Non-woven fabric processing system

Abstract

The invention relates to the technical field of non-woven fabric production equipment, and discloses a non-woven fabric processing system which comprises fiber surface pretreatment, fiber pretreatment, fiber carding, fiber lapping, dynamic structure forming, reinforcing, post-treatment, automatic control and environment-friendly treatment. The fiber carding comprises dynamic self-adaptive card clothing carding and ultrasonic-assisted carding, and the fiber lapping comprises multi-shaft collaborative lapping and laser-induced lapping. According to the non-woven fabric processing system, the fiber carding and lapping technology is optimized, carding card clothing is automatically adjusted according to the real-time condition of fibers, ultrasonic assistance is matched, fiber damage is reduced, the carding uniformity and efficiency are improved, the lapping path is flexibly adjusted through multi-axis cooperation, the fibers are locally heated and fused through laser induction, the lapping stability is improved, and the non-woven fabric processing efficiency is improved. The strength and the uniformity of the non-woven fabric are improved, so that the effects of ensuring the uniform distribution of fibers and the uniformity and the thin thickness of lapping can be achieved.

Description

Technical Field

[0001] This invention relates to the field of nonwoven fabric production equipment technology, specifically a nonwoven fabric processing system. Background Technology

[0002] Non-woven fabric, also known as non-woven cloth, is composed of oriented or random fibers. It is called cloth because it has the appearance and some properties of cloth. Non-woven fabric has the characteristics of being moisture-proof, breathable, flexible, lightweight, non-flammable, easy to decompose, non-toxic and non-irritating, rich in color, inexpensive, and recyclable. It is widely used in many fields such as medical and health care, packaging, clothing, agriculture, and industry.

[0003] Existing nonwoven fabric processing systems have some problems in the production process. In the fiber combing stage, traditional combing equipment is difficult to ensure the uniform distribution of fibers, resulting in unstable nonwoven fabric quality and affecting its physical properties and performance. In the fiber web laying process, the uniformity and thickness control of the web laying are poor, and uneven thickness is easy to occur. This not only reduces the yield of the product, but also causes waste of raw materials. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] In view of the shortcomings of the prior art, the present invention provides a nonwoven fabric processing system that has the advantages of ensuring uniform fiber distribution, uniformity of web laying and thickness, and solves the problems mentioned in the background art.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, the present invention provides the following technical solution: a nonwoven fabric processing system, comprising fiber surface pretreatment, fiber pretreatment, fiber combing, fiber web laying, reinforcement, post-treatment, automated control, and environmental protection treatment. The fiber pretreatment includes intelligent raw material identification and proportioning and low-temperature plasma pretreatment. The fiber combing includes dynamic adaptive combing of carding cloth and ultrasonic-assisted combing. The fiber web laying includes multi-axis collaborative web laying and laser-induced web laying. The reinforcement includes microwave thermal bonding, magnetic needle punching, and self-healing function implantation. The post-treatment includes supercritical fluid cleaning and nano-coating treatment. The automated control includes artificial intelligence optimized control and remote operation and maintenance and fault prediction. The environmental protection treatment includes biodegradable waste gas treatment, fiber dust recycling upgrade, and online recycling of waste gas nonwoven fabric.

[0008] Preferably, the intelligent raw material identification and proportioning system uses advanced technology to accurately identify fiber type and quality, and precisely adjusts the proportion of different fibers according to the product formula. The low-temperature plasma pretreatment is performed after the fibers are opened and before mixing, using low-temperature plasma to micro-etch the fiber surface, increase the specific surface area, and enhance the bonding force between fibers.

[0009] Preferably, the dynamic adaptive carding cloth is made of smart material and can adjust its own parameters in real time according to fiber stress, throughput, etc., to achieve efficient and high-quality carding. The ultrasonic-assisted carding adds an ultrasonic generator in the carding machine to promote fiber separation by emitting ultrasonic waves, reduce damage, and improve carding efficiency.

[0010] Preferably, the multi-axis collaborative web laying cross-laying machine adds vertical and lateral fine-tuning axes, which can flexibly adjust the web laying path according to product requirements to meet diversified production needs. The laser-induced web laying uses laser to selectively heat the fibers during web laying, causing them to soften and fuse locally, thereby improving web laying stability and nonwoven fabric quality.

[0011] Preferably, the microwave thermal bonding uses microwave heating to precisely control the heating depth and time, quickly and evenly heating the fibers and enhancing the bonding effect. The magnetic control system of the magnetic needle punching machine makes the needles magnetic, guiding the fibers to align in a specific direction and improving the mechanical properties of the nonwoven fabric. The self-healing function is incorporated into the reinforcement process with self-healing materials, enabling the nonwoven fabric to automatically repair minor damage during use and extend its service life.

