Composite non-woven fabric material for protective clothing and preparation method of composite non-woven fabric material
By combining spunbond PP nonwoven fabric with microporous PE breathable membrane through an online composite process, the problems of low production efficiency and high energy consumption of protective clothing materials have been solved, realizing the preparation of high-efficiency, energy-saving, and low-cost protective clothing materials, and improving the protective and breathable properties of the materials.
Patent Information
- Application Number
- CN202511400152.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-28
- Publication Date
- 2025-12-12
AI Technical Summary
Existing protective clothing material manufacturing processes suffer from problems such as long production processes, high energy consumption, low efficiency, high defect rates, and large material losses. Furthermore, traditional composite processes can easily lead to decreased breathability or poor material performance.
By employing an online composite process, spunbond PP nonwoven fabric is combined with microporous PE breathable membrane, and the inner and outer layers are formed by hot pressing. Combined with magnetic levitation tension control and glue-free heating and pressing, efficient and energy-saving production is achieved.
It improves production efficiency, reduces energy consumption and costs, ensures high protective and moisture-permeable properties of materials, and reduces scrap rate and VOC emissions, meeting the requirements of green manufacturing.
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of protective materials, in particular to a composite non-woven fabric material for protective clothing and a preparation method thereof. BACKGROUND
[0002] Protective clothing, especially medical protective clothing, is a key barrier to protect medical staff from blood, body fluids, droplets and microbial infections. The ideal protective clothing should have excellent liquid barrier property (water resistance, blood penetration resistance), high moisture permeability (wearing comfort), good mechanical property and necessary antistatic property. Traditional protective clothing materials are mostly composed of multi-layer composite materials, but their production often faces the problem of contradiction between "waterproof" and "breathable".
[0003] At present, the common preparation process of protective clothing materials on the market mainly adopts offline composite process, which needs to produce spunbond non-woven fabric substrate and functional film respectively, and then carries out secondary processing and compounding on another composite equipment. This process has the disadvantages of long production process, high energy consumption, low production efficiency, high scrap rate and large material loss caused by multiple winding and unwinding.
[0004] In the prior art, the preparation process of protective clothing materials is mostly focused on the material itself or offline compounding method, and there is still a large space for improvement in how to realize efficient, energy-saving and low-cost integrated production with excellent performance through integrated production process. For example, the glue in the offline compounding process is easy to block the micropores of PE film, affecting its breathability; and if the temperature and pressure control of traditional hot pressing compounding is improper, the fiber structure is easy to be damaged or the breathability is reduced.
[0005] Therefore, there is an urgent need in the art for an integrated solution that can combine high-performance materials with efficient, energy-saving and low-cost advanced manufacturing processes. SUMMARY
[0006] The primary purpose of the present application is to overcome the shortcomings of the prior art and provide a composite non-woven fabric material for protective clothing, which has high protection, high moisture permeability and good durability. The preparation method of the composite non-woven fabric material is also provided, which adopts online compounding process to simplify the production process, reduce energy consumption, improve production efficiency and optimize the comprehensive performance of the product.
[0007] The above technical purpose of the present application is achieved by the following technical scheme: A composite non-woven fabric material for protective clothing, comprising: an inner layer comprising a spunbond PP non-woven fabric, wherein the spunbond PP non-woven fabric has a grammage of 35-50 g / m 2 ; Outer layer: including PE breathable film, the thickness of the PE breathable film is 0.03-0.05mm, the PE breathable film is provided with a microporous structure, and the microporous aperture is 0.01-10μm; The inner layer and the outer layer are combined through an online compounding process.
[0008] As a further arrangement of the application, the moisture permeation amount of the PE breathable film is ≥8000g / (m 2 ·d, and the hydrostatic pressure resistance is ≥100cmH2O.
[0009] As a further arrangement of the application, the PE breathable film is embedded with an antistatic master batch, and the volume resistance is ≤1×10 12 Ω.
[0010] As a further arrangement of the application, the microporous structure is formed by adding 35-50% calcium carbonate in mass percentage in the PE base material, and the porosity is 15-35%.
[0011] A preparation method of the composite non-woven fabric material according to the above-mentioned arrangement, comprising the following steps: S1, providing a spunbonded PP non-woven fabric material and a PE breathable film; S2, after the spunbonded PP non-woven fabric is hot-rolled and formed on a spunbonded production line, the PE breathable film is hot-pressed and compounded on the PP non-woven fabric in line; S3, after the hot-pressing and compounding, the material is finally compressed to ensure complete lamination between the layers; S4, the composite non-woven fabric material after compression is cooled and shaped, and then the composite non-woven fabric material is wound.
