A pleated nonwoven fabric, a method for producing the same, and use thereof

Abstract

The application provides a kind of pleated non-woven fabric and its preparation method and application, belong to the field of thermal insulation materials.The pleated non-woven fabric is formed by non-woven fabric through pleating process, the formed pleats are continuous or discrete form, the pleat depth is 0.5-5mm, the ratio of pleat depth to pleat width is greater than or equal to 0.3, and the pleat density is 2-50 / cm2.The application designs non-woven fabric with specific pleat structure as thermal insulation material, realizes the four performance of anti-washing deformation, anti-drilling wool, high thermal insulation and air permeability, and breaks through the compromise, so that the pleated non-woven fabric of the application can be widely used in clothing, bedding and other fields.

Description

Technical Field

[0001] This invention relates to the field of thermal insulation materials technology, and in particular to a pleated nonwoven fabric, its preparation method, and its application. Background Technology

[0002] Thermal insulation materials are the core filling materials in the fields of clothing, bedding and industrial insulation, and their performance directly affects the insulation effect and safety reliability.

[0003] Traditional insulation materials (such as down and synthetic fiber cotton) rely on a static air layer for insulation. However, the fibrous aggregate structure is prone to collapse under pressure (such as down hardening when wet and synthetic fiber cotton undergoing repeated compression and deformation), resulting in a reduced air layer thickness and a sharp increase in thermal conductivity. Especially in high humidity environments (such as outdoor exercise with sweating, rain, and snow), the thermal conductivity of the material can increase by 30%-50% after absorbing moisture, causing serious heat loss. To improve insulation, current technologies generally employ multi-layer stacking, but this results in a heavy material with poor breathability. In addition, down and synthetic fiber cotton also suffer from problems such as easy deformation after washing and down leakage. That is, repeated washing causes shrinkage and deformation, resulting in a high rate of dimensional change, affecting service life, and the fibers can easily penetrate the fabric layer, reducing warmth and causing allergies. In other words, current insulation materials cannot simultaneously meet the requirements of resistance to washing deformation, down leakage prevention, high insulation, and breathability. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a pleated nonwoven fabric, its preparation method, and its application. It has the advantages of being resistant to washing deformation, preventing down leakage, having high thermal insulation properties, and being breathable, making it suitable for thermal insulation products such as clothing, home textiles, and outdoor equipment.

[0005] In a first aspect, the present invention provides a pleated nonwoven fabric, which is formed by pleating nonwoven fabric through a pleating process. The pleats formed are continuous or discrete, the pleat depth is 0.5-5mm, the ratio of pleat depth to pleat width is greater than or equal to 0.3, and the pleat density is 2-50 pleats / cm².

[0006] The present invention also provides a pleated nonwoven fabric, which is formed by setting an aluminum film on the surface of the nonwoven fabric and then forming it by a pleating process. The pleats formed are continuous or discrete, the pleat depth is 0.5-5mm, the ratio of pleat depth to pleat width is greater than or equal to 0.3, and the pleat density is 2-50 pleats / cm².

[0007] The pleated nonwoven fabric provided by the present invention has pleats that are continuous wavy patterns with a wave height of 1-3 mm and a wavelength of 5-10 mm.

[0008] The pleated nonwoven fabric provided by the present invention has pleats that are discrete honeycomb patterns with a pore size of 2-8 mm.

[0009] The pleated nonwoven fabric provided by the present invention is made of fiber raw material selected from polyester, polypropylene and nylon fibers.

[0010] According to the pleated nonwoven fabric provided by the present invention, the fiber raw material of the nonwoven fabric further includes an auxiliary agent, which is selected from one or more of masterbatch, antibacterial agent, and antistatic agent.

[0011] Secondly, the present invention provides the application of the above-mentioned pleated nonwoven fabric in the preparation of thermal insulation products.

[0012] Thirdly, the present invention provides a method for preparing the above-mentioned pleated nonwoven fabric, comprising: after producing nonwoven fabric by spunbonding, setting an aluminum film on the surface of the nonwoven fabric or not setting an aluminum film, and then forming it by pleating process.

[0013] The spunbond method includes the following steps: feeding, melt extrusion, spinning, cooling and molding, high-speed airflow stretching, filament splitting and web laying, hot rolling and bonding, and winding and slitting.

