Hybrid spray layer, nonwoven composite manufacturing apparatus, and nonwoven composite

Abstract

The application discloses a mixed spraying layer, a non-woven composite material preparation device and a non-woven composite material, and relates to the technical field of composite material manufacturing. The mixed spraying layer preparation device comprises an opening and mixing device, a driving device, a feeding amount control device, a fiber distribution device, a conveying assembly, a mixed spraying box and a polymer system. The driving device is used for driving the fibers discharged from the opening and mixing device to the feeding amount control device and feeding the fibers into the fiber distribution device through the feeding amount control device. The fiber distribution device is provided with a height detection device. The fiber distribution device can distribute the fibers along the width direction and discharge the distributed fibers through a discharge port. The conveying assembly conveys the fibers discharged from the discharge port of the fiber distribution device into the mixed spraying box. The polymer system is used for producing polymer filaments and spraying the polymer filaments into the mixed spraying box. The application can use short fibers to manufacture the composite material, and the quality of the manufactured product is good.

Description

Technical Field

[0001] This invention relates to the field of composite material manufacturing technology, and in particular to a sprayed layer, a nonwoven composite material preparation device, and a nonwoven composite material. Background Technology

[0002] Nonwoven fabrics are ubiquitous in daily life and industrial production, especially with the increasing demand for disposable hygiene products. Currently, products using multi-fiber blended dry web forming technology are gaining popularity in the nonwoven industry. This technology primarily uses meltblown fibers and cellulose fibers through blended spraying to create a highly absorbent composite material. Currently, similar technologies can only be used with sheets or rolls, requiring the fibers to be broken down before use. This necessitates specific requirements for the raw material's morphology, resulting in higher raw material prices and higher costs for producing sheets. Furthermore, the fiber breaking process damages the fibers, increasing the content of broken fibers. Additionally, the fiber breaking process easily leaves clumps, significantly impacting the product's appearance. Secondly, short fibers such as waste cotton, recycled cotton, and bamboo fiber exist in a loose fiber state, which traditional equipment cannot utilize. This means that some fibers cannot be produced using this blended web forming method. Summary of the Invention

[0003] The purpose of this invention is to provide a sprayed layer, a nonwoven composite material preparation device, and a nonwoven composite material to solve the problems existing in the prior art. It has low requirements for the form of raw materials, uses short fibers to make composite materials, and produces high-quality products.

[0004] To achieve the above objectives, the present invention provides the following solution:

[0005] This invention provides a mixed-spray layer preparation apparatus, comprising: an opening and mixing device, a conveying device, a feeding amount control device, a fiber distribution device, a conveying assembly, a mixed-spray box, and a polymer system. The opening and mixing device is used to open and mix raw materials. The conveying device is used to drive the fibers discharged from the opening and mixing device to the feeding amount control device, and feed the fibers into the fiber distribution device through the feeding amount control device. The fiber distribution device is equipped with a height detection device, which is used to detect whether the height of the raw materials in the fiber distribution device exceeds a set threshold. When the fiber... When the height of the raw material in the distribution device is lower than the set threshold, the feeding control device is controlled to feed the raw material toward the fiber distribution device. When the height of the raw material in the fiber distribution device is not lower than the set threshold, the feeding control device is controlled to stop feeding the raw material toward the fiber distribution device. The fiber distribution device can distribute fibers along the width direction and discharge the distributed fibers through the outlet. The conveying assembly conveys the fibers discharged from the outlet of the fiber distribution device to the mixing and spraying box. The polymer system is used to produce polymer filaments and spray the polymer filaments into the mixing and spraying box.

[0006] Preferably, the conveying assembly includes a vertically arranged conveying pipe and a horizontally arranged conveying screen. The bottom of the conveying pipe extends into the mixing and spraying box from the top. The fibers discharged from the outlet of the fiber distribution device are conveyed to the conveying pipe through the conveying screen. The bottom structure of the conveying pipe is a fiber nozzle. A CD scattering distributor is integrated on the conveying pipe. The CD scattering distributor includes multiple airflow nozzles arranged sequentially along the width direction. The gas jet direction of the airflow nozzles is downward. The flow rate of fibers at different width positions is adjusted by controlling the jet flow rate of each airflow nozzle.

[0007] Preferably, the spray direction of the fiber nozzle is adjustable.

[0008] Preferably, the fiber nozzle includes two outer plates arranged sequentially along the length direction, the length direction being perpendicular to the width direction. The two outer plates are inclined from top to bottom in opposite directions. Two baffles are arranged between the two outer plates, arranged sequentially along the length direction, parallel to each other, and movably arranged. The two baffles are driven to move by a baffle driving device, and the top edges of the two baffles are not lower than the top edges of the two outer plates.

[0009] Preferably, an inclined plate is fixedly provided on each of the two baffles on opposite sides, and the two inclined plates are parallel to the two outer plates respectively.

[0010] Preferably, the fiber distribution device is a flat screen rotor-type forming head or a dust cage-type forming head, and the fiber distribution is adjusted by controlling the relative rotation speed of the agitators at various points in the flat screen rotor-type forming head.

[0011] Preferably, a raw material storage position and a pusher plate are provided on the front side of the feed inlet of the opening and mixing device. The raw material storage position is used to place raw materials, and the pusher plate is used to push the raw materials in the raw material storage position toward the feed inlet of the opening and mixing device.