[0012] As a further arrangement of the application, in step S1, the PE breathable film is also subjected to corona treatment before compounding, and the corona voltage is 2-3kV.
[0013] As a further arrangement of the application, in step S1, a double-station unwinding system and a magnetic suspension tension control system are adopted in the production process, and the tension control precision is ±0.5N.
[0014] As a further arrangement of the application, in step S2, the temperature of the hot-pressing and compounding is 140-165℃, the pressure is 9-11MPa, the hot-pressing and compounding uses a point roller cooperating with a light roller, the point roller has a convex point area of 15-30% and a depth of 0.4-1.0mm.
[0015] As a further arrangement of the application, in step S4, the cooling and shaping is achieved by using a cold roller, and the cooling medium is circulating water.
[0016] The application has the following beneficial effects: The present application is compounded by microporous hydrophobic PE breathable film and spun-bonded PP non-woven fabric, so that the composite material has high protection and high moisture permeability, solving the problem of stuffiness of traditional protective clothing.
[0017] The present application is compounded by online compounding process, reducing intermediate links, improving production line speed, improving production efficiency, and reducing comprehensive energy consumption. Using PP / PE as raw material, the cost is low, and online compounding reduces labor, electricity and material loss, and the overall cost is lower than using traditional high-end material scheme. Hot-pressing compounding without glue avoids micropore blockage and ensures the consistency of product performance; at the same time, VOCs emission is reduced, which meets the green manufacturing trend. DETAILED DESCRIPTION
[0018] The technical solutions of the present application will be described below in conjunction with specific embodiments. Obviously, the described embodiments are only a part of the embodiments of the present application, not all. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the present application.
[0019] Embodiment 1 A kind of composite non-woven fabric material for protective clothing, including inner layer and outer layer, inner layer and outer layer are combined by online compounding process.
[0020] The inner layer includes spun-bonded PP non-woven fabric, and the spun-bonded PP non-woven fabric has a grammage of 35-50 g / m 2 , for providing mechanical support and wear resistance.
[0021] The outer layer includes PE breathable film, and the PE breathable film has a thickness of 0.03-0.05 mm. The PE breathable film uses LDPE / LLDPE as a base material, forms 0.01-10 μm microporous structure by adding 35-50% calcium carbonate master batch, realizes the balance of high moisture permeability and high hydrostatic pressure, and has a moisture permeability of ≥8000 g / (m 2 ·d) and a hydrostatic pressure of ≥100 cmH2O.
[0022] The PE breathable film also has a microporous hydrophobic mechanism and an antistatic modification. The microporous hydrophobic mechanism is realized by longitudinally stretching the PE breathable film, so that the microporous structure of the PE breathable film is more uniform, and the porosity reaches 15-35%. At the same time, the stretching can also adjust the thickness of the PE breathable film, so as to ensure that the PE breathable film allows water vapor to pass through but blocks liquid and microorganisms.
[0023] The antistatic modification is realized by embedding antistatic master batch in the PE breathable film, so that the volume resistance of the PE breathable film is ≤1×10 12 Ω, to avoid electrostatic adsorption of dust.
[0024] Embodiment 2 A method for preparing the composite non-woven material, comprising the following steps: S1, preparing the material of the spunbonded PP non-woven fabric and the PE breathable film; The PE breathable film has formed a microporous structure through processes such as filling and stretching. Before compounding, the PE breathable film can be subjected to corona treatment. This process increases the surface energy of the material through high-voltage discharge, which can significantly improve the peeling strength of subsequent compounding. This means that less glue or lower pressure can be used to achieve firm compounding, thereby reducing energy consumption and material consumption from the source.
[0025] S2, after the spunbonded PP non-woven fabric is hot-rolled and formed on the spunbond production line, the PE breathable film is hot-pressed and compounded on the PP non-woven fabric in line; A double-station automatic roll changing system is adopted to ensure continuous production and reduce energy waste caused by downtime.
[0026] This embodiment adopts a magnetic suspension tension control system, which replaces the traditional mechanical brake and precisely controls the substrate tension through non-contact. The friction loss is almost eliminated, and the tension control accuracy can reach ±0.5N. This not only saves 3%-5% of the substrate (reduces stretching and waste), but also comprehensively improves the energy efficiency by 8%-12% through the dynamic adjustment function of the AI algorithm.
[0027] Hot-pressing compounding is a glue-free compounding process that can avoid glue blocking the micropores of the PE breathable film, thereby better maintaining its breathability.