[0014] According to the preparation method of the pleated nonwoven fabric provided by the present invention, when polyester is selected as the fiber raw material of the nonwoven fabric, the spunbonding method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 260-270℃, compression section 275-285℃, metering section 280-290℃, melt pipe 285-295℃, spinning box 290-300℃, melt pressure 8-15MPa; (3) spinning and cooling molding: metering pump speed 20-50rpm, spinneret orifice diameter 0.25-0.35mm, spinneret orifice length-to-diameter ratio 2:1~4:1, side blowing temperature 20-25℃, wind speed 0.5~0.8m / s, wind distance 0.8~1.2 m; (4) High-speed airflow drawing: drawing wind speed 4000-6000m / min, drawing wind temperature 25~30℃, fineness 1.0~3.0dtex; (5) Splitting and web laying: diffuser angle 15º~25º, web forming speed 50~150m / min, negative pressure in web forming area 300-800Pa; (6) Hot rolling and consolidation: hot rolling roll temperature upper roll 220~240℃, lower roll 200~220℃, linear pressure 60~120N / mm, rolling point gap 0.05~0.15mm, rolling speed 50~150m / min; (7) Winding and slitting: winding tension 15~30N / m, slitting blade speed ratio 1.001~1.005;

[0015] Alternatively, when polypropylene is selected as the fiber raw material for the nonwoven fabric, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 180-190℃, compression section 200-210℃, metering section 210-220℃, melt pipe 215-225℃, spinning box 220-230℃, melt pressure 4-10MPa; (3) spinning and cooling molding: metering pump speed 20-60rpm, spinneret orifice diameter 0.3-0.5mm, spinneret orifice length-to-diameter ratio 2:1~4:1, side blowing air temperature 18-25℃, wind speed 0.5~0.8m / s, wind distance 0.5~1.0m; (4) high-speed airflow drawing: drawing wind speed 3000-5000m / min, drawing wind temperature 20~25℃, fineness 1.0~3.0dtex; (5) Splitting and laying: diffuser angle 20º~30º, web forming speed 30~120m / min, negative pressure in web forming area 200-600Pa; (6) Hot rolling and consolidation: hot rolling roll temperature upper roll 145~155℃, lower roll 135~145℃, linear pressure 40~80N / mm, rolling point gap 0.08~0.2mm, rolling speed 50~150m / min; (7) Winding and slitting: winding tension 10~25N / m, slitting blade speed ratio 1.001~1.005;

[0016] Alternatively, when the fiber raw material of the nonwoven fabric is nylon, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 240-250℃, compression section 260-270℃ / PA6, 270-280℃ / PA66, metering section 265-275℃ / PA6, 275-285℃ / PA66, melt pipe 270-280℃, spinning box 275-285℃, melt pressure 6-12 MPa; (3) spinning and cooling molding: metering pump speed 15-35 rpm, spinneret orifice diameter 0.25-0.40 mm, spinneret orifice length-to-diameter ratio 2:1-4:1, side blowing air temperature 20-24℃, wind speed 0.4-0.7 m / s, wind distance 1.0-1.5 m; (4) high-speed airflow drawing: drawing wind speed 4000-6500 m / min , , drawing air temperature 22~26℃, venturi tube pressure 0.4~0.8MPa, drawing channel length 2.0~3.0m, fineness control 0.8~2.2dtex; (5) filament splitting and web laying: diffuser angle 10º~20º, web forming speed 40~100m / min, negative pressure in web forming area 400-800Pa; (6) hot rolling consolidation: hot rolling roll temperature upper roll 190~205℃ / PA6, 200~215℃ / PA66, lower roll temperature 185~200℃ / PA6, 195~210℃ / PA66, linear pressure 50~90N / mm, rolling point gap 0.05~0.12mm, antistatic treatment: according to surface density 0.2~0.5g / m2 Coating with carbon nanotube dispersion, roller speed 50-150m / min; (7) winding and slitting: winding tension 15-35N / m, winding taper 8-12%.

[0017] According to the method for preparing pleated nonwoven fabric provided by the present invention, the pleating process adopts ultrasonic composite mechanical pleating method, wherein the ultrasonic power is 20-40kHz, the roller temperature is 110-140℃, the linear pressure is 0.3-0.8 MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] This invention provides a pleated nonwoven fabric, its preparation method, and its application. By designing a nonwoven fabric with a specific pleated structure as a thermal insulation material, it achieves a balance and breakthrough in four properties: resistance to water washing deformation, prevention of down leakage, high thermal insulation, and breathability. As a result, the pleated nonwoven fabric of this invention can be widely used in clothing, bedding, and other fields. Attached Figure Description

[0020] Figure 1 This is a physical image of the pleated nonwoven fabric obtained in Embodiment 1 of the present invention.

[0021] Figure 2 This is a picture showing the effect of the pleated nonwoven fabric after washing, obtained in Embodiment 1 of the present invention.

[0022] Figure 3 This is a picture showing the effect of the pleated nonwoven fabric after washing, obtained in Embodiment 2 of the present invention.

[0023] Figure 4 This is a picture showing the effect of the pleated nonwoven fabric after washing, obtained in Example 3 of the present invention. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this invention, not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0025] The endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

[0026] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "specific implementation," or "some specific implementations," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0027] Where specific techniques or conditions are not specified in the examples, they shall be performed in accordance with the techniques or conditions described in the literature in this field, or in accordance with the product instructions. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased through legitimate channels.