[0012] The present invention also provides a nonwoven composite material preparation apparatus, comprising: a negative pressure mesh curtain assembly, a first polymer system, several as described above mixing and spraying layer preparation apparatuses, a second polymer system, and a hot rolling mill;

[0013] The negative pressure mesh curtain assembly includes a mesh curtain and a negative pressure device for making the working surface of the mesh curtain negative pressure. The filament jetting head of the first polymer system, the mixing and spraying box, and the filament jetting head of the second polymer system are sequentially arranged above the mesh curtain along the transmission direction of the mesh curtain. The hot rolling mill is arranged on one side of the tail of the mesh curtain.

[0014] The present invention also provides a nonwoven composite material, which is manufactured by the nonwoven composite material preparation device described above, comprising a first polymer fiber layer, a spunbond layer, and a second polymer fiber layer arranged sequentially from top to bottom; the first polymer fiber layer and the second polymer fiber layer are composed of a thermoplastic polymer and a functional masterbatch; the average diameter of the filaments constituting the fiber layer ranges from 0.1 μm to 20 μm, and the basis weight of each layer ranges from 0.5 gsm to 15 gsm; and each fiber layer is prepared by a spunbond process or a meltblown process.

[0015] The mixed-spray layer is formed by mixing and spraying cellulose short fibers and polymer filaments. The length of the cellulose short fibers is 0.1 mm to 8 mm, and the average diameter of the polymer filaments is in the range of 0.1 μm to 10 μm. The mass ratio of cellulose short fibers to polymer filaments in the mixed-spray layer is 10:90 to 80:20. The mixed-spray layer is formed by mixing and spraying at least one layer of the cellulose short fibers and polymer filaments.

[0016] Preferably, the cellulose short fibers are wood pulp fibers, chopped cotton fibers, chopped bamboo fibers, chopped bamboo pulp fibers, and chopped viscose fibers. The chopped cotton fibers are derived from raw cotton, combed cotton waste, and recycled cotton from waste pure cotton textiles, and are obtained through processes such as boiling, bleaching, and cutting. The bamboo fibers are obtained through a soaking and cooking process.

[0017] The thermoplastic polymer is one or more of polypropylene, polyethylene, polyester, nylon, polyurethane, polylactic acid, and thermoplastic biodegradable plastics; the functional masterbatch is one or more of biodegradable masterbatch, hydrophilic masterbatch, soft masterbatch, elastomer masterbatch, and antibacterial masterbatch.

[0018] The present invention achieves the following technical effects compared to the prior art:

[0019] This invention utilizes an opening and mixing device to open short fibers such as waste cotton, recycled cotton, and bamboo fiber, which has low requirements for the form of raw materials. Furthermore, it uses a fiber distribution device to distribute short fibers along the width direction, resulting in uniform material distribution along the width direction of the manufactured product and improving product quality. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of the sprayed layer preparation device and the nonwoven composite material preparation device provided in the embodiments of the present invention;

[0022] Figure 2 This is a schematic diagram of the structure of a flat screen rotor-type forming head;

[0023] Figure 3 for Figure 2 Schematic diagram of the distribution of the stirrer;

[0024] Figure 4 This is a schematic diagram of the structure of a dust cage-type forming head;

[0025] Figure 5 A schematic diagram of a fiber nozzle with all three channels open;

[0026] Figure 6 A schematic diagram of a fiber nozzle with the middle and right channels open;

[0027] Figure 7 This is a schematic diagram of a fiber nozzle with the central channel open.

[0028] Figure 8 This is a schematic diagram of a fiber nozzle with the right channel open.

[0029] In the diagram: 1-Push plate; 2-Raw material storage position; 3-Opening and mixing device; 5-Feeding amount control device; 4-Driving pipe; 6-Driving device; 7-Fiber distribution device; 8-Transfer screen; 9-CD scattering distributor; 10-Transfer pipe; 11-First polymer system; 12-Third polymer system; 13-Fourth polymer system; 14-Fifth polymer system; 15-Sixth polymer system; 16-Second polymer system; 17-Spraying system; 18-Screen; 19-Bottom suction; 20-Mixing spray box; 21-Hot rolling mill; 22-Storage box; 23-Height detection device; 24-Agitator; 25-Drive motor; 26-Discharge port of fiber distribution device; 27-Rotation direction indicator line; 28-Dust cage; 29-Metal beater; 30-Fiber nozzle; 31-Left channel; 32-Middle channel; 33-Baffle; 34-Right channel; 35-Inclined plate. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] This invention provides a mixed spray layer preparation apparatus, such as... Figures 1-3As shown, the system includes: an opening and mixing device 3, a conveying device 6, a feeding quantity control device 5, a fiber distribution device 7, a conveying assembly, a mixing and spraying box 20, and a polymer system. The opening and mixing device 3 is used to open and mix the raw materials. The conveying device 6 is used to drive the fibers discharged from the opening and mixing device 3 to the feeding quantity control device 5, and then feed the fibers into the fiber distribution device 7 through the feeding quantity control device 5. The fiber distribution device 7 is equipped with a height detection device 23, which is used to detect whether the height of the raw materials in the fiber distribution device 7 exceeds a set threshold. When the height of the raw materials in the fiber distribution device 7 is lower than the set threshold, the device will detect whether the height of the raw materials exceeds a set threshold. When the threshold is set, the feeding amount control device 5 feeds raw materials to the fiber distribution device 7. When the height of the raw materials in the fiber distribution device 7 is not lower than the set threshold, the feeding amount control device 5 stops feeding raw materials to the fiber distribution device 7. The fiber distribution device 7 can distribute fibers along the width direction and discharge the distributed fibers through the outlet. The conveying component conveys the fibers discharged from the outlet of the fiber distribution device 7 to the mixing and spraying box 20. The polymer system is used to produce polymer filaments and spray the polymer filaments into the mixing and spraying box 20. After the polymer filaments and short fibers are mixed, they fall onto the negative pressure mesh curtain 18 to form a mixing layer.

