Lightweight thin thermal insulation composite non-woven material and preparation process thereof

Abstract

The invention provides a light-weight thin heat preservation and insulation composite non-woven material and a preparation process thereof, and relates to the field of non-woven material manufacturing, the light-weight thin heat preservation and insulation composite non-woven material comprises 23-30% of a first surface spunlace layer, 40-53% of a middle micro-needle-punched layer and 23-30% of a second surface spunlace layer, and the middle micro-needle-punched layer is arranged between the first surface spunlace layer and the second surface spunlace layer; and the first surface spunlace layer and the second surface spunlace layer have the same structure. The invention provides a light-weight thin heat-preservation and heat-insulation composite non-woven material and a preparation process thereof. The technical problems that a heat-insulation layer is separated, and the air permeability is poor are solved.

Description

Technical Field

[0001] The invention relates to the field of nonwoven material manufacturing, in particular to a lightweight, thin, thermal insulation composite nonwoven material and a preparation process thereof. Background Art

[0002] Firefighters' firefighting protective clothing is a protective equipment specially worn by firefighters during firefighting and rescue operations. It is designed to protect their upper body, lower body, neck, arms and legs from heat damage. The head, hands and feet are protected by fire helmets, fire gloves and firefighting protective boots respectively. The structure of the firefighting clothing from outside to inside is respectively an outer layer, a waterproof and breathable layer, a heat-insulating layer, and a comfort layer. The heat-insulating layer is mainly used to isolate heat sources to prevent firefighters from being harmed by high temperatures outside. The fabric of the heat-insulating layer is generally made of three-dimensional mesh knitted fabrics or non-woven materials. , usually needle-punched felt made of high-temperature resistant flame-retardant fiber through needle-punching process, common materials include aramid needle-punched felt, but the needle-punched felt is generally not too thin, and the gram weight is about 200gsm or more; the spunlace thermal insulation layer material is mainly spunlace felt blended with DuPont NOMEX and KEVALR. Spunlace material not only has good flame retardant properties, but also can effectively insulate, is thin and has excellent thermal stability, reaching the standards of similar international products, but the density of spunlace nonwoven material is too high, the puncture is too dense, the air intake is small, and the thermal insulation effect is not good

[0003] In the prior art, the thermal insulation layer is in a sandwich shape, with three layers of needle-punched non-woven fabrics bonded together by a diamond-shaped point method. Although the sandwich structure can provide good thermal insulation performance, the large number of layers and tight bonding may limit air circulation and reduce the breathability of the clothing, causing the wearer to sweat easily in a high temperature environment, thereby feeling uncomfortable; although the diamond-shaped point bonding can bond the various layers of materials together, under high-intensity use or in a high-temperature environment, the bonding points may fail, causing the thermal insulation layer to separate, affecting the overall performance; and the multi-layer structure and diamond-shaped point bonding may increase the overall weight of the clothing, and long-term wearing may cause firefighters to increase physical exertion and affect their efficiency. Summary of the invention

[0004] The invention provides a lightweight and thin thermal insulation composite nonwoven material and a preparation process thereof, which solves the technical problems of thermal insulation layer separation and poor air permeability.

[0005] In order to solve the above technical problems, the technical solution of the present invention is as follows:

[0006] In a first aspect, a lightweight, thin thermal insulation composite nonwoven material comprises a first surface spunlace layer of 23-30%, a middle micro-needle spunlace layer of 40-53% and a second surface spunlace layer of 23-30%, wherein the middle micro-needle spunlace layer is disposed between the first surface spunlace layer and the second surface spunlace layer;

[0007] The first surface spunlace layer and the second surface spunlace layer have the same structure.

[0008] Furthermore, the first surface spunlace layer comprises the following raw materials in terms of mass fraction:

[0009] 55-65% polyester, 20-30% nylon, 10-15% sea island fiber, 3-5% functional fiber.

[0010] Furthermore, the functional fiber comprises the following raw materials by mass fraction:

[0011] 55-65% antistatic fiber, 35-45% antibacterial fiber.

[0012] Furthermore, the intermediate microneedle layer comprises the following raw materials in terms of mass fraction:

[0013] 25-35% polyimide, 20-30% aramid, 15-25% pre-oxidized yarn, 5-15% thermal insulation material, 3-10% strength material.

[0014] Furthermore, the thermal insulation material includes the following raw materials by mass fraction:

[0015] 60-70% ceramic fiber, 30-40% glass fiber.

[0016] Furthermore, the strength material includes the following raw materials in terms of mass fraction:

[0017] 40-60% bonding fiber, 40-60% reinforcing fiber.

[0018] In a second aspect, a preparation process of a lightweight and thin thermal insulation composite nonwoven material comprises:

[0019] Prepare the raw materials according to the formula ratio:

[0020] Using the first carding machine cotton box and the first carding machine in sequence, 55-65% of polyester, 20-30% of nylon, 10-15% of sea island fibers, and 3-5% of functional fibers are carded into a web, and transported to the first transport curtain to obtain a first fiber web;

[0021] Using the second carding machine cotton box and the second carding machine in sequence, 55-65% of polyester, 20-30% of nylon, 10-15% of sea island fibers, and 3-5% of functional fibers are carded into a web, and transported to the third transport curtain to obtain a second fiber web;

[0022] A cross-lapping machine is used to cross-lap 25-35% of polyimide, 20-30% of aramid, 15-25% of pre-oxidized yarn, 5-15% of thermal insulation material, and 3-10% of strength material. The cross-lapped fiber web is entangled for the first time through a needle punching machine and transported to a second conveying curtain to obtain an intermediate micro-needle punching layer.

