Preparation process and application of high-liquid-absorption spunlace non-woven mask base cloth material

Abstract

The invention relates to the technical field of preparation of non-woven materials, in particular to a preparation process of a high-liquid-absorption spunlace non-woven mask base cloth material, which comprises the following steps: S1, selecting high-liquid-absorption viscose as a main raw material, and mixing with functional fibers; s2, blending the high-liquid-absorption viscose fibers and the functional fibers in proportion, carding the blended fibers into a single fiber state through a carding process, and performing cross lapping to form a fiber web; s3, a unique fiber distribution structure is formed through a multi-stage spunlace technology, and meanwhile ultrasonic vibration is applied in the spunlace process; and S4, carrying out hydrophilic treatment on the spunlaced base cloth. By adding hydrophilic nano-particles into a viscose spinning solution and adopting a dry-wet spinning process, the high-liquid-absorption viscose fiber with a multi-leaf-shaped structure is prepared, the specific surface area is increased, meanwhile, the liquid absorption capacity of the mask base cloth is further improved, essence can be fully absorbed and carried, and the requirement of consumers for the skin care effect of the mask is met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of non-woven material preparation, in particular to a preparation process of high-liquid-absorption spunlace non-woven mask base cloth material and application thereof. BACKGROUND

[0002] With the improvement of people's living standards, the quality requirements for mask products are increasing. Spunlace non-woven mask base cloth material has become a commonly used material for mask base cloth due to its softness, breathability, skin-friendliness and other advantages. However, the existing spunlace non-woven mask base cloth material still has some problems. On the one hand, the liquid absorption of traditional mask base cloth material is limited, which cannot fully absorb and carry enough essence liquid, resulting in insufficient essence liquid during use of the mask, and it is difficult to achieve good skin care effect. On the other hand, in the preparation process of mask base cloth, the uniformity of the fiber web is difficult to guarantee, and defects such as uneven thickness, impurities or holes are prone to occur, which not only affects the appearance quality of the mask base cloth, but also leads to differences in liquid absorption, liquid retention and mechanical properties of the mask base cloth, reducing the use experience and stability of the product. At the same time, the existing mask base cloth fiber distribution structure is relatively single, which is difficult to achieve a good balance in liquid absorption, liquid retention, essence liquid release and mechanical properties, and cannot fully exert the performance advantages of the mask base cloth. In order to solve the above problems, it is urgent to develop a preparation process and related products that can improve the liquid absorption of mask base cloth, improve the uniformity of the material and obtain better product performance. SUMMARY

[0003] In view of the deficiencies of the prior art, the present application provides a preparation process of high-liquid-absorption spunlace non-woven mask base cloth material and application thereof, which improves the liquid absorption of mask base cloth, improves the uniformity of the material, obtains mask base cloth material with better comprehensive performance, and expands its application in mask products by using high-liquid-absorption viscose fiber as raw material, online detection feedback of carding and laying and unique fiber distribution structure regulation technology.

[0004] To achieve the above purpose, the present application realizes the following technical scheme: a preparation process of high-liquid-absorption spunlace non-woven mask base cloth material, comprising the following steps: S1. Raw material preparation High-liquid-absorption viscose fiber is selected as the main raw material, and 10%-30% of functional fiber is mixed, the functional fiber including but not limited to antibacterial fiber, moisturizing fiber or elastic fiber; S2. Carding and laying The high liquid-absorbing viscose fiber and the functional fiber are blended in a ratio of (50-90):(10-50), the blended fiber is carded into a single fiber state through a carding process, and is cross-laid to form a fiber web, and an online detection feedback system is used to monitor the uniformity of the fiber web in real time, with a detection frequency of ≥10 times / s; S3. Hydroentanglement reinforcement A unique fiber distribution structure is formed through a multi-stage hydroentanglement process, and ultrasonic vibration is applied during the hydroentanglement process, with a frequency of 20-40 kHz and a power density of 0.5-1.5 W / cm 2 ; S4. Post-processing The base fabric after hydroentanglement is subjected to hydrophilic treatment, so that the contact angle of the base fabric is ≤30°.

