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

Abstract

The application relates to the technical field of non-woven material preparation, 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 fibers as main raw materials and mixing functional fibers; S2. mixing the high-liquid-absorption viscose fibers and the functional fibers in proportion, carding the mixed fibers into single fiber state through a carding process, and cross-laying to form a fiber web; S3. forming a unique fiber distribution structure through a multi-stage spunlace process, and applying ultrasonic vibration in the spunlace process; and S4. performing hydrophilic treatment on the base cloth after spunlace. By adding hydrophilic nanoparticles in viscose spinning liquid and adopting a dry-wet spinning process, high-liquid-absorption viscose fibers with a multi-leaf structure are prepared, the specific surface area is increased, the liquid absorption capacity of the mask base cloth is further improved, the mask base cloth can fully absorb and carry essence liquid, and the demand of consumers for the skin care effect of the mask is met.

Description

Technical Field

[0001] This invention relates to the field of nonwoven material preparation technology, specifically to a preparation process and application of a highly absorbent hydroentangled nonwoven mask base fabric material. Background Technology

[0002] As people's living standards improve, the quality requirements for face mask products are increasing. Spunlace nonwoven face mask base fabrics, due to their softness, breathability, and skin-friendliness, have become a commonly used material for face mask base fabrics. However, existing spunlace nonwoven face mask base fabric materials still have some problems.

[0003] On the one hand, traditional mask base materials have limited liquid absorption, which cannot fully absorb and hold enough essence, resulting in insufficient essence during mask use and making it difficult to achieve good skin care effects.

[0004] On the other hand, during the preparation of the mask base fabric, it is difficult to ensure the uniformity of the fiber web, which can easily lead to defects such as uneven thickness, knots, or holes. This not only affects the appearance quality of the mask base fabric but also causes differences in liquid absorption, liquid retention, and mechanical properties, reducing the user experience and stability of the product. Furthermore, the existing fiber distribution structure of mask base fabrics is relatively simple, making it difficult to achieve a good balance in terms of liquid absorption, liquid retention, essence release, and mechanical properties, thus failing to fully utilize the performance advantages of the mask base fabric.

[0005] To address the aforementioned issues, there is an urgent need to develop a preparation process and related products that can improve the liquid absorbency of the mask base fabric, enhance material uniformity, and achieve superior product performance. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a preparation process and application of a highly absorbent spunlace nonwoven mask base fabric material. By using highly absorbent viscose fiber as raw material, online detection and feedback during carding and web laying, and unique fiber distribution structure control technology, the liquid absorbency of the mask base fabric is improved, the material uniformity is enhanced, and a mask base fabric material with superior overall performance is obtained, thus expanding its application in mask products.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a preparation process for a highly absorbent hydroentangled nonwoven mask base fabric material, comprising the following steps:

[0008] S1. Raw Material Preparation

[0009] High absorbency viscose fiber is selected as the main raw material, and 10%-30% of functional fibers are mixed in. The functional fibers include, but are not limited to, antibacterial fibers, moisturizing fibers or elastic fibers.

[0010] S2. Sorting and Netting

[0011] High absorbency viscose fiber and functional fiber are blended in a ratio of (50-90):(10-50). The blended fiber is combed into a single fiber state through a carding process and then cross-laid to form a fiber web. The uniformity of the fiber web is monitored in real time using an online detection feedback system with a detection frequency of ≥10 times / second.

[0012] S3. Hydroentanglement reinforcement

[0013] A unique fiber distribution structure is formed through a multi-stage hydroentangling process, while ultrasonic vibration is applied during the hydroentangling process at a frequency of 20-40kHz and a power density of 0.5-1.5W / cm³. 2 ;

[0014] S4. Post-processing

[0015] The hydroentangled base fabric is hydrophilicated to make the contact angle of the base fabric ≤30°.

[0016] Preferably, the superabsorbent viscose fiber in step S1 is prepared by the following method:

[0017] Add 3%-8% by weight of hydrophilic nanoparticles to the viscose spinning solution, wherein the hydrophilic nanoparticles are silicon dioxide or aluminum oxide.

[0018] The dry-wet spinning process is adopted, and the spinning speed is 300-500m / min.

[0019] Preferably, the cross-section of the superabsorbent viscose fiber in step S1 has a multi-leaf structure with 5-8 leaves and a specific surface area ≥1.5m². 2 / g.

