A bamboo fiber material cloth with adsorption and air filtration functions and its manufacturing process

Abstract

This invention discloses a bamboo fiber material fabric with adsorption and air filtration functions and its manufacturing process, relating to the field of air filtration materials technology. The bamboo fiber material fabric comprises at least two non-woven fabric layers and a bamboo fiber layer disposed between adjacent non-woven fabric layers. The bamboo fiber layer is formed by weaving or laying bamboo fibers. The non-woven fabric layer and the bamboo fiber layer are needle-punched to form a fiber entanglement structure, thus combining the non-woven fabric layer and the bamboo fiber layer into an integrated composite fabric layer. This integrated composite fabric layer has a fibrous pore structure that allows air to pass through. During manufacturing, the bamboo fibers are opened, impurities removed, and dried to form the bamboo fiber layer, which is then laminated with the non-woven fabric layer, pre-pressed, needle-punched, shaped, and cut or rolled. This invention is advantageous in simultaneously achieving air filtration, odor adsorption, and interlayer bonding stability.

Description

Technical Field

[0001] This invention relates to the field of air filtration materials technology, specifically to a bamboo fiber material cloth with adsorption and air filtration functions and its manufacturing process. Background Technology

[0002] Air filtration materials are commonly used in automotive air conditioning filters, air purifier filters, indoor ventilation filters, and duct lining filters. They primarily intercept dust, lint, particulate matter, and other impurities in the air through the porous structure of their fiber layers. Existing filter cloths are mostly made of non-woven fabrics, meltblown fabrics, and composite fiber cloths, which offer a certain degree of breathability and filtration effectiveness, meeting the needs of general air filtration applications.

[0003] However, in environments such as car interiors, indoor air purification systems, and ventilation ducts, filter materials not only need to intercept airborne particulate matter but also need to adsorb odor molecules, odor-causing substances in humid air, or some volatile substances. Ordinary non-woven fabric materials mainly rely on fiber pores to intercept particles, and their own odor adsorption capacity is limited, making it difficult to meet the needs of both air filtration and odor adsorption.

[0004] To improve the deodorization or adsorption performance of filter materials, existing technologies include adding activated carbon particles, adsorption powders, or other functional fillers to the nonwoven fabric layer. However, these fillers typically need to be fixed to the base fabric by adhesive bonding, hot pressing, or clamping, which can easily lead to problems such as uneven filler distribution, localized accumulation, powder shedding, detachment, or unstable interlayer bonding. Furthermore, adhesives or excessive pressing can clog fiber pores, increasing airflow resistance and affecting the air permeability and stability of the filter material.

[0005] Furthermore, for multi-layer composite filter cloths, the bonding stability between the layers directly affects the processing, cutting, winding, and long-term performance of the cloth. If bamboo fiber, plant fiber, or other functional fibers are loosely laid between the non-woven fabrics, they are prone to shifting, wrinkling, local delamination, or peeling during transportation, cutting, or use, which affects the pore structure and filtration stability of the composite cloth layers.

[0006] Therefore, it is necessary to provide a bamboo fiber material cloth with adsorption and air filtration functions and its manufacturing process. By setting the bamboo fiber layer between adjacent non-woven fabric layers and forming a fiber entanglement structure through needle punching, the non-woven fabric layer and the bamboo fiber layer are combined into an integrated composite cloth layer to solve the problems of existing air filter cloths in terms of air filtration, odor adsorption, interlayer bonding stability and breathability. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a bamboo fiber material cloth with adsorption and air filtration functions and its manufacturing process, which solves the problem that existing air filter cloths cannot simultaneously achieve air filtration, odor adsorption, breathability, and interlayer bonding stability.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a bamboo fiber material cloth with adsorption and air filtration functions, comprising a non-woven fabric layer and a bamboo fiber layer, wherein the non-woven fabric layer has at least two layers, and the bamboo fiber layer is disposed between two adjacent non-woven fabric layers. The bamboo fiber layer is formed by weaving or laying bamboo fibers. The non-woven fabric layer and the bamboo fiber layer are needle-punched to form a fiber entanglement structure, thereby combining the non-woven fabric layer and the bamboo fiber layer into an integral composite cloth layer. The integral composite cloth layer has a fiber pore structure that allows air to pass through.

[0009] Furthermore, the integrated composite fabric layer includes multiple material layers stacked sequentially along the thickness direction. The total number of the multiple material layers is an odd number. The material layers on both outer sides of the thickness direction are non-woven fabric layers. The intermediate material layers between the two outer non-woven fabric layers are alternately arranged with bamboo fiber layers and non-woven fabric layers along the thickness direction. The intermediate material layers adjacent to the two outer non-woven fabric layers are all bamboo fiber layers.