[0028] Specifically, hot-pressing compounding uses a smooth surface roller and a point roller with protrusions on the surface for paired pressure. These protrusions are usually square structures with a side length of 0.6-1.0mm, and the protrusion area rate is controlled at 15%-30%, with a depth of 0.4-1.0mm. This design ensures firm mechanical engagement under pressure while retaining a large number of breathable channels.
[0029] This hot-pressing compounding process does not require glue heating, coating, and curing, directly saving related energy consumption and material costs. Combined with low-temperature compounding (temperature can be reduced to 80-120℃), it reduces heat energy consumption by about 30% compared to traditional high-temperature compounding.
[0030] S3, after hot-pressing compounding, the composite material is subjected to final pressing through a pair of pressing rollers to ensure complete lamination between the layers; S4, the pressed composite non-woven fabric material is cooled and shaped, and then the composite non-woven fabric material is wound.
[0031] The cooled roller adopts a circulating water cooling system to make the hot melt glue quickly crystallize or the hot-pressed part set, thereby enhancing the compounding firmness. The efficient heat exchange system can reduce the energy consumption of cooling water.
[0032] Then the composite material is rolled using a winding machine equipped with automatic tension control, ensuring that the roll is consistent in tightness, facilitating subsequent processing.
[0033] In addition, the composite material can also be detected and corrected online before rolling, integrating a visual detection system to monitor the surface defects, holes and other quality defects of the composite material in real time, and timely alarm or automatic marking, greatly reducing the waste rate and realizing energy saving driven by quality. The automatic correction device ensures that the material is always in the correct position during transmission, preventing material waste and equipment damage caused by deviation.
[0034] Through the fine management and technical innovation of the above steps, the modern online composite production line can achieve: Energy saving: The comprehensive energy consumption can be reduced by about 30% compared with traditional process.
[0035] Production efficiency improvement: High-speed continuous production, line speed up to 120-150 meters / minute, high degree of automation, efficiency improvement more than 20%.
[0036] Quality and environmental protection: While improving product consistency and performance, reducing waste and VOCs emissions, meeting the trend of green manufacturing.
[0037] Those skilled in the art will readily understand that the above description is only a preferred embodiment of the present application and is not intended to limit the present application. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims
1. A composite nonwoven material for protective clothing, characterized in that, The application relates to a composite non-woven fabric, which comprises the following layers: an outer layer comprising a PE breathable film, wherein the PE breathable film has a thickness of 0.03-0.05 mm, the PE breathable film is provided with a microporous structure, and the microporous structure has a pore size of 0.01-10 mu m; and an inner layer. Inner layer: comprising a spunbonded PP nonwoven having a grammage of 35-50 g / m 2 ; The inner layer and the outer layer are combined through an online compounding process. The microporous structure is formed by adding 35-50% calcium carbonate in the PE base material in terms of mass percentage, and the porosity is 15-35%.
2. The composite nonwoven material of claim 1, wherein, The PE breathable film has a moisture permeation amount ≥ 8000 g / (m 2 ·d) and a hydrostatic pressure resistance ≥ 100 cm H2O.
3. The composite nonwoven material of claim 1, wherein, The PE breathable film is embedded with antistatic masterbatch, and the volume resistance is less than or equal to 1*10 12 Ω.
4. The composite nonwoven material of claim 1, wherein, The application further discloses a production method of the composite non-woven fabric.
5. A method of producing a composite nonwoven material as claimed in any one of claims 1 to 4, characterized in that, S1, preparing a spun-bonded PP non-woven fabric material and a PE breathable film; S2, after the spun-bonded PP non-woven fabric material is hot-rolled and formed into a PP non-woven fabric through a spun-bonded production line, the PE breathable film is hot-pressed and compounded onto the PP non-woven fabric through an online process; S3, after the hot-pressing and compounding, the composite material is finally compressed to ensure that the layers are completely attached to each other; S4, the composite non-woven fabric material after compression is cooled and shaped, and then the composite non-woven fabric material is wound. In step S1, the PE breathable film is subjected to a corona treatment before compounding, and the corona voltage is 2-3 kV.
6. The method of claim 5, wherein, In step S1, a double-station unwinding system and a magnetic suspension tension control system are adopted in the production process, and the tension control precision is + / -0.5 N.
7. The method of claim 5, wherein, In step S2, the temperature of the hot-pressing and compounding is 140-165 DEG C, the pressure is 9-11 MPa, the hot-pressing and compounding uses a point roller and a smooth roller in cooperation, the point roller has a convex point area of 15-30% and a depth of 0.4-1.0 mm.
8. The method of claim 5, wherein, In step S4, the cooling and shaping is achieved by using a cold roller, and the cooling medium is circulating water.
9. The method of claim 5, wherein,