[0028] In a first aspect, the present invention provides a pleated nonwoven fabric, which is formed by pleating nonwoven fabric through a pleating process. The pleats formed are continuous or discrete, the pleat depth is 0.5-5mm, the ratio of pleat depth to pleat width is greater than or equal to 0.3, and the pleat density is 2-50 pleats / cm².

[0029] The present invention also provides a pleated nonwoven fabric, which is formed by setting an aluminum film on the surface of the nonwoven fabric and then forming it by a pleating process. The pleats formed are continuous or discrete, the pleat depth is 0.5-5mm, the ratio of pleat depth to pleat width is greater than or equal to 0.3, and the pleat density is 2-50 pleats / cm².

[0030] This invention designs pleats of specific shapes and densities on the surface of nonwoven fabric, which can form elastic buffer spaces to disperse stress during washing, thereby solving the problem of easy deformation during washing. At the same time, the pleats form a physical barrier, making the fiber migration path tortuous and greatly reducing the down leakage rate, eliminating the need for an additional anti-down leakage film. In addition, the pleats form non-connected air chambers, reducing heat convection, increasing air retention and thus improving thermal insulation performance. The thermal insulation performance of a single layer of pleated nonwoven fabric is equivalent to that of two layers of traditional thermal insulation cotton, thereby significantly reducing the material weight for the same thermal insulation effect. The pleats can also form directional airflow channels, which is beneficial to improving breathability and moisture permeability, and quickly wicking away sweat.

[0031] Furthermore, before the pleating process, an aluminum film is placed on the surface of the nonwoven fabric, which helps to increase the heat reflection function. The subsequent pleating will increase the heat reflection area. In other words, the aluminum film and the pleating work together to further improve the thermal insulation performance of the material.

[0032] The pleats of this invention can be of a standard shape (such as wavy, honeycomb, rhomboid, circular, stripe, etc.) or an irregular shape.

[0033] In some embodiments of the present invention, the pleats are continuous wavy patterns with a wave height of 1-3 mm and a wavelength of 5-10 mm. Designing the pleats as continuous wavy patterns with the above-mentioned wavelength and wave height helps to ensure the high resilience of the nonwoven fabric, thereby further enhancing its water resistance.

[0034] In some embodiments of the present invention, the pleats are discrete honeycomb patterns with a pore size of 2-8 mm. Designing the pleats as discrete honeycomb patterns with a certain pore size helps to ensure the nonwoven fabric's superior down-locking properties, thereby further improving its down-proof performance.

[0035] In some embodiments of the present invention, the fiber raw material of the nonwoven fabric is selected from polyester, polypropylene, and nylon fibers.

[0036] Furthermore, in order to enhance the performance or characteristics of the pleated nonwoven fabric, the fiber raw material of the nonwoven fabric also contains auxiliaries, which are selected from one or more of masterbatch, antibacterial agents, and antistatic agents.

[0037] In the above technical solutions, adding color masterbatch can make nonwoven fabrics into various colors; adding antibacterial agents gives nonwoven fabrics antibacterial and anti-mite effects; adding antistatic agents gives nonwoven fabrics antistatic effects.

[0038] Secondly, the present invention provides the application of the above-mentioned pleated nonwoven fabric in the preparation of thermal insulation products.

[0039] Thirdly, the present invention provides a method for preparing the above-mentioned pleated nonwoven fabric, comprising: after producing nonwoven fabric by spunbonding, setting an aluminum film on the surface of the nonwoven fabric or not setting an aluminum film, and then forming it by pleating process.

[0040] The spunbond method includes the following steps: feeding, melt extrusion, spinning, cooling and molding, high-speed airflow stretching, filament splitting and web laying, hot rolling and bonding, and winding and slitting.

[0041] Specifically, when polyester is selected as the fiber raw material for the nonwoven fabric, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 260-270℃, compression section 275-285℃, metering section 280-290℃, melt pipe 285-295℃, spinning box 290-300℃, melt pressure 8-15MPa; (3) spinning and cooling molding: metering pump speed 20-50rpm, spinneret orifice diameter 0.25-0.35mm, spinneret length-to-diameter ratio 2:1~4:1, side blowing temperature 20-25℃, wind speed 0.5~0.8m / s, wind distance 0.8~1.2m; (4) high speed Airflow drawing: drawing wind speed 4000-6000m / min, drawing wind temperature 25~30℃, fineness 1.0~3.0dtex; (5) Splitting and web laying: diffuser angle 15º~25º, web forming speed 50~150m / min, negative pressure in web forming area 300-800Pa; (6) Hot rolling and consolidation: hot rolling roll temperature upper roll 220~240℃, lower roll 200~220℃, linear pressure 60~120N / mm, rolling point gap 0.05~0.15mm, rolling speed 50~150m / min; (7) Winding and slitting: winding tension 15~30N / m, slitting blade speed ratio 1.001~1.005.

