Double-sided spunlace fabric with concave-convex pattern and pile and preparation method thereof

Abstract

This invention relates to the field of spunlace nonwoven fabrics, specifically to a double-sided spunlace fabric with textured surface and pile, and its preparation method. The spunlace fabric has textured surface formed by spunlace jacquard treatment on the front side, and a pile layer formed by brushing treatment on the back side. A method for preparing this spunlace fabric is also provided, comprising the following steps: Step 1) treating the fiber raw material with a spunlace process to obtain the spunlace fabric; Step 2) performing spunlace jacquard treatment on the front side of the spunlace fabric using a jacquard drum; Step 3) brushing treatment on the back side of the spunlace fabric to form a pile layer; Step 4) drying and winding the brushed spunlace fabric. The spunlace fabric prepared by this invention possesses both strong physical detergency and strong water absorption and softness, making it suitable for makeup removal, cleaning heavy kitchen grease, body exfoliation, baby care, and sensitive skin wiping.

Description

Technical Field

[0001] This invention relates to the field of spunlace nonwoven fabrics, specifically to a double-sided spunlace fabric with textured and napped surfaces and its preparation method. Background Technology

[0002] Spunlace nonwoven fabrics are widely used in dry and wet wipes, medical dressings, and personal care products due to their soft hand feel, unique fiber entanglement structure, lack of adhesives, and excellent moisture absorption. Traditional spunlace fabrics mostly use plain weave or simple mesh structures, resulting in relatively limited functionality. With the upgrading of consumption, the market demand for multifunctional spunlace fabrics with specific tactile feel, cleaning ability, and aesthetic effects is increasing.

[0003] Pearl-textured spunlace fabric, due to its textured structure, possesses a certain dust-holding capacity and a massaging effect, making it commonly used for cleaning, wiping, or beauty care. However, traditional high-grammage spunlace fabrics, due to their high weight, tend to be stiff, have a hard feel, and poor absorbency. While existing technologies utilize napping to improve fabric feel, these are primarily applied to woven or knitted fabrics and are not combined with jacquard spunlace technology to create distinctly different functional structures on both sides. How to achieve a combination on the same base fabric—one side maintaining a three-dimensional texture to increase thickness, and the other side forming a stable pile layer of a certain length to impart a soft touch and strong absorbency—is a pressing technical problem to be solved in this field. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a spunlace fabric that achieves a three-dimensional texture on one side to increase thickness and a stable pile layer of a certain length on the other side of the same base fabric, so that it simultaneously has strong physical cleaning ability, soft touch and strong water absorption.

[0005] The present invention is achieved through the following technical solution: On the one hand, a double-sided spunlace fabric with textured surface and pile is provided, characterized in that the front side of the spunlace fabric has textured surface formed by spunlace jacquard treatment, and the reverse side has a pile layer formed by brushing treatment. The textured surface includes a first protrusion and a second protrusion; the diameter ratio of the first protrusion to the second protrusion is 2-4:1, and the diameter of the second protrusion is 1.3-2.0 mm; the height ratio of the first protrusion to the second protrusion is 2-3:1, and the height of the second protrusion is 0.10-0.25 mm.

[0006] Further, the longitudinal and transverse spacing of the first protrusion is 3.0-10.0 mm; the longitudinal and transverse spacing of the second protrusion is 2.0-5.0 mm; the pile density of the pile layer is 50-400 fibers / cm²; and the pattern of the protrusion is circular, polygonal, or other predetermined pattern.

[0007] On the other hand, a method for preparing a double-sided spunlace fabric with textured surface and nap is provided, characterized by comprising the following steps: Step 1) The fiber raw material is subjected to hydroentangling process to obtain hydroentangled fabric; Step 2) Use a jacquard drum to perform jacquard treatment on the front side of the spunlace fabric; Step 3) The reverse side of the spunlace fabric is brushed to form a nap layer; Step 4) Dry and wind the spunlace fabric after the brushing process.

