Non-woven material as well as preparation method and application thereof

Abstract

The invention discloses a non-woven material which comprises low-melting-point fibers and crimped fibers, and the low-melting-point fibers account for 10-18% of the mass of the non-woven material; the crimped fibers account for 10-90% of the mass of the non-woven material. According to the non-woven material, a small number of low-melting-point fibers are adopted, cohesive force of high-crimp fibers is utilized, and the mode of needling and hot air reinforcement is applied, so that the material can obtain a good draw ratio in the transverse and longitudinal directions.

Description

Technical Field

[0001] The invention relates to the technical field of nonwoven materials, and in particular to a nonwoven material suitable for soft filling of clothing, home textiles and the like, application of the nonwoven material in filling materials and a preparation method of the nonwoven material. Background Art

[0002] At present, there are two types of non-woven materials used for soft filling in clothing, home textiles, etc., namely, glue-sprayed cotton and glue-free cotton. Both processes have a flat-laid layered structure. Glue-sprayed cotton is short fibers with no or a little low-melting-point components added to the fibers, and the structural stability of the material is achieved mainly by spraying glue before entering the oven. Glue-free cotton is a fiber ratio with more than 20% low-melting-point short fibers added to achieve structural stability, but the materials formed by these two processes are basically inelastic in the horizontal and vertical directions, or the stretch ratio is very small.

[0003] The disclosure of the above background technology content is only used to assist in understanding the inventive concept and technical solution of the present invention. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above content has been disclosed before the filing date of this patent application, the above background technology should not be used to evaluate the novelty and creativity of the present application. Summary of the invention

[0004] In view of this, in order to overcome the defects of the prior art, the object of the present invention is to provide an improved nonwoven material having an excellent transverse and longitudinal stretch ratio.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A nonwoven material comprises low-melting point fibers and curled fibers, wherein the low-melting point fibers account for 10-18% of the mass of the nonwoven material; and the curled fibers account for 10-90% of the mass of the nonwoven material.

[0007] According to some preferred implementation aspects of the present invention, the number of crimps of the crimped fiber is 10 to 20 / 25 mm.

[0008] According to some preferred implementation aspects of the present invention, the low-melting-point fiber has a fineness of 2 to 6D and a length of 38 to 64 mm.

[0009] According to some preferred implementation aspects of the present invention, the low-melting-point fiber has a fineness of 2 to 4D and a length of 38 to 51 mm.

[0010] According to some preferred implementation aspects of the present invention, the curled fiber has a fineness of 1 to 15D and a length of 38 to 101 mm.

[0011] According to some preferred implementation aspects of the present invention, the curled fiber has a fineness of 2 to 7D and a length of 64 to 88 mm.

[0012] According to some preferred implementation aspects of the present invention, the crimped fiber is a PTT / PET three-dimensional composite fiber with a high crimp number, and / or a PBT / PET three-dimensional composite fiber with a high crimp number.

[0013] According to some preferred implementation aspects of the present invention, the polyester fiber is included, and the polyester fiber accounts for 0-80% of the mass of the nonwoven material, preferably 20-80%.

[0014] According to some preferred implementation aspects of the present invention, the polyester fiber has a fineness of 0.5 to 15D and a length of 38 to 101 mm.

[0015] According to some preferred implementation aspects of the present invention, the polyester fiber has a fineness of 1 to 7D and a length of 38 to 64 mm.

[0016] According to some preferred implementation aspects of the present invention, the polyester fiber is PET fiber.

[0017] The nonwoven material of the present invention has a soft feel, 160g / m 2 The maximum stretch ratio of the material can reach 60%, of which the transverse stretch ratio can reach 4.5%-35%, and the longitudinal stretch ratio can reach 8-60%. The traditional spray-bonded sponge and glue-free sponge only have a transverse and longitudinal stretch ratio of 2-4%. Traditional materials pay more attention to the elasticity and recovery force in the filling thickness direction.

[0018] The present invention also provides a use of the non-woven material as described above in soft filling materials such as clothing and home textiles.