[0010] Furthermore, the bamboo fiber layer is formed by weaving or laying bamboo fibers.

[0011] Furthermore, the bamboo fibers in the bamboo fiber layer are distributed in an intermittent, mesh-like, or interlaced manner.

[0012] Furthermore, the nonwoven fabric layer is a polyester nonwoven fabric layer, a polypropylene nonwoven fabric layer, a viscose fiber nonwoven fabric layer, a polyamide nonwoven fabric layer, or a composite fiber nonwoven fabric layer.

[0013] Furthermore, the fiber entanglement structure includes nonwoven fibers introduced into the bamboo fiber layer by needle punching from at least one side of the nonwoven fabric layer. The nonwoven fibers are entangled with the bamboo fibers in the bamboo fiber layer, and adjacent nonwoven fabric layers are connected to the bamboo fiber layer.

[0014] A manufacturing process for a bamboo fiber material cloth with adsorption and air filtration functions includes the following steps: S1. Prepare non-woven fabric layer and bamboo fiber, and perform opening, impurity removal and drying treatment on the bamboo fiber to form a dispersed fiber state suitable for weaving or laying. S2. The processed bamboo fiber is woven, combed and laid in a net, cross-laid or multi-directionally laid to form a bamboo fiber layer; S3. The bamboo fiber layer is placed between two adjacent non-woven fabric layers, and the non-woven fabric layer and the bamboo fiber layer are overlapped along the thickness direction to form an overlapped fabric. S4. The laminated fabric is subjected to correction conveying and pre-compression treatment to keep the non-woven fabric layer and the bamboo fiber layer in an interlayer alignment state. S5. The pre-compressed composite fabric is needle-punched to allow the non-woven fibers in at least one side of the non-woven fabric layer to enter the bamboo fiber layer and entangle with the bamboo fiber in the bamboo fiber layer to form a fiber entanglement structure, thereby obtaining an integrated composite fabric layer. S6. Press and shape the integrated composite fabric layer to make the thickness of the integrated composite fabric layer more uniform. S7. Perform heat setting or leveling treatment on the integrated composite fabric layer after compression molding. S8. Cut, slit, or roll up the integrated composite fabric layer to obtain the bamboo fiber material fabric.

[0015] Furthermore, in S2, the bamboo fiber layer is formed by weaving, combing and laying, unidirectional laying, cross laying, multidirectional laying or mesh laying.

[0016] Furthermore, in S3, the bamboo fiber layer is disposed between the first nonwoven fabric layer and the second nonwoven fabric layer, or multiple layers of the bamboo fiber layer and multiple layers of the nonwoven fabric layer are alternately stacked along the thickness direction.

[0017] Furthermore, in step S5, the pre-compressed laminated fabric is subjected to single-sided or double-sided needle punching. Beneficial effects

[0018] This invention provides a bamboo fiber material cloth with adsorption and air filtration functions, and its manufacturing process. Compared with the prior art, it has the following advantages: This invention places a bamboo fiber layer between two adjacent nonwoven fabric layers and needle-punches the nonwoven fabric layer and bamboo fiber layer to form a fiber entanglement structure. This transforms the bamboo fiber layer from a simple sandwiched state to an integral composite state that is interconnected with the nonwoven fabric layer. This helps to improve the fixation stability of the bamboo fiber layer in the composite fabric layer and reduces the occurrence of displacement, loosening or interlayer separation of the bamboo fiber layer during transportation, cutting, winding or use.

[0019] In this invention, the integrated composite fabric layer has a fibrous pore structure that allows air to pass through. The bamboo fiber layer is located between adjacent non-woven fabric layers. When air passes through the composite fabric layer, it can pass through both the non-woven fabric layer and the bamboo fiber layer, allowing the bamboo fiber layer to participate in the air filtration and odor adsorption process. Therefore, this invention, while maintaining the breathability of the material fabric, is beneficial for simultaneously meeting the needs of air particulate matter filtration and odor adsorption.

[0020] This invention forms a bamboo fiber layer by weaving or laying bamboo fibers, and allows the bamboo fibers to be distributed in a spaced, meshed, or interlaced manner. This creates gaps or pores within the bamboo fiber layer, increasing the contact opportunities between air and bamboo fibers as it flows through the composite fabric layer. It also helps to improve the uniformity of the bamboo fiber layer distribution in the nonwoven fabric interlayer.

