Ultrathin high-strength wool blended needled felt as well as preparation method and application thereof

Abstract

The invention provides ultrathin high-strength wool blended needled felt as well as a preparation method and application thereof, and relates to the technical field of textiles. The preparation method of the ultrathin high-strength wool blended needled felt comprises the steps of wool mixing, slivering, weaving, first-time floating wool shearing, wool washing, first-time shaping, needling, second-time shaping, second-time floating wool shearing, wool decating and the like. The invention effectively solves the problems of strength defect and surface quality caused by insufficient fiber cohesion and stress concentration in the traditional wool blended needled felt preparation process, and solves the industrial problem that the traditional felt is difficult to be compatible with'ultrathin 'and'high strength' through collaborative optimization of the multi-section shaping process and the needling density. On the premise of keeping the ultrathin characteristic of the felt, the comprehensive performance of the wool blended needled felt is remarkably improved, and the wool blended needled felt has a good application prospect.

Description

Technical Field

[0001] The present invention relates to the field of textile technology, and particularly to an ultra-thin high-strength wool blended needled felt and its preparation method and application. Background Art

[0002] A wool blended needled felt is a felt product processed by needling technology after mixing wool with other fibers (such as chemical fibers, polypropylene, polyester, etc.). This blending method can combine the natural properties of wool and the performance advantages of other fibers to improve the comprehensive performance of the felt.

[0003] In the traditional preparation process of wool blended needled felt, single-time trimming of floating hairs and shaping processes are usually adopted. However, these process methods have many deficiencies. First of all, the single-time shaping process often fails to ensure the flatness of the fabric, resulting in a rough surface of the fabric, affecting the appearance and service performance of the final product. Secondly, the treatment of floating hairs is not thorough, causing residues on the fabric surface, affecting the effect of subsequent processes, and increasing the rework rate of the product. Finally, the cooperation between the needling process and the shaping process is poor, resulting in uneven fabric density and unstable strength, making it difficult to meet the requirements for ultra-thin and tough textiles.

[0004] The invention patent with the publication number of CN 113633059 A discloses a production process of a wool felt hat, which relates to the production technology of clothing and accessories, aiming to solve the problem that through processes such as gluing and pressing evenly, edge opening and forming, edge pulling and shaping, mold shaping, trimming, tape cutting, and sand pressing and shaping, the top hat is relatively thick in its thickness direction, feels too thin when touched, and lacks a fluffy and comfortable hand feeling. The key points of its technical solution are as follows: including the following steps. Step one, sending wool and antistatic fibers into a cotton mixing box for mixing to obtain a first mixed fiber mass. Step two, sending the first mixed fiber mass into a carding machine for fluffing treatment. Step three, sending the first mixed fiber mass into a first needling machine for felting treatment to obtain an inner layer. Step four, sending wool into the cotton mixing box for mixing to obtain a second mixed fiber mass. This method can make the hat maintain a relatively fluffy state, have a good hand feeling, and is relatively...

[0005] The invention patent with the publication number CN 118065057 A discloses a felt fabric based on needle punching technology and its preparation method. The method includes the following steps: laying yarns on a base cloth, and laying a layer of water-soluble non-woven fabric on the yarns; needling the laid materials by the direct needling method, and sequentially washing, drying, and ironing and shaping the needled fabric to obtain a felt fabric based on needle punching technology; the base cloth is a water-soluble non-woven fabric, and the yarns are woolen woven yarns or semi-worsted woolen woven yarns. This method uses a water-soluble non-woven fabric as the base cloth. After needling is completed, the water-soluble non-woven fabric melts after washing, which not only meets the requirement of laying materials on the base cloth for the needled felt fabric, but also avoids the influence of traditional base cloth on the thickness, softness, and fluffiness of the felt fabric; the main materials are woolen or semi-worsted woolen woven yarns, and the materials are easy to obtain; the produced felt fabric has less floating hair, and after needling into felt by the direct needling method, the surface anti-pilling and fuzzing property is enhanced compared with the yarn itself.

