Apparatus for manufacturing a flushable nonwoven fabric

Abstract

The embodiment of the present application provides a kind of dispersible nonwoven fabric manufacturing equipment, for manufacturing dispersible nonwoven fabric, including forming unit, forming unit includes headbox and forming wire, forming wire includes forming section, headbox includes lip plate, lip plate includes first upper lip plate and second upper lip plate, forming section includes the first forming section corresponding with first upper lip plate and the second forming section corresponding with second upper lip plate, second upper lip plate is arranged in parallel with second forming section, first upper lip plate and first forming section between including first forming area, second upper lip plate and second forming section between including second forming area, second upper lip plate further includes the microporous plate towards second forming area and the upper cavity located above microporous plate, microporous plate includes a plurality of micro-holes that are communicated with upper cavity and second forming area, and upper cavity is in positive pressure state, by above-mentioned setting, the dehydration capacity of forming end can be improved, and then reduce the slurry on wet fiber web form fish scale, improve and stabilize product quality.

Description

Technical Field

[0001] This invention relates to a device for manufacturing washable nonwoven fabric. Background Technology

[0002] In recent years, with the rapid economic development, people's pursuit of quality of life has gradually increased. Non-woven products (such as face masks, face towels, makeup remover wipes, wet toilet paper, etc.) have become an important part of daily life. As a commonly used material for non-woven products on the market, non-woven fabric has the advantages of wide availability of raw materials and soft and fluffy feel. With the increasing awareness of environmental protection, non-woven fabric is developing towards green and environmentally friendly directions, and washable non-woven fabric materials have emerged.

[0003] Typically, washable nonwoven fabrics are manufactured using equipment such as those shown in CN117604802A and CN117988149A. Specifically, this equipment usually includes a slanted wire forming machine, a hydroentangling reinforcement device, and a drying device. In practice, it has been found that when using this forming machine, a full-width fish-scale pattern can occur under certain conditions. These specific conditions include a machine speed of ≥130m / min, a basis weight of ≥75gsm, a thickness of ≥0.62mm, and a shaker chamber disintegration test result of ≥95%. Currently, there is no good solution.

[0004] Therefore, an improved technical solution is needed to solve the above-mentioned technical problems. Summary of the Invention

[0005] To address these issues, the present invention provides a washable nonwoven fabric manufacturing apparatus.

[0006] A washable nonwoven fabric manufacturing apparatus is provided for manufacturing washable nonwoven fabric. The washable nonwoven fabric manufacturing apparatus includes a forming unit, the forming unit includes a headbox and a forming net, the forming net includes a forming section, the headbox includes a lip plate, the lip plate includes a first upper lip plate and a second upper lip plate arranged sequentially along the slurry flow direction, the forming section includes a first forming section corresponding to the first upper lip plate and a second forming section corresponding to the second upper lip plate, the first upper lip plate is inclined to the first forming section, the second upper lip plate is arranged parallel to the second forming section, a first forming area is included between the first upper lip plate and the first forming section, a second forming area is included between the second upper lip plate and the second forming section, the second upper lip plate also includes a microporous plate facing the second forming area and an upper cavity located above the microporous plate, the microporous plate includes a plurality of micro-through holes connecting the upper cavity and the second forming area, and the upper cavity is under positive pressure.

[0007] The diameter of the micro-hole is 1-2 mm.

[0008] The distribution density of the micropores on the surface of the microporous plate is 1 to 4 per cm².

[0009] The pressure inside the upper cavity is 1–3 kPa.

[0010] The second upper lip plate is pivotally connected to the first upper lip plate and is configured to be adjustable to remain parallel to the second forming section.

[0011] The forming unit further includes an immersion and adsorption device, which includes an immersion device and an adsorption device. The immersion device includes an immersion tank filled with clean water. The immersion device is configured to immerse a portion of the forming net in the immersion tank. The adsorption device includes a suction box located downstream of the immersion device.