[0021] The integrated composite fabric layer of this invention can adopt a three-layer structure or an odd-numbered alternating layer structure, so that the outer material layers are all non-woven fabric layers, and the bamboo fiber layer is located between adjacent non-woven fabric layers. Thus, the non-woven fabric layers can clamp and protect the bamboo fiber layer, and the bamboo fiber layer can participate in the filtration and adsorption process as an interlayer, making it easy to adjust the number of layers and structure of the composite fabric layer according to different filtration, adsorption, and strength requirements.

[0022] In the manufacturing process of this invention, the bamboo fibers are opened, impurities removed, and dried to form a dispersed fiber state suitable for weaving or laying. Through lamination, correction conveying, pre-compression, and needle punching, the nonwoven fabric layer and the bamboo fiber layer form a fiber entanglement structure while maintaining interlayer alignment. After pressing, heat setting, or leveling, the uniformity of the material fabric thickness, the flatness of the fabric surface, and the stability of subsequent cutting, slitting, or winding are improved. Attached Figure Description

[0023] Figure 1 This is a flowchart illustrating the manufacturing process of the bamboo fiber material cloth with adsorption and air filtration functions of the present invention. Detailed Implementation

[0024] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments and accompanying drawings. It should be understood that the described embodiments are only some embodiments of the present invention and are not intended to limit the scope of protection of the present invention; other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort should all fall within the scope of protection of the present invention. In the description of the present invention, the terms "first," "second," etc., are only used to distinguish identical or similar components and do not indicate any sequential order, importance, or actual quantity limitation between components; unless otherwise explicitly defined, the terms "set," "connect," "combined," etc., should be interpreted broadly, and can refer to direct setting, direct connection, or direct combination, or indirect setting, indirect connection, or indirect combination through an intermediate structure.

[0025] This embodiment provides a bamboo fiber material fabric with adsorption and air filtration functions, comprising a non-woven fabric layer and a bamboo fiber layer. The non-woven fabric layer has at least two layers, and the bamboo fiber layer is disposed between two adjacent non-woven fabric layers. The bamboo fiber layer is formed by weaving or laying bamboo fibers. The non-woven fabric layer and the bamboo fiber layer are needle-punched to form a fiber entanglement structure, thus combining the non-woven fabric layer and the bamboo fiber layer into an integral composite fabric layer. The integral composite fabric layer has a fiber pore structure that allows air to pass through.

[0026] In one embodiment, the nonwoven fabric layer includes a first nonwoven fabric layer and a second nonwoven fabric layer, with a bamboo fiber layer sandwiched between the first and second nonwoven fabric layers, thereby forming a three-layer composite structure in which the first nonwoven fabric layer, the bamboo fiber layer, and the second nonwoven fabric layer are stacked sequentially. The first and second nonwoven fabric layers are located on both sides of the bamboo fiber layer, respectively, and can clamp and support the bamboo fiber layer, preventing it from being directly loose and exposed.

[0027] In another embodiment, the integrated composite fabric layer includes multiple material layers stacked sequentially along the thickness direction, with the total number of material layers being an odd number. The material layers located on both outer sides along the thickness direction are non-woven fabric layers. The intermediate material layers located between the two outer non-woven fabric layers alternately consist of bamboo fiber layers and non-woven fabric layers along the thickness direction, and the intermediate material layers adjacent to the two outer non-woven fabric layers are all bamboo fiber layers. Thus, a composite structure with three, five, seven, or more odd-numbered layers can be formed. For example, a three-layer structure can be a non-woven fabric layer, a bamboo fiber layer, and a non-woven fabric layer stacked sequentially; a five-layer structure can be a non-woven fabric layer, a bamboo fiber layer, and a non-woven fabric layer stacked sequentially; and a seven-layer structure can be based on a five-layer structure by continuously adding bamboo fiber layers and non-woven fabric layers alternately along the thickness direction.

[0028] The bamboo fiber layer can be a woven bamboo fiber layer, a unidirectional bamboo fiber layer, a cross-laid bamboo fiber layer, a multidirectional bamboo fiber layer, or a mesh bamboo fiber layer. A woven bamboo fiber layer can be formed by interlacing bamboo fibers along the warp and weft directions; a unidirectional bamboo fiber layer can be formed by laying bamboo fibers along the length or width of an integrated composite fabric layer; a cross-laid bamboo fiber layer can be formed by laying bamboo fibers along at least two intersecting directions; a multidirectional bamboo fiber layer can be formed by laying bamboo fibers along three or more directions; and a mesh bamboo fiber layer can be formed by combing bamboo fibers to create a continuous or nearly continuous mesh fiber layer.