[0006] Thus, at present, there are also some improved patents for needle punching processes or setting temperature control, but most of them focus on thick felt materials and lack a multi-stage collaborative optimization scheme. Therefore, it is necessary to develop a multi-stage collaborative optimization process for thin wool blended needled felt, in order to improve its physical strength and dimensional stability while maintaining the thinness requirement of the wool blended needled felt, so as to meet the production needs of high-performance textiles. Summary of the Invention

[0007] In view of this, the present invention provides an ultra-thin and high-strength wool blended needled felt, its preparation method and application. The present invention integrates multi-stage setting and multiple shearing processes, which can not only ensure that the fabric has sufficient strength in the ultra-thin state, but also significantly improve the problems of floating hair residue and surface flatness, so as to obtain a wool blended needled felt with excellent performance.

[0008] The first aspect of the present invention is to provide a preparation method of an ultra-thin and high-strength wool blended needled felt, including the following steps:

[0009] S1. Wool mixing: Opening and mixing wool and other fiber raw materials according to a preset mass ratio, and adding emulsifying oil by spraying to obtain a mixed fiber raw material;

[0010] S2. Sliver making: Combing and sliver making the mixed fiber raw material to obtain a combed sliver;

[0011] S3. Weaving: Using an electronic jacquard circular knitting machine (Hongjun PUZZ MT18C) with a reverse blowing cleaning system to weave a grey cloth with the combed sliver as the raw material.

[0012] S4. First floating hair shearing: Using a round knife to cut off the floating hair in a tensioned state, and the cut broken hair is sucked into a negative pressure suction hood;

[0013] S5. Scouring: Wash the greige cloth after shearing off the floating hairs with water to remove oil stains, floating dust and further eliminate the internal stress of the fibers;

[0014] S6. First setting: Perform the first setting on the greige cloth through a stenter;

[0015] S7. Needling: Needle the greige cloth after the first setting with barbed needles;

[0016] S8. Second setting: Perform the second setting on the greige cloth through a stenter to further stabilize the width and shape of the greige cloth;

[0017] S9. Second shearing of floating hairs: Cut off the floating hairs with a circular knife under tension to completely remove the residual floating hairs on the surface, and the cut fragments of hairs are sucked into the negative pressure air suction hood;

[0018] S10. Decating: Achieve the final setting through drying and cooling in a high-pressure machine to obtain an ultra-thin and high-strength wool blended needled felt.

[0019] Preferably, the other fiber raw material is polyamide fiber, and the mass ratio of the wool to the other fiber raw material is 7:3; the dosage of the emulsifying oil is 1.5 wt.% - 3.5 wt.% of the total amount of fibers, the spray particle size of the emulsifying oil is 50 - 80 μm, and the spray pressure is 0.15 - 0.25 MPa.

[0020] Preferably, the negative pressure for the first shearing of floating hairs is 150 - 250 Pa, and the rotational speed of the circular knife is 800 - 1200 rpm.

[0021] Preferably, the water temperature of the washing water is 30°C - 40°C, and the washing time is 15 - 20 min.

[0022] Preferably, the temperature for the first setting is 110°C - 120°C, and the pressure is 0.3 - 0.5 MPa.

[0023] Preferably, the needling density is 80 - 120 needles / cm 2 ;

[0024] Preferably, the temperature for the second setting is 130°C - 135°C, and the pressure is 0.4 - 0.6 MPa.

[0025] Preferably, the negative pressure for the second shearing of floating hairs is 150 - 250 Pa, 200 Pa, and the rotational speed of the circular knife is 800 - 1500 rpm, 1000 - 1300 rpm. More preferably, when the thickness of the greige cloth ≤ 0.3 mm, the negative pressure for the second shearing of floating hairs of the felt is 200 Pa, and the rotational speed of the circular knife is 1000 - 1300 rpm.

[0026] Preferably, the decatizing temperature is 110°C - 130°C, the decatizing pressure is 0.3 - 0.5 MPa, and the setting time is 90 - 120 s.

[0027] The second aspect of the present invention is to provide an ultra-thin high-strength wool blended needle-punched felt prepared according to the above method, and the thickness of the ultra-thin high-strength wool blended needle-punched felt is 0.5 - 0.9 mm.