[0008] Further, in step 1), the fiber raw material is any one or a combination of two or more of viscose fiber, lyocell fiber, polyester fiber, hemp fiber or cotton fiber; the basis weight of the spunlace fabric is 80-150 g / m².

[0009] Further, in step 1), the hydroentangling process includes: opening and mixing the fiber raw materials, combing them into a web and laying the web to obtain a fiber web; pre-wetting and hydroentangling the fiber web to obtain a hydroentangled fabric.

[0010] Furthermore, in step 2), the surface of the jacquard drum is provided with a first cavity and a second cavity; The diameter ratio of the first cavity to the second cavity is 2-4:1, the diameter of the second cavity is 1.3-2.0 mm, the protrusion height ratio of the first cavity to the second cavity is 2-3:1, and the height of the second cavity is 0.10-0.25 mm; the longitudinal and transverse spacing of the first cavity is 3.0-10.0 mm, and the longitudinal and transverse spacing of the second cavity is 2.0-5.0 mm.

[0011] Furthermore, in step 2), the hydroentangling pressure of the hydroentangling jacquard treatment is 80-150 bar.

[0012] Furthermore, in step 3), the sanding process involves using a sandpaper sanding roller to rub and furn up the reverse side; The linear velocity of the abrasive roller is 5-10 m / s different from the running speed of the spunlace fabric, and the running direction of the abrasive roller is the same as the conveying direction of the spunlace fabric; the number of abrasive rollers is 1 or 2, and the arc length of the spunlace fabric wrapping the abrasive roller is 10-20 mm.

[0013] Further, in step 4), the drying temperature is 110℃-190℃.

[0014] Beneficial effects This invention retains the textured, three-dimensional jacquard structure, which provides greater friction when in contact with objects, resulting in stronger physical cleaning power and a skin-massaging feel. It is suitable for makeup removal, cleaning heavy kitchen grease, or body exfoliation.

[0015] After being brushed, the spunlace fabric of this invention exhibits a more fluffy capillary structure, with the fiber ends opened, increasing the specific surface area. Compared to ordinary plain weave fabric, the piled surface has a stronger capillary effect, significantly improving water absorption speed and capacity; at the same time, it has an extremely soft feel, making it suitable for baby care, sensitive skin wiping, daily cleaning and care, or as a base material for wet wipes. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of a double-sided spunlace fabric with textured surface and nap provided by the present invention.

[0017] Figure 2 This is a simplified process flow diagram of the preparation method of the present invention.

[0018] Figure 3 This is a schematic diagram of the jacquard rotary drum structure.

[0019] The attached figures are labeled as follows: 1. Spunlace fabric body, 2-1. First protrusion, 2-2. Second protrusion, 3. Pile layer, A. First cavity, B. Second cavity, a. Spacing between first cavities, b. Spacing between second cavities. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] Example 1 Step 1) Preparation of fiber raw materials Viscose fibers with a fineness of 1.5D and a length of 38 mm are selected and fed into the cotton opening and cleaning unit for opening and mixing.

[0022] Step 2) Forming and laying the net The mixed fiber bundles are carded using a carding machine to form fiber web 1. Then, the carded fiber web 1 is cross-laid in multiple layers using a cross-laying machine to obtain fiber web 2 with a certain thickness and areal density, and a basis weight of 110 g / m².

[0023] Step 3) Pre-wetting and hydroentanglement reinforcement The laid-up fiber web 2 is fed into the hydroentanglement production line. First, it undergoes a pre-wetting treatment to compact the fiber web and remove air. Then, the fiber web enters the hydroentanglement zone, where the hydroentanglement pressure increases in a stepped manner, with an initial pressure of 70 bar and an end pressure of 110 bar, to fully entangle the fibers and form a partially consolidated hydroentangled fabric.