[0019] The present invention also provides a preparation method of the non-woven material as described above, which mainly comprises the following steps: batching - mixing - combing into a web - laying and stacking - needling to solidify - high temperature shaping in an oven - ironing - rolling and slitting, and specifically comprises the following steps: the fiber raw materials are batched according to the formula requirements; a mixer is used to mix and send the materials to a large bin; the large bin is opened and the materials are discharged to a vibrating cotton bin; a cotton web is combed out by a carding machine; the cotton web is laid and stacked by a web laying machine; the stacked cotton web is reinforced by needling with a needle punching machine; hot air is used to reshape in an oven; and the non-woven material is obtained by slitting and rolling.

[0020] Due to the adoption of the above technical scheme, compared with the prior art, the advantages of the present invention are: the non-woven material of the present invention adopts a small amount of low-melting-point fibers, utilizes the additional cohesive force formed by the high curl number of high-curl fibers, and applies needle punching and hot air reinforcement, so that the material can obtain a good stretch ratio in the transverse and longitudinal directions. DETAILED DESCRIPTION

[0021] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0022] The preparation method of the non-woven material in the following embodiment includes the following steps: the fiber raw materials are mixed according to the formula requirements; a mixer is used to mix the materials and send them to a large bin; the large bin is opened to loosen and discharge the materials to a vibrating cotton bin; a cotton web is combed out by a carding machine; the cotton web is laid and stacked by a web laying machine; the stacked cotton web is reinforced by a needle punching machine; hot air is used to reshape the fibers in an oven; and the non-woven material is obtained after slitting and rolling.

[0023] Example 1 (Ordinary two-dimensional PET fiber, PTT / PET composite fiber and low melting point fiber)

[0024] The fiber ratio (mass fraction) of the non-woven material in this embodiment is: 10% 2D*51 low-melting point fiber, 30% 3D*64 two-dimensional PET fiber, 60% 3D*88PTT / PET composite fiber, and the curl number of the composite fiber is 18 / 25mm.

[0025] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0026] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0027] Example 2 (Three-dimensional hollow PET fiber, PTT / PET composite fiber and low melting point fiber)

[0028] The fiber ratio (mass fraction) of the non-woven material in this embodiment is: 10% 2D*51 low melting point fiber, 30% 3D*64 three-dimensional hollow PET fiber, 60% 3D*88PTT / PET composite fiber, and the curl number of the composite fiber is 18 / 25mm.

[0029] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0030] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0031] Example 3 (Three-dimensional hollow PET fiber, PBT / PET composite fiber and low melting point fiber)

[0032] The fiber ratio (mass fraction) of the non-woven material in this embodiment is: 10% 2D*51 low melting point fiber, 30% 3D*64 three-dimensional hollow PET fiber, 60% 3D*64PBT / PET composite fiber, and the curl number of the composite fiber is 18 / 25mm.

[0033] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0034] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0035] Example 4 (Three-dimensional hollow PET fiber, PTT / PET composite fiber and low melting point fiber)

[0036] The fiber ratio (mass fraction) of the non-woven material in this embodiment is: 10% 2D*51 low melting point fiber, 70% 3D*64 three-dimensional hollow PET fiber, 20% 3D*64PBT / PET composite fiber, and the curl number of the composite fiber is 14 / 25mm.

[0037] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0038] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0039] Example 5 (Three-dimensional hollow PET fiber, PTT / PET composite fiber and low melting point fiber)

[0040] The fiber ratio (mass fraction) of the non-woven material in this embodiment is: 10% 2D*51 low-melting point fiber, 80% 3D*64 three-dimensional hollow PET fiber, and 10% 3D*64 PBT / PET composite fiber, and the curl number of the composite fiber is 18 / 25mm.

[0041] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0042] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0043] Example 6 (PTT / PET composite fiber and low melting point fiber)

[0044] In this embodiment, the fiber ratio (mass fraction) of the non-woven material is: 10% of 2D*51 low melting point fiber and 90% of 3D*88PTT / PET composite fiber, and the crimp number of the composite fiber is 18 / 25mm.

[0045] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0046] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0047] Example 7 (Three-dimensional hollow PET fiber, PTT / PET composite fiber and low melting point fiber)

[0048] The fiber ratio (mass fraction) of the nonwoven material in this embodiment is: 18% of 2D*51 low melting point fiber, 20% of 3D*64 three-dimensional hollow PET fiber, and 62% of 3D*72PTT / PET composite fiber with a curl number of 18 / 25mm.