[0005] Preferably, the high liquid-absorbing viscose fiber in the S1 step is prepared by the following method: 3%-8% of hydrophilic nanoparticles are added to the viscose spinning solution, and the hydrophilic nanoparticles are silicon dioxide or aluminum oxide; A dry-wet spinning process is used, and the spinning speed is 300-500 m / min.

[0006] Preferably, the high liquid-absorbing viscose fiber in the S1 step has a multi-lobed structure in cross-section, with 5-8 lobes, and a specific surface area of ≥1.5 m 2 / g.

[0007] Preferably, the multi-stage hydroentanglement process in the S3 step includes: Primary hydroentanglement: water pressure of 20-40 bar, forming a preliminary entanglement structure; Intermediate hydroentanglement: water pressure of 60-80 bar, forming a gradient density distribution; Surface layer hydroentanglement: water pressure of 40-60 bar, combined with a hydroentanglement head with a diameter of 0.1-0.3 mm, forming a microporous structure.

[0008] Preferably, the online detection feedback system includes: At least two uniformly distributed laser thickness sensors for detecting the thickness of the fiber web; A data processing unit connected to the sensor, configured to compare the real-time detection data with a preset threshold value; An automatic adjustment device for adjusting the parameters of the carding machine or the laying machine according to the feedback signal of the data processing unit, the automatic adjustment device including a variable frequency controller for adjusting the speed of the carding machine cylinder and a servo motor for adjusting the curtain speed ratio of the laying machine; An image recognition module for detecting knot or hole defects in the fiber web.

[0009] Preferably, the fiber distribution structure in the S3 step comprises: The surface layer of the mask base cloth forms a microporous structure with an average diameter of 5-10 μm; The internal layer of the mask base cloth forms a gradient density distribution, the surface layer density is 0.1-0.2 g / cm 3 , the middle layer density is 0.05-0.1 g / cm 3 .

[0010] Preferably, the grammage of the mask base cloth material is 30-80 g / m 2 , the thickness is 0.2-0.5 mm; the liquid retention rate of the mask base cloth material is ≥80%, the transverse breaking strength is ≥15 N / 5 cm, and the longitudinal breaking strength is ≥20 N / 5 cm.

[0011] The present application provides a preparation process of a high-liquid-absorption spunlace non-woven mask base cloth material and its application. It has the following beneficial effects: The present application selects high-liquid-absorption viscose fiber as the main raw material, adds hydrophilic nanoparticles in the viscose spinning solution, and adopts dry-wet spinning process to prepare high-liquid-absorption viscose fiber. The multi-leaf structure of the high-liquid-absorption viscose fiber increases the specific surface area, further improves the liquid absorption capacity of the mask base cloth, can fully absorb and carry the essence liquid, and meets the needs of consumers for the skin care effect of the mask.

[0012] The present application uses an online detection feedback system to monitor the uniformity of the fiber web in real time. The laser thickness sensor and the image recognition module can quickly and accurately detect the thickness, nodal heterogeneity and hole defects of the fiber web. The data processing unit and the automatic adjusting device can timely adjust the parameters of the carding machine and the laying machine according to the detection results, which can effectively ensure the uniformity of the fiber web, reduce the quality difference of the product, and improve the yield of the product.