[0033] This invention utilizes an opening and mixing device 3 to open short fibers such as waste cotton, recycled cotton, and bamboo fiber, and uses a fiber distribution device 7 to distribute the short fibers along the width direction, so that the material distribution of the manufactured product is uniform along the width direction, thereby improving product quality.

[0034] In the above embodiment, the height detection device 23 can be a photoelectric sensor. The photoelectric sensor is set at a suitable height position in the fiber distribution device 7. This height position is the set height threshold. When the fiber accumulation height in the fiber distribution device 7 blocks the detection end of the photoelectric sensor, it is determined that its height is not lower than the set height threshold. Otherwise, it is determined that its height is lower than the set height threshold.

[0035] The mixing chamber 20 in the above embodiments mainly serves to create a semi-enclosed space for the cross-mixing of polymer filaments and short fibers. It can be made of a variety of materials, such as metal, usually steel, but it can also be a sufficiently hard polymer material, such as polycarbonate, or even glass.

[0036] In some embodiments, the conveying assembly includes a vertically arranged conveying pipe 10 and a horizontally arranged conveying screen 18. The bottom of the conveying pipe 10 extends into the mixing and spraying box 20 from the top. Fibers discharged from the outlet of the fiber distribution device 7 are conveyed to the conveying pipe 10 via the conveying screen 18. The bottom structure of the conveying pipe 10 is configured as a fiber nozzle 30. A CD scattering distributor 9 is integrated on the conveying pipe 10. The CD scattering distributor 9 includes a plurality of airflow nozzles arranged sequentially along the width direction. The gas jet direction of the airflow nozzles is downward. The flow rate of fibers at different width positions is adjusted by controlling the jet flow rate of each airflow nozzle.

[0037] This embodiment utilizes an airflow web-forming process to prepare this nonwoven composite material. Each CD scattering distributor 9 adjusts its respective airflow rate via an electromagnetically controlled valve body, thereby controlling the flow rate of short fibers at the corresponding position.

[0038] The conveyor curtain 8 is equipped with a bottom suction device 19, which can prevent short fibers from being dispersed to the outside and pollute the air and equipment due to airflow disturbance. The conveyor curtain 8 transports the falling short fibers to the conveyor pipe 10, and after passing through the CD scattering distributor 9 and the fiber nozzle 30, it enters the mixing and forming box 20.

[0039] In some embodiments, the CD scattering distributor 9 is interconnected with an online weight detection device. The online weight detection device can detect the weight information at different positions in the width direction of the product on the mesh curtain 18 and transmit it to the controller. The controller can adjust the airflow of the CD scattering distributor 9 according to the online weight detection data, thereby satisfying the uniform control of weight.

[0040] In some embodiments, the spray direction of the fiber nozzle 30 is adjustable.

[0041] Specifically, the fiber nozzle 30 includes two outer plates arranged sequentially along the length direction, which is perpendicular to the width direction. The two outer plates are inclined from top to bottom in opposite directions. Two baffles 33 are arranged between the two outer plates. The two baffles 33 are arranged sequentially along the length direction, are parallel to each other, and are movably arranged. The two baffles 33 are driven to move by a baffle 33 driving device. The top edge of the two baffles 33 is not lower than the top edge of the two outer plates.

[0042] This embodiment allows adjustment of the cross-mixing area between short fibers and polymer filaments, enabling flexible adjustment according to different needs. This embodiment divides the fiber nozzle 30 into three channels: a left channel 31, a middle channel 32, and a right channel 34. The opening, closing, and size of the channels are adjusted by adjusting the position of the baffle 33. Figures 5-8 As shown.

[0043] In one feasible embodiment, sliding tracks are provided on the front and rear sides of the fiber nozzle 30, and two baffles 33 are slidably disposed on the sliding tracks. The driving device for the baffles 33 is a motor, which drives the baffles 33 to move back and forth through the motor and the matching transmission components. The transmission components can be gears and racks or chains and sprockets, etc. Alternatively, the driving device for the baffles 33 can be a linear motor, which controls the linear movement of the baffles 33.

[0044] In some embodiments, an inclined plate 35 is fixedly provided on each side of the two baffles 33 that are opposite to each other, and the two inclined plates 35 are parallel to the two outer plates respectively.

[0045] like Figures 5-8 As shown, this guides the direction of short fiber injection.

[0046] In some embodiments, the fiber distribution device 7 is a flat screen rotor-type forming head or a dust cage 28-type forming head, and the fiber distribution is adjusted by controlling the relative rotation speed of the agitators 24 at various points in the flat screen rotor-type forming head.

[0047] like Figure 4 As shown, short fibers enter the dust cage 28 from one side, and the metal beater 29 rotates in the opposite direction to the dust cage 28. The short fibers are evenly distributed along the width direction by the action of the metal beater 29, and fall onto the transmission screen 8 through the long waist hole on the outside of the dust cage 28.