[0023] The first fiber web, the middle micro-needle layer and the second fiber web are closed through a fourth conveying curtain, and the closing roller is used to compact and discharge air in the fiber webs to obtain a closed fiber web;

[0024] The fiber web after assembling is pre-spunlaced through a pre-wetting spunlaced head to obtain a pre-spunlaced fiber web;

[0025] The pre-hydroentangled fiber web is passed through a first hydroentanglement head of a first roller for front hydroentanglement to obtain a front hydroentangled fiber web;

[0026] The front side hydroentanglement is passed through the second hydroentanglement head of the second roller to perform back side hydroentanglement to obtain a fiber web after back side hydroentanglement;

[0027] The fiber web after the back side hydroentanglement is dried by a rotary screen dryer to obtain a dried nonwoven fabric;

[0028] The dried nonwoven fabric is wound up using a winder to obtain the lightweight, thin, thermal insulation composite nonwoven material.

[0029] Furthermore, the intermediate micro-needle layer is formed by a needle punching process, the needle punching depth is 2-5 mm, and the needle density of a single needle plate is 20,000-30,000 pieces / m 2 The output speed of the needle-punched fiber web is 10-30m / min.

[0030] Furthermore, the surface spunlace layer is formed by a spunlace process, and the spunlace pressure includes a pre-wetting pressure of 3-10 bar and an entanglement pressure of 30-80 bar.

[0031] Furthermore, the fibers used by the first carding machine and the second carding machine are 1.0-2.0D, and the fibers used by the cross-lapping machine are 1.5-8.0D.

[0032] The above solution of the present invention includes at least the following beneficial effects:

[0033] The above scheme of the present invention adopts hydroentanglement + micro-needle punching to form a "sandwich" structure. The combination of hydroentanglement and needle punching improves the performance and environmental friendliness of the material; the thin needle punched material provides excellent thermal insulation performance due to its low density and loose structure, and is lightweight and portable; the double-sided hydroentanglement process makes the surface smooth and the hand feel improved, modifying the roughness of the needle punched material; the middle needle punching process enhances the structural strength and stability of the material, making it both strong and soft, without the need for chemical additives, reducing the risk of environmental pollution and residual chemicals, and improving product safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic flow chart of a process for preparing a lightweight, thin, thermal insulation composite nonwoven material provided by an embodiment of the present invention.

[0035] Figure 2 It is a schematic diagram of equipment for a preparation process of a lightweight, thin, thermal insulation composite nonwoven material provided by an embodiment of the present invention.

[0036] Figure 3 It is another schematic diagram of the equipment for the preparation process of the lightweight and thin thermal insulation composite nonwoven material provided by an embodiment of the present invention.

[0037] Reference numerals:

[0038] 1. First carding machine; 2. First carding machine cotton box; 3. Net laying machine; 4. Needle loom; 5. Second carding machine; 6. Second carding machine cotton; 7. First conveying curtain; 8. Third conveying curtain; 9. Second conveying curtain; 10. Net closing roller; 11. No. 4 conveying curtain; 12. Pre-wetting water jet head; 13. First roller; 14. Second roller; 15. First water jet head; 16. Second water jet head; 17. Rotary net dryer; 18. Winding machine. DETAILED DESCRIPTION

[0039] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0040] like Figures 1 to 3 As shown, an embodiment of the present invention provides a lightweight, thin thermal insulation composite nonwoven material, characterized in that it includes a first surface spunlace layer of 23-30%, a middle micro-needle spunlace layer of 40-53% and a second surface spunlace layer of 23-30%, wherein the middle micro-needle spunlace layer is disposed between the first surface spunlace layer and the second surface spunlace layer;

[0041] The first surface spunlace layer and the second surface spunlace layer have the same structure.

[0042] In the embodiment of the present invention, more air layers are formed between the fiber layers to further enhance the thermal insulation effect of the material; the spunlace process can make the material softer and more flexible, and improve the wearing comfort; the needle punching process can enhance the strength and wear resistance of the fiber; the combination of the two processes can improve the uniformity and structural stability of the material, and reduce the risk of wear and tear; the spunlace nonwoven material of the first surface spunlace layer and the second surface spunlace layer has good moisture permeability and moisture resistance, can regulate indoor humidity to a certain extent, ensure the freshness and dryness of indoor air, and has good softness and can adapt to various forms of buildings. The spunlace nonwoven material usually also has good skin affinity and low allergenicity, and is suitable for direct contact with the human body or the environment; the first surface spunlace layer and the second surface spunlace layer not only provide good protection and isolation, but also can effectively regulate the overall air permeability of the material, prevent internal moisture accumulation, thereby keeping the material dry and comfortable, and at the same time, its softness and adaptability help the material to better fit various The micro-needle punching process can also make the fibers cross-arrange to form a tighter structure, which helps to improve the strength and stability of the material; the middle micro-needle punching layer plays a key role in thermal insulation, and the three-dimensional mesh structure can effectively block the transfer of heat and reduce the thermal conductivity of the material. The middle micro-needle punching layer also enhances the overall strength and stability of the material, making the composite material more durable and reliable; the composite nonwoven material of the present application adopts a lightweight and thin design, which not only reduces the weight and thickness of the material, but also improves the portability and processability of the material; by combining the advantages of the first surface spunlace layer, the middle micro-needle punching layer and the second surface spunlace layer, it also has excellent thermal insulation performance, so that the material can effectively block the transfer and loss of heat, thereby reducing energy consumption and improving energy utilization efficiency.