[0049] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0050] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0051] Comparative Example 1 (PET fiber and low melting point fiber)

[0052] The fiber ratio (mass fraction ratio) of the non-woven material in this embodiment is: 10% of 2D*51 low melting point fiber and 90% of three-dimensional hollow PET fiber.

[0053] The needling and oven parameters involved in the preparation process are: one pre-needling at 200 r / min, two needling at 400 r / min, oven at 160°C, and mesh belt speed of 5 m / min.

[0054] The cotton-like specifications of the prepared nonwoven material are: 160g / m 2 .

[0055] Comparative Example 2

[0056] The difference between this comparative example and Example 6 is that the crimp number of the composite fiber in this comparative example is 25 / 25mm. The other steps and parameters are basically the same as those in Example 6. With such a high crimp number, the fiber production is extremely difficult, and the fiber defect ratio is significantly increased, and the fiber production stability is poor. At the same time, the combing difficulty is increased during production, and it is very easy to wrap around the working roller, which increases the difficulty of production.

[0057] Comparative Example 3

[0058] The difference between this comparative example and Example 6 is that the number of crimps of the composite fiber in this comparative example is 5 / 25 mm. The other steps and parameters are basically the same as those in Example 6.

[0059] Comparative Example 4

[0060] The difference between this comparative example and Example 6 is that the fiber ratio (mass fraction ratio) of the nonwoven material in this example is: 5% of 2D*51 low melting point fiber, 95% of 3D*88PTT / PET composite fiber, and the crimp number of the composite fiber is 18 / 25mm. The other steps and parameters are basically the same as those in Example 6.

[0061] Comparative Example 5

[0062] The difference between this comparative example and Example 6 is that the fiber ratio (mass fraction ratio) of the nonwoven material in this example is: 25% of 2D*51 low melting point fiber, 75% of 3D*88PTT / PET composite fiber, and the crimp number of the composite fiber is 18 / 25mm. The other steps and parameters are basically the same as those in Example 6.

[0063] Tests and Results

[0064] The nonwoven materials prepared in the above examples and comparative examples were tested for transverse and longitudinal stretch ratios. The test method is: 10 cm*20 cm samples were taken in the transverse direction (sampling perpendicular to the longitudinal edge) and longitudinal direction (sampling perpendicular to the width) within 10 cm from the edge of the material.

[0065] Test items:

[0066] 1) Stretch ratio: Fix one end of the material with a width of more than 10 cm with a clip, and measure the length of the material L0. Then use a clip with a width of more than 10 cm to clamp the other end of 10 cm, and hang an object weighing 500 g (including the weight of the clip) on the clip. After the material is stretched and still, measure the total length of the material L1. Stretch ratio = (L1-L0) / L0*100%.

[0067] 2) Softness of hand feel: Three or more experienced personnel will compare the hand feel of several cotton samples, with the hardest being 1. If the hand feel is basically the same, the scores can be tied. Finally, the scores of each cotton sample given by the three people will be added up and divided by 3 to take the average.

[0068] After washing index test:

[0069] Material preparation: Use the same 60g 300T calendered polyester woven fabric on the top and bottom of the cotton sample to quilt into a quilting grid size of 7cm*7cm, take a 50cm*50cm sample, and fix it with stitches around. Use the same drum washing machine and the same washing method (normal temperature, dehydration speed 800r / min) to wash 10 times. Hang to dry.

[0070] Thickness loss rate after washing: Spread the dried material flat on the table and use a homemade ruler to measure the thickness before and after washing. Thickness loss rate after washing = (thickness before washing - thickness after washing) / thickness before washing.

[0071] Deformation of cotton sample after washing: After washing and drying the material, remove the quilting line and observe the cotton sample for looseness, kinks, holes and other problems. Compare with the cotton sample state before washing, and take the state before washing as the standard to rate it from 0 to 5. 0 is the initial state (i.e. the state before washing), and 5 is the worst state.

[0072] The results are shown in Table 1 below:

[0073] Table 1 Parameters and results

[0074]

[0075] The results in Table 1 show that the stretching ratio and hand softness of the embodiment are better than those of the comparative example. Under the same fiber ratio, the hand softness of the PTT / PET composite fiber is relatively the best. The higher the low melting point ratio, the greater the impact on the stretching ratio. The smaller the composite fiber ratio, the greater the impact on the stretching ratio.