[0028] The third aspect of the present invention is to provide an application of the ultra-thin high-strength wool blended needle-punched felt in the fields of clothing and fashion fabrics, industrial fabrics, medical and health products, handicrafts, home decoration, functional liners, etc.

[0029] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0030] The present invention adopts a two-stage treatment of low-temperature pre-setting first and then high-temperature finishing, combined with the regulation of the needle punching density, to promote the full entanglement of fibers and gradually release the internal stress, so that the tensile strength is significantly improved compared with the traditional process.

[0031] Through the optimization design of the tear strength, the present invention inserts needle punching processing during the secondary setting process, strengthens the three-dimensional holding structure of the fibers, and makes the warp / weft tear forces reach 45 N / 38 N respectively, which is significantly improved compared with the traditional process.

[0032] The stress balance effect of the segmented setting of the present invention makes the dimensional change rate of the product after washing stable at <1.8%, and avoids the problems of shrinkage or warping.

[0033] Through the synergistic effect of the secondary round knife shearing process and decatizing setting, the present invention reduces the floating hair residue rate to less than 6%, and optimizes the surface roughness Ra value to <2.3 μm.

[0034] The present invention effectively solves the strength defects and surface quality problems caused by insufficient fiber holding and stress concentration in the traditional process. Through the synergistic optimization of the multi-stage setting process and the needle punching density, the present invention solves the industry problem that it is difficult to be compatible between "ultra-thin" and "high-strength" in traditional felts. On the premise of maintaining the ultra-thin characteristics of the felt, the comprehensive performance of the wool blended needle-punched felt is significantly improved, and it has good application prospects. Description of the Drawings

[0035] The following further describes the present invention with reference to the drawings.

[0037] Figure 1 It is a physical diagram of the ultra-thin high-strength wool blended needle-punched felt in Example 1;

[0038] Figure 2 It is a physical diagram of the ultra-thin high-strength wool blended needle-punched felt in Example 2;

[0039] Figure 3 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Example 3;

[0040] Figure 4 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Comparative Example 1;

[0041] Figure 5 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Comparative Example 3;

[0042] Figure 6 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Scheme ① of Comparative Example 3;

[0043] Figure 7 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Scheme ② of Comparative Example 3;

[0044] Figure 8 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Scheme ③ of Comparative Example 3;

[0045] Figure 9 Figure for the physical object of the ultra-thin high-strength wool blended needled felt in Comparative Example 4. Detailed implementation method

[0046] The first aspect of the present invention is to provide a preparation method for an ultra-thin high-strength wool blended needled felt, including the following steps:

[0047] S1. Wool blending: Opening and mixing wool with other fiber raw materials according to a preset mass ratio, and adding emulsifying oil in a spray manner to enhance the fiber cohesion and reduce static electricity, obtaining a mixed fiber raw material;

[0048] In some specific embodiments of the present invention, in step S1, the other fiber raw material is polyamide fiber, and the mass ratio of the wool to the other fiber raw material is 7:3; the dosage of the emulsifying oil is 1.5wt.% - 3.5wt.% of the total fiber amount, preferably 2.5wt.%, the spray particle size of the emulsifying oil is 50 - 80μm, preferably 60 - 70μm, and the spray pressure is 0.15 - 0.25MPa, preferably 0.2MPa.

[0049] Research shows that when the spray particle size of the emulsified oil is in the range of 50 - 80 μm, the flight path of the particles in the air and the contact area with the fibers are relatively balanced. If the spray particle size is too large, larger oil droplets will be produced, which not only wastes the oil agent but also easily forms "oil lumps" or "agglomerations" locally on the fibers. If the spray particle size is too small, it is prone to diffuse or evaporate in the air and cannot effectively wet the fiber surface. When the spray pressure of the emulsified oil is 0.15 - 0.25 MPa, the oil droplets can have sufficient kinetic energy to penetrate the fiber layer and achieve a three-dimensional distribution, and it will not cause the atomized particles to fly and disperse and be difficult to deposit due to excessive pressure. If the spray pressure is too low, the oil mist is easily bonded near the nozzle and cannot form a uniform coverage. If the spray pressure is too high, the oil mist will disperse too far or cause impact damage on the fiber surface. Therefore, the present invention strictly limits the spray particle size and spray pressure of the emulsified oil.

