Process for manufacturing double-layer es composite fiber smooth fluffy hot air nonwoven fabric

Abstract

The application discloses a kind of double-layer ES composite fiber smooth fluffy hot air nonwoven fabric manufacturing process, belong to hot air nonwoven fabric technical field, including the following steps: S1, the fine denier ES composite fiber of fiber denier≤1D is respectively pre-opened after being sent to carding machine with thick denier ES composite fiber;S2, the fine denier ES composite fiber is taken off by fine denier carding machine single doffer and cancels the disorder treatment of disorder condensation roller, and the fine denier ES composite fiber layer is formed after netting;S3, thick denier ES composite fiber is taken off by thick denier carding machine double doffer and netting forms thick denier ES composite fiber layer;S4, thick denier ES composite fiber layer is laid on the surface of fine denier ES composite fiber layer after netting and forms double-layer ES composite fiber layer and obtains hot air nonwoven fabric after hot air bonding;S5, winding, slitting, packaging;The hot air nonwoven fabric of the application has the advantages of smooth, fluffy, can improve comfort.

Description

Technical Field

[0001] This invention relates to the field of hot air nonwoven fabric technology, specifically to a manufacturing process for a double-layer ES composite fiber smooth and fluffy hot air nonwoven fabric. Background Technology

[0002] Hot-air nonwoven fabric is produced by carding bicomponent fibers into a fiber web, then using hot air from a hot drying device to penetrate the fiber web. This causes the low-melting-point components of the bicomponent fibers to melt, resulting in the fibers adhering to each other and then cooling and fixing to form the hot-air nonwoven fabric. Because the melting and bonding caused by the hot air penetrating the fiber web is point-like rather than area-like, hot-air nonwoven fabric has advantages such as good bulkiness and breathability. These advantages make hot-air nonwoven fabric widely used in absorbent hygiene products such as diapers and sanitary napkins. Furthermore, hot-air nonwoven fabric is commonly used in absorbent hygiene products in combination with... For absorbent hygiene products, the top and bottom layers that come into direct contact with the human body require high strength in their internal nonwoven fabric to ensure structural stability. If high-density fibers are used to ensure strength, the surface of the hot-air nonwoven fabric will be rough, resulting in poor comfort when using such fabric as the top and bottom layers. If low-density fibers are used to ensure comfort, the weight of the hot-air nonwoven fabric needs to be increased to maintain strength, which will increase the production cost and affect its breathability.

[0003] Based on the above, Chinese Patent No. CN112323258A discloses a hot-air voluminous fabric manufacturing process, including the following steps: a) Opening: Composite short fibers and polyester short fibers are respectively placed into a first opening machine and a second opening machine for opening, so that the pre-opened fiber raw materials enter the cotton box storage tank under the action of airflow. Under the grip of the feeding roller and the cotton feeding plate, the beater roller opens the fibers into small and uniform fiber clusters; b) Impurity removal: The high-speed rotation of the beater roller separates the fibers and impurities in the composite short fibers and polyester short fibers. The impurities are adsorbed by the dust suction pipe, and the fibers are blocked by the dust bar and fall back to the beater. a) The fiber continues to move forward, propelled by airflow; c) In the carding process, composite short fibers and polyester short fibers are simultaneously fed into the carding machine, which further breaks up and evenly mixes the opened fiber clumps. The carded fibers are then transferred to the doffer and output as a fiber web; d) In the hot air web-setting process, the pre-shaped fiber web is transported to the oven for hot air penetration. After being transported to the oven, the fiber web is heated by hot air jet; e) In the softening process, the fiber web heated by hot air jet is transported to the forging roller for rolling while a layer of softener is applied; f) In the cooling process, after rolling, the fiber web is transported to the cold air blower for cooling.