[0012] Preferably, the supercritical fluid cleaning removes impurities from the surface of the nonwoven fabric before cutting and winding, improving cleanliness and hygiene. The nano-coating treatment adds different functional nano-coatings to the nonwoven fabric according to the product application, giving it new properties and broadening its application range.

[0013] Preferably, the artificial intelligence optimization control uses artificial intelligence algorithms in the automated control system to analyze production data, autonomously optimize operating parameters, and improve production efficiency and product quality. The remote operation and maintenance and fault prediction are connected to the Internet of Things system and remote platform, allowing operators to remotely monitor and operate equipment, while the system can predict faults in advance.

[0014] Preferably, the biodegradable waste gas treatment utilizes microbial flora to decompose organic waste gas pollutants, which is more environmentally friendly, has low energy consumption, and reduces secondary pollution. The upgraded fiber dust recycling classifies the collected fiber dust and adopts different regeneration processes to achieve efficient recycling, reduce costs and waste. The online recycling of waste non-woven fabrics in waste gas recovers the waste non-woven fabrics generated in production in real time, processes them, and puts them back into production, thereby improving resource utilization.

[0015] Compared with the prior art, the present invention provides a nonwoven fabric processing system with the following advantages:

[0016] This nonwoven fabric processing system optimizes fiber combing and web laying technology. The combing needle cloth is automatically adjusted according to the real-time condition of the fibers. With the assistance of ultrasound, fiber damage is reduced, and combing uniformity and efficiency are improved. Multi-axis collaborative flexible adjustment of the web laying path and laser-induced local heating and fusion of fibers improve web laying stability and enhance the strength and uniformity of the nonwoven fabric. This system can ensure the uniform distribution of fibers and the uniformity and thickness of the web laying. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall framework of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only 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.

[0019] Please see Figure 1 A nonwoven fabric processing system includes fiber surface pretreatment, fiber carding, fiber web laying, reinforcement, post-treatment, automated control, and environmental protection. Fiber surface pretreatment involves immersing the fibers in a reaction tank containing cellulase / protease before opening. The fiber surface pretreatment uses image recognition and spectral analysis to intelligently identify and proportion fiber raw materials. Low-temperature plasma micro-etching of the fiber surface enhances fiber bonding and improves product quality stability and strength. In the fiber carding step, the carding needle cloth automatically adjusts according to the real-time fiber condition, aided by ultrasonic waves to reduce fiber damage and improve carding uniformity and efficiency. The fiber web laying process involves multi-axis coordinated and flexible adjustment. The web-laying process involves laser-induced localized heating and fusion of fibers, improving web-laying stability and enhancing the strength and uniformity of the nonwoven fabric. The reinforcement step utilizes microwave thermal bonding for precise temperature control, magnetic needle punching guides the orderly arrangement of fibers, and the implantation of self-healing materials further strengthens the nonwoven fabric's strength and durability. The post-processing step uses supercritical fluid cleaning to remove impurities, and a nano-coating endows the nonwoven fabric with new functions, broadening its application range. Automated control leverages artificial intelligence to optimize production parameters, and remote operation and maintenance combined with fault prediction improves production efficiency and ensures production continuity. Environmental treatment utilizes microbial degradation of waste gas, graded regeneration of fiber dust, and online recycling of waste gas and nonwoven fabric, reducing pollution and lowering costs.

[0020] Fiber pretreatment includes intelligent raw material identification and proportioning and low-temperature plasma pretreatment; fiber carding includes dynamic adaptive carding and ultrasonic-assisted carding; fiber web laying includes multi-axis collaborative web laying and laser-induced web laying; reinforcement includes microwave thermal bonding, magnetic needle punching, and self-healing function implantation; post-treatment includes supercritical fluid cleaning and nano-coating treatment; automated control includes artificial intelligence optimized control and remote operation and maintenance and fault prediction; environmental protection treatment includes biodegradable waste gas treatment, fiber dust recycling upgrade, and online recycling of waste gas nonwoven fabric.

[0021] Intelligent raw material identification and proportioning uses advanced technology to accurately identify fiber type and quality, and precisely control the proportion of different fibers according to the product formula. Low-temperature plasma pretreatment is performed after the fibers are opened and before mixing, using low-temperature plasma to micro-etch the fiber surface, increase the specific surface area, and enhance the bonding force between fibers.

[0022] Through the above technical solutions, intelligent raw material identification and proportioning accurately control fiber raw materials, ensuring the consistency of raw materials for each batch of products, greatly improving product quality stability, reducing the defect rate caused by raw material differences, laying the foundation for high-quality nonwoven fabric production, and low-temperature plasma pretreatment increases the specific surface area of ​​fibers, significantly enhancing the bonding force between fibers, making the final nonwoven fabric product stronger and more durable, suitable for application scenarios with high strength requirements, such as industrial fabrics.

