the semi-finished fiber web forms the upper surface of the hot-rolled fiber web; The hot-rolled fiber web is pre-wetted and then subjected to high-pressure water spraying to obtain a jacquard high-pressure water-sprayed fiber web. The high-pressure water spraying includes sequentially performing flat-web forward spraying, rotary drum reverse spraying, rotary drum forward spraying, and flat-web jacquard forward spraying. The flat-web forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web while simultaneously drawing a vacuum on the lower surface. The rotary drum reverse spraying involves spraying water onto the lower surface of the hot-rolled fiber web on the rotating circumference of the drum. The rotary drum forward spraying involves spraying water onto the upper surface of the hot-rolled fiber web on the rotating circumference of the drum to form a jacquard pattern while simultaneously drawing a vacuum on the lower surface. The jacquard high-pressure water-jet fiber web is dried and then finished sequentially to obtain the composite multilayer nonwoven material.

2. The preparation method according to claim 1, characterized in that, The percentage of the first chemical auxiliary agent in the first chemical auxiliary agent aqueous solution by mass of the composite multilayer nonwoven material is 0.1-10%; The percentage of the second chemical auxiliary agent in the aqueous solution of the second chemical auxiliary agent is 0.1% to 10% of the total mass of the composite multilayer nonwoven material; The percentage of the third chemical auxiliary agent in the aqueous solution of the third chemical auxiliary agent is 0.1-10% of the total mass of the composite multilayer nonwoven material.

3. The preparation method according to claim 1, characterized in that, The mass percentage of the first raw material in the first fiber web layer to the total mass of the composite multilayer nonwoven material is 0.2-20%; the mass percentage of the first functional masterbatch in the first fiber web layer to the mass of the first polymer raw material is 0.1-10%. The second raw material for preparing the mixed-spray web in the intermediate fiber web layer accounts for 0.2% to 20% of the total mass of the composite multilayer nonwoven material; the mass of the second functional masterbatch in the intermediate fiber web layer accounts for 0.1% to 10% of the mass of the second polymer raw material. The mass percentage of the third raw material in the second fiber web layer is 0.2-20% of the total mass of the composite multilayer nonwoven material; the third raw material also includes a third functional masterbatch, and the mass percentage of the third functional masterbatch in the second fiber web layer is 0.1-10% of the mass of the third polymer raw material.

4. The preparation method according to claim 1 or 3, characterized in that, The first, second, and third polymer raw materials independently comprise thermoplastic fibers and / or thermoplastic polymer filaments, wherein the thermoplastic fibers are biodegradable or compostable; the biodegradable or compostable thermoplastic fibers include one or more of polylactic acid, polyhydroxyalkanoates, polycaprolactone, polyesteramides and their copolymers, polyvinyl alcohol, polyvinyl alcohol derivatives, cellulose, cellulose derivatives, proteins, starch, starch derivatives, chitosan, chitosan derivatives, hemicellulose, and hemicellulose derivatives; the thermoplastic polymer filaments are made of one or more of polyolefins, polyesters, polyhydroxyalkanoates, and polyhydroxybutyrates; the thermoplastic polymer filaments are monocomponent or bicomponent, wherein the bicomponents include one or more of core-sheath type, side-by-side type, trefoil type, and orange-segment type; the melt index of the thermoplastic polymer filaments ranges from 100 to 1500 g / 10 min; The spinneret temperatures of the first and second meltblown meltblown meltblown melts are independently 200℃~290℃; The long fibers obtained by the first meltblown, second meltblown, and second spunbonding processes have a diameter of 5~20μm and a basis weight of 0.1~3.0gsm.

5. The preparation method according to claim 1, characterized in that, The mass of the first absorbent fiber in the intermediate fiber web layer accounts for 10-47.5% of the total mass of the composite multilayer nonwoven material; When the intermediate fiber web layer comprises an air-laid fiber web, the mass of the second absorbent fiber in the intermediate fiber web layer accounts for 10-47.5% of the total mass of the composite multilayer nonwoven material; The first and second absorbent fibers independently comprise wood pulp fibers and / or paper pulp fibers; the wood pulp fibers comprise one or more of oak, poplar, birch, pine, spruce, and fir; the paper pulp fibers comprise one or more of rice straw pulp, reed pulp, sugarcane pulp, bamboo pulp, cotton pulp, hemp pulp, and natural fiber rag pulp. The length of the short fibers obtained by the first airflow web formation and the second airflow web formation is 0.5~8mm; The first airflow forming and the second airflow forming are independently distributed and laid out using a CD controllable injector or by using a forming head to evenly distribute and lay out the net along the width direction. The forming head is either a dust cage type or a flat screen type.