[0024] Step 4) Jacquard shaping The pre-reinforced spunlace fabric is introduced into a jacquard drum device. On the jacquard drum, a drum with a circular raised pattern is used to perform high-pressure hydroentangling jacquard on one side of the spunlace fabric. The jacquard hydroentangling pressure is set to 140 bar. The surface of the jacquard drum has a first cavity and a second cavity, arranged in an alternating equilateral triangle pattern. The center distance between adjacent first cavities is 7 mm, and the center distance between adjacent second cavities is 4 mm. The diameter of the first cavity is 5.0 mm, the diameter of the second cavity is 2.0 mm, the height of the first cavity is 0.50 mm, and the height of the second cavity is 0.20 mm. High-pressure water jets are used to impact the fibers, causing them to shift and rearrange at the mesh of the jacquard drum, thereby forming a raised texture on one side of the spunlace fabric.

[0025] Step 5) Smoothing The plain weave side of the jacquard spunlace fabric is then brushed. Two sandpaper brushing rollers are used, with the fabric wrapping around the rollers by an arc length of 12 mm. The difference between the linear speed of the brushing rollers and the running speed of the spunlace fabric is 6 m / s, and the running direction of the brushing rollers is the same as the conveying direction of the spunlace fabric. Subsequently, friction is used to create a fine pile on the plain weave surface, controlling the final pile density to be 50-400 fibers / cm². 2 This creates a velvety surface with uniform thickness and a delicate feel.

[0026] Step 6) Drying The jacquard spunlace fabric is fed into a hot air through-dryer for drying. The drying temperature is set to 180 ℃ to remove residual moisture from the spunlace fabric and bring it to the specified moisture content standard.

[0027] Step 7) Winding The dried spunlace fabric is wound into a master roll of a specified size by a winding machine under a set tension, resulting in a spunlace fabric with a heterogeneous double-sided structure of textured surface and pile.

[0028] Example 2 The difference between this embodiment and Embodiment 1 is that: Step 5) Sanding: Sand the plain weave side of the jacquard spunlace fabric. Use two sandpaper sanding rollers, with the fabric wrapping around the sanding rollers by an arc length of 16 mm. The difference between the linear speed of the sanding rollers and the running speed of the spunlace fabric is 8 m / s.

[0029] The other steps are exactly the same as in Example 1.

[0030] Example 3 The difference between this embodiment and Embodiment 1 is that: Step 1) Fiber raw material preparation: Select 1.5D viscose fiber with a length of 38 mm and 1.4D Lyocell fiber with a length of 38 mm, weigh them at a weight percentage of 75 / 25, and put them into the cotton opening and cleaning unit for opening and mixing.

[0031] Example 4 The difference between this embodiment and Embodiment 1 is that: Step 4) Jacquard forming: The center distance between adjacent first cavities is 3 mm, the center distance between adjacent second cavities is 2 mm, the diameter of the first cavity is 2.6 mm, the diameter of the second cavity is 1.3 mm, the height of the first cavity is 0.20 mm, and the height of the second cavity is 0.10 mm.

[0032] The other steps are exactly the same as in Example 1.

[0033] Example 5 The difference between this embodiment and Embodiment 1 is that: Step 4) Jacquard forming: The center distance between adjacent first cavities is 10 mm, the center distance between adjacent second cavities is 5 mm, the diameter of the first cavity is 8.0 mm, the diameter of the second cavity is 2.0 mm, the height of the first cavity is 0.75 mm, and the height of the second cavity is 0.25 mm.

[0034] The other steps are exactly the same as in Example 1.

[0035] Except as described, the other steps in the following comparative examples are exactly the same as in Example 1.

[0036] Comparative Example 1 The difference between this comparative example and Example 1 is that step 5) the sanding step is omitted, and the target finished product is directly wound after drying.

[0037] Comparative Example 2 The difference between this comparative example and Example 1 is that, in step 5), the arc length of the fabric wrapping the abrasive roller during the abrasive process is 20mm, and the difference between the linear speed of the abrasive roller and the running speed of the spunlace fabric is 10 m / s.