[0050] S2. Sliver making: The mixed fiber raw materials are carded into worsted sliver.

[0051] S3. Weaving: Using an electronic jacquard circular knitting machine (Hongjun PUZZ MT18C) with a reverse blowing cleaning system, the worsted sliver is used as the raw material to weave the grey cloth.

[0052] The present invention adopts a jacquard large circular knitting machine with a reverse blowing system, and at the same time combines the changes in the upper triangle and the surrounding needle triangle structures in the weaving organization to achieve high-density weaving of wool blended fibers.

[0053] S4. First floating hair cutting: Use a circular knife to cut the floating hair under tension, and the cut broken hair is sucked into the negative pressure suction hood;

[0054] In some specific embodiments of the present invention, the negative pressure for the first floating hair cutting is 150 - 250 Pa, and the rotational speed of the circular knife is 800 - 1200 rpm.

[0055] S5. Scouring: Wash the grey cloth after floating hair cutting with water to remove oil stains, floating dust and further eliminate the internal stress of the fibers;

[0056] In some specific embodiments of the present invention, the water temperature of the cleaning water is 30°C - 40°C, and the cleaning time is 15 - 20 min.

[0057] S6. First setting: The grey cloth is first set through a stenter;

[0058] In some specific embodiments of the present invention, the temperature for the first setting is 110°C - 120°C, and the pressure is 0.3 - 0.5 MPa.

[0059] S7. Needle punching: The grey cloth after the first setting is needle punched with barbed needles, and the needle punching density is 80 - 120 needles / cm 2 ;

[0060] The present invention ensures thinning of the felt while obtaining enhanced fiber entanglement strength by limiting the needling density. The needling depth should be appropriately adjusted according to the weight of the fabric, but should generally be kept within the range of 3-7 mm.

[0061] The essence of the needle punching process is to "interweave" the originally two-dimensionally spread fibers into a three-dimensional structure. Research shows that in the technical solution of the present invention, if the needle is too deep (>7mm), the fabric will be significantly thickened and lose its "ultra-thin" characteristics. When the needle stroke is too large, the damage to the fiber will be aggravated, and the finished product will easily have irregular holes or surface snagging. If the needle is too shallow (<3mm), it can only stir the surface of the fiber, and the internal fiber layer will remain loose, making it difficult to form effective reinforcement, resulting in low overall tensile strength or tear strength of the fiber. When the needle depth is within the range of 3-7mm, the movement distance can cover the key parts of the fabric (especially the surface and middle layers), driving the surface fibers to migrate inward and entangle with the middle and bottom fibers, achieving high-strength fiber entanglement, making the fibers entangled and increasing strength, while not penetrating too deep to cause the fabric to thicken or "burrs" to be exposed, thereby achieving a balance between fiber entanglement and fabric thickness control.

[0062] S8, Second shaping: The grey fabric is shaped for the second time through the stenter setting machine to further stabilize the width and shape of the grey fabric;

[0063] In some specific embodiments of the present invention, the second setting temperature is 130° C.-135° C., and the pressure is 0.4-0.6 MPa.

[0064] In this invention, the first setting temperature is set 15°C-25°C lower than the second setting temperature to optimize the setting effect. The first setting serves as a pre-setting and curing process, while the second setting serves as a final setting and curing process. Pre-setting and curing allow the fabric to partially stabilize its shape, allowing needle punching to enhance the needle punching effect while maintaining appropriate flexibility. Final setting and curing then complete the final setting of the fabric's dimensions and structure, ensuring a balanced balance of strength, flatness, and elasticity.

[0065] Wool blended fabrics contain natural protein fibers and synthetic fibers. If the temperature is raised to a high temperature for shaping at one time, local fiber embrittlement, scale damage or thermal fusion will easily occur, causing the fiber scales or thermoplastic components to be destroyed prematurely. The two-stage shaping process of the present invention allows the fiber to gradually adapt to deformation during the pre-shaping process. In the first stage (lower temperature), some stress in the fiber is first removed to make the fiber flat and pre-"fixed in width". At this stage, the fiber still retains a certain plasticity, which is convenient for subsequent needling or reheating without sudden deformation. Finally, "locking" is completed at the second high temperature, taking into account both softness and stability.