[0004] The aforementioned hot-air voile fabric is a type of hot-air nonwoven fabric. This hot-air voile fabric improves surface softness by applying a layer of fabric softener, thereby enhancing comfort during use. After the fabric softener is applied to the surface, it forms a coating. Whether this hot-air voile fabric is used to make masks or the outer layer of absorbent hygiene products, these products are all hygiene products. During use, chemical migration can easily occur through contact with human body fluids, causing some components of the fabric softener to be absorbed by the body, posing a potential threat to human health. Therefore, it needs to be used with caution in hygiene products. Thus, this hot-air voile fabric still has room for improvement. Summary of the Invention

[0005] To address the technical deficiencies in the background technology, this invention proposes a manufacturing process for a smooth and fluffy hot-air nonwoven fabric made of double-layer ES composite fibers, which solves the aforementioned technical problems and meets practical needs. The specific technical solution is as follows:

[0006] A manufacturing process for a double-layer ES composite fiber smooth and fluffy hot-air nonwoven fabric includes the following steps:

[0007] S1. The fine denier ES composite fiber and the coarse denier ES composite fiber are pre-opened separately. After opening, the two types of fibers are cleaned of impurities, accurately weighed, and then fed into the carding machine. The denier of the fine denier ES composite fiber is ≤1D.

[0008] S2. The fine denier ES composite fiber is stripped from the web by a single doffer in a fine denier carding machine. After the disorder treatment of the disordered agglomeration roller is eliminated, a fine denier ES composite fiber layer is formed and laid on the surface of the collection curtain. The ratio of the longitudinal to the transverse direction of the fiber in the fine denier ES composite fiber layer is 10:(0.5~1).

[0009] S3. The coarse denier ES composite fiber is stripped into a web by a coarse denier carding machine and then formed into a coarse denier ES composite fiber layer after random aggregation and web laying. The ratio of the longitudinal to the transverse direction of the fiber in the coarse denier ES composite fiber layer is (4~5):1.

[0010] S4. After the coarse denier ES composite fiber layer is produced, it is laid on the surface of the fine denier ES composite fiber layer to form a double ES composite fiber layer on the surface of the collecting curtain. The double ES composite fiber layer is then heat-bonded by a heat bonding machine and cooled and shaped to obtain hot air nonwoven fabric.

[0011] S5. The hot air nonwoven fabric is wound up, cut, and packaged to obtain hot air nonwoven fabric rolls.

[0012] As a further technical solution of the present invention, the outer layer structure of the fine denier ES composite fiber is made of polyethylene and the core layer structure is made of polypropylene, and the outer layer structure of the coarse denier ES composite fiber is made of polyethylene and the core layer structure is made of polyester.

[0013] As a further technical solution of the present invention, the basis weight of the hot air nonwoven fabric is 16~24 gsm.

[0014] As a further technical solution of the present invention, the basis weight of the fine denier ES composite fiber layer is 6~10 gsm.

[0015] As a further technical solution of the present invention, the basis weight of the coarse denier ES composite fiber layer is 10~14 gsm.

[0016] As a further technical solution of the present invention, the denier of the fine denier ES composite fiber is 0.4~1D, and the denier of the coarse denier ES composite fiber is 1.2~6D.

[0017] As a further technical solution of the present invention, in step S2, before the fine denier ES composite fiber layer is stripped from the web, the doffer needs to undergo roller surface cleaning treatment and roller surface static electricity elimination treatment.

[0018] As a further technical solution of the present invention, in step S2, the speed at which the fine denier ES composite fiber layer is stripped out of the web is 80~110m / min.

[0019] As a further technical solution of the present invention, in step S4, the temperature at which the hot air bonding machine hot-blows the double-layer ES composite fiber layer is 110~150℃.

