A gradient entangled spunlace fabric containing antibacterial fibers

Abstract

The application provides a gradient entangled spunlace fabric containing bacteriostatic fibers, and belongs to the technical field of spunlace fabrics. The spunlace fabric body is integrally formed by viscose fibers, lyocell fibers and bacteriostatic fibers through water jet entanglement. The upper surface of the spunlace fabric body is a surface functional layer, and the lower surface of the spunlace fabric body is an unbroken support layer. The fiber entanglement density of the surface functional layer is less than that of the unbroken support layer, thereby forming a porosity gradient decreasing structure from the surface layer to the bottom layer of the spunlace fabric body. The dry and wet strength and structural stability of the spunlace fabric are greatly improved. The spunlace fabric is integrally formed by viscose fibers, lyocell fibers and bacteriostatic fibers through water jet entanglement. The spunlace fabric has a support skeleton formed by long lyocell fibers, and the entanglement structure has a porosity gradient decreasing from the surface layer to the bottom layer, thereby improving the problem of insufficient wet strength of traditional full-viscose spunlace fabric.

Description

Technical Field

[0001] This invention relates to the field of spunlace fabric technology, and more specifically to a gradient entangled spunlace fabric containing antibacterial fibers. Background Technology

[0002] With the rapid development of the disposable cleaning and care industry, disposable face towels have become the mainstream product for daily facial cleansing and home cleaning due to their hygienic, convenient, skin-friendly, and non-irritating properties.

[0003] Spunlace nonwoven fabric is the core material of face towels. Among them, spunlace fabric made of viscose fiber has become the most widely used material type of face towel products on the market due to its excellent skin-friendliness, basic moisture absorption capacity and mature manufacturing process.

[0004] However, in practical applications, spunlace fabric made entirely of viscose still has some prominent technical defects: First, it has poor dry and wet strength stability. The dry strength of viscose fibers is acceptable, but the wet strength is greatly reduced. After getting wet, it is very easy to stretch, deform and break. After repeated rubbing, the structural stability is extremely poor, making it difficult to meet the needs of high-frequency rubbing such as cleansing and makeup removal. Secondly, it lacks active antibacterial properties. Pure viscose fiber can only achieve basic physical cleaning and does not have an active antibacterial effect, making it difficult to meet consumers' demand for healthy antibacterial cleaning and care products. Third, the structure and material performance are not well matched. The existing all-viscose spunlace nonwoven fabric mainly adopts a simple appearance pattern design, which is mainly used to increase friction and improve the cleaning effect. However, when the spunlace nonwoven fabric is wetted, the wet strength of the viscose fiber is insufficient, and the raised pattern is prone to collapse, falling, and deformation, resulting in a poor user experience and making it difficult to meet the market's growing demand for high-quality cleaning and care spunlace nonwoven fabric.

[0005] Utility model patent application number 202322036946.0 discloses a dual-purpose facial tissue, comprising a non-woven fabric layer, an inner layer of plant fibers, a breathable layer connected to the bottom of the plant fiber layer, a skin-friendly cotton layer at the bottom of the breathable layer, a pearl-textured layer connected to the lower surface of the non-woven fabric layer, a tear-resistant tensile strip inside the pearl-textured layer, antibacterial cotton fibers inside the tear-resistant tensile strip, and a friction cotton layer penetrating through the inner side of the antibacterial cotton fibers. This design, through the combined effect of its structure connected to the non-woven fabric layer and the cooperation between its pearl-textured layer and the disinfection layer, can alter the quality and thickness of the facial tissue, making it more resistant to tearing and deformation, and allowing for double-sided use.

[0006] However, these products often adopt a multi-layer composite and partially embedded functional structure design approach, which has obvious shortcomings: on the one hand, the multi-layer composite process is complex and has low production efficiency, and the composite layer is prone to delamination, resulting in low practicality; on the other hand, the antibacterial fibers are only partially deployed, the fiber distribution is scattered, the utilization rate of antibacterial components is low, and the overall antibacterial effect is uneven; these products still cannot solve the core problems of the texture collapsing when wet and the overall dry and wet strength of the fabric is insufficient. Summary of the Invention

[0007] This invention provides a gradient entangled spunlace fabric containing antibacterial fibers to solve the technical problems in the prior art.