[0020] Preferably, the multi-stage hydroentangling process in step S3 includes:

[0021] Primary hydroentanglement: Water pressure of 20-40 bar, forming a preliminary entangled structure;

[0022] Intermediate hydroentanglement: water pressure is 60-80 bar, creating a gradient density distribution;

[0023] Surface hydroentanglement: water pressure of 40-60 bar, combined with hydroentanglement heads with a diameter of 0.1-0.3 mm, forming a microporous structure.

[0024] Preferably, the online detection feedback system includes:

[0025] At least two uniformly distributed laser thickness sensors are used to detect the thickness of the fiber web;

[0026] The data processing unit connected to the sensor is configured to compare real-time detection data with a preset threshold.

[0027] An automatic adjustment device adjusts the parameters of the carding machine or web laying machine according to the feedback signal from the data processing unit. The automatic adjustment device includes a frequency converter for adjusting the cylinder speed of the carding machine and a servo motor for adjusting the curtain speed ratio of the web laying machine.

[0028] An image recognition module is used to detect knots or voids in the fiber web.

[0029] Preferably, the fiber distribution structure in step S3 includes:

[0030] The surface layer of the mask base fabric forms a microporous structure with an average diameter of 5-10 μm;

[0031] The mask base fabric has a gradient density distribution, with a surface density of 0.1-0.2 g / cm³. 3 The density of the middle layer is 0.05-0.1 g / cm³. 3 .

[0032] Preferably, the basis weight of the mask base fabric material is 30-80 g / m². 2 The thickness is 0.2-0.5mm; the liquid retention rate of the mask base fabric material is ≥80%, the transverse tensile strength is ≥15N / 5cm, and the longitudinal tensile strength is ≥20N / 5cm.

[0033] This invention provides a preparation process and application of a highly absorbent hydroentangled nonwoven mask base material. It offers the following advantages:

[0034] This invention uses highly absorbent viscose fiber as the main raw material, and prepares highly absorbent viscose fiber by adding hydrophilic nanoparticles to the viscose spinning solution and using a dry-wet spinning process. At the same time, the multi-leaf structure of the highly absorbent viscose fiber increases the specific surface area, further improving the liquid absorption capacity of the mask base fabric, which can fully absorb and carry the essence, thus meeting consumers' needs for the skin care effect of the mask.

[0035] This invention employs an online detection feedback system to monitor the uniformity of the fiber web in real time. The laser thickness sensor and image recognition module can quickly and accurately detect the thickness, knots, and pore defects of the fiber web. The data processing unit and automatic adjustment device adjust the parameters of the carding machine and web laying machine in a timely manner based on the detection results, which can effectively ensure the uniformity of the fiber web, reduce product quality differences, and improve the product yield.

[0036] This invention combines multi-stage hydroentangling with ultrasonic vibration to form a unique fiber distribution structure. The microporous structure of the mask base fabric surface facilitates the rapid absorption and release of the essence, while the gradient density distribution inside achieves a synergistic effect of surface liquid locking and middle liquid storage, improving the liquid retention rate and mechanical properties of the mask base fabric. This makes the mask base fabric less prone to damage during use and allows the essence to better exert its skincare effects. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0038] This invention provides a process for preparing a highly absorbent hydroentangled nonwoven mask base fabric material, comprising the following steps:

[0039] S1 Raw Material Preparation: 5% by mass of hydrophilic silica nanoparticles were added to the viscose spinning solution, and superabsorbent viscose fibers were prepared using a wet-dry spinning process (spinning speed 400 m / min). During the preparation process, the concentration of the viscose spinning solution was controlled at 12%-15%, and the temperature was maintained at 30-35℃ to ensure that the nanoparticles were uniformly dispersed in the spinning solution. Transmission electron microscopy revealed that the average particle size of the silica nanoparticles was approximately 50-80 nm, and they were monodisperse in the spinning solution. The prepared superabsorbent viscose fiber had a 6-lobed cross-section, and its specific surface area was measured to be 1.6 m². 2 / g; Mix super absorbent viscose fiber with 20% chitosan antibacterial fiber at a ratio of 70:30.