[0020] The beneficial effects of this invention are as follows:

[0021] The hot-air nonwoven fabric of this invention is composed of a fine denier ES composite fiber layer and a coarse denier ES composite fiber layer. One side of the fine denier ES composite fiber layer is the surface that directly contacts the human body. The fine denier ES composite fiber layer improves fiber straightness by using a single doffer to remove the web and eliminating the disorder treatment operation of the disorder agglomeration roller during the web removal process, making the surface that directly contacts the human body smoother and softer, thus improving the comfort of the hot-air nonwoven fabric. The coarse denier ES composite fiber layer is composed of larger diameter fibers, ensuring the overall strength and bulkiness of the hot-air nonwoven fabric. Furthermore, the web is removed by a double doffer and laid out by a disorder agglomeration method, ensuring the lateral strength of the hot-air nonwoven fabric and improving its durability. Detailed Implementation

[0022] The embodiments of the present invention will be described below with reference to relevant examples. The embodiments of the present invention are not limited to the following examples, and the present invention relates to relevant necessary components in this technical field, which should be regarded as well-known technology in this technical field and can be known and mastered by those skilled in this technical field.

[0023] A manufacturing process for a double-layer ES composite fiber smooth and fluffy hot-air nonwoven fabric includes the following steps:

[0024] S1. The fine denier ES composite fiber and the coarse denier ES composite fiber are pre-opened separately. After opening, the two types of fibers are cleaned of impurities, accurately weighed, and then fed into the carding machine. The denier of the fine denier ES composite fiber is ≤1D.

[0025] S2. Fine denier ES composite fibers are stripped from the web by a single doffer in a fine denier carding machine. After the disorder treatment of the disordered agglomeration roller is eliminated, a fine denier ES composite fiber layer is formed and laid on the surface of the collection curtain. The ratio of the longitudinal to the transverse direction of the fibers in the fine denier ES composite fiber layer is 10:(0.5~1).

[0026] S3. The coarse denier ES composite fiber is stripped into a web by a coarse denier carding machine with a double doffer. After random aggregation and web laying, a coarse denier ES composite fiber layer is formed. The ratio of the longitudinal direction to the transverse direction of the fiber in the coarse denier ES composite fiber layer is (4~5):1.

[0027] S4. After the coarse denier ES composite fiber layer is produced, it is laid on the surface of the fine denier ES composite fiber layer to form a double ES composite fiber layer on the surface of the collecting curtain. The double ES composite fiber layer is then heat-bonded by a heat bonding machine and cooled and shaped to obtain hot air nonwoven fabric.

[0028] S5. The hot air nonwoven fabric is wound up, cut, and packaged to obtain hot air nonwoven fabric rolls.

[0029] The hot-air nonwoven fabric of this invention is composed of two types of fibers with different properties: fine denier ES composite fibers and coarse denier ES composite fibers. The fine denier ES composite fibers, due to their extremely fine fiber diameter, significantly improve the fineness and softness of the hot-air nonwoven fabric, while also increasing the specific surface area of ​​the fibers and creating more inter-fiber gaps within the fabric, thereby improving its moisture absorption, breathability, and warmth retention. The coarse denier ES composite fibers, with their relatively larger diameter and higher strength, result in hot-air nonwoven fabrics with higher strength and better abrasion resistance. High density: After hot air bonding, the fibers at non-crossing points of the fiber web retain their original state, providing good support for the interior of the hot air nonwoven fabric and ensuring its fluffiness. The hot air nonwoven fabric is made by combining fine denier ES composite fibers and coarse denier ES composite fibers. The fine denier ES composite fiber layer is mainly used as the side that comes into direct contact with the human body, giving the surface of the hot air nonwoven fabric a soft and smooth feel, improving the comfort of use. The coarse denier ES composite fiber layer is mainly used to ensure the overall strength and fluffiness of the hot air nonwoven fabric and improve its durability.