[0008] To solve the above problems, the gradient entangled spunlace fabric containing antibacterial fibers provided by the present invention adopts the following technical solution: a spunlace fabric body, wherein the spunlace fabric body is integrally formed by hydroentanglement of viscose fibers, lyocell fibers and antibacterial fibers, the upper surface of the spunlace fabric body is a surface functional layer, and the lower surface of the spunlace fabric body is a plain weave support layer. The fiber entanglement density of the surface functional layer is less than that of the plain weave support layer, corresponding to the formation of a porosity gradient decreasing structure from the surface to the bottom layer of the spunlace fabric body; within the surface functional layer, antibacterial fibers and viscose fibers are enriched and attached to the inner walls of the pores formed by the interlacing of lyocell fibers, forming a functional surface layer with contact antibacterial and instantaneous moisture absorption; within the plain weave support layer, lyocell fibers are continuously entangled along the warp and weft directions of the fabric surface, forming a support skeleton that runs through the spunlace fabric body.

[0009] As a further improvement, the antibacterial fiber is selected from any one or more of the following: artemisia fiber, bamboo fiber, chitosan fiber, tea polyphenol fiber, quaternary ammonium salt modified fiber, zinc ion fiber, silver ion fiber, or copper ion fiber.

[0010] As a further improvement, the surface functional layer is selected from any one of the following: plain weave, pearl weave, EF weave, wave weave, or diamond weave.

[0011] As a further improvement, the surface functional layer has a pearl texture structure with a number of pearl texture protrusions arranged at intervals. A continuous recessed flow guiding area is formed between adjacent pearl texture protrusions. The fiber entanglement density of the pearl texture protrusions is less than the fiber entanglement density of the recessed flow guiding area.

[0012] As a further improvement, the pearl-patterned protrusions are hemispherical or ellipsoidal protrusions, the height of a single pearl-patterned protrusion is 0.6mm-1.2mm, the center-to-center distance between adjacent pearl-patterned protrusions is 1.5mm-2.5mm, and several of the pearl-patterned protrusions are arranged in a matrix or staggered pattern.

[0013] As a further improvement, the depth of the recessed guide zone is 1 / 4 to 1 / 3 of the height of the pearl texture protrusion, and the recessed guide zone is a continuous mesh-like interconnected channel.

[0014] As a further improvement, in the spunlace fabric body, the mass percentage of viscose fiber is 50%-80%, the mass percentage of lyocell fiber is 10%-30%, and the mass percentage of antibacterial fiber is 5%-30%.

[0015] As a further improvement, the lengths of the viscose fiber and the antibacterial fiber are 28mm-54mm, the length of the lyocell fiber is 28mm-68mm, and the length of the lyocell fiber is greater than the lengths of the viscose fiber and the antibacterial fiber.

[0016] As a further improvement, the spunlace fabric body is divided into an integrally entangled surface functional layer, an intermediate liquid storage layer and a bottom support layer along the thickness direction. The surface functional layer fully covers the outer surface of the surface functional layer, and the surface functional layer includes antibacterial fibers and viscose fibers, wherein the total mass percentage of antibacterial fibers and viscose fibers is ≥85%; The intermediate liquid storage layer is filled in the middle region of the spunlace fabric body, and the intermediate liquid storage layer includes viscose fiber, with the viscose fiber accounting for ≥80% by mass. The bottom support layer is the plain weave support layer, which includes lyocell fiber with a mass percentage of ≥80%.

[0017] As a further improvement, the basis weight of the spunlace fabric body is 50gsm-110gsm, and the total thickness is 0.5mm-1.5mm.

[0018] The beneficial effects of the above-described technical solution of the present invention are as follows: 1. Significantly improved wet and dry strength and structural stability. It adopts a hydroentangled molding process of viscose, lyocell and antibacterial fibers. The long-filament lyocell fibers form a supporting skeleton that runs through the fabric. Combined with the entangled structure with the porosity gradient decreasing from the surface to the bottom layer, it improves the problem of insufficient wet strength of traditional all-viscose hydroentangled fabric. It effectively avoids the fabric from stretching, deforming and breaking after getting wet. At the same time, it solves the defects of surface texture collapsing and flattening when it gets wet. It has strong structural stability and can withstand repeated rubbing.

[0019] Furthermore, the one-piece molding process eliminates the need for multi-layer composite designs, simplifying production processes and improving production efficiency.