[0042] When polypropylene is selected as the fiber raw material for the nonwoven fabric, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 180-190℃, compression section 200-210℃, metering section 210-220℃, melt pipe 215-225℃, spinning box 220-230℃, melt pressure 4-10MPa; (3) spinning and cooling molding: metering pump speed 20-60rpm, spinneret orifice diameter 0.3-0.5mm, spinneret orifice length-to-diameter ratio 2:1~4:1, side blowing air temperature 18-25℃, wind speed 0.5~0.8m / s, wind distance 0.5~1.0m; (4) high-speed airflow drawing: drawing wind speed 3000-5000m / min, drawing wind temperature 20~25℃, fineness 1.0~3.0dtex; (5) Splitting and laying: diffuser angle 20º~30º, web forming speed 30~120m / min, negative pressure in web forming area 200-600Pa; (6) Hot rolling and consolidation: hot rolling roll temperature upper roll 145~155℃, lower roll 135~145℃, linear pressure 40~80N / mm, rolling point gap 0.08~0.2mm, rolling speed 50~150m / min; (7) Winding and slitting: winding tension 10~25N / m, slitting blade speed ratio 1.001~1.005.

[0043] When the fiber raw material of the nonwoven fabric is nylon, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 240~250℃, compression section 260~270℃ / PA6, 270~280℃ / PA66, metering section 265~275℃ / PA6, 275~285℃ / PA66, melt pipe 270~280℃, spinning box 275~285℃, melt pressure 6~12 MPa; (3) spinning and cooling molding: metering pump speed 15~35rpm, spinneret orifice diameter 0.25~0.40mm, spinneret orifice length-to-diameter ratio 2:1~4:1, side blowing air temperature 20~24℃, wind speed 0.4~0.7m / s, wind distance 1.0~1.5m; (4) high-speed airflow drawing: drawing wind speed 4000~6500m / min , , drawing air temperature 22~26℃, venturi tube pressure 0.4~0.8MPa, drawing channel length 2.0~3.0m, fineness control 0.8~2.2dtex; (5) filament splitting and web laying: diffuser angle 10º~20º, web forming speed 40~100m / min, negative pressure in web forming area 400-800Pa; (6) hot rolling consolidation: hot rolling roll temperature upper roll 190~205℃ / PA6, 200~215℃ / PA66, lower roll temperature 185~200℃ / PA6, 195~210℃ / PA66, linear pressure 50~90N / mm, rolling point gap 0.05~0.12mm, antistatic treatment: according to surface density 0.2~0.5g / m 2 Coating with carbon nanotube dispersion, roller speed 50-150m / min; (7) winding and slitting: winding tension 15-35N / m, winding taper 8-12%.

[0044] In embodiments of the present invention, an aluminum film is deposited on the surface of the nonwoven fabric, which can be achieved using direct plating, transfer plating, or composite plating. Direct plating is the most direct method, where the nonwoven fabric substrate is directly fed into a vacuum aluminum plating machine. Under a high vacuum environment, high-purity aluminum wire (or aluminum ingot) is heated to a high temperature for evaporation (or sputtering). The aluminum atoms vaporize and condense on the surface of the nonwoven fabric, forming a very thin aluminum film. Transfer plating is an indirect aluminum plating method, where aluminum is first deposited onto a carrier film and then transferred and adhered to the nonwoven fabric. Composite plating involves bonding an aluminum-plated plastic film (aluminized film) to the nonwoven fabric using adhesives (dry lamination or hot melt adhesive lamination) or hot pressing (extrusion lamination) to form a composite structural material.

[0045] In a preferred embodiment of the present invention, the pleating process adopts an ultrasonic composite mechanical pleating method, wherein the ultrasonic power is 20-40kHz, the pressure roller temperature is 110-140℃, the linear pressure is 0.3-0.8 MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0046] This invention combines ultrasonic energy with mechanical pleating, achieving a synergistic effect of physical shaping and molecular-level bonding. Specifically: 1. Breakthrough in pleat shaping durability. Ultrasonic effect: High-frequency vibration reorganizes fiber molecular chains, forming micro-melting anchor points at the crests and troughs of the pleats, resulting in a pleat recovery rate of >92% after 50 washes; Temperature synergy: Roller heating maintains the overall temperature field, avoiding local overheating and carbonization. 2. Significant improvement in down-proof performance. Ultrasonic waves generate a micro-melting welding effect at the pleat junctions, increasing the fusion density at fiber cross-points by 5-8 times, greatly reducing down leakage and reaching medical protective clothing standards. 3. Significant energy saving and consumption reduction. Due to the presence of ultrasonic energy, the roller temperature can be reduced by about 30°C. 4. Precise control of air permeability. Ultrasonic selective welding technology: Only the pleat apex (occupying 10-15% of the area) is fused, preserving the through-type air permeable channels in the pleat grooves, achieving an air permeability of over 800mm / s.