[0030] It should be further explained that ES composite fiber, as a core-sheath structure fiber, has a polyethylene sheath structure and a polypropylene core structure in the fine denier ES composite fiber. The use of polyethylene in the sheath structure, with its lower melting point, ensures that the internal fiber surfaces of the fine denier ES composite fiber layer melt and bond together under the action of hot air. The ES composite fiber with a polypropylene core structure has better softness, which can further improve the comfort of the hot-air nonwoven fabric in direct contact with the human body. The coarse denier ES composite fiber has a polyethylene sheath structure and a polyester core structure. The ES composite fiber with a polyester core structure has higher strength and support, which can further improve the overall strength and bulkiness of the hot-air nonwoven fabric. After the coarse denier ES composite fiber layer is laid on the surface of the fine denier ES composite fiber layer to form a double-layer ES composite fiber layer, the polyethylene on the fiber surface is melted and bonded together by hot air heating to form the hot-air nonwoven fabric. One side of the hot-air nonwoven fabric is composed of fine denier ES composite fibers, which is used for direct contact with the human body and has good comfort, while the other side is composed of coarse denier ES composite fibers to ensure the strength of the hot-air nonwoven fabric.

[0031] Regarding the manufacturing process of the hot air nonwoven fabric of the present invention, in step S1, the fine denier ES composite fibers and the coarse denier ES composite fibers are pre-opened by an opening device. Opening reduces the scale of the transverse connection of the fibers, creating conditions for the fibers to be further loosened into a single fiber state, which is beneficial to the subsequent carding operation. Opening can make the fiber blocks or fiber bundles more loose and uniform, which is beneficial to the uniform distribution of fibers in the subsequent processing, thereby improving the quality and stability of the product. In addition, during the opening process, the density of the fiber blocks or fiber bundles decreases, the connection with impurities weakens, and some impurities with low adhesion can be effectively separated. Then, a strong airflow is generated by an airflow device to suck away or blow away the separated impurities, thereby achieving impurity removal from the fibers. After impurity removal, the uniform fiber clusters are conveyed to the carding machine. The fiber clusters are precisely weighed during the conveying process, which is beneficial to accurately control the basis weight of the fine denier ES composite fiber layer and the coarse denier ES composite fiber layer.

[0032] In step S2, the fiber clusters formed by the fine denier ES composite fibers are further dispersed and mixed evenly in the fine denier carding machine. Specifically, the fibers are hooked and stretched by the needles on the two roller surfaces through the reverse-configured front cylinder and carding doffer. A portion of the fibers existing between the two needle surfaces is carried away by each needle surface. Furthermore, the front cylinder and carding doffer rotate at different speeds. This speed difference causes the fibers to be subjected to carding forces in different directions on the needle surfaces between the front cylinder and carding doffer, thereby achieving fiber carding. The fibers undergo initial carding and straightening on the front cylinder needle surface and then transfer to the carding doffer needle surface. On the carding doffer needle surface, the fibers are further combed and evenly mixed to form a thicker fiber layer. The carding doffer gradually transfers the fiber layer to the rear cylinder, where it undergoes further carding to improve straightness. Then, the stripping doffer, with its needles aligned with the rear cylinder's carding teeth, strips the fiber layer from the rear cylinder surface. The linear velocity of the rear cylinder is much greater than that of the stripping doffer. The stripping doffer has a smaller working area, while the rear cylinder has a relatively larger rotating area. The fibers per unit area of ​​the stripping doffer are drawn from many unit areas of the rear cylinder and aggregated. During this aggregation process, the fibers on the rear cylinder gradually transfer to the stripping doffer to form a fiber web. The fiber web continues to rotate with the stripping doffer and is transferred to the collecting wheel. The collecting wheel lays the fiber web on the surface of the collecting curtain, resulting in a fine denier ES composite fiber layer, which is then transported to the coarse denier carding machine.

[0033] It should be further explained that when the fine denier ES fiber layer is laid on the surface of the collecting curtain for web exit, the disorder treatment operation of the disordered agglomeration roller is eliminated and the cross-laying method is not adopted. This makes most of the fibers in the fine denier ES composite fiber layer longitudinally distributed, which makes the fine denier ES composite fiber layer smoother after hot air bonding. Furthermore, after eliminating the disorder treatment operation of the disordered agglomeration roller, the fine denier ES composite fiber layer can achieve web laying with a lower basis weight. Given the high production cost of fine denier ES composite fibers, this operation can reduce the production cost of hot air nonwoven fabric.