[0043] like Figures 1 to 3 As shown, the first surface spunlace layer includes the following raw materials by weight:

[0044] 55-65% polyester, 20-30% nylon, 10-15% sea island fiber, 3-5% functional fiber.

[0045] In the embodiment of the present invention, polyester, also known as polyester fiber, is a synthetic fiber with good wrinkle resistance and shape retention, as well as high strength and elastic recovery. In the first surface spunlace layer, polyester is the main component, providing the material with good wear resistance, tear strength and stability; nylon, also known as nylon, is a synthetic fiber with excellent wear resistance, good elasticity and light weight. In the first surface spunlace layer, the addition of nylon further enhances the wear resistance and elasticity of the material, making it more durable and comfortable; sea island fibers are composed of fibers of two different components, one of which is wrapped by the other. In the first surface spunlace layer, the addition of sea island fibers can form a unique three-dimensional mesh structure, which increases the fluffiness and warmth retention of the material, and also helps to improve the moisture absorption and breathability of the material; functional fibers refer to fibers with special functions. Or fibers with good properties, such as antistatic fibers and antibacterial fibers; the addition of polyester and nylon makes the first surface spunlace layer have good wear resistance and tear resistance, can resist friction and tearing in the external environment, and extend the service life of the material; the elasticity of nylon and the three-dimensional network structure of the sea island fiber make the material have good elasticity and comfort, can adapt to different shapes and curvatures, and provide better fit and wearing experience; the addition of sea island fibers increases the fluffiness and warmth of the material, which can effectively block the invasion of external cold air. At the same time, the hygroscopicity of the sea island fibers also helps to keep the material dry and comfortable; the first surface spunlace layer has good wear resistance, tear resistance, elasticity, comfort, warmth, hygroscopicity and special functions and other performance improvements, which lays a solid foundation for the overall performance and application effect of the composite non-woven materials.

[0046] like Figures 1 to 3 As shown, the functional fiber includes the following raw materials by mass fraction:

[0047] 55-65% antistatic fiber, 35-45% antibacterial fiber.

[0048] In the embodiments of the present invention, the antistatic fiber is a synthetic fiber that can reduce or eliminate static electricity generated during use. The conductivity is improved by forming a conductive layer on the fiber surface or improving the hygroscopicity of the fiber surface, thereby reducing the accumulation of static electricity. The metal antistatic fiber is made by utilizing the conductive properties of metal and has good conductivity and antistatic effects. The antistatic fiber can effectively eliminate static electricity generated during use and prevent problems such as electric shock, discharge and dust absorption caused by static electricity accumulation. Eliminating static electricity can also reduce the stimulation of static electricity to the human body and improve the comfort of wearing. In flammable and explosive environments, the use of antistatic fibers can prevent fires or Explosion accident; antibacterial fiber refers to fiber with bactericidal and antibacterial effects, which is obtained by adding antibacterial agents to the fiber or making the fiber itself have antibacterial properties during the spinning process; artificial antibacterial fiber is obtained by adding antibacterial agents to the fiber through methods such as co-spinning, composite spinning, grafting modification, etc., such as silver-based antibacterial fiber; antibacterial fiber can effectively inhibit the growth and reproduction of microorganisms such as bacteria and fungi, and prevent textiles from being contaminated by microorganisms; textiles made of antibacterial fibers can reduce the cross-infection rate in public environments and protect the human body from pathogens; antibacterial fibers can also prevent textiles from being damaged by microbial erosion, thereby extending the service life of textiles.

[0049] like Figures 1 to 3 As shown, the intermediate microneedle layer includes the following raw materials by mass fraction:

[0050] 25-35% polyimide, 20-30% aramid, 15-25% pre-oxidized yarn, 5-15% thermal insulation material, 3-10% strength material.

[0051] In the embodiment of the present invention, polyimide is a kind of polymer material with excellent high temperature resistance, low temperature resistance, high insulation, high strength, high toughness and other properties; in the middle micro-needle layer, polyimide as the main component provides excellent high temperature resistance and mechanical strength, which helps to enhance the overall stability and durability of the material; aramid is a synthetic fiber with high strength, high modulus, high temperature resistance, acid and alkali resistance and other excellent properties; the addition of aramid further improves the strength and temperature resistance of the middle micro-needle layer, and also helps to improve the tear resistance and wear resistance of the material; pre-oxidized silk pre-oxidized silk is an intermediate product of polyacrylonitrile (PAN)-based carbon fiber precursor before carbonization. The fiber after pre-oxidation treatment has a stable structure and performance; the pre-oxidized silk plays a role in enhancing the bonding force between fibers in the middle micro-needle layer, and also helps to improve The overall stability and heat resistance of high-quality materials; thermal insulation materials have good thermal insulation properties, such as glass fiber and ceramic fiber; adding thermal insulation materials to the middle micro-needle punched layer can effectively improve the thermal insulation properties of the material and reduce the transfer and loss of heat; the strength material has high strength and stiffness; the addition of strength materials further enhances the strength and rigidity of the middle micro-needle punched layer, enabling it to withstand greater external forces and loads; the synergistic effect of polyimide, aramid and pre-oxidized silk enables the middle micro-needle punched layer to maintain a stable structure and performance under high temperature conditions; the addition of thermal insulation materials effectively improves the thermal insulation effect of the material and reduces the transfer and loss of heat; the reinforcing effect of aramid and pre-oxidized silk makes the middle micro-needle punched layer have better tear resistance and wear resistance; the middle micro-needle punched layer has excellent overall stability and durability.