[0040] S2 Carding and Web Laying: The mixed fibers are fed into the blending equipment. During blending, the roller speed ratio is controlled at 1.2:1 to ensure thorough and uniform mixing of the two fibers. A carding machine is then used for carding, with the cylinder speed set at 300 r / min, the doffer speed at 280 r / min, and the carding gap at 0.25 mm, carding the blended fibers into single fibers. Subsequently, cross-laying is performed, with the web laying machine's curtain speed ratio set at 1.5:1 to form the fiber web. An online detection feedback system monitors the uniformity of the fiber web in real time. This system includes two evenly distributed laser thickness sensors, installed 50 cm apart, located at 1 / 4 and 3 / 4 of the fiber web width, respectively. The data processing unit compares the real-time detection data with a preset threshold; the preset fiber web thickness tolerance range is ±0.05 mm. The automatic adjustment device adjusts the carding machine cylinder speed via a frequency converter based on feedback signals, and also adjusts the web-laying machine curtain speed ratio via a servo motor. Simultaneously, an image recognition module using an industrial camera detects knots or voids in the fiber web at a frequency of 12 times per second. When a local thickness of the fiber web is detected to exceed the tolerance range, the automatic adjustment device can respond within 0.3 seconds, adjusting the carding machine cylinder speed or the web-laying machine curtain speed ratio to restore the fiber web thickness to normal.

[0041] S3 Hydroentangling Strengthening: This process employs a multi-stage hydroentangling process using a three-roller hydroentangling machine. The primary hydroentangling stage uses a water pressure of 30 bar, with the hydroentangling head 15 mm from the fiber web surface, forming a preliminary entanglement structure. The intermediate hydroentangling stage uses a water pressure of 70 bar, with the hydroentangling head 12 mm from the fiber web surface, creating a gradient density distribution. The surface hydroentangling stage uses a water pressure of 50 bar, combined with a 0.2 mm diameter hydroentangling head 10 mm from the fiber web surface, forming a microporous structure. Ultrasonic vibration is applied during the hydroentangling process at a frequency of 30 kHz and a power density of 1 W / cm². 2 Ultrasonic vibration is achieved through ultrasonic transducers mounted on the frame of the hydroentanglement machine, with a transducer density of four per square meter of hydroentanglement area. Scanning electron microscopy revealed that after ultrasonic vibration-assisted hydroentanglement, the entanglement between fibers became tighter, and the micropore structure became more uniformly distributed.

[0042] S4 Post-treatment: The hydroentangled base fabric undergoes a hydrophilic treatment using a padding method. The base fabric is immersed in a solution containing 3% by mass of a cationic hydrophilic finishing agent, with the padding rate controlled at 80%. The pH value of the finishing agent solution is adjusted to 6-7. After padding, the fabric is dried at 120℃ for 3 minutes to achieve a contact angle of 25°.

[0043] The final weight of the superabsorbent hydroentangled nonwoven mask base fabric was 50 g / m². 2The material has a thickness of 0.3 mm, a liquid absorption rate of 1200%, a liquid retention rate of 85%, a transverse tensile strength of 18 N / 5 cm, and a longitudinal tensile strength of 22 N / 5 cm. When this mask base fabric is used in a mask product, the essence carrying capacity is 25 g / m². 2 The liquid release rate within 10 minutes after application is 65%. The mask base fabric has arc-shaped and V-shaped cuts on the edge. Through real-person wearing tests, the mask fits the face well and does not easily shift during activities. Example

[0044] This invention provides a process for preparing a highly absorbent hydroentangled nonwoven mask base fabric material, comprising the following steps:

[0045] S1 Raw Material Preparation: Hydrophilic alumina nanoparticles (3% by mass) were added to the viscose spinning solution. Highly absorbent viscose fibers were prepared using a wet-dry spinning process (spinning speed 300 m / min). During spinning, the sulfuric acid concentration in the coagulation bath was controlled at 100-120 g / L, the sodium sulfate concentration at 260-280 g / L, and the temperature at 45-50℃ to ensure fiber formation quality. The prepared highly absorbent viscose fiber had a 5-lobed cross-section and a specific surface area of ​​1.5 m². 2 / g. High absorbency viscose fiber and 15% moisturizing fiber (main component is sodium alginate, average degree of polymerization is 1000) are mixed in a ratio of 80:20.

[0046] S2 Carding and Web Laying: The blending and web laying processes are the same as in Example 1, with the online detection feedback system detecting 10 times per second. During the carding process, to improve fiber straightness and separation, the carding machine's carding cloth underwent special treatment, employing a sharper serrated carding cloth with a tooth density of 80 teeth / cm. 2 Monitoring through the online detection and feedback system revealed that the coefficient of variation in the thickness of the fiber web was controlled within 3%, meeting product quality requirements.