[0034] In step S3, the fiber clusters formed by the coarse denier ES composite fibers are further dispersed and mixed evenly in the coarse denier carding machine. Specifically, the fibers are hooked and stretched by the needles on the two roller surfaces through the reverse-configured front cylinder and carding doffer. A portion of the fiber existing between the two needle surfaces is carried away by each needle surface. Furthermore, the front cylinder and carding doffer rotate at different speeds. This speed difference causes the fibers to be subjected to carding forces in different directions on the needle surfaces between the front cylinder and carding doffer, thereby achieving fiber carding. The fibers undergo initial carding and straightening on the front cylinder needle surface and then transfer to the carding doffer needle surface for further carding. On the doffer needle surface, the fibers are further combed and uniformly mixed to form a thicker fiber layer. The combing doffer gradually transfers the fiber layer to the back cylinder. The fiber layer is further combed in the back cylinder to improve straightness. Then, two stripping doffers, which are arranged in the same direction as the needles of the back cylinder, strip the fiber layer on the surface of the back cylinder. The linear velocity of the back cylinder is much greater than that of the stripping doffer. The area of ​​action of the stripping doffer is small while the area of ​​the back cylinder is relatively large. The fibers per unit area of ​​the stripping doffer are taken from many unit areas of the back cylinder and aggregated. During the aggregation process, the fibers on the back cylinder are gradually transferred to the stripping doffer to form a fiber web.

[0035] With the above structure, it should be further explained that the coarse denier carding machine is equipped with two stripping doffers, which will form two layers of fiber web composed of coarse denier ES composite fibers. These two layers of fiber web form a coarse denier ES composite fiber layer through random aggregation and web laying. The random aggregation and web laying increases the proportion of transverse fiber distribution inside the coarse denier ES composite fiber layer, avoiding the problem of easy tearing of hot air nonwoven fabric due to insufficient transverse strength. In step S4, the coarse denier ES composite fiber layer is laid on the surface of the fine denier ES composite fiber layer to form a double-layer ES composite fiber layer. The double-layer ES composite fiber layer is heated by hot air to melt the polyethylene on the fiber surface and bond them together to form a hot air nonwoven fabric. The two sides of the hot air nonwoven fabric are composed of fine denier ES composite fibers and coarse denier ES composite fibers, respectively, so that the hot air nonwoven fabric has good strength and bulkiness, and the side that comes into direct contact with the human body is smoother and more comfortable.

[0036] As one of the preferred embodiments of the present invention, the basis weight of the hot-air nonwoven fabric is 16~24 gsm, and the preferred basis weight of the hot-air nonwoven fabric of the present invention is 20 gsm. Using this basis weight ensures sufficient strength while maintaining good air permeability and bulkiness. The basis weight of the fine denier ES composite fiber layer is 6~10 gsm, preferably 6 gsm. Since the fine denier ES composite fiber layer is formed by peeling and laying the web using only one peeling doffer, and the disordering process of the disordered agglomeration roller is eliminated during web laying, the fine denier ES composite fiber layer can achieve low basis weight output during web laying, and the fine denier... The amount of ES composite fiber used is based on the high production cost of fine denier ES composite fiber, which can reduce the production cost of hot air nonwoven fabric. The basis weight of the coarse denier ES composite fiber layer is 10~14 gsm, preferably 14 gsm. The coarse denier ES composite fiber layer is stripped out of the web by two stripping doffers. It consists of two layers of fiber web composed of coarse denier ES composite fibers with a basis weight of 7 gsm. This allows the coarse denier ES composite fiber layer to be formed by random aggregation and web laying. The high basis weight of the coarse denier ES composite fiber layer ensures the strength and bulkiness of the hot air nonwoven fabric and avoids damage during use.