[0066] S9. Second trimming of floating hairs: Use a round knife to trim the floating hairs under tension to completely remove the residual floating hairs on the surface. The cut hairs are sucked into the negative pressure air suction hood.

[0067] In some specific embodiments of the present invention, the negative pressure for the second trimming of floating hairs is 150 - 250 Pa, preferably 200 Pa, and the rotational speed of the round knife is 800 - 1500 rpm, preferably 1000 - 1300 rpm; when the thickness of the base fabric ≤ 0.3 mm, the negative pressure for the second trimming of floating hairs by the felt is 200 Pa, and the rotational speed of the round knife is 1000 - 1300 rpm.

[0068] The present invention ensures the shearing efficiency and the flatness of the fabric surface by limiting the rotational speed of the round knife and the negative pressure intensity in the process of trimming floating hairs. Experiments show that when the rotational speed of the round knife is 1000 - 1300 rpm, the instantaneous linear velocity can quickly cut off the slightly protruding floating hairs on the surface, and will not drive the overall vibration or wire drawing of the fabric due to too high knife speed. The cutting efficiency of the round knife is high and the floating hairs will not be lifted by the knife and adhered again. At the same time, a negative pressure of 200 Pa is sufficient to form an effective air flow to timely suck the cut hair debris into the dust collection system, avoid the broken hairs from falling back onto the fabric surface again, and reduce the secondary pollution on the fabric surface. However, if the rotational speed of the round knife (> 1300 rpm) or the negative pressure intensity (> 200 Pa) is further increased, it will damage the main body of the fiber, pull the fabric fibers away from the surface, causing damage or local shrinkage, resulting in defects such as weft skew and thinning of the fabric. Further reducing the rotational speed of the round knife (< 1000 rpm) or the negative pressure intensity (< 200 Pa) will cause some floating hairs to fly and remain on the fabric surface or accumulate near the knife head, unable to completely remove the floating hairs, affecting the shearing accuracy, resulting in a decrease in the flatness of the fabric surface and causing secondary pollution on the fabric surface, a significant reduction in production efficiency, and an increase in the rework rate.

[0069] S10. Decating: Achieve the final shaping through baking and cooling in a high-pressure machine to obtain an ultra-thin and high-strength wool blended needle-punched felt.

[0070] In some specific embodiments of the present invention, the decating temperature is 110°C - 130°C, the decating pressure is 0.3 - 0.5 MPa, and the shaping time is 90 - 120 s.

[0071] The second aspect of the present invention is to provide an ultra-thin and high-strength wool blended needle-punched felt prepared according to the above method.

[0072] The third aspect of the present invention is to provide an application of the ultra-thin and high-strength wool blended needle-punched felt in the fields of clothing and fashion fabrics, industrial fabrics, medical and health products, handicrafts, home decoration, functional linings, etc.

[0073] For example, in the field of clothing and fashion fabrics, the ultra-thin and high-strength wool blended needled felt of the present invention can be used to make high-grade suits, jackets, hat ornaments, etc. that are light, strong, and wrinkle-resistant; in the field of industrial fabrics, the ultra-thin and high-strength wool blended needled felt of the present invention can be used in scenarios that require high toughness and tear resistance, such as filter fabrics, composite lining fabrics, etc.; in medical and health supplies, the ultra-thin and high-strength wool blended needled felt of the present invention can be used to prepare dressings, nursing fabrics, etc. that are light, soft, have good strength, and good adsorption properties for materials.

[0074] Although the preparation process of the present invention increases the complexity of steps compared with the traditional process (such as two shaping processes and two shearing processes), the reason for the significant improvement in its economic benefits lies in multi-dimensional optimization and benefit balance. The products of the present invention have significantly increased unit prices and improved finished product rates, and significantly reduced rework rates due to the ultra-thin and high-strength characteristics. Therefore, compared with the traditional process, a significant increase in profit is achieved.