[0038] Comparative Example 3 The difference between this comparative example and Example 1 is that, in step 4) jacquard forming, only the first cavity is retained.

[0039] Effect verification experiment The following test methods were used to test the longitudinal / transverse stiffness, water absorption ratio, and longitudinal / transverse strength of each embodiment and comparative example: Longitudinal / Transverse Bending Length (Stiffness) Test: Perform the test according to GB / T 18318.1, randomly cutting 10 specimens with dimensions of (25±1) mm × (250±1) mm. Five specimens should have their long sides parallel to the fabric's longitudinal direction, and five specimens should have their long sides parallel to the fabric's transverse direction. When sampling, the specimens should be at least 100 mm from the fabric edge, and handling should be minimized. Select the test specimen direction, and conduct four tests per batch, first testing both sides of one end, then turning to the other end to test both sides. The testing speed is 3.0 mm / s, and the return speed is 10.0 mm / s.

[0040] Water absorption rate test: Follow the procedure specified in GB / T 24218.6. Cut a nonwoven fabric sample weighing approximately 2.0 g, weigh it on an electronic balance, and record the actual weight as M1. Fold the sample fabric to a suitable size, place it parallel to the water, and simultaneously start a stopwatch. After 1 minute, use a glass rod to lift it out of the water surface, suspend the sample vertically, and drip off excess liquid. After two minutes, weigh the sample on an electronic balance and record the weight as M2. Water absorption rate of spunlace fabric = (M2 - M1) / M1 × 100%.

[0041] Longitudinal / transverse strength test: Performed according to GB / T 24218.3, with a sample width of 50 mm, clamping distance of 100 mm, and tensile speed of 250 mm / min.

[0042] The test results are shown in the table below:

[0043] A comparison of the performance data of Examples 1-5 and Comparative Examples 1-3 shows that: Compared to Comparative Example 1, Example 1 showed significant improvements in water absorption ratio (1069.53%, an increase of 35.8%) and stiffness (20.75 mm laterally, an increase of 14.40% and 26.20 mm longitudinally, an increase of 21.49%), achieving a dual optimization of softness and water absorption performance. This indicates that the napping creates a capillary structure, making the surface fibers of the spunlace fabric more fluffy, increasing the porosity between fibers, reducing the rigid support points between fibers, providing more storage space for liquids, improving the water absorption ratio, and reducing the overall stiffness of the spunlace fabric surface. The strength of Example 1 (101.19 N laterally, a decrease of 12.07% and 123.35 N longitudinally, a decrease of 17.15%) was reduced because the napping broke some fibers, leading to a decrease in the strength of the spunlace fabric. In summary, the presence of the nap layer reduces strength but improves water absorption and softness.

[0044] Compared with Comparative Example 1, Examples 1-3 and 5 all showed good softness and higher water absorption ratio, indicating that the presence of the pile layer reduces stiffness and strength, but can significantly improve water absorption capacity.

[0045] Examples 1, 4, and 5 demonstrate that the spacing, size, and height between the cavities are key adjustable parameters. As the distance, size, and height increase, the softness and strength of the spunlace fabric significantly decrease, while its absorbency gradually increases. Therefore, for fabrics requiring high friction and high strength, smaller size parameters can be selected; for fabrics prioritizing high softness and high absorbency, larger size parameters can be chosen.

[0046] The results of Examples 1 and 2 and Comparative Example 2 show that when the napping wrapping arc is too large and the difference between the napping roller linear speed and the spunlace fabric running speed is greater, the water absorption ratio and softness of the spunlace fabric will be improved. However, due to the increased pressure between the spunlace fabric and the napping roller, the fiber breakage will be aggravated and the strength of the spunlace fabric will be significantly reduced. This indicates that the napping wrapping arc length and the difference between the napping roller linear speed and the spunlace fabric running speed are key adjustable parameters.