[0037] Furthermore, a double-layer ES composite fiber layer with a basis weight of 20gsm is obtained by combining a fine denier ES composite fiber layer with a basis weight of 6gsm and a coarse denier ES composite fiber layer with a basis weight of 14gsm. After subsequent hot air treatment, the internal fibers adhere to each other to form a hot air nonwoven fabric with a basis weight of 20gsm.

[0038] As one of the preferred embodiments of the present invention, the denier of the fine denier ES composite fiber is 0.4~1D. The lower the denier of the fine denier ES composite fiber, the better the softness. The denier of the fine denier ES composite fiber can be adaptively adjusted according to the softness requirements of the hot air nonwoven fabric. Considering the physical properties and processing difficulty of the fine denier ES composite fiber, the denier of the fine denier ES composite fiber of the present invention is preferably 0.8~1D; the denier of the coarse denier ES composite fiber is 1.2~6D. The higher the denier of the coarse denier ES composite fiber, the higher the strength. In order to avoid the coarse denier ES composite fiber being too high and affecting the overall softness of the hot air nonwoven fabric, the denier of the coarse denier ES composite fiber is preferably 2~4D.

[0039] As one of the preferred embodiments of the present invention, in step S2, before the fine denier ES composite fiber layer is stripped from the web, the doffer needs to undergo roller surface cleaning and roller surface static elimination treatment. Since the fine denier ES composite fiber has a lower fiber diameter and is softer and lighter, it is easier to remain on the surface of the stripping doffer. The stripping doffer needs to undergo roller surface cleaning and roller surface static elimination treatment. The roller surface cleaning treatment can use a structure of brush and negative pressure fan to remove the residual fibers on the surface of the stripping doffer. The roller surface static elimination treatment can use a static eliminator to eliminate the static electricity on the surface of the stripping doffer, so as to prevent the fibers from being continuously adsorbed on the surface of the stripping doffer through static electricity, thereby preventing the fine denier ES composite fiber from remaining and winding on the surface of the stripping doffer, affecting the stripping of the fine denier ES composite fiber layer from the web, so that the fine denier ES composite fiber layer can stably exit the web with a lower basis weight.

[0040] With the above structure, it should be further explained that in step S2, the speed at which the fine denier ES composite fiber layer is peeled out is 80~110m / min. Since the fine denier ES composite fibers are easy to remain and wrap around the peeling doffer surface, it is usually necessary to reduce the peeling speed of the fine denier ES composite fiber layer. The peeling speed is usually 60~70m / min to make the fine denier ES composite fiber layer be peeled out into a web more stably. However, this operation will affect the production efficiency of hot air nonwoven fabric. After the peeling doffer is cleaned by roller surface and static electricity is eliminated by roller surface, the fine denier ES composite fiber layer can be peeled out into a web stably. Therefore, the peeling speed of the fine denier ES composite fiber layer can be increased to 80~110m / min, thereby improving the production efficiency of hot air nonwoven fabric.

[0041] As one of the preferred embodiments of the present invention, in step S4, the temperature at which the hot air bonding machine hot air bonds the double-layer ES composite fiber layer is 110~150℃. Since the skin structure of both fine denier ES composite fiber and coarse denier ES composite fiber is polyethylene with a low melting point, heating it to 110~150℃ by the hot air bonding machine can transform the polyethylene into a molten state, thereby causing the fibers inside the double-layer ES composite fiber layer to stick together and be fixed. After subsequent cooling, a structurally stable hot air nonwoven fabric is formed.