[0047] S3 hydroentangled reinforcement: Primary hydroentanglement water pressure is 25 bar, hydroentanglement head distance from the fiber web surface is 18 mm; Intermediate hydroentanglement water pressure is 65 bar, hydroentanglement head distance from the fiber web surface is 15 mm; Surface hydroentanglement water pressure is 45 bar, hydroentanglement head diameter is 0.15 mm, hydroentanglement head distance from the fiber web surface is 12 mm, ultrasonic vibration frequency is 25 kHz, power density is 0.8 W / cm². 2 During the hydroentangling process, the water quality is strictly controlled. A reverse osmosis + ion exchange water treatment process is used to ensure that the water conductivity is less than 5 μS / cm, so as to reduce the impact of impurities in the water on the fibers and equipment.

[0048] S4 Post-treatment: The hydrophilic treatment is performed by immersion. The base fabric is immersed in a solution containing 2% by mass of an amphoteric hydrophilic finishing agent for 10 minutes at a temperature of 40°C. After immersion, it is dried at 110°C for 5 minutes. The contact angle of the base fabric after hydrophilic treatment is 28°.

[0049] The prepared mask base fabric material has a basis weight of 35 g / m². 2 It has a thickness of 0.25mm, a liquid absorption rate of 1100%, a liquid retention rate of 82%, a transverse tensile strength of 16N / 5cm, and a longitudinal tensile strength of 21N / 5cm. When applied to a face mask, it can hold 22g / m³ of essence. 2 The liquid release rate within 10 minutes after application is 62%. Through testing on consumers with different face shapes, the cut design at the edge of the mask base fabric can effectively improve the facial fit, especially in areas such as the nose and around the eyes. Example

[0050] This invention provides a process for preparing a highly absorbent hydroentangled nonwoven mask base fabric material, comprising the following steps:

[0051] S1 Raw Material Preparation: 8% by mass of hydrophilic silica nanoparticles were added to the viscose spinning solution, and superabsorbent viscose fibers were prepared using a wet-dry spinning process (spinning speed 500 m / min). To improve the compatibility between the nanoparticles and viscose, the silica nanoparticles were surface-modified before addition using a silane coupling agent KH-550. The modification conditions were: a nanoparticle to coupling agent mass ratio of 10:1, a reaction temperature of 80℃, and a reaction time of 2 hours. The resulting superabsorbent viscose fiber had an octagonal cross-section and a specific surface area of ​​1.7 m². 2 / g. Super absorbent viscose fiber and 30% elastic fiber are mixed in a ratio of 60:40.

[0052] S2 Carding and Web Laying: The operation is the same as in Example 1, and the online detection feedback system operates normally. During the cross-laying process, a multi-curtain web laying machine is used to improve the uniformity of the fiber web. By adjusting the speed and angle of each curtain, the fibers are distributed more evenly in both the transverse and longitudinal directions. The online detection feedback system shows that the areal density variation coefficient of the fiber web is less than 2.5%.

[0053] S3 hydroentangled reinforcement: Primary hydroentanglement water pressure is 40 bar, with the hydroentangle head 12 mm from the fiber web surface; intermediate hydroentanglement water pressure is 80 bar, with the hydroentangle head 10 mm from the fiber web surface; surface hydroentanglement water pressure is 60 bar, with a hydroentangle head diameter of 0.3 mm and a hydroentangle head distance of 8 mm from the fiber web surface; ultrasonic vibration frequency is 40 kHz, and power density is 1.2 W / cm². 2During the hydroentangling process, the water pressure system of the hydroentangling machine was optimized, and variable frequency constant pressure water supply technology was adopted, which can quickly respond to water pressure adjustment needs and ensure water pressure stability.

[0054] S4 Post-treatment: Hydrophilic treatment to achieve a contact angle of 22° for the base fabric. The specific treatment method is as follows: A 5% (by mass) anionic hydrophilic finishing agent solution is uniformly sprayed onto the base fabric surface using a spraying method, with a spraying amount of 10 g / m². 2 Then bake at 130℃ for 2 minutes.