[0013] The present application forms a unique fiber distribution structure through a multi-stage spunlace process combined with ultrasonic vibration. The microporous structure of the surface layer of the mask base cloth is beneficial to the rapid absorption and release of the essence liquid. The gradient density distribution in the internal layer realizes the synergistic effect of liquid locking in the surface layer and liquid storage in the middle layer, improves the liquid retention rate and mechanical properties of the mask base cloth, and makes the mask base cloth not easy to break during use, while better playing the skin care effect of the essence liquid. DETAILED DESCRIPTION

[0014] To make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor belong to the scope of protection of the present application. EMBODIMENT

[0015] The embodiment of the present application provides a preparation process of a high-liquid-absorption spunlace nonwoven mask base cloth material, which comprises the following steps: S1 raw material preparation: adding 5% of silica hydrophilic nanoparticles in total mass in viscose spinning solution, and preparing high-liquid-absorption viscose fibers by adopting dry-wet spinning process (spinning speed is 400 m / min). In the preparation process, the concentration of the viscose spinning solution is controlled to be 12%-15%, and the temperature is kept at 30-35 DEG C, so that the nanoparticles can be uniformly dispersed in the spinning solution. It can be known by transmission electron microscope observation that the average particle size of the silica nanoparticles is about 50-80 nm, and the silica nanoparticles are in monodispersed state in the spinning solution. The cross section of the prepared high-liquid-absorption viscose fiber is 6-leaf structure, and the specific surface area of the high-liquid-absorption viscose fiber is 1.6 m 2 / g measured by using a specific surface area analyzer; and mixing the high-liquid-absorption viscose fiber and 20% of chitosan antibacterial fiber at a ratio of 70:30.

[0016] S2 carding and laying: sending the mixed fibers into a blending equipment, controlling the roller speed ratio to be 1.2:1 in the blending process, so that the two kinds of fibers are fully mixed and uniform. The fibers are carded into single fiber state by a carding machine, the tin speed of the carding machine is set to be 300 r / min, the doffer speed is 280 r / min, and the carding gauge is 0.25 mm. Then cross-laying is carried out, the curtain speed ratio of the laying machine is set to be 1.5:1, and the fiber web is formed. An online detection feedback system is used to monitor the uniformity of the fiber web in real time. The system comprises two uniformly distributed laser thickness sensors, and the installation interval is 50 cm, and the sensors are respectively located at 1 / 4 and 3 / 4 of the width direction of the fiber web. The data processing unit compares the real-time detection data with the preset threshold value, and the preset fiber web thickness tolerance range is ±0.05 mm. The automatic adjusting device adjusts the tin speed of the carding machine through the frequency converter controller according to the feedback signal, and also adjusts the curtain speed ratio of the laying machine through the servo motor, and the image recognition module adopts an industrial camera to detect the defects such as knots and holes in the fiber web, and the detection frequency is 12 times / s. When the local thickness of the fiber web exceeds the tolerance range, the automatic adjusting device can respond within 0.3 seconds to adjust the tin speed of the carding machine or the curtain speed ratio of the laying machine, so that the thickness of the fiber web returns to normal.

[0017] S3 Hydroentanglement: A multi-stage hydroentanglement process is performed, and a three-roller hydroentanglement machine is used. The primary hydroentanglement pressure is 30 bar, the hydroentanglement head is 15 mm from the fiber web surface, forming a preliminary entanglement structure; the intermediate hydroentanglement pressure is 70 bar, the hydroentanglement head is 12 mm from the fiber web surface, forming a gradient density distribution; the surface hydroentanglement pressure is 50 bar, combined with a hydroentanglement head with a diameter of 0.2 mm, the hydroentanglement head is 10 mm from the fiber web surface, forming a microporous structure. Ultrasonic vibration is applied during the hydroentanglement process, with a frequency of 30 kHz and a power density of 1 W / cm 2 . The ultrasonic vibration is achieved through an ultrasonic transducer installed on the hydroentanglement machine rack, with a distribution density of 4 per square meter of hydroentanglement area. It is found through scanning electron microscopy that after ultrasonic vibration assisted hydroentanglement, the entanglement between fibers is more compact, and the microporous structure is more uniformly distributed.