[0042] In summary, the hot-air nonwoven fabric of the present invention is composed of a fine denier ES composite fiber layer and a coarse denier ES composite fiber layer. The side with the fine denier ES composite fiber layer is the surface that directly contacts the human body. The fine denier ES composite fiber layer improves fiber straightness by using a single doffer to remove the web and eliminating the disorder treatment operation of the disordered agglomeration roller during the web removal process, making the surface that directly contacts the human body smoother and softer, thus improving the comfort of the hot-air nonwoven fabric. The coarse denier ES composite fiber layer is composed of fibers with larger diameters, ensuring the overall strength and bulkiness of the hot-air nonwoven fabric. Furthermore, the web is removed by a double doffer and laid out by a disordered agglomeration method, ensuring the lateral strength of the hot-air nonwoven fabric and improving its durability.

[0043] The present invention will be further illustrated below through examples and comparative examples.

[0044] Example 1

[0045] S1. The fine denier ES composite fiber and the coarse denier ES composite fiber are pre-opened separately. After opening, the two types of fibers are cleaned of impurities, accurately weighed, and then fed into the carding machine. The fine denier ES composite fiber has a denier of 0.8D, and the coarse denier ES composite fiber has a denier of 2D.

[0046] S2. Fine denier ES composite fibers are stripped from the web using a fine denier carding machine and the disordered treatment of the disordered agglomeration roller is eliminated to form a fine denier ES composite fiber layer, which is then laid on the surface of the collection curtain. The ratio of the longitudinal to the transverse direction of the fibers in the fine denier ES composite fiber layer is 10:0.5, and the basis weight is 6 gsm.

[0047] S3. The coarse denier ES composite fiber is stripped into a web by a coarse denier carding machine and then randomly aggregated and laid into a web to form a coarse denier ES composite fiber layer. The ratio of the longitudinal to the transverse direction of the fiber in the coarse denier ES composite fiber layer is 5:1, and the basis weight is 14 gsm.

[0048] S4. After the coarse denier ES composite fiber layer is produced from the net, it is laid on the surface of the fine denier ES composite fiber layer to form a double-layer ES composite fiber layer on the surface of the collecting curtain. The double-layer ES composite fiber layer is then heat-bonded by a heat bonding machine. After cooling and shaping, a hot-air nonwoven fabric with a basis weight of 20gsm is obtained.

[0049] Comparative Example 1

[0050] S1. The fine denier ES composite fiber is pre-opened, and the opened fiber is cleaned of impurities, accurately weighed, and then fed into the carding machine. The denier of the fine denier ES composite fiber is 0.8D.

[0051] S2. Fine denier ES composite fibers are stripped into a web using a fine denier carding machine with a double doffer. After random aggregation and web laying, a fine denier ES composite fiber layer is formed and laid on the surface of the collection curtain. The ratio of the longitudinal to the transverse direction of the fibers in the fine denier ES composite fiber layer is 5:1, and the basis weight is 20gsm.

[0052] The S3 and fine denier ES composite fiber layers are thermally bonded using a thermal bonding machine, and after cooling and shaping, a hot-air nonwoven fabric with a basis weight of 20gsm is obtained.

[0053] Comparative Example 2

[0054] S1. The coarse denier ES composite fiber is pre-opened, and the opened fiber is cleaned of impurities, accurately weighed, and then fed into the carding machine. The denier of the coarse denier ES composite fiber is 2D.

[0055] S2. The coarse denier ES composite fiber is stripped into a web by a coarse denier carding machine and then formed into a coarse denier ES composite fiber layer after random aggregation and laying on the surface of the collection curtain. The ratio of the longitudinal to the transverse direction of the fiber in the coarse denier ES composite fiber layer is 5:1, and the basis weight is 20gsm.

[0056] The S3 and coarse denier ES composite fiber layers are thermally bonded using a thermal bonding machine, and after cooling and shaping, a hot-air nonwoven fabric with a basis weight of 20gsm is obtained.