[0020] 2. The antibacterial effect and raw material utilization rate are significantly improved. The antibacterial fibers are concentrated in the surface layer that comes into contact with the skin, and the effective utilization rate of antibacterial effect is improved. Compared with traditional products that locally deploy antibacterial fibers, the antibacterial ingredients are evenly distributed, the effective utilization rate is high, and the antibacterial effect is comprehensive and stable, meeting the health antibacterial needs of cleaning and care products.

[0021] 3. The cleaning and wiping effect and user experience are significantly improved. The pearl texture is raised and does not easily collapse or fall over, ensuring a stable wiping contact area. Attached Figure Description

[0022] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. In the drawings, several embodiments of the invention are illustrated by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein: Figure 1 This is a schematic diagram of the structure of Example 1 of the gradient entangled spunlace fabric containing antibacterial fibers of the present invention; Figure 2 This is a schematic diagram of the structure of Example 2 of the gradient entangled spunlace fabric containing antibacterial fibers of the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Pearl-textured raised surface; 2. Surface functional layer; 3. Recessed flow channel; 4. Intermediate liquid storage layer; 5. Plain-textured support layer. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Those skilled in the art should understand that the embodiments described below are only some, not all, of the embodiments disclosed. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] In the existing technology, the dry and wet strength stability of spunlace fabric is poor. The dry strength of viscose fiber is acceptable, but the wet strength is greatly reduced. It is very easy to stretch, deform and break after getting wet. In addition, the structure and material performance are not well matched. Currently, the wet strength of viscose fiber is insufficient after spunlace fabric gets wet, and the raised texture is very easy to collapse, fall over and deform, resulting in a poor user experience.

[0026] To address the aforementioned issues, this invention breaks away from the traditional approach of uniform blending of existing spunlace fabrics. By utilizing the spunlace fabric production process, a gradient structure is formed in the spunlace fabric. The entanglement density of the spunlace fabric body increases gradually from the surface functional layer 2 to the bottom plain weave support layer 5, resulting in a gradient decreasing porosity. Furthermore, based on this gradient structure, a directional enrichment distribution of ternary fibers is achieved. The surface layer is enriched with antibacterial fibers and viscose fibers to form a functional surface layer, while the bottom layer is enriched with lyocell fibers to form a strong skeleton. This significantly improves dry and wet strength and structural stability while ensuring the antibacterial effect.

[0027] The core working principle of this invention is to use the entanglement density gradient formed by differentiated hydroentanglement pressure to drive the directional migration of fibers of different lengths and moduli, so that the antibacterial fibers are enriched on the surface layer in contact with the skin, thereby greatly improving the effective utilization rate of antibacterial properties and achieving a precise match between structure and function. This principle is applicable to the production of spunlace fabrics with various surface textures such as plain weave, pearl weave, and mesh weave.

[0028] The preparation process is as follows: viscose fiber, lyocell fiber and antibacterial fiber are opened and mixed in proportion, and then carded into a uniform fiber web by a carding machine. The web is laid flat on a support screen with corresponding patterns and then enters the hydroentangling process. First, the fibers are initially shaped by low-pressure hydroentangling on the front side, and then the fabric is reinforced by high-pressure hydroentangling on the reverse side. As the hydroentangling energy gradually decreases from bottom to top, a natural entanglement density gradient is formed with a loose surface layer and a dense bottom layer. At the same time, the shorter viscose fiber and antibacterial fiber with lower modulus will accumulate in the looser surface layer, while the longer lyocell fiber with higher modulus will accumulate in the denser bottom layer. Finally, the finished product is obtained by drying, winding and slitting.

[0029] When producing pearl-textured spunlace fabric, the low-pressure hydroentangling on the front side pushes the fibers into the pearl-textured recesses of the support mesh, forming an alternating raised and recessed texture. When producing plain-weave spunlace fabric, a plain support mesh without texture is used, and the low-pressure hydroentangling on the front side only provides preliminary reinforcement to the fiber web, forming a flat surface structure. In use, the surface functional layer 2 directly contacts the skin or wiping surface, exerting antibacterial and instantaneous moisture-absorbing effects, while the bottom support layer provides strong overall support. The recessed flow-guiding areas 3 of the pearl-textured structure also enable uniform liquid flow and storage.

[0030] After introducing the basic principles of the present invention, various non-limiting embodiments of the present invention are described in detail below. Any number of elements in the accompanying drawings is for illustrative purposes only and not for limitation, and any naming is for distinction only and has no limiting meaning.