[0047] In the above method, ultrasonic power, pressure roller temperature, linear pressure, and cooling rate are key parameters. This invention has found that controlling these parameters within the above ranges is beneficial to achieving the desired effects of this invention.

[0048] Understandably, when product requirements are not high, other methods known in the art can also be used for pleating. For example, irregular pleats can be shaped using steam softening combined with mechanical methods (the pleat depth can be controlled by the number of processing steps).

[0049] To facilitate understanding of the pleated nonwoven fabric and its preparation method provided by the present invention, some specific embodiments are described below.

[0050] Example 1

[0051] This embodiment provides a pleated nonwoven fabric, which is formed by a pleating process. The pleats are continuous wavy patterns with a wave height of 3mm, a wavelength of 6mm, and a wave density of 2 pleats / cm². The fiber raw material of the nonwoven fabric is polyester.

[0052] This embodiment also provides a method for preparing the above-mentioned pleated nonwoven fabric, the specific steps of which are as follows:

[0053] (1) Feeding materials;

[0054] (2) Melt extrusion: Temperature control is 265℃ for the feeding section, 280℃ for the compression section, 285℃ for the metering section, 290℃ for the melt pipeline, and 295℃ for the spinning box. The melt pressure is 10MPa.

[0055] (3) Spinning and cooling molding: metering pump speed 30 rpm, spinneret orifice diameter 0.35 mm, spinneret orifice length-to-diameter ratio 4:1, side blowing air temperature 25℃, wind speed 0.8 m / s, wind distance 1 m;

[0056] (4) High-speed airflow stretching: stretching wind speed 5000m / min, stretching wind temperature 25℃, fineness 2.0dtex;

[0057] (5) Splitting and laying the net: diffuser angle 20º, net forming speed 100m / min, negative pressure in the net forming area 500Pa;

[0058] (6) Hot rolling consolidation: hot rolling roll temperature: upper roll 230℃, lower roll 210℃, linear pressure 90N / mm, rolling point gap 0.1mm, roll speed 100m / min;

[0059] (7) Winding and slitting: Winding tension 20 N / m, slitting blade speed ratio 1.002;

[0060] (8) Pleating: Ultrasonic composite mechanical pleating method is adopted, wherein the ultrasonic power is 20kHz, the pressure roller temperature is 120℃, the linear pressure is 0.5MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0061] The pleated nonwoven fabric obtained in the embodiments of the present invention is as follows: Figure 1 As shown.

[0062] Example 2

[0063] This embodiment provides a pleated nonwoven fabric, which is formed by a pleating process. The pleats are continuous wavy patterns with a wave height of 3mm, a wavelength of 6mm, and a wave density of 2 pleats / cm². The fiber raw material of the nonwoven fabric is polypropylene.

[0064] This embodiment also provides a method for preparing the above-mentioned pleated nonwoven fabric, the specific steps of which are as follows:

[0065] (1) Feeding materials;

[0066] (2) Melt extrusion: Temperature control is 185℃ for the feeding section, 205℃ for the compression section, 215℃ for the metering section, 220℃ for the melt pipeline, and 225℃ for the spinning box. The melt pressure is 7MPa.

[0067] (3) Spinning and cooling molding: metering pump speed 40 rpm, spinneret orifice diameter 0.4 mm, spinneret orifice length-to-diameter ratio 3:1, side blowing temperature 20℃, wind speed 0.6 m / s, wind distance 0.8 m;

[0068] (4) High-speed airflow stretching: stretching wind speed 4000m / min, stretching wind temperature 25℃, fineness 2.0dtex;

[0069] (5) Splitting and laying the net: diffuser angle 25º, net forming speed 80m / min, negative pressure in the net forming area 400Pa;

[0070] (6) Hot rolling consolidation: hot rolling roll temperature: upper roll 150℃, lower roll 140℃, linear pressure 60N / mm, rolling point gap 0.15mm, roll speed 100m / min;

[0071] (7) Winding and slitting: Winding tension 18 N / m, slitting blade speed ratio 1.003;

[0072] (8) Pleating: Ultrasonic composite mechanical pleating method is adopted, wherein the ultrasonic power is 30kHz, the roller temperature is 115℃, the linear pressure is 0.5MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0073] Example 3

[0074] This embodiment provides a pleated nonwoven fabric, which is formed by a pleating process. The pleats are continuous wavy patterns with a wave height of 2mm, a wavelength of 5mm, and a wave density of 4 pleats / cm². The fiber raw material of the nonwoven fabric is nylon PA66.