[0052] like Figures 1 to 3 As shown, the thermal insulation material includes the following raw materials by mass fraction:

[0053] 60-70% ceramic fiber, 30-40% glass fiber.

[0054] In the embodiment of the present invention, ceramic fiber is a fibrous lightweight refractory material, mainly composed of aluminum silicate (Al2O3·SiO2), silicon dioxide (SiO2), aluminum oxide (Al 2O3), and zirconium oxide (ZrO2), and has good high temperature resistance, a refractoriness greater than 1000°C, good chemical stability, and excellent thermal insulation performance; ceramic fiber can maintain a stable structure and performance in a high temperature environment, is not easy to melt or deform, has a low thermal conductivity and excellent thermal stability; it has excellent corrosion resistance to a variety of chemical media, and can resist erosion by corrosive substances such as acids and alkalis; ceramic fiber has a light weight and high strength, is easy to transport and install, and can reduce the overall weight of the equipment; glass fiber is an inorganic non-metallic material with excellent performance, mainly composed of silicon dioxide, aluminum oxide, calcium oxide, boron oxide, magnesium oxide, and sodium oxide, and has good mechanical properties and chemical stability, as well as excellent electrical insulation and thermal insulation properties; glass The high strength and high modulus of glass fiber can significantly improve the overall strength and rigidity of composite materials. It has low thermal conductivity and excellent thermal stability, excellent corrosion resistance to a variety of chemical media, and can resist erosion by corrosive substances such as acids and alkalis. Glass fiber is soft and easy to cut, has strong continuity, and is convenient for winding and processing into products of various shapes and sizes. Both ceramic fiber and glass fiber have low thermal conductivity and excellent thermal stability. The thermal insulation material made after mixing can effectively block the transfer and loss of heat. The high-temperature stability of ceramic fiber enables the thermal insulation material to maintain a stable structure and performance in a high-temperature environment, and is suitable for various high-temperature industrial applications. The mixed thermal insulation material has a lighter weight and higher strength, is easy to transport and install, and can reduce the overall weight of the equipment.

[0055] like Figures 1 to 3 As shown, the strength material includes the following raw materials in terms of mass fraction:

[0056] 40-60% bonding fiber, 40-60% reinforcing fiber.

[0057] In the embodiment of the present invention, the bonding fiber is a regenerated fiber, which is mainly made of natural cellulose and is made after chemical processing. The viscose fiber has excellent moisture absorption, air permeability, softness and spinnability, and has good cost-effectiveness; the bonding fiber plays the role of an adhesive in the strength material, which can enhance the bonding force between fibers and improve the overall strength and stability of the material; the softness and good spinnability of the viscose fiber make the strength material easier to handle during processing, and it has flexibility and comfort; the reinforcing fiber is a high-performance fiber material used to enhance the mechanical properties of various materials. It is a carbon fiber with high strength, high modulus, excellent wear resistance and corrosion resistance; as the main component of strength materials, reinforcing fibers can significantly improve the tensile strength, flexural strength and compressive strength of materials, making the materials stronger and more durable; the addition of reinforcing fibers helps to improve the wear resistance and corrosion resistance of materials and extend the service life of materials; reinforcing fibers can enhance the overall stability of materials and reduce deformation and damage of materials caused by external forces during use, thereby improving the durability of materials; the bonding effect of adhesive fibers combined with the high-strength characteristics of reinforcing fibers make the strength materials have excellent strength and stability, which can meet various application scenarios with high strength and high stability requirements.

[0058] like Figures 1 to 3 As shown, a preparation process of a lightweight and thin thermal insulation composite nonwoven material comprises:

[0059] 11. Prepare raw materials according to the formula ratio:

[0060] 12. Use the first carding machine cotton box 2 and the first carding machine 1 in sequence to card 55-65% of polyester, 20-30% of nylon, 10-15% of sea island fibers, and 3-5% of functional fibers into a web, and transport it to the first transport curtain 7 to obtain a first fiber web;

[0061] 13. Use the second carding machine cotton box 6 and the second carding machine 5 in sequence to card 55-65% of polyester, 20-30% of nylon, 10-15% of sea island fibers, and 3-5% of functional fibers into a web, and transport it to the third transport curtain 8 to obtain a second fiber web;

[0062] 14. Using a cross-lapping machine 3, 25-35% of polyimide, 20-30% of aramid, 15-25% of pre-oxidized yarn, 5-15% of thermal insulation material, and 3-10% of strength material are cross-lapped. The cross-lapped fiber web is entangled for the first time through a needle punching machine 4 and transported to a second transport curtain 9 to obtain an intermediate micro-needle punching layer.