[0075] Due to the reduction of waste materials, the production cost of the present invention has been reduced from the original about 1000 yuan / m 2 to about 850 yuan / m 2 or so. In terms of energy consumption, the existing technology is 500 kW·h, while the improved process of the present invention has been reduced to 420 kW·h, which benefits from the optimization of the spraying and negative pressure processes. In addition, the fiber utilization rate of the present invention has been increased from about 85% to about 95%, which is achieved through precise spraying. In terms of economic benefits, the return on investment (ROI) of the existing technology is 1.5 years, while the ROI of the improved process of the present invention has been increased to 2.0 years, indicating that the technical solution of the present invention can improve the investment benefits.

[0076] To further illustrate the present invention, the following will be described in detail through the following examples. The composition of the emulsified oil raw materials used in the following examples and comparative examples of the present invention is as follows:

[0077] Trimethylolpropane trioleate (TMPTO) 50 wt.%, Tween 80 10 wt.%, and the balance is water;

[0078] The method for preparing the emulsified oil is as follows: Mix and stir TMPTO and Tween 80 at 80°C for 30 minutes, slowly add water, and stir for 1 hour until a uniform emulsion is formed to obtain the emulsified oil.

[0079] All raw materials involved are commercially available.

[0080] Unless otherwise specified, all tests are repeated 3 times, and the results are expressed as averages.

[0081] Example 1 A preparation process for an ultra-thin and high-strength wool blended needled felt, the steps are as follows:

[0082] S1. Mix wool and nylon fibers in a mass ratio of 7:3. In the wool blending process, spray 1.0wt.%, 1.5wt.%, 2.0wt.%, 3.0wt.%, and 4.0wt.% of emulsified oil based on the total amount of fibers into the fibers respectively through a spraying device. The spraying particle size is 60μm, and the spraying pressure is 0.2MPa.

[0083] S2. Use a carding and roving machine to process the opened raw materials into uniform worsted roving.

[0084] S3. Weave into grey cloth with a knitting density of 60 needles / cm through an electronic jacquard circular knitting machine with a reverse air blowing cleaning system.

[0085] S4. Conduct the first trimming of floating hairs under the conditions of a tension of 0.8N / cm 2 , a negative pressure value of 200Pa, and a circular knife speed of 1000rpm.

[0086] S5. Wash the fabric for 15 minutes at a water temperature of 32°C to remove floating dust and floating hair debris.

[0087] S6. Conduct the first setting through a stenter at a temperature of 115°C and a pressure of 0.4MPa.

[0088] S7. Use a barbed needle and conduct needling treatment on the grey cloth after the first setting under the condition of a needling density of 90 needles / cm 2 .

[0089] S8. Conduct the second stenter setting through a stenter at a temperature of 130°C and a pressure of 0.5MPa.

[0090] S9. Conduct the second trimming of floating hairs under the conditions of a tension of 0.8N / cm 2 , a negative pressure value of 200Pa, and a circular knife speed of 1000rpm.

[0091] S10. Steam the fabric for 90s at 120°C and 0.4MPa in a high-pressure machine, and cool and set it to obtain an ultra-thin high-strength wool blended needle felt.

[0092] Example 2

[0093] The difference from Example 1 is that the needling density is 120 needles / cm 2 , the emulsified oil spraying particle size is 80μm; the first setting temperature is 120°C, and the second setting temperature is 135°C; the circular knife speeds in the first and second trimming of floating hairs processes are both 1200rpm, and the negative pressure intensities are both 250Pa.

[0094] Example 3

[0095] The difference from Example 1 is that the needling density is 80 needles / cm2 The emulsified oil spray particle size is 50 μm; the first setting temperature is 110 °C, and the second setting temperature is 130 °C; in the first and second floating hair trimming processes, the round knife rotation speed is 800 rpm and the negative pressure intensity is 150 Pa.

[0096] Comparative Example 1

[0097] The difference from Example 1 is that: a single floating hair trimming and a single setting process are adopted, where the single setting temperature is 130 °C, the setting time is 10 min, the round knife rotation speed in the single floating hair trimming process is 700 rpm, and the negative pressure intensity is 80 Pa; there is no needling; the emulsified oil spray particle size is not strictly controlled, and the average particle size > 100.