[0012] The shaped net submerged in the immersion tank is referred to as the first net segment. The immersion device includes an adjusting roller, and the first net segment is wrapped around the adjusting roller. The adjusting roller is configured to be adjustable so that the first net segment is submerged in clean water or detached from clean water.

[0013] The immersion device includes a swing roller, and the forming net includes a second net segment wrapped around the swing roller. The swing roller is linked with the adjusting roller, and the second net segment moves synchronously when the first net segment moves.

[0014] The forming unit further includes multiple spraying components, each including a first spray pipe and a second spray pipe. The immersion adsorption device is disposed between the first and second spray pipes. The forming unit includes a breast roller. The forming net includes a third net segment located between the breast roller and the first forming section. The second spray pipe is configured to spray cleaning water onto the third net segment.

[0015] The nonwoven fabric has a basis weight of 75g / m2 or more, a thickness of 0.60mm or more, and a dispersion rate of 95% or more.

[0016] Beneficial Effects: This invention provides a washable nonwoven fabric manufacturing device for manufacturing washable nonwoven fabric. The washable nonwoven fabric manufacturing device includes a forming unit, which includes a headbox and a forming net. The forming net includes a forming section. The headbox includes a lip plate. The lip plate includes a first upper lip plate and a second upper lip plate arranged sequentially along the slurry flow direction. The forming section includes a first forming section corresponding to the first upper lip plate and a second forming section corresponding to the second upper lip plate. The first upper lip plate is inclined to the first forming section, and the second upper lip plate is arranged parallel to the second forming section. A first forming area is included between the first upper lip plate and the first forming section, and a second forming area is included between the second upper lip plate and the second forming section. The second upper lip plate also includes a microporous plate facing the second forming area and an upper cavity located above the microporous plate. The microporous plate includes a plurality of micro-through holes connecting the upper cavity and the second forming area, and the upper cavity is under positive pressure. Through the above arrangement, the dewatering capacity at the forming end can be improved, thereby reducing the formation of fish scale patterns on the wet fiber web and improving and stabilizing product quality. Attached Figure Description

[0017] Figure 1 A schematic diagram of a washable nonwoven fabric manufacturing device according to an embodiment of the present invention; Figure 2 for Figure 1 Enlarged diagram of area A; Figure 3 for Figure 1 Actual design drawing of the headbox; Figure 4 for Figure 2 Enlarged diagram of area B in the middle; Figure 5 for Figure 2 A schematic diagram of the surface morphology of the microporous plate.

[0018] Component descriptions in the diagram: Headbox 10; First upper lip plate 11; First adjusting device 110; Second upper lip plate 12; Second adjusting device 120; Micro-perforated plate 121; Micro-through hole 122; Upper cavity 123; Forming mesh 20; First forming section 21; Second forming section 22; First mesh section 23; Second mesh section 24; Third mesh section 25; Breast roller 31; Adjusting roller 32; Swing roller 33; Immersion tank 41; Suction box 42; First spray pipe 43; Second spray pipe 44; First negative pressure dewatering box 51; Second negative pressure dewatering box 52. Detailed Implementation

[0019] Please refer to Figure 1 This invention provides a washable nonwoven fabric manufacturing apparatus, used to manufacture washable nonwoven fabrics, and more specifically, more suitable for manufacturing fabrics with a density of 30-80 g / m³. 2A washable nonwoven fabric with a basis weight of 0.35mm or more and a dispersion rate of ≥90% in a shaker test, especially capable of being manufactured at speeds of ≥140m / min with a density of 75g / m². 2 The above-mentioned basis weight, thickness of 0.60mm or more, and the ability to achieve a dispersion rate of ≥95% in a shaker box decomposition test are all washable nonwoven fabrics.

[0020] The washable nonwoven fabric manufacturing equipment includes a forming unit for forming a wet fiber web from a slurry, which is then hydroentangled and dried to form a washable nonwoven fabric.