[0029] The bamboo fibers in the bamboo fiber layer can be distributed in a spaced, mesh-like, or interlaced manner. When the bamboo fibers are spaced, gaps are left between adjacent bamboo fibers to allow air to pass through; when the bamboo fibers are mesh-like, mesh-like or interwoven areas are formed between the bamboo fibers; when the bamboo fibers are interlaced, bamboo fibers in different areas or in different directions are arranged in a staggered manner. Through the above distribution methods, air circulation channels can be maintained within the bamboo fiber layer, and air can come into contact with the bamboo fibers when passing through the integrated composite fabric layer.

[0030] The nonwoven layer can be a polyester nonwoven layer, a polypropylene nonwoven layer, a viscose fiber nonwoven layer, a polyamide nonwoven layer, or a composite fiber nonwoven layer. Polyester nonwoven layers can improve the dimensional stability of one-piece composite layers; polypropylene nonwoven layers can reduce material weight; viscose fiber nonwoven layers can improve material softness and hydrophilicity; polyamide nonwoven layers can improve material abrasion resistance and tear resistance; and composite fiber nonwoven layers can balance support strength, softness, and needle-punch bond stability.

[0031] The fiber entanglement structure includes nonwoven fibers introduced into a bamboo fiber layer from at least one nonwoven fabric layer via needle punching. The nonwoven fibers and bamboo fibers in the bamboo fiber layer become entangled, connecting adjacent nonwoven fabric layers and bamboo fiber layers. Specifically, during the needle punching process, the needle penetrates the composite material along the thickness direction of the integrated fabric layer, causing some of the nonwoven fibers in the nonwoven fabric layer to be introduced into the bamboo fiber layer. This creates an interlacing, hooking, or entanglement relationship between the nonwoven fibers and bamboo fibers, transforming the simple layered state of the nonwoven fabric layer and bamboo fiber layer into a mechanically bonded state.

[0032] This embodiment also provides a manufacturing process for bamboo fiber material cloth with adsorption and air filtration functions, including the following steps.

[0033] S1. Raw material preparation and pretreatment S1. Prepare the non-woven fabric layer and bamboo fiber. Open, remove impurities and dry the bamboo fiber to form a dispersed fiber state suitable for weaving or laying.

[0034] In S1, the nonwoven fabric layer can be supplied in roll form or pre-cut into sheets. The nonwoven fabric layer can be made of polyester PET or polypropylene PP nonwoven fabric. Preferably, the basis weight of the nonwoven fabric layer can be 30g / m² to 80g / m², and the thickness can be 0.15mm to 0.4mm. The nonwoven fabric layer can be made of short-fiber thermally bonded nonwoven fabric with a fiber fineness of 1.5D to 3D. Before use, the nonwoven fabric layer can be placed in a constant temperature and humidity environment for 4 to 6 hours. The ambient temperature can be controlled at 22℃ to 26℃, and the ambient humidity can be controlled at 55% to 65% to reduce wrinkles, shrinkage, or deformation of the nonwoven fabric layer during subsequent lamination, shaping, or winding processes.

[0035] Bamboo fiber can be extracted from moso bamboo. Preferably, the length of the bamboo fiber can be controlled between 30mm and 60mm, and the fiber fineness between 20μm and 40μm. Before use, the bamboo fiber can undergo a purification process to remove bamboo residue, bamboo powder, and coarse fiber impurities. Then, the bamboo fiber undergoes a progressive opening process using an opening machine at a speed of 800r / min to 1000r / min, with two opening cycles, dispersing the bundled bamboo fiber into a fiber state suitable for laying or weaving. After opening, the bamboo fiber can be dried and dehumidified at a temperature of 60℃ to 70℃ for 20min to 30min, controlling the moisture content of the bamboo fiber to 6% to 8%.

[0036] Through the above treatment, the bamboo fiber can be kept in a more dispersed, clean and stable state, reducing the problems of fiber clumping, local accumulation or needle pricks during the subsequent formation of the bamboo fiber layer.

[0037] S2, Bamboo fiber layer molding S2. The treated bamboo fibers are woven, combed and laid in a net, cross-laid or multi-directionally laid to form a bamboo fiber layer.

[0038] In S2, the bamboo fiber layer can be formed by flat laying, weaving, unidirectional laying, cross laying, multidirectional laying, or mesh laying.