[0075] This embodiment also provides a method for preparing the above-mentioned pleated nonwoven fabric, the specific steps of which are as follows:

[0076] (1) Feeding materials;

[0077] (2) Melt extrusion: Temperature control is 245℃ for the feeding section, 275℃ for the compression section, 280℃ for the metering section, 275℃ for the melt pipeline, 280℃ for the spinning box, and 9MPa for the melt pressure;

[0078] (3) Spinning and cooling molding: metering pump speed 25 rpm, spinneret orifice diameter 0.3 mm, spinneret orifice length-to-diameter ratio 4:1, side blowing air temperature 20℃, wind speed 0.5 m / s, wind distance 1.2 m;

[0079] (4) High-speed airflow stretching: stretching wind speed 5500m / min, stretching wind temperature 24℃, venturi tube pressure 0.6MPa, stretching channel length 2.5m, and fineness control 1.5dtex;

[0080] (5) Splitting and laying the net: diffuser angle 15º, net forming speed 70m / min, negative pressure in the net forming area 600Pa;

[0081] (6) Hot rolling consolidation: upper roll temperature 210℃, lower roll temperature 200℃, linear pressure 70N / mm, rolling point gap 0.08mm, antistatic treatment: based on surface density 0.5g / m 2 Carbon nanotube dispersion was coated, and the roller speed was 100 m / min.

[0082] (7) Winding and slitting: Winding tension 25 N / m, winding taper 10%;

[0083] (8) Pleating: Ultrasonic composite mechanical pleating method is adopted, wherein the ultrasonic power is 40kHz, the pressure roller temperature is 110℃, the linear pressure is 0.5MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0084] Example 4

[0085] This embodiment provides a pleated nonwoven fabric, which is formed by depositing an aluminum film on the surface of the nonwoven fabric and then forming it through a pleating process. The resulting pleats are discrete honeycomb patterns with a honeycomb pore size of 5mm, a depth of 3mm, and a honeycomb pattern density of 4 pores / cm². The fiber raw material of the nonwoven fabric is polyester.

[0086] This embodiment also provides a method for preparing the above-mentioned pleated nonwoven fabric, the specific steps of which are as follows:

[0087] (1) Feeding materials;

[0088] (2) Melt extrusion: The temperature is controlled as follows: 265℃ for the feeding section, 280℃ for the compression section, 285℃ for the metering section, 290℃ for the melt pipe, and 295℃ for the spinning box. The melt pressure is 10MPa.

[0089] (3) Spinning and cooling molding: metering pump speed 40 rpm, spinneret orifice diameter 0.3 mm, spinneret orifice length-to-diameter ratio 2:1, side blowing air temperature 25℃, wind speed 0.6 m / s, wind distance 1 m;

[0090] (4) High-speed airflow stretching: stretching wind speed 5000m / min, stretching wind temperature 28℃, fineness 2.0dtex;

[0091] (5) Splitting and laying the net: diffuser angle 20º, net forming speed 100m / min, negative pressure in the net forming area 500Pa;

[0092] (6) Hot rolling consolidation: hot rolling roll temperature: upper roll 230℃, lower roll 210℃, linear pressure 90N / mm, rolling point gap 0.1mm, roll speed 100m / min;

[0093] (7) Winding and slitting: Winding tension 28 N / m, slitting blade speed ratio 1.004;

[0094] (8) Directly deposit aluminum film on the surface of nonwoven fabric;

[0095] (9) Pleating: Ultrasonic composite mechanical pleating method is adopted, wherein the ultrasonic power is 20kHz, the pressure roller temperature is 120℃, the linear pressure is 0.5MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0096] Example 5

[0097] This embodiment provides a pleated nonwoven fabric, which is formed by depositing an aluminum film on the surface of the nonwoven fabric and then forming it through a pleating process. The resulting pleats are discrete honeycomb patterns with a honeycomb pore size of 5 mm, a depth of 2 mm, and a honeycomb pattern density of 4 pores / cm². The fiber raw material of the nonwoven fabric is polypropylene.

[0098] This embodiment also provides a method for preparing the above-mentioned pleated nonwoven fabric, the specific steps of which are as follows:

[0099] (1) Feeding materials;

[0100] (2) Melt extrusion: Temperature control is 185℃ for the feeding section, 205℃ for the compression section, 215℃ for the metering section, 220℃ for the melt pipeline, and 225℃ for the spinning box. Melt pressure is 8MPa.