[0063] 15. The first fiber web, the middle micro-needle layer and the second fiber web are closed through the fourth conveying curtain 11, and the closing roller 10 is used to compact and discharge the air in the fiber web to obtain a closed fiber web;

[0064] 16. The folded fiber web is pre-spunlaced through a pre-spunlaced head 12 to obtain a pre-spunlaced fiber web;

[0065] 17. The pre-hydroentangled fiber web is passed through the first hydroentanglement head 15 of the first roller 13 for front hydroentanglement to obtain a front hydroentangled fiber web;

[0066] 18. The front side hydroentangled fiber web is hydroentangled through the second hydroentanglement head 16 of the second roller 14 to hydroentangle the back side to obtain a hydroentangled fiber web;

[0067] 19. Drying the fiber web after the back side hydroentanglement through a rotary screen dryer 17 to obtain a dried nonwoven fabric;

[0068] 20. The dried nonwoven fabric is wound up using a winder 18 to obtain the lightweight, thin, thermal insulation composite nonwoven material.

[0069] In the embodiment of the present invention, a unique "sandwich" structure is formed by adopting a process combining spunlace and micro-needle punching, which combines the delicacy of the spunlace material and the strength of the needle punched material, so that the final product has both a delicate touch and sufficient structural strength. The combination of spunlace and needle punching not only improves the overall performance of the material, but also significantly improves the environmental friendliness of the product because it does not require the use of chemical additives. This process reduces the environmental pollution that may be generated in the traditional textile printing and dyeing process, and meets the current demand for green and environmentally friendly products; the thin needle-punched material provides excellent thermal insulation and heat preservation due to its low density and loose structural characteristics. While maintaining light weight and portability, it can also effectively isolate temperature and is suitable for a variety of occasions requiring thermal insulation or heat preservation; through the double-sided spunlace process, the surface of the material becomes smoother and the feel is significantly improved, which not only enhances the tactile comfort of the product, but also effectively modifies the roughness that may be caused by traditional needle-punched materials, making the product more in line with consumers' usage habits and needs; the middle micro-needle layer enhances the structural strength and stability of the material through needle-punching technology, which not only makes the material more durable and tough, but also maintains the softness of the material, thereby broadening the application range and service life of the material; since no chemical additives are required during the entire production process, this process significantly reduces environmental pollution and possible residual chemicals in the product, thereby improving the safety and health of the product.

[0070] Optionally, the equipment for the preparation process of the lightweight and thin thermal insulation composite nonwoven material is as follows Figure 2As shown, the first carding machine 1, the web laying machine 3, the needle loom 4 and the second carding machine 5 are arranged in sequence in the horizontal direction.

[0071] Optionally, the equipment for the preparation process of the lightweight and thin thermal insulation composite nonwoven material is as follows Figure 3 As shown, the web laying machine 3 and the needling machine 4 are arranged in parallel with the first carding machine 1 , and the second carding machine 5 is arranged in parallel with the web laying machine 3 and the needling machine 4 .

[0072] like Figures 1 to 3 As shown, the intermediate micro-needle layer is formed by a needle punching process, the needle punching depth is 2-5 mm, and the needle density of a single needle plate is 20,000-30,000 pieces / m 2 The output speed of the needle-punched fiber web is 10-30m / min.

[0073] In the embodiment of the present invention, the needle punching process makes the fibers entangled with each other, thereby enhancing the strength and stability of the fiber web. The high-density needle punching (20,000-30,000 pieces / m 2 ) ensures that more bonding points are formed between fibers, thereby improving the overall strength of the material; by adjusting the needling depth (2-5mm) and the output speed of the needle-punched fiber web (10-30m / min), the thickness and density of the fiber web can be precisely controlled, which helps to optimize the thermal insulation, air permeability and feel of the material; due to the controllability and flexibility of the needling process, the needling parameters can be adjusted according to different application scenarios and needs to obtain non-woven materials with specific properties; the fiber web is repeatedly punctured by the needles of the needling machine during transportation. After the needles penetrate the fiber web, some fibers are hooked out and entangled together to form a stable fiber web structure. The high-density needling ensures that more bonding points are formed between fibers, thereby improving the overall strength of the material. The fiber web reinforced by needling is output through the outlet of the needling machine.

[0074] like Figures 1 to 3 As shown, the surface spunlace layer is formed by a spunlace process, and the spunlace pressure includes a pre-wetting pressure of 3-10 bar and an entanglement pressure of 30-80 bar.

[0075] In the embodiment of the present invention, the spunlace process uses high-pressure water flow to puncture the fiber web, so that the fibers are entangled with each other, thereby significantly enhancing the bonding force between the fibers. The pre-wetting pressure (3-10 bar) helps the initial wetting and dispersion of the fibers, while the entanglement pressure (30-80 bar) ensures that the fibers are tightly and stably bonded. Due to the enhanced bonding force between the fibers, the overall strength of the surface spunlace layer is significantly improved, so that the material can better maintain its shape and stability when subjected to external forces, thereby extending its service life. By adjusting the spunlace pressure, key parameters such as the density, thickness and porosity of the fiber web can be accurately controlled, which helps to optimize the thermal insulation performance, air permeability and hygroscopicity of the material, and better adapt to different application scenarios and needs. The spunlace process can also give the material a more delicate and soft surface texture, which is especially important for products that need to directly contact the skin or require high comfort. The hydroentanglement machine first uses a lower pre-wetting pressure (3-10bar) to preliminarily wet the fiber web, which helps to disperse and soften the fibers and prepare for subsequent hydroentanglement. After the pre-wetting treatment, the hydroentanglement pressure is gradually increased to the entanglement pressure (30-80bar). The high-pressure water flow will penetrate the fiber web, causing strong mutual entanglement between the fibers. Through repeated hydroentanglement, a tight and stable fiber web structure is formed. After the hydroentanglement is completed, the fiber web is transported to the drying area for drying, and the fiber web is further shaped to improve its dimensional stability and service life.