[0039] In one embodiment, a bamboo fiber layer is formed using a carding and web-laying method. The pre-treated bamboo fibers are fed into a carding and web-laying integrated machine. The carding roller speed can be 300 r / min to 400 r / min, and the web-laying speed can be 5 m / min to 10 m / min. The bamboo fibers can be laid evenly layer by layer using a cross-laying method to form a bamboo fiber layer with a basis weight of 50 g / m² to 120 g / m² and a thickness of 0.3 mm to 0.8 mm. After web-laying, the bamboo fiber layer can be lightly pre-compressed with a pressure of 0.2 MPa to 0.3 MPa to initially maintain the layered morphology of the loose fiber web.

[0040] In another embodiment, the bamboo fiber layer is formed by weaving. The bamboo fibers can be woven using a weaving machine, with the warp and weft density controlled between 20×20 threads / cm² and 35×35 threads / cm², and the weaving aperture between 0.1mm and 0.3mm. After weaving, the bamboo fiber woven layer can be straightened and leveled to form a relatively regular layered structure.

[0041] In another embodiment, the bamboo fiber can be laid in a unidirectional manner to form the bamboo fiber layer. Specifically, the loosened bamboo fiber is laid out evenly and at a single horizontal conveying direction, so that the bamboo fiber is arranged in the same direction. The running speed of the web laying machine can be controlled between 5m / min and 8m / min, and the parallelism deviation of the fiber arrangement can be controlled to ≤5%.

[0042] In another embodiment, bamboo fibers can be laid in a cross-laying manner to form bamboo fiber layers. Specifically, bamboo fibers are laid in a cross-laying manner in both the transverse and longitudinal directions, and the laying directions of adjacent fiber layers can be 90° apart. The number of layers can be 2 to 4.

[0043] In another embodiment, the bamboo fiber can be laid out in a multi-directional manner to form a bamboo fiber layer. Specifically, the bamboo fibers are laid out alternately along the directions of 0°, 45°, 90° and 135°, so that a multi-directional interlaced fiber network is formed inside the bamboo fiber layer.

[0044] In another embodiment, the bamboo fiber can be laid in a mesh-like manner to form a bamboo fiber layer. Specifically, the bamboo fiber is first lightly combed into a mesh, and then mechanically laid to form a continuous mesh fiber pad, so that the bamboo fiber forms a slight overlapping structure.

[0045] S3, Multi-layer laminated fabric forming S3. Place the bamboo fiber layer between two adjacent nonwoven fabric layers and overlap the nonwoven fabric layer and the bamboo fiber layer along the thickness direction to form an overlapped fabric.

[0046] In one embodiment, the laminated fabric has a three-layer structure, namely, a first nonwoven fabric layer, a bamboo fiber layer, and a second nonwoven fabric layer are stacked sequentially. The first nonwoven fabric layer can serve as one side surface layer, the second nonwoven fabric layer can serve as the other side surface layer, and the bamboo fiber layer is sandwiched between the two.

[0047] In another embodiment, the laminated fabric adopts a multi-layered alternating layered structure. Multiple layers of nonwoven fabric and multiple layers of bamboo fiber are alternately layered along the thickness direction to form a composite structure with five or more odd-numbered layers. For example, the five-layer structure can be a nonwoven fabric layer, a bamboo fiber layer, a nonwoven fabric layer, a bamboo fiber layer, and a nonwoven fabric layer layer stacked sequentially.

[0048] The lamination process can be carried out using an automatic lamination conveyor unit. The lamination conveyor speed can be controlled between 4m / min and 8m / min. During the lamination process, a double-sided correction device can be used to align the edges of each layer of material, with a correction accuracy of ±1mm, to reduce misalignment, wrinkles, and voids between the layers. After lamination, a layered laminated fabric is formed.

[0049] S4, Track Correction Conveying and Pre-compression Processing S4. The stacked fabric is guided and pre-compressed to ensure that the nonwoven fabric layer and the bamboo fiber layer are aligned.

[0050] In S4, the laminated fabric can be conveyed to the needle punching station by a correction conveyor, and the edges of each layer of material are kept aligned during the conveying process. Subsequently, the laminated fabric can be lightly pre-pressed by pressure rollers or pressure plates, so that the bamboo fiber layer is initially and stably sandwiched between the two adjacent nonwoven fabric layers, reducing the loosening, wrinkling or displacement of the bamboo fiber layer before needle punching.