[0018] S4 Post-processing: The hydroentangled base fabric is subjected to hydrophilic treatment, and the dip padding method is used. The base fabric is immersed in a solution containing 3% mass fraction of cationic hydrophilic finishing agent, the pick-up rate is controlled at 80%, and the pH value of the finishing agent solution is adjusted to 6-7. After padding, the base fabric is dried at 120°C for 3 minutes, so that the contact angle of the base fabric is 25°.

[0019] The final high-liquid-absorption hydroentangled non-woven mask base fabric material has a grammage of 50 g / m 2 , a thickness of 0.3 mm, a liquid absorption rate of 1200%, a liquid retention rate of 85%, a transverse breaking strength of 18 N / 5 cm, and a longitudinal breaking strength of 22 N / 5 cm. The mask base fabric material is applied to a mask product, the serum carrying capacity is 25 g / m 2 , the liquid release rate within 10 minutes after skin contact is 65%, the mask base fabric edge is provided with an arc-shaped notch and a V-shaped notch, and through real person wearing test, the face fitting degree is good, and the mask is not easy to shift during activity. Embodiment

[0020] The embodiment of the present application provides a preparation process of a high-liquid-absorption hydroentangled non-woven mask base fabric material, which comprises the following steps: S1 Raw material preparation: 3% of alumina hydrophilic nanoparticles is added to the viscose spinning solution, and a dry-wet spinning process (spinning speed of 300 m / min) is used to prepare high-liquid-absorption viscose fibers. During the spinning process, the concentration of sulfuric acid in the coagulation bath is controlled at 100-120 g / L, the concentration of sodium sulfate is controlled at 260-280 g / L, and the temperature is controlled at 45-50°C to ensure the forming quality of the fibers. The prepared high-liquid-absorption viscose fibers have a 5-leaf cross-sectional structure and a specific surface area of 1.5 m 2 / g. The high-liquid-absorption viscose fibers are mixed with 15% moisturizing fibers (main component is sodium alginate, average polymerization degree is 1000) at a ratio of 80:20. S2 carding and laying: the blending and laying process is the same as in Example 1, and the detection frequency of the online detection feedback system is 10 times / s. During the carding process, in order to improve the straightness and separation of the fibers, the card clothing is specially treated, and a sawtooth card clothing with higher sharpness is used, with a tooth density of 80 teeth / cm 2 . Through the monitoring of the online detection feedback system, it is found that the thickness variation coefficient of the fiber web is controlled within 3%, meeting the product quality requirements. S3 water jet reinforcement: the primary water jet pressure is 25 bar, the water jet head distance from the fiber web surface is 18 mm; the intermediate water jet pressure is 65 bar, the water jet head distance from the fiber web surface is 15 mm; the surface water jet pressure is 45 bar, the water jet head diameter is 0.15 mm, the water jet head distance from the fiber web surface is 12 mm, the ultrasonic vibration frequency is 25 kHz, and the power density is 0.8 W / cm 2 . During the water jet process, the water quality is strictly controlled, and a reverse osmosis + ion exchange water treatment process is used to make the water conductivity less than 5 μS / cm, so as to reduce the influence of impurities in the water on the fibers and equipment. S4 post-treatment: the hydrophilic treatment adopts the immersion method, and the base cloth is immersed in a solution containing 2% mass fraction of amphoteric hydrophilic finishing agent, the immersion time is 10 minutes, and the temperature is 40℃. After immersion, it is dried at 110℃ for 5 minutes, and the contact angle of the base cloth after hydrophilic treatment is 28°. The prepared facial mask base cloth material has a grammage of 35 g / m 2 , a thickness of 0.25 mm, a liquid absorption rate of 1100%, a liquid retention rate of 82%, a transverse breaking strength of 16 N / 5 cm, and a longitudinal breaking strength of 21 N / 5 cm. After being applied to a facial mask product, the serum carrying capacity is 22 g / m 2 , and the liquid release rate within 10 minutes after skin contact is 62%. Through testing on consumers with different face shapes, the cut design of the edge of the facial mask base cloth can effectively improve the facial fit, especially in the nose wing and eye area. Example