[0076] like Figures 1 to 3 As shown, the fibers used by the first carding machine 1 and the second carding machine 5 are 1.0-2.0D, and the fibers used by the cross-lapping machine 3 are 1.5-8.0D.

[0077] In the embodiments of the present invention, "1.0-2.0D" refers to the fineness or denier range of the fiber. Denier is a unit for measuring the thickness of the fiber, which indicates the weight (in grams) of a 9000-meter-long fiber. "1.0-2.0D" indicates that the fineness of the fiber is between 1.0 denier and 2.0 denier. Specifically, 1.0D indicates that a 9000-meter-long fiber weighs 1 gram, 2.0D indicates that a 9000-meter-long fiber weighs 2 grams, and 1.5D indicates that a 9000-meter-long fiber weighs 1.5 grams. The smaller the denier of the fiber, the finer the fiber; the larger the denier, the thicker the fiber. By selecting fibers of different thicknesses, a fiber web structure with a sense of hierarchy and three-dimensionality can be formed during the combing process, which helps to improve the overall strength and stability of the material. qualitative, while giving the material better air permeability and moisture absorption; fibers of different thicknesses will be intertwined and entangled during the combing process to form a tighter and more stable fiber web, which helps to improve the tensile strength, wear resistance and durability of the material, making it more suitable for various high-demand application scenarios; by adjusting the fiber thickness used in the combing machine, non-woven materials with different performance and appearance can be produced, which helps to enrich the product variety and meet the diverse needs of the market; using fibers of different thicknesses for combing on the first combing machine and the second combing machine respectively can make full use of the production capacity of the combing machine and improve production efficiency. Since fibers of different thicknesses have different characteristics during the combing process, the combing process parameters can also be flexibly adjusted according to actual conditions to achieve the best production effect.

[0078] Example 1

[0079] A preparation process of a lightweight and thin thermal insulation composite nonwoven material, comprising:

[0080] 11. Prepare raw materials according to the formula ratio:

[0081] 12. Use the first carding machine cotton box 2 and the first carding machine 1 in sequence to card 55% of polyester, 20% of nylon, 10% of sea-island fibers, and 3% of functional fibers into a web, and transport it to the first transport curtain 7 to obtain a first fiber web;

[0082] 13. Use the second carding machine cotton box 6 and the second carding machine 5 in sequence to card 55% polyester, 20% nylon, 10% sea island fiber, and 3% functional fiber into a web, and transport it to the third transport curtain 8 to obtain a second fiber web;

[0083] 14. Using a cross-lapping machine 3, 25% of polyimide, 20% of aramid, 15% of pre-oxidized yarn, 5% of thermal insulation material, and 3% of strength material are cross-lapped. The cross-lapped fiber web is entangled for the first time through a needle punching machine 4 and transported to a second transport curtain 9 to obtain an intermediate micro-needle punching layer.

[0084] 15. The first fiber web, the middle micro-needle layer and the second fiber web are closed through the fourth conveying curtain 11, and the closing roller 10 is used to compact and discharge the air in the fiber web to obtain a closed fiber web;

[0085] 16. The folded fiber web is pre-spunlaced through a pre-spunlaced head 12 to obtain a pre-spunlaced fiber web;

[0086] 17. The pre-hydroentangled fiber web is passed through the first hydroentanglement head 15 of the first roller 13 for front hydroentanglement to obtain a front hydroentangled fiber web;

[0087] 18. The front side hydroentangled fiber web is hydroentangled through the second hydroentanglement head 16 of the second roller 14 to hydroentangle the back side to obtain a hydroentangled fiber web;

[0088] 19. Drying the fiber web after the back side hydroentanglement through a rotary screen dryer 17 to obtain a dried nonwoven fabric;

[0089] 20. The dried nonwoven fabric is wound up using a winder 18 to obtain the lightweight, thin, thermal insulation composite nonwoven material.

[0090] Example 2

[0091] A preparation process of a lightweight and thin thermal insulation composite nonwoven material, comprising:

[0092] 11. Prepare raw materials according to the formula ratio:

[0093] 12. Use the first carding machine cotton box 2 and the first carding machine 1 in sequence to card 60% of polyester, 25% of nylon, 12% of sea island fibers, and 4% of functional fibers into a web, and transport it to the first transport curtain 7 to obtain a first fiber web;

[0094] 13. Use the second carding machine cotton box 6 and the second carding machine 5 in sequence to card 60% polyester, 25% nylon, 12% sea island fiber, and 4% functional fiber into a web, and transport it to the third transport curtain 8 to obtain a second fiber web;

[0095] 14. Using a cross-lapping machine 3, 30% of polyimide, 25% of aramid, 20% of pre-oxidized yarn, 10% of thermal insulation material, and 6% of strength material are cross-lapped. The cross-lapped fiber web is entangled for the first time through a needle punching machine 4 and transported to a second transport curtain 9 to obtain an intermediate micro-needle punching layer.