[0051] In one embodiment, the alignment conveying and pre-compression treatment can be completed in conjunction with the automatic overlapping conveyor unit in S3. Before entering the needle punching equipment, the overlapping fabric is continuously conveyed forward by the conveying mechanism, and the edge positions of the nonwoven fabric layer and bamboo fiber layer are adjusted by the alignment mechanism to maintain alignment of each layer in the thickness direction. The pre-compression treatment can be carried out using a light compression method, the purpose of which is to maintain the stability of the layers, rather than to substantially compact the layers or block the pores.

[0052] S5, needle-punching composite molding S5. The pre-compressed composite fabric is needle-punched to allow the non-woven fibers in at least one side of the non-woven fabric layer to enter the bamboo fiber layer and entangle with the bamboo fiber in the bamboo fiber layer to form a fiber entanglement structure, thus obtaining an integrated composite fabric layer.

[0053] Needle punching can be performed using a high-speed needle punching machine. The needle density can be 800 needles / m² to 1200 needles / m², the needle punching frequency can be 800 times / min to 1200 times / min, the needle punching depth can be 8mm to 15mm, and the needle punching travel speed can be 3m / min to 6m / min. By piercing along the thickness direction of the laminated fabric with needles, some of the nonwoven fibers in the nonwoven fabric layer are brought into the bamboo fiber layer, where they interweave, hook, and entangle with the bamboo fiber, thus forming a mechanical bond between the nonwoven fabric layer and the bamboo fiber layer.

[0054] In one embodiment, a single-sided needle punching process can be used. A needle plate is positioned on one side of the laminated fabric, and the fabric is needle-punched from that side. During single-sided needle punching, the needle depth can be controlled between 8mm and 12mm, the needle frequency between 800 and 1000 times per minute, and the needle plate density between 800 needles per square meter and 1000 needles per square meter. Single-sided needle punching allows the nonwoven fibers in one side of the nonwoven fabric layer to enter the bamboo fiber layer and become entangled with the bamboo fibers in the bamboo fiber layer.

[0055] In another embodiment, a double-sided needle punching process can be employed. Double-sided needle punching can include forward needle punching and reverse needle punching, i.e., needle punching is performed first on one side of the stacked fabric, and then supplementary needle punching is performed on the other side. During double-sided needle punching, the needle depth can be controlled between 10mm and 15mm, the needle frequency can be controlled between 1000 times / min and 1200 times / min, and the needle density can be controlled between 1000 needles / m² and 1200 needles / m². Through double-sided needle punching, some of the nonwoven fibers in the two nonwoven fabric layers can enter the bamboo fiber layer, making the fiber entanglement structure more balanced in the thickness direction.

[0056] After needle punching, the nonwoven fabric layer and the bamboo fiber layer change from a superimposed state to a state of mechanical fiber entanglement. The bamboo fiber layer is penetrated, limited and connected by the nonwoven fabric fibers, and the integrated composite fabric layer still retains the fiber pore structure that allows air to pass through.

[0057] S6, Compression Shaping S6. Press and shape the integrated composite fabric layer to make the thickness of the integrated composite fabric layer more uniform.

[0058] Specifically, the needle-punched integrated composite fabric layer can be fed into an adjustable leveling and pressing unit, where it is flattened using symmetrical upper and lower pressure rollers. The pressure rollers can be high-temperature resistant rubber rollers, and the pressing pressure can be controlled between 0.3 MPa and 0.5 MPa, while the pressing speed can be controlled between 3 m / min and 6 m / min. This pressing and shaping process reduces localized fluffing, fiber protrusion, or fabric looseness after needle punching, resulting in a more uniform thickness and smoothness of the integrated composite fabric layer.

[0059] Depending on the application scenario, the thickness of the integrated composite fabric layer can be controlled within different ranges. For example, the thickness of conventional lightweight filter media can be controlled between 0.8mm and 1.5mm; the thickness of medium-thickness filter media can be controlled between 1.5mm and 3.0mm. During pressing and shaping, the thickness of the integrated composite fabric layer can be controlled by adjusting the gap between the pressure rollers or the pressing pressure, so that the composite fabric layer maintains a relatively stable shape during subsequent cutting, slitting, or winding processes.

[0060] S7, heat setting or leveling treatment S7. Perform heat setting or leveling treatment on the integrated composite fabric layer after compression molding.

[0061] In one embodiment, the pressed and shaped integrated composite fabric layer can be sent to a hot air setting machine for heat setting. The heat setting temperature can be 110℃~130℃, the setting speed can be 4m / min~7m / min, and the hot air velocity can be 1200m³ / h~1500m³ / h. Through heat setting, the size and shape of the integrated composite fabric layer can be stabilized.