[0021] The embodiment of the application provides a preparation process of a high-liquid-absorption water jet non-woven facial mask base cloth material, which comprises the following steps: S1 Raw material preparation: 8% of silica hydrophilic nanoparticles by total mass is added to the viscose spinning solution, and high liquid-absorbing viscose fibers are prepared by dry-wet spinning process (spinning speed is 500 m / min). In order to improve the compatibility of nanoparticles and viscose, the silica nanoparticles are modified on the surface before adding the nanoparticles. The modification is performed by using silane coupling agent KH-550, and the modification conditions are as follows: the mass ratio of nanoparticles to coupling agent is 10:1, the reaction temperature is 80°C, and the reaction time is 2 hours. The cross-section of the prepared high liquid-absorbing viscose fiber is 8-leaf structure, and the specific surface area is 1.7 m 2 / g. The high liquid-absorbing viscose fiber is mixed with 30% of the elastic fiber at a ratio of 60:40. S2 Carding and laying: the operation is the same as in Example One, and the online detection feedback system is running normally. In the cross-laying process, in order to improve the uniformity of the fiber web, a multi-curtain laying machine is used, and by adjusting the speed and angle of each curtain, the fiber distribution in the horizontal and vertical directions is more uniform. The online detection feedback system detects that the areal density variation coefficient of the fiber web is less than 2.5%. S3 Hydroentanglement reinforcement: the primary hydroentanglement water pressure is 40 bar, the hydroentanglement head distance from the fiber web surface is 12 mm; the intermediate hydroentanglement water pressure is 80 bar, the hydroentanglement head distance from the fiber web surface is 10 mm; the surface hydroentanglement water pressure is 60 bar, the hydroentanglement head diameter is 0.3 mm, the hydroentanglement head distance from the fiber web surface is 8 mm, the ultrasonic vibration frequency is 40 kHz, and the power density is 1.2 W / cm 2 . In the hydroentanglement process, the water pressure system of the hydroentanglement machine is optimized, and variable frequency constant pressure water supply technology is adopted, which can quickly respond to water pressure adjustment requirements and ensure the stability of water pressure.

[0022] S4 Post-processing: the hydrophilic treatment makes the contact angle of the base fabric to be 22°. The specific treatment method is as follows: a solution containing 5% mass fraction of anionic hydrophilic finishing agent is uniformly sprayed on the surface of the base fabric by spraying method, and the spraying amount is 10 g / m 2 , and then baking at 130°C for 2 minutes.

[0023] The face mask base fabric material obtained in this example has a grammage of 70 g / m 2 , a thickness of 0.4 mm, a liquid absorption rate of 1300%, a liquid retention rate of 88%, a transverse breaking strength of 20 N / 5 cm, and a longitudinal breaking strength of 25 N / 5 cm. The prepared face mask product has a serum carrying capacity of 28 g / m 2 , and the liquid release rate within 10 minutes after skin contact is 68%. Through the test of different use scenarios, the arc-shaped and V-shaped incisions at the edge of the face mask base fabric can maintain good fitting effect under various facial expressions and actions, effectively improving the use experience of consumers.

[0024] While embodiments of the application have been shown and described, it is to be understood that the embodiments described are merely exemplary of the principles and application of the present application. Numerous modifications and adaptions can be effected without departing from the spirit and scope of the present application, which is not limited to the exact construction and arrangement described. It is intended, therefore, to cover all modifications and adaptions that fall within the scope of the claims and their equivalents.