[0096] 15. The first fiber web, the middle micro-needle layer and the second fiber web are closed through the fourth conveying curtain 11, and the closing roller 10 is used to compact and discharge the air in the fiber web to obtain a closed fiber web;

[0097] 16. The folded fiber web is pre-spunlaced through a pre-spunlaced head 12 to obtain a pre-spunlaced fiber web;

[0098] 17. The pre-hydroentangled fiber web is passed through the first hydroentanglement head 15 of the first roller 13 for front hydroentanglement to obtain a front hydroentangled fiber web;

[0099] 18. The front side hydroentangled fiber web is hydroentangled through the second hydroentanglement head 16 of the second roller 14 to hydroentangle the back side to obtain a hydroentangled fiber web;

[0100] 19. Drying the fiber web after the back side hydroentanglement through a rotary screen dryer 17 to obtain a dried nonwoven fabric;

[0101] 20. The dried nonwoven fabric is wound up using a winder 18 to obtain the lightweight, thin, thermal insulation composite nonwoven material.

[0102] Example 3

[0103] A preparation process of a lightweight and thin thermal insulation composite nonwoven material, comprising:

[0104] 11. Prepare raw materials according to the formula ratio:

[0105] 12. Use the first carding machine cotton box 2 and the first carding machine 1 in sequence to card 65% of polyester, 30% of nylon, 15% of sea-island fibers, and 5% of functional fibers into a web, and transport it to the first transport curtain 7 to obtain a first fiber web;

[0106] 13. Use the second carding machine cotton box 6 and the second carding machine 5 in sequence to card 65% polyester, 30% nylon, 15% sea island fiber, and 5% functional fiber into a web, and transport it to the third transport curtain 8 to obtain a second fiber web;

[0107] 14. Using a cross-lapping machine 3, 35% of polyimide, 30% of aramid, 25% of pre-oxidized yarn, 15% of thermal insulation material, and 10% of strength material are cross-lapped. The cross-lapped fiber web is entangled for the first time through a needle punching machine 4 and transported to a second transport curtain 9 to obtain an intermediate micro-needle punching layer.

[0108] 15. The first fiber web, the middle micro-needle layer and the second fiber web are closed through the conveying curtain 11, and the closing roller 10 is used to compact and discharge the air in the fiber web to obtain a closed fiber web;

[0109] 16. The folded fiber web is pre-spunlaced through a pre-spunlaced head 12 to obtain a pre-spunlaced fiber web;

[0110] 17. The pre-hydroentangled fiber web is passed through the first hydroentanglement head 15 of the first roller 13 for front hydroentanglement to obtain a front hydroentangled fiber web;

[0111] 18. The front side hydroentangled fiber web is hydroentangled through the second hydroentanglement head 16 of the second roller 14 to hydroentangle the back side to obtain a hydroentangled fiber web;

[0112] 19. Drying the fiber web after the back side hydroentanglement through a rotary screen dryer 17 to obtain a dried nonwoven fabric;

[0113] 20. The dried nonwoven fabric is wound up using a winder 18 to obtain the lightweight, thin, thermal insulation composite nonwoven material.

[0114] The three embodiments were compared and the experimental items and data are as follows:

[0115]

[0116]

[0117] It shows that the use of finer fibers can help improve the softness and breathability of the fiber web; fine fibers have better combing and entanglement effects, which improves the overall strength of the fiber web; fibers with larger diameters have better air permeability; the use of fine fibers and the optimization of the combing process can help improve the tactile comfort of the material.

[0118] The present application adopts a thin needle-punched material, which provides a variety of unique performance advantages with its low density and loose needle-punched structure, and is particularly suitable for use as a thermal insulation layer; the low-density structure of the thin needle-punched material means that there is a large amount of still air between the fibers. Still air is a good thermal insulation material that can effectively reduce the transfer of heat through convection, can effectively lock in heat, and provide a good thermal insulation effect, so that the thin needle-punched material has excellent thermal insulation performance while maintaining lightness, and is suitable for the thermal insulation layer of firefighting clothing; the thin needle-punched material is extremely easy to handle and carry due to its light nature, and the lightness also means lower costs during transportation and storage, which is convenient for large-scale application; the thin needle-punched material is not only suitable for clothing and textiles, but can also be widely used in a variety of industrial applications such as building insulation and automobile interior sound insulation. The processing and cutting are relatively simple, and can be manufactured into different shapes and sizes to meet specific application requirements; the hydroentanglement process mainly relies on high-pressure water flow to act on the fibers to form an interwoven structure, thereby giving the material a more uniform and smooth surface. By applying the hydroentanglement process to both sides of the material, the roughness that usually exists on the surface of the needle-punched material can be effectively modified , making the surface of the final product smoother and improving the feel, which is particularly suitable for occasions such as clothing that require high comfort; the micro-needle punching process in the middle can increase the density and structural strength of the material, ensuring that it has high mechanical properties. The micro-needle punching process helps the fibers to be tightly bonded, giving the material better stability and durability. Combined with the two-sided spunlace process, it can balance strength and softness, so that the material has both strength and a certain degree of softness; the use of spunlace + micro-needle punching is environmentally friendly and safe, and the process flow is simple. Traditional spunbond or chemical bonding processes usually rely on the addition of chemical substances, such as adhesives or resins, which may cause pollution to the environment during production and disposal. The spunlace and micro-needle punching processes only use physical methods to achieve fiber bonding, and do not require the addition of any additional chemical additives, which fundamentally reduces the emission of harmful substances and the environmental burden, making this material more in line with modern environmental protection standards; in the absence of chemical adhesives, there is no risk of residual chemicals in the final product, thereby ensuring the safety of the material and avoiding possible chemical allergies or other health problems; chemical bonding or melt-blown processes are omitted, and the production process is more simplified.