[0101] (3) Spinning and cooling molding: metering pump speed 40 rpm, spinneret orifice diameter 0.4 mm, spinneret orifice length-to-diameter ratio 3:1, side blowing air temperature 20℃, wind speed 0.6 m / s, wind distance 0.7 m;

[0102] (4) High-speed airflow stretching: stretching wind speed 4000m / min, stretching wind temperature 25℃, fineness 2.0dtex;

[0103] (5) Splitting and laying the net: diffuser angle 25º, net forming speed 80m / min, negative pressure in the net forming area 400Pa;

[0104] (6) Hot rolling consolidation: hot rolling roll temperature: upper roll 150℃, lower roll 140℃, linear pressure 60N / mm, rolling point gap 0.15mm, roll speed 100m / min;

[0105] (7) Winding and slitting: Winding tension 18 N / m, slitting blade speed ratio 1.002;

[0106] (8) Directly deposit aluminum film on the surface of nonwoven fabric;

[0107] (9) Pleating: Ultrasonic composite mechanical pleating method is adopted, wherein the ultrasonic power is 30kHz, the roller temperature is 115℃, the linear pressure is 0.5MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0108] Example 6

[0109] This embodiment provides a pleated nonwoven fabric, which is formed by depositing an aluminum film on the surface of the nonwoven fabric and then forming it through a pleating process. The resulting pleats are discrete honeycomb patterns with a honeycomb pore size of 3mm, a depth of 1mm, and a honeycomb pattern density of 10 pores / cm². The fiber raw material of the nonwoven fabric is nylon PA6.

[0110] This embodiment also provides a method for preparing the above-mentioned pleated nonwoven fabric, the specific steps of which are as follows:

[0111] (1) Feeding materials;

[0112] (2) Melt extrusion: Temperature control is 245℃ for the feeding section, 265℃ for the compression section, 270℃ for the metering section, 275℃ for the melt pipe, 280℃ for the spinning box, and 10 MPa for the melt pressure;

[0113] (3) Spinning and cooling molding: metering pump speed 25 rpm, spinneret orifice diameter 0.3 mm, spinneret orifice length-to-diameter ratio 4:1, side blowing air temperature 24℃, wind speed 0.5 m / s, wind distance 1.3 m;

[0114] (4) High-speed airflow stretching: stretching wind speed 5500m / min, stretching wind temperature 25℃, venturi tube pressure 0.6MPa, stretching channel length 2.5m, and fineness control 1.5dtex;

[0115] (5) Splitting and laying the net: diffuser angle 15º, net forming speed 70m / min, negative pressure in the net forming area 600Pa;

[0116] (6) Hot rolling consolidation: upper roll temperature 200℃, lower roll temperature 195℃, linear pressure 70N / mm, rolling gap 0.08mm, antistatic treatment: based on surface density 0.3g / m 2 Carbon nanotube dispersion was coated, and the roller speed was 100 m / min.

[0117] (7) Winding and slitting: Winding tension 25 N / m, winding taper 10%;

[0118] (8) Directly deposit aluminum film on the surface of nonwoven fabric;

[0119] (9) Pleating: Ultrasonic composite mechanical pleating method is adopted, wherein the ultrasonic power is 40kHz, the pressure roller temperature is 110℃, the linear pressure is 0.5MPa, and the cooling rate is greater than or equal to 10℃ / s.

[0120] Performance testing

[0121] 1. Testing of fabric thermal resistance and clo value, etc.

[0122] Testing standard: GB / T 11048-2008

[0123] Pleated nonwoven fabric sample specifications: 45cm × 45cm

[0124] The test results are shown in Table 1.

[0125] Table 1

[0126]

[0127] 2. Water wash resistance test

[0128] Testing standard: GB / T 8629-2017

[0129] Washing method: 4N 3-time F program drying

[0130] Judgment Criteria: FZ / T64003-2021.6.7

[0131] Standard value: No exposed bottom, no obvious damage or delamination.

[0132] Test Results: The effect of washing the sample in Example 1 is shown in Figure 2. The effect of washing the sample in Example 2 is shown in Figure 2. Figure 3 As shown in the image. Example 3: Sample after water washing. Figure 4 As shown, although the folds are flatter after washing than before, there are no abnormal changes such as exposed base material, obvious damage, or delamination, so it meets the requirements.

[0133] The thermal resistance and clo value of the fabrics after washing in Examples 1-3 are shown in Table 2.

[0134] Table 2

[0135]

[0136] As can be seen from the above results, the embodiments of the present invention, by designing a non-woven fabric with a specific pleated structure as a thermal insulation material, achieve a balance and breakthrough in four properties: resistance to water washing deformation, prevention of down leakage, high thermal insulation and breathability, which is significantly superior to the existing technology.