Claims

1. A process for preparing a highly liquid-absorbent spunlace nonwoven facial mask base fabric material, characterized in that: The following steps are involved: S1. Raw material preparation Highly absorbent viscose fiber is selected as the main raw material and mixed with 10%-30% functional fiber, the functional fiber including but not limited to antibacterial fiber, moisturizing fiber or elastic fiber; S2. Carding and laying Highly absorbent viscose fibers and functional fibers are blended in a ratio of (50-90): (10-50). The blended fibers are combed into single fibers through a carding process and cross-laid to form a fiber web. An online detection and feedback system is used to monitor the uniformity of the fiber web in real time, with a detection frequency of ≥10 times / second. S3. Hydroentanglement A unique fiber distribution structure is formed through a multi-stage hydroentanglement process. At the same time, ultrasonic vibration is applied during the hydroentanglement process with a frequency of 20-40kHz and a power density of 0.5-1.5W / cm 2 ; S4. Post-processing The hydrophilic treatment is performed on the base fabric after spunlace to make the contact angle of the base fabric ≤30°.

2. The process for preparing a highly liquid-absorbent spunlace nonwoven facial mask base fabric material according to claim 1, wherein: The high liquid-absorbent viscose fiber in step S1 is prepared by the following method: Adding hydrophilic nanoparticles accounting for 3% to 8% of the total mass to the viscose spinning solution, wherein the hydrophilic nanoparticles are silicon dioxide or aluminum oxide; The dry-wet spinning process is adopted, and the spinning speed is 300-500m / min.

3. The process for preparing a highly liquid-absorbent spunlace nonwoven facial mask base fabric material according to claim 1, wherein: The cross section of the highly absorbent viscose fiber in step S1 is a multi-lobed structure with 5-8 leaves and a specific surface area of ​​1.5 m 2 / g.

4. The process for preparing a highly liquid-absorbent spunlace nonwoven facial mask base fabric material according to claim 1, wherein: The multi-stage spunlace process in step S3 includes: Primary hydroentanglement: water pressure is 20-40 bar to form a preliminary entangled structure; Intermediate hydroentanglement: water pressure is 60-80 bar, forming a gradient density distribution; Surface hydroentanglement: The water pressure is 40-60 bar, combined with a hydroentanglement head with a diameter of 0.1-0.3 mm to form a microporous structure.

5. The process for preparing a highly liquid-absorbent spunlace nonwoven facial mask base fabric material according to claim 1, wherein: The online detection feedback system includes: at least two evenly distributed laser thickness sensors for detecting the thickness of the fiber web; a data processing unit connected to the sensor, configured to compare the real-time detection data with a preset threshold; An automatic adjustment device for adjusting parameters of a carding machine or a web laying machine according to feedback signals from the data processing unit, the automatic adjustment device comprising a frequency conversion controller for adjusting the cylinder speed of the carding machine and a servo motor for adjusting the curtain speed ratio of the web laying machine; Image recognition module, used to detect knots or holes in fiber webs.

6. The process for preparing a highly liquid-absorbent spunlace nonwoven facial mask base fabric material according to claim 1, wherein: The fiber distribution structure in step S3 includes: The surface of the mask base fabric forms a microporous structure with an average diameter of 5-10μm; The mask base fabric forms a gradient density distribution inside, with a surface density of 0.1-0.2g / cm 3 , the middle layer density is 0.05-0.1g / cm 3 .

7. The highly liquid-absorbent spunlace nonwoven facial mask base fabric material obtained by the preparation process according to claim 1, characterized in that: The weight of the mask base fabric material is 30-80 g / m 2 , thickness is 0.2-0.5mm; the liquid retention rate of the mask base fabric material is ≥80%, the transverse breaking strength is ≥15N / 5cm, and the longitudinal breaking strength is ≥20N / 5cm.

8. The use of a highly liquid-absorbent spunlace nonwoven facial mask base fabric material according to claim 7 in a facial mask product, characterized in that: The edge of the base fabric of the facial mask product is provided with at least two cuts of different shapes, including an arc-shaped cut and a V-shaped cut, which are used to improve the fit to the face.