[0057] The longitudinal strength, transverse strength, and surface friction coefficient of the hot-air nonwoven fabrics obtained in the above embodiments and comparative examples were tested. The test results are shown in Table 1 below:

[0058]

[0059] Table 1

[0060] It should be noted that the surface friction coefficient is obtained by averaging the longitudinal and transverse friction coefficients of the hot-air nonwoven fabric. In Example 1, the surface friction coefficient was obtained by testing the surface of the hot-air nonwoven fabric that is in direct contact with the human body.

[0061] According to the data in Table 1, compared with the hot-air nonwoven fabric in Comparative Example 2, the surface friction coefficient of the hot-air nonwoven fabric in Example 1 is significantly lower, and its surface in direct contact with the human body is smoother and more comfortable. Although its overall strength is poor, its strength can meet the basic requirements of hygiene products. It can also meet the higher strength requirements of other fields for hot-air nonwoven fabrics by increasing the weight of the coarse denier ES composite fiber layer, without affecting its surface smoothness. The surface friction coefficient of the hot-air nonwoven fabric in Comparative Example 1 is close to that of Example 1, and its surface also shows the advantages of smoothness and comfort. However, the overall strength of the hot-air nonwoven fabric is significantly worse, and it is made entirely of fine denier ES composite fibers. Considering the performance and production cost of the hot-air nonwoven fabric, the hot-air nonwoven fabric obtained in Comparative Example 1 is difficult to meet the requirements of producers and users for low-cost and high-performance nonwoven fabrics.

[0062] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A manufacturing process for a double-layer ES composite fiber smooth and fluffy hot-air nonwoven fabric, characterized in that, Includes the following steps: S1. The fine denier ES composite fiber and the coarse denier ES composite fiber are pre-opened separately. After the two types of fibers are opened, they are cleaned of impurities, accurately weighed, and then fed into the carding machine. S2. Fine denier ES composite fibers are stripped from the web using a fine denier carding machine and the disordered treatment of the disordered agglomeration roller is eliminated to form a fine denier ES composite fiber layer, which is then laid on the surface of the collection curtain; wherein, the ratio of the longitudinal to the transverse direction of the fibers in the fine denier ES composite fiber layer is 10:(0.5~1). The outer layer of the fine denier ES composite fiber is made of polyethylene and the core layer is made of polypropylene. The fine denier ES composite fiber has a denier of 0.4~1D; The basis weight of the fine denier ES composite fiber layer is 6~10 gsm; S3. The coarse denier ES composite fiber is stripped from the web by a coarse denier carding machine and then formed into a coarse denier ES composite fiber layer after random aggregation and web laying; wherein, the ratio of the longitudinal direction to the transverse direction of the fiber in the coarse denier ES composite fiber layer is (4~5):

1. The outer layer of the coarse denier ES composite fiber is made of polyethylene and the core layer is made of polyester. The coarse denier ES composite fiber has a denier of 1.2~6D; The basis weight of the coarse denier ES composite fiber layer is 10~14 gsm; S4. After the coarse denier ES composite fiber layer is produced, it is laid on the surface of the fine denier ES composite fiber layer to form a double ES composite fiber layer on the surface of the collecting curtain. The double ES composite fiber layer is then heat-bonded by a heat bonding machine and cooled and shaped to obtain hot air nonwoven fabric. The temperature at which the hot air bonding machine hot-bends the double-layer ES composite fiber layer is 110~150℃. S5. The hot air nonwoven fabric is wound up, cut, and packaged to obtain a hot air nonwoven fabric roll; The weight of the hot air nonwoven fabric is 16~24 gsm.

2. The manufacturing process of the double-layer ES composite fiber smooth and fluffy hot air nonwoven fabric according to claim 1, characterized in that, In step S2, before the fine denier ES composite fiber layer is stripped from the web, the doffer needs to undergo roller surface cleaning and static electricity elimination treatment.

3. The manufacturing process of the double-layer ES composite fiber smooth and fluffy hot air nonwoven fabric according to claim 1, characterized in that, In step S2, the speed at which the fine denier ES composite fiber layer is stripped from the web is 80~110m / min.

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