[0062] In another embodiment, a constant tension leveling and winding system can be used to level the integrated composite fabric layer. The tension can be controlled between 50N and 80N to reduce stretching, thinning, pore deformation, wrinkling, or loosening caused by excessive or insufficient tension during the winding process.

[0063] It should be noted that heat setting and leveling can be performed individually or sequentially. When the nonwoven fabric layer contains heat-settable fibers, heat setting should be given priority; when the product mainly needs to improve surface smoothness or winding stability, leveling can be used.

[0064] S8. Cutting, slitting, or winding. S8. Cut, slit, or roll up the integrated composite fabric layer to obtain bamboo fiber material fabric.

[0065] Specifically, the integrated composite fabric layer can be cut to a fixed width, cut laterally, die-cut, or slit according to product requirements. The cutting accuracy can be controlled within ±1mm to remove irregular edges and obtain bamboo fiber material fabric of predetermined width, length, or shape. For continuously produced integrated composite fabric layers, constant speed winding can be used to form a roll of bamboo fiber material fabric.

[0066] Table 1. Experimental data on the core performance of the bamboo fiber material fabric of the present invention.

[0067] Table 2. Experimental data comparing existing filter materials

[0068] Table 3 Performance Comparison of Structures with Different Number of Layers

[0069] Table 4 Comparison of performance of different needle punching processes

[0070] Tables 1 to 4 above present the performance test and comparison data of the bamboo fiber material cloth of the present invention.

[0071] Table 1 shows the test results of the bamboo fiber material cloth of the present invention in terms of air permeability, PM2.5 filtration efficiency, formaldehyde adsorption rate, interlayer peel strength, thickness uniformity error, basis weight, average pore diameter, number of washes and deformation rate, etc., to illustrate that the material cloth can maintain air circulation while taking into account particle filtration, odor or harmful gas adsorption and interlayer bonding stability.

[0072] Table 2 compares the present invention with ordinary nonwoven fabrics and commercially available carbon-insulated filter cloths, demonstrating that the present invention has better overall performance in terms of formaldehyde adsorption, interlayer bonding, water resistance, and dust control.

[0073] Table 3 shows the performance differences between the three-layer basic structure and the five-layer composite structure, illustrating that adding bamboo fiber layers and non-woven fabric layers can further improve filtration efficiency and adsorption capacity, but the air permeability and thickness will change accordingly.

[0074] Table 4 shows the comparison results of single-sided needle punching and double-sided needle punching, illustrating that double-sided needle punching is beneficial for improving interlayer peel strength and improving the thickness uniformity and filtration efficiency stability of composite fabric layers.

[0075] The above test data are only the detection results in specific embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0076] The resulting bamboo fiber material can be further cut into automotive air conditioning filter media, air purifier filter media, indoor air filtration media, odor adsorption materials, or duct lining filter media. Specifically, automotive air conditioning filter media can be die-cut according to the installation dimensions of the vehicle's air conditioning filter element; air purifier filter media can be cut into flat, folded, or sizes adapted to the structure of the purifier filter element; indoor air filtration materials can be cut into rolls, sheets, or fresh air filter specifications; odor adsorption materials can be cut into adsorption filter sheets or adsorption cotton; and duct lining filter media can be cut into rolls or sheets suitable for laying on the inner wall of the duct.

[0077] Through the aforementioned structure and process, the bamboo fiber layer is sandwiched between two adjacent nonwoven fabric layers and needle-punched to form a fiber entanglement structure with the nonwoven fabric layers. This prevents the bamboo fiber layer from existing in a loose state within the interlayer and instead integrates it with the nonwoven fabric layers into a single composite fabric layer. This integrated composite fabric layer retains the fibrous pore structure that allows air to pass through. When air passes through the fabric, it can pass through both the nonwoven fabric layer and the bamboo fiber layer, thus enabling the bamboo fiber layer to participate in air filtration and odor adsorption processes.

[0078] It should be noted that the nonwoven fabric layer material, bamboo fiber layer formation method, number of layers, needle punching method, shaping method, cutting and winding method, and related process parameters involved in the above embodiments can all be selected or adjusted according to actual product needs. As long as they do not deviate from the technical concept of the present invention of forming an integrated composite fabric layer by sandwiching bamboo fiber layers between nonwoven fabric layers and needle punching, they should all fall within the protection scope of the present invention.