[0031] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0032] Example 1 of the gradient entangled spunlace fabric containing antibacterial fibers provided by the present invention: In this embodiment, a gradient entangled spunlace fabric containing antibacterial fibers is used to prepare disposable face towels; the spunlace fabric is a pearl-textured spunlace fabric. Figure 1 As shown, it includes a spunlace fabric body, which is integrally formed by spunlace of viscose fiber, lyocell fiber and artemisia fiber; the upper surface is a pearl-textured surface functional layer 2, and the lower surface is a plain weave support layer 5, forming an overall structure with a decreasing entanglement density gradient from the surface layer to the bottom layer.

[0033] Fiber composition (by weight): 75% viscose fiber, 20% lyocell fiber, and 5% antibacterial fiber; Fiber length: viscose fiber 38mm, artemisia fiber 38mm, lyocell fiber 52mm; Finished product parameters: 90gsm weight, 0.95mm total thickness.

[0034] Preparation process Opening and mixing: The above three types of fibers are put into the opening machine in proportion, and after opening, they are sent into the cotton mixing chamber for thorough mixing to ensure that the fibers are evenly dispersed and free of clumping.

[0035] Carding into a web: The mixed fibers are carded into a uniform fiber web by a carding machine.

[0036] Hydroentangling: The fiber mesh is laid flat on a stainless steel support screen with pearl-patterned pits (pit depth 0.8mm), and then undergoes the hydroentangling process. First step: Low-pressure hydroentangling on the front, pressure 55 bar, to initially shape the fibers and flush them into the recessed area of ​​the support curtain, forming the basic structure of pearl-patterned protrusions 1 and recessed guide areas 3. The second step: high-pressure hydroentangling on the reverse side, with a pressure of 135 bar, to reinforce the fabric as a whole and form a high-density entangled skeleton at the bottom layer. Third step (optional): front ultra-low pressure hydroentanglement, 20 bar pressure, to smooth the surface fuzz and further improve the softness of the product.

[0037] Post-processing: The hydroentangled fabric is dried with hot air at 120℃, inspected online, wound, and slit to obtain the finished product.

[0038] In addition to disposable face towels, the gradient entangled spunlace fabric containing antibacterial fibers of the present invention can also be used in dry towels, wet wipes, makeup remover wipes, baby cleaning wipes or medical care wipes.

[0039] Example 2 of the gradient entangled spunlace fabric containing antibacterial fibers provided by the present invention: In this embodiment, the gradient entangled spunlace fabric containing antibacterial fibers is used to prepare disposable dry towels. The spunlace fabric is a plain weave spunlace fabric, such as... Figure 2 As shown, it includes a spunlace fabric body, which is integrally formed by spunlace of viscose fiber, lyocell fiber and artemisia fiber; the upper surface is a plain weave surface functional layer 2, and the lower surface is a plain weave support layer 5, forming an overall structure with a decreasing entanglement density gradient from the surface layer to the bottom layer.

[0040] Fiber composition (by weight): 70% viscose fiber, 20% lyocell fiber, 10% artemisia fiber; Fiber length: viscose fiber 38mm, artemisia fiber 38mm, lyocell fiber 46mm; Finished product parameters: 70gsm weight, 0.57mm total thickness.

[0041] Preparation process Opening and mixing: The above three fibers are put into the opening machine in proportion, and after opening, they are sent into the cotton mixing bin for thorough mixing.

[0042] Carding into a web: The mixed fibers are carded into a uniform fiber web by a carding machine.

[0043] Hydroentangling: The fiber web is laid flat on the flat support screen and undergoes two hydroentangling processes in sequence: First step: Low-pressure hydroentangling on the front side, pressure 45 bar, to initially reinforce the fiber web and form a smooth surface structure; The second step involves high-pressure hydroentangling on the reverse side at a pressure of 125 bar to reinforce the fabric as a whole, forming a high-density entangled skeleton at the bottom layer.

[0044] Post-processing: The hydroentangled fabric is dried with hot air at 120℃, inspected online, wound, and slit to obtain the finished product.

[0045] Example 3 of the gradient entangled spunlace fabric containing antibacterial fibers provided by the present invention: The difference between this embodiment and Embodiment 1 is that: Matte lyocell fiber was used instead of lyocell fiber. Performance test results showed that the core properties of the product in this embodiment, such as dry and wet strength, antibacterial rate, and water absorption rate, were basically the same as those in embodiment 1, while the softness was significantly improved. According to third-party hand feel test, the softness score by subjective observation increased from 70 points in embodiment 1 to 86 points.