[0048] In some embodiments, a raw material storage position 2 and a pusher plate 1 are provided on the front side of the feed inlet of the opening and mixing device 3. The raw material storage position 2 is used to place raw materials, and the pusher plate 1 is used to push the raw materials on the raw material storage position 2 toward the feed inlet of the opening and mixing device 3.

[0049] In this embodiment, the short fiber raw materials in ton bag form (outer packaging needs to be removed) are placed in the raw material storage position 2. The pusher plate 1 applies auxiliary force to push the raw materials into the opening and mixing device 3 for opening and mixing. Since the selected short fiber raw materials are all clean raw materials after processing, there is no need to perform cleaning, impurity removal and other processes. The opened and mixed fiber raw materials are driven by the conveying fan and enter the feeding amount control device 5 through the driving pipe 4. That is, the driving device 6 in this embodiment is the conveying fan.

[0050] The present invention also provides a nonwoven composite material preparation apparatus, comprising: a negative pressure mesh curtain assembly, a first polymer system 11, a plurality of mixed spray layer preparation devices as described above, a second polymer system 16, and a hot rolling mill 21;

[0051] The negative pressure mesh curtain assembly includes a mesh curtain 18 and a negative pressure device for making the working surface of the mesh curtain 18 negative pressure. The filament ejector of the first polymer system 11, the mixing and spraying box 20, and the filament ejector of the second polymer system 16 are arranged sequentially above the mesh curtain 18 along the transmission direction of the mesh curtain 18. The hot rolling mill 21 is located on one side of the tail of the mesh curtain 18.

[0052] The nonwoven composite material preparation device includes multiple polymer systems. The filaments produced by the first polymer system 11 and the second polymer system 16 constitute the upper and lower layers of the material. The polymer system can be a meltblown production system. The spinneret used is either a coaxial meltblown spinneret or a traditional split-blade draft spinneret. The number of spinneret holes on the spinneret plate of the coaxial meltblown spinneret can be a single row or multiple rows. The spinneret holes on the spinneret plate of the traditional split-blade draft spinneret can be a single row or approximately double row staggered arrangement. The diameter of the spinneret holes is 1-5 μm. The first polymer system 11 and the second polymer system 16 can also be spunbond production systems. The polymer raw materials are spun and laid up through a slit draft spunbond system.

[0053] The polymer system used for mixing with cellulose short fibers in the mixing box 20 is a meltblown production system. The spinneret used is either a coaxial meltblown spinneret or a traditional split-blade stretch spinneret. The number of spinneret holes on the spinneret plate of the coaxial meltblown spinneret can be a single row or multiple rows. The number of spinneret holes on the spinneret plate of the traditional split-blade stretch spinneret can be a single row or an approximately double row staggered configuration.

[0054] The polymer systems involved in this patent can all be turned on and off independently, and each system is equipped with its own main raw material and auxiliary raw material adding device. Each system can operate independently without interfering with each other.

[0055] A spray system 17 is disposed below the first polymer system 11 and the second polymer system 16. After the polymer filaments are ejected, they undergo cooling treatment through the spray system 17, which can effectively accelerate the cooling of the fibers and improve their strength properties. The spray system 17 is located 5-50 cm below the spinneret, with an angle of 90-180° to the direction of chemical fiber ejection, and a spray rate of 0-200 L / h. Furthermore, the spray system 17 can spray pure water or functional additives. The functional additives can be antibacterial additives, water-absorbing additives, and softening agents. Additives such as softeners impart special functions to the fiber web; specifically, antibacterial agents include one or more of quaternary ammonium salt compounds, polyhexamethylene biguanide hydrochloride, and polyhexamethylene guanidine hydrochloride; the proportion of antibacterial agent concentrate used in the product is 0.1% to 1.5%; absorbents include one or more of polyether absorbents, polyamide absorbents, fatty acid ester absorbents, and quaternary ammonium salt absorbents; the proportion of absorbent concentrate used in the product is 0.1% to 3%; softeners include fatty alcohol polyoxyethylene ether and / or polyether-modified dimethyl silicone oil softener concentrate used in the product is 0.1% to 5%.

[0056] The fibers mixed in the mixing and spraying box 20 are finally adsorbed onto the forming curtain 18 by the bottom suction 19, thus completing the layering. The bottom suction 19 can adjust the suction by using different mesh air plates. The degree of mixing and overlapping of raw materials in the mixing and spraying box 20 can be controlled by the combination of different mesh air plates. At the same time, the outer chemical fibers in the forming area of ​​the forming curtain 18 can be adjusted.

[0057] The temperature of the hot rolling device is set to 90-160℃. The hot rolling mill 21 can realize rapid switching of the pattern rolls. It can be a "Y" type automatic roll changer, divided into working pattern rolls and spare pattern rolls. The spare pattern rolls can be disassembled and repaired without stopping the machine, which can minimize the impact on product production.

[0058] After being hot-rolled, the multi-layered nonwoven material is sequentially inspected for appearance defects and weight uniformity by an online defect detection device, then slit and wound by a slitting and winding device, and finally automatically packaged by an automatic conveying and packaging device, ultimately forming a new type of nonwoven composite material.