[0021] The forming unit includes a headbox 10 and a forming net 20. The forming net 20 is constructed as an endless ring and is supported and moved by a plurality of rollers. Among the rollers is a breast roller 31 located upstream of the headbox 10. A portion of the forming net 20 downstream of the breast roller 31 is configured to be inclined upward relative to the horizontal direction. This inclined upward section is called the forming section. The headbox 10 applies slurry from above to the forming section, and the slurry is dehydrated and formed into a wet fiber web.

[0022] The headbox 10 includes a lip plate located on the upper side of the forming section. In this embodiment, the lip plate includes a first upper lip plate 11 and a second upper lip plate 12 arranged sequentially along the slurry flow direction. The forming section includes a first forming section 21 corresponding to the first upper lip plate 11 and a second forming section 22 corresponding to the second upper lip plate 12. A first forming area is formed between the first upper lip plate 11 and the first forming section 21, and a second forming area is formed between the second upper lip plate 12 and the second forming section 22. It can be understood that the headbox 10 also includes a flow area upstream of the first forming area. The slurry flows from the flow area to the first forming area and the second forming area, and is dehydrated in the first forming section 21 and the second forming section 22 to form a wet fiber web.

[0023] The first upper lip plate 11 is inclined to the first forming section 21, and the distance between the first upper lip plate 11 and the first forming section 21 gradually decreases from the upstream direction to the downstream direction. Meanwhile, the second upper lip plate 12 is arranged parallel to the second forming section 22. The second upper lip plate 12 also includes a microporous plate 121 facing the second forming area and an upper cavity 123 located above the microporous plate 121. The microporous plate 121 includes a plurality of micro-through holes 122 connecting the upper cavity 123 and the second forming area, and the upper cavity 123 is in a positive pressure state.

[0024] Understandably, a first negative pressure dewatering tank 51 is provided below the forming section. The slurry is quickly dewatered and formed into a wet fiber web by the water flow in the headbox 10 and the first negative pressure dewatering tank 51.

[0025] Furthermore, the upper cavity 123 should be under a slightly positive pressure state. More specifically, the slightly positive pressure means that the pressure inside the upper cavity 123 is 1 to 3 kPa.

[0026] The applicant's research found that when preparing high-basis-weight, high-thickness, high-dispersion, and high-speed products, if rapid dehydration cannot be achieved at the end of the forming zone, a small amount of slurry still flows on the upper side of the wet fiber web after it flows out from the lip. This portion of slurry, after further dehydration, forms a full-width fish-scale pattern on the wet fiber web. In traditional solutions, the dehydration capacity of this area can be improved by increasing the flow rate of the first negative pressure dehydration tank 51, i.e., increasing the vacuum degree of the first negative pressure dehydration tank 51. However, this approach still has the following two problems: First, due to the requirements of high basis weight and high thickness, increasing the vacuum degree in the lower layer significantly increases the overall airflow, which will reduce the thickness of the wet fiber web, or make it impossible to simultaneously meet the basis weight and thickness requirements, increasing the difficulty of controlling basis weight and thickness. Second, due to the obstruction of the upper lip plate, when located at... When the airflow is increased in the lower layer of the lip region, an inward and downward airflow is likely to appear at the lip, causing damage or holes on the surface of the wet fiber web when it exits the lip. When a second upper lip plate 12 parallel to the second forming section 22 is set behind the first upper lip plate 11, and a slight positive pressure is applied to the second upper lip plate 12, firstly, when the slurry is in the second forming zone, its dewatering capacity is improved, preventing the slurry from accumulating on the wet fiber web after exiting the lip. Secondly, the slight positive pressure on the upper side will increase the efficiency of the first negative pressure dewatering box 51 located on the lower side. Furthermore, since the second upper lip plate 12 is set parallel to the second forming section 22, the airflow in this area will move perpendicular to the wet fiber web, further improving the dewatering efficiency. Thirdly, this arrangement can prevent the formation of an airflow inward at the lip, reducing surface damage.