[0023] The dynamic adaptive carding card cloth is made of smart materials and can adjust its own parameters in real time according to fiber stress and throughput to achieve efficient and high-quality carding. Ultrasonic-assisted carding adds an ultrasonic generator to the carding machine to promote fiber separation by emitting ultrasonic waves, reduce damage and improve carding efficiency.

[0024] Through the above technical solutions, the dynamic adaptive carding cloth automatically adjusts according to the real-time state of the fibers. Regardless of the fiber characteristics and production speed, it can achieve the best carding effect, improve the uniformity of fiber carding, and thus improve the overall quality of nonwoven fabrics, producing higher quality products. Ultrasonic-assisted carding promotes fiber separation, effectively reduces fiber damage, and at the same time increases carding speed, improves production efficiency, reduces production costs, and does not affect product quality. It is suitable for the production of various fine nonwoven fabrics.

[0025] The multi-axis collaborative web laying and cross-laying machine adds vertical and lateral fine-tuning axes, which can flexibly adjust the web laying path according to product requirements to meet diversified production needs. Laser-induced web laying uses laser to selectively heat the fibers during web laying, causing them to soften and fuse locally, improving web laying stability and nonwoven fabric quality.

[0026] Through the above technical solutions, multi-axis collaborative web laying can flexibly design web laying paths according to product requirements, achieve complex and precise web laying, meet diverse product structure and performance requirements, and provide the possibility of producing non-woven fabrics with special functions or structures. Laser-induced web laying can improve web laying stability, improve the strength and uniformity of non-woven fabrics, make products perform better in packaging, filtration and other fields, and enhance product market competitiveness.

[0027] Microwave thermal bonding uses microwave heating to precisely control the heating depth and time, quickly and evenly heating the fibers and enhancing the bonding effect. The magnetic control system of the magnetic needle punching machine makes the needles magnetic, guiding the fibers to align in a specific direction, improving the mechanical properties of the nonwoven fabric. The self-healing function is incorporated into the reinforcement process, integrating self-healing materials so that the nonwoven fabric can automatically repair minor damage during use and extend its service life.

[0028] Through the above technical solutions, microwave thermal bonding precisely controls heating, quickly and evenly bonding fibers, reducing energy consumption, enhancing the bonding effect between fibers, and improving product strength. It is suitable for production with high requirements for bonding quality and energy efficiency. Magnetic control needle punching guides the orderly arrangement of fibers to form a better structure, significantly improving the tensile and tear mechanical properties of nonwoven fabrics, meeting the stringent strength requirements of applications such as geotextiles and automotive interior fabrics. The self-healing function endows nonwoven fabrics with the ability to automatically repair minor damage, extending product life and reducing maintenance costs. It is especially suitable for nonwoven fabrics used in high-wear environments such as outdoor and industrial settings.

[0029] Supercritical fluid cleaning removes impurities from the surface of nonwoven fabrics before cutting and winding, improving cleanliness and hygiene. Nano-coating treatment adds different functional nano-coatings to nonwoven fabrics according to their intended use, giving them new properties and broadening their application range.

[0030] Through the above technical solutions, supercritical fluid cleaning can efficiently remove impurities, oil stains and processing aids from the surface of non-woven fabrics, improve the cleanliness and hygiene performance of the products, and meet the industry standards for extremely high cleanliness in medical and health, food packaging and other fields. The nano-coating treatment, without changing the original properties of the non-woven fabric, endows it with new functions such as waterproofing, antibacterial and antistatic properties, broadens the application range of products, meets different market demands and increases the added value of products.

[0031] Artificial intelligence-optimized control uses artificial intelligence algorithms in automated control systems to analyze production data, autonomously optimize operating parameters, and improve production efficiency and product quality. Remote operation and maintenance and fault prediction are achieved by connecting the system with a remote platform through the Internet of Things, allowing operators to remotely monitor and operate equipment, while the system can predict faults in advance.

[0032] Through the above technical solutions, artificial intelligence optimization control can automatically analyze a large amount of production data, optimize the parameters of each processing unit in real time, adapt to changes in raw material and product demand and equipment status, improve production efficiency and product quality, reduce manual intervention costs, and enable remote operation and maintenance and fault prediction. Operators can remotely monitor and operate the equipment, which is convenient and fast. At the same time, it can predict equipment failures in advance, arrange maintenance in a timely manner, reduce equipment downtime, ensure production continuity, and improve the economic benefits of enterprises.