[0098] Comparative Example 2

[0099] The difference from Example 1 is that: a single setting and a single floating hair trimming process are adopted, where the single setting temperature is 130 °C, the setting time is 10 min, the round knife rotation speed in the single floating hair trimming process is 700 rpm, and the negative pressure intensity is 80 Pa.

[0100] Comparative Example 3

[0101] The difference from Example 1 is that:

[0102] ① The needling density is 50 needles / cm 2 ;

[0103] ② The needling density is 150 needles / cm 2 ;

[0104] ③ There is no needling.

[0105] Comparative Example 4

[0106] The difference from Example 1 is that: a single setting process is adopted, where the single setting temperature is 130 °C and the setting time is 10 min.

[0107] The performances of the felts in Examples 1 - 3 and Comparative Examples 1 - 4 were tested and the handfeel / appearance of the felts was evaluated. The results are shown in Table 1.

[0108] Among them, the method of the water washing is as follows:

[0109] Place the felt sample in a programmable industrial drum washing machine, add deionized water with a bath ratio of 20:1, and add a non-ionic surfactant with a concentration of 0.8 g / L as a washing aid. Set the washing temperature to 40°C ± 2°C and gently agitate at a low speed of 30 rpm for 25 min to thoroughly remove the residual processing oil, dust impurities, and unfixed fibers on and inside the fiber surface. After the main washing is completed, drain the washing liquid completely, and then use deionized water with the same bath ratio to rinse at the same temperature for 10 min each time. Repeat this rinsing three times to ensure complete removal of detergent residues and suspended impurities until the rinsing drainage is clear. Finally, dehydrate the washed felt at 800 rpm for 5 min, then take it out and lay it flat on a drying net or place it in an oven set at 65°C ± 5°C to dry completely to a constant weight.

[0110] Table 1 Detection of felt properties and comprehensive evaluation results of handfeel / appearance

[0111]

[0112]

[0113] As can be seen from Table 1, the felt in Example 1 has high strength and flatness, with extremely few floating hairs on the surface, high dimensional stability after washing. The macro diagram shows obvious piercing and interlocking points between fibers, the overall structure is tighter and more uniform, the edge is more stable, and the felt has a more crisp feeling; the strength of the felt in Example 2 is further improved, but the fabric is slightly thickened, which is suitable for higher load or engineering fabrics; the felt in Example 3 can ensure basic strength and flatness, and the tensile / tear strength is slightly lower than that in Example 1 and Example 2, but it is still far better than the traditional process, with good dimensional stability, and is suitable for production scenarios with low energy consumption and slightly lower strength requirements but still requiring thinness and good appearance products.

[0114] The warp / weft strength of the felt in Comparative Example 1 is significantly low and it is easy to deform after washing; the residual floating hairs on the surface are as high as 17.5%, and the surface roughness Ra value reaches 3.4 μm, which is not suitable for high-end clothing and special fabric scenarios.

[0115] The surface of the sample in Comparative Example 2 is uneven, with obvious wrinkles, warping or uneven thickness, the handfeel is hard and lacks softness, and it looks rough overall, and floating hairs are visible (there is slight hair residue). The sample in Comparative Example 2 has obvious surface defects, local concavities and convexities or edge curling, and the stability of the sample is poor.

[0116] In Comparative Example 3, when there is no needling, if the web laying is uniform and the thickness is close to the target thickness, as the needling density increases, the fiber layer is compacted and the thickness tends to decrease. The compaction effect is more obvious at 150 needles / cm 2 When there is no needling, the dimensional stability is the worst and the water washing deformation rate is high. At 50 needles / cm 2Slightly improved. 150 needles / cm 2 Due to the tighter fiber binding, the dimensional stability is the best. In terms of tear strength, the weft direction is usually more sensitive to needling and the improvement is more obvious. The surface may look relatively smooth (because of two shearing and two setting processes), and the floating hair control may be acceptable due to the shearing process. However, upon close observation or at a specific angle, it will be found that the fiber arrangement lacks a tight interlocking feeling, and the fibers look more like being laid flat or stacked, rather than three-dimensionally intertwined. Edge state: Since the fibers are not effectively fixed by needling, even after setting, the edges of the felt are more likely to have fiber slippage or looseness when slightly pulled or rubbed. Overall structure: The felt as a whole appears loose, lacking a skeletal feeling and stiffness. When touched and pressed by hand, the resilience is poor, and it is easy to leave indentations or deformations. When gently stretched, relative sliding is likely to occur between the fibers, and the structure is unstable.