[0059] The present invention also provides a nonwoven composite material, which is manufactured by the nonwoven composite material preparation device described above, comprising a first polymer fiber layer, a spunbond layer, and a second polymer fiber layer arranged sequentially from top to bottom; the first polymer fiber layer and the second polymer fiber layer are composed of a thermoplastic polymer and a functional masterbatch; the average diameter of the filaments constituting the fiber layer ranges from 0.1 μm to 20 μm, and the basis weight of each layer ranges from 0.5 gsm to 15 gsm; and each fiber layer is prepared by a spunbond process or a meltblown process.

[0060] The mixed-spray layer is composed of short cellulose fibers and polymer filaments. The length of the short cellulose fibers is 0.1 mm to 8 mm, and the average diameter of the polymer filaments ranges from 0.1 μm to 10 μm. The mass ratio of short cellulose fibers to polymer filaments in the mixed-spray layer is 10:90 to 80:20. The mixed-spray layer consists of at least one layer of short cellulose fibers and polymer filaments.

[0061] In some embodiments, the cellulose short fibers are wood pulp fibers, chopped cotton fibers, chopped bamboo fibers, chopped bamboo pulp fibers, and chopped viscose fibers. The chopped cotton fibers are derived from raw cotton, combed cotton waste, and recycled cotton from waste pure cotton textiles, and are obtained through processes such as boiling, bleaching, and cutting. The bamboo fibers are obtained through a soaking and cooking process.

[0062] The thermoplastic polymer is one or more of polypropylene, polyethylene, polyester, nylon, polyurethane, polylactic acid, and thermoplastic biodegradable plastics; the functional masterbatch is one or more of biodegradable masterbatch, hydrophilic masterbatch, flexible masterbatch, elastomer masterbatch, and antibacterial masterbatch.

[0063] Specifically, the hydrophilic masterbatch preferably includes one or more of polyether-based hydrophilic masterbatches, polyamide-based hydrophilic masterbatches, and fatty acid ester-based hydrophilic masterbatches. In this invention, the biodegradable masterbatch preferably includes aerobic biodegradable masterbatch and / or anaerobic biodegradable masterbatch. In this invention, the softening masterbatch preferably includes amide-based softener masterbatch. In this invention, the antibacterial masterbatch preferably includes one or more of nano-cuprous oxide, nano-zinc oxide, and silver ion antibacterial agents.

[0064] For ease of understanding, the present invention also provides the following embodiments:

[0065] Example 1

[0066] A novel nonwoven composite material, comprising, from top to bottom, a first polypropylene fiber layer, a sprayed layer, and a second polypropylene fiber layer.

[0067] The first and second polypropylene fiber layers are prepared by mixing polypropylene with hydrophilic masterbatch purchased from Changzhou Wangyi New Material Technology Co., Ltd. and then using a melt-blowing process, with a mass ratio of 96:4. The two fiber layers are located at the top and bottom of the intermediate mixed-blowing layer, respectively, and play a role in covering and protecting the intermediate mixed-blowing layer. The average diameter of the filaments constituting the fiber layers is 2.5 μm, and the basis weight of each layer is 2.5 gsm.

[0068] The mixed-spray layer consists of two layers. The short fibers are obtained from recycled waste cotton fibers through processes such as boiling, bleaching, and cutting, with an average fiber length of 4 mm. The polymer filaments are made by mixing polypropylene particles and hydrophilic masterbatch at a mass ratio of 96:4 and then spinning them through a melt-blown system, with an average diameter of 2.9 μm. In the mixed-spray layer, the mass ratio of polymer filaments to cellulose fibers is 35:65, and the basis weight of each mixed-spray layer is 25 gsm, with an overall basis weight of 55 gsm for the composite material. The mixed-spray layer is formed by cross-spraying polymer fibers and cellulose fibers on the left side.

[0069] The equipment for preparing novel nonwoven composite materials includes an opening and mixing device 3, a conveying fan, a feeding control device 5, a fiber distribution device 7, a conveying screen 8, a conveying pipe 10, a CD scattering distributor 9, a fiber nozzle 30, a mixing and spraying box 20, a polymer system, a spraying system 17, a receiving screen 18, a bottom suction device 19, a hot rolling device, an online defect detection device, a slitting and winding device, and an automatic conveying and packaging device.

[0070] The opening and mixing device 3 places the processed cotton fibers in the raw material storage position 2, and the pusher plate 1 applies auxiliary force to push the raw material into the opening and mixing device 3 for opening and mixing; the opened and mixed cotton fiber raw material is driven by the transmission fan and enters the feeding amount control device 5 through the driving pipe 4.

[0071] The feeding amount control device 5 controls and adjusts the fiber feeding amount by transmitting signals through the height detection device 23 in the fiber distribution device 7, which can accurately measure and control the amount of raw materials fed in, so as to ensure the quantitative consistency of the product.

[0072] The cotton fibers further enter the flat screen rotor fiber distribution device 7 for the first uniform distribution along the width direction; the distributed fibers are transported to the short fiber transmission channel through the transmission screen curtain 8, and the fibers are then adjusted for the second uniformity of the short fiber distribution by adjusting the jet air flow rate in different areas through the CD scattering distributor 9 configured in the transmission channel.

[0073] The fiber nozzle 30 adjusts the position of the baffle 33 to maintain the outlet form of the lower mixed spray layer as the left channel 31 and the outlet form of the upper mixed spray layer as the right channel 34. The sprayed cotton fibers and polymer filaments are mixed in the mixing chamber 20, and the mixing cross area is greater than 50%. The main body of the mixing chamber 20 is made of metal, and the two sides of the chamber are made of high-hardness glass, which makes it easier for production operators to observe the situation inside the chamber.