6. The preparation method according to claim 1, characterized in that, The hot rolling and setting temperature is 80~200℃, and the speed is 0~1000 m / min, and is not 0; The pre-wetting water pressure is 0.1~5MPa; The water pressure of the flat-net positive spray is 0.5~10MPa; The water pressure of the rotary drum reverse jet and the rotary drum forward jet is independently 1~15MPa; The water pressure for a flat-net jacquard spray pattern is 3~20MPa; The drying temperature is 90~130℃.

7. The preparation method according to claim 1, characterized in that, The finishing process includes one or more of spraying, roll coating and dip coating; The chemical auxiliaries used in the finishing process include one or more of the following: antibacterial agents, hydrophilic agents, softeners, plasticizers, strength agents, adhesives, silicones, wetting agents, latexes, and thermochromic colorants; the latexes include acrylics and / or vinyl acetate; the strength agents include carboxymethyl cellulose and / or starch; and the adhesives include one or more of vinyl acetate, acrylics, and other elastic adhesives.

8. The composite multilayer nonwoven material prepared by the preparation method according to any one of claims 1 to 7.

9. The apparatus used in the preparation method according to any one of claims 1 to 7, characterized in that, The device includes a forming curtain, a forming device disposed above the forming curtain, the forming device including a plurality of first meltblown devices and / or a plurality of spunbond devices, and a plurality of mixing and spraying systems and / or a plurality of second grinding devices, the second grinding devices including a second crusher and a second airflow forming device; the mixing and spraying system including a plurality of second meltblown devices, a plurality of first grinding devices and a mixing and spraying forming box, the first grinding devices including a first crusher and a first airflow forming device; A hot rolling unit located downstream of the forming screen, a first conveying screen located downstream of the hot rolling unit, a pre-wetting unit and a first high-pressure water spraying unit located above the first conveying screen, a first vacuum dewatering unit located below the first conveying screen, a second high-pressure water spraying unit and a third high-pressure water spraying unit located downstream of the first conveying screen, a second conveying screen located downstream of the second high-pressure water spraying unit and the third high-pressure water spraying unit, a jacquard high-pressure water spraying unit located above the second conveying screen, a second vacuum dewatering unit located below the second conveying screen, a drying unit located downstream of the second conveying screen, and a finishing unit located downstream of the drying unit.

10. The apparatus according to claim 9, characterized in that, A first spraying device is provided below the spinneret of the first meltblown device, a second spraying device is provided below the outlet of the mixing and forming box, and a third spraying device is provided below the second airflow forming device. The spinnerets of the first meltblown device and the second meltblown device include a first spinneret, a second spinneret, or a third spinneret. The first spinneret is provided with a single row of first spinneret holes. The first spinneret holes are inverted conical holes. The outer conical surface of the first spinneret holes is fitted with a first airflow stretching hole. The first airflow stretching hole is an inverted conical hole and coaxial with the first spinneret holes. The long fiber ejected from the first spinneret holes and the stretching gas ejected from the first airflow stretching hole converge at the top of the cone. The angle between the stretching gas and the long fiber is 30~70°. The second spinneret is provided with a single row or multiple rows of second spinnerets. The second spinnerets are cylindrical holes. A second airflow stretching hole is sleeved on the outer circumferential surface of the second spinnerets. The second airflow stretching hole is an annular hole and coaxial with the second spinnerets. The third spinneret is provided with a single row or multiple rows of third airflow stretching holes. The third airflow stretching holes are cylindrical holes. The outer circumferential surface of the third airflow stretching holes is fitted with third spinnerets. The third spinnerets are annular holes and coaxial with the third airflow stretching holes.

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