[0046] While various embodiments of the invention have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will occur to those skilled in the art without departing from the spirit and essence of the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in the practice of the invention. The appended claims are intended to define the scope of the invention and therefore cover the modular compositions, equivalents, or alternatives within the scope of these claims.

Claims

1. A gradient entangled spunlace fabric containing antibacterial fibers, comprising a spunlace fabric body, wherein the spunlace fabric body is integrally formed by hydroentanglement of viscose fibers, lyocell fibers and antibacterial fibers, wherein the upper surface of the spunlace fabric body is a surface functional layer (2), and the lower surface of the spunlace fabric body is a plain weave support layer (5). Its features are: The fiber entanglement density of the surface functional layer (2) is less than that of the plain weave support layer (5), corresponding to the formation of a porosity gradient decreasing structure from the surface to the bottom layer of the spunlace fabric body; within the surface functional layer (2), antibacterial fibers and viscose fibers are enriched and attached to the inner wall of the pores formed by the interlacing of Lyocell fibers, forming a functional surface layer with contact antibacterial and instant moisture absorption; within the plain weave support layer (5), Lyocell fibers are continuously entangled along the warp and weft directions of the fabric surface, forming a support skeleton that runs through the spunlace fabric body.

2. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 1, characterized in that: The antibacterial fiber is selected from any one or more of the following: artemisia fiber, bamboo fiber, chitosan fiber, tea polyphenol fiber, quaternary ammonium salt modified fiber, zinc ion fiber, silver ion fiber, or copper ion fiber.

3. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 1, characterized in that: The surface functional layer (2) is selected from any one of the plain weave structure, pearl weave structure, EF weave structure, wave weave structure or rhombus weave structure.

4. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 3, characterized in that: The surface functional layer (2) has a pearl texture structure, with a number of pearl texture protrusions (1) arranged at intervals. A continuous recessed flow guiding area (3) is formed between adjacent pearl texture protrusions (1). The fiber entanglement density of the pearl texture protrusions (1) is less than the fiber entanglement density of the recessed flow guiding area (3).

5. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 4, characterized in that: The pearl-patterned protrusions (1) are hemispherical or ellipsoidal protrusions. The height of a single pearl-patterned protrusion (1) is 0.6mm-1.2mm, the center-to-center distance between adjacent pearl-patterned protrusions (1) is 1.5mm-2.5mm, and several of the pearl-patterned protrusions (1) are arranged in a matrix or staggered manner.

6. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 5, characterized in that: The depth of the recessed guide area (3) is 1 / 4 to 1 / 3 of the height of the pearl texture protrusion (1), and the recessed guide area (3) is a continuous mesh-like connecting channel.

7. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 1, characterized in that: In the spunlace fabric body, viscose fiber accounts for 50%-80% of the mass, lyocell fiber accounts for 10%-30% of the mass, and antibacterial fiber accounts for 5%-30% of the mass.

8. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 7, characterized in that: The viscose fiber and antibacterial fiber have a length of 28mm-54mm, and the lyocell fiber has a length of 28mm-68mm, with the lyocell fiber having a longer length than the viscose fiber and antibacterial fiber.

9. The gradient entangled spunlace fabric containing antibacterial fibers according to any one of claims 1 to 8, characterized in that: The spunlace fabric body is divided into an integrally entangled surface functional layer (2), an intermediate liquid storage layer (4), and a bottom support layer along the thickness direction. The surface functional layer (2) fully covers the outer surface of the surface functional layer (2), and the surface functional layer (2) includes antibacterial fibers and viscose fibers, wherein the total mass percentage of antibacterial fibers and viscose fibers is ≥85%; The intermediate liquid storage layer (4) is filled in the middle region of the spunlace fabric body, and the intermediate liquid storage layer (4) includes viscose fiber, with the mass percentage of viscose fiber being ≥80%. The bottom support layer is the plain weave support layer (5), which includes Lyocell fiber with a mass percentage of ≥80%.

10. The gradient entangled spunlace fabric containing antibacterial fibers according to claim 9, characterized in that: The weight of the spunlace fabric body is 50gsm-110gsm, and the total thickness is 0.5mm-1.5mm.

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