[0079] 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 bamboo fiber material fabric with adsorption and air filtration functions, comprising a non-woven fabric layer and a bamboo fiber layer, characterized in that: The nonwoven fabric layer has at least two layers, and the bamboo fiber layer is disposed between two adjacent nonwoven fabric layers. The bamboo fiber layer is woven or laid out from bamboo fibers. The nonwoven fabric layer and the bamboo fiber layer are needle-punched to form a fiber entanglement structure, so that the nonwoven fabric layer and the bamboo fiber layer are combined into an integral composite fabric layer. The integral composite fabric layer has a fiber pore structure that allows air to pass through.

2. The bamboo fiber material fabric with adsorption and air filtration functions according to claim 1, characterized in that, The integrated composite fabric layer includes multiple material layers stacked sequentially along the thickness direction. The total number of the multiple material layers is an odd number. The material layers on both outer sides of the thickness direction are non-woven fabric layers. The intermediate material layers between the two outer non-woven fabric layers are alternately arranged with bamboo fiber layers and non-woven fabric layers along the thickness direction. The intermediate material layers adjacent to the two outer non-woven fabric layers are all bamboo fiber layers.

3. The bamboo fiber material fabric with adsorption and air filtration functions according to claim 1, characterized in that, The bamboo fiber layer is formed by weaving or laying bamboo fibers.

4. The bamboo fiber material fabric with adsorption and air filtration functions according to claim 1, characterized in that, The bamboo fiber in the bamboo fiber layer is distributed in a spaced, mesh-like, or interwoven manner.

5. The bamboo fiber material fabric with adsorption and air filtration functions according to claim 1, characterized in that, The nonwoven fabric layer is a polyester nonwoven fabric layer, a polypropylene nonwoven fabric layer, a viscose fiber nonwoven fabric layer, a polyamide nonwoven fabric layer, or a composite fiber nonwoven fabric layer.

6. The bamboo fiber material fabric with adsorption and air filtration functions according to claim 1, characterized in that, The fiber entanglement structure includes nonwoven fibers introduced into the bamboo fiber layer from at least one side of the nonwoven fabric layer by needle punching. The nonwoven fibers are entangled with the bamboo fiber in the bamboo fiber layer, and adjacent nonwoven fabric layers are connected to the bamboo fiber layer.

7. A manufacturing process for a bamboo fiber material cloth with adsorption and air filtration functions, characterized in that, Includes the following steps: S1. Prepare non-woven fabric layer and bamboo fiber, and perform opening, impurity removal and drying treatment on the bamboo fiber to form a dispersed fiber state suitable for weaving or laying. S2. The processed bamboo fiber is woven, combed and laid in a net, cross-laid or multi-directionally laid to form a bamboo fiber layer; S3. The bamboo fiber layer is placed between two adjacent non-woven fabric layers, and the non-woven fabric layer and the bamboo fiber layer are overlapped along the thickness direction to form an overlapped fabric. S4. The laminated fabric is subjected to correction conveying and pre-compression treatment to keep the non-woven fabric layer and the bamboo fiber layer in an interlayer alignment state. S5. The pre-compressed composite fabric is needle-punched to allow the non-woven fibers in at least one side of the non-woven fabric layer to enter the bamboo fiber layer and entangle with the bamboo fiber in the bamboo fiber layer to form a fiber entanglement structure, thereby obtaining an integrated composite fabric layer. S6. Press and shape the integrated composite fabric layer to make the thickness of the integrated composite fabric layer more uniform. S7. Perform heat setting or leveling treatment on the integrated composite fabric layer after compression molding. S8. Cut, slit, or roll up the integrated composite fabric layer to obtain the bamboo fiber material fabric.

8. The manufacturing process of the bamboo fiber material cloth with adsorption and air filtration functions according to claim 7, characterized in that, In S2, the bamboo fiber layer is formed by weaving, combing and laying, unidirectional laying, cross laying, multidirectional laying or mesh laying.

9. The manufacturing process of the bamboo fiber material cloth with adsorption and air filtration functions according to claim 7, characterized in that, In S3, the bamboo fiber layer is disposed between the first nonwoven fabric layer and the second nonwoven fabric layer, or multiple layers of the bamboo fiber layer and multiple layers of the nonwoven fabric layer are alternately stacked along the thickness direction.

10. The manufacturing process of the bamboo fiber material cloth with adsorption and air filtration functions according to claim 7, characterized in that, In step S5, the pre-compressed laminated fabric is subjected to single-sided or double-sided needle punching.

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