[0117] The sample of Comparative Example 4 has problems of shrinkage and warping of the edges, poor surface flatness, obvious residual floating hair, hard and uneven hand feeling, unstable thickness appearance, and local deformation.

[0118] The color and pattern of the finished wool felt do not affect the test results of the indicators in Table 1.

[0119] Comparative Example 5

[0120] The differences from Example 1 are as follows: The amounts of emulsified oil are 1.0 wt.%, 2.0 wt.%, 3.0 wt.%, and 4.0 wt.% of the total amount of fibers respectively, and the softness of the products is scored. The results are shown in Table 2.

[0121] Table 2 Results of product softness scoring

[0122]

[0123] The above-described embodiments only represent several implementation manners of the present invention, and the description thereof is relatively specific and detailed, but it should not be construed as a limitation on the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention patent shall be subject to the appended claims.

Claims

1. A preparation method of an ultra-thin and high-strength wool blended needled felt, characterized in that It includes the following steps: S1. Blending wool: Opening and blending wool with other fiber raw materials according to a preset mass ratio, and adding emulsified oil by spraying to obtain a mixed fiber raw material; The spray particle size of the emulsified oil is 50 - 80 μm, and the spray pressure is 0.15 - 0.25 MPa; S2. Making sliver; S3. Weaving; S4. First trimming of floating hair: Using a circular knife to trim the floating hair under a tension state, and the cut broken hair is sucked into a negative pressure suction hood; S5. Scouring; S6. First setting: Conducting the first setting at a temperature of 110°C - 120°C and a pressure of 0.3 - 0.5 MPa; S7. Needling: The greige fabric after the first shaping is needled with barbed needles, and the needling density is 80 - 120 needles / cm 2 ; S8. Second setting: Conducting the second setting at a temperature of 130°C - 135°C and a pressure of 0.4 - 0.6 MPa; S9. Second trimming of floating hair: Using a circular knife to trim the floating hair under a tension state, and the cut broken hair is sucked into a negative pressure suction hood; S10. Decating: High-pressure decating and cooling to obtain an ultra-thin high-strength wool blended needled felt.

2. The preparation method according to claim 1, characterized in that, The other fiber raw material is polyamide fiber.

3. The preparation method according to claim 1, characterized in that, The mass ratio of the wool to the other fiber raw material is 7:

3.

4. The preparation method according to claim 1, characterized in that, The dosage of the emulsified oil is 1.5 wt.% - 3.5 wt.% of the total amount of fibers. The spray particle size of the emulsified oil is 60 - 70 μm, and the spray pressure is 0.2 MPa.

5. The preparation method according to claim 1, characterized in that The negative pressure for the first trimming of floating hair is 150 - 250 Pa, and the rotational speed of the circular knife is 800 - 1200 rpm.

6. The preparation method according to claim 1, wherein The water temperature for cleaning is 30°C - 40°C, and the cleaning time is 15 - 20 min.

7. The preparation method according to claim 1, characterized in that, The negative pressure for the second trimming of floating hair is 150 - 250 Pa, and the rotational speed of the circular knife is 800 - 1500 rpm.

8. The preparation method according to claim 1, wherein The decating temperature is 110°C - 130°C, the decating pressure is 0.3 - 0.5 MPa, and the setting time is 90 - 120 s.

9. An ultra-thin and high-strength wool blended needled felt, characterized in that, Prepared by the method according to any one of claims 1 - 8, the thickness of the ultra-thin high-strength wool blended needled felt is 0.5 - 0.9 mm.

10. Application of an ultra-thin high-strength wool blended needle-punched felt in clothing and fashion fabrics, industrial fabrics, medical and health products, handicrafts, home decoration, and functional liners, characterized in that, The ultra-thin high-strength wool blended needled felt is prepared by the method according to any one of claims 1 - 8.

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