[0074] The equipment for the novel nonwoven composite material includes four polymer systems. The filaments produced by the first polymer system 11 and the second polymer system 16 constitute the upper and lower layers of the material. These polymer systems are meltblown production systems, using coaxial meltblown spinnerets with eight rows of spinneret holes on the spinneret plate. The third polymer system 12 and the fourth polymer system 13, located within the mixing chamber 20, are also meltblown production systems used for mixing with cellulose short fibers. These systems also use coaxial meltblown spinnerets with fourteen rows of spinneret holes on the spinneret plate. Each polymer system is equipped with a separate main and auxiliary material supply system, and each system can operate independently without interference.

[0075] A spray system 17 is arranged below the first polymer system 11 and the second polymer system 16. After the polymer filaments are ejected, they are cooled by the spray system 17, which can effectively accelerate the cooling of the fibers and improve their strength properties. The spray system 17 is located 45cm below the spinneret, and the angle between it and the direction of movement of the polymer filaments is 120°. The spray volume is 120L / h for pure water spraying.

[0076] The fibers mixed in the mixing box 20 are finally adsorbed onto the netting curtain 18 by the bottom suction 19. After the layers are completed, they are transferred to the hot rolling device for hot rolling.

[0077] The hot rolling device is set to a temperature of 110℃, and the hot rolling pattern is a cartoon cat and dog pattern. The multi-layer composite nonwoven material after hot rolling is then subjected to an online defect detection device for appearance defects and weight uniformity detection, a slitting and winding device for slitting and winding, and an automatic conveying and packaging device for automatic packaging, finally forming a new type of nonwoven composite material.

[0078] Example 2

[0079] A novel nonwoven composite material comprises, from top to bottom, a first polypropylene fiber layer, a mixed-spray layer, and a second polypropylene fiber layer. The first and second polypropylene fiber layers are prepared by spunbonding a mixture of polypropylene and hydrophilic masterbatch purchased from Changzhou Wangyi New Material Technology Co., Ltd., and soft masterbatch purchased from Yancheng Ruize Color Masterbatch Co., Ltd., with a mass ratio of 91:4:5. The two fiber layers are located at the top and bottom of the intermediate mixed-spray layer, respectively, providing coverage and protection for the intermediate mixed-spray layer. The average diameter of the filaments constituting the fiber layers ranges from 4.5 μm, and the basis weight of each layer is 5 gsm.

[0080] The mixed-spray layer consists of two layers. The short fibers are obtained from bamboo raw fibers through processes such as boiling, bleaching, and cutting, with an average fiber length of 6 mm. The polymer filaments are obtained by spinning polypropylene particles through a melt-blowing system, with an average diameter of 3 μm. The mass ratio of polymer filaments to cellulose fibers in the mixed-spray layer is 35:65, and the basis weight of each mixed-spray layer is 30 gsm. The overall basis weight of the composite material is 70 gsm. The mixed-spray layer is formed by cross-spraying polymer fibers and cellulose fibers on the left and right sides.

[0081] The opening and mixing device 3 places the processed bamboo fiber in the raw material storage position 2, and the pusher plate 1 applies auxiliary force to push the raw material into the opening and mixing device 3 for opening and mixing; the opened and mixed cotton fiber raw material is then fed into the feeding amount control device 5 through the conveying pipe 4 by the action of the transmission fan.

[0082] The feeding amount control device 5 controls and adjusts the fiber feeding amount by transmitting signals through the height detection device 23 in the fiber distribution device 7, which can accurately measure and control the amount of raw materials fed in, so as to ensure the quantitative consistency of the product.

[0083] The cotton fibers further enter the flat screen rotor fiber distribution device 7 for the first uniform distribution along the width direction; the distributed fibers are transported to the short fiber transmission channel through the transmission screen curtain 8, and the fibers are then adjusted for the second uniformity of the short fiber distribution by adjusting the jet air flow rate in different areas through the CD scattering distributor 9 configured in the transmission channel.

[0084] The fiber nozzle 30 adjusts the position of the baffle 33 to maintain the left-center-right outlet channel 34 for the production of the lower mixed spray layer. The sprayed cotton fibers and polymer filaments are mixed in the mixed spray box 20, and the mixing cross area is greater than 75%. The main body of the mixed spray box 20 is made of metal, and the two sides of the box are made of high-hardness glass, which makes it easier for production operators to observe the situation inside the box.

[0085] The equipment for the novel nonwoven composite material includes six polymer systems. The filaments produced by the first polymer system 11 and the second polymer system 16 constitute the upper and lower layers of the material. These polymer systems are spunbond production systems, obtained after cooling and stretching. The third polymer system 12, the fourth polymer system 13, the fifth polymer system 14, and the sixth polymer system 15, located within the mixing and spinning chamber 20, are meltblown production systems used for mixing with cellulose short fibers. The spinnerets used are coaxial meltblown spinnerets, with fourteen rows of spinneret holes on the spinneret plate. Each polymer system is equipped with a separate main and auxiliary material supply system, and each system can operate independently without interference.