[0027] Furthermore, the aperture of the micro-hole 122 is 1-2 mm. In practice, it has been found that when the aperture of the micro-hole 122 is too small, air bubbles are likely to appear at the interface between the micro-hole plate 121 and the slurry, resulting in defects on the surface of the wet fiber web. When the aperture of the micro-hole 122 is too large, the micro-hole 122 itself will hinder the flow of the slurry or the movement of the wet fiber web or further cause surface damage. In a specific embodiment, the aperture of the micro-hole 122 is approximately 1.6 mm.

[0028] Furthermore, the distribution density of the micro-holes 122 on the surface of the microporous plate 121 is 1 to 4 per cm².

[0029] Furthermore, the first upper lip plate 11 is adjustable. In this embodiment, the first upper lip plate 11 includes a first adjustment device 110 to adjust the tilt angle of the first upper lip plate 11 to adapt to the forming of different products.

[0030] Furthermore, the second upper lip plate 12 is pivotally connected to the first upper lip plate 11 and is configured to be adjustable to remain parallel to the second forming section 22, so that when the tilt angle of the first upper lip plate 11 changes, the second upper lip plate 12 can remain parallel to the second forming section 22.

[0031] Furthermore, the second upper lip plate 12 includes a second adjustment device 120 to adjust the angle of the second upper lip plate 12.

[0032] Furthermore, the microplate 121 has a length of 100–400 mm.

[0033] Furthermore, a second negative pressure dehydration tank 52 is provided downstream of the second forming section 22 to further dehydrate the wet fiber web. In one specific embodiment, the vacuum degree of the second negative pressure dehydration tank 52 is less than that of the first negative pressure dehydration tank 51.

[0034] Further research revealed that when preparing products with high basis weight, high thickness, and high dispersion, a higher proportion of wood pulp fiber is required. For example, when the proportion of wood pulp fiber reaches 85% or more, the existing spray washing device still causes wood pulp fiber to adhere to the forming net 20. In this case, the dehydration capacity of the forming net 20 in the forming section is insufficient. In this embodiment, the forming unit also includes an immersion adsorption device to remove the wood pulp fiber adhering to the forming net 20. The immersion adsorption device includes an immersion device and an adsorption device.

[0035] The immersion device includes a washing tank 41 filled with clean water. The immersion device is configured to immerse a portion of the formed mesh 20 in the washing tank 41 and wet the formed mesh 20 with clean water. For ease of description, the formed mesh 20 immersed in the washing tank 41 is referred to as the first mesh segment 23. The adsorption device includes a suction box 42 located downstream of the immersion device. The suction box 42 is used to adsorb the first mesh segment 23 after it has been wetted. It can be understood that when wetted with clean water, the wood pulp fibers attached to the formed mesh 20 are transferred to the washing tank 41 or combined with clean water under the action of hydrogen bonds. When passing through the suction box 42, they are detached from the formed mesh 20 along with the clean water. The clean water refers to water that does not contain fibers.

[0036] Furthermore, the adsorption device also includes a blower box (not shown) disposed opposite to the suction box 42. The blower box is used to blow out airflow, which, in conjunction with the suction box 42, separates the wood pulp fibers and water from the forming net 20.

[0037] Furthermore, the immersion device includes an adjusting roller 32, and the first web segment 23 is wrapped around the adjusting roller 32. The adjusting roller 32 is configured to be adjustable so that the first web segment 23 is immersed in clean water or detached from clean water. In the study, it was found that when producing washable nonwoven fabrics with a low basis weight, such as below 50 g / m², it is not necessary to impregnate the first web segment 23, and the corresponding technical indicators can still be met.

[0038] Furthermore, the immersion device includes a swing roller 33, and the forming net 20 includes a second net segment 24 wrapped around the swing roller 33. The swing roller 33 is linked with the adjusting roller 32 so that when the first net segment 23 moves, the second net segment 24 moves synchronously, and the forming net 20 maintains stable tension.