[0033] Biodegradable waste gas treatment utilizes microbial communities to decompose organic waste gas pollutants, making it more environmentally friendly, energy-efficient, and reducing secondary pollution. Upgraded fiber dust recycling involves classifying collected fiber dust and employing different regeneration processes to achieve efficient recycling, reducing costs and waste. Online recycling of waste non-woven fabrics involves real-time recycling of waste non-woven fabrics generated during production, which are then processed and reused in production, improving resource utilization.

[0034] Through the above technical solutions, the biodegradation of waste gas treatment utilizes microorganisms to degrade organic waste gas pollutants, which is more environmentally friendly and energy-efficient than traditional methods, reduces secondary pollution, conforms to the concept of green production, and protects the ecological environment. The fiber dust recycling upgrade involves the graded treatment and regeneration of fiber dust, reducing production costs, reducing resource waste, achieving sustainable resource utilization, and improving enterprise production and environmental benefits. The online recycling of waste non-woven fabrics can recycle waste non-woven fabrics in real time and put them back into production, improving resource utilization, reducing waste emissions, lowering enterprise raw material procurement costs, and contributing to environmental protection.

[0035] 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 nonwoven fabric processing system comprising fiber surface pretreatment, fiber pretreatment, fiber carding, fiber laying, reinforcement, post-treatment, automation control, and environmental treatment, characterized by: The fiber pretreatment includes intelligent raw material identification and proportioning and low-temperature plasma pretreatment, the fiber carding includes dynamic self-adaptive carding clothing and ultrasonic auxiliary carding, the fiber laying includes multi-axis coordinated laying and laser-induced laying, the reinforcement includes microwave thermal bonding, magnetic control needling and self-repairing function implantation, the post-treatment includes supercritical fluid cleaning and nano coating treatment, the automatic control includes artificial intelligence optimization control and remote operation and fault prediction, and the environmental protection treatment includes biodegradable waste gas treatment, fiber dust recycling upgrade and waste gas non-woven fabric online recycling.

2. The nonwoven fabric processing system according to claim 1, characterized by: The intelligent raw material identification and proportioning can accurately identify the fiber category and quality by advanced technology, and accurately control the proportion of different fibers according to the product formula, and the low-temperature plasma pretreatment can etch the surface of the fiber by low-temperature plasma micro-etching after fiber opening and before mixing, increase the specific surface area, and enhance the bonding force between fibers.

3. The nonwoven fabric processing system according to claim 1, characterized by: The dynamic self-adaptive carding clothing is made of intelligent materials, which can adjust its parameters in real time according to the fiber stress and throughput, realize efficient and high-quality carding, and the ultrasonic auxiliary carding adds an ultrasonic generator in the carding machine to promote fiber separation by emitting ultrasonic waves, reduce damage and improve carding efficiency.

4. The nonwoven fabric processing system according to claim 1, characterized by: The multi-axis coordinated laying cross-laying machine adds vertical and lateral fine-tuning shafts, which can flexibly adjust the laying path according to product requirements, meet diversified production, and the laser-induced laying selectively heats the fiber with laser during laying to make it locally soften and fuse, improving the stability of the laying and the quality of the non-woven fabric.

5. The nonwoven fabric processing system according to claim 1, characterized by: The microwave thermal bonding adopts microwave heating to accurately control the heating depth and time, quickly and evenly heat the fiber, and enhance the bonding effect, the magnetic control system of the magnetic control needling machine makes the needles magnetic, guides the fiber to arrange in a specific direction, improves the mechanical properties of the non-woven fabric, and the self-repairing function implantation implants self-repairing materials in the reinforcement link to enable the non-woven fabric to automatically repair minor damage during use and prolong the service life.

6. The nonwoven fabric processing system according to claim 1, characterized by: The supercritical fluid cleaning uses supercritical fluid to remove impurities on the surface of the non-woven fabric before cutting and winding to improve cleanliness and hygiene performance, and the nano coating treatment adds different functional nano coatings to the non-woven fabric according to product use to give it new properties and broaden its application range.

7. The nonwoven fabric processing system according to claim 1, characterized by: The artificial intelligence optimization control analyzes production data by artificial intelligence algorithms through the automatic control system, optimizes operation parameters autonomously, improves production efficiency and product quality, and the remote operation and fault prediction connects the system and the remote platform through the Internet of Things, so that the operator can remotely monitor and operate the equipment, and the system can predict faults in advance.

8. The nonwoven fabric processing system according to claim 1, characterized by: The biodegradable waste gas treatment uses microbial flora to decompose organic waste gas pollutants, which is more environmentally friendly, low in energy consumption, reduces secondary pollution, the fiber dust recycling upgrade classifies the collected fiber dust and uses different regeneration processes to realize efficient recycling, reduce costs and waste, and the waste gas non-woven fabric online recycling recycles the waste non-woven fabric generated during production in real time, and puts it back into production after treatment to improve resource utilization.

Images