[0076] In addition, by comparing Example 6 with Comparative Examples 2 and 3, it can be seen that when the number of crimps exceeds 20 / 25mm (Comparative Example 2), the combing difficulty increases, and the higher the ratio, the easier it is to wind the cotton, the greater the process difficulty, and the greater the impact on production; but at the same time, when the number of crimps is less than 10 / 25mm (Comparative Example 3), the additional bonding function brought by the crimps is poor. Therefore, the high crimp fiber is preferably used with a crimp number of 10 to 20 / 25mm.

[0077] At the same time, by comparing Example 6 with Comparative Examples 4 and 5, it can be seen that when the proportion of low-melting-point fiber exceeds 18%, the stretching advantage in the transverse and longitudinal directions is significantly reduced. When it is less than 10%, the cotton sample is too loose, and the cotton sample is easy to clump and break after quilting and washing. Therefore, the proportion of low-melting-point fiber is preferably 10-18%.

[0078] The nonwoven material of the present invention adopts a reinforcement process combining the needle punch reinforcement method and the hot air method in the nonwoven process. On the one hand, the needle punch method is used to make the fibers entangled and entangled to form a certain consolidation force; on the other hand, a small proportion of low melting point fibers are appropriately added to melt and bond through the hot air method to increase a certain stability. However, a certain stretching elasticity in the horizontal and vertical directions can be maintained; through the application of high curled fibers, the stretching elasticity of the material in the horizontal and vertical directions is further increased.

[0079] The nonwoven material of the present invention uses a small amount of low-melting-point fibers, utilizes the cohesive force of high-curl fibers, and uses needle punching and hot air reinforcement to obtain a good stretch ratio in the transverse and longitudinal directions. For products that require such application performance, good product performance can be obtained, so that the nonwoven material can not only meet the washing, dry cleaning and other use requirements of the finished product, but also meet the requirements that the nonwoven material has a large elasticity or a large stretch ratio in the transverse and longitudinal directions, and has a soft hand feel, thereby improving the drape and fit of the material. For example, when used in cotton clothes, better stretch comfort can be obtained.

[0080] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A nonwoven material, characterized in that: The nonwoven material comprises low-melting point fibers and curled fibers, wherein the low-melting point fibers account for 10-18% of the mass of the nonwoven material; and the curled fibers account for 10-90% of the mass of the nonwoven material.

2. The nonwoven material according to claim 1, characterized in that The number of crimps of the crimped fiber is 10 to 20 per 25 mm.

3. The nonwoven material according to claim 1, characterized in that The low melting point fiber has a fineness of 2 to 6D and a length of 38 to 64 mm.

4. The nonwoven material according to claim 1, characterized in that The low melting point fiber has a fineness of 2-4D and a length of 38-51 mm.

5. The nonwoven material according to claim 1, characterized in that The fineness of the curled fiber is 1 to 15D, and the length is 38 to 101 mm.

6. The nonwoven material according to claim 1, characterized in that The fineness of the crimped fiber is 2-7D, and the length is 64-88mm.

7. The nonwoven material according to claim 1, characterized in that The curled fiber is a PTT / PET composite fiber; and / or the curled fiber is a PBT / PET composite fiber.

8. The nonwoven material according to claim 1, characterized in that The nonwoven material comprises polyester fibers, wherein the polyester fibers account for 0 to 80% of the mass of the nonwoven material.

9. The nonwoven material according to claim 1, characterized in that The polyester fiber has a fineness of 0.5 to 15D and a length of 38 to 101 mm.

10. The nonwoven material according to claim 1, characterized in that The polyester fiber has a fineness of 1 to 7D and a length of 38 to 64 mm.

11. The nonwoven material according to claim 1, characterized in that The polyester fiber is PET fiber.

12. Use of the nonwoven material according to any one of claims 1 to 11 in filling materials.

13. A method for preparing the non-woven material as claimed in any one of claims 1 to 11, comprising the following steps: mixing the raw materials with a mixer and sending them to a large bin; loosening and discharging the materials from the large bin to a vibrating cotton bin; combing out a cotton web with a carding machine; laying the cotton web in layers with a web laying machine; reinforcing the layered cotton web with a needle punching machine; reshaping with hot air in an oven; and obtaining the non-woven material after slitting and rolling.

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