[0137] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing a pleated nonwoven fabric, characterized in that, After producing nonwoven fabric using the spunbond method, an aluminum film is applied to the surface of the nonwoven fabric, or no aluminum film is applied, followed by a pleating process. After the nonwoven fabric is pleated, the resulting pleats are either continuous wavy patterns with a wave height of 1-3 mm and a wavelength of 5-10 mm, or discrete honeycomb patterns with a pore size of 2-8 mm. The fiber raw material of the nonwoven fabric is selected from one of polyester, polypropylene, and nylon fibers. The pleating process employs an ultrasonic composite mechanical pleating method, wherein the ultrasonic power is 20-40kHz, the pressure roller temperature is 110-140℃, the linear pressure is 0.3-0.8 MPa, and the cooling rate is greater than or equal to 10℃ / s. The spunbond method includes the following steps: feeding, melt extrusion, spinning, cooling and molding, high-speed airflow stretching, filament splitting and web laying, hot rolling and bonding, and winding and slitting. When polyester is selected as the fiber raw material for the nonwoven fabric, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 260-270℃, compression section 275-285℃, metering section 280-290℃, melt pipe 285-295℃, spinning box 290-300℃, melt pressure 8-15MPa; (3) spinning and cooling molding: metering pump speed 20-50rpm, spinneret orifice diameter 0.25-0.35mm, spinneret orifice length-to-diameter ratio 2:1~4:1, side blowing air temperature 20-25℃, wind speed 0.5~0.8m / s, wind distance 0.8~1.2m; (4) high-speed airflow traction (5) Splitting and web laying: diffuser angle 15º~25º, web forming speed 50~150m / min, negative pressure in web forming area 300-800Pa; (6) Hot rolling and consolidation: hot rolling roll temperature upper roll 220~240℃, lower roll 200~220℃, linear pressure 60~120N / mm, rolling point gap 0.05~0.15mm, rolling speed 50~150m / min; (7) Winding and slitting: winding tension 15~30N / m, slitting blade speed ratio 1.001~1.005; Alternatively, when polypropylene is selected as the fiber raw material for the nonwoven fabric, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 180-190℃, compression section 200-210℃, metering section 210-220℃, melt pipe 215-225℃, spinning box 220-230℃, melt pressure 4-10MPa; (3) spinning and cooling molding: metering pump speed 20-60rpm, spinneret orifice diameter 0.3-0.5mm, spinneret orifice length-to-diameter ratio 2:1~4:1, side blowing air temperature 18-25℃, wind speed 0.5~0.8m / s, wind distance 0.5~1.0m; (4) high-speed airflow drawing: drawing wind speed 3000-5000m / min, drawing wind temperature 20~25℃, fineness 1.0~3.0dtex; (5) Splitting and laying: diffuser angle 20º~30º, web forming speed 30~120m / min, negative pressure in web forming area 200-600Pa; (6) Hot rolling and consolidation: hot rolling roll temperature upper roll 145~155℃, lower roll 135~145℃, linear pressure 40~80N / mm, rolling point gap 0.08~0.2mm, rolling speed 50~150m / min; (7) Winding and slitting: winding tension 10~25N / m, slitting blade speed ratio 1.001~1.005; Alternatively, when the fiber raw material of the nonwoven fabric is nylon, the spunbond method specifically includes: (1) feeding; (2) melt extrusion: the temperature is controlled as follows: feeding section 240-250℃, compression section 260-270℃ / PA6, 270-280℃ / PA66, metering section 265-275℃ / PA6, 275-285℃ / PA66, melt pipe 270-280℃, spinning box 275-285℃, melt pressure 6-12 MPa; (3) spinning and cooling molding: metering pump speed 15-35 rpm, spinneret orifice diameter 0.25-0.40 mm, spinneret orifice length-to-diameter ratio 2:1-4:1, side blowing air temperature 20-24℃, wind speed 0.4-0.7 m / s, wind distance 1.0-1.5 m; (4) high-speed airflow drawing: drawing wind speed 4000-6500 m / min , , drawing air temperature 22~26℃, venturi tube pressure 0.4~0.8MPa, drawing channel length 2.0~3.0m, fineness control 0.8~2.2dtex; (5) filament splitting and web laying: diffuser angle 10º~20º, web forming speed 40~100m / min, negative pressure in web forming area 400-800Pa; (6) hot rolling consolidation: hot rolling roll temperature upper roll 190~205℃ / PA6, 200~215℃ / PA66, lower roll temperature 185~200℃ / PA6, 195~210℃ / PA66, linear pressure 50~90N / mm, rolling point gap 0.05~0.12mm, antistatic treatment: according to surface density 0.2~0.5g / m 2 Coating with carbon nanotube dispersion, roller speed 50-150m / min; (7) winding and slitting: winding tension 15-35N / m, winding taper 8-12%.

2. The method for preparing pleated nonwoven fabric according to claim 1, characterized in that, The fiber raw material of the nonwoven fabric also contains auxiliaries, which are selected from one or more of masterbatch, antibacterial agent, and antistatic agent.

3. The application of pleated nonwoven fabric in the preparation of thermal insulation products, characterized in that, The pleated nonwoven fabric is prepared by the method for preparing pleated nonwoven fabric according to claim 1 or 2.

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