[0055] The mask base fabric material obtained in this embodiment has a basis weight of 70g / m². 2 The thickness is 0.4mm, the liquid absorption rate is 1300%, the liquid retention rate is 88%, the transverse tensile strength is 20N / 5cm, and the longitudinal tensile strength is 25N / 5cm. The resulting mask product has an essence carrying capacity of 28g / m³. 2 The liquid release rate within 10 minutes after application is 68%. Through tests simulating different usage scenarios, the arc-shaped and V-shaped cuts at the edge of the mask base fabric can maintain a good fit under various facial expressions and movements, effectively improving the user experience.

[0056] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A preparation process for a highly absorbent hydroentangled nonwoven mask base fabric material, characterized in that: Includes the following steps: S1. Raw Material Preparation High absorbency viscose fiber is selected as the main raw material, and 10%-30% of functional fibers are mixed in. The functional fibers include, but are not limited to, antibacterial fibers, moisturizing fibers or elastic fibers. S2. Sorting and Netting High absorbency viscose fiber and functional fiber are blended in a ratio of (50-90):(10-50). The blended fiber is combed into a single fiber state through a carding process and then cross-laid to form a fiber web. The uniformity of the fiber web is monitored in real time using an online detection feedback system with a detection frequency of ≥10 times / second. S3. Hydroentanglement reinforcement A unique fiber distribution structure is formed through a multi-stage hydroentangling process, while ultrasonic vibration is applied during the hydroentangling process at a frequency of 20-40kHz and a power density of 0.5-1.5W / cm³. 2 ; S4. Post-processing The hydroentangled base fabric is hydrophilicated to make the contact angle of the base fabric ≤30°.

2. The preparation process of a highly absorbent hydroentangled nonwoven mask base fabric material according to claim 1, characterized in that: The superabsorbent viscose fiber in step S1 is prepared by the following method: Add 3%-8% by weight of hydrophilic nanoparticles 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 preparation process of a highly absorbent hydroentangled nonwoven mask base fabric material according to claim 1, characterized in that: The superabsorbent viscose fiber in step S1 has a multi-leaf structure in cross-section, with 5-8 leaves and a specific surface area ≥1.5m². 2 / g.

4. The preparation process of a highly absorbent hydroentangled nonwoven mask base fabric material according to claim 1, characterized in that: The multi-stage hydroentangling process in step S3 includes: Primary hydroentanglement: Water pressure of 20-40 bar, forming a preliminary entangled structure; Intermediate hydroentanglement: water pressure is 60-80 bar, creating a gradient density distribution; Surface hydroentanglement: water pressure of 40-60 bar, combined with hydroentanglement heads with a diameter of 0.1-0.3 mm, forming a microporous structure.

5. The preparation process of a highly absorbent hydroentangled nonwoven mask base fabric material according to claim 1, characterized in that: The online detection feedback system includes: At least two uniformly distributed laser thickness sensors are used to detect the thickness of the fiber web; The data processing unit connected to the sensor is configured to compare real-time detection data with a preset threshold. An automatic adjustment device adjusts the parameters of the carding machine or web laying machine according to the feedback signal from the data processing unit. The automatic adjustment device includes a frequency converter for adjusting the cylinder speed of the carding machine and a servo motor for adjusting the curtain speed ratio of the web laying machine. An image recognition module is used to detect knots or voids in the fiber web.

6. The preparation process of a highly absorbent hydroentangled nonwoven mask base fabric material according to claim 1, characterized in that: The fiber distribution structure in step S3 includes: The surface layer of the mask base fabric forms a microporous structure with an average diameter of 5-10 μm; The mask base fabric has a gradient density distribution, with a surface density of 0.1-0.2 g / cm³. 3 The density of the middle layer is 0.05-0.1 g / cm³. 3 .

7. The highly absorbent hydroentangled nonwoven mask base fabric material obtained by the preparation process according to claim 1, characterized in that: The base fabric material of the mask has a weight of 30-80 g / m². 2 The thickness is 0.2-0.5mm; the liquid retention rate of the mask base fabric material is ≥80%, the transverse tensile strength is ≥15N / 5cm, and the longitudinal tensile strength is ≥20N / 5cm.

8. The application of the highly absorbent spunlace nonwoven mask base fabric material according to claim 7 in mask products, characterized in that: The base fabric edge of the mask product has at least two different shaped cuts, including arc-shaped cuts and V-shaped cuts, to improve facial fit.