[0047] The results of Example 1 and Comparative Example 3 show that when only the first cavity is retained, the softness of the prepared spunlace fabric is lower than that of the spunlace fabric in which both the first and second cavities are present. This indicates that the presence of the second cavity can appropriately improve the softness of the spunlace fabric.

[0048] In summary, the double-sided spunlace fabric with textured surface and pile provided by this invention and its preparation method have both strong physical cleaning ability and strong water absorption and softness, making them suitable for makeup removal, cleaning heavy oil stains in the kitchen, body exfoliation, baby care, and wiping sensitive skin.

[0049] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A double-sided spunlace fabric with textured surface and nap, characterized in that, The spunlace fabric has a textured surface formed by spunlace jacquard treatment on the front side and a napped layer formed by brushing treatment on the back side. The textured surface includes a first protrusion and a second protrusion; the diameter ratio of the first protrusion to the second protrusion is 2-4:1, and the diameter of the second protrusion is 1.3-2.0 mm; the height ratio of the first protrusion to the second protrusion is 2-3:1, and the height of the second protrusion is 0.10-0.25 mm.

2. The double-sided spunlace fabric with textured surface and nap as described in claim 1, characterized in that, The longitudinal and transverse spacing of the first protrusion is 3.0-10.0 mm; the longitudinal and transverse spacing of the second protrusion is 2.0-5.0 mm; the pile density of the pile layer is 50-400 fibers / cm²; the pattern of the protrusion is circular or polygonal.

3. A method for preparing a double-sided spunlace fabric with textured surface and nap as described in any one of claims 1-2, characterized in that, Includes the following steps: Step 1) The fiber raw material is subjected to hydroentangling process to obtain hydroentangled fabric; Step 2) Use a jacquard drum to perform jacquard treatment on the front side of the spunlace fabric; Step 3) The reverse side of the spunlace fabric is brushed to form a nap layer; Step 4) Dry and wind the spunlace fabric after the brushing process.

4. The method for preparing the double-sided spunlace fabric with textured surface and nap according to claim 3, characterized in that, In step 3), the sanding process involves using a sandpaper sanding roller to rub and create nap on the reverse side; The linear velocity of the abrasive roller is 5-10 m / s different from the running speed of the spunlace fabric, and the running direction of the abrasive roller is the same as the conveying direction of the spunlace fabric; the number of abrasive rollers is 1 or 2, and the arc length of the spunlace fabric wrapping the abrasive roller is 10-20 mm.

5. The method for preparing the double-sided spunlace fabric with textured surface and nap according to claim 3, characterized in that, In step 2), the surface of the jacquard drum is provided with a first cavity and a second cavity; The diameter ratio of the first cavity to the second cavity is 2-4:1, the diameter of the second cavity is 1.3-2.0 mm, the protrusion height ratio of the first cavity to the second cavity is 2-3:1, and the height of the second cavity is 0.10-0.25 mm; the longitudinal and transverse spacing of the first cavity is 3.0-10.0 mm, and the longitudinal and transverse spacing of the second cavity is 2.0-5.0 mm.

6. The method for preparing the double-sided spunlace fabric with textured surface and nap according to claim 3, characterized in that, In step 1), the fiber raw material is any one or a combination of two or more of viscose fiber, lyocell fiber, polyester fiber, hemp fiber or cotton fiber; the weight of the spunlace fabric is 80-150 g / m².

7. The method for preparing the double-sided spunlace fabric with textured surface and nap according to claim 3, characterized in that, In step 1), the hydroentangling process includes: opening and mixing the fiber raw materials, combing them into a web and laying the web to obtain a fiber web; pre-wetting and hydroentangling the fiber web to obtain a hydroentangled fabric.

8. The method for preparing the double-sided spunlace fabric with textured surface and nap according to claim 3, characterized in that, In step 2), the hydroentangling pressure of the hydroentangling jacquard treatment is 80-150 bar.

9. The method for preparing the double-sided spunlace fabric with textured surface and nap according to claim 3, characterized in that, In step 4), the drying temperature is 110℃-190℃.

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