[0086] The fibers mixed in the mixing box 20 are finally adsorbed onto the forming curtain 18 by the bottom suction 19. After the layers are completed, they are transferred to a hot rolling device for hot rolling. The temperature of the hot rolling device is set to 115℃ and the hot rolling pattern is a sesame dot pattern. The multi-layer composite nonwoven material after hot rolling is then passed through an online defect detection device for appearance defects and weight uniformity detection, a slitting and winding device for slitting and winding, and an automatic conveying and packaging device for automatic packaging, finally forming a new type of nonwoven composite material.

[0087] Example 3

[0088] A novel nonwoven composite material comprises, from top to bottom, a first polypropylene fiber layer, a spunbond layer, and a second polypropylene fiber layer. The first and second polypropylene fiber layers are prepared by spunbonding a mixture of polypropylene and hydrophilic masterbatch, with a mass ratio of 95:5. The two fiber layers are located at the top and bottom of the intermediate spunbond layer, respectively, providing coverage and protection for the intermediate layer. The average diameter of the filaments constituting the fiber layers ranges from 2.5 μm, and the basis weight of each layer is 3 gsm.

[0089] The mixed-spray layer consists of two layers. The short fibers are ton-packaged wood pulp fibers with an average fiber length of 1.6 mm. The polymer filaments are polypropylene granules spun through a melt-blown system, with an average diameter of 3.5 μm. The mass ratio of polymer filaments to cellulose fibers in the mixed-spray layer is 40:60, and the basis weight of each mixed-spray layer is 25 gsm. The overall basis weight of the composite material is 56 gsm. The mixed-spray layer is formed by cross-spraying polymer fibers and cellulose fibers on the left and right sides, with a cross-mixing area of ​​more than 75%.

[0090] The equipment for preparing novel nonwoven composite materials includes a cotton grabbing device, a cotton blending device, a fiber distribution device 7, a conveying screen 8, a conveying pipe 10, a CD scattering distributor 9, a fiber nozzle 30, a mixing and spraying box 20, a polymer system, a spraying system 17, a receiving screen 18, a bottom suction device 19, a hot rolling device, an online defect detection device, a slitting and winding device, and an automatic conveying and packaging device.

[0091] The opening and mixing device 3 places the processed wood pulp fiber in the raw material storage position 2, and the push plate 1 applies auxiliary force to push the raw material into the opening and mixing device 3 for opening and mixing; the opened and mixed cotton fiber raw material is driven by the transmission fan through the transmission pipeline 4 into the feeding amount control device 5.

[0092] The feeding amount control device 5 controls and adjusts the fiber feeding amount by transmitting signals through the height detection device 23 in the fiber distribution device 7, which can accurately measure and control the amount of raw materials fed in, so as to ensure the quantitative consistency of the product.

[0093] The cotton fibers further enter the flat screen rotor fiber distribution device 7 for the first uniform distribution along the width direction; the distributed fibers are transported to the short fiber transmission channel through the transmission screen curtain 8, and the fibers are then adjusted for the second uniformity of the short fiber distribution by adjusting the jet air flow rate in different areas through the CD scattering distributor 9 configured in the transmission channel.

[0094] The fiber nozzle 30 adjusts the position of the baffle 33 to maintain the left-center-right outlet channel 34 for the production of the lower mixed spray layer. The sprayed cotton fibers and polymer filaments are mixed in the mixed spray box 20, and the mixing cross area is greater than 75%. The main body of the mixed spray box 20 is made of metal, and the two sides of the box are made of high-hardness glass, which makes it easier for production operators to observe the situation inside the box.

[0095] The equipment for the novel nonwoven composite material includes six polymer systems. The filaments produced by the first polymer system 11 and the second polymer system 16 constitute the upper and lower layers of the material. These polymer systems are meltblown production systems, using coaxial meltblown spinnerets with eight rows of spinneret holes on the spinneret plate. The mixing chamber 20 contains the third polymer system 12, the fourth polymer system 13, the fifth polymer system 14, and the sixth polymer system 15, which are used for mixing with cellulose short fibers. These are also meltblown production systems, using coaxial meltblown spinnerets with fourteen rows of spinneret holes on the spinneret plate. Each polymer system is equipped with a separate main and auxiliary material supply system, and each system can operate independently without interference.

[0096] The fibers mixed in the mixing box 20 are finally adsorbed onto the forming curtain 18 by the bottom suction 19. After the layers are completed, they are transferred to a hot rolling device for hot rolling. The temperature of the hot rolling device is set to 115℃ and the hot rolling pattern is a cartoon line pattern. The multi-layer composite nonwoven material after hot rolling is then passed through an online defect detection device for appearance defects and weight uniformity detection, a slitting and winding device for slitting and winding, and an automatic conveying and packaging device for automatic packaging, finally forming a new type of nonwoven composite material.

[0097] Table 1. Performance test results of the novel nonwoven composite materials prepared in Examples 1-3

[0098]

[0099] As shown in Table 1, the novel nonwoven composite material provided by this invention can maintain a longitudinal strength of over 15N, a transverse strength of over 8N, a water absorption time of less than 16s, a water absorption ratio of over 700%, and a lint-removal coefficient of less than 4.5. This indicates that this invention can effectively utilize ultra-short fibers such as waste cotton, recycled cotton, bamboo fiber, and bulk wood pulp fiber with a fiber length of less than 8mm to prepare wiping materials without having to prepare the raw materials into boards or rolls. It also possesses good strength, water absorption, and lint-removal properties.