[0039] Furthermore, the forming unit also includes multiple spraying components, each including a first spray pipe 43 and a second spray pipe 44. The immersion adsorption device is disposed between the first spray pipe 43 and the second spray pipe 44. Both the first spray pipe 43 and the second spray pipe 44 are configured to spray cleaning water onto the forming net 20 to clean it. The cleaning water can be clean water or white water. The white water is water that has been recycled after fiber removal during the production of washable nonwoven fabric.

[0040] Furthermore, the forming net 20 includes a third net segment 25 located between the breast roller 31 and the first forming section 21, and the second spray pipe 44 is configured to spray cleaning water onto the third net segment 25, preferably, the second spray pipe 44 sprays clean water.

[0041] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A washable nonwoven fabric manufacturing apparatus, used to manufacture washable nonwoven fabric, characterized in that, The washable nonwoven fabric manufacturing equipment includes a forming unit, which includes a headbox and a forming net. The forming net is constructed as an endless loop and is supported and moved by a plurality of idler rollers. Among the idler rollers is a breast roller located upstream of the headbox. A portion of the forming net downstream of the breast roller is configured to be inclined upward relative to the horizontal direction; this inclined upward section is called the forming section. A first negative pressure dewatering box is provided below the forming section. The headbox includes a lip plate, which includes a first upper lip plate and a second upper lip plate arranged sequentially along the slurry flow direction. The forming section includes... A first upper lip plate corresponds to a first forming section and a second upper lip plate corresponds to a second forming section. The first upper lip plate is inclined to the first forming section, and the second upper lip plate is arranged parallel to the second forming section. A first forming area is included between the first upper lip plate and the first forming section, and a second forming area is included between the second upper lip plate and the second forming section. The second upper lip plate also includes a microporous plate facing the second forming area and an upper cavity located above the microporous plate. The microporous plate includes a plurality of micro-through holes connecting the upper cavity and the second forming area, and the upper cavity is under positive pressure. The diameter of the micro-through holes is 1-2 mm.

2. The washable nonwoven fabric manufacturing equipment as described in claim 1, characterized in that, The distribution density of the micropores on the surface of the microporous plate is 1 to 4 per cm. 2 .

3. The washable nonwoven fabric manufacturing equipment as described in claim 1, characterized in that, The pressure inside the upper cavity is 1–3 kPa.

4. The washable nonwoven fabric manufacturing equipment as described in claim 3, characterized in that, The second upper lip plate is pivotally connected to the first upper lip plate and is configured to be adjustable to remain parallel to the second forming section.

5. The washable nonwoven fabric manufacturing equipment as described in claim 1, characterized in that, The forming unit further includes an immersion and adsorption device, which includes an immersion device and an adsorption device. The immersion device includes an immersion tank filled with clean water. The immersion device is configured to immerse a portion of the forming net in the immersion tank. The adsorption device includes a suction box located downstream of the immersion device.

6. The washable nonwoven fabric manufacturing equipment as described in claim 5, characterized in that, The shaped net submerged in the rinsing tank is referred to as the first net segment. The immersion device includes an adjusting roller, and the first net segment is wrapped around the adjusting roller. The adjusting roller is configured to be adjustable so that the first net segment is submerged in clean water or detached from clean water.

7. The washable nonwoven fabric manufacturing equipment as described in claim 6, characterized in that, The immersion device includes a swing roller, and the forming net includes a second net segment wrapped around the swing roller. The swing roller is linked with the adjusting roller, and the second net segment moves synchronously when the first net segment moves.

8. The washable nonwoven fabric manufacturing equipment as described in claim 7, characterized in that, The forming unit further includes multiple spraying components, each including a first spray pipe and a second spray pipe. The immersion adsorption device is disposed between the first and second spray pipes. The forming unit includes a breast roller. The forming net includes a third net segment located between the breast roller and the first forming section. The second spray pipe is configured to spray cleaning water onto the third net segment.

9. The washable nonwoven fabric manufacturing equipment as described in claim 1, characterized in that, The nonwoven fabric has a density of 75 g / m². 2 The above are the basis weight, thickness of 0.60 mm or more, and dispersion rate of 95% or more.

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