[0119] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A lightweight, thin, thermal insulation composite nonwoven material, characterized in that: It comprises 23-30% of a first surface spunlace layer, 40-53% of an intermediate micro-needle puncture layer and 23-30% of a second surface spunlace layer, wherein the intermediate micro-needle puncture layer is disposed between the first surface spunlace layer and the second surface spunlace layer; The first surface spunlace layer and the second surface spunlace layer have the same structure.

2. The lightweight, thin, thermal insulation composite nonwoven material according to claim 1, characterized in that: The first surface spunlace layer comprises the following raw materials by weight: 55-65% polyester, 20-30% nylon, 10-15% sea island fiber, 3-5% functional fiber.

3. The lightweight, thin, thermal insulation composite nonwoven material according to claim 2, characterized in that: The functional fiber comprises the following raw materials by mass fraction: 55-65% antistatic fiber, 35-45% antibacterial fiber.

4. The lightweight, thin, thermal insulation composite nonwoven material according to claim 3, characterized in that: The intermediate microneedle layer comprises the following raw materials by weight: 25-35% polyimide, 20-30% aramid, 15-25% pre-oxidized yarn, 5-15% thermal insulation material, 3-10% strength material.

5. The lightweight, thin, thermal insulation composite nonwoven material according to claim 4, characterized in that: The thermal insulation material includes the following raw materials by mass fraction: 60-70% ceramic fiber, 30-40% glass fiber.

6. The lightweight, thin, thermal insulation composite nonwoven material according to claim 5, characterized in that: The strength material includes the following raw materials in terms of mass fraction: 40-60% bonding fiber, 40-60% reinforcing fiber.

7. A process for preparing a lightweight, thin, thermal insulation composite nonwoven material as claimed in any one of claims 1 to 6, characterized in that: include: Prepare the raw materials according to the formula ratio: Using the first carding machine cotton box (2) and the first carding machine (1) in sequence, 55-65% of polyester, 20-30% of nylon, 10-15% of sea island fibers, and 3-5% of functional fibers are carded into a web, and transported to the first transport curtain (7) to obtain a first fiber web; Using the second carding machine cotton box (6) and the second carding machine (5) in sequence, 55-65% of polyester, 20-30% of nylon, 10-15% of sea island fibers, and 3-5% of functional fibers are carded into a web, and transported to the third transport curtain (8) to obtain a second fiber web; A cross-lapping machine (3) is used to cross-lap 25-35% of polyimide, 20-30% of aramid, 15-25% of pre-oxidized yarn, 5-15% of thermal insulation material, and 3-10% of strength material. The cross-lapped fiber web is entangled for the first time by a needle punching machine (4) and transported to a second transport curtain (9) to obtain an intermediate micro-needle punching layer. The first fiber web, the middle micro-needle layer and the second fiber web are closed together through a fourth conveying curtain (11), and the air in the fiber webs is compacted and discharged through a closing roller (10) to obtain a closed fiber web; The woven fiber web is passed through a pre-wetting spunlacing head (12) for pre-spunlacing to obtain a pre-spunlaced fiber web; Passing the pre-hydroentangled fiber web through a first hydroentanglement head (15) of a first roller (13) to perform front hydroentanglement to obtain a front hydroentangled fiber web; The front side hydroentanglement is passed through a second hydroentanglement head (16) of a second roller (14) to perform back side hydroentanglement to obtain a fiber web after back side hydroentanglement; The fiber web after the back side hydroentanglement is dried by a rotary screen dryer (17) to obtain a dried nonwoven fabric; The dried nonwoven fabric is wound up using a winder (18) to obtain the lightweight, thin, thermal insulation composite nonwoven material.

8. The process for preparing the lightweight, thin, thermal insulation composite nonwoven material according to claim 7, characterized in that: The intermediate micro-needle layer is formed by a needle punching process, the needle punching depth is 2-5 mm, and the needle density of a single needle plate is 20,000-30,000 pieces / m 2 The output speed of the needle-punched fiber web is 10-30m / min.

9. The process for preparing the lightweight, thin, thermal insulation composite nonwoven material according to claim 8, characterized in that: The surface spunlace layer is formed by a spunlace process, and the spunlace pressure includes a pre-wetting pressure of 3-10 bar and an entanglement pressure of 30-80 bar.

10. The process for preparing the lightweight, thin, thermal insulation composite nonwoven material according to claim 9, characterized in that: The fibers used by the first carding machine (1) and the second carding machine (5) are 1.0-2.0D, and the fibers used by the cross-lapping machine (3) are 1.5-8.0D.

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