[0100] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A mixed spray layer preparation apparatus, characterized in that: include: The system comprises an opening and mixing device, a conveying device, a feeding rate control device, a fiber distribution device, a conveying assembly, a mixing and spraying chamber, and a polymer system. The opening and mixing device is used to open and mix the raw materials. The conveying device drives the fibers discharged from the opening and mixing device to the feeding rate control device, which then feeds the fibers into the fiber distribution device. The fiber distribution device is equipped with a height detection device to detect whether the height of the raw materials in the fiber distribution device exceeds a set threshold. When the height of the raw materials in the fiber distribution device is lower than the set threshold, the controller controls the feeding rate control device. The device feeds raw materials into the fiber distribution device. When the height of the raw materials in the fiber distribution device is not lower than a set threshold, the feeding control device stops feeding raw materials into the fiber distribution device. The fiber distribution device can distribute fibers along the width direction and discharge the distributed fibers through the outlet. The conveying assembly conveys the fibers discharged from the outlet of the fiber distribution device to the mixing and spraying box. The polymer system is used to produce polymer filaments and spray the polymer filaments into the mixing and spraying box. The conveying assembly includes a vertically arranged conveying pipe and a horizontally arranged conveying screen. The bottom of the conveying pipe is located at the mixing and spraying box. The top of the housing extends into the mixing and spraying housing. Fibers discharged from the outlet of the fiber distribution device are conveyed through the conveying screen to the transmission pipe. The bottom structure of the transmission pipe is a fiber nozzle. A CD scattering distributor is integrated on the transmission pipe. The CD scattering distributor includes multiple airflow nozzles arranged sequentially along the width direction. The gas jet direction of the airflow nozzles is downward. The fiber flow rate at different width positions is adjusted by controlling the jet flow rate of each airflow nozzle. The jet direction of the fiber nozzle is adjustable. The fiber nozzle includes two outer plates arranged sequentially along the length direction, which is perpendicular to the width direction. In the width direction, the two outer plates are inclined from top to bottom in opposite directions. Two baffles are provided between the two outer plates, arranged sequentially along the length direction. The two baffles are parallel and movably arranged, driven by a baffle driving device. The top edge of the two baffles is not lower than the top edge of the two outer plates. An inclined plate is fixedly provided on the opposite side of each of the two baffles, and the two inclined plates are parallel to the two outer plates respectively. The fiber nozzle is divided into three channels: a left channel, a middle channel, and a right channel. The opening, closing, and size of the channels are adjusted by adjusting the position of the baffles.

2. The mixed spray layer preparation apparatus according to claim 1, characterized in that: The fiber distribution device is a flat screen rotor-type forming head or a dust cage-type forming head. The fiber distribution is adjusted by controlling the relative rotation speed of the agitators at various points in the flat screen rotor-type forming head.

3. The mixed spray layer preparation apparatus according to claim 1, characterized in that: The opening and mixing device has a raw material storage position and a pusher plate on the front side of the feed inlet. The raw material storage position is used to place raw materials, and the pusher plate is used to push the raw materials in the raw material storage position toward the feed inlet of the opening and mixing device.

4. A nonwoven composite material preparation apparatus, characterized in that: include: The negative pressure mesh curtain assembly, the first polymer system, the mixed spray layer preparation apparatus according to any one of claims 1 to 3, the second polymer system, and the hot rolling mill; The negative pressure mesh curtain assembly includes a mesh curtain and a negative pressure device for making the working surface of the mesh curtain negative pressure. The filament jetting head of the first polymer system, the mixing and spraying box, and the filament jetting head of the second polymer system are sequentially arranged above the mesh curtain along the transmission direction of the mesh curtain. The hot rolling mill is arranged on one side of the tail of the mesh curtain.

5. A nonwoven composite material, characterized in that: The nonwoven composite material is manufactured by the apparatus described in claim 4, comprising a first polymer fiber layer, a spunbond layer, and a second polymer fiber layer arranged sequentially from top to bottom; the first polymer fiber layer and the second polymer fiber layer are composed of a thermoplastic polymer and a functional masterbatch; the average diameter of the filaments constituting the fiber layer ranges from 0.1 μm to 20 μm, and the basis weight of each layer ranges from 0.5 gsm to 15 gsm; and each fiber layer is prepared by a spunbond process or a meltblown process. The mixed-spray layer is formed by mixing and spraying cellulose short fibers and polymer filaments. The length of the cellulose short fibers is 0.1 mm to 8 mm, and the average diameter of the polymer filaments is 0.1 μm to 10 μm. The mass ratio of cellulose short fibers to polymer filaments in the mixed-spray layer is 10:90 to 80:

20. The mixed-spray layer is formed by mixing and spraying at least one layer of the cellulose short fibers and polymer filaments.

6. The nonwoven composite material according to claim 5, characterized in that: The cellulose short fibers are wood pulp fibers, chopped cotton fibers, chopped bamboo fibers, chopped bamboo pulp fibers, and chopped viscose fibers. The chopped cotton fibers are derived from raw cotton, combed cotton waste, and recycled cotton from waste pure cotton textiles, and are obtained through scouring, bleaching, and cutting processes. The chopped bamboo fibers are obtained through soaking and cooking processes. The thermoplastic polymer is one or more of polypropylene, polyethylene, polyester, nylon, polyurethane, and thermoplastic biodegradable plastics; the functional masterbatch is one or more of biodegradable masterbatch, hydrophilic masterbatch, soft masterbatch, elastomer masterbatch, and antibacterial masterbatch.

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